Instruction manual for service engineers · stoker/feeder screw (constant speed of rotation). In...

Instruction manual for service engineers

41-BioLyt (50-75) with FFA 200, TTE and single rotary feeder

41-BioLyt (100-160) with FFA 200, TTE and double rotary feeder

and suction turbine integrated into pellet box

Issue: March 2015

Replaces: -----

Author: D. Vogt

Document Version: 4 213 953 / 00

Software Version: FFA 200 – V10003

Valid for 41-BioLyt(50-160)

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Page 1

1. Revision history .................................................................................................................... 4

2. Basic functions ...................................................................................................................... 5

2.1. Plant functioning .................................................................................................................... 5 2.2. Principle of combustion and air supply into the burner tube ................................................ 6

2.2.1. Burner BioLyt (50-75) ........................................................................................................ 6 2.2.2. Burner BioLyt(100-160) ..................................................................................................... 6

2.3. Construction of the plant ....................................................................................................... 7

3. Heat generator controller ...................................................................................................... 8

3.1. General ................................................................................................................................... 8 3.1.1. Selection of heat generator types (output parameter) ..................................................... 8 3.1.2. Switching conditions at heat generator request ............................................................... 9

3.2. Control ................................................................................................................................. 10 3.2.1. Output regulation ............................................................................................................ 10 3.2.2. Combustion regulation .................................................................................................... 11 3.2.3. Request for bus interrupt ................................................................................................ 12 3.2.4. Function "return maintenance with buffer control" ....................................................... 12

4. Burner states ...................................................................................................................... 15

4.1. Overview .............................................................................................................................. 15 4.2. Burner OFF [0] ...................................................................................................................... 16

4.2.1. OFF, quiescent state [0] ................................................................................................... 16 4.2.2. OFF, anti-blocking protection (ABS) [1] ........................................................................... 16 4.2.3. OFF, test lambda probe start [2] ..................................................................................... 17 4.2.4. OFF, residual heat use [5] ................................................................................................ 18

4.3. IGNITION PHASE [1] ............................................................................................................. 19 4.3.1. IGNITION PHASE, pre-filling [10]...................................................................................... 19 4.3.2. IGNITION PHASE, filling [11] ............................................................................................ 19 4.3.3. IGNITION PHASE, test lambda probe end [12] ................................................................ 19 4.3.4. IGNITION PHASE, ignition [13] ......................................................................................... 20 4.3.5. IGNITION PHASE, RUN-ON [14] ....................................................................................... 21 4.3.6. IGNITION PHASE, hot start (not for tube burner (50-160 kW)) ....................................... 21

4.4. FIRE-BED BUILD-UP [2] ......................................................................................................... 21 4.4.1. Fire-bed start [20] ............................................................................................................ 21 4.4.2. Fire-bed build-up [21] ...................................................................................................... 22

4.5. NORMAL OPERATION [3] ..................................................................................................... 22 4.5.1. NORMAL OPERATION, power modulation [30] ............................................................... 22 4.5.2. NORMAL OPERATION, lambda stop [31] ......................................................................... 23 4.5.3. NORMAL OPERATION, combustion chamber temperature stop [32] ............................. 23

4.6. FIRE-BED MAINTENANCE [4] ................................................................................................ 23 4.7. BURN-DOWN [5] .................................................................................................................. 24

4.7.1. BURN-DOWN, part 1: Burn-down of the fire-bed [50] .................................................... 24 4.7.2. BURN-DOWN, part 2: Cleaning the burner and combustion chamber cooling [51] ....... 24

4.8. BURNER FAULT [6] ............................................................................................................... 25 4.8.1. Fault management ........................................................................................................... 25 4.8.2. Safety-relevant functions ................................................................................................ 25 4.8.3. Overview of fault messages ............................................................................................. 28 4.8.4. Fault reporting output (SMA) .......................................................................................... 30 4.8.5. Fault memory .................................................................................................................. 30 4.8.6. Reset, acknowledgement of fault messages ................................................................... 30

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5. Other information on heat generator operation .................................................................. 31

5.1. Return pump, mixer, buffer sensor ..................................................................................... 31 5.2. Consumption meters ........................................................................................................... 31

5.2.1. Definition of the consumption meters ............................................................................ 31 5.2.2. Calibration of the meter .................................................................................................. 32

5.3. Cleaning functions ................................................................................................................ 32 5.3.1. Heating surface cleaning ................................................................................................. 32 5.3.2. Ash discharge ................................................................................................................... 33 5.3.3. Ash scraper (only on BioLyt 100-160) .............................................................................. 33 5.3.4. Forced burn-down ........................................................................................................... 34

5.4. Calibration of the lambda probe .......................................................................................... 34 5.5. Frost protection ................................................................................................................... 35 5.6. Minimum switch-off point ................................................................................................... 35 5.7. Variable outputs ................................................................................................................... 36 5.8. Query software version and revision, reset to factory setting ............................................ 37

5.8.1. Software Version/Revision .............................................................................................. 37 5.8.2. Reset FFA to factory setting ............................................................................................. 37

6. Pellets transfer, filling the pellet box ................................................................................... 37

6.1. Inputs and outputs for pellet feed ....................................................................................... 37 6.2. Selection of the room transfer system ................................................................................ 38

6.2.1. Filling without an automatic filling system ...................................................................... 38 6.2.2. Pneumatic/mechanical filling system .............................................................................. 38 6.2.3. Switchover unit with suction probes ............................................................................... 39 6.2.4. Lead and post-run times of the AST-SV ........................................................................... 41 6.2.5. Run and interval times for output AST-V ......................................................................... 41

6.3. Off-periods times, forced filling ........................................................................................... 42 6.4. Monitoring ........................................................................................................................... 44

6.4.1. Temperature switch, screw motor (AST-V Klixon)........................................................... 44 6.4.2. Suction turbine monitoring (AST-SV Klixon) .................................................................... 44 6.4.3. Door contact switch on the storage room (TKSV/ RAS) .................................................. 44 6.4.4. Fill level monitoring in the storage room ........................................................................ 44

6.5. Operating state FILLING ....................................................................................................... 45 6.5.1. FILLING, Wait ................................................................................................................... 45 6.5.2. FILLING, Switch on ........................................................................................................... 45 6.5.3. FILLING, Fill ...................................................................................................................... 46 6.5.4. FILLING, post-run ............................................................................................................. 46 6.5.5. FILLING, Interruption ....................................................................................................... 46 6.5.6. FILLING, Timeout ............................................................................................................. 47 6.5.7. FILLING, locking-off action ............................................................................................... 47

6.6. Overview of filling process ................................................................................................... 48 6.6.1. Start of filling ................................................................................................................... 48 6.6.2. Manual filling ................................................................................................................... 48 6.6.3. Suction turbine with screw .............................................................................................. 49 6.6.4. Suction turbine with screw and switchover unit ............................................................. 50 6.6.5. Suction turbine with screw and double switchover unit (two pellet storage rooms) ..... 51 6.6.6. Move to zero point or suction probe .............................................................................. 52

7. Display and operation ......................................................................................................... 53

7.1. Overview of operating elements on the heat generator control panel .............................. 53 7.2. Query options for operator and service engineer ............................................................... 54

7.2.1. Query options in the INFO level of the FFA-200 .............................................................. 54 7.2.2. Relay test ......................................................................................................................... 55

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7.2.3. Manual interruption of operation ................................................................................... 56 7.2.4. Emission metering ........................................................................................................... 57

8. Appendix ............................................................................................................................ 58

8.1. Various program flows ......................................................................................................... 58 8.1.1. Complete program flow – simplified display ................................................................... 58 8.1.2. Program flow alarms ....................................................................................................... 59 8.1.3. Program flow Stopping manually and calibrating timer .................................................. 60

8.2. Technical data of the components used .............................................................................. 61 8.2.1. Lambda - probe:............................................................................................................... 61 8.2.2. Combustion chamber temperature sensor (Ni-CrNi) ..................................................... 62 8.2.3. Temperature sensor KTY-210 .......................................................................................... 63 8.2.4. Filling level sensor in the pellet box (PBSu/PBSo) ........................................................... 63 8.2.5. Negative pressure characteristic curves, induced-draught fan ....................................... 64 8.2.6. Wiring of the individual electrical components and cables ............................................ 65 8.2.7. Overview of inputs and outputs, FFA-200 board ............................................................ 87 8.2.8. Electrical circuit diagrams ................................................................................................ 88

9. Notes .................................................................................................................................. 97

10. Parameter list ..................................................................................................................... 98

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1. Revision history

version date author note to the change

00 2015-03-30 Vogt First edition

Notice: Changes in relation to the previous version are marked in blue.

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2. Basic functions

2.1. Plant functioning

Pellets are transferred from the storage room into the pellets day box by a handling device (e.g. screw conveyor and suction turbine). The metering screw (modulating speed of rotation) conveys pellets into the stoker/feeder screw (constant speed of rotation). In the down-pipe, there is rotary feeder driven from the feeding screw via a chain (double version in 100-160 kW), which seals the section leading down tightly. The stoker/feeder screw conveys the pellets into the burner tube. There, complete combustion takes place through the primary air supply (primary air fan) into the fire-bed and secondary air supply (induced-draught fan) at the burner tube exit. The thermal energy is transferred to the water being heated via the flue gas heat exchanger (with automatic heating surface cleaning). The ash collects in the combustion chamber, from where it is discharged into the ash box by the ash discharge screw. The combustion is operated by means of negative pressure, which prevents the escape of flue gas. Ignition is effected automatically by a hot air blower.

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2.2. Principle of combustion and air supply into the burner tube

2.2.1. Burner BioLyt (50-75)

Introduction of secondary air for complete burn-down

Introduction of primary air directly into fire-bed

Ignition in the feeding screw pipe

Primary air supply by primary air fan

2.2.2. Burner BioLyt (100-160)

Introduction of secondary air for complete burn-down

Introduction of primary air directly into fire-bed

Secondary air supply by underpressure with induced-draught fan

Primary air supply by primary air fan

Mechanical ash removal via scraper

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2.3. Construction of the plant

Schematic simplified diagram of the components (Fig. BioLyt 160)

Suction turbine

AST-SV

Induced-draught

fan SZG

Exhaust gas

temperature AGF

Heating surface

cleaning HFR

Boiler temperature WF

Pressure fan DGAsh discharge AAT

Ash scraper ASS

Pressure switch PU

Stoker/feeder screw ES

Double rotary feeder

Metering screw DS

Filling level sensor

PBSu

Filling level sensor

PBSo

Lambda probe

O2

Automatic firing device

FFA200

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3. Heat generator controller

3.1. General

The heat generator request is made via TopTronic®E. The TopTronic®E calculates its own set value in accordance with the settings for hot water or heating operation and passes this value on to the automatic firing device. The heat generator switch-on and switch-off temperatures are derived from the set value PLUS switch-off differential or the switch-off temperature MINUS the switch-on differential. Power modulation is effected via the difference between setpoint temperature and actual temperature of the heat generator.

3.1.1. Selection of heat generator types (output parameter)

First, the heat generator type (output parameter) must be checked on the system and set if necessary. With parameter FFA200 boiler par. 35073, it is possible to load the complete factory setting of the required output parameter. If a new heat generator is supplied, the correct heat generator type will have been preset already. However, if an automatic firing device is ordered as a spare part, this parameter will first have to be set correctly.

Parameters Group Description Setting

35073 Boiler Heat generator type

8 = BioLyt 50 kW 9 = BioLyt 70/75 kW 10 = BioLyt 110 kW 11 = BioLyt 130 kW 12 = BioLyt 150/160 kW

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3.1.2. Switching conditions at heat generator request

The heat generator starts up when the heating controller defines a heat generator set value and the following condition is met: Heat generator temperature (WF) is lower than the set value PLUS switch-off hysteresis MINUS

differential gap relative to the switch-off point The heat generator switches off when the following conditions are met: Minimum switch-off temperature (heat generator temperature) exceeded Switch-off temperature (set value PLUS switch-off hysteresis) exceeded

Example:

Set value = 70 °C, switch-on differential relative to switch-off point = 10K, switch-off differential above target = 12 K, minimum switch-off temperature = 8 °C

Heat generator starts if heat generator temp. (WF) < 70 °C + 12 K – 10 K = 72 °C Heat generator stops if heat generator temp. (WF) > 8 °C AND WF > 70 °C + 12 K = 82 °C

SDoff SDonSwitch-on

difference (10 K)

Te

mp

era

ture

(°C

)

Hea

t ge

nera

tor

OF

F

ON

Time

Time

SDoff = Switch-off difference FFA200-BOILER par. 35076

SDon = Switch-on difference FFA200-BOILER par. 35077

Heat generator on WF setpoint + SDoff – SDon

Heat generator off WF setpoint + SDoff

Switch-off

difference (12 K)

Boiler set value (70)

Parameters for switch-on and switch-off conditions:

Parameters Group Description Factory setting BioLyt (50)

35076 Boiler switch-off differential 12 K

35077 Boiler switch-on difference 10 K

35085 Boiler Minimum switch-off point 10°C

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0

10

20

30

40

50

60

70

80

90

100

14 19 24 29 34 39 44 49

Spe

ed

of

rota

tio

n /

mo

du

lati

on

[%

]

Boiler output [kW]

Output regulation Example: BioLyt(50)

Drehzahl SZG Drehzahl DG Drehzahl DS Modulation Drehzahl ES

3.2. Control

The heat generator control consists primarily of the output regulation, which determines the degree of modulation of the heat generator control. Combustion regulation is carried out parallel within the heat generator control. Via the lambda probe, the former measures the residual amount of oxygen in the flue gas and sets a correction value for the fuel quantity.

3.2.1. Output regulation

Regulation of the output is effected within a modulation range of 1…100 %, which corresponds to an actual heat generator output of 30…100 % of the nominal output. Example: BioLyt(50) Nominal output 49 kW 100 % modulation corr. to 100 % output (49 kW) 1 % modulation corr. to 30 % output (14.7 kW) The output of the heat generator is determined by the speeds of rotation of the induced-draught fan, primary air fan and metering screw. Two points (settings for minimum and maximum output) are defined. Regulation of the output is carried out along the straight lines between these points (see following diagram).

Speed of Speed of Speed of Speed of rotation SZG rotation DG rotation DS rotation ES

Modulation

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Parameters for output regulation:


33549 Burner Full load speed of rotation, primary air fan 15 %

33550 Burner Full load speed of rotation, metering screw 32 %

33551 Burner Full load speed of rotation, induced-draught fan 65 %

33552 Burner Full load speed of rotation stoker/feeder screw 100 %

33553 Burner Part load speed of rotation, primary air fan 12 %

33554 Burner Part load speed of rotation, metering screw 11 %

33555 Burner Part load speed of rotation, induced-draught fan 25 %

33556 Burner Part load speed of rotation stoker/feeder screw 100 %

35078 Boiler Maximum output heat generator 100 %

3.2.2. Combustion regulation

Combustion is regulated according to a set residual proportion of O2 in the flue gas, measured by the lambda probe. The regulated value here is the speed of rotation of the metering screw, that is, the quantity of fuel fed. To prevent overshoot of the controller, the control range is limited in upward and downward direction (see following graph)

Example: Modulation = approx. 50 % corresponds to an output of approximately 65 % of the nominal output. Metering screw set point = approx. 43 % Metering screw max. due to O2 value = approx. 54 % Metering screw min. due to O2 value = approx. 25 % i.e. at 50 % modulation, the speed of rotation of the metering screw can lie between 54 % and 25 % (depending on fuel quality).

