Assembly and installation

instructions
-
Electrical documentation

HERZ firematic 20 - 60 BioControl

HERZ Armaturen Ges.m.b.H.

Geschäftsbereich HERZ Feuerungstechnik
A-8272 Sebersdorf 138
Tel.: +43 (0) 3333/2411-0
Fax.: +43 (0) 3333/2411-73
e-mail: office@herz-feuerung.com
www.herz-feuerung.com

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CONTENTS:

1. INTRODUCTION....................................................................................................4
SAFETY NOTES........................................................................................................5
INSTALLATION..........................................................................................................7
GENERAL NOTES.................................................................................................. 7
GENERAL SAFETY NOTES................................................................................... 8
OPERATION.............................................................................................................. 9
GENERAL SAFETY NOTES................................................................................... 9
MAINTENANCE......................................................................................................... 9
GENERAL SAFETY MEASURES............................................................................9

Assambly and installation instructions..............................................11

2. AREA OF APPLICATION, PLANNING PARAMETERS AND UPSTREAM

CONNECTIONS.......................................................................................................11
A. EXPANSION CONTAINER – SAFETY VALVE.................................................11
B. EXCESS TEMPERATURE OUTLET.................................................................11
4. INSTALLATION, BOILER ROOM AND SUPPLY AIR..........................................13
5. POSITIONING – BOILER ROOM........................................................................13
6. TRANSPORTATION TO THE BOILER ROOM....................................................14
A. INSPECTIONS AFTER TRANSPORTATION...................................................14
7. CHIMNEY.............................................................................................................15
A. CONDITION OF THE CHIMNEY......................................................................15
B. BOILER CONNECTION TO THE CHIMNEY CONFORMING TO
SPECIFICATIONS..........................................................................................16
C. CORRECT CHIMNEY DIMENSIONING (ACCORDING TO DIN 4705 OR
EN 13384).......................................................................................................17
8. STARTING UP.....................................................................................................19
9. IMPORTANT INFORMATION FOR HEATING INSTALLERS..............................20
10. FUELS....................................................................................................... 20
11. ELECTRICITY SUPPLY.............................................................................21
12. DIMENSIONS AND TECHNICAL DATA....................................................22
13. INSTALLATION......................................................................................... 24
13. STANDARD DIAGRAMS...........................................................................34

Electrical documentation.....................................................................49

HERZ – BIOCONTROL 3000...................................................................................49

SYSTEM DESCRIPTION.......................................................................................49
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 SCHEMATIC SYSTEM LAYOUT...........................................................................50
GENERAL..............................................................................................................51
PLUG SYSTEM USED..........................................................................................51
PLUG AND CLAMP ALLOCATION (TERMINAL)..................................................52
DRAWING (HC EXTENSION MODULE)...............................................................61
INSTRUCTIONS FOR CHANGING THE HC PLUG-IN MODULE.........................62
PLUG CONFIGURATION – HEATING CIRCUIT EXTENSION MODULE............63
DRAWING (SOLAR EXTENSION MODULE)........................................................64
INSTRUCTIONS FOR CHANGING THE PLUG-IN MODULE...............................65
(SOLAR EXTENSION MODULE)..........................................................................65
PLUG CONFIGURATION – SOLAR CIRCUIT EXTENSION MODEL...................66
PLUG AND CLAMP CONFIGURATION (ACTIVE COMPONENT).......................67
Safety temperature limiter cut-off (active component)...........................................75

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1. Introduction

Dear Customer,

Your heating system is operated using a HERZ firematic boiler unit and we are
pleased to be able to welcome you to the wide circle of satisfied operators of HERZ
equipment. The HERZ biomass furnace system is the result of many years of
experience and further development. Please take into account that a good product
also requires the correct service and maintenance, in order to be able to fulfil its
function.
Therefore, please read through this documentation carefully – it will be worthwhile.
Please take particular note of the safety notes.
Adhering to the operating regulations is a precondition of any claim against the
factory guarantee. In the event of faults, please contact your heating specialist or
the HERZ factory customer service.

Yours sincerely,

HERZ Feuerungstechnik (Fuel Technology)

The German documentation is the original and has been translated into other
languages.

Printing or copying, even of extracts, may only be carried out with the approval of
HERZ©.

Warranty / Guarantee (general)

For Herz fuel technology systems, there is a 5-year guarantee on the body of the boiler,
the storage devices and for Herz solar collectors. For electrical parts such as electronic
motors, electrical control boxes, ignition devices, etc. the guarantee is valid for 2 years
from commissioning of the system. Excluded from the guarantee are
wearing parts. Claims against the guarantee are invalid if the return flow bypass is missing
or is not working properly, if the commissioning / maintenance 1 has not been carried by
Herz specialist authorised staff, and if the recommended fuel pellets (ÖNORM M 7135,
DINplus or Swiss Pellets), wood chippings (ÖNORM M 7133) or logs are not being used 2.

We reserve the right to make technical changes.

Version 06/2009

1
Maintenance by the manufacturer
2
Furthermore, hot water quality must be fulfilled according to ÖNORM H 9195 or VDI 2025
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Safety notes
 Please read the operating instructions carefully prior to start-up and pay particular
attention to the safety notes marked. Please consult these instructions for
clarification.
 Ensure that you understand the directions in this manual and that you have
sufficient information about the functioning of the firematic biomass furnace
equipment. HERZ is at your disposal at all times for any questions.
 For safety reasons the operator of the equipment may not alter its construction or
condition without the agreement of the manufacturer or its authorised
representative.
 Ensure that there is sufficient fresh air supply to the boiler room.
(Please take into account the current federal state regulations)
 The gas and liquid tightness of all connecting points is to be monitored before the
equipment is started up.
 A portable fire extinguisher of the prescribed size must be placed in front of the
boiler room. (Please take into account the current federal state regulations)
 When opening the combustion chamber doors take care that no flue gas and
sparks are released. Never leave the combustion chamber door open. Toxic gases
may escape.
 Never heat up the boiler with liquid fuels such as petrol or similar.
 Carry out maintenance work regularly (maintenance plan) or use our customer
service. (Minimum TRVB maintenance intervals must be adhered to)
 For maintenance of the equipment or when opening the controls, the flow supply
must be interrupted and the general applicable safety rules must be adhered to.
 No fuels should be stored outside the equipment in the boiler room Furthermore,
items that are not required for the operation or maintenance of the equipment must
not be stored in the boiler room.
 It is vital that the boiler is switched off when filling the fuel bunker using a pump
vehicle. (Markings are on the lid of the filling nozzles). Non-compliance may allow
combustible and toxic gases to enter the storeroom.
 The fuel bunker must be safeguarded against entry by unauthorised persons.
 Always cut off the power supply if you have to enter the fuel bunker.
 Always use low voltage bulbs to light the storeroom (these must be approved for
this purpose by the manufacturer).
 The equipment may only be operated using designated fuels.
 Prior to onward transportation of ashes, these must be cooled down for a minimum
of 96 hours in the storeroom.
 In case of any questions please contact us by telephone ++43/3333/2411 – 0.
 The first start-up must be carried out by HERZ factory customer service or an
authorised specialist. (Otherwise the guarantee becomes invalid).

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 ...Warning notes
Risk of injury from incorrect handling of
the equipment
Material damage may also arise.
Warning – hot surface

Warning – injury to hands

Unauthorised entry prohibited

It is imperative that details of transportation, installation, operating and maintenance

notes as well as technical data is likewise are adhered to, in order to avoid faults that may
lead directly or indirectly to damage to people or materials.

GENERAL NOTE
For reasons of clarity and the possible permutations involved, these operating instructions
do not contain all detailed information and cannot take account of every conceivable
operating or maintenance scenario.
Should you require further information or encounter specific problems, which are not
handled in detail in the operating instructions supplied, you can obtain the required
information from your specialist dealer or direct from HERZ.

People (including children) who are not in a position to use the equipment safely due to
their physical, sensory or mental capacities or their inexperience or lack of knowledge
may not use this equipment without supervision or instruction by a responsible person.

