Installation & Operation

Manual

Cyclomatic

Wood Pellet Vacuum Transport

and Filtering System

woodenergysolutions.co.uk V.1.0 08/12

 Cyclomatic
Contents
Contents
Page 1

1. Introduction 2
1.1 Exploring your Cyclomatic Pellet Transport and Filtering System 3
1.2 The Vacuum Cycle Explained. 5
1.3 Cyclomatic Logic Flowchart 6
2. Installation Considerations 7
2.1 Planning the Route 7
2.2 Pellet Storage & Auger Options 8
2.2.1 Purpose Built Silos 8
2.2.2 Underground Silos 9
2.2.3 Purpose Built Storage Silo Data 10
2.2.4 Home Built Silos 11
3. Assembly of the Cyclomatic System 14
3.1 Mounting the Cyclomatic Unit 14
3.2 Fitting the Integrated Cyclone Lid to the Boiler 14
3.3 Fitting and adjusting the Cyclomatic sensors 15
3.4 Electrical Connections 16
3.5 Control Panel Schematic 16
3.6 Connecting the Auger 17
3.7 Connecting the Vacuum Hoses 18
4. Set-up and Calibration 19
4.1 Testing the I/O’s 19
4.2 First Run 20
5. Understanding error codes and alarms 21
6. Timers and Parameters 22
7. Safety / Warranty Information 23
7.1 Safety Instructions 23
7.2 Operating Warnings 24
7.3 Guarantee Conditions 24
7.3.1 Limitations 24
7.3.2 Exclusions 24
7.4 Claims under the Guarantee 25

Version 1.0 21/08/2012

Doc. Ref : CY001
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 Cyclomatic
Introduction
Page 2

1. INTRODUCTION

The Cyclomatic Vacuum Pellet Transport and Filtering System by Wood Energy Solutions is a fully
integrated fuel transport system with suit its E-Compact range of wood pellet boilers.
In order to get the best performance from your Cyclomatic system we recommend that you read
this booklet carefully before operating the Cyclomatic for the first time.
May we remind you that the Cyclomatic MUST NOT be used by children, and that they must always
be kept at a safe distance from it!

Revisions to the publication

In order to improve the product and to keep this publication up to date the manufacturer reserves
the right to make modifications without any advance notice. Any reproduction, even in part, of this
manual without the consent of the manufacturer is prohibited.

Care of the manual and how to consult it

• Take good care of this manual and keep it in a place which can easily and quickly be reached.
• If this manual should be lost or destroyed, or if it is in poor condition, ask for a copy from your
retailer or directly from the manufacturer, providing product identification data.
• Information which is essential or that requires special attention is shown in bold text.
• Italic text is used to call your attention to other paragraphs in the manual or for any additional
clarifications.

ATTENTION
This warning sign indicates that the message to which it
refers should be carefully read and understood, because
failure to comply with what these notices say can cause
serious damage to the boiler and put the user's safety at
risk.
INFORMATION
This symbol is used to highlight information which is
important for proper system operation. Failure to comply
with these provisions may cause your system not to
operate as it should.
OPERATING SEQUENCES:
Indicates a sequence of buttons to be pushed to access
menus or to make adjustments.

MANUAL
Indicates that you should carefully read this manual or the
related instructions.

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 Cyclomatic
Introduction
Page 3

1.1 EXPLORING YOU CYCLOMATIC PELLET TRANSPORT AND FILTERING SYSTEM

The Cyclomatic Pellet Transport and Filtering System has been designed to allow for the effortless
re-fuelling of the E-Compact range of wood pellet boilers. It offers the Customer the flexibility to
decide on how to plan the installation of a wood pellet heating systems without the usual
constraints associated with automatic auger feed systems and also deciding on where to locate
ones fuel store. The Cyclomatic system also utilises dust filtering technology which captures the
dust in the airflow during transportation and does not recycle the dust back into the fuel store
which can lead to issues with blocked augers and heavy duty electrical loads on both auger motors
and vacuum motors. The Cyclomatic is an essential accessory to our next generation renewable
heating products packed with cutting edge technology which makes it one of the most advanced
automated wood pellet heating systems on the market today.

