MCZ Pellet Stoves Technical Training

Technical Training Topics Installation

First Lighting

Comfort Air® Remote Control

Black LCD Panel

Active System Operating Parameters

Emergency Panel

Black LCD Panel Navigation

Alarms

Trouble Shooting

Re-Coding the Motherboard

Scheduled Maintenance

Cleaning Tips

End of the Season

Installation Basics

Venting 3” venting – over 20’ 4” is recommended. We suggest 5’ of vertical pipe at a minimum to insure draft in case of power outage.

Surge Protection Plug the stove power cord into a good quality surge protector. The stoves are well fused including 2 - 3.15 amp fuses in the power inlet box on the back of the stove.

Make Up Air In sleeping rooms or in manufactured homes outside air is required. Outside air or make up air may be needed in any tight building to insure proper combustion.

Air Filter The air filter that is supplied with the stove must be installed. If the stove is connected to outside air the filter should be installed at the end of the intake. It is important to keep this filter clean.

First Lighting Set the Date & Time

Instructions for setting up the date, time, & programming on the black panel or remote are included in the stove manual. A simplified version in provided in the Quick Start Guide (available at wittus.com).

Priming the burn pot Place 1 handful of pellets in the burn pot for the initial firing. This allows time for the auger to prime and maintain combustion. If the stove goes into Alarm 01 (failure to ignite) you must reset the stove and try again. Too much fuel in the burn pot can also be a problem.

Start Up Phase In the start up phase the stove will run at power level 3 with the fan speed at level 3. Adjustments to the power or fan speed can not be made in the start up phase which can take between 10 to 15 minutes. When the stove starts automatically in thermostat or program mode the fan speed goes to its previous setting after the start up phase.

Curing the paint As with most pellet stoves, it will take several hours to cure the paint. The paint on the stove will be soft until cured. To avoid finger prints do not touch the stove until the paint has had a chance to fully cure. It is advisable to ventilate the room.

Alarms An alarm indicates a problem with the stove or flue system. An alarm will make a beeping sound for 10 minutes and stop. After that the Alarm code will appear on the control panel. Most alarms will shut off the stove. If an alarm is triggered the control panel must be re-set by switching the stove off for 10 seconds. Otherwise the stove will not run.

Comfort Air® Remote Control ON/OFF button By pressing this button in combination with the MENU button (at right) you can set or adjust the internal clock

Button to select operating mode: MANUAL – AUTOMATIC – ECO-STOP Hold for 5 seconds with stove off to swtich from Celsius to Farenheight

Button for scrolling up or down to adjust flame power, fan, temperature and to set the SLEEP and the PROGRAM MODES

MENU button Lets you access the setting menus to adjust the flame, fan, SLEEP and TIMER

Black LCD Panel The LCD control panel on the

Star and Ego is the control and data center for the stove.

The panel will display the current status of the stove. i.e. Start-up or Auto

The Thermostat remote control is not included on the stoves that have the LED control panel but a small IR remote is available as an option.

This remote adjusts the fan and fire only.

EMERGENCY PANEL

The Emergency Panel on the Comfort Air stoves and the Black Panel on the Ego & Star are a window into the detailed functioning of the stoves. We will start by going over the Emergency Panel as the Black Panel is similar but easier. Some functions of the panel:

View the current operating status of individual components

Adjust the feed rate De-activate and Re-activate the air flow sensor See prompts for maintenance or service View operating hours of the stove Re-sinc a Remote Control Handset Set up a new Motherboard

EMERGENCY PANEL LEDS Flashing green = Stove starting up Steady green = Stove on Flashing red = Stove shutting down or in alarm condition. Steady red = Stove off

ON-REMOTE-OFF SELECTOR ON = The stove turns on WITHOUT the remote control. REMOTE = The stove is integrally controlled by the REMOTE

CONTROL OFF = The stove turns off WITHOUT the aid of the remote

control. Also turn the selector to OFF to cancel an Alarm code.