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 Basic safety information

Due to its functionally limited electrical and mechanical

characteristics with regard to usage, operation and
maintenance, if the equipment is not able to work
according to its appropriate use or improper interference
occurs, it may cause serious health and material damage.
It is therefore assumed that the planning and
implementation of all installations, transportation, operation and
maintenance will be carried out and supervised by responsible, qualified
persons.

When operating electrical equipment certain parts are inevitably under electrical tension
or mechanical stress. Only appropriately qualified staff may work on the equipment. Staff
must be basically familiar with the content of these and all other instructions. The smooth
and safe use of this equipment is dependent upon appropriate transportation and
storage as well as designated operation and careful maintenance. Notes and indications
on the equipment must also be observed.

INSTALLATION

General notes

In order to guarantee correct functioning of the system, the installation must be carried
out in adherence with the relevant standards and installation regulations from the
manufacturer.

Manufacturer documents for the heating equipment and components used are available
from Herz.

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OPERATION AND MAINTENANCE

General safety notes

For safe operation and maintenance of all equipment, it is assumed that

actions will be carried out appropriately by qualified staff, taking heed of the warning
notes in this documentation and the notes on the equipment.

The equipment may only be opened when “HEATING OFF” is indicated as there is
otherwise a risk of deflagration.

With unfavourable operating conditions temperatures of over 80°C may occur at parts of
the casing.

When opening the ash storage door during operation the fuel supply is cut off and the
boiler goes into burnout phase. This then changes into the “HEATING OFF” mode of
operation.

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OPERATION
GENERAL SAFETY NOTES

Covers that hinder contact with hot or rotating parts or which are required

for the correct circulation of air and thus effective functioning, must not be opened during
operation.

The system must be switched off immediately via EMERGENCY OFF

in the event of any faults or in unusual operating conditions such as smoke or flame
emission. The HERZ factory customer service must then be notified immediately.

 The equipment is then put out of operation immediately by activating the main
switch on the boiler room door or in the event of a power failure. The remaining
residual fuel amount burns independently without giving off toxic gases, provided
that the natural effect of the chimney draw is sufficiently high. The chimney must
therefore be dimensioned and designed according to DIN4705 or EN 13384.

 Where the minimum residual oxygen content of 5% in the flue gas is not reached,
the fuel supply is stopped automatically and is only activated once again when the
residual oxygen content is over 5%. ACTUAL O2 [‰] 50).

 The noise caused by the machinery during operation does not have any adverse
effects upon the health of people.

MAINTENANCE
GENERAL SAFETY MEASURES

Before commencing any work on the equipment, but particularly before

opening coverings of parts under voltage, the equipment must be enabled according to
the instructions. As well as the main electrical circuit, any additional or auxiliary circuits
should be noted. The usual

safety rules according to ÖNORM are:

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  Switch off all poles and all sides
 Ensure they is not switched on again
 Check for absence of voltage
 Earth and short-circuit
 Cover the adjacent voltage-free parts and
limit danger areas

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 These above mentioned measures many only be cancelled if the

equipment is completely installed and the commissioning completed.

For overhaul work in the combustion chamber, ash chamber, on flue gas-

carrying parts, emptying of the ash store, etc., the use of personal dust protection masks
and gloves is required.

For overhaul work in the storage room, low voltage bulbs must be used.

The design of electrical equipment in the storeroom must conform to ÖN M7137.

In order to prevent any commissioning errors due to incorrect maintenance, regular

maintenance service is recommended, to be carried out by authorised staff or the HERZ
factory customer service. No health risks will be caused to the customer from noise arising
from the machinery. Details of any residual risks can be requested from the residual risk
analysis from Herz as required.

Spare parts may only be obtained direct from the manufacturer or sales partner.
People (including children) who are not in a position to use the equipment safely due to
their physical, sensory or mental capacities or their inexperience or lack of knowledge
should not use this equipment without supervision or instruction by a responsible person.

INFO: Where speed controlled pumps are used, an additional relay should be fitted to
switch these pumps, as the high starting current of these pumps may damage the
relay in the control.

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 ASSAMBLY AND INSTALLATION
INSTRUCTIONS

2. Area of application, planning parameters and

upstream connections
The HERZ special boilers are suitable and permitted for use as heat generators for
heating equipment with
buffer storage with the highest permissible advance flow temperatures up to 90°C.

HERZ recommends the installation of a suitably dimensioned buffer storage.

Hot water quality according to ÖNORM H 5195, EN 12828 or VDI 2034.

All regulations from EN 12828 are to be adhered to with regard to installation.

A. Expansion container – safety valve

A closed expansion container and a type-tested safety valve must be installed in
accordance with DIN 4751, sheet 2 and / or ÖNORM B8130 and B8131.

B. Excess temperature outlet

In equipment according to DIN 4751 sheet 2, solid fuels may only be burned if the boiler is
equipped with a suitable safety heat exchanger and type-tested thermal flow protection
(ÖNORM B 8131). This safety equipment serves to protect the boiler against overheating,
and can only fulfil its task if:
 a flow pressure of at least 2 bar is available on the cold water input in the pipe coil 2
bar is available (and constant network voltage dependent in-house supplies are not
safe enough).
 the feed pressure at the flue pipe connector of the boiler does not exceed the
prescribed value.
Check in advance of boiler installation, whether these two pre-conditions are present or
achievable.
Local regulations must be observed for the connection of drinking water networks!

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Hydraulic connection
Boilers for solid fuels are not integrated into open equipment according to DIN 4751-1, but
according to the installation examples in closed equipment, DIN 4751-2.

Only regulated heating circuits with a mixer should be connected.

HERZ offers numerous recommended methods. If other methods are used at installation,
correct boiler operation cannot be guaranteed. Any customer service requests based on
this reason are the responsibility of the customer.

Return flow temperature bypass

The return flow temperature should not go below 60°C. A return flow temperature
bypass is absolutely vital.
Attention:
Corrosion damage that is caused by return flow temperatures that are too low, do not
come under the guarantee or warranty.

Selection of rated heat output

When selecting the size of the boiler, care should be taken that, according to the heating
equipment regulations, the rated capacity does not exceed the heat requirement set out in
.

Draught limiter and explosion flap

The installation of a draught limiter is required and the draught requirement is between 5
and 10Pa.
According to TRVB H 118 an explosion flap must be installed in the connection pipe or in
the chimney. (HERZ recommendation)

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4. Installation, boiler room and supply air
The building regulations for each country are applicable with regard to the structural
requirements for boiler rooms as well as their ventilation for furnace equipment. TAKE
CARE THAT SUFFICIENT FRESH AIR IS ENTERING THE BOILER ROOM, so that the
fresh air required for operating installed furnaces can flow in and does not cause a lack of
oxygen for the operative!
To uphold this requirement we recommend average air ingress of 400 cm 2 for boiler sizes
up to 50KW. For rectangular openings the aspect ratio should be no more than 1.5: 1, and
for grating a relevant supplement should be added so that the free average reaches the
abovementioned requirement.

Country-specific regulations must be adhered to by the client.

5. Positioning – boiler room

The installation should be on the level. To ensure trouble-free operation and maintenance of
the furnace equipment please make sure that the boiler and at least one side provides a free
passage of minimum 80cm (see picture). 80cm (see fig.). Sufficiently bright electrical lighting
is to be in place for the display and safety equipment, the operating regulation and the
access areas. Combustible items that are not required for operation or maintenance of the
boiler equipment, should not be kept in the boiler room.

(Take note of the building and safety regulations or country building regulations!)

HERZ recommends operating the entire heating system (i.e. furnace equipment, room
discharge, heating pipes etc.) in a “mechanically insulated” way. This mechanical
insulation is available as an accessory.

