SOLARFOCUS maximus 150 User manual

Operation manual for qualified personnel
Read carefully before operating.
DR-0160-EN / v4b-201903
Commercial boiler maximus

1 About this manual
1 About this manual 2
2 Safety information 3
3 Standards, guidelines, regulations 3
4 Product information 4
4.1 Fuel 4
4.2 Safety devices 5
4.3 Dimensions 7
4.4 Functional components, combustion prin-
ciple 9
4.5 Technical specifications 11
5 Prior to assembly 13
5.1 Transport 13
5.2 Boiler room 13
5.3 Chimney, flue gas pipe 14
6 Installation 16
6.1 Mount heat exchanger on the burner 16
6.1.1 Adjust spacing screws 16
6.1.2 Screw on flue gas pipe flange 17
6.1.3 Install automatic ash extraction 17
6.1.4 Connect flue gas recirculation line 18
6.1.5 Connect burner and heat exchanger hydraulically 19
6.2 Install the hot air fan 19
6.3 Mount feeder grate drive 19
6.4 Install the feeder unit 20
6.5 Install safety valve 20
6.6 Install return booster 20
6.7 Install thermal overload protection 21
6.8 Install temperature monitor (TM) 21
6.9 Fill the heating system 22
6.10 Bleed the heating system 22
6.11 Establish the chimney connection 22
6.11.1 Flue gas pipe: Hole for emission measurement 22
6.12 Mount ash container 22
6.13 Mount cladding on the boiler 23
7 Hydraulic connection 23
7.1 General information 23
7.2 Boiler connections 24
7.3 Make-up water requirements 25
8 Electrical connection 26
8.1 Boiler control cabinet 26
8.2 Connection assignment 26
8.3 Voltage supply for the heating system 27
8.4 Connect components to the control cabinet
(on site) 28
8.4.1 Connect overtemperature reset 28
8.4.2 Connect the boiler temperature sensor 28
8.4.3 Connect combustion chamber temperature sensor 28
8.4.4 Connect ash extraction burner 28
8.4.5 Connect rotary actuators 29
8.5 Connect additional components (on site) 30
8.6 Cable ducts on the boiler 31
8.7 Sensor resistance table 31
8.8 Connecting the control to the internet 32
9 Installing the intermediate pellet store 32
10 Initial start-up 33
11 Annex 34
11.1 Boiler covers - overview 34
11.2 Boiler power element, circuit boards 35
11.3 Electrical components: Overview 36
11.4 Connect pellet hose 37
11.5 Delivery systems (pellets, wood chips) 38
1 About this manual
Dear heating installer
To ensure reliable and efficient operation of the heating
system, the following points are extremely important:
–Correct installation
–Training of customers in commissioning
–Comply with the specifications and instructions in
this manual
–Regular maintenance by the system operator
–Regular maintenance by qualified personnel
Language
The language of the original manual is German. All
other language versions of this manual are trans-
lations of the original.
Storage
Keep the manual for the entire service life of the pro-
duct and ready to hand. The manual must be pas-
sed on to the new owner when the product is
dismantled/reused. If the manual is lost or
destroyed, request a new copy from the manu-
facturer.
Tips and Warnings
The tips used in this manual are highlighted with
symbols and signal words. The signal word indi-
cates the level and nature of the danger and how to
avert it.
iIndicates information for correct handling of the
product.
2 Operation manual maximus
Content

