Herz pelletstar 10, pelletstar 20, pelletstar 30, pelletstar 60, pelletstar 40 Operating Instructions Manual

...

Operating instructions

pelletstar 10 – 60

Introduction

2 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

INTRODUCTION

Dear Customer!

Your heating system is powered by a HERZ pelletstar boiler system and we are pleased to be able to count you as one of our many satisfied owners of a HERZ system. The HERZ boiler is the result of years of experience and continuous improvement. Please remember that in order to be able to work properly, a welldesigned product also needs to be operated and maintained correctly. We definitely recommend that you should read this documentation carefully while paying particular attention to the safety instructions.

Compliance with operating procedures is required for any claims made under the manufacturer’s warranty. In

the event of any faults or defects, please contact your heating specialist or the HERZ Customer Service department.

Yours sincerely

HERZ – Energietechnik

Warranty / Guarantee (general information)

HERZ boiler systems come with a 5-year warranty on the boiler body, storage tanks and HERZ solar collectors while electrical components such as electric motors, the control cabinet, ignition devices, etc. come with a 2-year warranty which starts when the system is first put into operation. Parts subject to wear are excluded from the warranty/guarantee. Furthermore, claims under warranty will not be applicable if there is no return flow temperature boost or it is not working properly, if commissioning1 is not carried out by specialist personnel authorised by HERZ, in the case of operation without a buffer storage tank with a heating load of less than 70% of the rated output (manually stoked boilers must always be operated with a sufficiently dimensioned buffer storage tank), if hydraulic diagrams2, not recommended by HERZ are used and if a non-prescribed fuel3, Pellets (ÖNORM M 7135, DINplus or Swiss Pellets) wood chips (ÖNORM M

7133) resp. log wood is used.

Any claim to warranty services requires maintenance to be carried out on an annual basis by specialist personnel authorised by HERZ.

The general warranty period will not be extended if work is carried out under warranty. In the event of a warranty claim, the due dates for payments owed to us will not be deferred. We will only provide a guarantee if all the payments owed to us for the product supplied have been made.

The warranty will be carried out at our discretion by repairing the item purchased or replacing any defective parts, by exchanging the item or by reducing the price. Parts or goods replaced are to be returned to us at our request free of charge. Wages and costs paid out in connection with installation and removal are to be paid for by the purchaser. The same applies to all warranty services.

The Supplier shall under no circumstances be liable to the Customer, for any direct, indirect or consequential costs incurred by the Customer for works carried out on HERZ equipment.

This document is the translation from the German original. The reproduction or copying, even of extracts, may only be undertaken with the permission of the company HERZ©.

Subject to technical modifications, Version 09/2013

Maintenance by the manufacturer

Recommended hydraulic diagrams can be found in the installation manual while hydraulic balancing will be carried out by the heating

contractor

Furthermore, the quality of the heating water must be in accordance with ÖNORM H5195 (current version) or VDI 2035

