Herz Firestar Lambda 18 Manuale utente

Operating instructions

firestar 18 –40 Lambda

Introduction

2 Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6

INTRODUCTION

Dear Customer,

Your heating system is operated using a HERZ firestar boiler unit and we are pleased to be able to welcome

you to the wide circle of satisfied operators of HERZ equipment. The HERZ biomass furnace system is the

result of many years of experience and further development. Please take into account that a good product

also requires the correct service and maintenance, in order to be able to fulfil its function. Therefore, please

read through this documentation carefully –it will be worthwhile. Please take particular note of the safety

notes. Adhering to the operating regulations is a precondition of any claim against the factory guarantee. In

the event of faults, please contact your heating specialist or the HERZ factory customer service.

Yours sincerely

HERZ- Energietechnik

We reserve the right to make technical changes.

Version 01/2014

Table of content

Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6 3

TABLE OF CONTENT

Page

1Safety notes................................... 4

1.1 Warning notes ...................................... 5

1.2 Installation ............................................ 5

1.3 Operation and maintenance................6

1.3.1 General notes.........................................6

1.3.2 Operation................................................6

1.3.3 Maintenance...........................................6

2Fuels............................................... 7

2.1 Suitable fuels........................................7

2.2 Not suitable fuels .................................7

3Starting up a cold system............. 8

4Handling of the heating system ... 9

4.1 Sealing the boiler ................................. 9

4.2 Operation with low performance

decrease................................................ 9

4.3 Overheating of the boiler.....................9

4.4 Sweating of the boiler.......................... 9

4.5 Taking out of operation ....................... 9

5Boiler operation........................... 10

5.1 Preparation for heating up ................10

5.2 Heating up...........................................10

5.3 Energy absorption capacity / STL ....11

5.4 Re-heating...........................................13

6Maintenance and cleaning.......... 13

6.1 De-ashing and cleaning general.......13

6.2 Cleaning of the heat recovery areas

(manual) ..............................................13

6.3 Cleaning of the combustion chamber14

6.4 Cleaning the flue pipe........................15

6.5 Filling shaft –Filling shaft door........15

6.6 Checking the heat exchanger...........15

6.7 Checking the water level for the

heating unit.........................................15

6.8 Keeping the boiler room clean..........15

7Fault-free operation..................... 15

8Boiler status ................................ 16

8.1 Unit off.................................................16

8.2 Burning phase ....................................16

8.3 High running phase............................16

8.4 Control phase .....................................16

8.5 Ready...................................................16

8.6 New start-up........................................16

8.7 Re-heating...........................................16

8.8 Chimney sweeper...............................16

8.9 Lambda calibration (password

protected)............................................17

8.9.1 Flue temperature control ......................17

8.9.2 Lambda control.....................................17

8.9.3 Control curve ........................................17

9Description of the menu

navigation and adjustment values18

9.1 Main menu...........................................18

9.1.1 Structure...............................................18

9.1.2 Display..................................................18

9.1.3 Modify value .........................................18

9.1.4 Code entry (only Service).....................19

9.2 Status menu (S) ..................................20

9.3 Parameter menu (P)............................22

9.4 Aggregate-Test Output (A) ................24

9.5 Aggregate-Test Input (E)....................25

10 Fault reports and their correction26

11 Emission measurement .............. 30

11.1 Measurement notes............................30

11.2 Measurement preparation..................30

11.3 Establish measurement condition

(continous operating state)...............30

11.4 Measurement performance................30

12 EC-Declaration of conformity..... 31

13 Index directory............................. 32

14 Notes............................................ 33

Safety notes

4 Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6

1 SAFETY NOTES

Please read the documentation carefully prior to commissioning and pay particular attention to the

marked safety notes. Please look up in these instructions anything about which you are unsure.

Ensure that you understand the instructions in this manual and that you are sufficiently informed about

the functioning of the biomass furnace system. HERZ is at your disposal at all times for any questions.

For safety reasons the operator must not alter the system, the construction or its condition, without the

agreement of the manufacturer or their authorised representative.

Ensure you have sufficient fresh air entering the boiler room. (Please take note of any regional

regulations or directives).

The tightness of all connecting points is to be monitored before the system is started up.