2 Safety information
!CAUTION - Failure to comply with this instruc-
tion could result in damage to property.
DANGER - Failure to comply with this instruc-
tion poses a danger to people.
Explanation of symbols
þPrecondition for an action
► Instruction
ÄResult of an action
>Reference to page, figure, Chapter,...
Manufacturer
SOLARFOCUS GmbH
Werkstrasse 1, A-4451 St.Ulrich
Company register no. 281755x
Tel.: [phone], Fax: [phone]
[e-mail]
www.solarfocus.com
Technical questions about our products
–Service-Hotline
0043 7252 50002-4920
[e-mail]
2 Safety information
Qualification of personnel
–The work procedures described in this manual
must be carried out by qualified specialist per-
sonnel.
–Work on electrical components must be performed
by trained electricians and in accordance with the
relevant laws and directives.
Installation and commissioning
–System may only be serviced and put into ope-
ration by certified qualified personnel
(SOLARFOCUS service technician or
SOLARFOCUS service partner.
Keep unauthorized persons and children away
–Danger of burns due to hot lines and hot com-
ponents, risk of injury from mechanically moving
parts. Keep unauthorised persons away, do not
leave children unattended, and control access to
the boiler room and fuel storage room.
Safety devices
–Never disengage the safety equipment > 5 of the
heating system. In case of failure, arrange for
immediate repair.
Maintenance and repair
–Perform maintenance activities at the specified
intervals. No or incorrect maintenance leads to inef-
ficient operation, higher failure risk of the boiler and
increased potential for hazards.
–Have repairs done by qualified personnel only
Improper repairs can lead to risks for the user and
impaired operation
–Store hot ashes only in metal containers. Never
put hot or warm ash in the dustbin. There is a great
danger of fire.
–For repairs use only original spare parts or parts
approved by the manufacturer (e.g. standard
parts).
Damage to the system
–If the electrical insulation on cables, plugs, swit-
ches becomes damaged, switch off the voltage
supply and have the insulation repaired.
–In the case of visible damage (e.g. thermal defor-
mation, mechanical damage) the operation of the
system must not be continued. The system may
only be operated if it is in perfect technical con-
dition.
3 Standards, guidelines, regu-
lations
The following bodies of regulations must be con-
sidered and adhered to during planning, installation and
operation of the heating system:
–Respective state building codes
–Firing ordinance of the respective country
–Commercial and fire department rules and regu-
lations
–VDI 2035 - Preventing scale formation in hot water
heating and hot water warming systems
–DIN EN 12828 Heating systems in buildings - plan-
ning for water-based heating systems
–EN13384 - Flue gas systems - thermal and flow-
based calculation methods
Operation manual maximus 3

4 Product information
Austria
–TRVB H 118 -Technical guidelines for preventive
fire protection
–ÖNORMH 5170 - Heating systems - requirements
for construction and safety technology as well as
for fire and environmental protection
–ÖNORMH 5195-1 - Heat transfer media for buil-
ding services systems, Part 1: Preventing damage
from corrosion and scale formation in closed hot
water heating systems
–Art. 15a Agreement - Protective measures for
small solid-fuel boilers
–Art. 15a Agreement on energy savings
Germany
–EnEG - Law on energy savings, with the relevant
issued decrees
–EnEV - Ordinance on energy-saving thermal insu-
lation and energy-saving plant technology in buil-
dings
–DIN18160 - Flue gas systems - planning and exe-
cution
–1. BImSchV (Federal Immission Control Ordinance
- Ordinance on Small and Medium Solid-fuel
Boilers
Switzerland
–VKF/AEAI - Fire Protection Guidelines (25-03 and
105-03)
4 Product information
Fig. 2-1
4.1 Fuel
Pellets
Use wood pellets only in accordance with these spe-
cifications:
–Pellets according to the ISO 17225-2 standard,
class A1.
–Pellets that meet the additional ENplus cer-
tification.
–Pellets that meet the additional DINplus cer-
tification.
Wood chips
Use wood chips only in accordance with these spe-
cifications:
–Wood chips according to the EN ISO 17225-
4:2014 standard
–Classes A1, A1, A2, B1
–Sizes P16S and P31S
–Moisture content maximum 40%(M40)
4 Operation manual maximus