0

10

20

30

40

50

60

70

80

90

100

30 40 50 60 70 80 90 100

Spe

ed

of

rota

tio

n /

mo

du

lati

on

[

%]

Boiler output [%]

Combustion control with metering screw Example: BioLyt(50)

Soll-Drehzahl DS DS max. DS min. ModulationDS max. DS min. Modulation Set point speed of rotation DS

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Parameters for combustion regulation:


34056 Lambda DS upper limit O2 regulation at part load 16 %

34057 Lambda DS lower limit O2 regulation at part load 7 %

34058 Lambda DS upper limit O2 regulation at full load 35 %

34059 Lambda DS lower limit O2 regulation at full load 22 %

3.2.3. Request for bus interrupt

If there is a bus interrupt, the FFA200 generates its own set point (FFA200 boiler par. 35074). The set point for bus interrupt is only active if the FFA200 boiler par. 35075 is set to 1.


35074 Boiler Set point for bus interrupt 70 °C

35075 Boiler Activate set point for bus interrupt 1

3.2.4. Function "return maintenance with buffer control"

With the help of this function, the set value for the return temperature is varied in dependence on the buffer temperature (measured in the centre of the buffer storage tank) in order to achieve better modulation and thus a longer burner run time per burner start. If the ACTUAL temperature at the PF-A rises above the set value, the set value for the return temperature (RLF) is increased. This results in: reduced heating-water volume flow through the heat generator the heat generator temperature rises the heat generator starts modulating faster and earlier the burner run time is extended

Requirements for using this function: a buffer storage tank with a volume > 20 l/kW must be installed (system with PF1 and PF2 control) an immersion sleeve must be installed in the centre of the buffer storage tank for mounting the

additional sensor (PF-A) Parameters for buffer control:


35086 Boiler Buffer sensor operating mode 0 = no display 1 = buffer sensor info display 2 = return flow maintenance with buffer control

0

35087 Boiler Buffer operating mode buffer deduction 10 K

35088 Boiler Buffer operating mode RLF set value elevation 1.5 K

35089 Boiler Buffer operating mode max RLF set value elevation

8 K

Activation of function: FFA200 boiler par 35086 =2 The following applies: PF-A set value = H-Gen set value MINUS PF-A deduction (FFA200 boiler par. 35087)

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Example: H-Gen setpoint temperature: 70 °C (specified by TopTronic®E) Return setpoint temperature: 53 °C (FFA boiler par. 35079) PF-A deduction: 10 K (FFA boiler par. 35087) PF-A setpoint temperature: 70 °C - 10 K = 60 °C PF-A actual temperature: 62 °C (assumed) Setpoint-actual temperature deviation PF-A: 62 °C - 60 °C = 2 K deviation Return increase: 2 K x 1.5 (factor) = 3 K return setpoint increase max. return increase: 8 K (FFA200 boiler par. 35089) Increase of return setpoint temperature by 3 K from 53 °C to 56 °C

The return setpoint temperature is increased by a maximum of 8 K (FFA200 boiler par. 35089).

H-Gen setpoint /

buffer setpoint 75°

Te

mp

era

ture

(°C

)

Time

PF1

PF-A

PF2

65°

PF deduction

FFA200 boiler par. 35087

66°

67°

56°

54.5°

53°Return setpoint

Modulation boiler

Return mixer OPEN

Parameter settings for the example above:

FFA200 boiler par. 35086 (FFA buffer sensor) 2

FFA200 boiler par. 35087 (PF deduction) 10

FFA200 boiler par. 35088 (return temperature set value elevation) 1.5

FFA200 boiler par. 35089 (max. return temperature set value elevation) 8

H-Gen reference 75

FFA-PF-A reference (75°-10°) = 65°

Legend:

PF1 is buffer sensor 1 (top of buffer)

PF2 is buffer sensor 2 (bottom of buffer)

PF-A buffer sensor from the FFA board

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General hydraulic diagram with position of sensor:

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4. Burner states

4.1. Overview

The various operating states are numbered as follows: e.g. : Operating state "Filling” = 13 ("1" for "Ignition phase" PLUS "3" for "Ignite") Operating state "Lambda stop" = 31

Operating state Bottom state Display

BURNER OFF [0]

Quiescent state 0 Anti-blocking protection (ABS) 1 Test lambda probe start 2 End status locking off 3 Start meter calibration 4 Residual heat use 5

IGNITION PHASE [1]

Pre-filling 10 Filling 11 Test lambda probe end 12 Ignition 13 Ignition blower run-on 14 Ignition fault 15

FIRE-BED BUILD-UP [2] Start 20 Structure 21

NORMAL OPERATION [3] Power adjustment 30 Lambda stop 31 BRT stop 32

FIRE-BED MAINTENANCE [4] Fire-bed maintenance 40

BURN-DOWN [5] Burn-down part 1 (burn down fire-bed) 50 Burn-down part 2 (cleaning, blow out) 51

FAULT [6]

Heat generator excess temperatures 60 Blocking fault 61 Locking-off fault 62 Activation locking-off fault 62 Burn-back 63

Notice: NOTE: All the states or parameter values described below refer to the factory setting for the 41-BioLyt(50).

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4.2. Burner OFF [0]

4.2.1. OFF, quiescent state [0]

Drives:

Metering screw (DS) 0 %

Stoker/feeder screw (ES) 0 %

Induced-draught fan (SZG) 0 %

(Ball valve (AP) CLOSED) only if a ball valve is set in the parameters

State change occurs if Temp. at BRF ≥ FFA200 burner par 33543 Burn down part 1 [50] Burner request Test lambda probe start [2] ABS is activated Burner OFF, anti-blocking protection [1] WF temp > FFA200 boiler par 35091 and WF temp minus PF-A temp > FFA200 boiler par 35092 and the

after-run time of the KKP has expired residual heat use [5]

4.2.2. OFF, anti-blocking protection (ABS) [1]

The anti-blocking protection can be activated/deactivated via a parameter. When the function is activated (Factory Setting = ON, FFA200 system par-35333), the ABS is activated once a day at the set time (08.00 hours, FFA200 system par.35334). As a prerequisite, the heat generator must have been in quiescent state for more than 24 hours. Drives:

Return pump (KKP) ON The pump switches on with 35 seconds delay.

Return mixer (YKR) CLOSED/OPEN for 15 sec., then OPEN again for 20 sec.

Induced-draught fan (SZG)

45 % FFA-200 ignition par. 33286

Primary air fan (DG) 20 % FFA200 ignition par. 33284

(Ball valve (AP) OPEN) For 70 sec. only if a ball valve is set in the parameters

State change occurs if ABS completed Burner OFF, quiescent state [0]

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4.2.3. OFF, test lambda probe start [2]

Preconditions for start of the probe test: Lambda probe fitted FFA200 lambda par. 34053 at "ON"

In the first part of the probe test, the measured value must rise to > (FFA200 safety par. 34825) within the set time (FFA200 lambda par. 34064). If this value is not reached, the system locks off (E:19). If this initial test is successful (the lambda stop function is then also active), the actual lambda test starts. In this case, the O2 value must rise to 21 % minus 7% (FFA200 lambda par. 34051) within the set time of 10 min. (FFA200 lambda par. 34049). If this value is not reached (= W19) or if the flue gas temperature rises to above 100 °C FFA200 lambda par. 34050 during this time, the test is cancelled and the burner starts up without the lambda probe. The operating states "Pre-filling" and "Filling" run parallel to the lambda test. Notice: If the lambda test is not successful, combustion regulation is not activated. Regulation is then performed in accordance with the set characteristic curve (FFA200 burner par. 33549…33555) with a 5 % reduction in the speed of rotation of the modulating stoker (FFA200 lambda par. 34060). Combustion then runs with excess air. (We have the same function if we deactivate the lambda probe, set FFA200 lambda par. 34053 to 0) A state change occurs if there is no O2 probe present (FFA200 lambda par. 34053 = OFF)

IGNITION PHASE pre-filling [10] O2 probe test not successful IGNITION PHASE pre-filling, with warning W:19 [10] O2 probe test not successful IGNITION PHASE pre-filling [10]

Additional information: Only O2 values of 2.10 % and above can be displayed. In the case of a fault or if the heating is switched off in quiescent mode, the O2 value of the probe is displayed as "--.-- %".

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4.2.4. OFF, residual heat use [5]

The residual heat use can be activated by the parameter (FFA200 boiler par 35090). If the heat generator has exceeded the minimum temperature (FFA200 boiler par 35091) for the residual heat use and the switch-on difference (FFA200 boiler par 35092) is reached, the boiler changes to "residual heat use" status. The switch-on difference is calculated as follows: heat generator sensor (WF) minus automatic buffer temperature sensor (PF-A) A change from "residual heat use" status to "quiescent state" status can be performed by three independent conditions:

1. Heat generator temperature (WF) is less than the minimum temperature for the residual heat use (FFA200 boiler bar 35091).

2. The switch-off differential (FFA200 boiler par 35093) is undershot: heat generator (WF) minus automatic buffer temperature sensor (PF-A)

3. A heat generator set value greater than 5 °C is present Drives:

Return pump (KKP) ON

Return mixer (YKR) CLOSED (i.e. heat dissipation from the boiler to the buffer)

Te

mp

era

ture

(°C

)

Time

WF

PF-A

40°

Parameter settings for the example above:

FFA200 boiler par 35090 (activate residual heat use) ON

FFA200 boiler par 35091 (min. temp for residual heat use) 40.°

FFA200 boiler par 35092 (switch-on differential residual heat use) 10 K

FFA200 boiler par 35093 (switch-off differential residual heat use) 5 K

Dies ist ein unerlaubter Weg!Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape!Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalho

T

T

T

M

KSPFPF2

PF1

PF-A

RLF

YKR

P

KKP

T

Dies ist ein unerlaubter Weg!Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape!Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhovalhovalhovalhovalhovalhovalhoovalhovallhovalhov

BioLyt

WF

45°

50°

KK

P

Time

OFF

ON

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4.3. IGNITION PHASE [1]

4.3.1. IGNITION PHASE, pre-filling [10]

Start preparation and filling of the feeding screw.

Drives:

Induced-draught fan (SZG) 45 % FFA200 ignition par. 33286

Ash discharge (AAT) See ash outfeed function under 5.3.2

(Ball valve (AP) OPEN) only if a ball valve is set in the parameters If a ball valve is set in the parameters (FFA200 system par. 35340 FA-ID 334 at 9), the following outputs are activated after expiry of the run time of the ball valve (FFA200 safety par. 34827 FA-ID 102). Otherwise the outputs are activated immediately at the entry to filling.


Metering screw (DS) 55 % FFA200 ignition par. 33285

Stoker/feeder screw (ES) 30 % FFA200 ignition par. 33281

Primary air fan (DG) 20 % FFA200 ignition par. 33284

Ash discharge (AAT) See ash outfeed function under 5.3.2

A state change occurs if the time FFA200 ignition par. 33282 has expired IGNITION PHASE, filling

4.3.2. IGNITION PHASE, filling [11]

Filling of the pellets burner with the start quantity of pellets. Drives:


(Ball valve (AP) OPEN) only if a ball valve is set in the parameters

If a ball valve is set in the parameters (FFA200 system par. 35340 at 9) and the ball valve is not already open, the following outputs are activated after expiry of the run time of the ball valve (FFA200 safety par. 34827). Otherwise the outputs are activated immediately at the entry to filling.


Metering screw (DS) 55 % FFA200 ignition par. 33285

Stoker/feeder screw (ES) 30 % FFA200 ignition par. 33281

Primary air fan (DG) 20 % FFA200 ignition par. 33284 A state change occurs if the time FFA200 ignition par. 33283 has expired Test lambda probe end [12]

4.3.3. IGNITION PHASE, test lambda probe end [12]

The lambda probe test is recognised as completed if: Test completed with positive result, i.e. O2 value has risen within 10 min. (FFA200 lambda par. 34049)

to a value of 21 % MINUS 7 % (FFA200 lambda par. 34051) = 14 % IGNITION PHASE, ignition [13]

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the max. time for the probe test (FFA200 lambda par. 34049, 10 min.) has expired and the O2 value has not risen to the value given above (W:19 or E:19) IGNITION PHASE, ignition [13] and further procedure without combustion regulation if O2 reduction is activated as ignition detection (FFA200 burner par. 33287 = 2), then locking-off fault E:19 [50, 62]

4.3.4. IGNITION PHASE, ignition [13]

Drives:

(Ball valve (AP) CLOSED) only if a ball valve is set in the parameters Metering screw (DS) OFF

Stoker/feeder screw OFF

Ignition blower – [1] fan ON

Ignition blower – [2] ignition element

ON


after 10 sec. delay (FFA200 ignition par. 33290)

Primary air fan (DG) OFF (optionally alternating with the following parameters) 0 % FFA200 ignition par. 33291

0 % FFA200 ignition par. 33292

0 sec. Run time FFA200 ignition par. 33293

0 sec. Pause time FFA200 ignition par. 33294

Ignition is recognised as successful if the time "Ignition run time" (FFA200 ignition par. 33288) has not yet expired and: with detection of ignition via combustion chamber temperature increase (FFA200 ignition par. 33287=

3,H-Gen) the combustion chamber temperature (BRT) has risen 10 K (FFA200 ignition par. 33296) since the beginning of the ignition process IGNITION PHASE RUN-ON [14]

with detection of ignition via flue gas temperature increase (FFA200 ignition par. 33287= 2), the flue gas temperature (AGT) has risen 10 K (FFA200 ignition par. 33297) since the beginning of the ignition process IGNITION PHASE RUN-ON [14]

with detection of ignition via O2 reduction (FFA200 ignition par. 33287 = 1), the O2 level in the flue gas has fallen below the value of 14.8 % (FFA200 ignition par. 33295) since the beginning of the ignition process IGNITION PHASE RUN-ON [14]

Ignition is recognised as not successful if: the time "Ignition run time" (FFA200 ignition par. 33288) has expired and none of the three conditions

above has been met IGNITION PHASE, filling [11]

The ignition process is repeated a maximum of 2x (FFA200 ignition par. 33298). If ignition is not successful after the second attempt BURN-DOWN, part 1 with locking-off fault E:33 [50, 62] Notice: If the burner request ceases during the IGNITION PHASE operating states, or if the system is blocked off, these states are nevertheless maintained until ignition is detected. The heat generator only switches to BURN-DOWN, part 1 [50] after detection of an ignition or after expiry of the operating time for ignition.

