Herz BioFire 500 Manuale utente

OPERATING INSTRUCTIONS

Wood chips & pellets heating system

BioFire

500

600

800

1000

1250

1500

Introduction

2 Betriebsanleitung_BioFire_500-1500_T-Control_2_eng_V1.0

INTRODUCTION

Dear Customer!

Your heating equipment is powered using HERZ BioFire boiler equipment and we are delighted to be able to

welcome you into the large circle of satisfied operators of HERZ equipment. 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 well-designed product also needs to be operated and maintained correctly. Please therefore read

this documentation carefully –you will find it worthwhile. Please pay particular attention to the safety notes. It

is a precondition of any warranty claim that all operating rules are maintained. 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. We generally guarantee freedom from defects of mobile objects purchased for a period of 2 years,

to a maximum of 6.000 hours of operation. For non-moving purchased items, the guarantee is generally for a

period of 3 years to a maximum for 9.000 hours of operation. Wearing parts are not covered by the

guarantee/warranty. Furthermore, claims under warranty will not be applicable if there is no return flow

temperature boost or it is not working properly, if commissioning

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 diagrams

not recommended by HERZ are used and if a non-prescribed fuel

as well as pellets for non-industrial use according to ENplus, Swisspellet, DINplus resp. EN 17225-2; wood

chips according to EN 17225-1/4 with specification and classes: A1, A2, B1 resp. G30, G50 resp. log wood is

used

All business is subject to the general terms and conditions of HERZ Energietechnik GmbH as well as the

agreements confirmed with the order acceptance.

These are available at www.herz-energie.at .

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. A guarantee claim

does not delay the due date of our accounts. 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 03/2022

Maintenance by 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 H 5195 (current version) or VDI 2035

Table of content 
 
 

TABLE OF CONTENT 
Page 
 
page 
 
 
 
1SAFETY NOTES....................................4 
1 Basic safety information.............................5 
2 Installation ...................................................5 
3 Operation and maintenance.......................5 
3.1 General notes................................................5 
3.2 Operation ......................................................5 
2WARNING NOTES ................................6 
3FUELS....................................................7 
1 Wood chips..................................................7 
2 Wood pellets................................................7 
3 General fuel properties...............................7 
4 Unsuitable fuels...........................................8 
5 Fuel change .................................................8 
4SAFETY DEVICES ................................9 
5SYSTEM...............................................10 
1 System overview .......................................10 
2 Boiler..........................................................11 
6MODE OF OPERATION ......................12 
1 Feeding system .........................................12 
2 Feeding type..............................................12 
3 Combustion air control.............................12 
4 Boiler operation.........................................12 
5 Commissioning .........................................12 
6 Operating and impermissible 
temperatures..............................................13 
7OPERATING CONDITIONS ................13 
8TEMPERATURE MANAGER ..............15 
9MENU NAVIGATION AND 
ADJUSTMENT VALUES.....................19 
3 Main menu .................................................20 
4 Symbols explanation ................................21 
5 Code –entry...............................................22 
6 Switching the boiler on and off 
(Chimney sweeping function) ..................23 
7 Date and time.............................................24 
8 Main menu values .....................................25 
8.1 Adding / defining display values..................25 
8.2 Delete values...............................................26 
9 Fault messages and warnings .................27 
10 Modules......................................................28 
11 Module-configuration................................29 
12.1 Boiler ...........................................................30 
12.2 Buffer...........................................................36 
12.3 Hot water tank .............................................38 
12.4 Heating circuit..............................................40 
12.5 Time mode...................................................45 
12.6 Solar............................................................46 
12.7 Hydraulic compensator................................48 
12.8 Net pump.....................................................49 
12.9 Zone valve...................................................51 
12.10 External requirement ...................................52 
12.11 Additional boiler...........................................55 
13 System settings.........................................57 
13.1 Network configuration..................................58 
13.2 Modbus –settings .......................................59 
13.3 Screensaver ................................................60 
13.4 Remote........................................................60 
13.5 Information overview....................................61 
13.6 Sending E-mails ..........................................61 
13.7 Mail Server settings.....................................63 
13.8 E-Mail status report......................................63 
13.9 Service special ............................................64 
13.10 Cascade ......................................................64 
FAULT REPORTS AND THEIR 
CORRECTIONS...................................65 
1 Not indicated faults ...................................75 
MAINTENANCE SCHEDULE..............76 
1 Weekly Inspection .....................................76 
2 Monthly inspection....................................76 
3 Biannual inspection...................................79 
4 Annually inspection...................................80 
5 Lubrication schedule (customer 
inspection after operating hours) ............81 
6 As needed ..................................................85 
EU DECLARATION OF CONFORMITY86 
1 Correct disposal of this product ..............87 
INDEX DIRECTORY ............................88 
ANNEX.................................................89 
1 Additional boiler module...........................89 
2 Solar module..............................................91 
NOTES .................................................97 

Safety notes

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. Check all screw connections for strength.

◼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.

◼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 storage room is to be protected against unauthorised access.

◼Always disconnect the power supply if you need to enter the fuel storage room.

◼Always use low-voltage lamps in the fuel 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.

◼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 fuel storage room for ~ 60 minutes before trespassing /Please refer to the respective country

regulations).

◼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

1.1 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 safety 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.

1.3 Operation and maintenance

1.3.1 General notes

Don´t open the boiler doors until

“HEATING OFF” is displayed,

otherwise a risk of deflagration

(explosion) is given.

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.

In unfavourable operating

conditions, the temperatures of

parts of the housing may exceed

80 °C.

If the door to the ash container is

opened during operation, the fuel

supply will be shut off and the

boiler will switch to the burnout

phase. Afterwards the boiler will

switch to the operating mode

“HEATING OFF”.

Ambient conditions

Operating temperature:

+10 to +40 °C

Warehouse-/ transport

temperature:

-20 to +70 °C

Humidity:

operation

5 to 85 %

storage

5 to 95 %

1.3.2 Operation

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 or flames, the

system is to be switched off

immediately by operating the

emergency stop button. Notify

the HERZ Customer Service

department immediately.

◼If the boiler room door main switch is operated

or if a power failure occurs, the system will be

taken out of operation immediately. The

remaining quantity of residual fuel will burn

independently without giving off any toxic

gases, if the chimney draught is sufficiently.

Therefore, the chimney must be designed and

produced in accordance with DIN 4705 or EN

13384. When the boiler is switched on again,

the system has to be checked in order to make

sure that it is fully functional and a safe

operation of the whole system must be

guaranteed!

◼The generated system noise during operation

does not present any danger to the operator´s

health.

◼If the residual flue gas oxygen content drops

below the required minimum of 5 %, the fuel

supply will be stopped automatically and will

not be activated again until the residual oxygen

content has risen to more than 5 % (fault text:

MIN O2 [%] 5.0. see chapter maintenance

Warning notes

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 in the combustion

chamber or the ash collector or on

flue gas-carrying parts and when

emptying the ash container, etc.!

Extra-low-voltage lamps are to be

used when carrying out

maintenance in the fuel storage

room. Electrical equipment in the

fuel storage room must be

designed in accordance with

ÖNORM_EN_ISO_20023!

In order to prevent any maintenance errors, if

maintenance is not carried out properly, it is

recommended to be carried out regularly by

authorised personnel or by the HERZ Customer

Service department.

Spare parts must be obtained directly from the

manufacturer or a distribution partner. Due to the

noise caused by the machine, the customer is not

exposed to health risks.

2 WARNING NOTES

Risk of injury and damage to

property due to improper

handling of the system. Damage

to property is possible.

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 safety notes

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.

Fuels

3 FUELS

3.1 Wood chips

Wood chips for non-industrial use with low fines

content according to EN 17225-1/4 with following

specification:

◼Property class A1, A2, B1

◼Particle size P16S, P31S and P45S

•G30 resp. G50

◼Water content min. 15 % to max. 40 % *

◼Ash content in m-%: <1.0 (A1), <1.5 (A2), <3.0

(B1) m-%

◼Calorific value at as-delivered condition >

3,1 kWh/kg

◼Bulk density (BD) at as-delivered condition >

150 kg/m³

The property classes A1 and A2 represent fresh

wood and chemically untreated wood residues. A1

contains fuels with low ash content, which

indicates little or no bark and fuels with lower

water content, while class A2 has a slightly higher

ash content and/or water content. B1 extends

origin and source of class A and includes

additional materials, such as short rotation

plantation wood, wood from gardens and

plantations etc., as well as chemically untreated

industrial wood waste. Class B2 also includes

chemically treated industrial wood waste and used

wood.

3.2 Wood pellets

Wood pellets for non-industrial use according to

ENplus, Swisspellet, DINplus resp. pellets

according to EN 17225-2 with following

specifications:

◼Property class A1, A2

◼The maximum permissible fines content in the

fuel storage room must not exceed 8 % of the

fuel volume (determined using a perforated

screen with holes 5 mm in diameter)!

◼Fines content at loading: < 1.0 m-%

◼Calorific value at as-delivered condition >

4,6 kWh/kg

◼Bulk density (BD) at as-delivered condition >

600 kg/m³

◼Mechanical Strength (DU), EN 17831-1 at as-

delivered condition in m-%: DU 97,5 ≥ 97,5

◼Diameter 6 mm

The nominal power and the emission values can

be guaranteed up to a maximum water content of

Only if using an agitator with 3x400 Volts

* at execution @M50 to water content 50%

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 < 3,5 kWh/kg a reduced output is

expected.

Prevent the entering of debris such as stones

or metal particles into the system! Sand and

soil lead to higher level of ash and slagging

precipitation.

There may be a formation of slag according to the

fuel quality, which has 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.

If a different fuel is named explicitly on the order

respectively the order confirmation, the system

can be operated with the mentioned fuel.

Note: The system is set to the agreed fuel at the

commissioning. This setting (ID-fan speed, fuel,

flow and backflow, cycle times, etc.) should not be

changed when using constant fuel quality.

3.3 General fuel properties

Calorific value (Minimum calorific value (Hu) of the

fuels to be used):

•6-20% wt M20 water content „W20“: 4,0kWh/kg

•21-30% water content M30 or „W30“: 3,0kWh/kg

•31-40% water content M40 or „W40“: 2,5kWh/kg

•41-50% water content M50 or „W50“: 2,5kWh/kg *

Calorific value (Minimum calorific value (of the

fuels to be used)) E = 800kWh/m³

Minimum heat consumption (Permanent minimum

heat consumption (24 hours) to maintain the

combustion):

•20% the nominal output for dry fuelM20 or „W20“

•40% the nominal output for wet fuel M40 or „W40“

•40% the nominal output for wet fuel M50 or „W50"

Fuels

Fuel variability: In order to ensure the stability of the

combustion and power output of the boiler, a gradual

change in the fuel (heating value Hu, sizes, density,

water content) is accepted, which does not exceed 10%

of each value mentioned in less than 30 minutes.

3.4 Unsuitable fuels

The burning of unsuitable fuels could lead to

uncontrolled combustion. Operational faults and

consequential damage are likely to occur.

Possible consequential damage:

−Damage to the thermodynamic combustion chamber,

the lambda probe, the flue gas sensor and the

combustion chamber sensor 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).

3.5 Fuel change

If you use a different fuel type as specified mind:

•allowed fuels (see clean air act)

•Water content and the fuel size are in

admissible range.

•it is eventually necessary the adjustment of

the blower engine speed and fuel level

adjustments to tune new.

Safety devices

4 SAFETY DEVICES

The safety devices must be dimensioned and installed according to ÖNORM EN 12828.

The safety valve in the boiler circulation serves as a final safety device against malfunctions of the

equipment.

All legal safety regulations must be adhered to on-site via the authorised specialist company.

Earthing or potential equalisation must be carried out on the whole heating system according to EN 60204-1

by an authorised specialist company.

1 Safety temperature limiter

If the boiler temperature exceeds 95 °C, the

equipment must be switched off for safety

reasons. The safety temperature limiter (STL) will

lock in this case.

Possible causes may be:

◼Performance decrease in the boiler was

interrupted abruptly. This can occur due to

the switching off 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.

At First the cause of the failure must be found and

be corrected, afterwards the safety temperature

limiter can be unlocked.

The boiler temperature must be lower than 75

°C before unlocking.

Only then the problem can be acknowledged. For

this purpose, the cover of the STL is screwed off.

The STL can be unlocked by a light pressure with

a sharp object. After unscrewing the cover the

fault acknowledgement must be performed at the

switch box. The location of the STL is on the left

side next of the display.

2 and 3 automated extinguishing devices

The Boiler features an automated extinguishing

device. The device consists of a thermal safety

valve, a thermostat valve (3) and a water tank (2).

If the feeding screw temperature gets exceeded,

the valve opens independently and flushes the

feeding pipe. This extinguishing device is used as

a safety device at burn back.

4 Burn-back safety unit

The burn-back safety unit prevents a burn-back

into the fuel storage room. It separates

additionally the combustion chamber and the fuel

storage room. The burn-back safety unit is

conducted like a fire flap. It opens only when fuel

is fed to the boiler.

5 Safety valves

The safety valve automatically releases, when the

pressure or temperature exceeds preset limits.

The safety valve has to release at the maximum

allowable pressure (according to boiler plate).

6 Safety heat exchangers

The safety heat exchanger is a built in safety

device and has to be connected to a thermal

release valve and installed, according to applied

standards. The safety heat exchanger has to be

connected directly to a cold water pipe (pressure

≤ 3 bar)

7 Ash container and burning chamber

safety device

The ash containers are connected contact-free

(inductive sensor) to the boiler.

Fuel storage room temperature monitoring

The fuel storage room temperature monitoring is

placed directly above the transport screw. There

is placed a temperature sensor which is setting to

the release temperature. If the storage room

temperature exceeds its preset limit, the boiler will

switch to the operate condition „HEATING OFF“

and displays a fault report. Additionally, a fault

sensor output gets active. Conduct alerting in

accordance with national standards.

System

5 SYSTEM

5.1 System overview

Figure 5. 1 an example of a system with the following components is shown:

(1) Discharge system

(2) Boiler

(3) Ash discharge system

(4) Fuel storage room

(5) Drop shaft

(6) Burn back protection device

(7) Intermediate hopper

(8) Dust extractor

(9) Ash container

In the present case, the discharge is a 3-row hydraulic walking floor, cross auger and vertical auger (1).

Please consider that the installed room discharge and storage room filling system can be different to the

displayed system. If all discharge and storage room filling systems of HERZ would be presented, the scope

of this guide would be exceeded considerably. More information can be provided by the company HERZ.

Figure 5. 1: System overview (Example with walking floor)

In the following chapter the boiler (2) and the room discharge system (3) and its individual components are

described and displayed.

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