2 Safety information
4.2 Safety devices
Heat dissipation
–This function of the boiler control is a safety device
that prevents overheating of the boiler.
–Functioning: If the boiler temperature exceeds the
set Heat dissipation maximum boiler temperature
(in the service menu - General Settings), all pumps
relating to the energy consumer units (e.g. heating
circuit, DHW tank, buffer tank, etc.) will be swit-
ched on and the heating circuit mixer opened. In
this way, energy is drained from the boiler and it
may be possible to prevent other safety devices
tripping.
–If the boiler temperature falls below the set Heat
dissipation maximum boiler temperature minus
1°C again, the pumps and mixers will be operated
in standard mode again.
Thermal overload protection
–The thermal overload protection prevents an uncon-
trolled increase in temperature and pressure of the
boiler.
–Functioning: At a boiler water temperature > 95°C,
the valve opens and directs cold water through the
two series-connected safety heat exchangers.
This lowers the temperature of the boiler and avo-
ids the need for further safety precautions or equip-
ment damage.
►Install thermal overload protection > 21
Overtemperature reset (OTR)
The safety temperature limiter (STL) is a safety device
that prevents overheating of the boiler.
Functioning: The STL stops the heating process at a
boiler temperature ~95°C (exclusively electrical func-
tion; fuel and air supply are interrupted).
After tripping, the STL must be manually released
again by unscrewing the black sealing cap 1and pres-
sing the button as soon as the boiler temperature falls
below 60°C.
If the safety overtemperature reset trips, this is indi-
cated in the boiler control display.
Fig. 2-2:Unscrew the closure cap
►Install overtemperature reset > 28
Safety valve (to protect against excess pres-
sure in the system)
–The safety valve 1is a safety device for protecting
against overpressure in the water circuit of the hea-
ting system.
–Functioning: The valve opens when the system
pressure exceeds 3 bar. Water/steam are dischar-
ged into an open drain via a discharge line, which
avoids consequential damage to the heating sys-
tem. The valve is closed during normal operation.
–For normative specification see EN 12828.
Fig. 2-3: Safety valve integrated into boiler safety group
►Install safety valve > 20
Operation manual maximus 5

2 Safety information
EMERGENCY OFF switch
–The EMERGENCY OFF switch is a manually ope-
rated safety device. The burner and the fuel supply
to the boiler are stopped. Circulation pumps remain
in operation to dissipate heat and cool the boiler.
–The switch must be installed outside the heating
room in a safe place that is easy to access.
►Install EMERGENCY OFF switch > 30
Temperature monitor in the fuel storage
room (TM)
–Required according to guideline TRVB 118 H for
wood chips, depending on system design, heating
capacity and fuel storage quantity.
–Functioning: On the channel of the fuel delivery
auger, a temperature sensor of a protected design
must be installed in the area of the wall penetration
(inside the storage room). When a temperature of
about 70°C is exceeded, the warning device is
(optically or acoustically)triggered.
–Art. No.: 6565 and 6567
►Install temperature monitor > 21
Automatically triggered extinguishing
device (ATED)
Fig. 2-4
1 Pocket sleeve for temperature sensor
2 Connection for water discharge
–Functioning: If at the temperature sensor 1the
temperature exceeds 50°C (direct extraction) or 95
°C (downpipe extraction), the valve 2opens and
floods the feeder channel with water.
–This extinguishing device serves to automatically
suppress burn-back within the feeder. Due to the
proper nature and location of the fire detection
element, burn-back must be reliably detected and
the extinguishing device must be triggered instanta-
neously and automatically (this must be ensured
even in the event of a power failure).
–The extinguishing device must be connected either
directly to a pressurised water supply or to a water
reservoir (Note: Domestic waterworks may also be
affected in case of power failure).
–The water supply must be equal to three times the
volume of the feeder equipment, but at least 20
litres. The container must be equipped with a fill
level monitor, including connection to the warning
device (temperature monitor > 6). The extinguis-
hing water inlet opening in the feeder is to be
arranged and executed so that blockage by
delivery operation is not possible and this can
easily be checked at any time. The routing of the
extinguishing system must be made as a non-
combustible version.
–Art. No.: 63260 and 6553
–Specification yes/no see TRVB 118 H
Manually triggered extinguishing device
(MTED)
–This extinguishing device is used to combat a fire
source in the fuel storage room, or fuel storage in
the area of the extraction/delivery line. The trig-
gering must be done manually.
6 Operation manual maximus