MAX-MED-MIN SELECTOR This selector sets the power of the flame when the stove is used

without the remote control. • The minimum power corresponds to speed 1 (P-1)

• The medium power corresponds to speed 3 (P-3)

• The maximum power corresponds to speed 5 (P-5)

• The Distribution fan speed will be equal to the flame setting.

With the TEST button it is very easy to read the total operating hours of the stove, air flow, and flue temperature. PRESS ONCE

With the switch at MIN to view the number of hours the stove has been in operation: 000-145=145 operating hours 001-145=1145 hours

With the switch at MED you can read the RPM of the combustion blower and the litre/minute of fresh air that is passing through the air sensor: 195 = 195 L/min entering the stove 230 = 2300 rpm of the Comb. Blower

With the switch at MAX to view the temperature reading of the flue temperature sensor: 132 = 132°C

EMERGENCY PANEL DETAILS

Operating Parameters The ACTIVE SYSTEM stoves are controlled by operating parameters that determine the product's response in the various conditions.

ACTIVE SYSTEM PARAMETERS CAN NOT BE CHANGED but knowing what they are can be very useful to assess whether or not the stove is operating correctly.

The most important information to pay attention to, is the air flow - the liters/minute read by the air flow sensor and the RPM’s of the combustion fan.

The speed of the combustion fan changes continuously in order to keep the air flow as close as possible to the set parameters.

The combustion fan has its own reference value. To determine whether the stove is working correctly or if an anomaly has occurred you check the current RPM’s against the reference value given in the service manual.

Example: At power 3, in a EGO stove, the flow sensor needs 160 L/min as minimum intake, the combustion blower will adjust to guarantee this amount of incoming air.

– In this case the combustion blower has a reference value of 1,600 rpm. – With normal installation and fuel quality, in a clean stove, the running values will remain close to the

reference value with a tolerance of ~ 20 rpm. – EXAMPLE: If you check the stove & the combustion blower is spinning 400 RMP higher than the reference

value for the current power level, this is a clear signal that there is some problem with air flow. This could be caused by a dirty burn pot or flue pipe. It could also be caused by negative pressure in the room. The stove will adjust up to a set point and then trigger an alarm code if it exceeds the set parameters.

– If the combustion blower hits the alarm threshold - 2,500 rpm and is unable to supply the 160 L/min required for 20 consecutive minutes, the stove triggers an alarm A06 (abnormal ratio between the number of revolutions of the fan and the flow of incoming combustion air). The stove will shut down and display A06.

