Centrometal BioTec Plus 25, BioTec Plus 35, BioTec Plus 45 Installation, Use And Maintenance Manual

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TECHNICAL INSTRUCTIONS

for installation, use and maintenance of hot water boiler and installation additional equipment

BioTec Plus

HEATING TECHNIQUE

Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia, tel: +385 40 372 600, fax: +385 40 372 611

TUBTP-01-2018-eng

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These instructions are an integral part of this product. All rights reserved. Reproduction of content of this document and transfer to third parties is not allowed without written approval from manufacturer. Make sure the instructions are always with the device, even if its sale / transfer of another owner to the user or staff authorized for maintenance or repairs to consult.

READ THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLING THE BOILER TO HEATING SYSTEM!

Boiler must not be used by children or disabled persons (either physicallyor mentally), as well as by person without knowledge or experience, unless they are under control or trained by s person responsible for their safety. Children must be supervised in the vicinity of the product.

Boiler must not operate in flammable and explosive environment.

Before any work on the boiler, electric energy must be switched off.

Insufficient combustion air for chimney vent boilers with room air for combustion can lead to dangerous conditions.

Make sure that the combustion air supply and discharge openings are not reduced or closed off.

Keep doors to the boiler room closed.

Protect the boiler room and avoid rodents and birds from entering and blocking the air openings.

Boiler cannot be placed in operation until above points are not met.

Technical instructions BioTec Plus

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BioTec Plus 35

TIP

(kW) (kW) (kW)

(Pa)

(lit.) (°C) (°C) (°C) (°C)

(kg/s) (kg/s) (kg/s) (kg/s)

(h) (h)

(°C)

(°C/bar)

(°C)

(mbar)

(%)

(lit.)

(mm)

(lit.)

(W)

(V~) (Hz)

(A)

(kg)

(bar) (bar)

(°C)

(mm)

(pcs.)

(R) (R) (R) (R)

12,5-25

7,5-25

138 90-170 90-130 70-110 60-110

0,019

0,0206

0,010

0,0055

3,5

12,8

1,6

10,4

1100

110

1100

45 30

5,1

750

150

35 17 -3,5 5 10,2-35

167 90-170 90-130 70-110 60-110

0,022 0,030 0,012

0,0080

25,1

144

1,6

10,4

148

1100

116

1100

48 33

5,1

875

160

45 22,5-45 13,5-45

187 90-170 90-130 70-110 60-110

0,027

0,0385

0,014

0,0121

41,6

176

2,5

20,2

148

1100

122

1100

50 35

5,1

930

180

600×250×600 600×400×600 600×400×735

Boiler connections

Flow and return pipe (male thread) Charge/discharge (female thread) Heat exchanger connector (male thread) Connector of exchanger sensor (female thread)

WOOD: A by 303-5:2012; B by EN ISO 17225-5:2014-09 WOOD PELLETS: C1 by EN 303-5:2012; A1 by EN ISO 17225-2

Nominal heat output Heat output range (wood) Heat output range (wood pellets) Boiler class (wood / wood pellets) Required chimney underpressure Water amount in boiler Exhaust gas temperature at nominal heat output (wood) Exhaust gas temperature at nominal heat output (wood pellets) Exhaust gas temperature at minimal heat output (wood) Exhaust gas temperature at minimal heat output (wood pellets) Exhaust mass flow at nominal heat output (wood) Exhaust mass flow at nominal heat output (wood pellets) Exhaust mass flow at minimal heat output (wood) Exhaust mass flow at minimal heat output (wood pellets) Minimum operating time at rated power (nominal Q ) (wood)

Minimum operating time at rated power (nominal Q ) (wood pellets)

Min. inlet water tem. at the boiler supply water connection Cold water tem. and pressure for safety heat exchanger Setting range for temperature controller (wood / wood pellets) Boiler resistance on water side at nominal output (dT=10°C)

