Operating instructions - PDF Free Download

ENG Operating instructions Wood burning boiler AgroLyt (20-50) Hoval Export Austrasse 70 9490 Vaduz Principality of Liechtenstein Phone: +423 399 2400 Fax: +423 399 2618 Export@hoval.com Hoval LTD Northgate Newark Nottinghamshire NG24 1JN Phone: 01636 672 711 Fax: 01636 673 532 4 205 193 / 00-06/06 Subject to modifications

Overview of contents 4 205 193 / 00 Information about your heating system... 3 Important notes... 4 Function...5-7 Heating system control...8-19 - N5.1 controller... 10-13 - N5.2 TopTronic lambda controller... 14-19 Start-up (heat-up phase)... 20 Reloading (wood refilling)... 21 Suitable and permitted fuels... 22 Cleaning the heating boiler...23-24 Maintenance and checks / Shutdown... 25 Check list in case of faults... 26 Error message checklist for TopTronic lambda controller...27-28 How you can save energy... 29 Brief operating instructions... 31 2

4 205 193 / 00 Information about your heating system Dear Heating System Owner, With the purchase of this Hoval AgroLyt wood burning boiler, you have made an excellent choice. This boiler - in conjunction with a domestic hot water storage tank - offers you all the advantages of a modern and efficient heating system. Please read these instructions carefully. They describe how the heating boiler works, how it is operated and maintained. Further information can be obtained from our Sales and Service Centres (see last page for contact details). Important addresses and telephone numbers Heating installer Plumbing installer Electrical installer Chimney sweep INTENDED USE The AgroLyt wood burning boilers were designed for firing air-dried naturally seasoned logs in the most optimal manner. The boiler may not be used for burning waste, coated wood and saw dust. It is also not intended to be utilised for direct heating of the boiler room. AgroLyt wood burning boiler To be completed by the heating engineer: Serial No.: Order No.: Boiler type: Boiler power rating: kw Domestic hot water storage tank size: Water heater size: Heating controller type: Heating pump type: Mixing valves type: Calculation basis for heating system Lowest outdoor temperature: C Thermal output required: kw Max. flow temperature: C 3

Important notes 4 205 193 / 00 = Safety information: (Information on personal protection) Keep open the air supply into the room: air supply and exhaust openings may not be closed. This is important to ensure that the combustion air required for the correct operation of the heating boiler can flow unhindered and to protect the operating personnel from an oxygen depleted atmosphere. Never operate the boiler with open doors. Any sparks emitted from the boiler could cause a fire and damage the boiler. While the boiler is in operation, the doors may only be opened during start-up and for refilling purposes. This should be done very slowly and carefully. Sparks and tongues of flame can emerge through the door. In case of power failure: Do not open any door and do not refill with wood. Daily and monthly cleaning of the system is necessary and must be carried out; otherwise any possible warranty claims may be rejected. If you have any doubts on the operation of the boiler, call the heating engineer or the Hoval customer service. Parents must keep their children away from the boiler room (the heating system is not a toy). Do not burn unsuitable fuels (see page 22), otherwise any possible warranty claims may be rejected. = Warning information: (Information on the protection of the heating system) Controlling the water level Control the water level in the system at regular intervals (page 25). Flue gas temperature If the flue gas temperature exceeds 230 ºC for a longer period of time, it will be necessary to clean the boiler or change the primary air setting (see page 12). Circulation pumps During the time periods when no heating is required, the circulation pumps should be operated at least once every month for approx. 2 minutes. This will effectively prevent the pumps from getting stuck. Gas tightness Check the doors for gas tightness every month. Smoke leaks should be avoided in order to prevent any poisonous smouldering gases from escaping into the boiler room. The door hinges have to be readjusted in case of leakage; see technical information / installation instructions. Cleaning Periodic cleaning and inspection by the heating engineer or the Hoval customer service not only extend the useful life of the wood burning boiler, but also increase its operating safety and ensure that high combustion efficiency is maintained. Protection of the boiler heating surfaces Do not use any sprays, solvents, chlorine based cleaning products, paint, glue, etc. in the proximity of the heating boiler. These substances can cause corrosion within the boiler and the flue gas system. Thermal safety valve, forced draught fan, draught damper and safety valve Correct functioning must be checked periodically by the heating engineer. Do not make any modifications to the system (possible danger to persons; warranty claims may be rejected). 4

4 205 193 / 00 Function Functional description of the heating system It is important that the perfectly coordinated individual components function properly at all times to ensure that your home stays warm in winter. COMPONENTS Wood burning boiler FUNCTION: Burns the wood safely and environmentally friendly. Extracts the heat from the combustion gases and transfers it to the heating water. Wood The wood is combusted within the heating boiler to release and convert the natural energy contained therein into heat. Domestic hot water storage tank It is used as an intermediate storage of hot heating water (max. 90ºC). It compensates any differences between heat generation and demand. Storage tank water heater It holds a reserve of domestic hot water for consumption (e.g. for showering). Boiler control unit Controls and monitors the operation of the heating boiler. Heating controller Adjusts the room temperature optimally and fuel efficiently, independently of the outdoor temperature. Radiator or underfloor heating Releases the heat of the heating water into the room. Heating pump Transports the heating water from the heating boiler to the radiators and back into the heating boiler, where it is reheated. Heating water and heating pipes Transport the generated heat from the heating boiler to the radiators. 5