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4.3.5. IGNITION PHASE, RUN-ON [14]

Drives: Ignition phase – fan (Z1) ON FFA200 ignition par. 33299

Ignition blower – ignition element (Z2)

OFF


A state change occurs if the run-on time of 20 sec. for the ignition blower (FFA200 ignition par. 33299)

has expired. FIRE-BED BUILD-UP - START [14]

4.3.6. IGNITION PHASE, hot start (not for tube burner (50-160 kW))

The additional function hot start can be activated using the parameter (FFA200 ignition par. 33311) by setting a value greater than 0. If the value 0 is set, the hot start function is deactivated. During the ignition phase (prefilling, filling, lambda probe test end), the temperature increase should be checked. If the temperature increase during the "prefilling" or "filling" phases is more than the value set in parameter 33311 (new parameter), there is immediately a change to "Test lambda probe end" status. Any residual time of "prefilling" or "filling" is no longer processed Immediate change to "Test lambda probe end" status. After the "test lambda probe end" status, the "ignition" and "run-on ignition blower" is skipped and the sequence goes directly to the "fire-bed start" status.

Parameters Group Description BioLyt (50)

33311 Ignition Hot start monitoring dT 0

4.4. FIRE-BED BUILD-UP [2]

4.4.1. Fire-bed start [20]

Drives:

Ignition phase – fan (Z1) OFF


Stoker/feeder screw (ES) 100 % for 13 sec. (FFA200 ignition par. 33300)

(Ball valve (VA5) OPEN) for xx sec. (FFA200 safety par. 34827)

A state change occurs if the run time "feeding screw after ignition detection" (FFA200 ignition par. 33300) and any run time ball valve has expired. (If a ball valve is set in the parameter FFA200 system par. 35340 to 9). FIRE-BED BUILD-UP [20]

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4.4.2. Fire-bed build-up [21]

Drives:

Ignition phase – fan (Z1) OFF

Induced-draught fan (SZG) 80...60 % FFA200 ignition par. 33306 / 33307

Primary air fan (DG) 15..15 % FFA200 ignite par. 33303 / 33304

Metering screw (DS) 0...X % FFA200 ignite par. 33305 (30 %)

Stoker/feeder screw (ES) X...100 % FFA200 ignite par. 33310 (0)

A state change occurs if the minimum run time of 5 min. (FFA200 ignite par. 33301) for fire-bed build-up has expired and: if the combustion chamber temperature (BRT) > 160 °C (FFA200 ignite par. 33308)

NORMAL OPERATION [30] if the BRT after expiry of the max. run time fire-bed build-up 5 min. (FFA200 ignite par. 33302)

< 160 °C (FFA200 ignite par. 33308) IGNITION PHASE, filling [11]

if, after the 2nd attempt (FFA200 ignite par. 33309) the BRT < 160 °C (FFA200 ignite par. 33308) Locking-off fault E:16 [50, 62]

4.5. NORMAL OPERATION [3]

4.5.1. NORMAL OPERATION, power modulation [30]

Drives:

Induced-draught fan (SZG) 25...65 % FFA200 burner par. 33555 / 33551

Primary air fan (DG) 12...15 % FFA200 burner par. 33553 / 33549

Metering screw (DS) 11...32 % FFA200 burner par. 33554 / 33550

Stoker/feeder screw (ES) 100..100 % FFA200 burner par. 33556 / 33552

Power modulation means that there is an attempt to reach and maintain the set value defined by the controller. On commencement of normal operation, output is always 100 % and is then reduced and adjusted. The parameter FFA200 boiler par. 35078 (H-Gen=100 %) can be used to set the maximum heat generator output (and, for example, reduce it) without the need to adjust the blower and screw speeds of rotation individually. A state change occurs if: the heating request ceases or the heat generator temperature rises above the heat generator set point

PLUS 12 K switch-off differential FFA200 boiler par. 35076 BURN-DOWN part 1 [50]

the O2 content in the flue gas falls below 4.5 % (FFA200 safety par. 34825) NORMAL OPERATION, lambda stop [31]

the combustion chamber temperature rises above 750 °C (FFA200 safety par. 34826) NORMAL OPERATION, BRT stop [32]

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4.5.2. NORMAL OPERATION, lambda stop [31]

If a lambda probe is set in the parameters (FFA200 lambda par 34053 FA-ID 83 = 1), the lambda stop function is activated. If the O2 content in the flue gas drops too sharply during normal operation, the fuel infeed is stopped to prevent the formation of dangerous low-temperature gases. Drives:




Stoker/feeder screw (ES) 100 % FFA200 burner par. 33556 / 33552 A state change occurs if: the O2 value rises above 4.5 % (FFA200 safety par. 34825) PLUS 0.2 %

NORMAL OPERATION, output modulation [30] the heating request ceases or the heat generator temperature rises above the heat generator set point

PLUS 12 K switch-off differential (FFA200 boiler par. 35076) BURN-DOWN part 1 [50]

4.5.3. NORMAL OPERATION, combustion chamber temperature stop [32]

If, during normal operation, the combustion chamber temperature rises too strongly, the fuel infeed is stopped in order to reduce the thermal load on the components in the combustion chamber. Drives:




Stoker/feeder screw (ES) 100 % FFA200 burner par. 33556 / 33552

A state change occurs if: the combustion chamber temperature BRT falls below 750 °C (FFA200 safety par. 34826) MINUS 5 K

NORMAL OPERATION, power modulation [30] the heating request ceases or the heat generator temperature rises above the heat generator set point

PLUS 12 K switch-off differential (FFA200 boiler par. 35076) BURN-DOWN part 1 [50]

4.6. FIRE-BED MAINTENANCE [4]

This function is not enabled.

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4.7. BURN-DOWN [5]

4.7.1. BURN-DOWN, part 1: Burn-down of the fire-bed [50]

This state empties the stoker/feeder screw and burns out the fire-bed still remaining in the burner. Heating surface cleaning starts. Drives:

Induced-draught fan (SZG) 90 % FFA200 burner par. 33540

Primary air fan (DG) 20 % FFA200 burner par. 33539

Stoker/feeder screw (ES) 100 % for 240 sec. FFA200 burner par. 33541


Ignition phase – fan (Z1) OFF FFA200 burner par. 33537

Heating surface cleaning (HFR) ON for 60 sec. FFA200 cleaning par. 33793

(Ball valve (AP) CLOSED) only if a ball valve is set in the parameters A state change occurs after 7 min. (FFA200 burner par. 33538) BURN-DOWN, part 2 [51]

4.7.2. BURN-DOWN, part 2: Cleaning the burner and combustion chamber cooling [51]

During the cleaning process, the residue is blown out of the burner, and/or the scraper (BioLyt 100-160) is activated to push any remaining residue into the combustion chamber. Induced-draught fan and primary air fan are triggered in blocks. (FFA200 burner par. 33546/33547/33548) In addition, during this state, the combustion chamber is cooled down to the temperature for "Burn-down OK" less than 160 °C (FFA200 burner par. 33543). Drives:



Ash scraper (ASS) ON FFA200 cleaning par. 33803

In parallel with burn-down part 2, the pellet hopper filling starts. See chap. 6. A state change occurs when all cleaning cycles have been completed. (FFA200 burner par. 33546/33547/33548 AND if filling of the pellet hopper is completed: if the combustion chamber temperature BRT < 160 °C (FFA200 burner par. 33543)

OFF, quiescent state [0] if the combustion chamber temperature BRT > 160 °C (FFA200 burner par. 33543)

BURN-DOWN part 1 [50]

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4.8. BURNER FAULT [6]

4.8.1. Fault management

Fault messages are divided into 3 categories: Warnings

Shown on the display as: "W" + fault code When a warning message is issued, heat generator operation is maintained if necessary/possible (depending on the nature of the warning message) with an emergency function.

Blockings Shown on the display as: "B" + fault code When a blocking action occurs, the heat generator is shut down for the duration of the blocking action. When the block has been remedied, the heat generator starts up again automatically.

Lockings Shown on the display as: "E" + fault code When a locking-off action occurs, the heat generator is shut down. It can only be put back into operation after pressing RESET.

When blocking and locking-off actions occur, the heat generator switches to state BURN-DOWN part 1 [50]. Fault B:20 (heat generator over-temperature, see chap. 4.8.2) is an exception here. As long as a fault ("B" and "E") is active, the room transfer system is not activated during burn-down. The lambda probe heater is also switched off. This means that the probe cannot be calibrated if the blocking switch is set to "0" (i.e. blocking B:20 is active). In general, the following applies: If the cause of a fault has not been remedied, the fault will occur again immediately after acknowledgement. Example: If the BRF is interrupted, the message "E:04" appears. If the fault is acknowledged via the Reset button but has not been remedied, this fault will reoccur as soon as the controller is rebooted.

4.8.2. Safety-relevant functions

4.8.2.1. Burn-back [63]

The temperature can be monitored at the stoker/feeder screw tube (ESF) by setting FFA200 safety par. 34820 to 1. If the temperature at the ESF rises above 120°C (FFA200 safety par. 34821), locking-off fault E15 is triggered. From the 32 generation with rotary feeder onwards, no burn-back safety temperature limiter is fitted any longer. Drives:

Induced-draught fan (SZG) 100 %

Primary air fan (DG) 0 %




Ignition blower (Z1 and Z2) OFF

A state change occurs if: The temperature at the ESF falls below 88 °C (FFA200 safety par. 34817) MINUS 5 K)

BURN-DOWN, part 1 [50]

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4.8.2.2. Heat generator excess temperature [60] This state serves to transfer the temperature when the heat generator temperature exceeds 88 °C (FFA200 safety par. 34817). Drives:





Return pump (KKP) ON

Return mixer (YKR) CLOSED


Ignition blower (Z1 and Z2) OFF A state change occurs if: Heat generator temperature (WF) < 88 °C (FFA200 safety par. 34817) MINUS 5 K)

BURN-DOWN, part 1 [50] As long as the heat generator temperature > 88 °C (FFA200 safety par. 34817) MINUS 5 K the blocking action B:20 is active.

4.8.2.3. Stoker/feeder screw rotation monitoring The rotation of the feeding screw and of the rotary feeder with chain drive is monitored via a microswitch. The microswitch is located at the uppermost position to be monitored, i.e. on the (uppermost) rotary feeder. The time between two switching positions is measured. If a time of 90 sec. (FFA200 safety par. 34819) is exceeded, locking-off fault "E:12" is triggered. The rotation monitoring function can be switched on and off via parameter (FFA200 safety par. 34818 FA-ID 95) (1=ON / 0=OFF). Factory setting (1=ON)

4.8.2.4. Negative pressure monitor The negative pressure monitor is only active if the induced-draught fan is active and the negative pressure monitor is activated (FFA200 safety par. 34822 = 1). Whenever the output of the fan is triggered, the negative pressure switch (PU) must be closed within 60 sec. (FFA200 safety par. 34823). If this is not the case, the speed of rotation of the induced-draught fan is increased by 10 % (FFA200 safety par. 34824), and at the same time, warning message W:30 is issued. If the pressure switch is active after this increase in the speed of rotation, the increase is maintained for all further states until the heat generator switches to state BURN-DOWN, part 1. If the pressure switch is still not closed after a further 60 sec. despite the increase in the speed of rotation (FFA200 safety par. 34823 FA-ID 99), locking-off fault E:29 is triggered.

4.8.2.5. Safety temperature limiter STB The heat generator safety temperature limiter (STB) monitors the heat generator temperature and trips if the heat generator temperature becomes too high and the controller does not react (e.g. if the heat generator sensor is not mounted in the immersion sleeve). The STB sensor is in the same position as the boiler sensor (WF), the STB itself is mounted in the electrical box under the control panel. The STB is self-locking, i.e. it must be unlocked after tripping. The locking-off fault E:01 appears on the display.

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4.8.2.6. Fire-bed monitoring If, within operating states NORMAL OPERATION [30], Lambda stop [31], BRT stop [40] and FIRE-BED MAINTENANCE [40], the combustion chamber temperature falls below 160 °C (FFA ignite par. 33308), a state change occurs BURN-DOWN part 1 [50], warning display W:23 The parameter (FFA200 burner par. 33574) can be used to set a delay time for this monitoring function (H-Gen = OFF). If this case occurs more frequently within a burner request than set at (FFA200 burner par. 33575) (H-Gen=OFF), warning W:23 is issued.

4.8.2.7. Over-filling of the burner The lambda probe monitors whether there is over-filling of the burner during operation. If too much fuel is fed in for the available amount of combustion air (meaning that the burner is over-filled), the O2 content in the flue gas falls. If the value falls below 4.5 % (FFA200 safety par. 34825), first, the lambda stop function becomes active (see chap. 4.5.2). If the O2 value remains below 4.5 % (FFA200 safety par. 34825) for longer than 20 min. (FFA200 lambda par. 34055), a state change occurs: of (FFA200 ignite par. 33287) = 2 (ignition detection via lambda probe)

BURN-DOWN, part 1, locking-off fault E:34 [50, 32] if (FFA200 ignite par. 33287) = 1 or 3 (ignition detection via BRT or AGT)

BURN-DOWN, part 1, warning display W:34 [50] Notice: If the lambda probe is deactivated (FFA200 lambda par. 34053), the over-filling monitoring and the lambda stop function are not active.

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4.8.3. Overview of fault messages

Fault code Description

Locking-off actions

E:01

STB active Heat generator safety temperature limiter has tripped. The STB must be unlocked before resetting the fault message.

E:02/E:03 Interruption/short-circuit flue gas sensor (AGF)

E:04/E:05 Interruption/short circuit of the combustion chamber sensor (BRF)

E:06/E:07 Interruption/short circuit of the heat generator sensor (WF)

E:08/E:09 Interruption/short circuit of the return sensor (RLF)

E:10/E:11 Interruption/short-circuit buffer temperature sensor (PF-A)

E:12 Feed signal stoker/feeder screw Stoker/feeder screw is blocked or motor and/or microswitch defective

E:13 Interruption ESF

E:14 Short circuit ESF

E:15 Burn-back shut-down

E:16

Number of attempts to build up fire-bed exceeded After 2 attempts, at the end of fire-bed build-up, the combustion chamber temperature of 160 °C (FFA200 ignition par. 33308) was not reached.

E:19 Lambda probe test failed (see chap. 4.2.3)

E:24/W:24

Lambda probe test cancelled through AGT (see chap. 4.2.3) Depending on the setting of (FFA200 ignition par. 33287 FA-ID 13) (H-Gen=3): with (FFA200 ignition par. 33287) = 2 E:24 with (FFA200 ignition par. 33287) = 1/3 W:24

E:25 Lambda probe interrupted

E:26 Lambda probe short circuit

E:29 Pressure switch does not switch Negative pressure in the combustion chamber is not OK (see chap. 4.8.2.4)

E:33

Ignition not successful After 2 ignition attempts - no increase in the combustion chamber temperature by 10 K (FFA200 ignition par. 33296), if (FFA200 ignition par. 33287) = 3 or - no increase in the flue gas temperature by 10 K (FFA200 ignition par. 33297), if (FFA200 ignition par. 33287) = 1 or - no drop in the O2 value below 14.8 % (FFA200 ignition par. 33295, if (FFA200 ignition par. 33287) = 2 has been measured or registered.