Fuel moisture content Fuel size Fuel loading chamber capacity (wood) Fuel loading chamber dimensions (D×W×H) (wood) Firebox volume (wood pellets) Combustion chamber volume (wood pellets) Pellet tank volume Combustion chamber type Required minimum accumulation volume (tank) next to boiler Maximal electrical power input (wood) Auxiliray power requirements at Q (wood)

Auxiliray power requirements at Q (wood)

min

Standby power (wood) Maximal electrical power input (wood pellets) Auxiliray power requirements at Q (wood pellets)

Auxiliray power requirements at Q (wood pellets)

min

Standby power (wood pellets) Supply voltage Frequency Max. electrical current Current type Total mass - (boiler with casing and accessories) Max. operating overpressure Test pressure Max. operating temperature Flue gas tube - external diameter Number of turbulators

Heating appliance working Heating appliance working

10-15°C / 2 bar

max. 90 / 65 - 90

max 25 % for wood, max. 12% for wood pellet

(450-550) x 70 x 50 for wood, fi6

underpressure

by EN 303:2012-point 4.4.6

230

2,5 5,5

6/4" 3/4" 3/8" 1/2"

with fan

under non-condensing conditions

Fuel type

Technical instructions BioTec Plus

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Boiler dimensions

(A)

Depth

(B)

Width

(C)

Height

Other dimensions

(C1)

Height

1450 1260 1585

1260

1450 1255 1450

760

1605 1055 1350

760

BioTec Plus 25 / 35

BioTec Plus 45

BioTec Plus 35

BioTec Plus 25

INNER PARTS VIEW FOR BOILERS BioTec Plus 25-45

Technical instructions BioTec Plus

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BioTec Plus 45

DM - Flue gas tube connection DO - Cover of lower openings of the flue gas chamber DS - Lower refractory stone (chamotte) (2 parts) DV - Lower boiler door (wood) EH - Electric heater (pellets) FO - Photocell GV - Upper boiler door (wood) KA - Heat exchanger connection (safety cooling

system) (wood) KR - Digital boiler controller LS - Lambda probe MA - Magnetic valve ME - Cleaning mechanism assembly (pellets) MP - Primary air actuator MS - Secondary air actuator MV - Upper door microswitch OD - Air-vent OL - Combustion chamber temperature sensor PAD - Ash tray (wood) PAP - Ash tray (wood pellets) PB - Pellet burner PL - Main flow PO - Door for cleaning of pellet burner PP - Filling / drainage PR - Return flow PS - Pellet tank cover PT - Pressure switch RG - Fuel level sensor (pellet) RSE - Backfire protection valve (RSE) SK - Main switch SO - Casing cover (removable) for acces to electric

parts (pellets) ST1 - Safety thermostat (wood) ST2 - Safethy thermostat (wood pellets)

SV - Middle boiler door (wood) TI - Heat exchanger output (safety cooling system) (pellet) TO - Thermal safety valve sensor connection (safety cooling system) (wood) TU1 - Heat exchanger connection thermal safety valve connection point (safety cooling system) (wood) TU2 - Heat exchanger input (safety cooling system) (pellet) TV - Built-in thermal safety valve (safety cooling

system) VC - Connection tube VD - Opening for cleaning of the flue gas chamber VR - Lower boiler door (pellet) VT - Fan ZL - Sheet metal protection cover (wood) ZP - Flue gas tube cleaning lever

CLEANING SET:

CC - Flue gas tubes cleaning brush GG - Scraper for upper refractory stone (chamotte),

flue gas chamber and place around lower chamotte cleaning

GS - Scraper for cleaning of the lower refractory stone (chamotte)

ZN - Holder for cleaning set

Technical instructions BioTec Plus

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1.1. CHARACTERSTICS OF THE BioTec Plus BOILER