2 Safety information
–This device consists of an empty pipe with a mini-
mum nominal size of DN 20 and is to be installed in
the fuel storage as specified by the manufacturer
of the firing system directly above the delivery line
in front of the wall or ceiling passage in such a way
that the greatest possible success can be achie-
ved in extinguishing. The empty piping must be
connected directly to a pressurized water supply
and provided with a shut-off valve arranged in the
boiler room. Mark this valve with a sign "Extin-
guisher - Fuel Storage Room".
–The execution of the extinguishing system must be
done so that damage during fuel feed or from the
extraction device is not possible. In addition, make
sure that the fuel supply to the delivery line is not
affected.
–Specification yes/no see TRVB 118 H.
Rotary valve
The rotary valve installed in the standard equipment ful-
fils all normative requirements for the approved fuels
regarding fire protection, burn-back safety, backflow of
gases:
Fig. 2-5:Rotary valve
–Complies with requirements regarding burn-back
protection devices (BPD) according to TRVB 118
H.
–Prevents backflow of flammable products of com-
bustion into the fuel supply or into the intermediate
store (according to EN 303-5).
–Prevents spreading of fire into the fuel supply or
into the intermediate store (according to EN 303-5).
Safety switch on the channel cover
Opening the channel cover interrupts the power supply
to the motor of the extraction auger.
Heating system encompassing several fire
compartments
If the boiler room and fuel storage room are located in
different fire compartments, optional equipment must
be installed in addition to the factory safety equipment,
e.g.
–a temperature monitor (TM) > 6
–a manually triggered extinguishing device (MED) >
6
4.3 Dimensions
Side view
Operation manual maximus 7

2 Safety information
Top view
Front
8 Operation manual maximus

2 Safety information
Operation manual maximus 9
4.4 Functional components, combustion principle
Burner
Fig. 2-6
Functional components
1 Rotary valve 5 Ash extraction burner 9 Secondary air opening
2 Feeder unit 6 Ash container 10 Combustion chamber temperature sensor
3 Push grate 7 Primary air opening 11 Flue gas recirculation line
4 Ash scraper 8 Primary air outlet
Fuel path
–The fuel falls through the rotary valve 1into the channel of the feeder unit 2. The auger delivers the fuel to the
feed grate 3.
–During combustion, the fuel is transported on the feed grate, and the resulting ash falls down through the grate.
–The ash pusher 4push the ashes to the ash auger 5, and auger takes over the transport into the ash box 6.
Airflow
–Primary air is sucked in at the opening 7, forwarded in a space on the left and right side of the boiler; at the holes
8the primary air exits under the combustion grate.
–Secondary air is sucked in at the opening 9, and passes through holes in the fire brick (left, right, back) above the
combustion grate in the combustion chamber.
–Recirculation opening 10: If the sensor measures 11 too high a combustion chamber temperature, then air from
the flue gas pipe 12 is introduced here and added to the primary air. This leads to the cooling of the combustion
chamber and thus to lower stress on the components.

Heat exchanger
Fig. 2-7
Functional components
13 Ash container 15 Ash extraction heat exchanger
14 Electrostatic separator 16 Heat exchanger
Ash path
–The ashes falling on the feed grate are transported from the transverse ash auger into the ash container 13.
–The ashes falling on electrostatic separator 14 are transported forward by the auger 15 into the ash container.
Airflow
–The flue gas from the combustion chamber flows past the heat exchanger 16, on the electrostatic separator into
the flue gas pipe and into the chimney.
2 Safety information
10 Operation manual maximus

