Hoval biolyt 10-26 User manual

Hoval LTD
Northgate
Newark
Nottinghamshire NG24 1JN
Phone: [phone]
Fax: [phone]
Hoval Export
Austrasse 70
9490 Vaduz
Principality of Liechtenstein
Phone: [phone]
Fax: [phone]
[e-mail]
Wood pellet heating boiler
BioLyt (10-26)
Operating instructions
EN
Subject to change4 204 827 / 02 - 06/07

1. Safety information 3
1.1 Safety and precautionary measures 3
1.2 Suitable fuels 3
1.3 Functional test 3
1.4 Hazards 3
2. Guarantee and warranty conditions 4
3. Operation 5
3.1 Functional characteristics, functional parts and control elements 5-7
3.2 Checks prior to start-up 8
3.3 Filling the storage container 8
3.4 Boiler control panel 9-12
3.5 Operating modes 13-16
3.6 Operating phases 17-18
3.7 Info texts 19-20
3.8 Menu navigation 21-34
3.9 Emergency mode (manual operating mode) 35
4. Care, cleaning and maintenance 36
4.1 Overview of cleaning and de-ashing intervals 36
4.2 Cleaning the heating surfaces (BioLyt Standard only) 37
4.3 Emptying the ash pan (BioLyt Standard) 37
4.4 Emptying the ash container (BioLyt Comfort) 37-38
4.5 Combustion chamber (deflector plate, combustion chamber temperature sensor) 38
4.6 Burner pot 39
4.7 Fan wheel, fan box 40
4.8 Exhaust pipe to the flue 41
4.9 Water tank fill level 41
4.10 Cleaning the storage container and the feed unit flap 41
4.11 Storage room and storage tank 42-43
5. Fault correction 44
5.1 IN-Messages 44
5.2 FE-Messages 44-45
5.3 AL-Messages 46-48
6. Quick guide 49-51
Contents
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1. Safety information
1.1 Safety and precautionary measures
The BioLyt heating boiler reflects the state of the art
and meets all applicable safety regulations.
The boiler is operated using 230 VAC electrical cur-
rent. Improper installation or repair can cause danger
to life from electric shock.The installation may be car-
ried out only by appropriately qualified engineers
Please observe the cautionary notes marked
with a warning symbol.
1.2 Suitable fuels
Pellets are made from 100% seasoned wood resi-
dues (wood shavings, saw mill waste, etc.).The dry
wood residues are ground and formed into wood pel-
lets in special high pressure presses. 3 m3of pellets
are equivalent to approx. 1000 litres of heating oil, 2
kg pellets = 1 litre heating oil.
Pellets must be transported and stored
under totally dry conditions. Pellets
swell up under humid conditions. For
this reason, they must be protected
from moisture until they are burnt, i.e.
during transport and while stored.
The pellets must comply with ÖNORM M 7135, DIN
51731 (class HP5) DINplus or SN 166000 „Swisspel-
lets“.
- Diameter: 6 mm
- Length: 80 % between 15-30 mm
- Surface: plane
- Residual moisture: maximum 10 %
- Energy consumption: min. 18 MJ/kg (in water-free
state)
- Ash fraction: max. 0,5 %
- Abrasion: max. 2,3 %
- strict prohibition of using chemical synthetic
binder
- No contamination caused by lacquer and
paint leavings
1. Safety information
1.3 Functional check
The correct functioning of the system and safety de-
vices must be checked and certified annually by a
qualified engineer (ÖNORM B8131, EN 12828).
The condition of the heating water must be checked
every 2 years by a heating engineer (installer) in order
to prevent corrosion damage and sediment accumu-
lation in the heating system and boiler. This check
must be performed annually for heating systems with
more than 1,500 litres of heating water (e.g. systems
incorporating a water storage tank).
Any work involving a change in the water content of
the heating system will require a check of the heating
water within a time period of 4 to 6 weeks.
Corrosion damage and sediment deposits resulting
from inadequate heating water are not covered by
the guarantee and warranty.