1.0. GENERAL

The BioTec Plus boiler is produced in compliance with the EN 303-5:2012 norm, which enables the required level of functioning and minimal environmental pollution, through the firing with wood logs and wood pellets. The system of flue gases conduction and their additional burning out, enables its high efficiency, which makes this product extremely economical. Widely sized left side fuel loading door enables firing with large pieces of wood logs and very simple and easy cleaning and maintenance. The wood gasification principle enables a complete fuel burning so maintenance of left part of the boiler is set to minimum. One filling of logs lasts up to 4 hours, depend about nominal heat output. There is also a possibility of prolonging the firing process to the entire day, if the heating requirement is decreased. The boiler can keep the glow up to 12 hours (depends on the quality of the wood), during which period it is not necessary to repeat the start firing process. In the right side of the boiler is installed the burner for wood pellet firing with the automatic firing and automatic self-cleaning function which enables the reliable operation also with the low quality wood pellets. The boiler must be connected to the central heating system with return flow protection and with properly sized water accumulation tank(s). Boiler operation is managed with inbuilt boiler control unit using two boiler sensors, sensor in combustion chamber, flue gas sensor and lambda probe, motors for primary and secondary air intake for combustion and modulating underpressure fan on flue gases outlet from boiler. Boiler control unit can run return flow protection, buffer tank management, one heating circuit with circulation pump and 3-way mixing valve with actuator steered by outer temperature sensor and room corrector and DHW water heater tank pump. With boiler BioTec Plus it is easy to handle, integrated control unit with color touch screen assures reliable and simple boiler operation. With installed accumulation (buffer) tank excess of produced heat is accumulated into the tank and can be consumed when needed. Because of accumulation tank, firing of the wood can be planned in a reasonable time, and in the case of mild outside temperature, space heating and DHW heating without firing boiler is also possible for several days, or just start pellet side of the boiler. The boiler is delivered together with thermal insulation, covered by a metal casing on two wood pallets.

Steel hot water boiler BioTec Plus has two separate combustion chambers inside the common boiler water chamber. Boilers BioTec Plus, nominal heat output 25, 35 and 45 kW, are designed for wood log firing in left part and wood pellet firing in right part of the boiler. The wood gasification principle enables a complete fuel burning in left part of the boiler. Logs up to 550 mm long can be inserted into the large combustion chamber. The burning period of a single fill of logs is up to 4 hours, depend about nominal heat output. The boiler can keep the glow even 12 hours, which means that in this period it is not necessary to fire up the boiler in order to keep the heating process. In the right side of the boiler is installed the burner for wood pellet firing with the automatic firing and automatic selfcleaning function which enables the reliable operation also with the low quality wood pellets. Boiler operation is controlled with inbuilt boiler control unit using two boiler sensors, sensor in combustion chamber, flue gas sensor and lambda probe, motors for primary and secondary air for combustion and modulating underpressure fan on flue gases outlet from boiler. Boiler must be connected to one adequately designed chimney and to the central heating system with return flow protection and adequately designed water accumulation tank (CAS).

Technical instructions BioTec Plus

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All local regulations, including those referring to national and European standards need to be complied with when installing the appliance. The boiler must not be modified unless using the tested original accessories we provide or if the work is undertaken by our Customer Service. Only fit original spare parts. These can be obtained from your customer service partner or directly from ourselves. European standards need to be complied with when installing the appliance.

Regular care and cleaning of the appliance, flue gas outlets, connecting piece and flue.

CAUTION:

The flue may block if the boiler is heated again after a long period of it not being used. Before starting the boiler, have the flue checked by a specialist (chimney sweep). Ensure sufficient

supply of fresh air in the installation room when heating. The air must be replaced at least 0.8 times an hour through constant and reliable room venting. Fresh air may have to be provided from outside if the windows and doors in the room where the boiler is installed are well sealed or if this room contains other equipment, such as extractor hoods, clothes dryer, fan etc.

1.2. SAFETY PRECAUTIONS

1.3. IMPORTANT INFORMATIONS

This symbol indicates measures for protection against accidents and warning for the user and / or exposed persons.