Its features include :

• Cyclomatic unit can be wall mounted or free standing.
• High vacuum pressure leading to fast transportation of fuel.
• High – Low level sensor control and cycle management.
• Dust filtering system for airborne dust removal.
• Automatic filter cleaning.
• Easy read LCD graphic display.
• ‘Sleep Mode’ to prevent operation during ‘sleeping hours’.
• Suitable for a variety of auger systems – standard auger, floor track, mole.
• Easy fit integrated boiler cyclone lid.
• Easy adjust level sensors
• Fully programmable controller.
• Can be operated whilst the boiler is in operation therefore providing uninterrupted
heated.

In order to fully understand the operation of the Cyclomatic system let us explain the main system
components.
• (A) Cyclomatic unit – This contains the control system, vacuum motor and dust filter.
• (B) Cyclone- the cyclone separates the pellets from the airflow and once the vacuum
cycle is complete the pellets exit the cyclone into the boiler hopper.
• (C) Auger – An auger, whether it is a standard auger from a fabric silo or a floor track
system, is used to draw a consistent quantity of fuel to the vacuum suction pipe where
the pellets are transported to the cyclone on the boiler via special earth bonded suction
hoses.

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 Cyclomatic
Introduction
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(A) Cyclomatic control Unit

Self cleaning dust filter

Dust collection bag

(B) Cyclone lid

(open for illustration purposes)

(C ) Standard Short Auger

Auger screw

Suction pipe

Cyclomatic suction pipe

Fuel delivery hose

from fuel store

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 Cyclomatic
Introduction
Page 5

1.2 THE VACUUM CYCLE EXPLAINED

Basic Operating Principles - The purpose of the Cyclomatic system is to draw wood pellets from a
remote fuel store and deposit the pellets into the boiler hopper as required. When the level of fuel
in the boiler hopper falls below sensor 1 the vacuum cycle is initiated. The vacuum motor P2 is
activated. The auger P3 draws pellets into a vacuum suction pipe, which is connected to the suction
hose, and from here the pellets are transported into a separating cyclone where the they are
collected until the vacuum motor stops. The pellets are then released into the boiler hopper. The
cycles are repeated until enough of batches are transferred until the pellets reach Sensor 2. At the
start of each cycle sensor 3 indicates that the cyclone door is closed so that the pellets can be
transported in suspension. At the end of each cycle the cyclone door opens allowing the pellet to
fall into the boiler hopper. At this stage also the filter cleaning motor P4 is activated allowing the
cleaning paddles in the filter to clean the surface of the filter membrane.

P2 Vacuum Motor - (Output)

P3 Auger Motor - (Output)
P4 Filter Cleaning Motor – (Output)
1 Low Level Sensor (Capacitive) – (Input)
2 High Level Sensor (Capacitive) – (Input)
3 Flap Door Sensor (Inductive) – (Input)

Detailed Operation
Hopper Loading
• If the pellets in the boiler hopper fall below the low level sensor S1 the Loading Cycle Starts.
• The pellets must reach sensor S1 within a period of time (TIM000)
• Once sensor 1 is reached the cycles continue until the pellets reach the high level sensor 2.
• Once sensor 2 is reached the loading cycles stop until the pellets drop below sensor 1 again.
Loading Cycle
Each cycle includes the loading of the boiler hopper from the bulk hopper via the cyclone. This is
done in batches.
• Vacuum motor (P2) starts.
• TIM002 verifies the closing of the flap door (sensor 3)
• At the end of TIM002 if sensor 3 is closed the auger motor (P3) is activated
• TIM003 counts the time to load the cyclone. Once TIM003 is reached the auger motor P3 is de-
activated and the vacuum motor continues to run for a time TIM004
to allow for the emptying of the vacuum hose.
• Once TIM004 is reached the vacuum motor P2 is de-activated. TIM005 is a time delay to allow the
cyclone to empty and start the next cycle.