2 Safety information
Operation manual maximus 11
4.5 Technical specifications
maximus 150 200 250 300
Wood chips output [kW] 149 201 240 -
Pellets output [kW] 149 201 250 299
Boiler class (acc. to EN305:5
2012) 5 5 5 5
Dimensions
Width [cm] 189 189 189 189
Height incl. adjustable feet [1] [cm] 207 207 207 207
Depth with ID fan [cm] 222 222 222 222
Burner insertion dimension
(width) [cm] 90 90 90 90
Heat exchanger insertion dimen-
sion (width) [cm] 110 110 110 110
Minimum room height [2] [cm] 275 275 275 275
Weight
Burner weight [kg] 700 700 700 700
Hat exchanger weight [kg] 950 950 950 950
Total weight [kg] 1650 1650 1650 1650
Water side
Water content [l] 565 565 565 565
operating temp. [°C] 70 - 90 70 - 90 70 - 90 70 - 90
Maximum permissible tem-
perature [°C] 90 90 90 90
Max. permissible operating pres-
sure [bar] 3 3 3 3
Min. return flow temperature [°C] 60 60 60 60
Connection Boiler inflow/Boiler
return flow [“] G 2“OT G 2“OT G 2“OT G 2“OT
Drain connection [“] 1” 1” 1” 1”
Connection for thermal overload
protection [“] G 1/2“OT G 1/2“OT G 1/2“OT G 1/2“OT
Electrical systems
Electrical connection 400 V AC, 50 Hz,
16 A, 3P+N+PE
400 V AC, 50 Hz,
16 A, 3P+N+PE
400 V AC, 50 Hz,
16 A, 3P+N+PE
400 V AC, 50 Hz,
16 A, 3P+N+PE
Fuel
Fuel - wood chips Wood chips in accordance with EN ISO 17225-4, classes A1, A2, B1, B2;
sizes P16S and P31S; water content max. 40% (M40) > 4
Fuel - wood pellets Wood pellets according to ENISO17225-2 > 4
Flue gas side
Flue gas pipe diameter [cm] 25 25 25 25
Height of flue gas pipe [1] [cm] 207 207 207 207
Minimum draught requirement [3] [Pa] 5 5 5 5
Maximum flue gas temperature
[4] full load [°C] 140 140 140 140

maximus 150 200 250 300
Emissions according to test
report:Wood chips
Flue gas value [5] from test
report:
Test institute / test report no.
18-IN-AT-UW-OÖ-
EX-205/3
TÜV Austria
Interpolation accor-
ding to EN303-5
18-IN-AT-UW-OÖ-
EX-205/4
TÜV Austria
-
CO full load [mg/m³] 19 30 38 -
CO Partial load [mg/m³] 20 20 20 -
NOXfull load [mg/m³] 120 120 115 -
NOXpartial load [mg/m³] 93 93 93 -
Org. C full load [mg/m³] 2 2 2 -
Org. C partial load [mg/m³] 2 2 2 -
Dust content full load [mg/m³] 9.5 11.6 13.8 -
Dust content partial load [mg/m³] 6.5 6.5 6.5 -
Flue gas mass flow full load [g/s] 97.9 130.5 156.7 -
Flue gas mass flow partial load [g/s] 29.4 39.2 47.0 -
Emissions according to test
report:Pellets
Flue gas value [5] from test
report:
Test institute / test report no.
18-IN-AT-UW-OÖ-
EX-205/1
TÜV Austria
Interpolation accor-
ding to EN303-5
Interpolation accor-
ding to EN303-5
18-IN-AT-UW-OÖ-
EX-205/2
TÜV Austria
CO full load [mg/m³] <3 3 3.6 3.6
CO Partial load [mg/m³] 29 29 29 29
NOXfull load [mg/m³] 112 112 113 113
NOXpartial load [mg/m³] 83 83 83 83
Org. C full load [mg/m³] 2 2 2 2
Org. C partial load [mg/m³] 2 2 2 2
Dust content full load [mg/m³] 6.5 8 8.7 10.2
Dust content partial load [mg/m³] 5 5 5 5
Flue gas mass flow full load [g/s] 94.5 126.0 157.6 189.1
Flue gas mass flow partial load [g/s] 28.4 37.8 47.3 56.7
[1] Adjustable feet at maximum depth of thread
[2] The minimum room height is required for maintenance work
[3] A draught stabiliser must be fitted if the specified draught of 15 Pa is exceeded
[4] Flue gas temperature can be adjusted electronically.
[5] Flue gas values in mg/m3are based on 13% O2of the volume flow
2 Safety information
12 Operation manual maximus