EGO - STAR AIR version Example of Perameters Chart in the Service Manual

Release Software 0503 0504 Revolution and flow parameters Values Values Unit

Air flow in load wood phase 230 230 lpm

Minimum value of revolutions of the smoke fan in load wood phase 1900 1900 rpm

Air flow in fire on phase 180 180 lpm

Minimum value of revolutions of the smoke fan in fire on phase 1500 1500 rpm

Air flow in power 1 150 150 lpm

Minimum value of revolutions of the smoke fan in power 1 1300 1300 rpm

Air flow in power 2 155 155 lpm

Minimum value of revolutions of the smoke fan in power 2 1450 1450 rpm

Air flow in power 3 160 160 lpm

Minimum value of revolutions of the smoke fan in power 3 1600 1600 rpm

Air flow in power 4 165 165 lpm

Minimum value of revolutions of the smoke fan in power 4 1750 1750 rpm

Air flow in power 5 170 170 lpm

Minimum value of revolutions of the smoke fan in power 5 1900 1900 rpm

Air flow during thermal shutdown 150 150 lpm

Minimum value of revolutions during shutdown 2500 2500 rpm

Air flow during grate cleaning 350 350 lpm

Minimum value of revolutions of smoke fan during grate cleaning 2500 2500 rpm

Air flow during pre-lighting phase. 150 150 lpm

Minimum value of revolutions during pre-lighting 2500 2500 rpm

Minimum revolutions to detect a flow 500 500 rpm

Minimum operating flow 120 90 lpm

Rev/flow ratio to detect anomalies 20 27 Smoke temperature parameters Unit

Minimum smoke temperature to consider the stove on 50 50 °C

Maximum smoke temperature to consider the stove off 45 45 °C

Temperature increase when lighting flame LW when hot 5 5 °C

Minimum smoke temperature to start up the exchanger. 60 60 °C

Smoke temperature to reduce the exchanger to minimum in ST. 100 100 °C

Maximum smoke temperature to shut down the exchanger. 55 55 °C

Pre-alarm threshold for smoke temperature 180 180 °C

Alarm threshold for smoke temperature 200 200 °C

Hysteresis for smoke temperature alarm thresholds 5 5 °C

Using the TEST button you can modify certain functions of the stove: To Adjust Feed –

HOLD THE TEST BUTTON DOWN FOR 5 SECONDS

The display will show 0: by pressing the right button with a sharp instrument You can increase or decrease the quantity of pellets using the following scale:

-3 = -30% -2 = -20% -1 = -10% 0 = No modification 1 = +5% 2 = +10%

EMERGENCY PANEL ADJUSTMENTS

To de-activate the Air Flow sensor: You may need to de-activate the air sensor in the event that it is broken and you need to keep the stove working. With the air sensor disactivated the combustion blower runs at a fixed rate. HOLD DOWN THE TEST BUTTON FOR 10 SECONDS

The display will show ON

Press the button to switch between ON or OFF

To re-set the counter or clear maintenance warnings:

HOLD DOWN THE TEST BUTTON FOR 15 SECONDS The display will show SEr (service) Press the button to re-set The Values are: SEr = Maintenance needed 000 = Re-set the counter

EMERGENCY PANEL ADJUSTMENTS

Re-syncing a Remote Control When the stove is off turn switch to

Remote position

Press the button

Three lines appear - - -

Press the Off/On Button on the remote

Three beeps from the Emergency panel indicate that the Sync was successsful

EMERGENCY PANEL TOOLS

Replacing the Motherboard and Programming the Software

Turn the stove off and disconnect the power Remove and replace the motherboard by unscrewing the 3

screws on the mounting panel on the back of the stove Re-connect power and switch the stove on Within the first 10 seconds (while the Green & Red lights

flash) press and hold the button. Press the test button to select the correct software

01 = Ego – Star 02 = Suite Club Musa Toba – Air 03 = Suite Club Musa – Multi–Air

Release the button Off will appear on the screen meaning the software has

loaded correctly If 000 still appears, go through the steps again

EMERGENCY PANEL TOOLS

Navigating the Black LCD Panel

The LCD control panel on the Star and Ego has all the functions for the remote and the emergency panel combined.

The panel will display the current status of the stove i.e. Off, Start-up, Manual, Auto, Auto Eco

Using the 4 buttons it is very simple to scroll through the menus & set the desired operational settings.

Illustration of the display in the adjustment phase

Illustration of the display in stand-by

Black Panel Menu Items The Menus & Sub-Menus

DATE and TIME To set the time.

TIMER To set the set back programs already saved in the motherboard. The programs are identical to those saved in the ACTIVE SYSTEM remote control.

SLEEP Sets stove to turn off by setting a countdown timer in minutes or hours.

INFO Real time details concerning the state of the stove such as:

• The temperature of the smoke sensor • The RPM of the combustion blower • The liters/minute detected by the flow sensor • The working hours • Voltage to the distribution fan

SETTINGS To Set preferences or functions of the stove such as: • The LANGUAGE of the display • Set the ECO-STOP • Modify the TONES • Modify the pellet recipe • Activate external thermostat • Activate pellet feed screw (prime) • °C / °F • Enter the TECHNICAL MENU

Note:

Pressing the on/off button, the display returns to the initial display.