E:34/W:34

VALUE MEASURED BY THE LAMBDA PROBE DOES NOT RECOVER DEPENDING ON THE SETTING OF (FFA200 IGNITION PAR. 33287) (H-GEN=3): with (FFA200 ignite par. 33287) = 2 E:34 with (FFA200 ignite par. 33287) = 1/3 W:34

If the O2 value remains below the set value (9.0 %, (FFA200 lambda par. 34052) for longer than 20 min. (FFA200 lambda par. 34055), the lambda controller is deactivated until the O2 value has recovered.

E:37

Filling time exceeded, but PBSu=0 After 45 min. filling time (FFA200 filling par. 34561), both FS sensors in the pellet box still report "empty".

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E:38

Number of filling attempts exceeded After the start-up of the suction turbine and 3 start attempts (FFA200 filling par. 34573) …. …the over-temperature switch of the discharge screw (AST-V) or …the overfill fuse for the suction system (RAS) or …the door contact switch of the storage room (TKSV) is still open.

E:45

Feeder does not draw in pellets (only with use of suction probe switchover unit (FFA200 filling par. 34575) = 3): After moving to all available suction probes/positions and expiry of the maximum filling time, the upper FS sensor (PBSo) still reports empty.

E:46

Max. run time for suction probe switchover/move to zero point exceeded (only with use of the suction probe switchover unit (FFA200 filling par. 34575) = 3) The maximum run time for moving to the zero point/a suction probe was exceeded twice in succession.

Blocking actions

B:20 Heat generator maximum temperature exceeded Heat generator temperature > 88 °C (FFA200 safety par. 34817)

B:21 Blocking switch active:

- Blocking switch or emergency off switch "B5" is activated.

B:22 Relay test active

B:32

Filling level sensors wrong signal sequence The top filling level sensor in the pellet box reports "full" although the bottom filling level sensor still reports "empty".

Warnings

W:17

Filling time exceeded The max. run time for filling, 45 min. (FFA200 filling par. 34561), has been exceeded and the top filling level sensor in the pellet box still reports "empty".

W:18 Storage room almost empty Is only active if filling level monitoring is connected in the storage room (BFSV).

W:19 Lambda probe test failed (see chaps. 4.2.3 and 4.3.3)

W:22 Filling blocked through off-period Filling is blocked/disabled during the set off-periods (FFA200 filling par. 34566...34569).

W:23

Fire-bed extinguished during operation During operation, the combustion chamber temperature falls to below 160 °C (FFA200 ignition par. 33308) for longer than the time (FFA200 burner par. 33574) (H-Gen=OFF) for the Xth time (FFA200 burner par. 33575)

W:24 Test lambda probe cancelled

W:30 Negative pressure low The speed of rotation of the induced-draught fan is increased. (See chap. 4.8.2.4)

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W:40

Empty ash box Note that the ash box may require emptying, message appears after a fuel throughput of 4/4/9/9/9 t (FFA200 cleaning par. 33801). Message is acknowledged by resetting the meter "Ash box" (FFA200 meter par. 33031) Message can be deactivated via (FFA200 cleaning par. 33800) (=OFF). The message can also be displayed on the control module directly. Or with the Reset key. INFO: Ash screw continues to run even when W:40 is not acknowledged.

W:41

Heat generator cleaning necessary Note that the burner and the combustion chamber require cleaning, message appears after a fuel throughput of 6/8/12/15/18 t (FFA200 cleaning par. 33802). Message is acknowledged by resetting the meter "Heat generator cleaning" (FFA200 meter par. 33032) Message can be deactivated via (FFA200 cleaning par. 33800) (=OFF). The message can also be displayed on the control module directly. Or with the Reset key.

W:42

Pellet box empty If (FFA200 filling par. 34575) = OFF (that is, no automatic filling system is present), the message is displayed when the pellet box is empty. The message is automatically deleted as soon as pellet infeed resumes (i.e. the PBSu once again signals "full").

4.8.4. Fault reporting output (SMA)

The automatic firing device has a 230V output with which fault messages can be displayed and which can be used to connect up further functions (e.g. SMS module, external fault lamp etc.). Parameter (FFA200 system par. 35355) can be used to select which fault messages can be displayed at this output: - FFA200 system par. 35355 = 1: only locking-off actions (factory setting) - FFA200 system par. 35355 = 2: Locking-off actions and blocking actions - FFA200 system par. 35355 = 3: Locking-off actions, blocking actions and warnings

4.8.5. Fault memory

The automatic firing device is equipped with an internal fault memory which can store up to 25 fault messages. The following information is stored with every entry: serial no, fault/error code, date/time, op. state, WF, SZG speed, BRF, O2, modulation. The fault memory is accessed via the parameter level Service H-Gen automatic FFA200 fault message. To see the next fault message, it is necessary to scroll down. The content of the fault memory can be deleted via parameter FFA200 system par. 35343 (change from OFF to SET and acknowledge).

4.8.6. Reset, acknowledgement of fault messages

Faults can be acknowledged with the "RESET" button (see Fig. in chap. 7).

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5. Other information on heat generator operation

5.1. Return pump, mixer, buffer sensor

In the case of the BioLyt (50-160), the return temperature is always controlled via the automatic firing device. The outputs KKP (for the return pump) and YKR (for the return mixer) are provided for this purpose. The return temperature is measured via the RLF sensor. The return pump starts up as soon as a burner request is pending. Parallel to the operation of the pump, the return mixer is also active and regulates the temperature to the CW set point of 53 °C (FFA200 boiler par. 35079). After cessation of the burner request and when the operating state burner OFF [0] is reached, the return pump runs in follow-on operation for a period of 45 min. (FFA200 boiler par. 35081). Then the pump switches off and return temperature control is no longer active. The mixer moves to position OPEN. Aid to distinguishing return mixer positions OPEN/CLOSED: If the sensor is "too cold," the mixer opens, i.e. position OPEN (this means no heat is transferred into

the system) If the sensor is "too warm," the mixer can close again, i.e. position CLOSED (this means that heat is

transferred into the system)

5.2. Consumption meters

The FFA-200 features 3 different consumption meters. Fuel consumption is calculated on the basis of speed of rotation and run time of the metering screw and a calibrated flow rate per hour. The meters can be accessed in the tree FFA200-Information. The FFA200 meter par. 33030/33031/33032 parameters can be used to reset the individual meters to 0 (access desired meter, change selection to 1 and acknowledge). As a result of variations in the properties of different consignments of pellets, the values shown by the meters may deviate by ±20 % from the actual consumption. In order to achieve precise results, the meter should be recalibrated several times a year, depending on the frequency of pellets deliveries (see chap. 5.2.2)

5.2.1. Definition of the consumption meters

USAGE Total consumption

The content of this meter should not be deleted (FFA200 meter par. 33030). Here, you can read off the total fuel consumption of the system.

ASH BOX Meter "Empty ash box" Shows the fuel consumption since the last emptying of the ash box. If the cleaning messages are activated (FFA200 cleaning par. 33800) = ON, H-Gen = ON, message W:40 (Empty ash box) becomes active after a throughput of 4/9 t (FFA200 cleaning par. 33801). When the meter is reset (FFA200 meter par. 33031) the message W:40 is also acknowledged.

CLEANING Meter "Clean heat generator" Displays the fuel consumption since the last heat generator cleaning operation. If the cleaning messages are activated (FFA200 cleaning par. 33800) = ON, H-Gen = ON, message W:41 (Clean heat generator) becomes active after a throughput of 6/8/12/15/18 t (FFA200 cleaning par. 33802). When the meter is reset (FFA200 meter par. 33032) the message W:41 is also acknowledged.

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5.2.2. Calibration of the meter

The meters must first be calibrated to adjust them to the available fuel. Procedure: The burner must be in state "0, burner OFF". The blocking switch must be activated and there must be enough fuel (bottom sensor = "full") in the

pellet box. The burner must be swung open so that the down-pipe beneath the pellet box is free, and a suitable

container must be in place to catch the pellets. Start calibration function: (FFA200 meter par. 33025) to ON. Then the metering screw (DS) is activated for 6 min. at a speed of rotation of 100 % (the screw stops

automatically when this time has expired). The discharged quantity of pellets must be weighed and the result multiplied by ten. The resulting

value is then entered in the (FFA200 meter par. 33026 FA-ID 112) (unit: kg/h). See flowchart in the appendix. Notice: Calibration should not be performed before the first burner-start, as the metering screw may not yet be completely filled, thus distorting the reading.

5.3. Cleaning functions

5.3.1. Heating surface cleaning

When changing to the BURN-DOWN operating state, part 1, heating surface cleaning (HFR) is activated once for 60 sec (FFA200 cleaning par. 33793). Heating surface cleaning is linked with the off-periods of the room transfer system (FFA200 filling par. 34566/34567/34568/34569) to prevent unpleasant noise levels at sensitive times. As long as an off-period is active, heating surface cleaning is blocked in addition to room transfer and is not activated. This block can be deactivated via parameter (FFA200 cleaning par. 33805).


33793 Cleaning Heating surface cleaning, run time 60

33805 Cleaning AAT+HFR blocking parallel to filling block 1

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5.3.2. Ash discharge

The ash discharge depends on the pellet consumption. If the throughput specified in (FFA200 cleaning par. 33804) is reached, the ash discharge is activated at the next start. Switch-on conditions: Activation only in ignition phase operating state, pre-fill Activation at the next start after reaching a throughput of 50 kg (FFA200 cleaning par. 33804) Runtime 60 min. (FFA200 cleaning par. 33794) The AAT can be blocked as an option (FFA200 cleaning par. 33805). If the block is active, the same off-

periods apply as for filling


33794 Cleaning Ash discharge duration in minutes 60

33804 Cleaning Pellet consumption in kg for ash removal 50

33805 Cleaning AAT-HFR blocking parallel to filling block 1

5.3.3. Ash scraper (only on BioLyt 100-160)

The burner of the BioLyt(100-160) is equipped with a scraper which pushes the ash remaining after blow-out out of the burner and into the combustion chamber. In rest position, the scraper is always positioned at the rear end of the burner. The scraper is triggered via variable output VA1 on the automatic firing device. The output is parameterised as follows: Variable output 1 (VA1): (FFA200 system par. 35336 = 3)

On change to the state BURN-DOWN, part 2, the scraper is activated for a period of 450 sec. (FFA200 cleaning par. 33803) and returns to its original position when this time has elapsed.


33803 Cleaning Ash scraper discharge duration 450

35336 System Variable output 1 0

CAUTION: During commissioning or when performing a manual start-up of the burner, ensure that the scraper has moved completely back to its original position! Otherwise, material can collect behind the scraper and damage it during ignition or in operation. !

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5.3.4. Forced burn-down

After a maximum pellets throughput of 85 kg (FFA200 cleaning par. 33799) during a burner request, a forced burn-down is started to allow the heat generator to fill the pellet box and clean the burner. State change: BURN-DOWN, part 1, [50]


33799 Cleaning High consumption meter readings up to forced burn-down

85

5.4. Calibration of the lambda probe

When the heat generator is commissioned and a new oxygen sensor is installed, the sensor must be calibrated. After a heating-up time of approx. 5 min. or when the O2 value displayed remains constant, the correction value at parameter FFA200 sensors lambda probe must be adjusted so that the probe displays a value of 20.5…20.8 %. This value must be checked during operation with an instrument and adjusted if necessary. Attention: The maximum O2 value which can be displayed is 21 %. However, as a result of calibration, the value can be set to above 21 %, even though it is not displayed. If the O2 value displayed is already 21 % at the start of calibration, the correction value must first be adjusted in the negative range to approx. 20.5 % to ensure that not more than 21 % is displayed. Notice: The probe cannot be calibrated when blocking or interlocks are active. The probe heater is deactivated during the above states. If the probe "deteriorates" over time, that is, if it no longer displays the maximum value of 21% with air, it can be readjusted via this parameter.


35591 Sensors Lambda probe (O2) 0

Notice for commissioning: If both filling level sensors report "empty" and the blocking switch is not active, the controller switches to operating state "BURN-DOWN, part 1"directly after switch-on. This means that the probe cannot be calibrated. To avoid unnecessary waiting times (until burn-down parts 1+2 have been completed), we recommend covering the bottom filling level sensor PBSu with pellets by hand or bypassing it temporarily with a cable bridge. The controller then remains in state 0 after switch-on (if there is no burner request pending), and the probe can be calibrated.

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5.5. Frost protection

The FFA-200 is equipped with its own frost protection function. This function can be activated / deactivated via a parameter (FFA200 system par. 35329) H-Gen = 1. The frost protection function is divided into: Pump frost protection:

If the temperature at the return sensor (RLF) falls to below 5 °C (FFA200 system par. 35330), the return pump (KKP) is activated until the RLF is above 5 °C again.

Heat generator frost protection: If the temperature at the heat generator sensor (WF) falls below 2 °C (FFA200 system par. 35331), the FFA receives the "Set point for bus interrupt" as a burner request (FFA200 boiler par. 35074) and starts up. The set point (or the request) is maintained until the minimum heat generator temperature (KT = 10 °C, FFA200 boiler par. 35085) or the minimum flue gas temperature of 80 °C (FFA200 system par. 35332) is reached.

Note: If a locking-off or blocking fault is active, frost protection is not permitted.


35329 System Frost protection enable 1

35330 System Frost protection pump 5

35331 System Frost protection heating 2

35332 System Minimum flue gas temperature 80

35085 Boiler Minimum switch-off point 10

35074 Boiler Set point for bus interrupt 70

35075 Boiler Activate set point for bus interrupt 1

5.6. Minimum switch-off point

For every heat generator start, the conditions of the "minimum switch-off point" must be met before the heat generator can switch off again: Heat generator temperature (WF) > 10 °C, (FFA200 boiler par. 35085) or Flue gas temperature (AGF) > 80 °C, (FFA200 system par. 35332)


35332 System Minimum flue gas temperature 80

35085 Boiler Minimum switch-off point 10

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5.7. Variable outputs

The FFA-200 has 5 variable outputs: VA4 (potential-free), VA1-3 and 5 (relay output). The respective functionality can be set via parameters (FFA200 system par. 35336-35340) as follows:


35336 System Function variable output 1 OFF





Setting VA1/2/3/4/5) = OFF, no function Setting VA1/2/3/4/5) = 1, Locking contact oil/gas (for bivalent plants)

The output is active (i.e. the contact is closed), when the FFA-200 is ready for operation. If a locking-off action, blocking action or room transfer off-period is active, the output is deactivated (and thus the blocking of the second heat generator lifted).

Only applies to BioLyt(50-160): Setting VA1/2/3/4/5) = 2, Burn-back signal The output is active (i.e. the contact is closed) if the fault E:15 (burn-back) occurs. A visual or acoustic signal can be connected (prescribed by VKF in some Swiss cantons).

Only applies to BioLyt(100-160): Setting VA1/2/3/4/5) = 3, Ash scraper In status "Burn-down part 2", the output for the ash scraper is activated.