1.4. Hazards
1.4.1 Power failure (or fan not functioning)
Maintain the combustion chamber door
closed to avoid the risk of a deflagration
when opening the combustion chamber
door. In case of a power failure during
combustion, the system will perform a
self-test and resume operation automati-
cally.
1.4.2 Burner pot
Never fill the burner pot with pellets by
hand. Too much material in the burner
pot will prevent the pellets from lighting
properly. This can result in excessive
smouldering gas build-up and subse-
quent deflagration.
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2. Guarantee and warranty conditions
The guarantee and warranty conditions require that
the boiler and its accessories be properly and pro-
fessionally installed and commissioned, otherwise
the manufacturer’s guarantee will not be honoured.
Malfunctions resulting from improper operation or
adjustment are not covered by the guarantee and
warranty.
The warranty shall be void if the required pellet quality
is not met, or if other pellet feeds than the Hoval pel-
let feed or transport hoses from other manufacturers
are used.
To ensure a safe, environmentally friendly
and therefore energy saving operation,
commissioning by a heating engineer and
an annual maintenance are required.Com-
missioning by the installer or by a Hoval
service engineer are conditions for the
manufacturer’s guarantee. In addition, we
recommend that you take out a service
contract.
2. Guarantee and warranty conditions
Fig. 1
On/Off
Switch
1.4.3 Filling the pellet storage room or storage
tank
At least 15 minutes before filling the
storage, the pellet boiler must be
switched off with the On/Off switch.
(Fig. 1).
The filling process causes a reduction in pressure
in the pellet storage, which, in turn, can cause a
flash-back within the pellet boiler. For this reason,
the boiler must be inoperative while the fill process
takes place.
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3. Operation
3.1 Functional characteristics, functional parts and control elements
The BioLyt (10-26) pellet boiler and the TopTronic®T heating control system form a perfect unit. The BioLyt
(10-26) will start up automatically every time the control system requires the burner to operate. Once the pre-
purge (safety function) has been completed, the ignitor is switched on and the pellet metering screw starts
operating. The burner pot is filled with pellets automatically. Once a flame has been detected (combustion
chamber temperature sensor), the boiler goes into control mode (modulated control), where it automatically
maintains the predefined boiler setpoint temperature (60-75°C). The boiler goes into burnout mode if the
extracted heat falls below the minimal boiler output or when there is no heat requirement from the control
system. The fan continues to operate until the burner pot has cooled down.
3.1.1 BioLyt Standard
The storage container is loaded manually (or, upon request, fully automatically). The heating surfaces are
manually cleaned with the help of cleaning levers. Any cleaning residues from the heating surfaces as well
as the combustion residues from the burner pot fall into the ash pan.
BioLyt Standard without combustion chamber door and with open cladding door
InfoDisplay control unit
Front cladding cover
Rear cladding cover
Safety thermostat for
boiler temperature
Safety thermostat for
screw tube
Heating surface lever
Deflector plate
Collection channel
Burner pot
Ash pan
Fully automatic pellet
feed (option)
Top inspection cover
Bottom inspection cover
Pellet storage container
Cleaning brush
Spatula
Cone removal tool
Cladding door
Screw motor
Water tank level indicator
3. Operation
TopTronic®T heating
control system
Fig. 2
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3.1.2 BioLyt Comfort
In addition to the features of BioLyt Standard, this model includes a fully automatic heating surface
cleaning system, as well as a fully automatic ash removal system
Fully automatic heating surface cleaning system:
The motor-driven heating surface cleaner moves vertically along the heating surfaces to keep them clean at all
times .
Fully automatic ash removal system:
In the fully automatic ash removal system the ash is removed from the combustion chamber and from the
heating surfaces by means of a motor-driven screw which transports the ash to the ash container located
underneath the storage container. Because of the pellets’ low ash content (approx. 0.5%), the ash container
only needs to be emptied after about combusting about 4000 kg of pellets.