The boiler and related accessories are state of the art and meet all applicable safety regulations. The control unit, wiring chamber, el. heater, safety cut-out STB thermostat, fan, grid cleaning mechanism, flue gas tubes cleaning mechanism and pellet supply mechanism are integrated into

the BioTec Plus. They are operate at a voltage of 230V AC. Improper installation or repair can pose the danger of life-threatening electric shock. Installation may beperformed only by appropriately qualified technicians.

Caution symbols:

Please take careful note of the following symbols in this Operating Manual.

Concerning the specific need of sanitary hot water, the BioTec Plus boiler can be connected to one of water heaters produced by our company. We suggest the combination with wall hanged SKB Digi or LKB Digi water heaters, as well as with floor standing TB water heaters or accumulation tanks CAS-B. If the future connection to the solar system has been planned, boiler can be connected to combined accumulation tank CAS-BS or STEB solar water heater. Boiler is tested and certified according to the European standard EN 303-5:2012 and meets class 5. It is manufactured in compliance with ISO 9001 and ISO 14001 standards. Although the boiler has two separate furnaces, boiler connects to one properly selected chimney.

Technical instructions BioTec Plus

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1.4. WOOD GASIFICATION COMBUSTION PROCESS (wood side)

Combustion process is carried out in double combustion chamber in several phases. After filling the upper chamber with logs, glow dry the logs, and at temperature 100÷300°C logs are beeing gasified. The gases created in such process are mixed with the oxygen from air and burn out completely with high temperature. Fuel: wood logs with moisture content up to 20% (max. 25%), minimum size must be bigger than a nozzle in refractory stone (chamotte) of the upper chamber. This demand for moisture content is fulfilled with wood dried on air at least 12 months.

Wood pellets are used as fuel in right side of BioTec Plus boiler. Wooden pellets are bio-fuel made of wooden wastes. Pellets can be packed in different packaging: in bags (15 kg or 1000 kg), or as

bulk in large (underground) tanks ( 4 - 15 m ) or in basement spaces. Recommended properties of pellets for firing in BioTec Plus boilers are the following:

- heating value >= 5 kWh/kg (18 MJ/kg)

-diameter <= 6 mm

-max. moisture content <= 12 %

-max. dust content <= 1,5 %.

1.5. FIRING PROCESS IN WOOD PELLET SIDE

Technical instructions BioTec Plus

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2.0. DELIVERY PACKAGE

Boiler BioTec Plus is delivered in parts for easier transportation and mounting to boiler room.

Basic equipment is delivered seperately:

- left part of the boiler for wood firing with mounted thermal insulation (on wood pallet) with inbuilt:

- color touch screen display control unit

- sensor in combustion chamber

- flue gas sensor

- boiler sensor

- lambda probe

- 2 actuators for primary and secondary air

- flue gas modulating fan

- microswitch for upper boiler door

- STB safety thermostat

- right part of the boiler for wood pellet firing with mounted thermal insulation (on wood pallet) with inbuilt:

- photocell

- cleaning mechanism with movable grate

- pellet tank

- feeder screw

- backfire protection by rotation valve (RSE)

- pellet level sensor

- magnetic valve for air

- thermal safety valve

- electric heater

- pressure switch

- STB safety thermostat

- boiler sensor

- ash tray

- Additional sensors in basic delivery:

- 2 × Buffer tank sensors

- 1 × Outer temperature sensor

- 1 × Return flow sensor

- 1 × DHW sensor

- 1 × Room corrector (CSK)

- cleaning brush, two scrapers and holder for cleaning set and portable ash tray (for left part of the boiler (wood))

- set for connecting left and right side of the boiler: gasgets, screws, nuts.