A portable fire extinguisher of the prescribed size must be placed in front of the boiler room. (Please

take note of any regional regulations or directives).

When opening the combustion chamber doors take care that no flue gas and sparks are released.

Never leave the combustion chamber door open. Toxic gases may be emitted.

Never heat up the boiler with liquid fuels such as petrol or similar.

Carry out maintenance work (maintenance plan) regularly or make use of our customer services. (TRVB

minimum maintenance interval are to be respected)

When maintaining the system or opening the control system the power supply must be interrupted and

the general valid safety regulations respected.

No fuels should be stored outside the equipment in the boiler room Furthermore, the storage of items

not required for operating the equipment is not permitted in the boiler room.

Always use low voltage lamps for lighting the storeroom (these must be approved for use by each

manufacturer).

The equipment can only be operated using designated fuels.

Prior to further transportation of ashes, these must be cooled down for a minimum period of 96 hours

before storage.

If you have any questions, please contact us on telephone no. +43 3357 / 42840-840.

The first start-up must be carried out by HERZ factory customer service or an authorised specialist.

(otherwise guarantee claims are invalid)

The boiler conform the regulation of the Swiss VKF and respectively the particular state regulations

regarding fire prevention. The costumer is fully responsible for the compliance with those regulations.

Safety notes

Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6 5

1.1 Warning notes

Risk of injury from incorrect

handling of the equipment.

Material damage may also

occur.

Warning –hot surfaces

Warning –injury to hands

No access for unauthorised

persons

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 are not in a

position to use the equipment safely due to their

physical, sensory or mental capacities or their

inexperience or lack of knowledge should not use

this equipment without supervision or instruction

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 equipment certain parts

are inevitably under electrical tension or

mechanical stress. Only appropriately qualified

staff may work on the equipment. Staff must be

basically familiar with the content of these and all

other instructions. The smooth and safe use of

this equipment is dependent upon appropriate

transportation and storage as well as designated

operation and careful maintenance. Notes and

indications on the equipment must also be

observed.

1.2 Installation

General notes

In order to guarantee correct functioning of the

equipment, the installation of the equipment must

be carried out with adherence to the relevant

standards and installation regulations of the

manufacturer.

Manufacturer documents for the devices and

components being used the equipment are

available from HERZ upon request.

Safety notes

6 Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6

1.3 Operation and maintenance

1.3.1 General notes

For safe operation and

maintenance of all equipment, it is

assumed that actions will be

carried out appropriately by

qualified staff, taking heed of the

warning notes in this

documentation and the notes on

the equipment.

Under incorrect operating

conditions, temperatures above

80°C could occur at parts of the

casing.

1.3.2 Operation

General safety notes

Coverings that prevent the

moving of hot or rotating parts or

which are required for the correct

supply of air and effective

functioning must not be opened

during operation.

Any faults or unusual operating

conditions such as the emission

of smoke or the appearance of

flames mean that the equipment

must be immediately switched off

using EMERGENCY OFF. The

HERZ factory customer service

must then be notified of this

straight away.

When the main switch at the back of the

boiler is deactivated or if the power supply

fails, the equipment immediately goes out of

operation. The residual amount of fuel burns

independently without toxic gases being

given off, provided that the naturally

occurring chimney draw is sufficiently high.

The chimney must therefore be dimensioned

and designed according to EN 13384. When

resetting the installation it is obligatory to

check for serviceability and to ensure safe

operation of the total installation.

The noise caused by the machinery during

operation does not have any adverse effects

upon the health of people.

1.3.3 Maintenance

General safety measures

Before commencing any work on the equipment,

but particularly before opening coverings of parts

under voltage, the equipment must be enabled

according to the instructions. As well as the main

electrical circuit, any additional or auxiliary circuits

should be noted. The usual safety rules according

to ÖNORM are:

Switch off all poles on all sides

Ensure that they is not switched on again

Check that there is no voltage

Earth and short-circuit

Covering neighbouring live parts and isolate

dangerous parts

The aforementioned measures

may only be retracted once the

equipment is completely installed

and the maintenance completed.

For overhaul work in the

combustion chamber, ash

chamber, on flue gas-carrying

parts, emptying of the ash store,

etc., the use of personal dust

protection masks and gloves is

required.