Entering the Technical Menu The Technical Menu is a password protected area where the technician can adjust the following: Re-set hours of operation (after cleaning)

De-activate the air flow sensor Activate the small remote Re sync a new motherboard

We will walk through 2 examples:

De-activating the Air Flow Sensor

Press the button in TOP RIGHT to access the menu

Scroll with the two bottom buttons until you reach the SETTINGS menu

Press the button next to SET Scroll with the two bottom buttons to

TECHNICAL MENU

Press SET, and insert the password C 93 with the bottom keys, confirming with OK first the letter and then the number

Confirm by pressing SET

Scroll through the various menus to AIR FLOW SENSOR

Confirm pressing SET Select OFF or ON with the lower keys

Confirm by pressing SET

Technical Menu Example 2 Replacing the Motherboard

As before Scroll through the various menus, to TECHNICAL MENU

Press SET, and insert the password C 93 with the bottom keys, confirming with OK first the letter and then the number

Confirm by pressing SET

Scroll through the various menus to STOVE TYPE

On the display the 00 appears

Confirm by pressing SET Modify the value with the lower buttons.

Confirm pressing the SET

The software codes are:

01 = Ego – Star AIR 02 = Suite – Club – Musa AIR 03 = Suite – Club – Musa COMFORT AIR

ALARMS – Emergency Panel

Along with enabling operation of the stove in an emergency The emergency panel is the window for system diagnosis. If the Motherboard detects a problem it will display an Alarm code on the panel. By consulting the table in the service manual we can identify the type of problem the stove is reporting. The alarm codes start with the letter A - Alarm followed by a two digit number (ie. A01 = Stove did not light) An alarm is signaled by a beeping tone that will last for 10 minutes. The panel will continue to display the alarm code until it is re-set.

USE THE EMERGENCY CONTROL PANEL TO CANCEL THE ALARM SHOWN AND RE-START THE STOVE: Switch top button to OFF for 10 seconds or until the display shows OFF

A01 Failure to ignite

A02 Fire extinguishes abnormally

A03 Excessive temp. @ pellet hopper sensor (> 110 c)

A04 Excessive flue temperature sensor reading

A05 Blocked or obstructed Chimney

A06 Draught Problems (insufficient LPM of air) could signal a blocked grate

A07 The door is ajar

A08 Combustion Blower broken (registers 0 rpm)

A09 Flue Temperature sensor is broken

A10 Igniter is broken

A11 Feed motor or wiring to the feed motor

A12 Remote out of Range for more than 3 Hours

A13 Motherboard or loss of communication with one of the components & the motherboard

A 14 Air flow sensor is disconnected or broken

A 17 Hopper lid open

ALARMS – Active System

Trouble Shooting Alarms For a better understanding of the alarms it helps to group them in categories

Alarms 1 2 4 and 9 all involve the flue sensor: A 01 Flue sensor needs to reach 50°C within 15 minutes

A 02 The stove has gone past start up and the flue sensor cooled to 45 °C - Most likely the stove ran out of fuel.

A 04 Flue exceeds 200° C [392° F] (air) or 210° C (multi-air) this is very rare because at 180° C the stove goes to minimum feed but it can be caused by very hot fuel such as olive pits.

A 09 Flue sensor disconnected or broken

Alarms 3 and 5 – safety issues: A 03 Hopper exceeded 110° C. Stove must cool for 10 to 15 minutes before re-setting A 05 Comb blower hit 2,700 RPM with < 90 L/min air flow = flue is blocked

Trouble Shooting Alarms - Continued Alarms 5 , 6 and 14 involve the Air Flow Sensor A 05 Comb blower 2,700 RPM with < 90 L/min air flow for 20 seconds – blocked flue

A 06 Comb blower 2,500 RPM with < 160 L/min air flow for 20 minutes. This indicates a dirty stove or air filter a plugged grate or a poor door seal. A 06 can also be caused by a dirty air flow sensor. The sensor is very delicate and should never be touched. Clean with a soft brush.

A 14 Air Flow sensor disconnected or broken. If there is no replacement sensor available the stove can still be run in a pinch by de-activating the flow sensor. The stove will run but will burn poorly, especially if there is no vertical pipe.

Other Alarms A 07 Combustion blower working properly < 40 L/min air flow

A 08 Combustion blower at < 500 rpm. At a 452 rpm reading on the panel the combustion blower is actually not running at all.