Setting VA1/2/3/4/5) = 4, Ash box/heat generator cleaning If the warnings "W:40" and "W:41" (i.e. ash box or heat generator cleaning required) appear, the output is activated. The message can then be passed on via a visual/acoustic signal or an SMS module.

Setting VA1/2/3/4/5) = 5, Fill level storage room Not yet implemented

Setting VA1/2/3/4/5) = 6, AST-V2 When the double switchover unit is used (two pellet storage rooms) (FFA200 filling par. 34575) at 3, the second outfeed screw (AST-V) must be allocated to a variable output.

Setting VA1/2/3/4/5) = 7, Operation message If the burner is operating (fire-bed build-up and normal operation), the variable output is switched.

Setting VA1/2/3/4/5) = 8, KKP The variable output is activated in the same way as the boiler circuit pump.

Setting VA5 = 9, Ball valve function If there is a ball valve, the parameters for it can be set here.

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5.8. Query software version and revision, reset to factory setting

5.8.1. Software Version/Revision

The current software version can be queried in the information tree of the FFA200.

5.8.2. Reset FFA to factory setting

The automatic firing device can be reset to the factory setting: By briefly changing the boiler type.


35073 Boiler Boiler type 8

6. Pellets transfer, filling the pellet box

The pellet box can be filled by hand or automatically via a suction module. A wide range of room transfer systems can be used here: Suction turbine + room transfer screw Suction turbine + mole Suction turbine + underground storage tank Suction turbine + suction probes with switchover unit Fire damper + screw conveyor (often implemented in the UK) etc.

6.1. Inputs and outputs for pellet feed

The following inputs and outputs are available for actuation and monitoring of pellet feed: Outputs: AST-SV e.g. for actuation of the suction turbine or fire-protection damper (i.e. the component that must be started first when filling) AST-V e.g. for actuation of a room transfer screw/mole or a

flexible conveyor screw connected to the pellet box on the heat generator. AST-V2 e.g. for actuation of a second room transfer screw/mole or a

second flexible conveyor screw connected to the pellet box on the heat generator.

UE-LL Activation of the switchover unit for anti-clockwise rotation UE-RL Activation of the switchover unit for clockwise rotation Inputs: TKSV connected to the terminal strip and divided there to enable up to three monitoring elements to be connected (for more information see chap. 6.4). UE-S1 Normally open contact for zero position of the switchover unit UE-S2 Normally closed contact for selection of the suction probes

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CAUTION: The filling system must be correctly adjusted (FFA200 filling par. 34575)! If a suction turbine is used, parameter (FFA200 filling par. 34584) must be set to 1! Incorrect setting may result in damage to the system as a result of burn-back! !

6.2. Selection of the room transfer system

The parameter (FFA200 filling par. 34575) can be used to set the installed filling system.


34575 Filling Filling system OFF= No filling system 1= Pneumatic/mechanical filling system 2= Switchover unit with suction probes 3= Double switchover unit with two storage rooms

OFF

6.2.1. Filling without an automatic filling system

FFA200 filling par. 34575 = OFF: no automatic filling system installed. The pellet box is filled manually from bags.

6.2.2. Pneumatic/mechanical filling system

FFA200 filling par. 34575 = 1: Pneumatic filling system (suction turbine + screw/mole/underground tank suction probe/…) FFA200 filling par. 34584 = 1 (filling was only released during burn-down) When using this system the pellet box can only be filled if the burner is shut off and burnt out (burn-back hazard by underpressure in the pellet box) Electrical connection of components: AST-SV: Suction turbine AST-V: Removal element (screw, mole, vibrator, etc.) Continuous filling system (mechanical filling system (fire damper, etc. + screw conveyor)) FFA200 filling par. 34584 = 2 (continuous filling released during normal operation) Where a mechanical filling system is used, the pellet box can be filled during normal operation without having to switch off the burner (no negative pressure in the pellet box and thus no danger of burn-back). This ensures continuous operation without interrupting the heat supply. To authorise continuous filling, parameter (FFA200 filling par. 34584) must be set to two. Continuous filling is only allowed to be activated if the BioLyt is equipped with a double rotary feeder. Electrical connection of components:

AST-SV: Fire-protection damper (e.g. RAS 51) AST-V: Removal element (e.g. screw)

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6.2.3. Switchover unit with suction probes

FFA200 filling par. 34575 = 2: Switchover unit with suction probes Additional inputs and outputs are required when using suction probes with a switchover unit. The outputs are assigned to the two variable outputs VA2 and 3 when the parameter (FFA200 filling par. 34575 = 2) is set: Outputs: Anti-clockwise rotation: VA2=UE-LL

Clockwise rotation: VA3=UE-RL Inputs: Limit switch S1 for zero point monitoring (N.O. CONTACT): UE-S1 Limit switch S2 for position monitoring (N.C. CONTACT): UE-S2

6.2.3.1. Additional or extended parameters:


34576 Filling Number of filling level sensors 1: only PBSo 2: PBSo and PBSu

2

34577 Filling Number of suction probes 1...10 probes 4

34578 Filling Selection of suction probe AUTO…10 probes

0 (AUTO)

34579 Filling max. run time suction probe switchover CW 110

34580 Filling max. run time travel to zero point CCW 420

34581 Filling Time for probe alignment 0

34582 Filling Reset switchover unit OFF

34585 Filling Number of fillings per probe/outfeed before changing

8

6.2.3.2. Move to zero point

After a power failure or reset (FFA200 filling par. 34582 = 1), the switchover unit always moves to zero point (S1) first:

UE-LL = ON to S1 = ON If the zero point has not been reached after 420 sec. (FFA200 filling par. 34580), a second attempt is started. After two failed attempts, locking-off action E:46 is triggered.

6.2.3.3. Positioning options, movement to a suction probe and alignment The switchover unit allows travel to maximum 10 positions: The max. number of positions available depends on the number of suction probes parameter (FFA200 filling par. 34577) The unit always travels to the individual suction probes/positions in clockwise direction: Position 1: Anti-clockwise rotation (UE-LL) = ON, travel to zero point

Clockwise rotation (UE-RL) ON to S2 = OFF--> Pos. 1 has been reached or time FFA200 filling par. 34579 exceeded --> 2nd attempt

then align (if aligning is activated, FFA200 filling par. 34581)

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Position 2: Clockwise (UE-RL) = ON to S2 = ON --> Pos. 2 is reached or time FFA200 filling par. 34579 exceeded --> 2nd attempt then align (if aligning is activated, FFA200 filling par. 34581) and so on, until all other positions have been reached. Suction probe switchover is always performed in the clockwise direction; that is in ascending order: 1 --> 2 --> 3 --> 4 --> …. plus aligning (if aligning is activated, FFA200 filling par. 34581). No suction probe is approached directly in descending order, that is in anti-clockwise rotation. Movement is always first to the zero point and then to pos. 1 again.

6.2.3.4. Filling process for switchover unit in automatic mode or with fixed probe setting At parameter (FFA200 filling par 34578), automatic mode (0) or operation with a preset suction probe can be selected.

a) FFA200 filling par. 34578 = 0 (AUTO)

Before the filling process begins, a check is performed to ascertain the state of the switchover unit: if S2 = OFF (that is, correct suction probe positioned) --> Start filling

if S2 = ON (that is, suction probe not positioned) --> Travel to zero point, then to Position 1 (like reset)

The filling process starts and runs until PBSo = FULL ==> Filling OK

or after expiry of time (FFA200 filling par. 34561) (maximum run time filling) ==> Switch to next position ==> Filling process starts again and runs until

PBSo = FULL ==> Filling OK or after expiry of time (FFA200 filling par. 34561) (maximum run time filling) ==> Switch to next position ==> Filling procedure starts again until … and so on, until all available positions have been approached. When all available positions have been approached and PBSo still reports "empty," locking-off action E:45 is activated.

b) FFA200 filling par. 34578 = 1, 2, …. 10 (probe with fixed setting)

The set suction probe is approached directly. The filling sequence is the same as for automatic mode. Procedure when the max. run time (FFA200 filling par. 34561) has been exceeded depends on the setting of FFA200 filling par. 34577: FFA200 filling par. 34577 > 1

(the next possible suction probe is approached) If FFA200 filling par. 34577 = 1, locking-off action E:45 is activated.

The suction turbine (AST-SV) is not activated until the correct switchover unit position has been reached (that is, S2 = OFF). Simultaneous operation of the switchover unit and the suction turbine is not possible.

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6.2.3.5. Double switchover unit (from 2016) How are the parameters of a double switchover unit set (two pellet rooms with two outfeed screws): FFA200 filling par. 34575 must be set to 3. FFA200 filling par. 34577 must be set to 2. In addition, the function of the outfeed screw 2 (AST-V2) must be allocated to a variable output. (Either VA1, VA4, VA5, although with VA4 it should be noted that this is a potential-free contact.)

6.2.3.6. Fault messages Filling process not successful, E:45

If filling has not been successful after moving to all available positions (that is, pellet box empty), locking-off action E:45 (Feeder does not draw in pellets) is triggered.

Max. run time suction probe switchover/zero point exceeded, E:46

After 2 attempts to switch over suction probes / move to zero point and when the max. permissible time defined by (FFA200 filling par. 34579/34580) has been exceeded, locking-off action E:46 is triggered.

6.2.4. Lead and post-run times of the AST-SV

A lead and post-run time can be set for the AST-SV output in relation to the AST-V output. This is necessary, for example, to allow the build-up of negative pressure in the conveying system or to open a fire protection device before the discharge element is started.


34562 Filling Pre-run time vacuum feed 15

34563 Filling Post-run time vacuum feed 35

the output AST-SV is started 15 sec. (FFA200 filling par. 34562) earlier than output AST-V the AST-SV output is ON 35 sec. (FFA200 filling par. 34563) longer than the AST-V output

6.2.5. Run and interval times for output AST-V

With some extraction systems, (e.g. the pellet mole manufactured by Schellinger), it is necessary to activate the AST-V cyclically. The run and interval times of the output can be set for this during the filling process.


34570 Filling Run time room transfer screw (AST-V) 120

34571 Filling Pause time room transfer screw (AST-V) 5

Example: If (FFA200 filling par. 34570) = 30, (FFA200 filling par. 34571) = 5 during the filling process the output AST-V is ON for 30 sec., 5 sec. OFF, 30 sec. ON, 5 sec. OFF, ... If the interval time (FFA200 filling par. 34571) is set to 0, the output is continuously ON.

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6.3. Off-periods times, forced filling

It is possible to bar the room transfer system (RAS) for two periods of time per day (e.g. when refilling causes unpleasant noise levels):


34566 Filling Filling off-period 1 Start 0

34567 Filling Filling off-period 1 Stop 0

34568 Filling Filling off-period 2 Start 23.0

34569 Filling Filling off-period 2 Stop 7.0

In order to as far as possible prevent the pellet box running empty during these periods, forced filling is performed 30 min. before the start of an off-period: if FFA200 filling par. 34575 = 1 (pneumatic/mechanical filling system), and FFA200 filling par. 34584 = 1

BURN-DOWN, part 1 [50] (if burner in operation) FILLING, switch-on (if burner not in operation)

if FFA200 filling par. 34584 = 2, then FILLING, switch on (if burner in operation)

If in use without automatic filling system (i.e. FFA200 filling par. 34575 = 0) there is no change of state. If a filling operation is prevented during an off-period, the warning message W:22 appears on the display. If the pellet box becomes completely empty during an off-period (PBSo and PBSu = "empty"), the room transfer nevertheless remains barred. If there is a burner request during this period: it is ignored, unless a criterion of the frost protection function is met, see chap. 5.5 after expiry of the off-period, the pellet box is first completely filled (until PBSo = "full") before the heat

generator is started up again Note: Heating surface cleaning and ash discharge is also blocked parallel to the RAS off-periods. This block can be deactivated via parameter FFA200 cleaning par. 33805 = 0 (see also chap. 5.3.1)

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AD off-period=activeFilling par. 34566

…Filling par. 34569

[30]Normal operation

Burner req. =ON

PBSo&PBSu= OFF

Program flow FFA-200

AD off-period=activeFilling par. 34566 FA-ID 6

…Filling par. 34569 FA-ID 9

&[51]

Burn down, part 2

[50]Burn down,

part 1

[50,51]Burn down, part 1 & 2No filling

[0]Burner, OFF

Display: "W22"

Wait until

& yes

Filling

[51]Burn down,

part 2

- Burner operation during ash discharge off-period

[30]Normal operation

Filling par. 34584

Time=Off-period – 30 min.

&PBSo=empty

=2continuous transport

&[51]

Burn down, part 2

[50]Burn down,

part 1

=1 (pneum.

requirement)

Filling[30]

Normal operation

& yes

Filling

[0]Burner, OFF

Program flow FFA-200

- Burner operation before ash discharge off-period

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6.4. Monitoring

Up to three monitoring devices for the filling system can be connected to the FFA-200 (see the electrical circuit diagram on the right). As a rule, these are: Suction turbine monitoring (AST-SV) Door contact switch on the storage room (TKSV) Temperature switch, screw motor or (AST-V)

As these switches are all connected in series, all possibilities must be checked in the event of a fault. Before the fault E:38 "Number of filling attempts exceeded" is displayed, a maximum of 3 (FFA200 filling par. 34573) filling attempts are started. That means: After output "Suction turbine discharge” (AST-SV) is switched, input

"TKSV" (i.e. all monitoring devices connected in series) must be closed within 15 sec. (FFA200 filling par. 34562) so that output "Storage room discharge” (AST-V) can be activated.

If "TKSV" does not close, two further attempts are started after a wait period of 5 sec. (FFA200 filling par. 34574) in each case.

If all 3 attempts () fail, locking-off fault "E:38" is activated. Run time monitoring is also implemented in addition to the monitoring functions listed above: Filling process takes more than 45 min. (FFA200 filling par. 34561) and

PBSu = "full" & PBSo = "empty" Warning W:17 (see chap. 4.8.3) PBSu = "empty" & PBSo = "empty" Locking-off fault E:37 (see chap. 4.8.3)

6.4.1. Temperature switch, screw motor (AST-V Klixon)

When using discharge screw RAS 42, this thermo switch must (!) be connected. Otherwise, there is danger of the winding in the screw motor fusing if the screw jams.

6.4.2. Suction turbine monitoring (AST-SV Klixon)

The thermo switch of the suction turbine is monitored. If the turbine overheats as a result of overloading, the switch opens.

6.4.3. Door contact switch on the storage room (TKSV/ RAS)

Optionally, a negative pressure switch can be installed in the suction system. If the door is not closed, the discharge element in the storage room cannot start up. If this switch is not present, it must be bridged on the input terminal strip. Notice: Other volt-free monitoring switches (e.g. a fault reporting output for a mole) can be connected at the input terminals for the door contact switch.

6.4.4. Fill level monitoring in the storage room

A filling level monitoring device for the storage room can be connected at input "BFSV" on the FFA-100. If the storage room is empty, the warning message W:18 appears on the display. This message is automatically removed when the storage room has been refilled. FFA200 filling par. 34587 = 1 must be activated.