5 Prior to assembly
5 Prior to assembly
iConsult a competent chimney sweep
before connecting the heating system. He
must approve the installation and is the
contact person regarding technical and
legal issues.
5.1 Transport
Option 1: Transport with a lift truck
In both parts (burner and heat exchanger), the webs 3
are used on the bottom as a support for the truck.
►Approach the burner 1from the back
►Approach the heat exchanger 2from the front.
Fig. 2-8: Transport boiler with truck
Option 2: Lifting with a crane
!WARNING - When using a hoist (e.g. chain),
make sure that the angle does not fall below 45
degrees. If it falls below this, excessively high
forces act on the components and damage is
possible.
►Secure the heat exchanger at four metal eyelets
1.
►Secure the burner at both metal eyelets 1.
Fig. 2-9: Metal eyelets for crane transport
5.2 Boiler room
Structural specifications
–The boiler may only be installed in a dry, frost-free
room; the permissible room temperature is 5 to
30°C.
–The boiler may only be used on a sufficiently stable
and non-combustible surface.
–Observe spacing to flammable materials (regional
regulations).
–Note the installation dimensions to ensure suf-
ficient space is provided (e.g. for service and main-
tenance work).
–For normative specifications see Austrian standard
ÖNORM H 5170
Fire extinguishers
–Austria: A 6 kg ABC powder extinguisher is spe-
cified as the minimum requirement. Install it out-
side the boiler room in an easily visible and quickly
accessible place.
–Germany, Switzerland: In private homes, no fire
extinguisher is required for heating systems.
However, having a fire extinguisher is recommen-
ded.
Keep escape routes clear
–Under staircases, on escape routes and in unfi-
nished attics, the installation of fireplaces is inad-
missible.
Operation manual maximus 13

5 Prior to assembly
Supply air/exhaust air in Boiler room
For Austria (according to standard H 5170):
–For the supply air, 2 cm² per kW thermal output of
the fuel, but allow at least 200 cm² free cross-sec-
tion. (Fuel heat capacity = boiler capacity / effi-
ciency)
–For the exhaust air, allow at least 180 cm² free
cross-section up to 100 kW nominal heat and an
additional 1 cm² free cross-section for every further
kW.
iCalculate at least a further 20 % for wire mesh
in the aeration cross-section.
For Germany In accordance with the Model Firing Ordi-
nance:
–For heating appliances with a nominal output of up
to 35 kW, a combustion air opening of at least 150
cm² or 2 x 75 cm² routed directly into the open air
must be provided.
–Alternatively, a door/window leading outside and a
room content of at least 4 m³/kW nominal heat out-
put are suitable. If the Boiler room does not abut
onto an outside wall, combustion air supply via
connecting rooms is possible. Here, the com-
bustion air is supplied via a sufficiently dimen-
sioned adjacent room which abuts onto an outside
wall.
–From 35 to 50 kW, provide a free aeration cross-
section of at least 150 cm². From 50 kW upwards,
for aeration and ventilation, provide a minimum
free cross-section of 150 cm² for each, plus 2 cm²
per KW in excess of 50 kW.
iCalculate at least a further 20 % for wire mesh
in the aeration cross-section.
Boiler
power
[In kW]
Minimum space [in cm²] including 20%
surcharge for grids
Austria Germany Switzerland
Supply
air
Exhaust
air
Supply
air/Exhaust
air
Supply air
20 kW
>240 >216
>180 >206
25 kW >180 >258
35 kW >180 >361
50 kW >228 >515
70 kW >228 >721
90 kW >276 >927
130 kW >347 >252 >372 >1339
200 kW >533 >336 >540 >2060
400 kW >1067 >576 >1020 >4120
5.3 Chimney, flue gas pipe
Chimney cross-section and chimney height
The necessary cross-section depends on the nominal
output of the heating system and the effective chim-
ney height (at least 6.5 m). We recommend that you
have the calculations performed by an expert.
Chimney execution
–The chimney must be resistant to moisture. Use
fire brick or stainless steel.
–The chimney must conduct away the flue gases
reliably at all times.
Connect the chimney condensate drain to the
sewage system
–Connect the condensate drain line of the chimney
to the domestic sewage system (to drain con-
densate, rainwater).
–Use DN 25 diameter pipe, install siphon.
Provide each boiler with its own chimney
–The boiler and the fireplace must be coordinated.
This is the only way to ensure the proper func-
tioning of the heating system and the correct
discharge of the flue gases.
–If there is only one chimney available for two boi-
lers, there is a risk (considering the different ope-
rating states of the boilers - full load/partial load).
This can lead to problems (e.g. the flue gas has too
low energy during the ascent, and does not lift off
sufficiently from the chimney mouth, ...odour pol-
lution by flue gases).
–Singly equipped chimneys are more reliable and
safer than multi-fuelled fireplaces.
Do not connect a gas boiler and blower boiler to
the same chimney
Do not connect a wood-burning stove and blower
boiler to the same chimney
–A wood-burning stove typically requires a larger
chimney diameter than the blower boiler.
–Acoustic disturbance from the blower boiler may
be possible in the living room (by the wood-burning
stove).
–Unnecessary risk due to gas leakage, e.g. if the
blower boiler is defective.
14 Operation manual maximus