Function 4 205 193 / 00 Mixing valve Adjusts the heating flow temperature to the radiator to maintain the desired room temperature, independently of the outdoor temperature. This is achieved by admixing colder return heating water. Flue gas thermometer Indicates the boiler flue gas temperature. Pressure gauge Displays the hydraulic pressure in the heating system. Air bleeder Eliminates any air from within the heating pipes. Safety valve Prevents overpressure in the installation. Diaphragm expansion tank Maintains constant the pressure in the system and accepts the expanding water. Depending on the selected type of heating system, some of the components can be missing or some might be added. The heating engineer will explain the system to you. Radiator or floor heating Mixing valve Heating pump Flue gas thermometer Water heater Wood burning boiler Domestic hot water storage tank The heating water heated by the boiler is fed into the domestic hot water storage tank from where it is distributed to heat the rooms (radiators) or for heating the domestic hot water (water heater). 6

4 205 193 / 00 Function What happens inside the AgroLyt? The Hoval AgroLyt is a state-of-theart, environmentally friendly wood burning boiler that operates with 3- stage combustion technology. The fuel is introduced into the loading chamber through the fuel loading door. The AgroLyt bottom combustion system operates on the basis of three combustion stages: 1. Primary air is supplied to the loading chamber, drying the wood and causing its gasification. 2. The combustible gases flow through the layer of embers into the combustion chamber cone. 3. The hot gases are mixed with the secondary air in the adjacent refractory-lined vortex combustion chamber, where they are completely combusted. The hot flue gases are subsequently passed through and toward the back of the vortex combustion chamber and, from there, in upward direction through the downstream heating surface, where they transfer the heat to the heating water. From there the flue gases pass through the flue gas collector and are finally exhausted into the flue by means of an extractor fan. 13 Extraction of smouldering gases: The AgroLyt is equipped with a smouldering gas extractor which prevents any smouldering gases from escaping while the fuel loading door is open. The extractor operates while the fuel loading door is open. 4 12 15 7 11 8 14 9 16 10 1 2 Figure 3 1 Fuel loading door 2 Combustion chamber and ash removal door 3 Lighting and stoking door 4 Smouldering gas extraction 5 Primary air regulation 6 Secondary air regulation 7 Loading chamber 8 Grate and grate openings 9 Combustion chamber cone 10 Vortex combustion chamber 11 Ash chamber 12 Thermolytic downstream heating surface 13 Fan 14 Cleaning aperture 15 Flue gas adapter pipe 16 Thermal safety valve 4 5 6 3 Figure 2 7

Heating system control 4 205 193 / 00 Heating system control What is the function of the heating controller TopTronic T (optional)? The boiler control unit and the temperature sensor connected to it represent, so to speak, the brain of the heating system. The unit s main functions are: - maintaining the desired room temperature independently of the outdoor temperature - heating the living space when required - producing domestic hot water (e.g. for showering) only when required - displaying information Further functions: - allows the input of the desired temperatures - temperature monitoring The correct settings for the heating system have already been applied by Hoval or the installer during commissioning. Any changes to those settings should only be carried out if you go away on a trip or if your home is too cold or too warm. An overview including a section with frequently asked questions/ answers is available in the operating manual of the TopTronic T heating controller. 8

4 205 193 / 00 Heating system control Function of the TopTronic T operating elements (optional) The central rotary pushbutton and the labelled keys are designed for easy and straightforward operation. Rotary pushbutton: Change and store values Function keys Function keys Basic procedure for changing settings An example Select the desired function. Turn the rotary pushbutton to select or change the desired parameter (flashing word or number). Press the Info key at any time to go back to the basic display without storing the values set. Press the rotary pushbutton to store the set value. It is also possible to store the value using the selected function key. 9

Heating system control 4 205 193 / 00 Operating elements of the heating boiler equipped with the N5.1/ZN2 TopTronic T controller 15 10 11 2 14 13 1 7 8 9 12 6 5 4 3 16 18 17 1 2 3 Key Designation Function Main switch ON/OFF Electronic heating controller TopTronic T (optional) Daytime room temperature 0 = Heating boiler OFF; Heating boiler is shut down. I = Heating boiler ON; Heating boiler is operational. Note: The main switch should always be turned on (also in summer when the boiler is not in operation). This will prevent the pumps from getting stuck. Maintains the desired room temperature independently of the outdoor temperature; regulates the output of the water heater. Special brief operating instructions are provided with the heating controller. Further information can be obtained from the detailed operating instructions. Set the daytime room temperature. 4 Reduced room temperature Set the room temperature for reduced heating. 5 DHW temperature Set the domestic hot water temperature. Manual DHW reloading. 6 Rotary pushbutton Change the values by turning. Confirm the values by pressing. Function selection by pressing and turning. 7 Information key Show the operating data on the display or return to the start page. 10