TKSV

10 118 96 7

TKSV/RAS

AST-SV

Klixon

AST-V

Klixon

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6.5. Operating state FILLING

The operating state "FILLING" is divided into several sub-functions: The process is always the same regardless of the type of filling system (FFA200 filling-par 34575), only the starting conditions are different.

6.5.1. FILLING, Wait

Drives:

Output AST-SV OFF

Output AST-V OFF If no request for filling the pellet box is pending, the "FILLING, wait" operating state is active. When a state change to "FILLING, switch on" occurs depends on the type of filling system: with (FFA200 filling par. 34584) = 1:

operating state BURN-DOWN, part 2 is active & PBSo = empty & no off-periods active FILLING, switch on

with (FFA200 filling par. 34584) = 2:

operating state BURN-DOWN, part 2 is active & PBSo = empty & no off-periods active

OR

operating state NORMAL OPERATION active & PBSo = empty & PBSu = empty & no off-periods active

FILLING, Switch on

6.5.2. FILLING, Switch on

Drives:

Output AST-SV ON

Output AST-V OFF State change occurs if Input TKSV = ON

& Suction pre-run time (15 sec., FFA200 filling par. 34562) expired FILLING, filling

Input TKSV = OFF & Suction pre-run time (15 sec., FFA200 filling par. 34562 FA-ID 2) expired & max. number of room transfer attempts (FFA200 filling par. 34573) not exceeded FILLING, switch on

Input TKSV = OFF & Suction pre-run time (15 sec., FFA200 filling par. 34562) elapsed & max. number of room transfer attempts (FFA200 filling par. 34573) exceeded FILLING, Interruption with locking-off action E:38

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6.5.3. FILLING, Fill

Drives:

Output AST-SV ON

Output AST-V ON State change occurs if PBSo = full FILLING, post-run TKSV = OFF FILLING, Interruption Max. filling time of 45 min. (FFA200 filling par. 34561) exceeded & PBSO = empty

FILLING, post-run, then W:17 Max. filling time of 45 min. (FFA200 filling par. 34561) exceeded & PBSO = empty

& PBSU = empty FILLING, Locking-off action E:37

6.5.4. FILLING, post-run

Drives:

Output AST-SV ON

Output AST-V OFF State change occurs if Post-run time AST-SV of 35 sec. (FFA200 filling par. 34563) expired

FILLING, end Post-run time AST-SV of 35 sec. (FFA200 filling par. 34563) expired

& max. filling time (FFA200 filling par. 34561) exceeded FILLING, Timeout W:17

6.5.5. FILLING, Interruption

This state occurs if the input TKSV opens during the filling process. Drives:

Output AST-SV ON

Output AST-V OFF State change occurs if Number of start attempts (FFA200 filling par. 34573) not exceeded

FILLING, Switch on Number of start attempts (FFA200 filling par. 34573) exceeded

FILLING, End with locking-off action E:38

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6.5.6. FILLING, Timeout

Drives:

Output AST-SV OFF

Output AST-V OFF If max. filling time of 45 min. (FFA200 filling par. 34561) exceeded

& PBSO = empty Warning message W:17

Room transfer is still started again during next burn-down, and the warning message W:17 is deactivated.

6.5.7. FILLING, locking-off action

Drives:

Output AST-SV OFF

Output AST-V OFF If max. filling time of 45 min. (FFA200 filling par. 34561) exceeded

& PBSo = empty & PBSu = empty Locking-off fault E:37

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6.6. Overview of filling process

6.6.1. Start of filling

6.6.2. Manual filling

PBSO = empty & off-period = OFF &

(APS = CLOSED)

FILLINGWait

PBSo = empty & PBSu = empty + FA-ID 308

& off-period = OFF

BURN DOWN part 2 active?

yes

NORMAL OPERATIONPower mod.

active?

BURN DOWNpart 2 active?

PBSO = 0 & off-period = OFF

no

yes

yes

2

FA-ID 322FILLING

Switch on1 yes

no

no

yes

yes

no

FILLING-FA-ID 300PBSo = empty + FA-ID

308 & off-period = OFF1

yes

2

no

no

FA-ID 151>1 no

Move to zero point or

probe()yes

FA-ID 151>1

no

Move to zero point or

probe()

yes

2

Display W:42Burn down

part 1+2

PBSo==empty&&PBSu==empty&&

FA-ID 308

PBSu==empty&&FA-ID 308

1FILLING

FA-ID 300

FILLING-FA-ID 151 = OFF

Display W:42Burn down

part 1+2Operating state 0 quiescent state

Operating state 0 quiescent state

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6.6.3. Suction turbine with screw

[1]FILLING

Switch on

TKSV = ON[5]

FILLINGInterruption

Start attempts > FA-ID 110

[2]FILLING

Fill

Max. filling time

expired

PBSO = full

[3]FILLINGpost-run

[4]FILLING

end

[6]FILLINGTimeout

Warning W:17

no

[7]FILLING

locking-off actionE:38

no

no

yes

[3]FILLINGpost-run

no

yes

[7]FILLING


FILLING-FA-ID 300

yes

1

no

FFA FILLING-FA-ID 151 = 1

PBSU = full

yes

2

yes

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6.6.4. Suction turbine with screw and switchover unit

[1]FILLING

Switch on

TKSV = ON[5]

FILLINGInterruption

Startattempts

> FA-ID 110

[2]FILLING

Fill

Max. filling time expired P1

PBSO = full

[3]FILLINGpost-run

[4]FILLING

end

no

[7]FILLING


no

yes

no

yes

FFA FILLING-FA-ID 151 = 2

yes

Counter fillings on suction probe x increase

by 1

Move to zero pointor probe()

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6.6.5. Suction turbine with screw and double switchover unit (two pellet storage rooms)

[1]FILLING

Switch on

TKSV = ON[5]

FILLINGInterruption

Startattempts

> FA-ID 110

[2]FILLING

Fill

Max. filling time expired

FA-ID 1PBSO = full

[3]FILLINGpost-run

[4]FILLING

end

no

[7]FILLING


no

yes

no

yes

yes

Counter fillings on suction probe x increase

by 1

Move to zero pointor probe()

FFA FILLING-FA-ID 151 = 3 / FA-ID 324 = 1

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6.6.6. Move to zero point or suction probe

yes

no

Move to zero point

UE-LL = ON

Max. run time FA-ID 305

2x exceeded?

Probe XMove to

UE-RL = ON

Max. run time FA-ID 304

2x exceeded?

[7]FILLING


no

yes

UE-S1 = CLOSED no

yes

UE-S2 = OPEN&&Probe X active

no

yes

Move to zero point or probe/change

UE-S2 = X-times opened?

no

Probe X reached and active

yes

Zero point reached

No. fillings on probe X <FA-ID 323

Probe X+1Move to

UE-RL = ON

Probe X+1 reached and

active

yes

Max. run time FA-ID 304 2x exceeded?

UE-S2 = 1-time opened?

no

no

yes

no

yes

Timer filling<FA-ID 1

yes

Number of suction probes

moved to in th is filling cycle<FA-ID 301&FA-ID 302=AUTO

no

yes

no

[7]FILLING


Position of the probe<FA-ID 301yes

no

yes

ALIGNINGUE-RL=ON fort=FA-ID 306

UE-LL=ON untilUE-S2 opens

yes

ALIGNINGUE-RL=ON fort=FA-ID 306

UE-LL=ON untilUE-S2 opens

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7. Display and operation

7.1. Overview of operating elements on the heat generator control panel

No. Designation Function

1 TopTronic® E control module

Touchscreen with black frame and high-gloss trim. Used as operator terminal for the plant, and can be operated by touching with the finger or stylus (no. 4).

2 Blocking switch 1 = ON Burner in operation 0 = OFF Burner not in operation (no frost protection)

Even when the blocking switch is set to 0, the plant is still live. To isolate the plant from voltage, the electrical power supply must be interrupted externally (e.g. main switch, fuse, etc.)

3 Folding lid To protect the folding compartment with stylus (no. 4), reset button (no. 6) and service plug (no. 9). Safety temperature limiter optional (no. 8)

4 Stylus Stylus for operating the control module.

5 Burner fault light Lights up if there is a fault in the burner.

6 Reset Used for resetting if the burner fault lamp lights up

The reset button is allowed to be pressed twice at most. If the burner fault lamp continues to be lit, please contact Hoval Customer Service

7 Bivalent switch (optional)

Used for switching priority in plants with several heat generators or for other plant-specific switching functions.

8 Safety temperature limiter (optional)

Optional installation of a safety temperature limiter. Used for interrupting the heat generator if a set temperature is exceeded.

9 Service plug Used exclusively by the service technician.

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7.2. Query options for operator and service engineer

7.2.1. Query options in the INFO level of the FFA-200

Access via parameter level FFA-200 information Parameters Group Description Unit

257 Information SOFTWARE

258 Information STATUS

259 Information MODULATION %

260 Information BOILER °C

261 Information RLF ACTUAL °C

262 Information RLF SETPOINT °C

263 Information BUFFER °C

264 Information EXHAUST °C

265 Information COM. CHAMBER °C

266 Information ESF °C

267 Information ID FAN %

268 Information PRESSURE BLOWER

269 Information PU

270 Information DG MODULATION %

271 Information SPEED rpm

272 Information METERING %

273 Information FEEDER SCREW %

274 Information ESDU

275 Information LAMBDA HEAT

276 Information OXYGEN SENSOR %

277 Information AAT

278 Information HFR

279 Information APS

280 Information IGNITION BLOWER

281 Information IGNITION

282 Information FILLING

283 Information AST-SV

284 Information AST-V

285 Information BFSV

286 Information TKSV

287 Information PBSo

288 Information PBSu

289 Information KKP

290 Information YKR CLOSED

291 Information YKR OPEN

292 Information OUTPUT VA1





297 Information UE-S1

298 Information UE-S2

299 Information BLOCK

300 Information STB

301 Information ES-STB

302 Information FAULT MESSAGE

303 Information CONSUMPTION 1 kg

304 Information STORAGE ROOM kg

305 Information ASH BOX kg

306 Information CLEANING kg

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7.2.2. Relay test

Access to the relay test is via the parameter level FFA-200 relay test. To test the individual actuators, the parameter "Activate relay test" (FFA200 relay test par. 35841) must first be set to 1. Only one actuator can be activated at a time. Before the next actuator is activated, the active actuator must be switched off again. If you forget to switch off the activated actuator, it will be deactivated as soon as another actuator is activated. The required value can be entered using the display or changed with the + and – key. Notice: The relay test can only be activated in operating state BURNER OFF, quiescent state (0). Interlocks or blockings can be active simultaneously, access is still possible. Example: Relay test induced-draught fan Access via parameter level Service H-Gen Automatic function FFA-200 Relay test Activate relay test: Set FFA200 relay test par. 35841 to 1 Select induced-draught fan and enter the required value or adjust using + - key. Exit the relay test by setting the induced-draught fan to 0 and setting the "Activate relay test"

parameter to 0 again. Important note: If parameter (FFA200 relay test par. 35841) has not been reset to 0, the heat generator is blocked and message B22 is active. This means there is no automatic timeout in the relay test.

The following list shows all outputs/actuators which can be activated in the relay test.

Parameters FA-ID Group Description Unit Access

35841 818 Relay test Activate relay test 3

35842 801 Relay test Induced-draught fan % 3

35843 802 Relay test Primary air fan % 3

35844 803 Relay test Stoker/feeder screw % 3

35845 804 Relay test Metering screw % 3

35846 805 Relay test Mixer pump 3

35847 806 Relay test Mixer valve OPEN, CLOSED 3

35848 807 Relay test Lambda probe heating 3

35849 808 Relay test Heating surface cleaning 3

35850 809 Relay test Ash discharge 3

35851 810

Relay test Room transfer OFF -> 1=Turbine -> 2=Turbine+screw

3

35852

819

Relay test

Switchover unit 0-> zero point, 1-> probe position 1, 2 probe position 2, 3 -> probe position 3,…….

3

35853 812

Relay test Suction blower OFF -> 1=Blower ON -> 2=Blower+heating

3

35854 815 Relay test Fault reporting output 3

35855 816 Relay test Variable (VA1) 3





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7.2.3. Manual interruption of operation

7.2.3.1. Blocking switch The shut-down and controlled shut-down of the heat generator is carried out via the blocking switch (see Fig. on the right, position "0"). After actuation, a burn-down is performed and the heat generator is then blocked (display: blocking switch active) and only starts up again when the blocking switch has been set to "1" again. As with every blocking fault, room transfer remains deactivated during burn-down/cleaning. Note: As long as the blocking switch is set to "OFF," calibration of the lambda probe cannot be carried out, as the probe heating is switched off.

7.2.3.2. External heat generator block. An "external H-Gen block" can be programmed at one of the two variable inputs (VE1, VE2) on the TopTronic®E unit:

1. Allocation external block input H-Gen par 30026 2. Activate external heat generator block function via parameter 9074

To block the heat generator, a plug with a wire jumper must be plugged in at the programmed input: if a wire jumper is installed (i.e. H-Gen block = ON), the heat generator is blocked if a wire jumper is removed (i.e. H-Gen block = OFF), the heat generator is released Advantage: heat generator is really only blocked when the plug is plugged in.

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7.2.4. Emission metering

No. Designation Function

1 Selection heat generator Display of the heat generators present in the heating system. The horizontal arrows (<>) are used for selecting the required heat generator.

2 Time Duration of emission measurement. Calibrating the required time with plus ( ) and minus ( ), i.e. to be defined by the heating before the start of the measurement. The heat generator is switched off after the time has elapsed.

3 Power limitation Entry of the required power limitation. Regulation of the required power limitation by plus ( ) and minus ( ).

4 Plant information Information about the system in the selected heat generator. Additional information can be displayed with the horizontal arrows (<>).

5 ON Switching on the heat generator.

6 OFF Switching off the heat generator.

7 Position in the menu Name of the currently selected location / menu item.

8 Time of day Displays the current time.

9 Help No function is available at present.

10 Back Used as a button for returning to the main menu.

i The emission measurement is automatically deactivated when the "Emission" menu item is exited!