- connection tube for connecting left and right side of the boiler

Technical instructions BioTec Plus

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25 35 45

5/4'' 5/4'' 5/4''

Magna3 32-60 Magna3 32-60

Magna3 32-60

6/4'' 6/4'' 6/4''

Recommendations for the VTC valve, circulation pump and water accumulator CAS - according to the boiler output:

Heat output

range

(kW)

Connection

VTC 512

(outer thread)

Connection

VTC 531

(internal thread)

Circulation pump type

(like Grundfos)

Volume of CAS accumulation

tank for BioTec Plus

wood gasification boilers

Minimum 50 litres / kW of boiler

2.1. ADDITIONAL EQUIPMENT

Recommendations for the LTC units and the water accumulators CAS - according to the boiler

output:

Minimum 50 litres / kW of boiler

25, 35

5/4''

6/4''

Heat output

range

(kW)

Connection

LTC 261

(internal thread)

Connection

LTC 271

(internal thread)

Volume of CAS accumulation

tank for BioTec Plus

wood gasification boilers

Additional equipment is not included in basic delivery. Obligatory additional equipment must be purchased seperately. Other additional equipment can be purchased optionally.

For closed heating systems:

- Thermal safety valve

- Safety-airvent group (2,5 bar)

- Expansion vessel for closed heating systems (size according the volume of heating installation, including buffer tank volume)

For open heating systems:

- Open expansion vessel (size according the volume of heating installation, including buffer tank volume)

2) OTHER ADDITIONAL EQUIPMENT:

- CAL alarm box (light/speaker)

- CM2K-B module for regulation 2+ heating circuits (max. 4 units.)

- GSM alarm module for mobile network

- Room thermostat

- Automatic flue gas tubes cleaning

- Pellet suction system CVT + CentroPelet box (pellet feeding box)

- Pellet suction system CVT + Feeder screw

- Pellet tank on wheels with volume of 780 l with feeder screw for filling standard installed pellet tank

CAL alarm box

(light/speaker)

CM2 K-B module

for regulation

2+ heating circuits

GSM alarm module

for mobile network

Room corrector (CSK)

(basic equipment)

1) OBLIGATORY ADDITIONAL EQUIPMENT:

- accumulation (buffer) tank for heating system (CAS (min. liter according to local regulation), m ).inimum 50 litres / kW of boiler

- return flow protection - 3-way mixing valve with actuator (protection valve) or 3-way thermostat valve (60°C) (like ESBE VTC 512, VTC 531, LTC 261, LTC 271).

Technical instructions BioTec Plus

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3.0. BOILER / ADDITIONAL EQUIPMENT POSITIONING AND ASSEMBLY

The positioning of the boiler has to be carried out the authorized person. We suggest the positioning on the solid concrete basis, which height is between 50-100 mm. The boiler room has to be absolutely protected from freezing and properly ventilated. The boiler has to be positioned in order to enable its connecting to the chimney (see point 3.) and heating installation as well as its servising during the functioning process, cleaning and maintenance (Figure 1). The connection of the boiler to the central heating system is obligatory with the one or more CAS water accumulator buffer tanks, depending of the boiler's power. It is recommended to connect minimum 50 liters water accumulation to each 1 kW boiler power (i.e. for the 45 kW boiler minimal water accumulation should be 2.250 liters). The boiler should not be used without being connected to the water accumulation tank. It must be connected to the CAS water accumulator obligatory with return flow protection through an 3-way mixing valve with actuator (protection valve) or 3-way thermic valve (like ESBE VTC 512, VTC 531 (60°C), LTC 261, LTC 271 (60°C)).

WARNING! Flammable items must not be placed on the boiler and within the minimum distances

shown in Figure 1.

Figure 1. Minimum distance from the boiler room walls

*valid for closest tank to the wall

Technical instructions BioTec Plus

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3.1. INSTALLATION OF DELIVERED PARTS

BioTec Plus is delivered on two wooden pallets. It must be mounted like is described on next pages of these technical instructions. After the boiler is mounted, should be positioned in the boiler room (see point 2.0.). Base protection with stone wool push under the boiler as shown in figure 2.a.