Table of content

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 3

TABLE OF CONTENT

page page

1 Safety notes ................................... 5

1.1 Warning notes ...................................... 6

1.2 Installation ............................................ 6

1.3 Operation and maintenance ................ 7

1.3.1 General notes ......................................... 7

1.3.2 Operation ................................................ 7

1.3.3 Maintenance ........................................... 7

2 Fuels............................................... 8

2.1 Wood pellets ......................................... 8

3 System ........................................... 9

4 Equipment funtioning ................. 10

4.1 Feeder system .................................... 10

4.2 Type of feed ........................................ 10

4.3 Combustion air control ...................... 10

4.4 Removing the two ash pans .............. 10

4.5 Boiler operation .................................. 11

4.6 Safety devices .................................... 11

4.6.1 Safety temperature limiter STL ............ 11

4.7 Start-up ................................................ 11

4.8 Operating temperatures and

impermissible temperatures ............. 12

4.8.1 Boiler temperature ................................ 12

4.8.2 Return flow temperature ....................... 12

4.8.3 Boiler temperatures that are too high ... 12

4.8.4 Flue gas temperature ........................... 12

5 Operating conditions .................. 13

6 Temperature manager ................. 15

7 Description of the menu

navigation system and settings . 16

7.1 Starting the system ............................ 16

7.2 Main menu ........................................... 17

7.3 Operation and handling ..................... 18

7.4 Explanation of the symbols .............. 18

7.5 Code – entry ........................................ 19

7.6 Switching the boiler on and off ......... 20

7.7 Selecting date and time ..................... 21

7.8 Determining values for the main

menu .................................................... 22

7.8.1 Adding display values to the main menu22

7.8.2 Deleting display values from the main

menu ..................................................... 23

7.9 Fault messages and warnings .......... 24

7.10 Modules ............................................... 25

7.10.1 Boiler ..................................................... 26

7.10.2 Buffer .................................................... 29

7.10.3 Hot water tank ...................................... 31

7.10.4 Heating circuit ....................................... 34

7.10.5 Time mode ............................................ 37

7.10.6 Solar ..................................................... 38

7.10.7 Hydraulic compensator ......................... 46

7.10.8 Net pump .............................................. 47

7.10.9 Zone valve ............................................ 48

7.10.10 External requirement ............................ 49

7.11 Menu settings ..................................... 50

7.11.1 Network configuration ........................... 51

7.11.2 Modbus – settings ................................ 52

7.11.3 Screensaver ......................................... 53

7.11.4 Information overview ............................ 53

7.11.5 Sending e-mails .................................... 54

7.11.6 E-Mail status report .............................. 56

7.11.7 Server – settings ................................... 57

8 Terms and definitions ................. 58

8.1 Boiler module ...................................... 58

8.2 Buffer module ..................................... 64

8.3 Hot water tank module ....................... 66

8.4 Heating circuit module ....................... 69

8.5 Time mode ........................................... 72

8.6 Solar module ....................................... 73

8.7 Hydr. compensator module ............... 75

8.8 Net pump ............................................. 76

8.9 Zone valve ........................................... 77

8.10 External requirement .......................... 77

9 Fault reports and their correction80

Table of content

4 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

page

9.1 Faults not indicated on the display

(Maintenance) ..................................... 87

9.2 Maintenance schedule (Customer

inspection) .......................................... 88

10 EC declaration of conformity...... 89

11 Index directory ............................ 90

12 Annex ................................ ........... 91

12.1 Functioning of the operation mode

„Screed drying“ .................................. 91

13 Notes ............................................ 92

Safety notes

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 5

1 SAFETY NOTES

 Before commissioning, please read the documentation carefully and pay attention to the safety

instructions given in particular. Please consult this manual if anything is unclear.

 Make sure that you understand the instructions contained in this manual and that you are sufficiently

informed regarding the way in which the biomass boiler system works. Should you have any queries at any time, please do not hesitate to contact HERZ.

 For safety reasons, the owner of the system must not make any changes to the construction or the state

of the system without consulting the manufacturer or his authorised representative.

 Make sure that there is a sufficient supply of fresh air to the boiler room (please heed the relevant

national regulations)

 All connections are to be checked before the commissioning of the system in order to make sure that

they are leak-tight.

 A portable fire-extinguisher of the prescribed size is to be kept by the boiler room. (Please heed the

relevant national regulations).

 When opening the door to the combustion chamber, make sure that no flue gas or sparks escape.

Never leave the combustion chamber door open unattended as toxic gases may escape.

 Never heat the boiler using liquid fuels such as petrol or similar.  Carry out maintenance regularly (in accordance with the maintenance schedule) or use our Customer

Service department. (The minimum maintenance intervals specified in the TGPF are to be observed).

 When carrying out maintenance on the system or opening the control unit, the power supply is to be

disconnected and the generally valid safety regulations are to be heeded.

 In the boiler room, no fuels may be stored outside the system. It is also not permitted for objects which

are not required for the purpose of operating or carrying out maintenance on the system to be kept in the boiler room.

 When filling the fuel bunker using a pump truck, the boiler must always be switched off (this is stamped

on the cover of the filling connection). If this instruction is not heeded, flammable and toxic gases may get into the storage room!

 The fuel bunker is to be protected against unauthorised access.  Always disconnect the power supply if you need to enter the fuel bunker.  Always use low-voltage lamps in the storage room (these must be approved for this type of use by the

relevant manufacturer).

 The system is only to be operated using the types of fuel prescribed.  Before the ash is transported further, it must be stored temporarily for at least 96 hours in order to let it

cool down.

 Should you have any queries, please call us on +43/3357 / 42840-840.  Initial commissioning must be carried out by the HERZ Customer Service department or an authorised

specialist (otherwise any warranty claim will not be applicable).

 Ventilate the pellet storage area for ~ 30 minutes before going in.  The boiler meets the requirements of the Association of Swiss Canton Fire Insurance Companies or

national fire safety regulations. The customer himself shall be responsible without exception for ensuring that these regulations are complied with on site!

Safety notes

6 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

1.1 Warning notes

Risk of injury and damage to property due to improper handling of the system.

Caution – hot surface

Warning – against hand injuries.

No admittance without authorisation.

However, adherence to guidelines for transportation, installation, operation and maintenance notices as well as technical data (in the operating instructions, product documentation and on the equipment itself) which are not specifically highlighted, is also vital to avoid breakdowns which may directly or indirectly cause major personal or material damage.

