Hargassner ECO-HK 20-60kW Installation Manual
Contents
1. warning device and pellets wood constr Boiler min tube 3 4 manu Press al water pipe Control Boiler room RSE RZS 2 Fire wall RSE RZS Heat output smaller than 150 kW Fire area lt 500 m Size of storage room smaller than 200 m Residential tract agricultural building 30 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 12 6 Fire extinguisher Install verified fire extinguisher every 2 years easily accessible outside of the boiler room right next to the boiler room door Amt of ext powder Certification TE atl en 12 7 Exhaust system Flue pipe a i iB HK 20 HK30 HK35 HK40 HK 45 __NominalPower kw 20 32 35 40 4 Minimum Power ew __ 9 105 12 1 150 Pas as u u we u u anen Ira s s s s 5 5 _Fluedraftmax Pa 10 10 10 10 10 10 10 __Flue pipe diameter mm 150 150 150 150 150 150 150 _ Install the exhaust system according to federal and local requirements verified ONORM EN 13384 1 O The flue pipe is rising towards the chimney and should be as short as possible O Install appropriate openings for cleaning O An explosion flap with draught stabilizer must be installed O Insulate the flue pipe Protection of a hot surface Risk of burn Protection of flammable materials and parts e2. e g doors stairway O Dismantle covering door HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 5 1 Dismantling cover door 5 1 1 Dismount Touch display BCE a O disconnect the BUS connection a at the back of the BCE O pull BUS cable out cover door O Put aside BCE 5 1 2 Dismantle cover door O Slide touch display upwards until it detaches from the cover O Tip over touch display and remove from the cover panel b O firstly pull lower and then upper hinge b upwards Secure door against tipping O Remove cover door and put aside O after the placement of the boiler the assembly of the cover door takes place in reverse order e Hang in door e Pull in BUS cable e Mount touch display NOTE Hargassner recommends to dismantle the cover door also for the assembly of the trim panel HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at gt Ill Installation 6 Mounting the trim panel Cover door O Place trim panel 3 flush to cover door c O fix with flange screw M6 x 10 3 1 7 Assembly Exhaust fan motor 71 Standard Exhaust fan IT gt _ O Fix exhaust fan motor 4 to exhaust fan housing 4 1 A Fan wheel and motor pre assembled enclosed O Mount motor with 4x copper nuts M8 d onto the housing Do not da
3. 25 and nut M10 Select assembling position depending on wall thickness Mount inlet metal sheet 2 5 3 at the inlet trough 2 5 flat head screw M10 x 25 and nut M10 take care that the inlet metal sheet touches the lateral wall of the auger trough 2 6 3 screw M8 x 20 O Mount trough covers 2 6 3 onto the extension troughs 2 6 flat head screw M8 x 20 amount depending on size of cover The joint of the trough covers should not be placed in the wall opening 20 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 10 5 Secure RA gearbox at the floor NOTE check the height adjustment and the correct position of the RA gearbox prior securing the gearbox top the fuel storage room 2 3 1 2 3 4 lool M spring blades 2 3 1 2 3 4 may not touch the ground with the tips f the ground is touched the stabilizer 2 7 1 has to be changed in height h Mido not exceed the maximum angle of the agitator system adjust height as required stabilizer can be used horizontally or vertically MiPay attention that non of the spring blades touches the wall f a connection of the blades and the wall can not be avoided center agitator in the fuel storage room layout A A so that the bend ing of the spring blades on the wall takes place unifomly on the wall with the wall opening the blades may not to
4. is intended solely to be used by authorised persons The transfer to third parties is prohibited and is liable to compensation All rights reserved also translations No part of this manual may be reproduced or processed using electronic systems duplicated or distributed without permission of Hargassner GmbH 1 1 Special measures prior commissioning through the operator Licensing requirements for safe operation and accident prevention regulations must be observed Work on hydraulic systems must be carried out only by personnel with specialised knowledge and experience in hydraulics 1 2 Liability The AUTOMATIC WOOD BIOMASS BOILER is a state of the art product and manufactured and tested according to recognised safety reg ulations However improper use may cause lethal hazards for the operator or third parties or may damage the unit and other property The AUTOMATIC WOOD BIOMASS BOILER must only be operated as intended and in technically perfect condition Especially errors tending to affect the safety shall be cleared immediately Liability for the function of the AUTOMATIC WOOD BIOMASS BOILER shall be borne by the owner or user insofar as the device has been used by persons without the necessary knowledge or authorisation from Hargassner GmbH has been improperly used serviced or repaired or has been handled in a manner that does not conform to proper use In the interest of the continuous development and improvement of our products we re
5. main power switch 11 to position lt 0 gt O Close with padlock supplied by others for maintenance repairs J During assembly keep locked to prevent unexpected acti vation of moving parts A Kepp key safe 14 3 Cable assembly NI N N N wood chip storage room 5 Hz gt H u at O Connect the cable according to the diagramm in the cabinet note the numbers on the connectors J Mount sensors according to the attached wiring diagram 36 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 15 Sensor installation 15 1 Outside sensor Position M non sunny side of building North North East coldest side of building M Installation height min 2 m VI Check for external heat sources falsification Chimney warm air ducts windows and doors M Cable outlet from sensor on bottom Prevent sensor from moisture M electrical installation with 2 pole cable Min profile see wiring diagram 15 2 Flow Accumulator External sensor according to hydraulic scheme M Execution of the temperature sensors except flue gas sensor PT 1000 immersion sensor with pre connected sensor cable Do not damage break sensor cable f required extend cable Min profile see wiring diagram 15 2 1 Flow sensor for heat circuits M Installation and position e approx 50 cm after heat circuit pump e metallic bl
6. stoker auger gt see Room Agitator RA assembly and adjustment on page 13 Lower part of the front cover door see Mounting the trim panel Cover door on page 10 nee Transports the flue gas from the boiler into the chimney m see Assembly Exhaust fan motor on page 10 Adjusts a stable return temperature packed loose in cardboard gt see Back end protection on page 32 To collect the ash from the combustion process see Ash box on page 24 7 Flow return Safety temperature breaker STB thermostat flue gas sensor lambda sensor etc according to sensor pack list Wall socket for the chimney companion set To clean the boiler 10 To clean the combustion chamber em ON OFF switch to provide electrical power to the boiler gt see Mount main power switch on page 36 Transports the flue gas from the boiler into the chimney gt see Rotatable exhaust fan optionally on page 10 HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill l Unloading the heating system DANGER Correct installation Death risk of injury damage from falling loads e The installation of the boiler has to be done by trained staff from HARGASSNER approved only use approved lifting gear e sufficient capacity and condition gt Weights see Transport weight on page 4 Do not exceed the m
7. ER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill Setting the spring blades Exact positioning of the blades G Screw M10 x 25 j u Sr ea as far as the desired 1 DO NOT TIGHTEN only possible at short extraction augers e screw the hex screw M10 x 20 into the shaft of the head part and turn with an appropriate tool as far as the desired spring blade is in the setting position the blades have to be movable M12 x 20 Turnstile DA Screw M10 x 35 Mount short blades low for tightening the blades and cnablades han mount spring blades with paddles RA 450 500 o Springbiede Length GapHimm o Spring biade Length Gap H tmm 770 65 200 1 2 3 1040 6 2 4 85 Cover plate 840 mm Cover plate 610 mm 3 pod w 1 8 a 0 Cover plate 1300 mm Springblade Length Gap H mm Cover plate 992 mm 4 pod Cover plate 990 mm Cover plate 710 mm 3 pod HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at O Ill Installation 10 4 Auxiliary trough equipment Inlet metal sheet trough covers and sensor tube 10 4 1 Inlet metal sheet and TUB sensor tube at the inlet trough z Screw M10 x25 Screw M10 Mount TUB sensor tube 2 5 2 at the inlet trough 2 5 flat head screw M10 x
8. INSTALLATION MANUAL WOOD CHIP BOILER ECO HK 20 60 HARGASSNER HEIZTECHNIK MIT Zu Exactly read follow and save these instructions HARGASSNER Heating technology for Biomass A 4952 Weng Upper Austria Phone 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at www hargassner com Installation Manual_Wood Chip_ECO HK_20 60_V04 Chapter Ill Installation 1 Genef als 220 0 ur ea dae naar Reese stew es 11 3 2 WANSDON soreer renr uren perra asien eu ed eaeans 11 4 3 Scope of delivery 2 00 cee es III 6 4 Unloading the heating system 22005 II 7 5 Positioning zu 24 220 Erima are een se aianee sts 1 8 6 Mounting the trim panel Cover door 000000es Il 10 7 Assembly Exhaust fan motor 0 00 eee eee Il 10 8 Mounting levelling feet 0 00 es 11 11 9 Assembly stoker unit 2 2uunnnn nun nn nn nun nenn 11 11 10 Room Agitator RA assembly and adjustment 11 13 11 Ash Box 2 2000 aaa ans nesner nennen I 24 12 Facilities ON SNC sc occ cece cette seme tee nennen III 26 13 Hydronic Installation 22 cee anne nun 11 32 14 Electrical installationS 0 00 ce nun nn 11 35 15 Sensor installation 00 00 nn nn nun 11 37 16 Remote control FR 25 FR35 FRAO III 39 17 HKM HKA or HKR 0002 nn nn nn III 40 18 Stickers for the storage room 00000e eee eee Il 40 19 Permits an
9. M H 5195 1 VDI 2035 SIA 384 1 treat heating water at first fill or refill VI The water in the heating system should be clean and free of corrosive elements Water from waterworks normally meet these requirements Extract ONORM EN 5195 1 Refill of water in the heating system Vent filling tube prior refill to prevent air in the hydraulic system Fill tube with water 13 1 Back end protection Corrosion in the boiler through condensing water Damage of the system through aggressive condensate e Install back end protection properly and according to hydraulic scheme If the plant drops under the dewpoint condensing water is produced This in combination with residual pieces of the combustion leads to the production of aggressive condensate in the boiler As long as the heating water return is under the minimum return temperature of the boiler an admixture of the flow takes place Regulation to constant return temperature at almost any time an admixture takes places Use a Haraassner back end protection The Hargassner back end protection is designed for a perfect operation of this boiler 32 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 13 1 1 Hargassner back end protection Boiler left from stoker auger Boiler _ Heating stoker auger Heating Boiler Vu Boiler RL
10. a pe a a L a M See adjoining images Back end protection RAG of a LEFT and RIGHT boiler The following shall be respected The back end protection shall be mounted on the boiler s lateral side For mounting the back end protection please see enclosed installation manual pay attention to the mixer direction The mixer is CLOSED when the circuit is closed the mixer is OPEN when the return RL is open During operation the return temperature increases when the mixer CLOSES and the return temperature decreases when the mixer OPENS O Install a safety venting device O Vent the pump 13 1 2 Back end protection on site R cklaufanhebegruppe Bauseits i Heizung Vorlauf Verschlie en lHeizung IRucklauf Kessel RL Adjoining image shows the back end protection connections of a LEFT boiler for a RIGHT boiler use the image mirrored The following shall be respected J remove lateral boiler cover O close not used pipes A pay attention to the mixer direction O Install a safety venting device O Vent the pump HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at G Ill Installation 13 2 HWS mixer Hot water on M Hot water heating with accumulator and integrated HWS coil or integrated accumulators HWS to prevent any burnings install a temperature limiter Temperature limiter 13 3 Secur
11. al at the bottom hole with flange screw M16x30 and tighten slightly N shrew me 10 2 5 place agitator on stoker unit Misecond worker needed JMount head part onto ball socket in between a downpipe or connection auger can be mounted special nut M10 high MRound head screw M10 x 130 placed from below upwards into the tension clamp Place ball head onto the ball pan of the stoker panel and fix slightly with screw M10 x 130 and special nut M10 high retrieved side down the agitator can also be connected to the stoker unit after the installation of the extension augers see Installation of the augers into the auger channel on page 16 not recommended Smore difficult positioning of the agitator due to the addi tional weight of the extension auger parts HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at gt Ill Installation 10 2 6 Installation of the augers into the auger channel Option 1 Option 2 Ui gt ei a Detail B As TIAC N a Hint Align the winding ends ofthe Option 1 augers to the top as it is O Insert the augers from top into the auger channel easier to check the exact Sequence for the insertion flush e Auger of the inlet trough 2 5 1 e auger of the extension trough s depending on execution 2 6 1 e Top auger from the head 2 8 1 Option 2 O Insert the augers from the back
12. ank surface e Fix with enclosed brass housing a and strap b prior mounting the sensor apply heat conducting paste c for better heat transfer M Thermal element Type K with pre connected sensor cable Do not damage break sensor cable If required extend cable Min profile see wiring diagram M Mounting the flue gas sensor Put sensor top into the aperture provided d stick into exhaust fan and fix with feather HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at G Ill Installation 15 2 3 Boiler HWS Accumulator and External heat sensor M Mount with provided immersion sleeve M Positioning of accumulator and HWS sensor Correct sensor position e To control the HWS and accumulator loading place the sensors correctly Sensor resistance Boiler HWS Accumulator Flow Return and External heat sensor 2 m 10 1000 15 1058 20 1077 25 1097 30 1116 35 1136 40 1155 45 1174 1232 75 1290 1309 85 1328 1347 95 1366 100 1385 EL BE Room temperature sensor Remote control FR25 Switch setting AUTOMATIC Clock and mid setting of the remote adjuster independent of the room temperature 3340 3650 Q external HWS Kessel fuhler R cklaufanhebe Boiler Bypasspumpe fuhler 1 Bei Hocheffizienzpumpe Parameter C1 auf RUck laufanhebung mit Mischer Optional einen bauseitigen An
13. assner at E Ill Installation 10 2 Delivery channel assembly Remove augers and covers prior assembly 10 2 1 Gearbox Trough Assembly O Connect gearbox 2 7 with inlet trough 2 5 O Place inlet trough with hex nut M12 on the threaded bolt A O 4 x Flat round screw M12 x 40 and 4 x Hex nut M12 Mount screws with screw head on side of the trough WE 4 M12x40 10 2 2 Trough assembly O Place the troughs according to the customers drawing on the floor Detail A 4x Nut M10 joint trough cov 4x Washer o 10 5 4x Screw M10 2 x 25 4x Nut MIO 4x Washer 10 5 4x Screw M1 0 x 25 2 O Place extension trough 2 6 correctly at the inlet trough 2 5 The joint of the trough covers should not be placed in the wall opening O Place sealing 2 6 2 between troughs O Screw the troughs 4x flat headed screw M10 x 25 4 x hex Nut M10 and 4 x Washer 10 5 mm Screw direction see Detail A 5 10 2 3 RA Head assembly 4x Screw MIO J Mount head part 2 8 at the last trough 4 x flat headed screw M10 x 25 4 x hex Nut M10 and 4 x Washer 10 5 mm 4x Nut M10 4x Washer 10 5 X for an easier assembling ask for a second worker da HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 10 2 4 Mount floor stabilizer Mount floor stabilizer 2 7 1 at the RA gearbox Place stabilizer vertic
14. aximum permissible exposure or the forklift truck See type plate Lock the slings against slipping Do not hang the plant plant parts screws shaft ends or moving parts Never stand under suspended loads At first lift the plant slowly from the ground Check that the load attaching points are chosen correctly and sit tight Only when the load is taken properly it is allowed to trans port it over longer distances Pay attention to the balance point Pick up point at the boiler is not the balance point Secure against tipping Lift the plant during transport with a forklift only as far from the ground that it can be transported safely Set up the boiler on a horizontal even place O Open the lid of the boiler A O Hang in hoist into eyebolt a When lifting focus on balance point Pick up point at the boiler is not the balance point HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at O Ill Installation 5 Positioning There are several possibilities to transport the boiler into the boiler room For a safe transport do not dismantle transport timbers O Transport boiler via rolls For a proper rolling performance use at least 1 tubes O Boiler is transported by a forklift or a forklift truck O Boiler positioning O Unscrew transport timbers from the boiler Tight space conditions at transportation
15. ccess area of the fuel storage room eg Fuel stor age door that it can be seen and noticed immediately PRIOR refilling Affix the sticker to a smooth well adhering surface o HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation I 19 Permits and reporting requirements The heating system has to be approved through the responsible authority body The construction or reconstruction of the heating system has to be approved by the appropriate regulatory authority e Report reconstruction to the supervising office Austria responsible building authority Germany Chimney sweep or building authority Other countries Follow the requirements of the state s own reg ulations 20 Commissioning of the heating system DANGER Unauthorized commissioning Commissioning through Hargassner authorised staff only e Prevent unauthorized commissioning e Absolute no working processes on running heating system e Only operate the system independently after signed commissioning protocol HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at a X Appendix Chapter X Appendix Please be advised that we are not responsible for damages or malfunctions resulting from non observance of the operation manual 1 Copyright notice This manual should be kept confidential The manual
16. d reporting requirements 0000008 Ill 41 20 Commissioning of the heating system 1 41 Chapter X Appendix 1 Copyright notice 6 2 u u eee ee Ved Haas X 42 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill Chapter Ill Installation 1 General This installation manual is part of the Operation manual for this boiler series Observe safety and operational instructions Death injury damage due to ignoring of safety instructions e Strictly read and follow the safety instructions in this manual e Exactly read and follow the operation manual e The accomplishment of the activities described in this manual are only al lowed to be carried out by Hargassner trained installation personnel Observe execution of the boiler and the fuel storage room Death injury damage through wrong execution of the installation room or fuel storage room e Boiler room Mcarry out as defined in the given local fire safety regulations Mfireproof floor MEnsure sufficient supply of combustion air according to local regulations MEnsure protection against wet conditions and frost proof execution MCarrying capacity of the foundation Weight of the boiler e Fuel storage room MiEnsure static execution Weight of fuel MlProtection against moisture water and dust MiEnsure dust proof execution MEnsure easy access and easy refill of th
17. e fuel storage room MSafety devices according to local requirements TUB ETU SLE MFuel storage room sticker HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Ill Installation 2 Transport 2 1 Transport weight The delivery of the heating system is in individually packaged units on pallets Term 20 35 kW 40 60 kW Boiler pallet depending on execution kg Pallet with stoker unit and agitator depending on execution kg system max 300 Unloading inspection and damage report After unloading J Remove transport packaging J Dispose packaging waste in accordance with law O Check all pallets for transport damage O Check delivery for completeness gt see Scope of delivery on page 6 In case of an incomplete delivery O put down a written record and report to HARGASSNER immediately If a transport damage occurs O put down a written record and take pictures of the damage O Send all documents to HARGASSNERRENNERGY lf a transport damage occurs also not it on the documents delivery note of the shipping company 2 2 Place of installation gt see Construction of boiler room on page 26 Conditions on site M sufficient light M fireproof plane and solid floor and ceiling construction M free of disturbing electrical installations and tubes 2 3 Space requirements of the heating system See data sheet or individual custom
18. e of the shaft to prevent losing 2 2 A MAttach 3 pod turnstile 2 2 with threaded sleeves A on top to the shaft of the gearbox Attach 4 pod turnstile with sliding jaws B on topside grease output shaft before assembling HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at lt i Ill Installation 10 3 Mounting spring blades place spring blades correctly Do not tighten main screws of the spring blades Place the spring blades at the correct position e The diameter of the agitator defines the length the position and the height of the spring blades Due to the varying lengths of the spring blades at RA350 500 an efficient extraction of the fuel out of the storage room is guaranteed e Do not tighten main screws of the spring blades The individual spring blades should have free space 2x Screw M10 x 35 Direction o rotation 2x nut M10 self locking Guide screw D 234 IScrew spring blades 2 3 1 2 3 3 at the turnstile 2 2 RA 150 400 3 spring blades 2 3 1 2 3 3 2 3 2 RA 450 500 4 spring blades 2 3 1 2 3 4 Mount 2 x hex screw M10 x 35 and 2 x Self locking hex nuts M10 Pay attention to the right position and the right length of the spring blades gt see Setting the spring blades on page 19 Mount spring blades with paddles out Spring blade paddles show in direction of rotation Bd HARGASSN
19. er drawing Observe minimum space requirements Drawing of the dimensions required To access the chimney 600 mm are required ECO HK 20 35 ECO HK 40 60 Room height min 190 cm min 190 cm D HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill Dimensions in E y room height min 190 cm For all diameters RA angle max 15 Important Watch for bumps on the floors and i d Draught stabilizer compensate if neede i GASENER ia a aj UF p E optimum 6 at chimney front min 600 Dimensions omw 20 o la I 45 50 60 _ Nominal heating output kW 2 s ss a 45 40 60 Boiler wit SB mm OOO Flue pipe connection ws Stan Height Return connection mm PO Maximum operating pressure bar PS 95 t d er gh Ma Wat Min draught o Pa PO Electricity supply Cd 400V AC 50HZ 13 A HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Ill Installation 3 Scope of delivery The add on parts might be packed inside the boiler or on separate pallets Transports the fuel into the combustion chamber see Assembly stoker unit on page 11 Carries the fuel from the fuel storage room into the
20. er unit 1 10 1 9 1 O Place 2 feather keys 10x8x60 1 6 on rotor shaft of the rotary valve O Plug motor with gear box 1 7 onto shaft of the rotary valve 1 8 Motor pointing to boiler back side O Fix motor on shaft with large washer 1 9 and hex screw M12 x 30 1 10 O Remove ring seal 1 12 from ball socket O Remove transport protection 1 11 from rotary valve O Reinstate ring seal again 9 2 Mount rotary valve design cover J Loosen 2x fastening screws from the motor protective cover Do not remove protective cover from motor J Place rotary valve design cover O Fix 2x fastening screws NE HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 10 Room Agitator RA assembly and adjustment 10 1 Overview Agitator RA 140 160 w O a OOOO OO RA Motor Drives the spring blades and the extraction auger Cover plate Hides spring blades underneath Inlet trough auger extensions Carries the fuel Auger extensions delivery channel with Carries the fuel 2 7 RA Gearbox with stabilizer Drivers spring blades 28 RA Head with auger Carries the fuel into the stoker auger 29 Gearbox stabilizer Stabilizes the gearbox Ea Spring blades Carry the fuel into the extraction auger HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office harg
21. g electrical wiring To reduce condensation Execution Insulation 30 mm Rockwool with aluminium coating Optimum Insulation gt 50 mm Tape joints O No flammable materials within 20 cm of an insulated flue pipe 12 8 Explosion flap Draught stabilizer Draft stabilizer with gas meter correctly set to 10 Pa The draught stabilizer may be installed at two different positions Pos 1 Distance to chimney max 500 mm e less sensitive against over pressure e high neg pressure may only be reduced slightly e more installation work Pos 2 Distance to flue gas sensor min 200 mm Neg pressure may be reduced well e Easy installation e sensitive against over pressure boiler flue gas sensor HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at G Ill Installation 13 Hydronic Installation M Install the hydraulic according to enclosed hydraulic scheme Design criteria according to EN 12828 M Note description on boiler VI Accumulator with sufficient volume M Accumulator with integrated HWS coil HWS mixer mandatory M Connection of all safety devices HLE SLE Thermal safety circuit M Check opening direction of mixing valve M Install the hydraulic control valves according to scheme M Install sensors according to hydraulic scheme see enclosed information sensor installation MI Heating water according to NOR
22. ilding Residential tract with extension lower side of roof must be fire protective F30 Acoustical signal horn bell or covered __ visual rotating or flash light No openings above or within 5 m left or right of warning device the fuel storage room Boiler Press water pipe Fuel storage room or fine and medium sized wood chips wood shavings and pellets Control RSE Size of storage room smaller than 50 m Heat output smaller than 400 kW additional HLE required if 50 m lt storage room lt 200 m HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at 29 Ill Installation Agricultural building If the fuel storage room is a agricultural used building of a farm HLE SLE independent of the fuel storage room size Residential tract with agricultural building Acoustical signal horn bell or visual rotating or flash light warning device Press water pipe min tube 3 4 Fuel storage room For fine and medium sized wood chips wood shavings and pellets Fire wall RSE RZS Fire area lt 500 m Boiler room Size of storage room smaller than 200 m Heat output smaller than 150 kW Residential tract agricultural building Residential tract with agricultural building Acoustical signal horn bell or Fuel storage room visual rotating or flash light For fine and medium sized wood chips wood shavings
23. into the auger channel Sequence for the insertion e auger of the extension trough s depending on execution 2 6 1 e Auger of the inlet trough 2 5 1 e Insert Top auger from the head 2 8 1 in the front Prior assembly of the different auger parts all auger connections have to be lubricated with grease gt See Detail B and Detail D Turns of the auger must be flush gt See Detail C To ensure complete connection of the auger parts push the final part of the auger Hint push the auger parts with a timber M check the connection points of auger parts gt See Detail C and Detail D O HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 10 2 7 Assembly of the bearing plates 4x Screw al 2 8 2 2 8 3 2 8 1 2 8 4x Nut M10 remaining balancing rings 4x Washer 10 5 45 47 mm m gt Move test sleeve 2 8 3 and balance rings 2 8 4 onto the a Ik Id on shaft 2 8 1 take 3 pcs balance rings Check distance to the balance rings 45 47 mm Adjust distance with the number of balance rings OSecure bearing plate 2 8 2 with 4 x flat head screw M10 x 25 Mount 4 x hex Nut M10 and 4 x Washer 10 5 mm at head 2 8 check free movement of test sleeve 2 8 3 Test sleeve has to move easily max gap 1 balance ring 2 mm clearance JPlace the remaining balance rings at the outsid
24. ion works regarding statics electrics hydronics components of flue gas system and fire protection only through authorized staff e The system operator is obliged to allow the test of the exhaust system and the fire protection of licensed authorized agencies In addition to the operation manual and the mandatory regulations for accident prevention in the country where the system is installed also the technical rules for safety and proper installation has to be considered 12 3 Construction of boiler room Boiler room must be executed according to legislation in your country fireproof plane and solid floor and ceiling construction free of disturbing electrical installations and tubes 12 3 1 Austrian regulations M Country specific boiler room regulation M O Norm M7510 Inspections of heating systems of solid fuels M TRVB H 118 Wood chip storage M TRVB F 124 First and extended extinguishing help M TRVB H 105 Fireplaces for solid fuels M O Norm H5170 Heating systems requirements for buildings and safety technology as well as fire and environmental protection Walls and ceilings REI30 F30 Doors EI30 C2 F30 Width 2 0 8 m Height 2 2 m Protect fuel storage room against water 26 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 12 3 2 German regulations VI FeuVO Fire regulation of provinces 12 3 3 Swis
25. ity group Safety valve 13 3 1 Security group at ECO HK 20 60 O Install a 3 bar over pressure valve Security group on top of the boiler B M Check tightness Connect drain to over pressure valve To ensure a proper drain after the overpressure valve triggered a hose or tube must be installed between the over pressure valve and the drain The drain with cone must be free to inspect to easily see any leakage of the valve 34 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 14 Electrical installations For electrical installation a detailed circuit diagram is included e Wiring diagram e Electrical scheme of the sensor motors pumps mixers initiators e Instructions for connecting the main switch next to the boiler room e Information for lengthening of cables Works on electrical equipment may only be carried out through e authorized staff e according to VDE or OVE During electrical installation pay attention to the position of the exhaust fan and the flue pipe Fire hazard e The insulation of cables and cable shafts are flammable e Distance of electrical wires to naked flue pipe minimum 40 cm Ensure minimum distance of electrical wires from parts outside of the boiler to the hot flue gas pipe and the exhaust fan Main power supply sensors pumps mixer control M Main powre supply to the contro
26. l M Protection of the supply line with fuse according to electrical scheme Note instructions in wiring diagram M Heating main switch emergency stop in front of the boiler room door Complete disconnection of electrical supply to the control M Connection of necessary safety equipment ET Temperature monitoring at stoker auger TUB Temperature monitoring at fuel storage room Install warning light or horn so that it can be noticed easily All sensors for a safe operation of the boiler according to wiring diagram M Connections of heating circuits pumps mixers sensors M Install outside temperature sensor do not mount the sensor in direct sunlight 14 1 Fault lamp To display errors a fault lamp has to be installed gt Wiring diagrams of the boards in the cabinet e Acoustical horn or visual warning device rotating light HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at G II Installation 14 2 Mount main power switch O Open turn type lock 11 1 with plastic key on boiler door handle O Open and remove covers from the control box O Loosen 2x tapping screws a from control board plate O Remove main power switch 11 and place correctly Position ON must be on top O Fix main power supply on the two fixing points of the board ground plate O 2x tapping screw a O Refit covers from the control box J relock with turn type lock O Turn
27. legether mostat installieren a gt a a ES lt z ATH AUS bei 55 C vor Bypass einbauen R cklauf SN i f hler Boilerpumpe 1 Ausgleichsbeh lter Accumulator with external HWS R cklaufanhebung RL Mischer inkl SM Pumpe Kessel Kugelh hne f hler RAG ECO A 1 od RAG ECO M 1 Boiler f hler 1 2 HARGASSNER ij Um Boilerpumpe 1 R cklauf f hler Ausgleichsbeh lter G HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 16 Remote control FR 25 FR 35 FR40 For a professional installation and operation of the remote see user manual of the according remote control Attention The remote control has to be parametrised to the heat circuit in the installer level O Install remote control in light switch height Place of installation M no direct sunlight draught radiators chimney etc Measurement of the real room temperature M in appropriate room e g Living room etc in those room no stove should be installed tile stove etc Increase radiator thermostat valve to a higher value as the value in the Control Influences the room sensor The flow of the according heat circuit will be changed as a result other rooms will be too cold or too warm 16 1 Remote control FR25 analogue FR25 can be used for heat circuits connec
28. logy for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at 23 Ill Installation 11 Ash box 11 1 Installation ash box flange 1 Open cover door E r A r i 3 Fix flange with 4 pcs ISK M6 x 16 in ECO HK screw package HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 11 2 Adjust ash box wheels 1 BALL Place ash box onto boiler correctly 2x Loosen nut M8 SW13 Press wheel tight onto the floor and refix nuts similar at other side HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at 2 Ill Installation 12 Facilities on site 12 1 Consider federal state laws and public safety regulations Observe federal safety regulations The rules and safety regulations for the operation of biomass heating sys tems and storage of fuels can be different in your country e Check government regulations prior commissioning of the heating system Fire protection Operation of heating systems Storage of heating fuels Construction requirements for boiler rooms and fuel storage rooms Requirements from chimney sweep 12 2 Qualification of installation staff Installation through qualified authorized and experienced staff only Death injury damage through inappropriate installation e Construc
29. mage the sealing of the exhaust fan motor 7 2 Rotatable exhaust fan optionally OFix intermediate piece 12 1 onto boiler sided exhaust fan housing O Ofix rotatable housing 12 on intermediate piece Put sealing in between OMount motor with 4x copper nuts M8 d onto the housing Do not damage the sealing of the exhaust fan motor do HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 8 Mounting levelling feet When the boiler is placed at its final position 4 levelling feet need to be horizon tally set O Screw hex screw M12x30 from top into the boiler body O Place levelling feet under screws O Lower boiler onto levelling feet O Align boiler with screws O Insert the two adjusting feet 1 1 and fix Fix them according to the floor Distance to the floor 180 mm Round head screw M10x30 washer M10 and hex nut M10 1 2 O Screw in 4x stud bolt M8 x 20 Total length 30 mm 1 3 with short thread side thread length 10 mm to boiler flange O Insert 1 4 seal O Fix stoker unit 1 to boiler flange 4x hex nut M8 1 5 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at lt i Ill Installation 9 1 mounting the motor of the stok
30. o 0 17 2 Heat circuit board A The heat circuit board A is for the extension of heat and HWS circuits from the boiler The connection to the boiler control board is done with a Bus cable On the heat circuit board the selection switch is set to A HC A HWS A 17 3 Heat circuit controller HAR For a maximum extension of heat and HWS circuits as well as accumulators or external boilers eight HKR s may be connected The connection to the boiler control board is done with a Bus cable to CAN Bus plug On the HKR the selection switch is set to 1 at HKR 1 2 at HKR 2 and so on when delivered this switch is always 1 18 Stickers for the storage room BRENNSTOFFLAGERRAUM Selbstt tig anlaufende F rdereinrichtun g Unbefugten ist der Zutritt zum Brennstoff Lagerraum verboten Kinder fernhalten Vor dem Betreten Anlage mit Netzhauptschalter an der Steuerung ausschalten Zugriff zur Transportschnecke und zu beweglichen Teilen vermeiden Nicht im Bereich der Federarme verweilen verwenden Vor und w hrend dem Bef llen des Lagerraumes mit Brennstoff die Anlage unbedingt einschalten Damit sich die Federarme unter der Deckscheibe einziehen Achtung Beim Bef llen mit Pellets unbedingt Betriebsanleitung lesen Brennstoff vor Feuchtigkeit sch tzen AUF H Lagerraum ger V02 i HARGASSNER m Detailed explain the contents of the sticker to the operator Affix the sticker in the a
31. orted in the extraction auger of the agitator 12 5 1 Austrian regulations M TRVB H118 The certified rotary valve RSE and the burn back protection RZS are integrated in the boiler The temperature monitoring of the fuel storage room T B is mandatory and therfore required in each case Depending on the construction of the fuel storage room there are several possi bilites for the installation of HLE and SLE 28 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill Closed fuel storage room Basement or outside storage room 4 Acoustical signal horn bell or visual rotating or flash light warning device Protective Horizontal filling Boiler Fuel storage room or fine and medium sized wood chips wood shavings and pellets acc TRVB Table 2 Fuels 3 1 and 3 2 Size of storage room smaller than 50 m Heat output smaller than 400 kW additional HLE required if 50 m lt storage room lt 200 m F90 for outside walls floor and ceiling F30 F90 for intermediate wall between boiler room and fuel storage T30 for the boiler room door and the fuel storage door fthe building is equipped with a fire alarm system the fuel storage room must be integrated Size of the enclosed storage area Additional safety requirements lt 50 m no additional requirements Extension of the fuel storage room to a residential bu
32. s regulations M VKF Association provincial fire insurances important aspects of VKF Fire protections standards Version 26 03 2003 Doors and rooms with fire resistance El nbb Walls behind heating systems must be executed out of fire resistant material and at least 0 12 m thick Highly flammable materials like wood insulation wool straw paper or similar materials shall not be stored in the boiler room 12 3 4 Fire resistance of the wall breakthrough a ensure fire resistance of the wall breakthrough F90 l O Cover with steel sheets thickness at least 1 5 mm en ii O Cover with fire resistant plates thickness at least 8 mm gt Use steel dowels for fixing the cover O Ensure that there is a gap between the hutch of the extraction auger and the wall also prevents the transmission of noise O Filling with rockwool F90 12 4 Ventilation of the boiler room For the combustion process an air supply and exhaust opening in the boiler room need to be installed Please find the size of air ventilation openings in your local regulations Hargassner Minimum requirements Provide an air ventilation opening of 5 cm per kW Boiler Nominal heating output but at least a total square of 200 cm Ensure that no impairments through air steamings or climatic influ ences arise If there are gratings installed the cross section area has at least to be the minimum of 200 cm HARGASSNER Hea
33. serve all rights to make technical changes to the in formation contained in our printed material Changes errors and printer s errors do not justify claims for damages Only original Hargassner spare parts must be used In addition to the guidelines in this operation manual please follow general guidelines for safety and accident prevention The AUTOMATIC WOOD BIOMASS BOILER must at least be switched off 15 minutes prior any works on the boiler Maintenance works unscrew covers etc The manufacturer Hargassner GmbH shall not be liable for direct or consequential damage resulting from failure to observe the technical instructions guidelines and recommendations The vast experience of Hargassner GmbH latest production technology and highest quality standards guarantee the reliability of this boiler system Hargassner GmbH UNDER NO circumstances be held liable for a safe operation of the product for damage to the product itself or for consequential damage caused by the product if the damage has been caused by incorrect use or handling of the product The customer has NO warranty claims e if heating fuel is missing wrong or of poor quality e if damages occur through incorrect assembly misuse or lack of maintenance e ifthe installation manual and operation manual is NOT observed e for defects that do not affect the performance of the system E g Paint defects e for damages arising from force majeure like fire flooding lightning stroke elec
34. ted to the HKM or HKR not available for heat circuits from the Heat circuit board A Remote control with room sensor O Connect clamp 1 and 2 to FR 25 Remote control with room sensor O Connect clamp 1 and 3 to FR 25 Fault lamp The remote control is equipped with a red LED which may be connected to the boiler This LED lights if a warning or an error occurs on the boiler display O Connect clamp 4 and 5 at FR 25 16 2 Remote control FR35 digital FR35 can be used for all heat circuits HKM HKR HKA ise he M Bus cable 2x2x0 5 mm shielded pair twisted e g LiYCY rir TOE ONE gt for a length of more than 100 m a diameter of 0 75 mm 16 3 Remote control FR40 digital FR40 can be used for all heat circuits HKM HKR HKA M Bus cable 2x2x0 5 mm shielded pair twisted e g LIYCY for a length of more than 100 m a diameter of 0 75 mm HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at G Ill Installation 17 HKM HKA or HKR 17 1 Heat circuit module HKM 0 1 2 A maximum of three HKM s may be connected The connection to the boiler control board is done with a Bus cable to the CAN Bus plug At the HKM the selection switch is set to 0 at HKM 0 1 2 HC and 1 HWS circuit to 1 at HKM 1 3 4 HC and 2 HWS circuit and to 2 at HKM 2 5 6 HC and 3 HWS circuit when delivered this switch is always set t
35. ting technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at en Ill Installation 12 5 Possible safety equipment on site Water pipeline HLE manual extinguishing device Heating main switch for switching off the complete boiler system For outside installation please check federal regulations Serves for shut down of the heating system in case of fire only K Acoustical e 7 or visual Z warning device J lt EMERGENCY 7 STOP gt _ rareassuer I I g ul 3 ET SLE HLE TUB Temperature monitoring at fuel storage room Exceeding 60 C in the fuel storage room an acoustical or visual warning signal occures Manual extinguishing device with water in the fuel storage room HLE Water pipe under pressure min 3 4 with a stop valve in the boiler room The pipe ends about 15 cm above the extraction auger Automatic extinguishing system SLE At a temperature of 50 C measured below the stoker unit the valve of the extinguishing device opens and floods the stoker auger Temperature monitoring at stoker unit ET At a temperature of 50 C measured on top of the stoker auger an error message is sent to the control unit Installation of HLE and TUB Install HLE and TUB prior filling the storage room Ensure easy accessibility to fuel storage room To start up the boiler fill the storage room only as far that the fuel is transp
36. trical surge power loss e if a non licensed installer or non licensed plumber installs the product e for damages arising through air pollution very dusty surrounding aggressive vapours corrosion through oxygen non diffusion resistant plastic tubing installation in inappropriate rooms laundry room or through further use even though a defect has been recognised For the correct reparation maintenance and service or any other error not mentioned in this manual Hargassner GmbH has to be contacted prior any works on the plant Warranty and liability of the general terms and conditions of Hargassner GmbH are not to be extended because of hints pointed out in this manual The safety instructions in this manual must be observed Only use Hargassner GmbH spare parts or from Hargassner GmbH released equivalent spare parts Constant technical innovations mean that we reserve the right to modify the design of our products and services with out notice For any questions always prepare the Hargassner Boiler number We wish you all the best with the WOOD BIOMASS BOILER a2 HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Notes HARGASSNER Heating technology for Biomass A 4952 Weng O Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at a
37. uch to protect the wall install a wooden board or a metal sheet Z between spring blades and the wall O after positioning the agitator correctly secure the stabilizer of the RA gear box to the floor Manchor the agitator in the fuel storage room with the stabilizer 2 7 1 on the floor 4 x anchor bolt M12 anchor bolt M12 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at a Ill Installation 10 6 mounting the 3 pod cover plate OAttach cover plate to the shaft of the agita tor gearbox Align the cover plate to the turnstile and secure it with M12x 25 Add balancing disc to the shaft of the agi tator gearbox Ofix cover plate together with grease screw and washer disc to the shaft Lubricate with grease gun 7 x annually 10 7 mounting the 4 pod cover plate OAttach the cover plate onto the shaft of the gear box align the cover plate including brake shoes on top to the turnstile Place fixing point of the cover plate spring return the turnstile pod no Stop point D of the cover plate behind the turnstile stop point Add balancing disc to the shaft of the agita tor gearbox Ofix cover plate together with grease screw and washer disc to the shaft Lubricate with grease gun 7 x annually 10 7 1 Mounting the spring return insert spring on the turnstile pod No ere steel cable on the attachment he head scre
38. w M10 x 30 flange adaptor and nut M10 mount flange adaptor with flang in direction of the cover plate Hang in steel cable on the other end to the spring 22 HARGASSNER Heating technology for Biomass A 4952 Weng OO Tel 43 7723 5274 0 Fax 43 7723 5274 5 office hargassner at Installation Ill 10 8 Installation of the RA motor 214 Olnsert feather key 2 1 1 into the end of shaft grease shaft end MAttach RA motor 2 1 to the shaft end Torque arm 2 1 3 must be placed into the gap of the bear ing plate JSecure the motor with disc 2 1 2 and screw M10 x 25 RA Motor auger length less than 5 m gt AN N y i i y R muy 7 I A tf XK N D special nut 0 25 kW from 5 m E N21 M10 high tighten ball head with clamp manually by hand screw M10 x 25 10 9 mounting the limit switch O Undo hex cap nut M6 2 8 6 and flange screw M6 2 8 5 O Put bow with anchor point to threaded bolt M6 i and fix with hex cap nut M6 2 8 6 J Fix switch to head part horizontally 2x allen screw M5 x 25 O Close RA cover completely and refix flange screw M6 2 8 5 10 10 Mounting the trough support foot only at RA 400 500 mount support foot 2 9 at the inlet trough of the fuel Flat head screw M12 x 35 and hex nut M12 Hargassner recommends for very long augers to implement an addi tional support foot on site HARGASSNER Heating techno
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