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 Cyclomatic
Introduction
Page 6

1.3 CYCLOMATIC LOGIC FLOWCHART

Cyclomatic powered Alarm A04 if sensor 2

Alarm A01 if fuel does not ON indicates fuel and sensor 1
reach sensor 1 within time does not. Check sensors.
TIM000

If sensor 1 is o.k. then check

Verify status of sensor 1.
sensor 2.
No Fuel – Start Cycle to fill above
No fuel – Fill to sensor 2 within
sensor 1 within time TIM000
time TIM001

Vacuum motor
(Output P2) Alarm A02 if fuel
activated does not reach
sensor 2 within
time TIM001
Cyclone Door (sensor 3) to
close and hose emptying
during time TIM002

Auger P3 activated and runs

for a time TIM003 to fill the
cyclone
Auger stops and vacuum
continues to run for time
TIM004 to empty hose.
Vacuum motor stops and
counter TIM005 allows for
the emptying of the cyclone
If sensor 3 does not detect
the cyclone door closed
within time TIM002 the
vacuum motor goes off
and waits for a time
TIM006. After this time
the vacuum will start
again and it will make
another attempt to close
the door. It will make
COU000 attempts to close
the door after which
Alarm A03 will be
displayed.

Filter cleaning motor is

activated for a time TIM013

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 Cyclomatic
Installation Considerations
Page 7

2. INSTALLATION CONSIDERATIONS

2.1 PLANNING THE ROUTE

Time spent carefully planning the transportation route from the bulk fuel store to the boiler and
the location of the Cyclomatic at an early stage will overcome any un-foreseen difficulties during
the installation and assembly of the various components. Below are guidelines on how a successful
installation may be achieved:
Min. bend radius 600 mm

Max .vertical rise

6000mm or
2x3000mm rises

Max .2000mm

Max .horizontal travel 25,000mm (25m)

The Golden Rules When Planning the Route

Maximum horizontal travel 30m

For each 1m vertical rise subtract 2m off the horizontal travel

Each 90 degree bend must have a minimum radius of 600mm

For each 90° bend subtract 2m off the horizontal travel.

Cyclomatic unit can be a maximum of 2m from the cyclone on the boiler.

Ensure the hose is securly clipped to walls and ceiling to avoid sagging in areas of high ambient
temperatures such as plantrooms

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 Cyclomatic
Installation Considerations
Page 8

2.2 PELLET STORAGE & AUGER OPTIONS

There are various types and forms of pellet storage from Purpose Built Silo Systems to
Underground Silos to Home Built Storage Rooms. The storage solutions illustrated below can all be
used in conjunction with the Cyclomatic system.

2.2.1 PURPOSE BUILT SILOS

Silo of Fabric on a Wooden Frame with Flat Bottom Conical Silo

Elevating Silo
Trough Silo
(base raises as the silo empties)

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 Cyclomatic
Installation Considerations
Page 9

2.2.2 UNDERGROUND SILOS

Below-ground silo made of concrete, discharge

from above

Large below-ground silo up to 60 m³

Below-ground silo made from synthetic

materials, discharge from below

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 Cyclomatic
Installation Considerations
Page 10

2.2.3 PURPOSE BUILT STORAGE SILO DATA

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 Cyclomatic
Installation Considerations
Page 11

2.2.4 HOME BUILT SILOS

Home built silos or storage rooms are a good alternative where a bespoke solutions is required. The
following illustrations may be used as a guide when planning and building a home built storage
room.

Pellet silo with inclined bottom and screw conveyor

Pellet silo with inclined bottom and suction extraction

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 Cyclomatic
Installation Considerations
Page 12

Pellet silo without inclined bottom and screw conveyor

Pellet silo without inclined bottom and suction extraction

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 Cyclomatic
Installation Considerations
Page 13

Minimum distance 200mm

Filling connector

Impact protection mat

Exhaust connector

Ground plan of pellet storage room with homemade silo

Filling Connector Exhaust Connector

Air Space

Useable Volume
= 2/3 of room Inclined Bottom
volume

Empty Space

Extraction System

Tight connection to building

(foam strip as noise prevention)

18 – 25mm plywood base

Beam

Pressure Release

Angle support

Extraction system

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 Cyclomatic
Assembly of the Cyclomatic System
Page 14

3. ASSEMBLY OF THE CYCLOMATIC SYSTEM

3.1 MOUNTING THE CYCLOMATIC UNIT

The Cyclomatic unit can be either wall mounted, using the fixing holes provided in the back frame,
a wall bracket or a floor bracket can also be supplied to allow the unit to be free standing. In all
cases the Cyclomatic unit must be secured to prevent movement during operation. The
Cyclomatic unit must be within 2000mm of the cyclone to achieve maximum performance.

Wall mounting bracket

3.2 FITTING THE INTEGRATED CYCLONE LID TO THE BOILER

The cyclone lid is designed to be easily fitted by replacing the existing hopper lid.

• Disconnect the gas strut from the hopper lid and allow the strut to extend fully.

Exercise caution as the gas strut is pressurised and may cause injury

• Remove the hinge nuts holding on the lid and remove the lid from the boiler.

Disconnect gas strut at this end

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 Cyclomatic
Assembly of the Cyclomatic System
Page 15

• Fit the lid containing the cyclone and secure to the hinge with the four M6 nuts
• Tilt back the lid and refit the gas strut.

3.3 FITTING AND ADJUSTING THE CYCLOMATIC SENSORS

• Fit the round Inductive Sensor (sensor 3) to the cyclone unit leaving a 3mm gap
between the sensor tip and door when fully closed.
• Fit the lower level sensor (sensor 1) approx 25mm above the boiler sensor.
• Fit the upper level sensor (sensor 2) 250mm above sensor 1.
• Fit the sensor socket to the lid using the clip flange and screws provided.

Sensor 3

Sensor 2

Sensor 1

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 Cyclomatic
Assembly of the Cyclomatic System
Page 16

3.4. ELECTRICAL CONNECTIONS

The main components in the Cyclomatic unit are pre-wired. The only electrical connection to be
made on site are the mains power supply into the isolation switch and the connection of the auger
at the bulk fuel store. The power supply shall be 230V 60Hz fused with an 13A circuit breaker.

Connection to electrical supply should only be carried out by qualified personnel

Main Power In
Isolation Switch

Bulk Fuel Store Auger

Power Supply

3.5. CONTROL PANEL SCHEMATIC

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Assembly of the Cyclomatic System
Page 17

3.6. CONNECTING THE AUGER

Augers should be fitted as per manufacturers instructions. Always make sure that the auger is fully
secured to prevent movement while operating. Always check before filling the bulk fuel store with
fuel that the auger rotation is correct. Refer to manufacturers instructions for correct rotation and
safe electrical connections.

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 Cyclomatic
Assembly of the Cyclomatic System
Page 18

3.7 CONNECTING THE VACUUM HOSES

Always make sure that only anti-static hoses is used and that an earth bonding wire is inbuilt into
the hose.

It is essential that the earth wire in the vacuum hose is properly bonding both at the
bulk store auger, the cyclone and at the Cyclomatic unit. This will prevent static
electricity and reduce the risk of dust explosions.

Hose from bulk store

Suction hose from Air inlet hose
Cyclomatic Always point air inlet hose
downwards to prevent vermin
from entering the airflow

Correct earth bonding

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 Cyclomatic
Set-Up and Calibration
Page 19

4 SET-UP AND CALIBRATION

4.1 TESTING THE I/O’s

Once the auger is fixed in position and all the vacuum hoses are connected and bonded and the
electrical connections are complete, a test of the inputs and outputs (I/O’s) can be undertaken
through the Cyclomatic controller.
• Press the SET button on the controller to enter the USER MENU.
• Scroll down to INSTALLER MENU and press SET.
• Enter the Password (provided by Wood Energy Solutions)
• Select OUTPUTS TEST and press SET.
• Select which output you wish to test from the list below and press SET.
• Press SET and select ON and press SET again. The output should activate.
• Press ESC to stop the Output Test.
• Repeat the procedure for the next Output.

• Once the outputs have been checked and are working correctly the inputs can now
verified.
• Hold an object in front of sensor 1 and observe if the pellet line move between 1 and 2.
• With sensor 1 still covered cover sensor 2 and observe if the pellet line moves above
sensor 2.
• Close the cyclone door and observe if the graphic at sensor 3 indicates the closing of the
door.
• Closing the cylclone door without the vacuum motor on will cause an error so press ESC
to clear the error.

Pellet Level Indicator Line

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 Cyclomatic
Set-Up and Calibration
Page 20

4.2 FIRST RUN

If the I/O tests are successful fuel can now be added to the bulk fuel store.. The Cyclomatic unit
can now be turned ON by holding key F1 for three seconds. The vacuum motor should
immediately start and ON should indicate on the display. The graphic will indicate which I/O’s are
operational and their status.

Key F1 for
turning the
Cyclomatic
ON / OFF

Observe to make sure that the vacuum cycle is being followed according to the flow chart. Wait
until all the cycles have finished to fill the boiler hopper with pellets above sensor 2. The vacuum
cycle to re-start once the pellet level falls below sensor 1.

In the event that the vacuum cycle stops and alarm A03 is display this indicates that the cyclone
door has not been able to close due to an obstruction by pellets and sensor 2 has not been
reached. The height of sensor 2 may have to be adjusted in order to avoid an obstruction in
future. After adjustment repeat the cycles until sensor 2 is covered without alarm. The system is
now fully calibrated and ready for use.

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 Cyclomatic
Understanding Error Code and Alarms
Page 21

5 UNDERSTANDING ERROR CODES AND ALARMS

The Cyclomatic system contains a diagnostic system that will alert the Customer in the event of a
system fault. The error codes and their explanation are listed below.

If a fault occurs an exclamation symbol will appear on the display. By pressing the key the
alarm code in the form A0x will be displayed. Once the issue has been rectified the alarm can be
cleared by pressing the ESC key and the system will restart.

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 Cyclomatic
Timers & Parameters
Page 22

6 TIMERS & PARAMETERS

Code Description Set Unit

TIM000 Maximum time to reach the Minimum level S1 10 min

TIM001 Maximum Time Filling to reach the Maximum level S2 20 min
TIM002 Waiting Time to verify sensor door (S3) closed and
to allow the tube emptying (System 1) 5 s
TIM003 Loading Time of Intermediary Tank 45 s
TIM004 Waiting Time of tube emptying (System 1) at the end the loading of the
Intermediary Tank 10 s
TIM005 Waiting Time to discharge Intermediary Tank 10 s
TIM006 Waiting Time with Vacuum Motor OFF after fail close sensor door (S3)
to retry the sequence 5 s
TIM009 Waiting Time, Fan ON before Auger activation, to emptying tube 10 s
TIM013 Activation Time of Filter Cleaning Motor (System 7,8) 1 s
COU000 Maximum number of attempts to close the door (S3) 5 n
TYP001 Sensor type S1 N.C. type
TYP002 Sensor type S2 N.C type
TYP003 Sensor type S3 N.C type
TYP004 Sensor type S4 N.C type

System set: _____________________________________

Set on: _________________________________________

Set by: _________________________________________

Installation Note:

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 Cyclomatic
Safety / Warranty Information
Page 23

7 SAFETY / WARRANTY INFORMATION

7.1. SAFETY INSTRUCTIONS

• Installation of the Cyclomatic system, making the electrical connections, checking
its operation, and maintenance are all tasks which should be carried out by
qualified and authorised personnel.
• Install the Cyclomatic in accordance with the regulations in force in your local
area, region and country.
• For the correct use of the appliance and to prevent accidents, the instructions
given in this booklet must always be followed.
• Use, adjustment and programming must be carried out by adults. Errors or
incorrect settings may cause hazardous conditions and/or poor operation.
• Before beginning any operation, the user, or whoever is preparing to operate on
the appliance, must have read and understood the entire contents of this
instruction booklet.
• All responsibility for improper use is taken entirely by the user and such use
relieves WES of any civil or criminal responsibility.
• Any kind of tampering or unauthorised substitution of non-original spare parts can
be hazardous for the safety of the operator and relieves WES of any civil or criminal
responsibility.
• Carefully explain this hazard to elderly people, disabled people and particularly to
all children, keeping them away from the appliance while it is running.
• Under no circumstances should the appliance be run with the door open.
• Always make sure the inspection covers on fuel stores are in place at all times as
working augers represent a danger and can cause injury
• Before carrying out any cleaning or maintenance operation, make sure in advance
that the appliance is isolated from the mains electricity supply, by removing
the mains isolator fuse.
• The appliance must be connected to an electrical system which is equipped with an
earth conductor, as laid down in directives 2006/95 EC and 2004/108 EC.
• The fuse must be of adequate rated capacity for the stated electrical power of
the appliance.
• Incorrect installation or faulty maintenance (not conforming to the requirements
set out in this booklet) can cause harm to people, animals or property. In such
cases WES is absolved from any civil or criminal responsibility.

Adhesives sealants and paints used in the manufacture of the product are cured and
present no known hazards when used in the manner for which they were intended.
The appliance contains no asbestos.

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 Cyclomatic
Safety / Warranty Information
Page 24

7.2. OPERATING WARNINGS

• Shut the appliance down in the event of a breakdown or bad running.

• Do not wash the inside of the heat exchanger with water.
• Do not wash the appliance with water. The water could get inside the unit and
damage the electrical insulation and cause electric shocks.
• Do not put any fuel, other than wood pellets, in the hopper .
• Install the appliance in a location which is suitable for fire-fighting, and equipped
with all services such as air and electricity supply and provision for discharging
combustion gases.
• If the appliance is in storage, it should be in a place that is free of damp, and it
should not be exposed to extremes of temperature.

INFORMATION
• In case of any problems, get in touch with your dealer, or a qualified engineer
authorised by WES, and if a repair is necessary, insist on the use of original spare
parts.
• Use only the fuel recommended by WES (ENplus-A1) may be used with this
appliance.
• Always keep the cover of the fuel hopper closed.
• Keep this instruction manual carefully because it must stay with the appliance
throughout its working life. If the appliance is sold or transferred to another user,
always make sure that the booklet goes with the product.
• If it gets lost, ask WES or your authorised dealer for another copy.

7.3. GUARANTEE CONDITIONS

WES offers the following warranties on this appliance :
• Vacuum Motor, Sensors, Filter Cartridge, Controller – 12 months
• Auger / Filter Motors (if supplied by WES) – 2 years
The guarantee is conditional on the a copy of page 22 being returned to WES within
10 days following the installation and commissioning of the system. The term
'guarantee' is to be understood to denote the free of charge replacement or repair
of parts only, recognised to have been defective at the start by reason of
manufacturing defects.
7.3.1. Limitations
The above guarantee does not cover parts subject to normal wear such as gaskets, hoses, filter
membranes, etc. The replacement parts will be guaranteed for the remainder of the guarantee
period starting from the date of commissioning of the product.

7.3.2. Exclusions
The warranty excludes all ancillary products associated with the system ( e.g. purpose built or
home built silos and third party auger systems). The warranty does not cover Third Party damage
to the product or damage caused by the electrical system. Warranty does not cover issues arising
from pellets that do not conform to Enplus-A1 and exceed 6mm in diameter. Compliance with
Local Building Regulations must be adhered to.
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 Cyclomatic
Warranty Information
Page 25

The warranty does not cover misuse of the product or sabotage.

Any consequential loss or damage caused by the failure of a component on this product is not
covered.
WES refuses to accept any responsibility for any damage which may be caused, directly or
indirectly, by persons, animals or things in consequence of the failure to observe all the
prescriptions laid down in the instruction booklet, especially those concerning warnings on the
subject of installation, use and maintenance of the appliance.
Damage caused by transport and/or handling is excluded from the guarantee.
The guarantee will be invalidated in the event of damage caused by tampering with the
appliance, atmospheric agents, natural disasters, electrical discharges, fire, defects in the
electrical system, and caused by lack of, or incorrect, maintenance in terms of the
manufacturer's instructions.

7.4 CLAIMS UNDER THE GUARANTEE

The request for action under the guarantee must be addressed to the
Dealer/Retailer, who will forward the claim to WES's technical assistance
service.
WES DECLARES THAT THE APPLIANCE WHICH YOU HAVE PURCHASED COMPLIES
WITH EEC DIRECTIVE 2004/108 EC and 2006/95/EC and SUCCESSIVE
AMENDMENTS

WES refuses to accept any responsibility in the event that the appliance or any
other accessory has been improperly used or modified without authorisation.
For all replacement of parts, only original WES spare parts must be used.

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 Wood Energy Solutions
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Booths Hall, Chelford Rd., Knutsford, England WA16 8GS.

info@woodenergysolutions.co.uk
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