General note

For reasons of clarity and possible permutations, this documentation does not contain all detailed information and cannot take account of every conceivable operating or maintenance scenario. Should you require further information or encounter specific problems, which are not handled in detail in the documentation supplied, you can obtain the required information from your specialist dealer or direct from HERZ.

People (including children) who, because of their physical, sensory or mental capabilities or because of their lack of experience or knowledge, are unable to use the equipment safely must not use this equipment unless they are supervised or instructed by a responsible person.

Basic safety information

Due to its functionally limited electrical and mechanical characteristics with regard to usage, operation and maintenance, if the equipment is not able to work according to its appropriate use or improper interference occurs, it may cause serious health and material damage. It is therefore conditional that the planning and implementation of all installations, transportation, operation and maintenance will be carried out and supervised by responsible, qualified persons.

When operating electrical systems, certain parts of those systems will always carry a hazardous electrical voltage or be exposed to a mechanical load. Only appropriately qualified personnel may carry out work on the system. They must be thoroughly familiar with the content of this and all other manuals. In order for this system to function safely and without any problems, transportation, storage, operation and maintenance must be carried out properly and carefully. Instructions and information on the systems must also be heeded.

1.2 Installation

General notes

In order to ensure that the system will function properly, the relevant standards and the

manufacturer’s installation instructions are to be

heeded during the installation of the system! Documents from the manufacturer relating to the

heating devices and components used are available from HERZ on request.

Safety notes

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 7

1.3 Operation and maintenance

1.3.1 General notes

In order for the system to be operated and maintained safely, it must be operated and maintained properly by qualified personnel while heeding the warnings in this documentation and the instructions on the systems.

The system must not be opened

until “HEATING OFF” is displayed

as otherwise there will be a risk of deflagration (explosion).

In unfavourable operating conditions, the temperatures of parts of the housing may exceed 80 °C.

If the door to the ash pan is opened during operation, the fuel supply will be shut off and the boiler will switch to the burnout phase. After that, it will go into the operating mode “HEATING OFF”.

1.3.2 Operation

General safety instructions

Covers which prevent contact with hot or rotating parts or which are required in order to direct the flow of air correctly and thus ensure the effective functioning of the system must not be opened during operation.

In the event of a fault or unusual operating conditions such as the emission of smoke and flames, the system is to be switched off immediately by operating the emergency stop button. The HERZ Customer Service department is then to be notified immediately.

 If the main switch is operated on the boiler

room door or if there is a power failure, the system will be taken out of operation immediately. The remaining quantity of residual fuel will burn independently without giving off any toxic gases provided that the chimney draught is sufficiently high. Therefore the chimney must be designed and produced in accordance with DIN 4705 or EN

13384. When it is switched on again, the system is to be checked in order to make sure that it is fully functional and the safe operation of the whole system must be guaranteed!

 If the residual oxygen content in the flue gas

drops below the minimum of 5% required, the fuel supply will be stopped automatically and will not be activated again until the residual oxygen content has risen to more than 5% (message displayed: MIN O2 [%] 5.0, see Figure 7.21)

 The noise generated by the machine during

operation does not present any danger to health.

1.3.3 Maintenance

General safety measures

Before starting to carry out any work on the system, but especially before opening covers protecting live parts, the system is to be properly disconnected from the power supply. Besides the main circuits, attention is also to be paid to any existing additional or auxiliary circuits in the process. The normal safety rules according to ÖNORM are:

 Disconnect all poles and all sides!  Ensure that the system cannot be switched

on again!

 Check to ensure that no voltage is

connected!

 Earth and short-circuit!  Cover adjacent live parts and locate

hazardous areas!

These above-mentioned measures must not be reversed until the system has been fully installed and maintenance has been completed.

Personal dust masks and gloves must be worn when carrying out maintenance work in the combustion chamber or the ash collector or on flue gas-carrying parts, when emptying the ash pan, etc.!

Extra-low-voltage lamps are to be used when carrying out maintenance work in the storage room. Electrical equipment in the storage room must be designed in accordance with ÖN M7137!

Fuels

8 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

In order to prevent any maintenance errors, if maintenance is not carried out properly, it is recommended for maintenance to be carried out regularly by authorised personnel or by the HERZ Customer Service department.

Spare parts must only be obtained directly from the manufacturer or a distribution partner. The customer will not be exposed to any health risks as a result of the noise generated by the machine. Details on the residual risks can be requested from the residual risk analysis at HERZ if required.

2 FUELS

The HERZ pelletstar – boiler should be operated with the fuels and their properties which are described in this chapter.

2.1 Wood pellets

Wood pellets for non-industrial use after ENplus, Swisspellet, DINplus or ÖNORM M 7135 resp. pellets after EN14961-2 according to following specifications:

 Property class A1  The maximum permissible fines content in

the fuel store must not exceed 8% of the fuel volume stored (determined using a perforated screen with holes 5 mm in diameter)!