For overhaul work in the storage

room, low voltage bulbs must be

used. The design of electrical

equipment in the storeroom must

conform to ÖNM7137.

In order to prevent any commissioning errors due

to incorrect maintenance, it is recommended that

regular maintenance servicing be carried out by

authorised staff or the HERZ factory customer

service.

Spare parts may only be obtained direct from the

manufacturer or sales partner. No health risks will

be caused to the customer from noise arising from

the machinery. Details of any residual risks can be

requested from the residual risk analysis from

Herz as required.

Fuels

Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6 7

2 FUELS

The HERZ –firestar is suitable for burning logs to

operate central heating systems for closed hot

water installations. Smaller split logs enable

higher boiler performance than whole ones. We

recommend triangular firewood with side lengths

of 50cm and edge lengths of 8cm. Too coarse or

too long firewood may lead to reduced

performance and hollow fire. The heat value of the

wood is primarily dependent on its moisture

content. The heat value decreases with increased

moisture. The combustion of wood with high

moisture content also causes a decrease in the

degree of efficiency of the boiler.

Wood should therefore be stored for at least two

years in a dry, ventilated place. Oak needs to be

stored for about a year longer. Dry bark displays a

heat value similar to wood but there is more likely

to be increased formation of ash.

The burning of unsuitable fuels could lead to

uncontrolled combustion. The guarantee becomes

invalid! Operational faults and consequential

damage are likely to occur.

Possible consequential damage:

Damage to the thermodynamic combustion

chamber, the lambda probe, the flue gas

probe due to aggressive residues in the

boiler.

Sooting or corrosion in the filling area due to

condensation as a result of using fuel that is

too moist.

The escape of flue gas from the airflow

apertures through uncontrolled combustion

(deflagrations).

Combustion time at nominal load up to

Combustion time in hours

Type

FS 18

FS 20

FS 30

FS 40

Softwood

6,5

3,5

Hardwood

4,5

Wood chips

3,5

2,5

2.1 Suitable fuels

The firewood must be air dried, that is, dried at

least one year with water content below 20%,

preferable half-meter logs with an average

diameter of 10cm. Are the cleavage planes of the

log much longer, according to the log should be

thinner, in extreme cases 20 to 5cm.

Small sized material may be burned only as

admixture. From the smaller material may be

added less. Wood briquette with 6 to 10 cm

diameter according EN 14961-3.

Only one oversized log each boiler filling.

To split a root stock to such thin pieces is very

hard work. Per boiler filling maximum one large

root stock piece are burned up in the stack.

Type of

wood

Calorific values (by wood

moisture 25%) in kWh/ster

Beech

1890

Oak

1930

Pine

1520

Spruce

1330

We recommend the use of beech

wood. Do not mix different types

of wood. The use of one type of

wood promotes a consistent burn-

off. However, if it cannot be

avoided to use different types of

wood, the boiler must be filled in

layers (softwood below,

hardwood above)

2.2 Not suitable fuels

When burning wet fuel with more than 30% water

content, condensation water formation and

corrosion on the walls of the filling chamber occur.

Furthermore should not be burned:

Garbage, plastics, paper and cardboard (only for

starting the fire) sanding dust, wood shavings,

wood chips smaller than thumb-size, coal and

coke, the respective Clean Air Act (state law)

usually prohibited fuels such as old railroad ties,

plastics, particle board, impregnated wood….

Starting up a cold system

8 Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6

3 STARTING UP A COLD

SYSTEM

After a long period of not being used, you should

take particular note of the following points when

starting up the system:

Where the equipment has cooled down, the

boiler requires a proportionate amount of

time to reach temperature if all heat

consumers are switched on during the

heating up process. Therefore, firstly put only

one small heating circuit into operation and

only switch the other heating circuits on when

the boiler has reached its operating

temperature. The first start-up should only be

carried out by HERZ factory customer service

or persons authorised as such.

Handling of the heating system

Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6 9

4 HANDLING OF THE

HEATING SYSTEM

4.1 Sealing the boiler

It is imperative that all doors are closed during

operation so that no leak air can disrupt the

combustion process. If this is not observed then

damage to the boiler may result.