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8. Appendix

8.1. Various program flows

8.1.1. Complete program flow – simplified display

Program flow FFA-200 - simplified display -

[0]OFF,

quiescent state

RESETMains

[50]BURN DOWN,

part 1

[01]OFF,

anti-blocking protection

BRT >160 °CIgniting par 33308 FA-ID 32

[10]IGNITION PHASE,

Pre-filling

[11]IGNITION PHASE,

Filling

[02]…[12]TEST LAMBDA PROBE,

part 2

[13]IGNITION PHASE,

Ignition

[62]LOCKING

E:33

[20]FIRE BED BUILD-UP

[62]LOCKING

E:16

[30]NORMAL OPERATION

Modulation


Lambda stop


BRT stop[50]BURN DOWN

part 1

[51]BURN DOWN

part 2FILLING

Burner req.=ON

Ignition 1x not OK

Ignition OK

min. BRT 130 °CIgniting par 33308 FA-ID 32

2x not reached(igniting par 33309 FA-ID 33)

BRT >160 °CIgniting par 33308 FA-ID 32&&

Time>P33301 FA-ID 174

O2<4.5 %Safety par 34825 FA-ID 100

BRT>750 °CSafety par 34826 FA-ID 101Burner req. = OFF

[0]OFF,

quiescent state

Time= System par 35334 FA-ID 109 &&

Burner OFF > 24h &&

System par 35333 FA-ID 108 = ON

&

Ignition 2x not OK

(igniting par 33298 FA-ID 326)

[02]TEST LAMBDA PROBE,

part 1

[62]LOCKING

E:19Part 1 not OK

Part 1 OKO2 > 5.5 % (safety par 34825 FA-ID 100)

[62]LOCKING

E:34

>20 min.Lambda par 34055 FA-ID 136

Part 2 OK, O2 > 14 % (21 % - lambda par 34051 FA-ID 81)

min. BRT 130 °C(igniting par 33308 FA-ID:32)

1x not reached

BRT increase >

Par 33311 FA-ID 161)

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8.1.2. Program flow alarms

Occurrence of a "WARNING"

If possible, emergency operation

Program flow FFA-200- Burner fault, general -

Shown on display "W" + error code

Reset at next burner start

Occurrence of "blocking"

[50]BURN DOWN, part 1

Display:"B" + error code

Automatic reset after rectification

of the block

Occurrence of a "locking"

[50]BURN DOWN, part 1

Display:"E" + error code

Reset only by manual RESET

possible

No filling

No filling

Program flow FFA-200- Burner fault, boiler over-temperature -

Any operating state

WF>88 °CSafety par 34817 FA-ID 94

[60]Boiler over-temperature

Display: "B:20"

[50]BURN DOWN

part 1

WF<83 °CSafety par 34817 FA-ID 94

MINUS 5 K

Program flow FFA-200- Burner fault, lacking negative pressure -

Any operating state

SZG = ON

Warning "W:30"Reset at next burner

start

PU = OFF >60 sec.Safety par 34823 FA-ID 99

IncreaseSpeed of rotation

SZG

Locking "E:29"manual RESET

required

PU = OFF >60 sec.Safety par 34823 FA-ID 99

PU = ON

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8.1.3. Program flow Stopping manually and calibrating timer

Program flow FFA-200- Manual stop, blocking switch -

[0]BURNER, off

[10, 11, 13]Pre-filling, filling,

igniting

[20, 30, 31, 32, 50]Fire bed build-up, normal operation, lambda-&BRT stopBurn down, part 1

[13]Igniting

until ignition = OK

[0]BURNER, Off

with blocking "B:21"

[50]Burn down, part 1

with blocking "B:21"no filling

[50]Burn down, part 1

with blocking "B:21"no filling

Blocking switch(BLOCK)= active



Program flow FFA-200- Calibration pellet meter -

[0]BURNER, off

[0]BURNER, Off

with blocking "B:21"


Start calibration:DS = 100 %

PBSu = full(counter par 33025

FA-ID 144) = ON

- Weigh output quantity- Multiply value in kg by "10" (produces kg/h)- Enter calculated value for counter par 33026 FA-ID 112

Running time = 6 min.

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8.2. Technical data of the components used

8.2.1. Lambda - probe:

O2 [%] Voltage [mV]

21.00 -10.00

17.00 -6.50

14.50 -3.00

12.30 0.50

10.50 4.00

9.10 7.50

8.00 11.00

7.00 14.50

6.10 18.00

5.20 21.50

4.50 25.00

3.90 28.50

3.40 32.00

3.00 35.50

2.70 39.00

2.55 42.50

2.35 46.00

2.20 49.50

2.10 53.00

-20.00

-10.00

0.00

10.00

20.00

30.00

40.00

50.00

60.00

0.00 5.00 10.00 15.00 20.00 25.00

Vo

ltag

e [

mV

]

O2 [%]

Wiring:

1 2 3

O2

O2

wh

wh

gy

bk

4

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8.2.2. Combustion chamber temperature sensor (Ni-CrNi)

Voltage [mV] Temperature [C°] Voltage [mV] Temperature [C°]

0.00 0.00 8.50 211.68

0.50 12.79 9.00 223.81

1.00 25.54 9.50 235.91

1.50 38.23 10.00 247.98

2.00 50.88 10.50 260.03

2.50 63.49 11.00 272.06

3.00 76.05 11.50 284.06

3.50 88.57 12.00 296.04

4.00 101.04 12.50 308.00

4.50 113.48 13.00 319.94

5.00 125.88 13.50 331.86

5.50 138.24 14.00 343.76

6.00 150.56 14.50 355.65

6.50 162.85 15.00 367.52

7.00 175.11 15.50 379.38

7.50 187.33 16.00 391.23

8.00 199.52 16.50 403.06

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

450.00

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00

Tem

pe

ratu

re [

°C ]

Voltage [mV ]

Wiring: green = + = terminal 1

white = - = terminal 2

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8.2.3. Temperature sensor KTY-210

8.2.4. Filling level sensor in the pellet box (PBSu/PBSo)

Technical data Design: M30x1.5, plastic casing Cable length: 2 m Design of the output: Normally open/N.O. Operating voltage: 10-60 V DC Polarity reversal protection: There is no damage to the sensor if the wires are inverted Sensitivity adjustable by potentiometer:

Turn clockwise to increase the sensitivity Turn anti-clockwise to reduce the sensitivity

Function displays via LEDs

Attention: The LED display must not be used to check for correct functioning of the sensor. The switching status must always be checked via the display on the automatic firing device!

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8.2.5. Negative pressure characteristic curves, induced-draught fan

Notice: The negative pressures are measured with a T-piece at the negative pressure switch on the burner mechanism with a clean boiler and burner in operating state "BURNER OFF, quiescent state". In practice the values may deviate.

0

20

40

60

80

100

120

140

160

180

200

220

240

260

280

300

320

340

360

380

400

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Un

der

pre

ssu

re [

Pa]

Rotational speed [%]

Pressure characteristic curve Induced-draught fan BioLyt (50-160)

Saugzuggebläse BioLyt (50-75) Saugzuggebläse BioLyt (100-160)Induced-draught fan BioLyt (50-75) Induced-draught fan BioLyt (100-160)

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8.2.6. Wiring of the individual electrical components and cables

8.2.6.1. Lambda probe set E15.2 cpl. O2 6037451 Lambda probe NGK, 2053188

plus lambda probe cable, 2056728

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8.2.6.2. Sensor_TF / 1.1P /5 /4 /S2BH -AGF, L=5.0,(exhaust sensor 2056795)

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8.2.6.3. Sensor_TF / 2P /5 /6T /S2 -WF, L=5.0 m (heat generator sensor 2056793)

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8.2.6.4. Sensor_TF / NiCr-Ni /2.5 /6 /S2H -BRF (combustion chamber sensor 2056798) for BioLyt (50-75)

6

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8.2.6.5. Sensor_TF / NiCr-Ni /2.5 /3 /S2H -BRF (combustion chamber sensor 2056799) for BioLyt (110-160)

3

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8.2.6.6. Sensor_TF / 2P /2 /6T /S2 -ESF, L=2.0 m (feeding screw sensor 2056792)

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8.2.6.7. Sensor_TF / 2P /5 /6T /S2 -PF-A, L=5.0 m (buffer sensor automat function 2056874)

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8.2.6.8. Bottom filling level sensor cpl. PBSu, 2055872

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8.2.6.9. (Rotational speed monitoring 2056161)

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8.2.6.10. Air pressure switch assembly PU, 6033621

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8.2.6.11. Connection cable, induced-draught fan SZG, 2056158

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8.2.6.12. Connection cable HFR,2038176

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8.2.6.13. Connection adapter cpl HFR 2056162

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8.2.6.14. Hot air blower cpl. 1.4 kW 41-BL, 6033841

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8.2.6.15. Connection cable, primary air fan DG, 2056158

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8.2.6.16. Connection cable, primary air fan DG-PWM, 2055906

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8.2.6.17. Connection cable, ash discharge AAT, 2056160

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8.2.6.18. Connection cable RAS 81/85-FFA200 (6034379)

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8.2.6.19. Extension cable RAS 85-FFA200, 6037527

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8.2.6.20. Flat gear motor FAH17-86-IT90XL (2056157) stoker/feeder screw

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8.2.6.21. Motor cpl. metering screw (6033839) 6 rpm, all BioLyt (50-160)

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8.2.6.22. Linear drive SH230A300, 245247 (only BioLyt (100-160))

0 1

Movement direction

by L1

bn

wh

bu

12

NP

E

2000

Note:

- Direction of rotation switch must be set to "1". - In normal status, the drive must move through L1 direction burner rear wall.

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8.2.7. Overview of inputs and outputs, FFA-200 board

Legend F1= AST-SV and ignition 10AT F2 = AST-V, YKR, RLP, HFR, AAT, SMA, VA1/2/3/4, 6.3AT F3 = DG, VA5 6.3AT F4 = DS/HS 2AT F5 = SZG 2AT F6 = SK 2AT F7 = mains adapter 2AT F8 = ES/DR 2AT

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8.2.8. Electrical circuit diagrams

8.2.8.1. Internal wiring and external connection diagram

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9. Notes

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10. Parameter list

The following table shows all parameters and the factory settings for the various heat generator sizes. The column "Access" shows the level in which the parameter in question can be adjusted/viewed. The levels are defined as follows: 4: Parameters can only be set in the manufacturer level (accessible with OEM code) 3: Parameters can only be set in the service engineer and manufacturer levels (accessible with service engineer code) 0: Parameters can be set in operator, service engineer and manufacturer levels (without code) Remarks: To provide a clearer overview, not all factory settings are given. The settings for types 70/75, 100/110,

130, 150/160 only differ from the factory setting for the BioLyt(50) in the case of the parameters listed. The following parameter table is laid out so it can be printed out at the system and filed in the system

folder. One column is blank between the columns "H-Gen 150/160" and "Access" in which parameters that have been changed for the system can be entered.

Parameter list 41-BioLyt (50-160), FFA 200 – V10003

Description Par. FA-ID Group max. range

50

max. range 70/75

max. range 110

max. range 130

max. range 150/ 160

Access Unit

Start meter calibration 33025 144 Counter OFF OFF OFF OFF OFF 4

Ratio metering screw speed (100 %) to pellet throughput (kg/hr.)

33026 112 Counter 40 40 62 62 62

4 kg/h

Activate warning message "fill storage room"

33027 314 Counter OFF OFF OFF OFF OFF

4

Residual quantity for warning message "fill storage room"

33028 315 Counter 1 1 1 1 1

4 t

Storage room fill level 33029 313 Counter 0 0 0 0 0 0 t

Reset - consumption meter 1 33030 113 Counter 0 0 0 0 0 0

Reset - emptying of ash box 33031 145 Counter 0 0 0 0 0 0

Reset - message cleaning 33032 146 Counter 0 0 0 0 0 0

Cycle ES during pre-filling and filling 33281 14 Ignition 30 30 30 30 30 5 %

Time for pre-filling 33282 15 Ignition 60 60 5 5 5 5 s

Time for filling 33283 16 Ignition 120 120 200 200 200 4 s

Filling, primary air fan 33284 17 Ignition 20 20 15 15 15 5 %

Cycle DS during pre-filling / filling 33285 18 Ignition 55 55 55 55 55 5 %

Induced-draught fan during lambda test, pre-filling and filling

33286 79 Ignition 45 45 45 45 45

5 %

Ignition detection 1 = AGF / 2 = O2 / 3 = BRF

33287 13 Ignition 3 3 3 3 3

5

Ignition run time 33288 19 Ignition 540 540 540 540 540 5 s

Ignition induced-draught fan 33289 21 Ignition 65 65 65 65 65 5 %

Ignition induced-draught fan delay 33290 22 Ignition 10 10 10 10 10 5 s

Ignition primary air fan speed 1 33291 20 Ignition 0 0 0 0 0 5 %

Ignition primary air fan speed 2 33292 162 Ignition 0 0 0 0 0 5 %

Ignition primary air fan run time 33293 163 Ignition 0 0 0 0 0 5 s

Ignition primary air fan pause time 33294 164 Ignition 0 0 0 0 0 5 s

O2 threshold for ignition 33295 23 Ignition 14.8 14.8 14.8 14.8 14.8 5 %

Delta T comb. chamb. temp. for ignition

33296 24 Ignition 10 10 5 5 5

5 K

Delta T flue gas temp. for ignition 33297 25 Ignition 10 10 10 10 10 5 K

Attempts ignition 33298 326 Ignition 2 2 2 2 2 5

Ignition blower run-on 33299 26 Ignition 20 20 20 20 20 5 s

runtime ES after ignition detection 33300 152 Ignition 13 13 13 13 13 5 s

Fire-bed build-up min. run time 33301 174 Ignition 5 5 4 4 4 5 min

Fire-bed build-up max. run time 33302 27 Ignition 5 5 4 4 4 5 min

Fire-bed build-up, primary air fan start 33303 28 Ignition 15 15 15 15 15 5 %

Fire-bed build-up primary air fan end 33304 169 Ignition 15 15 15 15 15 5 % Fire-bed build-up dosing screw (0 %->value) 33305 29 Ignition 30 30 35 35 35 5 %

Fire-bed build-up, SZG Start 33306 30 Ignition 80 80 100 100 100 5 %

Fire-bed build-up SZG end 33307 31 Ignition 60 60 70 70 70 5 %

Start OK at comb. chamb. temperature >

33308 32 Ignition 160 160 160 160 160

5 °C

Attempts fire-bed 33309 33 Ignition 2 2 2 2 2 5 Fire-bed build-up ES start (value -> 100 %) 33310 335 Ignition 0 0 0 0 0

Hot start monitoring delta T 33311 161 Ignition 0 0 0 0 0 5 K

Run time ignition blower during burn-down

33537 34 Burner 0 0 0 0 0

5 s

Burn-down part 1 run time 33538 35 Burner 7 7 14 14 14 5 Min.