 Fines content at the time of loading: <1.0 m-

 Calorific value in as-delivered condition > 4.6

kWh/kg

 Bulk density BD in as-delivered condition >

600 kg/m³

 Mechanical Strength DU, EN 15210-1 in as-

delivered condition, m-%: DU97.5 ≥ 97.5

 Diameter 6mm

The nominal power and the emission values can be guaranteed up to a maximum water content of 25 % and a minimum calorific value of 3.5 kWh/kg of the permissible fuel.

From a water content of about 25% and a calorific value <3.5kWh/kg a reduced output is expected.

Foreign bodies such as stones or metal particles should be prevented from entering the system! Sand and soil lead to more ash and slagging.

According to the fuel there may be a formation of slag, which may need to be removed by hand.

In the case of non-compliance, any warranty or guarantee will be rendered null and void.

The burning of unsuitable fuels could lead to uncontrolled combustion. Operational faults and consequential damage are likely to occur.

Is a different fuel on the order named and explicit on the order confirmation noted, the system can also be operated with this fuel.

Note: The system is set to the agreed fuel at the commissioning. This setting (fan speed settings, fuel settings, flow/backflow fan, cycle time, and so on) should not be changed by constant fuel quality.

System

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 9

3 SYSTEM

3D view from the side

Side view

Legend

1 … Induced-draught fan

7 … Filling shaft

2 … BSD feed screw

2 … Heat exchanger

8 … Feed screw

3 … Ash pans

3 … Turbulators

VL .. Heatinf feed flow

4 … Burner

4 … Rear ash pan

RL .. Heating return flow

5 … Pellet inlet

5 … Front ash pan

6 … Operating display

6 … Burner

3D view of the boiler from the back

Boiler with intermediate container

Legende

1 … Bushing for feed connection

2 … Bushing for flue pipe for temperature sensor

3 … Cable bushing for electrical connections

4 … Bushing for return connection

5 … Feed screw opening for screw feed system

Return air hose opening for suction feed system

6 … Bushing for fill and drain valve

7 … Connection to the power supply (additional

electrical connections are required for a screw feed system)

8 … Induced-draught fan

1 2 3 4 5

Equipment funtioning

10 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

4 EQUIPMENT

FUNTIONING

4.1 Feeder system

The fuel is transported from the fuel storeroom by means of a feeder screw with flat spring stirrer for burnback protection devices. It then passes through the drop shaft and the burnback protection device. The burnback protection device is driven by a spring-loaded servo-motor. If the servo-motor has no power supply then the flap closes independently. Then the plug-in screw feeds the fuel upwards. These are then directed to the combustion chamber via a drop level. The fuel level reached is crucial for the boiler capacity and the operating condition of the equipment.

4.2 Type of feed

The operation of the pelletstar based on a pulseno-pulse ratio which controls the feed system. All

the values are to be set via the menu “Fuel values” (only available in the service area). These

feed values are corrected by the combustion control system.

4.3 Combustion air control

Differentiation is made between primary and secondary air (1+2) in the combustion air supplied. The primary air is supplied directly into the embers. Using secondary air an attempt is made to fully develop the flame arising from the primary air. The air supply is supplied via a lateral opening (underneath the lateral panelling).

The flue gas ventilator is a suction fan and this is located at the back of the boiler. It generates low pressure in the boiler. The secondary and the primary air are sucked out by this low pressure.

The blower is time-controlled by the variablespeed electronic control. The blower speed is controlled according to the boiler temperature and rectified by the lambda control.

4.4 Removing the two ash pans

Only for pelletstar 45 – 60

Open the ash pan door

You can then take out the first ash pan (at the

front)

The second ash pan is removed by using the

hook provided

Equipment funtioning

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 11

4.5 Boiler operation

The equipment goes into operation automatically when heat is required due to its built-in automatic ignition.

The heat requirement can be weather-driven, and can be used in conjunction with a remote sensor (optional) from any heating circuit. It is also possible to generate demand using a room thermometer. The boiler can also switch on the equipment via its heat requirement.

The control or local data of the boiler capacity can be adjusted or changed.

The regulation prevents boiler temperatures falling too low as this can affect the life expectancy of the boiler.

Boiler temperatures that are too high are not permitted for operational safety reasons.

Any elongation fissures on the insulation plates or combustion chamber bricks do not affect their functioning and therefore do not represent a claim against the guarantee.

4.6 Safety devices

These must be dimensioned and installed to conform to ÖN B8133.

The safety valve in the boiler circulation serves as a safety last resort against malfunctions of the equipment.

All legal safety regulations must be adhered to onsite via the authorised specialist company. All legal safety regulations must be adhered to onsite via the authorised specialist company.