4 205 193 / 00 Heating system control 8 9 Key Designation Function Heating curve set-up Operating mode selection key Holiday Set the heating curve Operating mode selection Switch off the heating system during the holidays (frost protection) Absence Temporarily switch off heating Party Extended heating Automatic Automatic heating programme according to the preset heating times Summer Only domestic hot water; no heating Constant heating Continuous heating Reduced heating Continuous reduced heating Standby Frost protection activated 10 Manual mode / emission measurement For heating engineer only. 11 Display The basic screen displays the day of the week, date and time of the day, as well as the current boiler temperature and room temperature (room station). 1 2 3 4 5 6 7 Possible readouts: 1 Active heating time 24h 2 Weekday display 3 Display of the active operating mode and the clock programme 4 Time of the day 5 Selected operating mode 6 Date / Day / Month / Year 7 Room temperature (when activated) 12 Brief operating instructions Brief operating instructions for heating controller (2) only 13 Boiler temperature control Use this function to set the required boiler water temperature. Recommendation: Turn the control to + to store as much heat as possible in the storage tank. (Setting range 75 ºC - 85 ºC) 14 Boiler temperature indicator The current boiler temperature is shown here. 11

Heating system control 4 205 193 / 00 15 16 17 18 Key Designation Function Fuse Door lock lever Flue gas thermometer Check the 6.3 A fuse if all the displays are dark. This should only be done by the heating engineer. Locks the door and prevents it from being opened during operation. The door may only be opened for refilling. This should be done slowly and carefully. Sparks and tongues of flame can emerge through the door. The flue gas temperature is shown here. If the flue gas temperature is over a longer period over 240 C, (or 210 ºC for boilers with heating surface cleaning) the boiler must be cleaned. If the flue gas temperature remains excessive, it will also be necessary to adjust the air flow rate. See next position or call a heating engineer. To guarantee that the combustion is optimal, it is necessary to adjust the necessary air flow rate. The initial setting is performed by the heating engineer. The required air flow rate depends on various criteria (e.g. type and humidity of wood, type of chimney, position of building, etc.). Therefore, each boiler has to be adjusted on-site. Air flow adjustment (primary air) A flue gas thermometer is essential for setting the air flow rate! Pre-condition for a correct setting: The boiler must be clean; particularly the downstream heating surface! The primary air flow is adjusted as follows: Set the upper adjusting knob (18) to 3 (i.e. basic setting) If the flue gas temperature at full load exceeds 230 C *): Turn back knob to 2 or, if necessary, to 1. If the flue gas temperature at full load is less than 180 C **): Turn knob to 4 or, if necessary, to 5. Ensure that the setting is not changed by accident! If the flue gas temperature rises only after few weeks: Clean the downstream heating surface! Air flow adjustment (secondary air) i The adjustment of the secondary air flow is carried out and fixed by the heating engineer as part of the commissioning work. *) For boilers with heating surface cleaning system WiKo 200 C **) For boilers with heating surface cleaning system WiKo 160 C 12

4 205 193 / 00 Heating system control Function of the N5.1 controller The controller is switched on via the main switch 1. Closing the loading door initiates an automatic function sequence - The forced draught fan is switched on at high speed (for low boiler water temperature). - When the boiler water temperature has risen (10 K below the temperature setpoint) the fan switches over to the 1st stage. - The fan is switched off when the temperature setpoint at the boiler temperature control (point 13, page 11) is reached. - If the boiler temperature falls below the temperature setpoint at the boiler temperature control, the fan is turned back on. The fan is switched off if the boiler runs out of fuel. A small quantity of embers is preserved for the next fuel load. The smouldering gas extractor is turned on when the fuel loading door is opened to prevent any smouldering gases from escaping. If the fuel does not light during heat-up, the automatic cut-out switches off the fan unit. 13

Heating system control 4 205 193 / 00 Operating elements of the heating boiler equipped with the N5.2/N2 TopTronic lambda controller 1 20 13 14 9 10 11 2 3 4 5 19 17 16 15 18 8 7 6 12 1 2 3 Key Designation Function Main switch Electronic heating controller TopTronic T (optional) Daytime room temperature 0 = Heating boiler OFF; Heating boiler is shut down I = Heating boiler ON; Heating boiler is operational Note: The main switch should always be turned on (also in summer when the boiler is not in operation). This will prevent the pumps from getting stuck. Maintains the desired room temperature independently of the outdoor temperature; regulates the output of the water heater. Special brief operating instructions are provided with the heating controller. Further information can be obtained from the detailed operating instructions. Set the daytime room temperature. 4 Reduced room temperature Set the room temperature for reduced heating. 5 DHW temperature Set the domestic hot water temperature. Manual DHW reloading. 6 7 Rotary pushbutton Information key Change the values by turning. Confirm the values by pressing. Function selection by pressing and turning. Show the operating data on the display or return to the start page. 14