4.2 Operation with low

performance decrease

Should fuel be burned in the transition period

(spring or autumn) it is vital to ensure that for low

decreased performance (less than 50%) the filling

shaft is not completely put on. Decreased

performance of less than 50%, means the boiler

and the chimney may become clogged with soot.

It is also possible that smoke may develop in the

chimney. The firestar boiler should therefore

basically be operated equipped with a correctly

dimensioned buffer (according to EN 303-5).

Recommended dimensions are listed in the

document “installation instructions”.

4.3 Overheating of the boiler

Should the boiler temperature exceed maximum

boiler temperature, the safety temperature limiter

switches the controls off and the warning light

illuminates. After the equipment has cooled off

under about 75°C, the Safety Temperature Limiter

(STL) should be tripped by unscrewing the

covering cap (press the knob). Then screw up the

covering cap again afterwards. Before re-starting

the cause of the overheating should be identified

and corrected.

Thermal flow protection

If the boiler overheats then the “thermal flow

protection” opens automatically (at 95°C) via a

sensor and cold water flows through the heat

exchanger. The boiler water is thereby cooled off

and dangerous operating conditions are

prevented. The water heated up in the heat

exchanger must be able to run away freely

(directly into the waste water channel). After the

boiler water has cooled off to about 90°C the

"thermal flow safeguard” automatically interrupts

the cold water feed. After cooling off, the

equipment pressure and/or water level of the

equipment is to be controlled and if necessary the

missing amount of water topped up. According to

DIN 4751 sheet 2, the operator is obliged to

regulate the functioning of the “thermal flow

safeguard” and the heat exchanger belonging to it

at least once a month by activating the test button.

Furthermore this safety instruction is to be

monitored once a year by the manufacturing

company or another competent organisation.

Note:

Where there is a combined non-functioning of the

“thermal flow protection” and heat exchanger, the

set-up of the equipment is prohibited.

4.4 Sweating of the boiler

During long-term operation it should be

guaranteed that the return flow temperature does

not fall below 65°C. For this reason a return flow

temperature bypass is obligatory.

Note:

Corrosion damage caused by too low return flow

temperatures, do not come under the guarantee

or warranty claims.

4.5 Taking out of operation

The mains switch should not be turned to “OFF”

during the burn-off but only after complete burn-

off. (Status: unit off (1))

Boiler operation

10 Betriebsanleitung_firestar_18-40_Lambda_Englisch_V1.6

5 BOILER OPERATION

5.1 Preparation for heating up

If possible, store enough fuel for two or three

combustion processes near the boiler room.

Prepare firewood

The firewood must correspond to size

(circumference 8 –10cm) and dimensions to the

size of the boiler. Firewood without bark burns

better.

5.2 Heating up

Warning: Risk of system damage

due to improper maintenance!

Wrong position or lack of

firebricks inside the boiler can

lead to damage or destruction of

the boiler.

Before heating up the boiler,

check the position of the

firebricks.

Warning: Risk of system damage

due to improper maintenance!

Excessive fuel feeding can cause

overheating and damage to the

boiler.

Adapt the amount of fuel to

the energy absorption

capacity of the heating

system.

Crucial for the clean burn-off in

the boiler are the correct

operation of the boiler as well as

a sufficient feed pressure of the

exhaust system.

In the following a possibility for the heating up of

the boiler is described. Depending on the ambient

conditions (draft, exhaust system, wood, and so

on) other heating up processes may be better.

Get familiar with the boiler and find out the best

handling for you to use. Test the best opportunity

for heating up the boiler.

Please note always the safety notes!

Switch on the main switch [2] and regulator

(On/Off –button, page 18). The regulator

displays status 1.

1 … Cable bushing

2 … Main switch

3 … Electric supply

After the casing door is opened the “burning”

phase (Status: 2) starts automatically.

If it is not desired or necessary to

heat up the boiler, this process

can be interrupted with a long

press of the On/Off button.

To form a good flame it is recommended that

the lower third of the filling shaft be filled with

small pieces of wood.

After that normally chopped wood (size

around 8cm) can be used for filling.

Then open the lighting up door (4) and light

up with an oil ignition, wood shavings or

cardboard.

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