Earthing or potential equalisation must be carried out on the machinery for the whole heating system according to EN 60204-1 by an authorised specialist company.

4.6.1 Safety temperature limiter STL

Should the boiler temperature exceed 95°C, the equipment must be switched off for safety reasons. The safety temperature limiter locks in this event.

Possible causes may be:

 Performance decrease in the boiler was

interrupted abruptly. This can occur due to the switching off of a pump or sudden shutting of the heating circuit mixer.

 The load pumps are being controlled by the

HERZ Control. The so-called excess temperature flue gas would be automatically activated by the HERZ Control. This avoids higher boiler temperatures.

 The boiler is too large.  The fuel level is set too high.  Loss of power supply  Etc.

Firstly the cause of the failure must be found and corrected and only then can the safety temperature limiter be unlocked.

The boiler temperature must be under 75°C before unlocking.

Only after this can the malfunction be rectified. To do this the covering of the safety temperature limiter must be unscrewed. Through gentle pressure using a sharp object the safety temperature limiter can be unlocked again. After the cover unscrewed the rectification of the fault must be carried out via the control box. The safety temperature limiter is located right from the operating terminal.

4.7 Start-up

The first start-up must be carried out by HERZ factory customer service or an authorised specialist (Otherwise the guarantee becomes invalid).

Besides this the low pressure in the flue pipe connecting piece of the boiler is measured after firing with the designated solid fuels at least one hour during running time and an advance flow temperature of 70-85°C is achieved.

It can thereby be determined whether feed pressure for the correct operation of the boiler

(formerly described as draw requirement“) has set

itself. If the existing chimney has not been measured correctly or if the calculated chimney values have not been met (inappropriate connection, entry of secondary air, connection piece too long, etc.) deviating values will result and it will not be possible to operate the boiler correctly.

During start-up and handover to the operator, the functioning of all control and safety equipment must also be monitored and the operation and maintenance of the boiler and equipment must be explained to the operator in detail.

The hydraulic balancing of the equipment (pipe installation) must be carried out by an authorised specialist company (installer). It is also the duty of the installer (according to ÖNORM 12170) to create documentation for the complete system and this must be deposited in the boiler room.

Equipment funtioning

12 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

4.8 Operating temperatures and

impermissible temperatures

4.8.1 Boiler temperature

The HERZ pelletstar boiler is operated at a boiler temperature between 65 und 90°C. If the return flow temperature is below 55°C some of the flue gases condense on the inside of the boiler. When the boiler is started up, the operating temperature (from 65 to 90°C) must therefore be reached as quickly as possible in order to avoid condensation. The return flow temperature may also be under the permissible value at correct boiler operating temperature. This condition should be avoided by a functioning increase in return flow temperature (at least 55°C, or preferably 60°C).

Note!

All guarantee or warranty claims are invalidated in the event of damage from corrosion arising due to impermissible operation temperatures.

4.8.2 Return flow temperature

The return flow temperature must increase to over 55°C (60°C) as quickly as possible, depending upon the type of boiler. Retention of the temperature level for the return flow or the boiler temperature is achieved using a so-called return flow bypass or return flow temperature maintenance. In this the advance flow water, for example, is admixed via a pump and the appropriate valve.

The heat energy of the boiler can only be used from the time that the return flow temperature has exceeded 60°C.

4.8.3 Boiler temperatures that are too

high

The HERZ pelletstar boiler can be operated up to a maximum boiler temperature of 90°. If the performance of the boiler is suddenly reduced (mixers shut off, hot water tank load pump switches off) it is sometimes the case that the saved heat energy in the boiler heats up the heating water above this value.

In the pelletstar equipment there are three safety measures installed in order to prohibit a further increase in temperature:

 Excess temperature outlet (above 92°C boiler

temperature) From this temperature the consumer pump is

switched on in order to divert the excess heat energy. To do this, the loads are set to their maximum value. The precondition for this is that these are controlled using HERZ controls. Should this not be the case then

there is a greater probability that the boiler will overheat and result in a breakdown.

 Thermal flow protection

No thermal overload safety device is required for the PS 10, 20 and 30 systems. Pelletstar 45-60 systems have a safety heat exchanger installed in the boiler to which a thermal overload safety device must be connected.

 Safety temperature limiter – STL (above

95°C boiler temperature) The equipment is switched off above this

temperature. The safety temperature limiter locks itself and the equipment operation. A breakdown is indicated and the equipment stops.

4.8.4 Flue gas temperature

The flue gas temperature depends upon the operating condition of the equipment, the fuel, the ventilator setting and the type of boiler.