3. Operation
BioLyt Comfort without combustion chamber door and with open cladding door
InfoDisplay control unit
Front cladding cover
Rear cladding cover
Safety thermostat for
boiler temperature
Safety thermostat for
screw tube
Deflector plate
Collection channel
Burner pot
Ash baffle
Fully automatic pellet
feed (option)
Top inspection cover
Bottom inspection cover
Pellet storage container
Cleaning brush
Spatula
Cone removal tool
Cladding door
Screw motor
Ash container
Water tank level indicator
TopTronic®T
Fig. 3
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3.1.3 Option: Fully automatic pellet feed
The pellet feed system automatically fills the BioLyt storage container with pellets from the pellet storage
room or pellet storage tank by means of a maintenance free vacuum turbine. The pellet feed is turned on
either by the bottom fill level switch (proximity switch) in the storage container, or at the end of the enable
time or at the beginning of the start time, and operates until the storage container is full. The filling process
will not start while the boiler is operating in heating mode, or when the pellet feed has been stopped by the
control system (outside the enable time, e.g. at night time). If the storage container needs to be filled while
the boiler is operating in heating mode, then the boiler will switch over to burnout mode.
The changeover to suction head 1, 2 and 3 takes place automatically. After a specific number of fills of the
storage container the system switches over to the next suction head. This ensures that, to a large extent,
the storage room is emptied in a uniform manner.
BioLyt with fully automatic pellet feed system
3. Operation
Storage container with fill level switch
Feed unit:
Vacuum turbine
Cyclone separator
Intermediate container
with flap
Suction heads
Pellet feed and
return hose
Automatic changeover unit
Fig. 4
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3.2. Checks prior to start-up
a) System pressure (heating water pressure):
Fill the system and remove all the air. The system pressure of the cold system must be at least 1.0 bar
(max. 1.8 bar). Please consult the heating installer if you have any questions.
b) Heating room ventilation:
The heating room must be adequately ventilated. The air supply should be free of dust.
c) Flue:
The flue should be checked and cleaned (if necessary) by a chimney sweep.
d) Water tank:
Check the fill level of the water tank for the flash-back protection (page 41).
3.3 Filling the storage container
3.3.1 System without fully automatic pellet feed: Manual filling of the storage container
Open the storage container lid (Fig. 2) and fill the container up to no higher than 1 cm below the edge. Close
the lid.
3.3.2 System with fully automatic pellet feed: Fully automatic filling of the storage container
The storage container is filled by the fully automatic pellet feed system. The Hoval Customer Service will
conduct the first fill (boiler start-up) and commission the boiler together with the pellet feed system, as well
as familiarise the customer with the operation and cleaning of the boiler with reference to the operating
manual.
3. Operation
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3. Operation
3.4 Boiler control panel
1. ON/OFF key
2. Boiler control
3. Heating controller
4. Set day room
temperature
5. Set reduced room
temperature
6. Set hot water
temperature
7. Turn/Push key
Caption Function
ON- Heating boiler in operation
OFF - Boiler and burner are out of operation
Note: - No frost protection
- TopTronic®T heating control is still energised
Controls and monitors the operation of the heating boiler. See page 12!
Controls the room temperature as a function of the outdoor temperature.
See separate instructions!
Use this function key to set the desired room temperature during day
time
Use this function key to set the desired room temperature during reduced
heating operation
Use this function key to set the desired hot water temperature during day
time
Use the turn/push key to select or change the desired parameters
(flashing word or number)
- Turn clockwise to the right (+): increase value
- Turn anticlockwise to the left (-): decrease value
- Short tap:
Accept and save the selected and displayed value
- Press for approx. three seconds:
Move to programming level (level selection)
10 6 5
4
12
11
79 8
Fig. 5
2
1
3
9
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8. System information key
9. Heating curve set-up key
10.
Operating mode selec-
tion key
- Check temperatures and hours of operation
- This key also provides the option to return to base level without sav-
ing the selected value.
The heating curve shows the flow temperature of a heating system as
a function of the outdoor temperature. Use this function key to modify
the heating curve.