4 205 193 / 00 Heating system control 8 9 Key Designation Function Heating curve set-up Operating mode selection key Holiday Adjust the heating curve Operating mode selection Heating system off during the holidays (frost protection) Absence Temporarily switch off heating Party Extended heating Automatic Automatic heating programme according to the preset heating times Summer Only domestic hot water; no heating Constant heating Continuous heating Reduced heating Continuous reduced heating Standby Frost protection activated 10 Manual mode / emission measurement For heating engineer only 11 Display The basic screen displays the day of the week, date and time of the day, as well as the current boiler temperature and room temperature (room station). 1 2 3 4 5 6 7 12 Brief operating instructions Possible readouts: 1 Active heating time 24h 2 Weekday display 3 Display of the active operating mode and the clock programme 4 Time of the day 5 Selected operating mode 6 Date / Day / Month / Year 7 Room temperature (when activated) Brief operating instructions for heating controller (2) only 15

Heating system control 4 205 193 / 00 13 Key Designation Function Operating modes The red luminous figure indicates the currently active operating mode. 14 Temperature indicator The red luminous figures indicate the current boiler temperature. 15 Temperature query With this key the 5 indicated temperatures can be viewed sequentially. The dot behind the individual figure indicates that the value now relates to the individual temperature and not the operating mode. 16 STOP key a) To stop the heat-up phase (operating mode 1) if the loading door was opened when the boiler did not have to be heated up. This eliminates the need for the fan to operate unnecessarily for 30 minutes. 17 18 19 20 Chimney sweep key Plus / Minus key Boiler safety temperature limiter unlocking Fuse b) If the loading door is opened during burnout, glowing ember preservation or residual heat utilisation modes (i.e. during operating mode 4, 5 or 6), the boiler automatically switches over to operating mode 1 (heat-up phase) after closing the door. If, however, no additional wood had been loaded, then it is possible to return to the original operating mode (i.e. 4, 5 or 6) by pressing the Stop key. Executes the emission measurement function. This function should only be used by the heating engineer! For adjusting the parameters. The Plus key is also used to cancel error messages. This function should only be used by the heating engineer! If the fan unit was turned off as a result of excessive boiler temperature (> 100ºC) and is now locked out to prevent automatic start-up, use this key to unlock it. Unlocking is possible once the boiler temperature has dropped below 80ºC. The current boiler temperature is shown on the display (e.g. 100ºC) and on the temperature indicator field (14). Please contact your Hoval Customer Service point if the boiler safety temperature limiter keeps locking out. Check the 6.3 A fuse if the displays 11, 13 and 14 are dark. This should only be done by the heating engineer! 16

4 205 193 / 00 Heating system control Function of the N5.2TopTronic lambda controller The controller is switched on via the main switch 1. The individual operating mode is shown on the display (point 13, page 16). Closing the loading door initiates an automatic function sequence: - The forced draught fan is switched on at high speed (operating mode 1, optimised heat-up phase). - The system changes over to full load mode (operating mode 2) when the flue gas temperature exceeds about 170 ºC. - If the storage tank temperature exceeds about 70 ºC (parameter P01, see page 19), the boiler output is reduced to adjust it to the effectively required thermal output (operating mode 3, modulating output). - If the storage tank temperature drops below 70 ºC during burnout, the boiler is switched back to full load operation (operating mode 2). When the wood is used up and there are only embers left in the loading chamber, the burnout optimisation mode is initiated (operating mode 4). The flow rate of the air supplied to the embers is reduced by slowing down the fan and partially closing the air dampers. A drop in the flue gas temperature to below 120 ºC indicates that there is no fuel left and that only glowing charcoal remains in the boiler. This condition triggers the shut-down of the pump and the fan unit, and the air dampers are closed off completely; this prevents the boiler from cooling down and allows a certain quantity of embers to remain for subsequent reloading of wood without the need for relighting (operating mode 5, ember preservation). After expiry of the ember retention time (default setting 90 minutes), the system switches over to operating mode 6 (residual heat utilisation). The heat remaining in the boiler is now transferred to the storage tank. The residual heat utilisation mode is completed when the boiler temperature drops below 40 ºC and the boiler is switched off (operating mode 0, boiler off). The smouldering gas extractor is turned on when the fuel loading door is opened to prevent any smouldering gases from escaping (operating mode 8). In this operating mode the forced draught fan runs at increased speed and extracts the smouldering gases directly through the smouldering gas channel. If the fuel does not light during heat-up and the flue gas temperature does not rise above 120 ºC within 30 minutes, the automatic cut-out switches off the fan unit; the operating mode changes automatically from 1 (heat-up phase) back to 0 (boiler off). The boiler control unit should always be operational (also in summer when the boiler is not operating) in order to keep both the boiler protection function and the regular lambda sensor function test in an active state. The associated electrical consumption is negligible. When the main switch is turned off and then on again, the control unit reacts as if a power failure had occurred: it automatically changes over to operating mode 1 (heat-up phase). If the boiler does not subsequently heat up, it is possible to cancel this operating mode by pressing the Stop key (press for 5 seconds) to prevent the fan from running unnecessarily for 30 minutes. 17

Heating system control 4 205 193 / 00 What are the additional benefits of the TopTronic lambda combustion controller? The lambda sensor continuously monitors the residual oxygen content in the flue gas and allows the secondary air flow rate to be carefully adapted to the particular operating mode and specific fuel by means of motorised dampers. The existing advantages of 3-stage combustion (see page 7) are thus substantiated by further emission reductions and enhanced efficiency. Moreover, the TopTronic lambda controller provides the following additional services: thanks to the parallel measurement of flue gas temperature and continuous monitoring of the loading condition of the storage tank, the thermal output of the AgroLyt can be continuously adapted to the actual heat demand. This prevents an overheating or underheating when changing fuel types. Longer burning times result in longer intervals and thus in more flexibility when refilling. Power modulation between 100 % and 50 % of the nominal rating takes place by means of continuous speed regulation of the forced draught fan and the motorised primary air damper. The range of functions of the TopTronic lambda controller includes heat-up optimisation for rapid and low emission ramping up of the boiler, return temperature control, storage tank management, burnout optimisation with ember preservation, residual heat utilisation during standby, etc. In addition, it also offers the possibility of remote reloading indication. 18

4 205 193 / 00 Heating system control Settings of the N5.2 TopTronic lambda controller The following settings are possible: 1) Storage tank - temperature setpoint (Parameter P 01): Setting range 60-95 C Default setting: 70 C Function: When this temperature is exceeded, the operating mode changes from 2 (full load) to 3 (part load). Recommended settings: If the boiler is to be operated mainly under full load: 75-80 C If the boiler is to be operated mainly under part load (results in longer burning time): 65-70 C. 2) Boiler - temperature setpoint (Parameter P 02): Setting range 80-95 ºC Default setting: 80 C; P 02 must be at least 5 C higher than P 01 Function: When this temperature is exceeded the operating mode changes from 2 (full load) to 3 (part load). 3) Selection: Comfort- or energy-optimised operation (Parameter P 03; Co or Eo) Default setting: Co Function: In the mode comfort-optimised operation, the ember preservation time set by the Hoval engineer is adhered to, i.e. the comfort of the ember preservation is utilised. Alternative: Eo Function: In the mode energy-optimised operation, the ember preservation time (operating mode 5) is reduced to 10 minutes, after which the operating mode is changed to energy efficient residual heat utilisation (operating mode 6). The parameters P 01, P 02 and P 03 are adjusted as follows: Temperature displays 1.... 5. Normal display Normal display & adjustable with or adjustable with or adjustable with or Normal display 19

Start-up 4 205 193 / 00 Start-up (heat-up phase) When starting up the system, it is advisable to observe the notes in the installation manual. 1. Checks: Are the slide valves in the heating flow and return lines open? Is the combustion air supply into the boiler room adequate? Is the main switch on the boiler control unit set to ON? Are the combustion chamber door and the ash removal door 1 closed? Only for N5.1 controller: Has the desired temperature been set on the boiler temperature control (pos. 13, figure on page 11)? Please note the information on fuels on page 22. The loading chamber can be filled up to the top with wood. During the periods of lower heat demand (e.g. autumn, spring), or when the heating water storage tank is already at the desired temperature (65 ºC or higher), the boiler should be filled with less wood (see page 31 of the brief operating instructions). Stoking and burnout control is carried out through the lighting door. All doors must be kept closed during operation! 2. Open fuel loading door 2 and lighting door 3 (lift door lock lever). 3. Place paper and easily ignitable kindling on the loading chamber and light it. Fill height approx. 15 cm. 4. Close the fuel loading door 2. Lighting door 3 stays open. 5. Wait approx. 10 minutes to allow the wood to catch fire before loading more wood into the fuel loading chamber. Align the split logs in line with the longitudinal direction of the boiler (not criss-cross) to avoid any gaps as much as possible. Any wood that does not fill the full length of the loading space should be loaded first and placed at the very back of the chamber. The remaining space at the front should then be filled crossways with wood. 6. Proceed to close the lighting door 3. From this moment everything is done automatically. 2 3 7. When the fuel is consumed, the automatic cut-out switches off the fan unit. 1 Figure 5 20

4 205 193 / 00 Reloading Reloading (wood refilling) 1. Open the fuel loading door 2 only slightly until the door lock lever 4 latches into place. Any smouldering gases escaping through the door are then extracted through the smouldering gas channel. Wait about 15 seconds before completely opening the fuel loading door. 2. Stoke and level the embers. 3. Add wood to the fuel loading chamber according to the heat requirements. Match the total amount of wood to the heat requirements. It might be necessary to add paper or kindling on the embers before reloading to help lighting the new wood. 4 4. Close the fuel loading door 2. Closing the door starts the automatic burnout process. Approximate burning time in hours for different nominal thermal outputs AgroLyt 20 25 35 45 50 Hardwood 7,5 6,5 5 5 4,5 Softwood 5,5 5,0 3,5 3,5 3,0 21

Suitable and unsuitable fuels 4 205 193 / 00 Suitable and unsuitable fuels The Hoval AgroLyt is a wood burning heating boiler and, as such, it is suitable for firing the wood types described below. Air-dried naturally seasoned wood pieces, e.g. cut and split logs, billet wood and rounds with a maximum diameter of 12 cm, wood length: ½ m Approximate storage times (for dry storage): Soft wood 1 to 1 ½ years Hard wood 2 to 2 ½ years It is forbidden to burn waste material and wood that has been treated with wood preservatives or that comprises a coating based on halogen organic compounds. The generation of highly poisonous fumes has a serious impact on the environment and poses a risk to humans and animals as well as to technical equipment. It also destroys the lambda sensor (in units fitted with N5.2/0 controller)! Wood that has not been stored long enough, or moist wood, provides only about half of the possible useful heat and shortens the lifetime of your boiler. Course wood chips with a length of at least 5 cm. Only mixed up to 50 % with wood pieces. Please note! The following fuels shall not be used: Coke, coal Saw dust Plastic coated wood waste Treated or lacquered wood Synthetic materials Waste material Figure 6 Wood briquettes/wood pellets, as long as they are manufactured without binders. Minimum size 8 cm diameter and 12 cm length. Only mixed up to 50 % with wood pieces. 22 Figure 6a

4 205 193 / 00 Cleaning the heating boiler Cleaning the heating boiler Daily cleaning 1. Open the combustion chamber door 1 (Figure 7). Remove the fly ash (residues) from the vortex combustion chamber and from the ash collecting space below with the wood scraper. 4 Loading door Every 3-4 weeks (or more often, depending on requirements) For models without heating surface cleaning 1.1 Open cleaning aperture 4 (Figure 7) to the flue gas collector and clean the thermolytic downstream heating surface with the cleaning brush. Brush or vacuum the dust and soot from the flue gas collector (Figure 7b). For the AgroLyt (20) and (50) you must first remove the regulator and, after the cleaning, install it again in the centre. 2 Figure 7b 1 2. Open the lighting door 2 (Figure 7). Clean the grate and the lateral openings in the loading chamber lining using the wood scraper (Figure 7a). The ash layer on the loading chamber floor shall not exceed 2-3 cm in height 7 Figure 7 For models with heating surface cleaning 1.2 The thermolytic downstream heating surface is cleaned by means of the heating surface cleaning system. Move the heating surface cleaning lever 5 (Figure 7c) 2-3 times back and forth. 5 Figure 7c 2. Proceed with the steps described in Daily cleaning. Figure 7a 3. Use the scraper to level the residues and charcoal that have entered the vortex combustion chamber through the grate. They will burn to fly ash in the next burnout. 23

Cleaning the heating boiler 4 205 193 / 00 3. Remove cast grate 6 (Figure 7d). 4. On the floor plate, clean the area underneath the grate with a vacuum cleaner. It is important to ensure that the two air inlets in the floor plate between the wind box 7 (Figure 7) and the grate are clean. If no vacuum cleaner is available: pull the front cladding 8 forward (Figure 7e). 6 Figure 7d 8 9 11 10 Figure 7f Annual maintenance by a heating engineer (or more often, if required) See chapter Maintenance in the Technical information/installation instructions. 9 Figure 7e Unscrew cover 9 on the wind box. Thoroughly clean both air inlets 10 with the round brush 11 (Figure 7f). Wipe any residues through the combustion chamber cone (see pos. 9, page 7) into the combustion chamber. Reinstall the grate and mount the wind box cover and the front cladding (slots on top). Please note! It is essential to clean the entire boiler thoroughly at the end of the heating season. Insufficient cleaning does not only lead to increased fuel consumption, but also shortens the useful life of the boiler. Note: Small tension cracks in the refractory do not affect the correct functioning of the boiler. They are the result of stresses caused by temperature changes. The boiler should be thoroughly cleaned in accordance with the applicable country-specific regulations - and no less than 1 x per year - by a heating engineer (chimney sweep, installer, Hoval Customer Service). 24

4 205 193 / 00 Maintenance and checks / Shutdown Maintenance and checks The following tasks are usually carried out by the heating engineer as part of the yearly maintenance. You should nevertheless conduct the following checks throughout the year and perform the described procedures, if necessary. Controlling the water level If the water level in the system is too low (check pressure gauge), inform your installer or top up the water. Shutdown If the boiler is not in operation for several weeks, follow the procedures described below: Clean the boiler. If there is a risk of frost, empty the system in accordance with the instructions from the heating installer. Refilling the heating system The boiler must be tension free! (disconnected from the power supply). Open the shut-off valves in the flow and return lines. Connect a hose filled with water (no air should be introduced into the heating system) between the boiler filling/draining cock and the water tap. Unscrew the hose again after filling to break the connection securely. Water quality: The heating system can normally be topped up with mains water. No chemical additives should be added to the water. The water quality can vary strongly in different parts of the country (you can obtain information about the water quality from your local water) and it might not always be suitable for filling the heating system (highly corrosive or hard water). Please contact your heating engineer in those cases. Introduce the water slowly while controlling the water level on the pressure gauge (the installer will tell you the fill pressure for your system). Leave the bleed valves on the radiators open until you can see only water flowing out. The complete filling and emptying of the system must be carried out by the heating engineer. Caution: Never fill the hot system with cold water. 25

Check list in case of faults 4 205 193 / 00 Fault Boiler switches off about 20 min. after heat-up Check/Cause The fuel has not ignited correctly and the flue gas temperature has not risen beyond 110 ºC within 20 minutes. The automatic cut-out has switched off the boiler. Solution Repeat heat-up phase. The fan unit repeatedly turns on and off during operation Check the settings of the boiler temperature control, the minimum boiler temperature control and the return temperature control. Check that the heating water storage tank charging pump is operational. Only fill an amount of fuel that corresponds to the heat storage capacity of the heating water storage tank. - Switch on the pump Unscrew the lock screw, turn the shaft end with a strong screwdriver to reduce the resistance. - Read the pump operating instructions or inform the installer. Smoke or smouldering gas escapes from fuel loading door Check door seals for tightness? Readjust the door hinges and replace the door seal, if necessary (see installation instructions, page 43). Radiators are not warm Check that the slide valves in the flow and return lines are open. Check that the timer on the heating controller is set correctly. Check that the setpoints have been set correctly on the heating controller or remote setting device. Check the water level and pressure. Check that the radiator valves are open. Check that the heating pump and the storage tank charging pump are operational. Open them. Follow the separate operating instructions of the heating controller to check. In case of low outdoor temperatures change the boiler temperature setpoint to a higher setting. Refill the heating system and bleed the air. Open them. Switch on the pump. Unscrew the lock screw, turn the shaft end with a strong screwdriver to reduce the resistance. Check that the mixing valve opens automatically. Open manually. Call the customer service (caution with floor heating). No domestic hot water available Check that the water heater charging pump is operational. Unscrew the lock screw, turn the shaft end with a strong screwdriver to reduce the resistance. Check the charging line for air. Manually operate the automatic bleeder. Running noise although heating is off Fan unit, actuators or pumps are switched on temporarily Normal function (self-test) to prevent malfunctions. Please note! Please use above checklist when carrying out the checks in case of malfunctions. If you are not able to resolve the fault, please contact the heating installer or the Hoval Customer Service. 26

4 205 193 / 00 Error message checklist for TopTronic lambda controller Fault F 01 Check/Cause Clean heating surface! STL (Safety Temperature Limiter) activated Solution See page 23, Fig. 7b or 7c. Press the Plus key for 5 seconds after cleaning to clear the display. See page 16, point 19. Unscrew the cap and press in the button. Press the Plus key (5 seconds) to cancel the error message. F 02 Flue gas temperature sensor - open circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 03 Flue gas temperature sensor -incorrect polarity Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 04 Boiler temperature sensor - open circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 05 Boiler temperature sensor - short circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 06 Return temperature sensor - open circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 07 Return temperature sensor - short circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 08 Storage tank top temperature sensor - open circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 09 Storage tank top temperature sensor - short circuit Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 10 Storage tank bottom temperature sensor - open circuit Contact Hoval engineer. This fault has no influence on the boiler operation. F 11 Storage tank bottom temperature sensor - short circuit Contact Hoval engineer. This fault has no influence on the boiler operation. F 13 Primary air damper defective Contact Hoval engineer In the meantime the boiler can still be operated; an emergency mode program is executed automatically. Important: the actuator of the top damper must be unlocked with the black key; then manually open the damper to approx. 30-40%. F 14 Secondary air damper defective Contact Hoval engineer In the meantime the boiler can still be operated; an emergency mode program is executed automatically. Important: the actuator of the bottom damper must be unlocked with the black key; then manually open the damper to approx. 70-80%. 27

Error message checklist for TopTronic lambda controller 4 205 193 / 00 Fault Check/Cause Solution F 15 Lambda sensor defective Contact Hoval engineer. In the meantime the boiler can still be operated; an emergency mode program is executed automatically. F 16 - F 22 Controller - Internal error Contact Hoval engineer. In the meantime the boiler can still be operated normally. --- Mixing motor for return temperature control defective Contact Hoval engineer. In the meantime the boiler can still be operated normally. Important: the mixing motor must be unlocked (press button in with a screwdriver and turn to hand symbol); then open the mixer manually to approx. 70-80%. The display of the individual errors alternates with the normal display (= operating state display). The control unit can still be operated while an error is displayed. This means that temperature information can be obtained and that the settings P01 to P03 can be changed, if required. In case of a faulty temperature sensor, uuu, for cable open circuit, or ---, for sensor short circuit, is shown during the temperature poll. Once the fault has been corrected, press the Plus key (5 seconds) to cancel the error message. Note: The reported errors are shown, also after the fault has been corrected, until they are cancelled by pressing the Plus key. If the fault was not corrected, the error message appears again 3 seconds after the cancellation attempt (after 300 seconds in the case of damper actuators). 28