Therefore applies: The chimney must not be sensitive to moisture

and must be calculated and dimensioned according to DIN 4705 or EN 13384. HERZ does not carry out chimney calculations. This calculation must be carried out by an authorised specialist company. A chimney that is incorrectly designed may lead to malfunction of the equipment.

Operating conditions

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 13

5 OPERATING

CONDITIONS

Heating off

In this condition the equipment is switched off, i.e. the burner is blocked.

Ready

The boiler or buffer temperature is sufficient to sustain the loads or the boiler temperature has reached the switch-off temperature.

Prepare ignition

In this condition the grate has been cleaned and the lambda probe pre-heated.

Pre-ventilate

This condition serves to flush the combustion chamber and the chimney with air.

Cold start

If the boiler room temperature is below the boiler room ignition identifying temperature (standard 150 °C), a cold start is carried out. Materials are pushed in at intervals. At the same time the material is ignited by the ignition fans. During the ignition phase there is a check as to whether the ignition was successful.

After successful ignition, the equipment changes over to the burning phase. At the same time the final ignition fan phase is carried out. During the final ignition fan phase the ventilator of the ignition fans runs for a minute longer in order to cool down the heating element.

Should there be no ignition in the maximum ignition period (3 x the set time) then the equipment is switched off using the remote status signal => F: IGNITION (see Error 66)

Scorch phase

This phase serves to achieve an even fire bed. The length of the phase is set in the fuel values (only in the service area available). Care should be taken here that combustion takes place with a higher surplus of oxygen. This serves to achieve the desired even fire bed more quickly. This phase should not be set for longer than 5 minutes.

Run up phase

In the run up phase the equipment runs at rated output. When the boiler temperature is reached it then goes over to the control phase.

Control phase

In this phase the boiler is modulated between nominal load and partial load. When the partial load stage generates too much energy, i.e. the target boiler temperature + regulation hysteresis are exceeded and are then changed to the ready condition.

Burn out phase

When the boiler switches off, then the fuel remaining in the combustion chamber is burnt out. Care should be taken here that this time is set exactly, as otherwise it is possible that material present in the combustion chamber will not be burnt correctly.

Burner cleaning

During burner cleaning the burner is cleaned of ash. Firstly the fuel is burnt out. When the burnout time is completed, then the burner plate is cleaned. After successful cleaning the equipment goes back into normal mode. The interval is calculated via the runtime of the plug-in screw.

This can be set via the “Cleaning interval”

parameter in the service area, i.e. in order to achieve more frequent cleaning of the combustion chamber the parameter simply has to be shortened.

Heatexchanger cleaning

Heat exchanger cleaning serves to increase the degree of efficiency. Here the heat exchanger is automatically cleaned and the fly ash falls into the so-called fly ash chamber. The interval and duration of the cleaning can be set in the service

area via the “HEC INTERVAL” or “HEC

DURATION”.

Output control

The output control is controlled within the boiler target temperature and the control end phase. The control end phase is the boiler target temperature + control hysteresis. When the control end phase is reached the equipment goes to burnout.

Flue gas temperature control

When the maximum flue gas temperature is exceeded, then the output of the equipment is reduced. If the temperature is not reached the equipment goes back to normal output control.

Flame monitoring

Where the combustion values fluctuate too greatly during operation, this is detected and the equipment is switched off.

Operating conditions

14 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

Frost protection

When the equipment goes into frost protection then the return flow bypass pump is switched on

provided that the equipment is in “HEATING OFF”

or “BURNER STOP” condition. Otherwise the

equipment is started up and started up to a minimum temperature of 65°C.

Lambda control

The amount of material and the suction ventilator are controlled via the lambda control. This serves to optimise the combustion and can detect slight fuel fluctuations. Therefore, it is not necessary to re-set the combustion after the silo is filled.

Temperature manager

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 15

6 TEMPERATURE MANAGER

The control of the heat demands of the individual modules (=heating circuits) happens with a so-called temperature manager. To understand the operation of the temperature manager the scheme which is illustrated in Figure 6.1 is used. It can be seen that a module has inputs and outputs. The module gives a so-

called temperature demand to his “heat supplier”. This temperature demand is the sum of an internal

calculated temperature demand and an adjustable temperature increase. The heat supplier must provide this temperature demand to the modules.

The heat supplier (= heat generator resp. boiler/buffer) which gets the information’s of the temperature demand of the modules must provide heat to the individual modules. Thereby the maximum of the temperature demands of the individual modules is generated. These modules will receive the existing temperature.