Heating system off during the holidays
(frost protection)
Heizbetrieb unterbrochen
Extended heating operation
Automatic heating programme
according to the preset heating times
Hot water only
Heating off
Continuous heating
Continuous reduced heating
System off
Frost protection active
� � �
Caption Function
HOLIDAY TIL
27.08
ABSENT TIL
19:45
PARTY TIL
02:30
AUTOMATIC
SUMMER
WW
HEATING
RED. HEATING
STANDBY
3. Operation








10
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11. Key for manual operation
and emission measure-
ment
12. Display
Caption
See attached instruction manual for a detailed description of the TopTronic®T controller!
3. Operation
2
1
3
4
6
7
5
Fig. 6
Function
The emission measurement key may only be used by the chimney
sweep or by a qualified person!
(except emergency operation, see page 35)
The basic screen shows the day of the week, date and time of the
day, as well as the current heat production temperature or another
temperature (system dependent).
Possible readouts:
1 Active heating time 24h
2 Weekday display
3 Display of the active operating mode and the clock programme
4 Time of the day
5 Selected operating mode
6 Date / Day / Month / Year
7 Heat production temperature or another temperature (system de-
pendent).
11
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3. Operation
InfoDisplay (Boiler control)
The following operating modes are available:
- OFF
- ON (incl. self-test, illumination ON, illumination OFF)
- Pellet feed
- Manual operation
- Chimney sweep function
- Shut down process

The following operating phases are
available:
- Standby
- Pre-purge
- Ignition phase
- Flame stabilisation
- Modulated control
- Burnout
- Burner OFF
- Switch off heat generator (WE)
No adjustments to the boiler control are normally required by the user. All the necessary adjust-
ments were conducted by the installer or by the manufacturer.
The InfoDisplay consists of a generously sized full-text display, an On/Off key with a control light (LED) indicat-
ing normal operation (green) and fault (red), a key for the manual/chimney sweep function, and 4 individually
used menu keys. The individual function on the menu keys is displayed on the menu bar.
Note: If the readout on the display shifts its position, this will be corrected at the next automatic refresh af-
ter about 30 minutes. This shift in position or distortion can be caused, for example, by an electromagnetic
discharge or similar.
Menu keys
On/Off key
Control light (LED)
“Normal operation”
green, and “Fault” red
Full-text display
(Illuminated
display)
Manual operation
/ Chimney sweep
function
Assignment of keys to
the individual function
The different ope-
rating phases are
shown here, e.g.
Standby, Burner
Menu bar
The different operating modes are displayed on the InfoDisplay, together with the corresponding operating
phase.
Boiler temperature
Operating phases
Lighting ON
Fig. 7
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3. Operation
5s
RESET
5s
RESET
3.5 Operating modes
3.5.1 OFF-mode
In the Off-mode, the display is turned off and all the keys, apart from
the On/Off key are disabled. The LED on the InfoDisplay is not il-
luminated (Fig. 8).
3.5.2 ON-mode, illumination ON,
self-test, illumination OFF
Press the On/Off key. The self-test is initiated automatically (Fig. 9)
Once the self-test has completed successfully, an operating phase
and the temperature of the water in the boiler (standard display) are
shown. The control light (LED) is green and the keys can be used to
select the individual function (Fig. 10).
If the self-test is not successful, an information message (e.g.IN, FE,
AL) appears (see page 44-48).
The display illumination is turned off automatically after 45 sec. (Fig.
11).The display illumination is turned on again for 45 sec. when one
of the 6 keys is pressed.
The InfoDisplay identifies and saves the different operating modes
and operating states. For this reason, when starting the system, it is
possible to display a different operating mode (e.g. manual operat-
ing mode) or a fault instead of the standard display. These operating
modes and operating states are described later in the text.