5 Prior to assembly
Execution of the flue gas pipe
–Run the flue gas pipe towards the chimney in
a short and rising direction, with as few chan-
ges of direction as possible.
–Change direction in the form of aerodynamically
favourable arcs, do not build kinks.
–The diameter of the flue gas pipe to the chimney
may be enlarged if required, but may not be redu-
ced.
–Place the inlet of the flue gas pipe in the chimney
just below the ceiling.
–The flue gas pipe must be tight. Seal seal-less flue
gas pipes on site with heat-resistant silicone.
Insulate flue gas pipe
–Insulate the flue gas pipe continuously from the boi-
ler to the chimney.
–Recommended insulation thickness: 50 mm rock-
wool.
–Serves to prevent temperature loss and prevents
the consequential formation of condensation.
Cleaning opening in the flue gas pipe
–To clean the flue gas pipe (e.g. removal of accu-
mulated fly ash) there must be an easily acces-
sible cleaning opening.
–Recommendation:Coordinate the number and pla-
cement of the cleaning openings with the chimney
sweep.
Opening for emissions measurement in the flue
gas pipe
Make an opening (hole) in the flue gas pipe to perform
the prescribed emission measurement > 22
Minimum draught requirement for boiler: 5 Pa
A draught stabiliser must be fitted if the specified
draught of 15 Pa is exceeded.
►Establish the chimney connection > 22
Recommended chimney diameter
For all maximus Boilers (150 to 300 kW output), a chim-
ney diameter of 25 cm is recommended.
Install explosion damper
Fig. 2-10:Explosion damper integrated into draught limiter
iBefore longer horizontal pipe sections
(L>20xD) and at the high point before dropping
down the flue gas pipe, an explosion damper
must be installed, independent of the boiler out-
put.
From 100 kW boiler output, an explosion damper is
required in the flue gas pipe. This avoids damage to
the boiler or the flue gas system even when defla-
grations occur.
Operation manual maximus 15