4 205 193 / 00 How you can save energy The temperature of the rooms and the operating times of the heating system have a significant influence on the fuel consumption. A 1 ºC lower room temperature will result in a fuel saving of up to 6%. For this reason, bear in mind the following tips: It pays to turn off the radiators in unused rooms, as long as there is no risk of frost and no moisture damage on the building or furniture is to be expected. Set the switch on your heating controller to Summer as soon as the daily average outside temperature rises above 12ºC. In the main living areas, additional heat can often be generated by people, televisions, fire places, tiled stoves and also by direct sun light. This can not be compensated by a weather dependent regulation. The installation of thermostatic radiator valves in these rooms might be a sensible measure. Unwanted air drafts at home are not only unpleasant, but also indicators of heating energy losses. You can save fuel if you... keep the doors and windows closed in winter. close the chimney dampers when the fire is out. operate the kitchen and bathroom ventilation fans only when vapours and smells need to be extracted. only vent the house for short time periods and more often. seal doors and windows to prevent constant leakages. Insulation will help retaining precious heat. Take advantage of these options and... close the window and door shutters at night. draw the window curtains in the evening. Make sure that the heating and domestic hot water pipes are insulated in unheated rooms. Maintaining the temperature of the radiators as low as possible will prevent unnecessary heat losses. For this reason, it is important that the radiator can release its heat into the room without any obstructions. You should therefore avoid: Covered radiators floor-length curtains in front of radiators windowsills that do not let air through because they are cluttered with objects. Savings are also possible in water heating. If you have installed a hot water circulation pump, it is worth switching it off during the night by means of a timer. 29

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4 205 193 / 00 Brief operating instructions 1. Fuel Burn only dry, naturally seasoned (min. 2 year old) wood to ensure environmentally friendly combustion and lower fuel consumption. 2. Lighting Remove ash from and beneath the combustion chamber. Stack paper, flammable kindling and wood for approx. 15 cm. Switch on (main switch ) the boiler. Close combustion chamber door and loading door. Light the fire through the lighting door. Close the lighting door after 5-10 minutes. Open the loading door carefully and fill up the loading chamber (Insert split logs as parallel as possible). Close the loading door. 3. Reloading Open the loading door carefully! Before reloading, briefly loosen and level the embers. Add more fuel only if the fuel in the loading chamber is mostly burnt and the heat of the new load can be absorbed by the heating system and / or the storage tank. Recommended approach for reloading the boiler: If the temperature at the top of the storage tank exceeds 60 C, but is less than 50 C in the middle and at the bottom, fill the chamber completely. If the temperature at the top and the middle of the storage tank exceeds 60 C, but is less than 50 C at the bottom, fill the chamber partially (depending on the outside temperature). Do not add any new fuel if the temperature at the top of the storage tank exceeds 70 C and has reached more than 60 C at the bottom. For the rest of the day and the night the necessary heat will be provided by the storage tank. On the following day repeat the steps above, depending on the heat requirements. 4. Flue gas temperature The flue gas temperature must not exceed 250 C. If the temperature approaches this limit, the boiler needs cleaning or you should call a heating engineer. 5. Cleaning and Maintenance Regularly remove ash from the loading chamber, from the space below the grate and from the combustion chamber. Clean flue gas tracts every 3-4 weeks. Once a year an inspection and readjustment should be carried out by a heating engineer and the boiler should be thoroughly cleaned. 6. Shutdown If the boiler is to be switched off for a long period of time (e.g. in summer), it should be thoroughly cleaned after the last heating cycle (loading chamber, flue gas tracts, fan unit, combustion chamber, air ducts). 7. Waste Burning waste is illegal. Burning contaminated material is environmentally harmful and shortens the life of the boiler. In particular the lambda sensor will be destroyed. 8. Operating instructions Please observe the detailed operating instructions of the AgroLyt! 31

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4 205 193 / 00 United Kingdom Hoval LTD Northgate Newark Nottinghamshire NG24 1JN Phone: 01636 672 711 Fax: 01636 673 532 Switzerland Hoval Herzog AG General-Wille-Strasse 201 CH-8706 Feldmeilen Telefon 044 / 925 61 11 Telefax 044 / 923 11 39 Germany Hoval (Deutschland) GmbH Karl-Hammerschmidt Strasse 45 D-85609 Aschheim-Dornach Telefon 089 / 92 20 97-0 Telefax 089 / 92 20 97-77 Austria Hoval Gesellschaft mbh A-4614 Marchtrenk Hovalstrasse 11 Telefon 07243 / 550-400 Telefax 07243 / 550-17 Italy Carival S.r.l. Via Per Azzano S. Paolo, 26/28 I-24050 Grassobbio (BG) Tel.: 0039 / 35-525069 Fax: 0039 / 35-525858 France Carival SA F-91743 Massy Cedex 2 route de la Bonde Tél. 01 69 30 83 00 Fax 01 69 30 22 54 Responsibility for energy and environment 34