5s
RESET
5s
RESET
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Self-test
active
Boiler temperature
(Operating phases)
Boiler temperature
(Operating phases)
Lighting ON
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3.5.3 Pellet feed
Pellet feed - Burnout
The system first sends a request to convey pellets from the storage
room into the storage container. Combustion is stopped.The transport
of pellets into the burner pot is stopped, the forced draught fan con-
tinues to run until the remaining pellets are burnt and/or the burner
pot has cooled down sufficiently (Fig. 12).
Pellet feed during normal operation
The pellet feed is in operation. Pellets are fed from the storage room
into the storage container. The burner is locked out (Fig. 13).
3.5.4 Solid fuel operation / Storage tank operation
If the BioLyt pellet boiler operates in combination with a solid fuel
boiler or a storage tank, the changeover between the pellet and the
solid fuel/storage tank operating modes is done automatically by the
TopTronic®T controller, which is integrated into the control panel.
3. Operation
Fig. 12
Fig. 13
Pellet feed
Burnout
Pellet feed
in operation
Burner locked
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3. Operation
Press the Manual operation/Chimney-sweep key for longer than 5
sec. to start the manual operating mode (Fig. 14). In this mode,
the boiler temperature is regulated at the defined setpoint value for
manual operation (standard temperature 60ºC). This does not influ-
ence the available control. The illumination is turned off after the
time defined by the illumination timer (45 sec.), while the function or
display remain unchanged.
Press the Cancel key or the Manual operation/Chimney-sweep key
to end this function (Fig. 15) and return the boiler to the automatic
mode.
Setpoint settings for manual operating mode
Press the + or - keys to take the display into the temperature setpoint
adjustment mode (Fig. 16). Use the + or - keys to modify the setpoint
in 1 K steps.The setpoint modified in this way will not be stored per-
manently, returning to its original value once the manual operating
mode is completed.
The display can be returned to the previous state by pressing the
Back key (Fig. 17), or after 10 sec.
3.5.5 Manual operation
5s
RESET
5s
RESET
5s
RESET
5s
RESET
Fig. 14
Fig. 15
Fig. 16
Fig. 17
The different operating phases are
shown here, e.g. burner in operation,
burner OFF, etc..
5 seconds press
Manual operation
Boiler temperature
(Operating phases)
Cancel
Manual operation
Boiler temperature
(Operating phases)
Cancel
Manual operation
Temperature setpoint
back
Manual operation
Setpoint
back
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3. Operation
Press the Manual operation/Chimney-sweep key to turn on the il-
lumination. Press the key again to start the chimney sweep function
(Fig. 18). The boiler temperature is regulated to approx. 60°C.
Note: To ensure that heat dissipation is taking place, press the
“Emission Measurement” key on the TopTronic®T control!
Press the individual menu keys to run the boiler at 30% or at 100%
output (Fig. 19). The illumination is turned off after the time defined
by the illumination timer (45 sec.), while the function or display re-
main unchanged. The illumination is turned on every time you press
a key.
The chimney sweep function ends,
- when the Cancel key or the Manual operation/Chimney-sweep key
is pressed (Fig. 20).
- automatically after approx. 45 minutes
3.5.7 Shut down process
The boiler is turned off (Fig. 21).
3.5.6 Chimney sweep functions
This function is used to conduct the statutory emission measurements.
5s
RESET
5s
RESET
5s
RESET
5s
RESET
Fig. 20
Fig. 21
Fig. 18
Fig. 19
The different operating phases are shown
here, e.g. burner in operation, burner
OFF, etc.
The green LED flashes
Chimney sweep function
Output 30%
(Operating phases)
Cancel
Chimney sweep function
Output 100%
(Operating phases)
Cancel
Chimney sweep function
Output 30%
(Operating phases)
Cancel
Shut down process
Burnout
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3. Operation
3.6 Operating phases
3.6.1 Standby
In this operating phase, the control unit is not transmitting a heat
demand signal. The burner is turned off and the boiler temperature
setpoint is set at 0ºC (Fig. 22).
3.6.2 Pre-purge
The forced draught fan operates and the BioLyt combustion cham-
ber is purged with fresh air. This phase can last a few minutes
before the burner is turned on (Fig. 23).
3.6.3 Ignition phase
The forced draught fan operates and pellets are fed to the burner
pot, where they ignite. As soon as a flame is detected, the boiler
goes into flame stabilisation mode (Fig. 24).
3.6.4 Flame stabilisation
Once the ignition process is completed, the system waits until a
uniform combustion has been achieved before switching over to
modulated operation (Fig. 25).
3.6.5 Modulated operation
The burner runs in the modulated mode, where the output is con-
tinuously regulated between 30% and 100% (Fig. 26).
Fig. 22
Fig. 26
Fig. 25
Fig. 24
Fig. 23
Boiler temperature
Standby
Boiler temperature
Pre-purge
Boiler temperature
Ignition phase
Boiler temperature
Flame stabilisation
Boiler temperature
Modulated operation
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3.6.6 Burnout
Combustion is stopped. The transport of pellets into the burner pot
is stopped, the forced draught fan continues to run until the remain-
ing pellets are burnt and the burner pot has cooled down sufficiently
(Fig. 27).
3.6.7 Burner OFF
The control unit is sending a heat demand signal, but the boiler tem-
perature (actual value) is higher than the boiler temperature setpoint.
For this reason the combustion is stopped and the burner is off (Fig.
28).
3. Operation
Fig. 28
Fig. 27
Boiler temperature
Burnout
Boiler temperature
Burner OFF
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3.7 Info texts
Press the Info key to obtain the essential information on the BioLyt
(Fig. 29).
Use the Arrow keys to select and display the sub-items (Fig. 30).The
display can be returned to the default state by pressing the Back key
(Fig. 31), or after 45 sec.
The following Info texts are available
-Actual boiler temperature (°C)
-Boiler temperature setpoint (°C)
-Flue gas temperature (°C)
-Current boiler output (%)
-Hours of operation (hr)
-Total consumption of pellets (t)
-Software version display module (InfoDisplay)
-Software version automatic burner control
-Boiler model
3.7.1 Actual boiler temperature
Displays the actual temperature of the BioLyt (Fig. 32).
3.7.2 Boiler temperature setpoint
The boiler temperature setpoint calculated by the control unit is dis-
played. This setpoint is used for the burner control (Fig. 33).
3.7.3 Flue gas temperature
Use this function to display the current flue gas temperature. This is
used for monitoring the boiler efficiency. (Fig. 34)
5s
RESET
5s
RESET
3. Operation
5s
RESET
Fig. 32
Fig. 31
Fig. 30
Fig. 29
Fig. 33
Fig. 34
(Operating phases)
Boiler temperature
Actual boiler
temperature
back
Actual boiler
temperature
back
Actual boiler
temperature
back
Boiler temperature setpoint
back
Flue gas temperature
back
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3. Operation
3.7.4 Current boiler output
The current boiler output is shown in %.The boiler output (modulation
range) can range between 30% and 100%.
3.7.5 Hours of operation
Displays the totalised operating time of the BioLyt (Fig. 36).
3.7.6 Total consumption of pellets
Displays the total amount (in tons) of pellets used so far. The con-
sumption of pellets is a indicator for the cleaning- and maintenance range
(see page 36, Care, Cleaning, Maintenance) (Fig. 37).
3.7.7 Software version display module
Displays the current software version of the display module (InfoDis-
play) (Fig. 38).
3.7.8 Software version automatic burner control
Displays the current software version of the automatic burner control
(Fig. 39).
3.7.9 Boiler model
Displays the pellet boiler model (Fig. 40).
Pelletsverbrauch
gesamt
zurück
1.30
t
Fig. 39
Fig. 38
Fig. 37
Fig. 36
Fig. 35
Fig. 40
Current boiler output
back
Hours of operation
back
Total consumption of pellets
back
Software version
display module
back
Software version
automatic burner control
back
Boiler model
Pellet boiler model 100
back
The „total consumption of pellets“ is a calculated value, which can diverge +-15% of the real value.
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