6 Installation
6 Installation
6.1 Mount heat exchanger on the burner
This chapter describes how to make the necessary
connections between the heat exchanger and the bur-
ner.
!WARNING - Before connecting the burner and
heat exchanger, check that the sealing cord 1
in the flue gas pipe flange is in the correct posi-
tion.
Fig. 2-11: Sealing cord in the flue gas pipe of the burner
6.1.1 Adjust spacing screws
►The two lower holes 1serve to receive the spa-
cing adjustment screws.
Fig. 2-12: Hole for screws
►Set the two hexagonal screws so that a spacing
of 25 mm is maintained between the bottom pla-
tes of the burner and the heat exchanger.
►Push the heat exchanger to the burner (spacing
screws) until the stop.
Fig. 2-13: Distance between the bottom plates
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6 Installation
6.1.2 Screw on flue gas pipe flange
►Connect the flange of the flue gas pipe with 6 pcs.
hexagonal screws and nuts.
Fig. 2-14: Screw on flue gas pipe flange
6.1.3 Install automatic ash extraction
iCheck the correct position of the ash auger
heat exchangers:The auger must be locked in
the rear drive in the bayonet mount.
Fig. 2-15:Check auger drive
►Mount Auger channel 1on the heat exchanger.
Fig. 2-16:Mount the auger channel
►Slide metal rings 1and 2, and gasket 3onto the
auger channel.
Fig. 2-17: Slide on sealing elements
►Screw flange plate onto the screw channel.
Fig. 2-18:Mount flange plate
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6 Installation
►Mount the auger channel onto the burner with 4
pcs. hexagonal screws.
Fig. 2-19:Mount the auger channel
►Tighten metal rings with 2 pcs. hex nuts onto the
threaded bolts; the (white) sealing ring is pressed
axially, creating a radial seal.
Fig. 2-20:Tighten sealing elements
►Slide the ash extraction auger 1into the auger
channel.
Fig. 2-21:Insert the auger
►Dismantle cover 1
►Fix auger shaft 2into the receptacle 4with hexa-
gonal screw 3and hex nut.
Fig. 2-22:Connect the auger shaft
6.1.4 Connect flue gas recirculation line
►On the back, connect the flue gas recirculation
line from the burner 1to the ID fan 2.
Fig. 2-23
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6 Installation
6.1.5 Connect burner and heat exchanger
hydraulically
►Make piping between the two connections.
(Connection is not pre-fabricated).
Fig. 2-24: Connect the water circuit
6.2 Install the hot air fan
►Install hot air fan 1in the ignition tube.
►Connecting to terminals:
FanA1:X7
Heating element A1:X4
►The cable is pre-routed in ducts 3 and 2 > 31.
Fig. 2-25: Install the hot air fan
6.3 Mount feeder grate drive
►Mount drive unit 1(plate, housing, motor/gearbox)
to the burner with 4 pcs hexagonal screws.
►Mount connecting rod 2with washer and circlip on
the bolt 3.
►If necessary (to turn the crank), remove motor/-
gearbox 4.
►Connect motor to X4.7-X4.9; the cable is pre-rou-
ted in ducts 3 and 2 > 31.
Fig. 2-26:Mount feeder grate drive
Connect the feed grate motor
►Connect the pre-routed cable as shown in the ter-
minal area of the motor.
Fig. 2-27: Connect the cable in the motor terminal area
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6 Installation
6.4 Install the feeder unit
►Mount the feeder unit 1including installed rotary
valve, to the burner with 4 pcs. hexagonal screw;
enclose seal 2.
►Set adjustable foot 3.
►Connect the feeder motor 4to the cable FU1 pre-
routed in ducts 3 and 2 > 31: U,V,W.
iCheck - swap two phases if the direction of
rotation is wrong.
Fig. 2-28:Install the feeder unit
Install the feeder sensor
►Fix the feeder sensor 1in the retaining tube
►Connect to A1:X33, cable is pre-routed in ducts 3
and 2 > 31.
Fig. 2-29:Install the feeder sensor
Connect the feeder motor
►Connect the pre-routed cable as shown in the ter-
minal area of the motor.
Fig. 2-30: Connect the cable in the motor terminal area
6.5 Install safety valve
►Install the safety valve in the boiler supply line, at
the highest point of the line, as close as possible
to the boiler. Observe installation position.
!CAUTION - Do not install any barriers in the
pipework that could render the boiler safety
group ineffective.
6.6 Install return booster
Information on return booster > 24
20 Operation manual maximus