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6. Transportation to the boiler room
If a crane is available for transportation, the HERZ special boiler can be placed using a
transportation hook and loading chain. A further option is for the boiler to be carried to the
transportation pallet using a forklift, but care must be taken that the transportation pallet is
long enough to prevent the boiler from tipping over. If there is limited space after the boiler is
removed from the transportation pallet it can be carefully transported across even flooring
using rollers. To negotiate stairs all doors can be taken off (to reduce the weight). During
transportation it is vital that care is taken not to damage the underside of the floor insulation
and that it is not pulled off.
Attention:
If the boiler is to be tipped, it is recommended that the panelling be removed before tipping
in order to avoid damaging it.

A. Inspections after transportation

After transportation to the boiler room the following points are to be noted:

Correct positioning of:

the entire combustion chamber
all electronic parts
drive motors
panelling parts

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7. Chimney
The HERZ special boiler is a technically high-quality product, the advantages of which are
only ensured with careful set-up of all factors required for good combustion. The boiler and
chimney form a functioning unit and must fit together in order to ensure fault-free and
economic operation. It is therefore absolutely essential for each boiler type to reach the right
“feed pressure”.
A feed pressure that is too low prevents the correct removal of the flue gases and can lead
to
 Poor burning behaviour
 Smoke escaping from the draw controller
 Smoke escaping from non-tight flue gas pipes
 Excess pressure at the chimney with the risk of deflagration

If the feed pressure is too high the combustion is accelerated which leads to
 an expansion of the flame, possibly up to the heat exchanger areas
 Increased wear on the combustion chamber parts
 High flue gas temperatures and therefore decreased efficiency
 A high flow rate and therefore increased emission of dust and/or soot

Achieving the correct feed pressure is dependent upon three significant factors
 State of the chimney
 A boiler connection conforming to specifications for chimneys with throttle valve +
explosion flap
 Correct dimensioning of the chimney

A. Condition of the chimney

The preconditions for a reduced loss of draw in the chimney are:
 Good heat insulation to avoid rapid cooling of the flue gases.
 A smooth inner surface to avoid turbulence.
 Tightness of the chimney to avoid incorrect air entry (the cooling of flue gases is speeded
up by incorrect air entering).
 The chimney must not be sensitive to moisture and must be calculated and dimensioned
according to DIN 4705.
 These requirements correspond to chimneys of design types I and II according to DIN
4705 part 2.
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B. Boiler connection to the chimney conforming to specifications
The boiler must be connected upwards to the chimney with as short a connection piece as
possible. Ideally this would be a connection piece 1mm long with a shaped piece. The use of
further shaped pieces cause a greater loss of pressure in the flue gas channel and is
therefore to be avoided. Connection pieces must be sufficiently insulated.

Further points to be noted:

 The connection piece must not project into the chimney.

 B-rackets should not be used but only arcs. The inner radius of the arc must not be
smaller than the diameter of the pipe.
 The chimney connection point must be carefully sealed.
 Vertical, straight chimney ducts with no irregularities (particularly in built-on areas).
 All cleaning doors and measuring openings on the chimney must be sealed closed.
 To avoid incorrect air entry only one heat generator is to be connected to a chimney.
 A draw controller must be fitted. This brings an improved level of efficiency and thus
maximum economy.

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C. Correct chimney dimensioning (according to DIN 4705 or EN
13384)
The boiler may only be attached to a chimney which has been calculated for the intended
fuels and loads and which corresponds to the building regulations applying to the place of
installation. The following local situations can only be taken into account with difficulty for the
chimney calculation but are significant for the perfect functioning of the boiler and chimney:

 The position of the building (due to an elevated position or

differing building heights, down draughts or dynamic pressure areas may arise)

 Position of the chimney on the roof (the mouth of the chimney

must be at least 0.5m above the highest edge of the roofs with a decline of more than
20°, with a gap of at least 1m from roof surfaces which have a slope of less than 20°.

 Development of the mouth of the chimney (congestion and

turbulence result for and from decorative attachments, which prevent the undisturbed
passage of flue gases into the wind flow).

In practice it often happens that a chimney constantly or occasionally has too high a feed
pressure (due to changes in the weather, gusty winds, etc.). The burn-off conditions are
sometimes almost consistent due to installation of a draw controller, which leads to an
improvement in the efficiency level. In any case it is to be recommended, however, to
include the relevant chimney specialist (flue sweeper) at the planning stage!

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 A
D

B
C

A: Effective chimney height

B. Chimney draw controller with explosion flap
C Grout opening
D Flue pipe upwards and insulated

Permissible feed pressure (formerly described as draw requirement) 1mm WS = 0.1mbar

Effective chimney height = height difference between the flue gas inlet in the chimney and
the chimney mouth (according to DIN 4705 or EN 13384)

Boiler type Min./Max. Examples for suitable chimneys

permissible feed
pressure [mbar]
diameter Feed height Design type
firematic 20 0.05 / 0.10 140,160 minimum 7m FU
firematic 35 0.05 / 0.10 140,160 minimum 7 FU
m
firematic 45 0.05 / 0.10 160,180 minimum 7m FU
firematic 60 0.05 / 0.10 160,180 minimum 7m FU

ATTENTION:
All the chimney equipment must be set out according to the DIN 4705 or EN 13384 in
force. Wrongly dimensioned chimney equipment may lead to functioning faults (dangerous
circumstances)

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8. Starting up
The first start-up must be carried out by HERZ factory customer service or an authorised
specialist.
Besides this the low pressure in the flue pipe connecting piece of the boiler has been
measured after the combustion with the designated solid fuels at least one hour during the
operation and an advance flow temperature of 70-85°C has been achieved. It can thereby
be determined whether feed pressure for the correct operation of the boiler (formerly
described as draw requirement“) has set itself. If the existing chimney has not been
measured correctly or if the calculated chimney values have not been met (inappropriate
connection, entry of secondary air, connection piece too long, etc.) it will not be possible
to operate the boiler correctly. During start-up and handover to the operator, the
functioning of all control and safety equipment must also be monitored and the operation
and maintenance of the boiler and equipment must be explained to the operator in detail.
It is also the duty of the installer to create an operation manual for the complete
installation and this manual must be deposited in the boiler room.

According to the recognised engineering regulations, the specialist heating company is

obliged, without exception, to carry out hydraulic balancing.
Furthermore, the specialist heating company is also obliged to install a correctly laid out
membrane expansion vessel.
All recognised regulations and standards are to be applied by the specialist heating
company.

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9. Important information for heating installers
The operator must confirm in writing that:
 He has been sufficiently instructed on the correct operation and maintenance of the
equipment.
 He has received and familiarised himself with the operating instructions and any other
documents, etc.
 He is therefore sufficiently familiar with the equipment.

Note: The boiler return flow sensor is to be operated as a submerged sensor.

Heating water
With regard to the quality of the heating water, take into account ÖNORM H 5195, for
Germany – EN 12828 part 1, VDI 2034 (prevention of damage through corrosion and
calcification in closed hot water heating systems with operating temperatures up to
100°C).
Requirements, e.g.:
Chloride maximum 30 mg/l
pH value 8 – 9.5
Oxygen maximum 0.1mg/l

When using frost protection the following parameters must be adhered to:
 At least 25% and maximum 50% proportion of ethylene or propylene-based frost
protection agents, depending on the temperature level
 It is vital to take note of manufacturer details
 Mix well before filling and do not mix any different frost protection agents (mark on
the equipment)
 Do not add any water to ready-mixed products
 Check equipment once a year for proportion of frost protection, pH value 7.5-9.5,
corrosion protection and visual water quality.

10. FUELS
Fuel options

Wood chips up to a maximum size of G30, maximum water content 35 %, conforming to

ÖNORM M7133, G30 – W35

The nominal power is generated up to a maximum water content of 25%.

Pellets with PVA/PVD quality label

The wood must always be natural and untreated. Impurities such as stones or metal parts
must be removed prior to use.

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11. Electricity supply
Electrical connection
HERZ firematic heating equipment is delivered fully wired and will be connected on-site by
experienced HERZ staff. The electricity supply on site should be made ready.
The boiler is only suitable for placement in dry areas.
Installation must be carried out by an authorised specialist company according to local
regulations.
Electrical connection: 230V, 50Hz, 16A. Ensure that it is correctly fitted according to
phase.
A main switch controlling all poles must be installed outside the boiler room with
a distance of at least 3mm for the contact. Electrical connection to the existing local power
grid must be carried out by an authorised company.

Attention:

Do not clamp electric cables or damage their insulation. Avoid mechanical damage on
capillary cables (creasing, breaking off or clamping).
Claims caused by mechanical damage to capillary cables and electrical controls, are not
covered by the guarantee or warranty.
It must be ensured that the fuel feeding device can be turned off at any time using the
emergency switch located outside the boiler room (according to the sample fire
regulations and/or VDE 0116). This emergency switch firebox must be clearly and
permanently marked and it must conform to the valid regulations, especially according to
VDE 0116 (=DIN 57116 Electric equipment in furnace systems) and/or ÖVE as well as the
technical connection rules of the local electric supply company. (also refer to building and
fire regulations!)

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12. Dimensions and technical data

firematic BioControl 20 35 45 60
Output range – measured [kW} 7,3-25 7,3-34,4 13,1 -48,5 13,1 - 63,5
(n.g.) (10,2-41,3) (n.g.) (n.g.)
Output area – specification on the 7,3-25 7,3-35 13,1 -45 13,1 - 60
name plate [kW] (n.g.) (10,2-40) (n.g.) (n.g.)
Dimensions [mm]
A1length 1450 1450 1480 1490
A2 length 960 960 1070 1070
B1 width 600 600 710 710
B2 width 1300 1300 1410 1410
C1 height 395 395 395 395
C2 height 440 440 500 500
C3 height 1280 1280 1375 1375
C4 height 1490 1490 1590 1590
C5 height 650 650 650 650
C6 height 1372 1372 1475 1515
C7 height 1200 1200 1300 1300
C8 height 1040 1040 1125 1125
D1bore flue pipe 150 150 150 180
Boiler weight [kg] 517 517 620 620
Minimum / maximum permissible
0,05/0,1 0,05/0,1 0,05/0,1 0,05/0,1
feed pressure [mbar]
Permissible operating pressure [bar] 3 3 3 3
Maximum permissible operating
95 95 95 95
temperature

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Water content [L] 80 80 - -
Electrical connection [V, Hz, A] ~230,50,16 ~230,50,16 ~230,50,16 ~230,50,16
connection output [kW] /0,1 /0,1 /0,1 /0,1
Upstream resistance for t=20K
5,4 10,8 (13,4) - -
[mbar]
Upstream resistance for t=10K
20,6 39,9 (51,9) - -
[mbar]
Full load – emission values
Flue gas temperature [°C] ~136
~109 (n.g.) ~ 110 ~140
(~153)
Flue gas mass flow [kg/s] 0,0165 0,0235
0,0299 0,0366
(n.g.) (0,0268)
C02 content [Vol. %] 12,6 (n.g.) 12,3 (12,2) 13,8 15,0
Partial load emission values
Flue gas temperature [°C] ~58 (n.g.) ~58 (~68) ~ 60 ~ 60
Flue gas mass flow [kg/s] 0,0063
0,0063 0,0084 0,0084
(n.g.)
C02 content [Vol. %] 9,4 (n.g.) 9,4 (9,4) 13,0 13,0

721797224.doc Seite 24 von 78

13. Installation

Boiler in
as-delivered
condition

Removing the guard plate

Undo both screws from the plate and then take the
plate up.
(view, rear right)

Removing the safety screws Releasing the sleeve for the

Remove the safety screws rear left and front right. immersion shell
Remove the insulation until you see
the pipe for the immersion shell.

(View from front left)

Connection of thermal cooling coil!
The connection of the thermal cooling coil is on the back side of the boiler.
!!Attention!! During fasten hold up with screw wrench (spanner)!!
Thermal valve
(Accessories – HERZ ) Sensor into sleeve
Outflow to sewage
Cold water connection effluent

721797224.doc Seite 25 von 78

Placing the boiler according to the plan Installing the ash container for the boiler
(Sketch – on the floor) First, open the casing door.
Then push the ash container in the direction of
the boiler (take care that ash discharge fits in
the opening of the ash container)! Wheels also
vertical possible.

Fixing the ash container for the boiler Boiler with

After you have pushed the ash container right ash container
into the boiler, press the fixing lever to the left.
Now the ash container sits tight and you can
close the casing door.

Placing the sound insulation underneath Casing body strut!

Lift the boiler up and then lay the sound Screws down at the lining framework up
insulation underneath. to the soil unscrew and with nut fix

721797224.doc Seite 26 von 78

Plug-in screw in as-delivered condition Tightening up the ignition pipe

Tighten
the ignition
pipe using
the screw
below it!

Measuring the height of the flange on Measuring the height of the flange on the
the boiler plug-in screw
Position the height of the flange on the plug-in
Measure the screw in such a way that it is the same as the
height on the height of the flange on the boiler. The height
flange of the can be adjusted using the lower screw (arrow).
boiler and
compare this
with the height
on the flange
of the plug-in
screw.

Sound insulation and screwing on the entry screw

Firstly place the entry screw on the sound insulation and
then screw the flange of the entry screw to that of
the boiler.

721797224.doc Seite 27 von 78

installing the ignition fan Screwing in the ignition fan
Place the ignition fan into the ignition Lightly tighten the screw on the ignition pipe
pipe.

Make the electrical connection to the hopper

Connection via AS (auger screw), ES (plug-in screw), BFP, sensor storage room TÜB-
limit switch - light barrier) connect to sockets using colours. The cables must be laid
loosely and must not touch the plug-in screw, ignition pipe or, ignition blowers, etc.

Installing the sensor for the plug-

in screw temperature
Plug in the sensor as indicated (see
arrow).

721797224.doc Seite 28 von 78

Discharge screw in as-delivered Undoing the safety screws
condition Remove the safety screws

Removing the plate Undoing the nuts

Remove the 6 screws and take off Removing the four nuts
the plate

Greasing the screw supports Putting together both the screw parts
Grease the supports so that they are
easier to put together. Connect both screw parts. Take care that the
screw is completely in.

721797224.doc Seite 29 von 78

Connecting and screwing together both Sealing and lifting up the discharge
flanges screw on to the plug-in screw!
Firstly, seal the flange
Firstly, connect both flanges and put the and then place the
inserts in place. Then screw the flanges using discharge screw
the 4 nuts. on the flange of the
plug-in screw.

Removing the security tape and unscrew Greasing the connecting pieces for the
the screws screw on the gears
Remove the sticky tape and unscrew the Grease the connection piece well.
screws.

Placing the sound insulation underneath Loosening the bracket screws

In order Loosen the bracket screws on both sides
to facilitate the connection of the
screw with
the gears

place the wood

etc. under the
discharge
screw.

721797224.doc Seite 30 von 78

Connecting and screwing in the screw Positioning the gear
to the gears
Connect the screw with the gears and Measure the
screw this using the 4 screws. gear on both sides
and align the
gears so that
there is the same gap
on both sides
of the wall.

Sound insulating the gear Open the bracket screw on both sides!

Lift the Open the

gear and bracket screws
place the on both sides
sound insulation and align the
under it. flange of the
discharge screw
so that it is just lying on
the flange of the
plug-in screw

Remove the guard plate and the screws Fixing the brackets to the flange
on the flanges Drill a hole of 5.5mm next to the preset hole.
Remove the guard plate and screw both Then drill an M6 thread (on both sides).
flanges using the screws provided. After
you have screwed the flanges, screw the
guard plate up and screw the bracket
screws.

721797224.doc Seite 31 von 78

Fixing the brackets to the flange Fixing the brackets to the flange using silicone
Screw
the M6 Spread the silicone
screw around the edges of the
into both brackets so that no
sides more dust can escape.

Installing the extinguishing hose Positioning and fixing the motor

Place the motor on the axle so that the nut goes into
Place the the spring. Then fix this sing the disc and nut
hose in the provided.
direction for extinguishing
and screw
this in using
the
hose clip provided.

Installing the temperature monitor. Screwing in the end switch.

Screw the distributor box on to the holder. Place the
capillary pipe in the bracket.

Push up the lid. Fixing the frames for the interim container
casing.
Option for adjusting the cross member via the slots.

721797224.doc Seite 32 von 78

First place the jack stay on the boiler. Then connect it Frame ready installed
with the cross-member and and screw in

Installing the guard plate Installing the guard plate

Screw the side cover on to the pre-set
holes. Feed the cable through the cable Feed the
conduit. extinguisher hose
through
the pre-set hole.
Screw in the
second side cover.

Installing the rear guard casing Installing the extinguisher container

Place the rear casing between the two Screw in the extinguisher container to the
side casing panels and screw these in boiler wall using the tapping screw provided.
Place the hose behind it and fix this using the
hose clip.

721797224.doc Seite 33 von 78

Fixing the chamber discharge Fixing the chamber discharge

Drill the 4 fixing holes Screw the

Then place the dowels into the holes foot strut firmly to the floor using the
four screws on the floor.

Fixing the bracket screws on to the Fixing the plate

gears Lift the plate on to the gears and screws in
the six screws.
Fix the
screws in
flush to the gears
(on both sides)

Installing the discharge springs Discharge in its finished condition

First screw the bundle of springs at the
start of the springs. Then stretch the
bundle in order to screw in the second
screw.

721797224.doc Seite 34 von 78

721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T

1 2622 xx 1 2622 xx

HKP HKP

S (AF)
Mx Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

13. Standard diagrams

1 4215 xx 1 4215 xx

CAN-Bus CAN-Bus

1 2608 xx S (PO) 1 2608 xx

Seite 35 von 78
1 4217 xx 1 4217 xx

S (KF) S (KF2)

S (PU)

S (RL) S (RL)
1 4215 xx 1 4215 xx
RLP RLP

HYDRAULIKSCHEMA
BCA 404 BCA 404.dwg
721797224.doc
(Option)

S (VF) S (RL)

1 4215 xx 1 4215 xx

T Th T WW
1 4215 xx

1 2622 xx
T T
HKP 1 2622 xx

Mx BP
1 4037 xx
1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

1 4215 xx

1 4217 xx 1 4217 xx

S (AF)

1 4217 xx 2 7766 xx

1 2608 xx S (PO)

Seite 36 von 78
1 4215 xx

1 4215 xx

S (KF)
1 4215 xx

S (SPF)
S (PU)
KW
S (RL)
1 4215 xx 1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 411 BCA 411.dwg
721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T

1 2622 xx 1 2622 xx

HKP HKP

Mx Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)
1 4215 xx 1 4215 xx

1 2608 xx S (SP)

Seite 37 von 78
1 4217 xx 1 4215 xx

1 4215 xx
S (PO)

S (KF)
1 4215 xx

S (PU)

S (RL)
1 4215 xx 1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 413 BCA 413.dwg
721797224.doc
Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control

(Option) (Option) (Option) (Option) (Option) (Option)

S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) WW

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

1 4215 xx
T Th T T Th T T Th T T Th T T Th T T Th T

1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx

T T
HKP HKP HKP HKP HKP HKP
1 2622 xx

BP
Mx Mx Mx Mx Mx Mx
1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx
S (AF) 1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

Regelung / Control 1 4215 xx 1 4215 xx

1 4217 xx
2 7766 xx

1 2608 xx

Seite 38 von 78
1 4215 xx

S (KF)

S (SPF)

KW
S (RL)
1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 416 BCA 416.dwg
721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T
1 4215 xx

1 2622 xx 1 2622 xx WW
T T
HKP HKP 1 2622 xx

Mx BP
Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

1 4215 xx
S (AF)

1 4217 xx 1 4217 xx 1 4217 xx

1 4217 xx 2 7766 xx
S (PO)
1 2608 xx

Seite 39 von 77
1 4215 xx 1 4215 xx

1 4215 xx 1 4215 xx

S (KF)
1 4215 xx 1 4215 xx

S (SPF)
S (PU)
KW
S (RL)
1 4215 xx 1 4215 xx 1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 418 BCA 418.dwg
721797224.doc
Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control

(Option) (Option) (Option) (Option) (Option) (Option)

S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

WW
1 4215 xx
T Th T T Th T T Th T T Th T T Th T T Th T

1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx

T T
HKP HKP HKP HKP HKP HKP
1 2622 xx

BP
Mx Mx Mx Mx Mx Mx
1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx

Regelung/ Control

2 7766 xx

1 2608 xx S (PO)

Seite 40 von 77
1 4217 xx 1 4215 xx

1 4217 xx
S (KF2)

S (KF)
RLP

S (SPF)
S (PU)

1 4215 xx
KW
S (RL)
1 4215 xx Mx
RLP 1 4037 xx
1 7712 5x

HYDRAULIKSCHEMA
BCA 422 BCA 422.dwg
721797224.doc
(Option) (Option) (Option) (Option)

S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL)

Solar
1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T T Th T T Th T S (S1)

1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx

HKP HKP HKP HKP

Mx Mx Mx Mx
1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx
WW

1 2608 xx S (SP)

Seite 41 von 77
1 4217 xx

A1
S (PO)
S3

S (PU)
S (KF)

S4 ADG

S (RL)
1 4215 xx
RLP Solarventil
Solar valve

A2

HYDRAULIKSCHEMA
BCA 423 BCA 423.dwg
721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

Solar
T Th T T Th T
S (S1)
1 2622 xx 1 2622 xx

HKP HKP

Mx Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx

WW

S2
1 2608 xx S (SP)

Seite 42 von 77
1 4217 xx

S3 A1

S (PO) A2

Mx
1 4037 xx
S (KF)
1 7712 5x

S (PU) ADG

S (RL)
1 4215 xx Mx
RLP 1 4037 xx
1 7712 5x
A1

HYDRAULIKSCHEMA
BCA 426 BCA 426.dwg
721797224.doc
(Option) (Option)

Solar
S (VF) S (RL) S (VF) S (RL)

S (S1)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T
1 4215 xx

1 2622 xx 1 2622 xx
T T
HKP HKP 1 2622 xx

Mx BP
Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)
1 4215 xx
WW
1 4215 xx

2 7766 xx
1 2608 xx S (PO)
1 4217 xx

Seite 43 von 77
S (BF)

S (KF)

ADG
S (PU)

S (RL) KW S (S2)
1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 439 BCA 439.dwg
721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T

1 2622 xx 1 2622 xx

HKP HKP

Mx Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx

S (SP)

Seite 44 von 77
1 4217 xx

S (PO)

S (KF)

S (PU)

S (RL)
1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 440 BCA 440.dwg
721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

WW
T Th T T Th T
1 4215 xx

1 2622 xx 1 2622 xx
T T
HKP HKP 1 2622 xx

BP
Mx Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx

2 7766 xx

Seite 45 von 77
1 2608 xx S (PO) 1 2608 xx

1 4217 xx 1 4217 xx

S (KF) S (KF2)

S (SPF)
S (PU)
KW
S (RL)
1 4215 xx 1 4215 xx
RLP RLP

HYDRAULIKSCHEMA
BCA 441 BCA 441.dwg
721797224.doc
Regelung / Control Regelung / Control Regelung / Control Regelung / Control Regelung / Control

(Option) (Option) (Option) (Option)

S (VF) S (RL) S (VF) S (RL) S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

1 4215 xx WW
T Th T T Th T T Th T T Th T

1 2622 xx 1 2622 xx 1 2622 xx 1 2622 xx

T T
HKP HKP HKP HKP
1 2622 xx

BP
Mx Mx Mx Mx
1 4037 xx 1 4037 xx 1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x 1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx

Regelung / Control

2 7766 xx

1 2608 xx S (PO)

Seite 46 von 77
1 4217 xx

S (KF)

S (SPF)
S (PU)

KW
S (RL)
1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 450 BCA 450.dwg
721797224.doc
(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T

1 2622 xx 1 2622 xx

HKP HKP

Mx Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)

1 4215 xx 1 4215 xx

1 2608 xx S (PO)

Seite 47 von 77
1 4217 xx

S (KF)

S (PU)

S (RL)
1 4215 xx
RLP

HYDRAULIKSCHEMA
BCA 455 BCA 455.dwg
721797224.doc
Solar
S (S1)

(Option) (Option)

S (VF) S (RL) S (VF) S (RL)

1 4215 xx 1 4215 xx 1 4215 xx 1 4215 xx

T Th T T Th T
1 4215 xx

1 2622 xx 1 2622 xx
T T
HKP HKP 1 2622 xx

Mx BP
Mx
1 4037 xx 1 4037 xx
1 7712 5x 1 7712 5x

1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx 1 4217 xx 1 4215 xx

S (AF)
1 4215 xx A1
WW
1 4215 xx

2 7766 xx
1 2608 xx S (PO)
1 4217 xx

Seite 48 von 77
ADG

S (BF)

S (KF)

S (PU)

S (RL) KW S (S2)
1 4215 xx
RLP S (S3)
WT
Heat exchanger
A2

HYDRAULIKSCHEMA
BCA 457 FNAME.dwg
 ELECTRICAL DOCUMENTATION

HERZ – BioControl 3000

Controls for:

 Wood gasifier equipment  Firestar and minifire

 Automatic wood chip and pellet equipment  Firematic and BioMatic
 Automatic pellet equipment  Pelletstar
 Automatic pellet equipment with wood gasifier equipment  Pelletfire

System description
There is usually a common terminal for all different heating systems. Only the external
active component for controlling the burner boiler is suitable for the actual furnace
requirement.

All extension modules (heating circuit, solar, etc.) are plugged in directly to the terminal.

Thus there are the following modules:

 Heating control user terminal

 SOLAR – extension module
 HEATING CIRCUIT – extension module
 Active component for FIREMATIC and BIOMATIC (automatic wood chip and
pellet equipment)
 Active component for FIREMATIC and BIOMATIC (automatic wood chip and
pellet equipment)
 Active component for FIREMATIC and BIOMATIC (automatic wood chip and
pellet equipment)

These modules are specified in detail in the following pages.

721797224.doc Seite 49 von 77

 Schematic system layout

Erxtension module 3
Erxtension module 1

Extension module 4
Erxtension module 2
Operating terminal – the control
intelligence is located in the terminal

CAN bus
Plug on the rear side of
the terminal:
Plug system – Phoenix
Flat strip cable

RM 5.08 and 3.5mm

Plugs on the modules:

Plug system – Phönix
......

RM 5.08 u. 3.5mm
230V AC supply

230V outuputs,...
Sensor inputs,
(standard – boiler,
sensor inputs
230V outputs

etc.)

E.g:
Ext. heating circuit, solar,
boiler or buffer control
module
Specific active
component
E.g:
Plug on the active component

Ext. operating and display

230V AC supply

module
Plug system,– Phoenix
Phase section outputs,

RM 5.08 and 3.5mm

..........
24V DC inputs,...
Relay contact,
230V outputs,

Control options
via CAN bus interface
for future extension of the
control system.

721797224.doc Seite 50 von 77

General
All inputs / outputs and supplies are plugged in direct to the terminal, extension module or
active component.

It is ensured that it is not possible to change to change between 230V AC, 400V AC and
low voltage, which may lead to electronic defects of connected equipment as well as
sensors. However, it is possible for 230V AC connections (pumps, mixers, etc.) to be
swapped around. This can no longer be avoided due to the number of connections.

It is also possible to swap around low voltage inputs / outputs, however, this does not
cause any electronic defects to the sensor.

Plug system used

Multipoint
connector on the
circuit board, grid:
5.08mm (230V AC)

Screw clamps.
grid: 5.08mm Multipoint connector
(230V AC) on the circuit board,
grid: 35mm

Screw clamp.
Grid: 3.5mm

721797224.doc Seite 51 von 77

Plug and clamp allocation (terminal)
The left pin is
always no. 1
Overview allocation

X1 - Supply
X2 - relay output pump for additional heat source
X3 - relay output for reverse flow pump
X4 - relay output for boiler pump
X5 – relay output for admixer pump
X6 - relay output pump for HC1
X7 - relay outputs for reverse mixer ON OFF
X8 - relay outputs for rapid heating up ON OFF
Front View X9 - relay output pump for HC 2
X10 - relay outputs for HC1 mixer ON OFF
X11 - relay outputs for HC2 mixer ON OFF
X12 – Potential-free relay output for the storeroom temperature monitor
X13 – Potential-free relay output release for external control
X14 – Potential-free relay output alarm
X15 – Digital inputs
1/2/3 : Input - release for external control
4/5/6 : Input - Heat exchanger cleaning control
X16 – Analogue outputs 0 – 10V DC
1/2 : Analogue outputs– Secondary air injection flap
3/4: Analogue outputs– Primary air injection flap
X17 - Boiler temperature inputs
1/2 : Flue gas temperature PT1000
3/4 : Combustion room temperature Thermoelement
5/6 : Terminal connection compensation KTY
X18 – Temperature inputs heating circuit 2
1/2 : Advance flow temperature
3/4 : Target temperature
5/6 : Actual temperature
X19 – Temperature inputs heating circuit 1
1/2 : Advance flow temperature
3/4 : Target temperature
5/6 : Actual temperature
X20 – Temperature inputs
1/2 : External temperature
3/4 : Stoker channel temperature
5/6 : Ext. temperature / rotation temperature
7/8 : Return flow temperature HK1
9/10: Return flow temperature HK2
X21 – Temperature inputs
1/2 : Boiler temperature
3/4 : Hot water tank temperature
5/6 : Buffer temperature below
7/8 : Buffer temperature above
9/10 : Return flow temperature
X22 – Lambda sensor
X23 – CO probe (not used)
X24 – Connection to SECONDARY air volume sensor (not used)
1/2 : Secondary fan
3/4 : Secondary air
X25 – Connection to PRIMARY / low pressure box
air volume sensor (not used)
1/2 : Primary fan
3/4 : Primary air / actual low pressure
X26 – Connection to the active component – 50 pin
X27 – Connection to the active component – 20 pin
X28 – CAN Bus interface (galvanically isolated)
X29 – CAN Bus interface (galvanically isolated)
X30 - RS232 interface

721797224.doc Seite 52 von 77

Note:
The entire system must be integrated with potential equalisation.
The maximum series fuse should amount to no more than 13 amps.

X1 - supply - Phoenix RM 5.08

Pin Function
1 L – supply
2 N – supply
3 PE
4 PE

X2 - 230V AC relay output pump for additional heat source - Phoenix RM 5.08

Pin Function
1 L
2 N
3 PE

X3 - 230V AC relay output for the return flow pump - Phoenix RM 5.08

Pin Function
1 L
2 N
3 PE

X4 - 230V AC relay output for boiler pump - Phoenix RM 5.08

Pin Function
1 L
2 N
3 PE

X5 - 230V AC relay output for admixer pump - Phoenix RM 5.08

Pin Function
1 L
2 N
3 PE

721797224.doc Seite 53 von 77

X6 - 230V AC relay output pump for HC1 - Phoenix RM 5.08

Pin Function
1 L
2 N
3 PE

X7 - 230V AC relay outputs for the return flow mixer ON OFF - Phoenix RM 5.08

Pin Function
1 L – mixer ON
2 L – mixer OFF
3 N
4 PE

X8 - 230V AC relay outputs for rapid heating up ON OFF – Phoenix RM 5.08

Pin Function
1 L – motor valve ON
2 L – motor valve OFF
3 N
4 PE

X9 - 230V AC relay output pump for HC 2 – Phoenix RM 5.08

Pin Function
1 L
2 N
3 PE

X10 - 230V AC relay outputs for HC1 mixer ON OFF – Phoenix RM 5.08

Pin Function
1 L – HC1 mixer ON
2 L – HC1 mixer OFF
3 N
4 PE

721797224.doc Seite 54 von 77

X11 - 230V AC relay outputs for HC2 mixer ON OFF – Phoenix RM 5.08

Pin Function
1 L – HC2 mixer ON
2 L – HC2 mixer OFF
3 N
4 PE

X12 – Potential-free relay output for the storeroom temperature monitor - Phoenix RM
5.08
Pin Function
1 Root
2 Normal Open
3 Normal Close
Relay contact

X13 – Potential-free relay output release for external control - Phoenix RM 5.08

Pin Function
1 Root
2 Normal Open
3 Normal Close
Relay contact

X14 – Potential-free relay output alarm - Phoenix RM 5.08

Pin Function
1 Root
2 Normal Open
3 Normal Close Relay contact

X15 – Digital inputs - Phoenix RM 3.5

Pin Function
1 +24V DC
2 Input – release of external control
3 GND
4 +24V DC
5 Input – burner stop
6 GND

Actuating drive (LM 24 A) Y3 cable (brown/red) on X15 Pin 1

Flue gas temperature guard 4-5 open

721797224.doc Seite 55 von 77

X16 – Analogue outputs 0 – 10V DC - Phoenix RM 3.5

Pin Function
1 GND
2 Analogue output – secondary air flap
3 GND
4 Analogue output – FU suction
5 GND
6 Reserve

Actuator drive (LM 24 A) 1 black on X16 Pin 1

Actuator drive (LM 24 A) 2 white on X16 Pin 2
X17 – Boiler temperature inputs - Phoenix RM 3.5

Pin Function
1 GND
2 Flue gas temperature PT1000 0-600°C
3 Combustion room temperature thermoelement
NI/CRNI -
4 Combustion room temperature thermoelement
NI/CRNI +
5 GND
6 Terminal connection compensation KTY

X18 – Temperature inputs for heating circuit 2 - Phoenix RM 3.5

Pin Function
1 GND
2 Advance flow temperature HC2 PT1000 0-120°C
3 GND
4 Target temperature potential HC2 +/-5°C
5 GND
6 Actual temperature HC2 0-40°C

721797224.doc Seite 56 von 77

X19 – Temperature inputs for heating circuit 1 - Phoenix RM 3.5

Pin Function
1 GND
2 Advance flow temperature HC1 PT1000 0-120°C
3 GND
4 Target temperature potential HC1 +/-5°C
5 GND
6 Actual temperature HC1 0-40°C
Remote control connection for HC1:
Remote control clamp 1 on X19 pin 6
Remote control clamp 2 on X19 pin 5
Remote control clamp 3 on X19 pin 4

X20 – Temperature inputs - Phoenix RM 3.5

Pin Function
1 GND
2 External temperature PT1000 -50 to +70°C
3 GND
4 Stoker channel temperature PT1000 0-120°C
5 GND
6 Ext. temperature / rotation temperature PT1000 0-
120°C
7 GND
8 Return flow temperature HC1 PT1000 0-120°C
9 GND
10 Return flow temperature HC2 PT1000 0-120°C
X21 – Boiler temperature inputs - Phoenix RM 3.5

Pin Function
1 GND
2 Boiler temperature PT1000 0-120°C
3 GND
4 Boiler temperature PT1000 0-120°C
5 GND
6 Buffer temperature lower PT1000 0-120°C
7 GND
8 Buffer temperature upper PT1000 0-120°C
9 GND
10 Return flow temperature PT1000 0-120°C

721797224.doc Seite 57 von 77

X22 – Lambda probe - Phoenix RM 3.5

Pin Funktion
1 Lambda probe signal +
2 Lambda probe signal GND
3 Probe heating 12V AC
4 Probe heating 12V AC
Lambda sensor, black cable on X22 pin 1
Lambda sensor, grey cable on X22 pin 2
Lambda sensor, white cable on X22 pin 3
Lambda sensor, white cable on X22 pin 4

X23 – CO probe - Phoenix RM 3.5 (not used)

Pin Function
1 Not used
2 Not used
3 Not used
4 Not used

721797224.doc Seite 58 von 77

X28 – CAN Bus interface (galvanically isolated)

X24 – Connection to SECONDARY air volume sensor (not used)

Pin Row a
1 Secondary fan
2 GND
Pin 1 3 Secondary air
4 GND
5 + 24V

X25 – Connection to PRIMARY/low pressure box air volume sensor (not used)

Pin Row a
1 Primary fan
2 GND
Primary air / actual low
Pin 1 3
pressure
4 GND
5 + 24V

X26 – Connection to the active component

50-pin ribbon cable connector for connection with the active component.

X27 – Connection to the active component

20-pin ribbon cable connector for connection with the active component.

Pin
9-pin DSUB socket
Function
1 CAN1 A
2 not used
3 not used
4 not used
5 GND
6 CAN1 B
7 not used
8 not used
9 +5V

721797224.doc Seite 59 von 77

X29 – CAN Bus interface (galvanically isolated)

9-pin DSUB socket Pin Function

1 CAN1 A
2 not used
3 not used
4 not used
5 GND
6 CAN1 B
7 not used
8 not used
9 +5V

Note:
X28 and X29 are one and the same CAN interface, which run to both plugs so that a
CAN connection can be made to and from the terminal to another device!
 The CAN station number is 0 fixed.
 The CAN Bus connection must be made externally.
 This CAN interface is galvanically isolated.

X30 - RS232 interface

Pin Function
9-pin DSUB plug
1 DCD
2 Rx
3 Tx
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 RI

DIAS Bus MEMO - plug

Interface for a memo module that can be also be inserted. This memo can be used for
updating the program or the regulating data.

721797224.doc Seite 60 von 77

Drawing (HC extension module)

Extension module
Cable

Cable

Terminal elektronics

Terminal side view

721797224.doc Seite 61 von 77

Instructions for changing the HC plug-in module

1. Switch off the terminal! The module should ONLY be changed when the unit is
disconnected from the mains!!!

2. Mark off all the extension module plugs.

3. Open the two screws on the topside of the terminal and remove the covering from
the module slot.

4. Take out the plug-in module from the top.

5. Place the new or additional module in the position required.

6. If an additional module is used, the pre-punched sheet metal part must be clipped
in advance with pliers for the module slot required.

7. Put the cover back again whilst ensuring that the extension module is resting in the
notches of the cover.

8. Re-attach the covering using both screws.

9. Carry out all wiring for the additional plug-in module and replace the existing plugs.

10. Start up the terminal.

ATTENTION:
An extension module should only be exchanged or installed by a trained member of
staff.

721797224.doc Seite 62 von 77

 Remote control connection:
Remote control clamp 1 on X2 pin 8
Remote control clamp 2 on X2 pin 7
Remote control clamp 3 on X2 pin 6

Plug configuration – heating circuit extension module

Circuit board

10 X1
Circuit board
1

Pin 1
8

X2
1

Module view View from the rear side of the

terminal

X1 – Supply and relay outputs - Phoenix RM 5.08

Pin Function
10 PE – supply
9 N – supply
8 L – supply 230V AC
7 PE
6 N
5 L – pump
4 PE
3 N
2 L – mixer OFF
1 L – mixer ON

X2 – Temperature inputs for heating circuit 1 - Phoenix RM 3.5

Pin Function
8 Actual temperature HC 0-40°C
7 GND
6 Target temperature potential HC +/-5°C
5 GND
4 Advance flow temperature HC PT1000 0-
120°C
3 GND
2 Reverse flow temperatur HC PT1000 0-
120°C
1 GND

721797224.doc Seite 63 von 77

Drawing (solar extension module)

Extension module
Cable

Cable

Terminal elektronics

Casing, side view

721797224.doc Seite 64 von 77

Instructions for changing the plug-in module
(Solar extension module)
1. Switch off the terminal! The module should ONLY be changed when the unit is
disconnected from the mains!!!

2. Mark off all the extension module plugs.

3. Open the two screws on the topside of the terminal and remove the covering from
the module slot.

4. Take out the plug-in module from the top.

5. Place the new or additional module in the position required.

6. If an additional module is used, the pre-punched sheet metal part must be clipped
in advance with pliers for the module slot required.

7. Put the cover back again whilst ensuring that the extension module is resting in the
notches of the cover.

8. Re-attach the covering using both screws.

9. Carry out all wiring for the additional plug-in module and replace the existing plugs.

10. Start up the terminal.

ATTENTION:
An extension module should only be exchanged or installed by a trained member of
staff.

721797224.doc Seite 65 von 77

Plug configuration – Solar circuit extension model

Circuit board

12
X1
Circuit board

112
Pin
X2 1
1

Module view View from the rear side of the terminal

X1 – Supply and relay outputs - Phoenix RM 5.08

Pin Function
12 PE – supply
11 N – supply
10 L – supply 230V AC
9 PE
8 N
7 L – output 1 (pump)
6 PE
5 N
4 L – output 2 (switching valve)
3 PE
2 N
X2 – Temperature inputs
1 - Phoenix RM 3.5L – output 3 (reserve)

Pin Function
12 Solar temperature 5 - PT1000 -50-200°C
11 GND
10 Solar temperature 4 - PT1000 -50-200°C
9 GND
8 Solar temperature 3 - PT1000 -50-200°C
7 GND
6 Solar temperature 2 - PT1000 -50-200°C
5 GND
4 Solar temperature 1 (collector) - PT1000 -50-200°C
3 GND
2 +24V digital input – Measurement of flow rate amount
1 +24 VDC

721797224.doc Seite 66 von 77

Plug and clamp configuration (active component)

X1 – Supply - Phoenix basic cabinet RM 5.08

3-pin connector
with screw connection

Pin Function
1 Phase L1
2 Neutral
3 Earth

Supply ~ 230v, 50Hz

X2 – +24V DC output: Soot cleaning –

Phoenix basic cabinet, RM 5.08 (not assembled)

2-pin connector with screw

connection
Pin Function
1 (not assembled)
2 (not assembled)

721797224.doc Seite 67 von 77

X3 – 230V AC relay output: Suction – Phoenix basic cabinet, RM 5.08 (not used)
3-pin connector with screw
connection
Pin Function
1 Not used
2 Not used
3 Not used

X4 – 230V AC relay output: Ventilator ignition – Phoenix basic cabinet RM 5.08

3-pin connector with screw

connection

Pin Function
1 Phase L1
2 Neutral
3 Not used

Plug for ventilator ignition L1 (black) on X4 pin 1

Plug for ventilator ignition N (blue) on X4 pin 2

X5 – 230V AC relay output: Heating ignition – Phoenix basic cabinet RM 5.08

3-pin connector with screw

connection

Pin Function
1 Phase L1
2 Not used
3 Not used

Plug for ventilator ignition L1 (brown) on X5 pin 1

721797224.doc Seite 68 von 77

X6 – 230V AC relay output: Discharge screw probe motor – Phoenix basic cabinet
RM 5.08
3-pin connector with screw
connection Pin Function
1 Phase L1
2 Neutral
3 Earth

X7 – 230V AC relay output: Reserve 1– Phoenix basic cabinet RM 5.08

(Not used)

3-pin connector with screw

connection
Pin Function
1 Phase L1
2 Neutral
3 Earth

X8 – 230V AC relay output: BBD flap OPEN – Phoenix basic cabinet RM 5.08
3-pin connector with screw
connection

Pin Function
1 Phase L1
2 Neutral
3 Earth

721797224.doc Seite 69 von 77

X9 – 230V AC relay output: Ash discharge motor – Phoenix basic cabinet
RM 5.08
3-pin connector with
screw connection
Pin Function
1 Phase L1
2 Neutral
3 Earth

X10 – 230V AC relay output: Heat exchanger cleaning - Phoenix

Basic cabinet, RM 5.08
3-pin connector with
screw connection

Pin Function
1 Phase L1
2 Neutral
3 Earth

X11 – 230V AC relay output: Soot cleaning – Phoenix basic cabinet RM 5.08
3-pin connector with screw
connection

Pin Function
1 Phase L1
2 Neutral
3 Earth

721797224.doc Seite 70 von 77

X12 – 230V AC synchronised triac output: Plug-in screw – Phoenix
Basic cabinet, RM 5.08
3-pin connector with screw
connection

Pin Function
1 Phase L1
2 Neutral:
3 Earth

X13 – 230V AC phase section output suction – Phoenix basic cabinet RM 5.08
3-pin connector with screw
connection

Pin Function
1 Phase L1
2 Neutral:
3 Earth

X14 – Potential-free relay output release for frequency inverter plug-in screw –
Phoenix RM 5.08 basic cabinet (not used)
3-pin connector with screw
connection

Pin Function
1 Not used
2 Not used
3 Not used

721797224.doc Seite 71 von 77

 Level sensor cable, brown on clamp, X15 Pin 4

12-pin connector with screw

X15 – +24V DC digital inputs -
connection
Phoenix basic cabinet RM 3.5
12-pin connector with
screw connection
Pin Function
1 +24V DC
2 Temp. monitor (opener)
3 GND
4 +24V DC
5 Interim container level.
6 GND
7 +24V DC
8 Ash container door open
9 GND
10 +24V DC
11 Discharge screw motor protection
12 GND

Level sensor cable, black on clamp, X15 Pin 5

Level sensor cable, blue on clip, X15 Pin 6

X16 – +24V DC digital inputs - Phoenix basic cabinet RM 3.5

12-pin connector with Pin Function

screw connection
1 +24V DC
2 (Lid end switch)
3 GND
4 +24V DC
5 Vacutrans flap
6 GND
7 +24V DC
8 Grate cleaning
9 GND
10 +24V DC
11 Combustion room door
12 GND

Vacutrans flap cable, brown on clamp X16 pin 4

Vacutrans flap cable, blue on clamp, X 16 pin 5

721797224.doc Seite 72 von 77

X17 – +24V DC digital inputs - Phoenix basic cabinet RM 3.5

Pi Function
12-pin connector with screw 1 +24V DC
connection 2 BBD closed
3 GND
4 +24V DC
5 BBD open
6 GND
7 +24V DC
8 Ash discharge monitor
9 GND
10 +24V DC
Actuating
11 drive (LM 24 A)Reserve
pin 1 on4 X 17 pin 1
Actuating
12 drive (LM 24 A) pGND
in 2 on X 17 pin 2
Actuating drive (LM 24 A) pin 9 on X 17 pin 4
Actuating drive (LM 24 A) pin 6 on X 17 pin 1
Actuating drive (LM 24 A) pin 2 on X 17 pin 2
Actuating drive (LM 24 A) pin 9 on X 17 pin 4
Actuating drive (LM 24 A) pin 6 on X 17 pin 5

X18 – Speed reserve – Phoenix basic casing, RM 3.5 (not used)

3-pin connector with screw
connection

Pin Function
1 +24V DC
2 Suction
3 Not

721797224.doc Seite 73 von 77

X19 – Speed suction – Phoenix basic casing RM 3.5

3-pin connector with screw

connection

Pin Function
1 +24V DC
2 Reserve
3 GND

X20 – +24V DC output: Soot cleaning – Phoenix basic casing,

RM 5.08 (not assembled)

2-pin connector with screw

connection

Pin Function
1 (not assembled)
2 (not assembled)

721797224.doc Seite 74 von 77

Safety temperature limiter cut-off (active component)
The STL shut-off must be made externally.

STL
Active

230V AC
component

supply
L1
N
PE

STL shut-off,
supply of active component,
L1 must be removed.

All 230V AC active component outputs are no longer supplied.

721797224.doc Seite 75 von 77

Notes:

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