Example:

Heat supplier = Boiler Module 1 & 2 = Heating circuit 1 & 2

Heating circuit 1

Heating circuit 2

Buffer

calculated required temperature in °C

Temp. increase in °C

5 3 0

Required temperature of the

modules in °C

Required temperature

(=maximum formation)

Module 2

(Consumer)

Temp.existing

Temp.required

+ Temp increase

OUTPUTS

INPUTS

Buffer

Temp.existing

OUTPUTS

INPUTS

Temp.existing

Temp.required

Module 1

(Consumer)

Temp.existing

Temp.required

+ Temp increase

OUTPUTS

INPUTS

Heat supplier

(Boiler)

Temp.existing

Temp.required

+ Temp increase

Figure 6.1: Temperature manager

Description of the menu navigation system and settings

16 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

7 DESCRIPTION OF THE MENU NAVIGATION SYSTEM AND

SETTINGS

In this chapter all menu pictures are shown, which occur on the Touch-display. The individual terms, which are visible on these menu pictures, are explained in chapter 8 – Terms and definitions (starting on page 58). To find a term and its explanation, the pictures are labelled. The same labelling is also shown in chapter 8 – Terms and definitions (starting on page 58).

7.1 Starting the system

To switch on the display, the following condition must be met:

 The boiler must be connected with the following plug to the power supply (see Figure 7.1)

If this condition is fulfilled, the starting process of the display, which takes 1-2 minutes, begins.

Figure 7.1: Plug on the boiler for the connection to the power supply

Description of the menu navigation system and settings

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 17

7.2 Main menu

After the starting process of the display, Figure 7.2 appears. In the middle of the screen important values for boiler, buffer, hot water tank, heating circuit, and so on, are shown, which can be adapted individual (see chapter 7.8).

Figure 7.2: Main menu

By touching the following button

the main menu will be displayed.

(see Figure 7.2)

fault messages (warnings & alarms) will be displayed.

(see Figure 7.16)

the individual modules (boiler, hot water tank, buffer, heating circuit, solar, Hydr. compensator, net pump, zone valve, ext. demand) will be displayed.

(see Figure 7.17)

the menu settings (network configuration, E-Mail, screen saver) will be displayed.

(see Figure 7.96, visible only with code!)

you can set and modify date & time.

(see Figure 7.8, Modification only with code!)

you will be taken to the code entry screen.

(see Figure 7.4)

the heating system can be switched on/off. (see Figure 7.6 and Figure 7.7) In general the field is used to display the operating conditions, which are shown in chapter 5.

you will be taken to the second page of the value overview on the main menu.

Description of the menu navigation system and settings

18 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

7.3 Operation and handling

The touch panel is a touch-sensitive screen and a display and control unit. By touching the screen you can change released values or move to other pages. The touching can be done with finger, pen, pencil, etc.

Figure 7.3: Operation of the screen with fingers or pen

NOTE: The values shown in the individual screenshots are not default values!

7.4 Explanation of the symbols

In this section important symbols are explained, which are displayed on the following menu pictures.

The CHIMNEY SWEEPING FUNCTION is available as a test mode for the chimney sweeper. The boiler is precisely operated using rated output and the chimney sweeper can carry out its test measurements. This condition is exited with deactivation or exceeding of the boiler maximum temperature or where the maximum chimney sweeping time is exceeded. All loads are set to the permissible maximum value. Any measurements should

only be carried out if the “chimney sweeping mode” appears on the display and an

appropriate flame has been formed. Otherwise there is no guarantee that the boiler will demonstrate optimum combustion. It is possible that the boiler will only work in ignition or burning phase.

By the Aggregate-Test the connected components can be tested individually The symbol is only visible, when

the code has been entered (see chapter 7.5, page 19) and the boiler is in the operating condition “Heating off” (only applies to the Agg-test for

the boiler!)

When the Aggregate-Test is active, the symbol turns green and the message “AGG-Test ACTIVE” is shown on the display area of the operating conditions.

Information’s such as firmware-module, hardware-module, software version etc., of each module (boiler, hot water tank, buffer, solar, heating circuit) are shown here.

These symbols (navigation) can be used to navigate between the pages in each module (boiler, hot water tank, buffer, solar, heating circuit, hydr. compensator, net pump, zone valve, ext. demand). An alternative to the illustrated method of navigation is the wiping to the right or left on the screen.

Pressing this button returns you to the overview of the modules (boiler, hot water tank, buffer, solar, heating circuit, hydr. compensator, net pump, zone valve, ext. demand).

Description of the menu navigation system and settings

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 19

7.5 Code – entry

By entering the code, the following can be performed:

 Changing values  Activate the Aggregate-Test (Explanation see chapter 7.4)  Setting or changing date & time (see chapter 7.7)  Navigation is in the menu settings possible (see chapter 7.11)

Navigation:



Screen:

Figure 7.4: Code - entry

Figure 7.5: Editor for Code - entry

By touching the following button:

Note:

Figure 7.5 is displayed.

