Herz Pelletfire Manuale utente

Operating instructions

Log Wood & Pellet heatingsystem

pelletfire

20-40

Introduction

2 Betriebsanleitung_pelletfire_Touch_Englisch_V1.2

INTRODUCTION

Dear Customer!

Your heating system is powered by a HERZ pelletfire 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 well-

designed 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. 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. 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 commissioning1is 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, Wood pellets for non-industrial use after ENplus, Swisspellet, DINplus or ÖNORM M 7135 resp. pellets

after EN ISO 17225-2; Wood chips after EN ISO 17225-1/4 according to the following specification: Property

class A1, A2, B1 respectively G30, G50 according to ÖNORM M7133 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 04/2015

1Maintenance by the manufacturer

2Recommended hydraulic diagrams can be found in the installation manual while hydraulic balancing will be carried out by the heating

contractor

3Furthermore, the quality of the heating water must be in accordance with ÖNORM H5195 (current version) or VDI 2035

Table of content

Betriebsanleitung_pelletfire_Touch_Englisch_V1.2 3

TABLE OF CONTENT

Page

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

2Warning notes................................. 6

2.1 Installation ..............................................6

2.2 Operation and maintenance...................7

2.2.1 General notes.........................................7

2.2.2 Operation................................................7

2.2.3 Maintenance...........................................7

3Fuels............................................... 8

3.1 Wood chips.............................................8

3.2 Suitable fuels..........................................8

3.3 Not suitable fuels....................................8

3.4 Wood pellets...........................................9

3.5 Storage area...........................................9

3.5.1 Filling......................................................9

5Handling of the heating system ..... 10

5.1 Sealing the boiler..................................10

5.2 Operation with low performance

decrease...............................................10

5.3 Overheating of the boiler......................10

5.4 Sweating of the boiler...........................10

5.5 Taking out of operation.........................10

6Boiler operation............................. 11

6.4 Feeder system (Pellet).........................12

6.5 Type of feed .........................................12

6.6 Combustion air control .........................12

6.7 Boiler operation....................................12

7System.......................................... 13

7.1 Re-heating............................................14

8Fault-free operation....................... 14

9Operating conditions ..................... 14

9.1 Operation mode with log wood.............14

9.1.1 Heating off............................................14

9.1.2 Burning phase......................................14

9.1.3 High running phase..............................14

9.1.4 Control phase.......................................14

9.1.5 Ready ...................................................15

9.1.6 New start-up .........................................15

9.1.7 Re-heating............................................15

9.1.8 Chimney sweeper.................................15

9.1.9 Lambda calibration ...............................15

9.1.10 (password protected)............................15

9.1.11 Flue temperature control ......................15

9.1.12 Lambda control.....................................15

9.1.13 Control curve ........................................15

9.2Operating conditions with pellet ...........16

9.2.1 Heating off ............................................16

9.2.2 Ready ...................................................16

9.2.3 Prepare ignition ....................................16

9.2.4 Pre-ventilate .........................................16

9.2.5 Cold start ..............................................16

9.2.6 Scorch phase........................................16

9.2.7 Run up phase .......................................16

9.2.8 Control phase .......................................16

9.2.9 Burn out phase .....................................16

9.2.10 Burner cleaning ....................................16

9.2.11 Heatexchanger cleaning.......................16

9.2.12 Output control.......................................16

9.2.13 Flue gas temperature control ...............16

9.2.14 Flame monitoring..................................16

9.2.15 Frost protection.....................................16

9.2.16 Lambda control.....................................16

10 Temperature manager................... 17

11 Description of the menu navigation

and adjustment values................... 18

11.2 Starting the system...............................19

11.3 Operation and handling........................21

11.4 Explanation of the symbols...................21

11.5 Code –entry.........................................22

11.6 Switching the boiler on and off .............23

11.7 Date and time .......................................24

11.8 Determining main menu values............25

11.8.1 Adding main menu display values........25

11.8.2 Deleting main menu display values......26

11.9 Fault messages and warnings..............27

11.10 Modules overview.................................28

11.11 Module configuration ............................29

Table of content

4 Betriebsanleitung_pelletfire_Touch_Englisch_V1.2

12 Fault reports and their correction... 68

13 Maintenance schedule (Customer

inspection)..................................... 77

13.4 If required .............................................82

14 CE- DECLARATION OF

CONFORMITY.............................. 83

15 Index............................................. 84

16 Annex............................................ 85

16.1 Additional boiler-module.......................85

16.2 Solar module ........................................87

17 Notes............................................. 93

Safety notes

Betriebsanleitung_pelletfire_Touch_Englisch_V1.2 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!

Warning notes

6 Betriebsanleitung_pelletfire_Touch_Englisch_V1.2

2 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.

2.1 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.

Warning notes

Betriebsanleitung_pelletfire_Touch_Englisch_V1.2 7

2.2 Operation and maintenance

2.2.1 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“.

2.2.2 Operation

General safety notes

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

chapter boiler Status IV)

The noise generated by the machine during

operation does not present any danger to

health.

2.2.3 Maintenance

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!

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.

Fuels

8 Betriebsanleitung_pelletfire_Touch_Englisch_V1.2

3 FUELS

The HERZ pelletfire –boiler should be operated

with the fuels and their properties which are

described in this chapter.

3.1 Wood chips

The HERZ –pelletfire 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

Woodchips

3,5

2,5

3.2 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).

3.3 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...

Fuels

Betriebsanleitung_pelletfire_Touch_Englisch_V1.2 9

3.4 Wood pellets

Wood pellets for non-industrial use after ENplus,

Swisspellet, DINplus or ÖNORM M 7135 resp.

pellets after EN ISO 17225 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 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 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.

Is a different fuel on the order named and explicit

on the order confirmation noted, the system can

also be operated with this fuel.

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

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.

3.5 Storage area

The storage must conform to ÖNORM M 7137:

Filling pipe maximum 30m

Sloping floor 35° - 40°

A rubber mate opposite the blow-in supports

Protection against water and moisture

Dust proof

Fire protection category F 90

Filling nozzle near outside wall

Easy to access

No electrical installation in the storage room

Wall thickness minimum. 12cm on both sides

Plaster or 10 cm cement

3.5.1 Filling

At least 1 hour before filling of the

storage the boiler must be in the

operating condition „Heating

OFF“.

After filling the corresponding lock

cover must be attached.

Handling of the heating system

10 Betriebsanleitung_pelletfire_Touch_Englisch_V1.2

4 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.

5 HANDLING OF THE

HEATING SYSTEM

5.1 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.

5.2 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.

5.3 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!

5.4 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.

5.5 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))

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