A 10 Igniter broken or disconnected. If you get A 10 with a new stove, moisture could be causing a ground. Dry out the stove and try again.

A 12 Remote out of range for 3 hours. This is the only alarm that does not need to be cancelled. The stove will continue to work in the last mode set until communication is restored.

A 13 Motherboard. Not always a bad Motherboard can also be triggered by a poor wire connection or overheating of a component which disables communication back to the Motherboard.

Re-Coding a Motherboard If you need to use a motherboard that has already been programmed with a different software than the stove you are putting it into you will need to Clear and Reset the hardware of the motherboard.

Unplug and then reconnect the stove to the power supply through the ON/OFF main switch. 1. Within the next few seconds locate and

press the reset button on the motherboard (indicated with an arrow) until a first ‘bip’ is heard.

2. IMMEDIATELY release the button until a second ‘bip’ is heard, confirming the reset (In case the second sound is not heard, repeat the operation).

3. Select the correct program code on the Black panel or Emergency panel as you would with a Virgin board

Trouble Shooting Advice Try the simplest things first. Does the user understand the controls? Are the batteries fresh? When was the stove last cleaned or serviced Check environmental issues such as negative air pressure or lack of make up

air If there is an alarm that indicates a problem with a component check for loose

wire connections or dirt before replacing the part If the stove is started in Auto or Auto-eco mode and the set temperature is

lower than ambient room temperature the stove will start-up and then turn off. Consult the service manual. The manual is very comprehensive and is a great

follow up to this training. It covers every point in detail.

If you need to contact support please get as much information as possible:

– Product Type – Date of installation and year/month of use. – Type of installation – Frequency of maintence performed on product – Code and description of alarm – Number of service calls already carried out if the problem is ongoing

Components to check Daily Every 2-3 days Every 30 days Every 60-90 days

Every end of season

Every 2 seasons

Clean the grate Clean the ash collection compartment with a

vacuum cleaner Cleaning the ash drawer Clean the fire door glass

Remove the ash from the lower heat exchanger.

Clean all the heat exchangers and remove ash and encrustations

Clean the discharge “T” Clean the pipe connection

Replace the door seal Control and replace the ignition plug

Control and clean the pollen filter (ACTIVE SYSTEM)

Replace the remote control batteries (especially for ACTIVE stoves)

SCHEDULED MAINTENANCE This is the Maintenance schedule in the owners manual.

Cleaning Tips Besides the regular user maintenance procedures like cleaning burn pot, ash drawer and glass, it is

important to check the air filter once a month. Do not use a vacuum to clean the filter while it is attached to the stove to avoid possible damage to the air flow sensor.

The stove should never be operated without the air filter. Damage to components caused by lack of the air filter in not covered by the warranty.

Be very careful when cleaning the smoke sensor. A soft brush or gentle blowing is best.

CLEANING THE HEAT EXCHANGER Removing the cast heat exchanger will expose the heat exchange chambers running down the sides of the stove. Run

a brush through so that the dust and soot falls into the lower chamber. Open the lower inspection panel under the ash pan and vacuum out the lower chamber. Replace the seal gaskets on the panels to guarantee a perfect seal.

CLEANING COMBUSTION BLOWER AND BLOWER HOUSING After cleaning the lower exchange chamber, assess whether it is necessary to clean the fan housing and/or the

combustion blower. You can sometimes just vacuum it out from above. Cleaning the fan housing requires the removal of the fan. The fan is best cleaned with a small brush.

ATTENTION:

Once the combustion blower is removed, it is compulsory to replace all the seals and redo any silicon. A MCZ gasket replacement kit is available from Wittus.

The chamber must be perfectly airtight.

Be careful not to put too much force on the fan blades . If they twist or the blade becomes unbalanced, the fan will vibrate .

End of the Season

At the end of the heating season turn the stove off with the switch at the rear and remove the power cord from the wall

Remove the batteries from the remote to avoid damaging the remote with corroded batteries. Fresh batteries should be used each fall.

The End –