Burn-down part 1 primary air fan 33539 36 Burner 20 20 20 20 20 5 %

Burn-down part 1 induced-draught fan 33540 37 Burner 90 90 90 90 90 5 %

runtime ES during burn-down 33541 153 Burner 240 240 240 240 240 5 s

Activate burn-down manually 33542 135 Burner OFF OFF OFF OFF OFF 5

Burn-down OK at comb. chamb. temp.<

33543 309 Burner 160 160 160 160 160

5 °C

Burn-down part 2 SZG 33544 317 Burner 100 100 100 100 100 5 %

Burn-down part 2 DG 33545 318 Burner 100 100 100 100 100 5 %

Burn-down part 2 number of cleaning blocks

33546 85 Burner 5 5 7 7 7

5

Burn-down part 2 block duration 33547 86 Burner 120 120 120 120 120 5 s

Burn-down part 2 block pause time 33548 87 Burner 60 60 20 20 20 5 s

Full load speed of rotation, primary air fan

33549 38 Burner 15 15 12 12 12

4 %


50

max. range 70/75

max. range 100/ 110

max. range 130

max. range 150/ 160

Access Unit

Full load speed of rotation, metering screw

33550 39 Burner 32 47 38 46 52

4 %

Full load speed of rotation, induced-draught fan

33551 40 Burner 65 75 80 90 100

4 %

Fill load speed of rotation, stoker/feeder screw

33552 50 Burner 100 100 100 100 100

4 %

Part load speed of rotation, primary air fan

33553 41 Burner 12 12 12 12 12

4 %

Part load speed of rotation, metering screw

33554 42 Burner 11 16 15 17 19

4 %

Part load speed of rotation, induced-draught fan

33555 43 Burner 25 25 35 35 35

4 %

Part load speed of rotation, stoker/feeder screw

33556 51 Burner 100 100 100 100 100

4 %

Fire-bed maintenance enable 33557 44 Burner OFF OFF OFF OFF OFF 5

Fire-bed maintenance from TA 33558 45 Burner 5 5 5 5 5 5 °C

DS in fire-bed maintenance 33559 46 Burner 5 5 5 5 5 5 %

SZ in fire-bed maintenance 33560 47 Burner 35 35 35 35 35 5 %

DG in fire-bed maintenance 33561 48 Burner 15 15 15 15 15 5 %

Fire-bed maintenance duration 33562 116 Burner 60 60 60 60 60 5 Min.

Burner power regulation K 33564 125 Burner 4 4 4 4 4 5 %K

Burner power regulation Ta 33565 126 Burner 20 20 20 20 20 5 s

Burner power regulation Tn 33566 127 Burner 180 180 180 180 180 5 s

Number of primary air fan Hall sensors 33567 128 Burner 2 2 2 2 2 5

Primary air fan - speed control K 33568 129 Burner 7 7 7 7 7 5 %K

Primary air fan - speed control Ta in milliseconds

33569 130 Burner 10 10 10 10 10

5 ms

Primary air fan - speed control Tn in milliseconds

33570 131 Burner 2000 2000 2000 2000 2000

5 ms

Primary air fan minimum speed (working range blower)

33571 132 Burner 1000 1000 1000 1000 1000

5 Rpm

Primary air fan maximum speed (working range blower)

33572 133 Burner 9900 9900 9900 9900 9900

5 Rpm

Code display mode (OFF / 1=Hoval code

33573 134 Burner 1 1 1 1 1

5

Delay time BRT<Para 32 for detection "NO FIRE-BED"

33574 137 Burner OFF OFF OFF OFF OFF

5 Min.

Delay number for warning message "NO FIRE-BED"

33575 138 Burner OFF OFF OFF OFF OFF

5

Number of SZG Hall sensors 33576 325 Burner 0 0 0 0 0 5

Heating surface cleaning, run time 33793 88 Cleaning 60 60 60 60 60 5 s

Ash discharge duration 33794 89 Cleaning 60 60 40 40 40 5 min

Short cleaning, start after 33795 90 Cleaning 45 45 45 45 45 5 min

Short cleaning duration 33796 91 Cleaning OFF OFF OFF OFF OFF 5 s

Short cleaning primary air fan 33797 92 Cleaning 80 80 80 80 80 5 %

Short cleaning, induced-draught fan 33798 93 Cleaning 80 80 80 80 80 5 %

High consumption meter readings up to forced burn-down

33799 49 Cleaning 85 120 210 230 250

5 kg

Activation of interval messages 33800 142 Cleaning ON ON ON ON ON 5

Interval until message "Empty ash box" 33801 143 Cleaning 4 4 9 9 9 5 t

Interval until message "Clean boiler" 33802 141 Cleaning 6 8 12 15 18 5 t

Ash scraper discharge duration 33803 149 Cleaning 450 450 450 450 450 5 s

Pellets throughput for ash removal 33804 154 Cleaning 50 50 130 130 130 5 kg

AAT+HFR blocking parallel to filling block

33805 312 Cleaning ON ON ON ON ON

5

Rotating grate – switch-on time 33806 166 Cleaning 15 15 15 15 15 5 s

Rotating grate - switch-off time 33807 167 Cleaning 600 600 600 600 420 5 s

Time for lambda test at start 34049 78 Lambda 10 10 10 10 10 5 min

O2 test max. flue gas temperature 34050 80 Lambda 100 100 100 100 100 5 °C

O2 max. deviation from 21.0 % 34051 81 Lambda 7 7 7 7 7 5 %

O2 set point 34052 82 Lambda 9 9 9 9 9 4 %

Lambda probe present 34053 83 Lambda ON ON ON ON ON 5

Lambda probes heating (ON = continuous heating/OFF = in "Burner off quiescent state" the lambda heating switches off)

34054 84 Lambda ON ON ON ON ON

5

Timer lambda stop 34055 136 Lambda 20 20 20 20 20 5 min


50

max. range 70/75

max. range 100/ 110

max. range 130

max. range 150/ 160

Access Unit

DS upper limit O2 regulation at part load

34056 55 Lambda 16 22 22 26 30

4 %

DS lower limit O2 regulation at part load

34057 56 Lambda 7 9 11 13 15

4 %

DS upper limit O2 regulation at full load

34058 57 Lambda 35 52 50 58 65

4 %

DS lower limit O2 regulation at full load

34059 58 Lambda 22 30 19 22 25

4 %

DS reduction without lambda probe 34060 59 Lambda 5 5 5 5 5 5 %

PI controller O2 K 34061 60 Lambda 0.6 0.6 0.6 0.6 0.6 5 %/K

PI controller O2 Ta 34062 61 Lambda 2 2 2 2 2 5 s

PI controller O2 Tn 34063 62 Lambda 20 20 20 20 20 5 s

Timer test lambda probe readiness for operation

34064 311 Lambda 200 200 200 200 200

5 s

Induced-draught fan – characteristic curve 1: Fan A R2E 150 AN91 2: Fan B R2E 180 CQ82 3: Fan C RB 0.09/2-71RQ 4: Fan D fan without performance chart

34305 65 ID fan CD 3 3 4 4 4

5

Performance chart - 1 - output for 5 % 34306 901 ID fan CD 15 % 15 % 5 %



















Performance chart - 1 - output for 100 %

34325 920 ID fan CD 100 % 100 %

5 %

Max. run time filling/timeout 34561 1 Filling 45 45 45 45 45 4 min

Pre-run time vacuum feed 34562 2 Filling 15 15 15 15 15 5 s

Post-run time vacuum feed 34563 3 Filling 35 35 35 35 35 5 s

Full detector, debounce (PBSo) 34564 4 Filling 5 5 5 5 5 5 s

Empty detector, debounce (PBSu) 34565 5 Filling 20 20 20 20 20 5 s

Filling off-period 1 Start 34566 6 Filling 00:00 00:00 00:00 00:00 00:00 0

Filling off-period 1 Stop 34567 7 Filling 00:00 00:00 00:00 00:00 00:00 0

Filling off-period 2 Start 34568 8 Filling 23:00 23:00 23:00 23:00 23:00 0

Filling off-period 2 Stop 34569 9 Filling 7:00 7:00 7:00 7:00 7:00 0

Run time room transfer screw (AST-V) 34570 10 Filling 120 120 120 120 120 5 s

Pause time room transfer screw (AST-V)

34571 11 Filling 5 5 5 5 5

5 s

Filling level sensor 0=N.O. contact / 1=N.C. contact

34572 12 Filling 0 0 0 0 0

5

Number of attempts, room transfer 34573 110 Filling 3 3 3 3 3 5

Wait time after room transfer abort 34574 111 Filling 5 5 5 5 5 5 s

Filling system OFF: = no auto system, manual filling 1: Suction turbine with outfeed 2: Suction turbine with suction probes 3: Suction turbine with double switchover

34575 151 Filling 1 1 1 1 1

4

Number of filling level sensors 1: only PBSo 2: PBSo and PBSu

34576 300 Filling 2 2 2 2 2

5


50

max. range 70/75

max. range 100/ 110

max. range 130

max. range 150/ 160

Access Unit

Number of suction probes 1...10 probes

34577 301 Filling 4 4 4 4 4

4

Suction probe selection AUTO… 10 probes

34578 302 Filling AUTO AUTO AUTO AUTO AUTO

0

max. run time suction probe switchover CW

34579 304 Filling 110 110 110 110 110

5 s

max. run time travel to zero point CCW

34580 305 Filling 420 420 420 420 420

5 s

Time for probe alignment 34581 306 Filling 0 0 0 0 0 4

Reset switchover unit 34582 307 Filling OFF OFF OFF OFF OFF 5

Residual quantity after sensor = "empty"

34583 308 Filling 0 0 0 0 0

5 kg

Start conditions filling 1=only with burn-down 2= continuous filling during burn-down mode

34584 322 Filling 1 1 1 1 1

5

Number of fillings per probe/outfeed before changing

34585 323 Filling 8 8 8 8 8

4

Version with double switchover unit 1=1 boiler with 2 extraction systems

34586 324 Filling 1 1 1 1 1

5

BFSV activation 34587 333 Filling 0 0 0 0 0 5

Boiler over-temperature 34817 94 Safety 88 88 88 88 88 5 °C

ES monitoring enable 34818 95 Safety 1 1 1 1 1 5

ES monitoring timeout 34819 96 Safety 90 90 90 90 90 5 s

ES burn-back enable 34820 97 Safety ON ON ON ON ON 5

ES burn-back temperature max. 34821 98 Safety 120 120 120 120 120 5 °C

Negative pressure monitor enable 34822 328 Safety ON ON ON ON ON 5

Time for negative pressure monitoring

34823 99 Safety 60 60 60 60 60

5 s

Increase SZG on negative pressure warning

34824 310 Safety 10 10 10 10 10

5 %

Lambda stop at O2 < 34825 100 Safety 4.5 4.5 4.5 4.5 4.5 5 %

BRT stop at BRT > 34826 101 Safety 750 750 750 750 750 5 °C

Ball valve run time 34827 102 Safety 150 150 150 150 150 5 s

Time for opening APS 34828 319 Safety 25 25 25 25 25 5 s

Time for closing APS 34829 320 Safety 25 25 25 25 25 5 s

TimerStopBRT 34830 327 Safety 200 200 200 200 200 5 s

Heat generator type 35073 329 Boiler 8 9 10 11 12 4

Setpoint for bus interrupt 35074 66 Boiler 70 70 70 70 70 4 °C

Activate set point for bus interrupt 35075 332 Boiler ON ON ON ON ON 5

Switch-off hysteresis via setpoint 35076 67 Boiler 12 12 12 12 12 5 K

Switching difference to switch-off point

35077 68 Boiler 10 10 10 10 10

5 K

Maximum boiler output 35078 69 Boiler 100 100 100 100 100 4 %

Return set point temperature / minimum boiler temperature

35079 70 Boiler 53 53 53 53 53

4 °C

Mixer run time 35080 71 Boiler 150 150 150 150 150 4 s

Return pump follow-on time 35081 74 Boiler 45 45 45 45 45 4 min

Mixer P proportion K 35082 75 Boiler 6 6 6 6 6 5 %/K

Mixer scan time Ta 35083 76 Boiler 20 20 20 20 20 5 s

Mixer reset time Tn 35084 77 Boiler 180 180 180 180 180 5 s

Minimum switch-off point 35085 106 Boiler 10 10 10 10 10 5 °C

Buffer sensor operating mode 1: Only info display 2:Additional buffer function with "PF-A"

35086 150 Boiler OFF OFF OFF OFF OFF

4

Buffer operating mode 2 - buffer deduction

35087 155 Boiler 10 10 10 10 10

5 K

Buffer operating mode 2 - return set value elevation

35088 156 Boiler 1.5 1.5 1.5 1.5 1.5

5 K

Buffer operating mode 2 - maximum return set value elevation

35089 157 Boiler 8 8 8 8 8

5 K

Activate residual heat use 35090 170 Boiler ON ON ON ON ON 5

Minimum temperature for residual heat use

35091 171 Boiler 40 40 40 40 40

5 °C


50

max. range 70/75

max. range 100/ 110

max. range 130

max. range 150/ 160

Access Unit

Switch-on differential residual heat use

35092 172 Boiler 10 10 10 10 10

5 K

Switch-off differential residual heat use

35093 173 Boiler 5 5 5 5 5

5 K

Frost protection enable 35329 103 System ON ON ON ON ON 5

Frost protection pump 35330 104 System 5 5 5 5 5 5 °C

Frost protection heating 35331 105 System 2 2 2 2 2 5 °C

Minimum flue gas temperature 35332 107 System 80 80 80 80 80 5 °C

ABS anti-blocking protection 35333 108 System ON ON ON ON ON 5

ABS time daily 35334 109 System 8:00 8:00 8:00 8:00 8:00 5

SMA function 1:E, 2:E+B, 3:E+B+W 35335 139 System 1 1 1 1 1

5

Function VA1 OFF 1:blocking contact 2:burn-back signal 3:ash scraper 4:ash box boiler cleaning 5:fill level storage room 6:AST-V2 7:operating message 8:KKP boiler circuit pump

35336 123 System OFF OFF 3 3 3

5


35337 148 System OFF OFF OFF OFF OFF

5



5



5

Function VA5 OFF 1:blocking contact 2:burn-back signal 3:ash scraper 4:ash box boiler cleaning 5:fill level storage room 6:AST-V2 7:operating message 8=OFF 9:ball valve


5

Constant return increase 35341 316 System ON ON ON ON ON 3

Reset to factory settings 35342 330 System OFF OFF OFF OFF OFF 5

Reset fault signals 35343 720 System - - - - - 5


50

max. range 70/75

max. range 100/ 110

max. range 130

max. range 150/ 160

Access Unit

Flow temperature (WF) 35585 701 Sensors - - - - - 5 K

Return temperature (RLF) 35586 702 Sensors - - - - - 5 K

Buffer temperature (PF-A) 35587 703 Sensors - - - - - 5 K

Stoker/feeder screw temperature (ESF)

35588 704 Sensors - - - - -

5 K

Exhaust gas temperature (AGF) 35589 705 Sensors - - - - - 5 K

Combustion chamber temperature (BRF)

35590 706 Sensors - - - - -

5 K

Lambda probe (O2) 35591 708 Sensors - - - - - 5

Sensor type WF (1=KTY/ 2=PT1000) 35592 712 Sensors 1 1 1 1 1 5

Sensor type RLF (1=KTY/ 2=PT1000) 35593 713 Sensors 1 1 1 1 1 5

Sensor type PF-A (1=KTY/ 2=PT1000) 35594 714 Sensors 1 1 1 1 1 5

Sensor type ESF (1=KTY/ 2=PT1000) 35595 715 Sensors 1 1 1 1 1 5

Sensor type AGF (1=KTY/ 2=PT1000) 35596 718 Sensors 2 2 2 2 2 5

(*) "Correction lambda probe" Attention: The correction must be reset and checked at every commissioning at every replacement of the FFA every time the lambda probe is replaced every time the system is maintained

set to different values and checked.

Instruction manual for service engineers · stoker/feeder screw (constant speed of rotation). In...

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Transcript of Instruction manual for service engineers · stoker/feeder screw (constant speed of rotation). In...