Enter the corresponding code (see below) and then press „OK“ to confirm.

the main menu will be displayed (if you have already entered a code, this will lock the field that has been changed)

The Code is:

111

the previous page will be displayed

After that, the open padlock-icon appears:

Description of the menu navigation system and settings

20 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

7.6 Switching the boiler on and off

Navigation:

Screen:

Figure 7.6: Switching on the boiler

Figure 7.7: Switching off the boiler

By touching the following button:

the boiler will be switched on.

the boiler will be switched off.

the boiler will remain switched off and the previous page will be displayed.

the boiler will remain switched on and the previous page will be displayed.

Note:

The system can only be switched on if the code (see chapter 7.5) has already been entered.

In all operating states (except cold start or Ready), the system will then proceed to the burnout phase. If the system is switched off during a cold start, the cold start will finish and then the system will proceed to the burnout phase. This will prevent an unacceptably high amount of fuel building up in the combustion chamber.

The system can only be switched on if the code (see chapter 7.5) has already been entered.

Description of the menu navigation system and settings

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 21

7.7 Selecting date and time

Navigation:



Navigation:



Screen:

Figure 7.8: Selecting date and time

Figure 7.9: General settings for NTP

By touching the following button:

ENGLISH

you can select the language to be used.

ENGLISH

you can select the language to be used.

12:42:29

you can set the time.

pool.ntp.org

you can enter the name of the server. (The server gets from the network an IP-address and can so communicate with the network.)

25.04.2013

you can set the date.

UTC+1

you can set the time zone.

you can activate NTP, which means that the time and date will be updated automatically. (Is NTP active, time and date will be updated automatically over the network (=connection of the boiler with the internet via LAN cable).

you can enter the update interval in hours (Date and time can be updated in the entered time interval over the network, i. e. in the case entered the time and date will be updated every 12 hours.)

you can choose between summer and winter time.

NTP Update

you can carry out an NTP update (If you activate that update, time and date will be updated

immediately and you don’t have to

wait for the act. interval). you can lock the screen.

the main menu will be displayed.

Note:

NTP (Network Time Protocol) is used to synchronize date and time automatically over the network.

A valid network connection via a LAN cable and the connection with the internet is required.

In case of power failure:

Is NTP activated, the date and time will be automatically updated after the switching on of the system. Is NTP not activated, the date and time will be updated over an internal memory up to days

(manufacturer’s data). Is the boiler more than 10

days out of service, date and time must be set manually.

Description of the menu navigation system and settings

22 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

7.8 Determining values for the main menu

7.8.1 Adding display values to the main menu

Navigation:



111  OK

Navigation:



111  OK



Show value

Screen:

Figure 7.10: Adding display values

Figure 7.11: Determining display values

By touching the following button:

Show value

an overview will be displayed in which you can load values or add individual values (see Figure

7.11).

Delete actual

you can delete the selected value (see Figure 7.15)

the second page of the main menu will be displayed.

Load scheme

you can load a default diagram (see Figure 7.12)

Delete all

all the display values will be deleted (see Figure 7.14)

BOILER 000

the boiler values which can be selected manually will be displayed (see Figure 7.13)

BUFFER i000

the buffer values which can be selected manually will be displayed

HOT WATER

TANK i001

the hot water tank values which can be selected manually will be displayed

HEATING

CIRCUIT i002

the heating circuit values which can be selected manually will be displayed

TIME MODE

000

the time mode values which can be selected manually will be displayed

SOLAR i004

the solar values which can be selected manually will be displayed

Description of the menu navigation system and settings

Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3 23

Navigation:



111  OK



Show value  Load scheme

Navigation:



111  OK



Show value  BOILER 000

Screen:

Figure 7.12: Load scheme

Figure 7.13: Determining display values

Note:

By touching the following button:

The values of the default scheme can also be adapted individually. Thereby press 3-5 seconds on the value and then follow the procedure described in Figure 7.13.

Boiler-must,

Power, Back

flow-must, etc.

the value will be confirmed so that it will be displayed on the main menu.

the page for selecting the individual modules will be displayed again (see Figure 7.11)

the second page of display values for the boiler or the individual module will be displayed

Note:

The same applies to all other modules.

7.8.2 Deleting display values from the main menu

Navigation:



111



Show value  Delete

all

Navigation:



111



Keep your finger on a random display value for 3-5 seconds  Delete actual

Screen:

Figure 7.14: Delete all display values

Figure 7.15: Delete actual display value

Description of the menu navigation system and settings

24 Betriebsanleitung_PS_10_60_Touch_Englisch_V1.3

7.9 Fault messages and warnings

Navigation:



Screen:

Figure 7.16: Fault messages

By touching the following button:

Actual

current fault messages will be displayed.

Herz pelletstar 10, pelletstar 20, pelletstar 30, pelletstar 60, pelletstar 40 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual