Turbotec User Operating Manual

Turbotec User Operating Manual

2

Display and control elements

1 ‘Heating ON’ indicator

2 ‘Add fuel’ indicator

3 ‘Malfunction’ indicator

4 Text display

5 ‘Heating ON / Plus’ button

‘Heating ON’ indicator

Lights up when the combustion sequence is started by pressing the ‘Heating ON’ button or automatically due to the sufficient exhaust fume temperature.

Goes out when the combustion sequence is stopped by pressing the ‘Heating OFF’ button or automatically due to spent fuel.

‘Add fuel’ indicator

Lights up when the heating function has been switched off and the heating requirement of the installation requires, respectively enables fuel to be added again.

Blinks during the 'Add fuel' function.

Goes out when the heating function is switched on or the ‘Add fuel’ function has been suspended.

4

6 ‘Heating OFF / Minus’ button

7 ‘Arrow’ button

8 ‘Add fuel’ button

9 Restart button for the safety

temperature limiter (STL)

‘Malfunction’ indicator

Lights up when malfunctions occur which prevent the continuation of the heating function, respectively do not allow the heating function to be switched on.

Blinks if malfunctions occur which allow the continuation of the heating function, respectively the heating function to be switched on (automatic steerage towards alternative program until the malfunction is fixed ).

Goes out when the malfunctions have been fixed and acknowledged.

Text display

Switched on in the operating mode ‘Heating ON’ or by pressing a button in the operating mode ‘Heating OFF’.

Switched off in the operating mode ‘Heating OFF’ and at the end of a period of 15 minutes.

‘Heating ON / Plus’ button

Function level 1:

Pressing this button activates the operating mode ‘Heating

ON’

Function level 2:

Functions can be selected or settings changed by pressing this button.

Control settings by the user

Heating up

‘Heating OFF / Minus button

Function level 1:

This button can be used to switch the operating mode to

'Heating OFF' or to end the

‘Add fuel’ function prematurely.

Function level 2:

Functions can be selected or settings changed by pressing this button.

‘Arrow’ button

This button is used to enter the

Selection menu and to shift to

Function level 2.

Pressing the button once again confirms the selected function or changed settings.

‘Add fuel’ button

Pressing this button causes the induced draft fan to operate at high speed, and after 15 seconds the electromagnetic door opener is released for 10 seconds. The ‘Add fuel’ function is ended automatically after 10 minutes.

Restart button for the safety temperature limiter (STL)

If the STL has tripped due to the boiler temperature being too high, and if the boiler temperature has gone down to approx. 80

°C, then the STL must be reset and the error acknowledged by pressing the restart button.

Controller settings by the user

Setting the boiler temperature

Following the first commissioning of the control and the ensuing system settings by a professional, the following message appears on the text display:

Heating

OFF

The Selection menu is entered by pressing the 'Arrow' button and the following message appears on the display:

S E L E C T I O N + _

INFORMATION

The menu item ‘SETTINGS’ is selected by pressing the ‘Plus’ button. The following appears on the text display:

S E L E C T I O N + _

SETTINGS

The selected menu item is confirmed by pressing the

‘Arrow’ button. The following appears on the text display:

Boiler set point + _

TK S [

°C] ##

The value can be changed by pressing the 'Plus' or 'Minus' button.

Setting range: 70 – 85

°C

By changing the boiler set point, the storage charging behaviour also changes. The value should only be changed after consulting your heating installer.

The changed value is saved by pressing the ‘Arrow’ button.

Pressing the ‘Arrow’ button once again will take you via the next menu item back to the text display:

Heating

OFF

Heating up

Heating up when the installation is cold

During the initial commissioning, or after a long standstill, the following should be observed:

A ‘cold’ chimney has no, or too little outlet pressure, so that in this case the exhaust fumes are poorly expelled. Heating up will be facilitated if you heat up the chimney with paper through the cleaning hatch.

Boiler operating behaviour

Particular attention must be paid to the operating behaviour of the boiler in interaction with the hydraulic system, when starting from a cold condition.

In doing so:

- the boiler must first of all heat up its own water content including its material weight,

- the water content of the heating system (pipes, radiators, thermal storage mass of the floor) must be heated up.

Heat can only be released into the room after this heating process has been completed.

The time to complete this process differs, depending on the water content in the heating system. This means that you may have to start heating up earlier due to this delay. During this heating up period the boiler produces its full power = rated power. The lambda control regulates the combustion sequence in such a way that the boiler power produced, corresponds with the actual power consumption of the heating system.

Standard values for the heating-up time in minutes for an increase in the boiler temperature from 20

°C to 70

°C – see table:

Additional control functions

Important information:

If the exhaust fume temperature exceeds 300

°C during the fuel addition procedure, there is a danger of overheating.

O

2

control program = standard program with O

2

probe

TA control program = alternative program in the event of a malfunction of the O

2

probe

The following appears on the text display:

Exhaust gas temperature too high [

°C] ###

Set target values

Display of the target values set by the user or the heating installer:

TK S = Boiler temperature and the ‘malfunction’ indicator

blinks.

Stop adding fuel immediately!

(user)

TSmax = Max. storage tank temperature (installer)

TSmin = Min. storage tank

- Close the interior door and the filling door

- Unlatch the operating handle of the gas vent flap and close temperature (installer)

TKmin = Min. boiler temperature (installer)

O

2

S = Residual oxygen content

the flap.

Additional control functions

The Selection menu is entered of the exhaust fumes

(manufacturer)

CO

2

S = Carbon dioxide content of the exhaust fumes by pressing the 'Arrow' button and the following message appears on the display:

(calculated from the O

2 nominal value)

Current actual values

S E L E C T I O N + _

INFORMATION

The desired menu item can be

Display of the current actual values

TK I = Boiler temperature

TS I = Storage tank selected by pressing the 'Plus' or 'Minus' button.

The selected menu item is confirmed by pressing the temperature

TA I = Exhaust fumes temperature

O2 I = Residual oxygen content

‘Arrow’ button.

The selection menu is abandoned automatically if no button is pressed for more than of the exhaust fumes

CO2 I = Carbon dioxide content of the exhaust fumes

Lambda = Air ratio

30 seconds.

Information

By selecting and confirming the

ETA-F = Combustion efficiency

Exhaust fume temperature

Display of the highest exhaust menu item

S E L E C T I O N + _

INFORMATION the information menu is called up and the following appears on the text display:

Information + _

E N D fume temperature reached.

Operating hours

Display of the number of operating hours in the operating mode 'Heating ON'.

Standby hours

The following information can be displayed by pressing the

'Plus' or 'Minus' button.

Display of the proportion of standby hours as a percentage of the operating mode ‘Heating

ON’.

Control program

Display of the control program according to which the

Malfunction

Display of the last malfunction.

The Information menu is combustion process is controlled (automatic switchover). abandoned by pressing the

‘Arrow’ button.

Settings

By selecting and confirming the menu item

S E L E C T I O N + _

SETTINGS the settings menu is opened.

Setting the boiler set point

The following appears on the text display:

Boiler set point + _

TK S [

°C] ##

The value can be changed by pressing the 'Plus' or 'Minus' button.

Setting range: 70 – 85

°C

The changed value is saved by pressing the ‘Arrow’ button and the display gets to the next menu item.

System settings

The following appears on the text display:

Service code with +

E N D

The settings menu for the heating installer or the manufacturer is accessed by pressing the ‘Plus’ button (more detailed information can be found in the installation manual).

The settings menu is abandoned by pressing the

‘Arrow’ button. The setting menu is abandoned automatically if no button is pressed for more than 30 seconds.

Chimney sweep test and safety test

Unit test

Cleaning

Chimney sweep test and safety test

Only possible in the operating mode 'Heating ON'.

The chimney sweep test can be activated after the boiler has been cleaned, heated up and stoked up in accordance with the regulations.

By selecting and confirming the menu item

S E L E C T I O N + _

CHIMNEY SWEEP TEST the ‘Chimney sweep test’ menu is called up and the following appears on the text display:

CHIMNEY SWEEP TEST +_

E N D

By pressing the ‘Plus’ or ‘Minus’ button, it can be selected whether the chimney sweep test should be performed at the rated power or with a partial load (emission check) or whether the safety test

(check of the STL and thermal discharge safety device) should be performed.

The selected function is confirmed by pressing the ‘Arrow’ button.

The chimney sweep test at rated power, respectively with a partial load is cancelled:

- at the end of 30 minutes,

- at a boiler temperature higher than 88

°C (standby),

- in the operating mode ‘Heating

OFF’.

The safety test is finished:

- if the ‘Plus’ button is not pressed for 30 seconds,

- if the safety temperature limiter

(STL) trips,

- at the end of 60 minutes

- in the operating mode ‘Heating

OFF’.

8

Aggregate test

Only possible in the operating mode 'Heating OFF'.

For safety reasons, the aggregate test may only be carried out when there is no fuel in the boiler.

By selecting and confirming the menu item

S E L E C T I O N + _

AGGREGATE TEST the test run is called up and the function of the aggregates can be tested.

The displayed function or displayed aggregate is switched

on by pressing the ‘Plus’ button.

The displayed aggregate is

switched off by pressing the

‘Minus’ button.

You can progress to the next test

step by pressing the ‘Arrow’ button.

The test run can be ended

prematurely by pressing the

‘Plus’ and ‘Minus’ buttons simultaneously.

Cleaning

(Heating to ‘OFF’)

Removal of ashes

The ashes must be removed from the filling chamber and the ashes chamber regularly after 5 fillings

(but at least once a week).

Filling chamber

After approx. five fillings, let the boiler burn out completely and then clean the filling chamber floor with the flat scraper and the primary air apertures with the poker; clean out the ashes through the grating in the flame duct. Do not remove the grating during this procedure, as otherwise the secondary air apertures in the burner port can get blocked by ashes!

Open the ashes door and remove the ashes from the flame duct and the boiler floor (tar coating on the side walls above the primary air apertures and on the rear wall of the boiler should not be removed!); close the ashes door.

After that, heat up in accordance with the operating manual.

Flame duct and ashes chamber

After around five fillings (but in any case once a week), the flame duct and the ashes chamber must be cleaned of ashes using the flat scraper. If the boiler is not in operation during the summer, it is important that no ashes are left in the boiler (service life!)

Burner grating (weekly)

Clean the floor of the filling chamber, lift out the grating using the hook and clean the secondary air aperture and grating support in the burner. The secondary air apertures in the burner port must not be covered with ashes.

Replace the grating.

Cleaning the control

Maintenance

Important instructions

Ancillary heating surface

(monthly)

Remove the cleaning lid, lift up the

Remount the air control unit together with the seals (use new seals if need be), connect the exhaust fume baffle plate by about

10 cm and fix it using the poker.

Cleaning can now take place at the rear and from the front through the ashes door using the scraper.

Push the exhaust fume baffle plate back down (otherwise danger of overheating). Screw the cleaning lid back on tightly.

Induced draft fan (annually)

At the end of the heating season, disconnect the fan from the mains by pulling the plug out of the multiple socket. Unscrew the fan and clean the fan blades with a brush (vacuum cleaner). Remount the fan and connect the plug again.

Air duct (annually)

Unscrew the air duct and clean it using the scraper and a vacuum cleaner.

Cleaning the control

Before doing this, it is essential to turn off the main heating switch or to disconnect the control from the mains by disconnecting the mains plug.

The operating panel of the lambda control can be cleaned using a moist cloth and a glass cleaning agent.

O

2

probe (annually)

Detach the O

2 probe by unscrewing the cap nut, clean the probe head with a hand brush, clean out the mounting tube and carefully retighten the O

2 probe together with the seal (use a new seal if need be).

Air box (annually)

Disconnect the plugs for the two air flap actuators and dismount the air control unit (but do not disassemble the control flap and actuator!) Clean the air box and the secondary air ducts using a vacuum cleaner. plugs again.

Maintenance

(Heating to ‘OFF’)

Filling chamber

At the end of the heating period, clean the filling chamber floor and the primary air apertures using the scraper and poker. Remove ashes and wood scraps. The tar coatings on the walls of the filling chamber should not be removed.

Door closure bolts

The door closure bolts must be oiled regularly.

Sealing integrity of the doors

If smoke escapes through the doors, this is due to poor sealing caused by the sealing material yielding. The doors are adjustable on both the hinge and the closure sides and the sealing integrity can therefore be restored.

Sealing integrity of the gas venting flap

The gas venting flap must lie tightly against the frame for proper, low-emission operation

(see installation manual).

Sealing integrity of the O

2 probe

The screw fitting of the O

2 probe must be checked for tightness (if necessary carefully re-tighten using a spanner).

Safety devices

The reliability performance of the safety devices must be checked once a year by the heating installer or by another authorised person. The safety valve and the thermal discharge safety device must be checked. It is recommended to take out a service contract with a specialist firm!

Important instructions

Tripping of the thermal discharge safety device

If the maximum permissible boiler temperature of 100

°C is exceeded, the safety temperature limiter (STL) interrupts the power supply to the fan (to switch on the

STL again, refer to the

‘Troubleshooting’ section). If the boiler temperature continues to rise, the ‘thermo-mechanical valve’ opens automatically via the temperature sensor. Cold water flows through the heat exchanger into the boiler and absorbs the excess heat. As a result, the boiler water is cooled down, preventing a dangerous operating condition.

After cooling down, the system pressure, respectively the water level in the system, must be checked and the water topped up if necessary.

Water level and water pressure in the heating system

Regular checks are necessary!

Protective functions

The boiler must be cleaned thoroughly if it is not to be fired for a longer period of time (for precise information about this, please refer to the ‘Cleaning’ section).

Power supply must be guaranteed also during the summertime via the main heating switch (no continuous heating operation).

The control can then perform the integrated protective functions: venting of the boiler and protection of the aggregates against seizing up.

During the performance of the protective functions, the following appears on the display:

Protective functions

Please wait

Troubleshooting

Troubleshooting

The control recognises malfunctions automatically and executes malfunction-related alternative programs or safety measures.

There are two malfunction categories: the ‘malfunction’ indicator either lights up

continuously or it blinks.

‘Malfunction’ indicator lights up continuously

In the case of the following malfunctions, the continuation or switching on of the heating function is not possible and the malfunction indicator is activated automatically:

Safety temperature limiter has tripped

STL tripped

Reset!

Cause: boiler temperature is too high (no heat consumption, power failure, pump or valve defective). After the boiler temperature has dropped to approx. 80

°C due to heat consumption, the STL is reset by pressing the restart switch, thus automatically acknowledging the malfunction.

Measured values of the exhaust fume temperature are incorrect

Exhaust fume temperature

Measured values wrong

Causes: plug contact, sensor cable, control, exhaust fume sensor. After rectification of the malfunction it will be acknowledged by pressing the

‘Arrow’ button.

Measured values of the boiler temperature are incorrect

Boiler temperature

Measured values wrong

Causes: plug contact, sensor cable, control, boiler temperature sensor. After rectification of the malfunction it will be acknowledged by pressing the ‘Arrow’ button.

Loss of control data

Data loss

Control defective

Cause: data memory in the control is defective. The control must be repaired by the manufacturer.

‘Malfunction’ indicator blinks

In the case of the following malfunctions, the continuation respectively the switching on of the heating function is possible until the malfunction has been rectified:

The malfunction message is shown on the text display in the operating mode ‘Heating OFF’ and after the ‘Arrow’ button is pressed:

Measured oxygen values

Oxygen

Measured values wrong

Causes: plug contact, probe cable, O

2 probe dirty/worn or screw fitting of the O

2 probe and protective tube is loose, control.

Check the O

2 probe by means of the aggregate test.

If the result of the aggregate test is ‘Probe OK’, then the malfunction is automatically deleted.

Important instruction:

Only perform the aggregate test if there is no fire or residual embers in the boiler.

Measured values of the storage tank temperature are incorrect

Storage tank temp.

Measured values wrong

Causes: plug contact, sensor cable, control, storage tank temperature sensor.

After rectification of the malfunction it must be acknowledged by pressing the

‘Arrow’ button.

Boiler temperature too low

Boiler temperature too low [

°C] ###

Causes: plug contact, cables, non-return valve, actuator drive, control.

After rectification of the malfunction it must be acknowledged by pressing the

‘Arrow’ button.

Exhaust fume temperature too high

Exhaust fume temperature too high [

°C] ###

Cause: exhaust fume temperature has exceeded 300

°C.

Refer to pages 5 & 6 ‘Important instruction’.

Work on the electrical equipment may only be carried out by a qualified electrician after disconnecting the installation from the mains!

Notes

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