In upper chamber of the left side of the boiler are delivered (figure 2.b):

1. holder for cleaning set and 2 cleaning scrapers and cleaning brush

2. room corrector and sensors (2 buffer tanks sensors, 1 return flow sensor, 1 DHW sensor, 1 outer sensor)

Holder for cleaning set can be positioned on lateral side of the boiler (A) or to the wall (B), near the boiler and easy accessible. On this holder should be placed cleaning set (2 scrapers and brush).

Sensors and room corrector should be connected according heating installation and connecting scheme.

CHECKING FLUE GAS CHAMBER LID

Before connecting of left (fuel: wood) and right (fuel: wood pellets) sides of boiler is necessary to check if is right flue gas chamber lid it properly tight. Remove casing cover lid and additionally tight screws on flue gas chamber lid (like is shown on figure below). Acces to right flue gas chamber will be disabled after connection left and right side of the boiler.

Technical instructions BioTec Plus

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CONNECTING LEFT AND RIGHT SIDE OF THE BOILER

Left part of the boiler (fuel: wood)

Right part of the boiler (fuel: wood pellets)

Detail 1

Detail 2

Detail 1 Detail 2

Prepared flange with holes on left part of the boiler. First hole (left) have circle shape, other five holes are slitted (have possibility for height niveling).

Prepared flange on right side of the boiler. Flange have factory glued gasket and factory mounted six screws M12.

Technical instructions BioTec Plus

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STEP 1:

Sheet metal protection cover

BioTec Plus - left part of the boiler section view

Remove sheet metal protection cover through the upper boiler door.

STEP 2:

It’s necessary draw closer left side of the boiler to right side of the boiler. Screws from flange on right side of the boiler must get into flange holes on left side of the boiler. See figure on the next page.

Technical instructions BioTec Plus

Page 15

A - hole with circle shape; other holes are slitted for height niveling possibility.

Screws from flange on right side of the boiler must get into flange holes on left side of the boiler like is showned on figure above.

BioTec Plus - left part of the boiler section view

STEP 3:

Put washer, toothed washer and nut on screw like is showned on figure above (B). Tight nut but not completely tight.

BioTec Plus - left part of the boiler section view

Technical instructions BioTec Plus

Page 16

STEP 4:

BioTec Plus - left part of the boiler section view

Put washers, toothed washers and nuts on all other screws and start tigth them. If is needed, nivel boiler (holes are slitted for niveling). Thight hard all six nuts.

STEP 5:

Left and right side of the boiler have adjustable foots. Adjust it if is necessary. Boiler foots must touching boileroom floor.

Technical instructions BioTec Plus

Page 17

STEP 6:

prepared sockets on left side of the boiler (wood)

prepared plugs on right side

of the boiler (wood pellets)

On left side of the boiler (wood) are prepared sockets, on right side of the boiler (wood pellets) are prepared plugs. Cabels must be connected in right order: 1-1; 2-2; 3-3;

Technical instructions BioTec Plus

Page 18

Figure 2.b Delivered parts

Cleaning set

Sensor set

Position od cleaning set - on the boiler. Position od cleaning set - on the wall.

Figure 2.a Base protection with mineral wool

Push base protection under the boiler

Technical instructions BioTec Plus

Page 19

4.0. CONNECTION TO THE CHIMNEY

Properly dimensioned and built chimney is the precondition for a safe and reliable operation of the boiler and economic heating. The chimney has to be good insulated, gas-proof and smooth. On the lower part of the chimney, a cleaning door has to be built in. Brick layed chimney has to have 3 layers with an stone wool thermal insulation in the middle. The thickness of the insulation should be 30 mm, if the chimney is situated inside the building, i.e. 50 mm if the chimney is situated outside the building. Inside chimney diameter dimensions depend on its height and on the boiler thermal output (Figure 5.). The temperature of the flue gases on chimney exit point should be minimum 30°C higher then the temperature of their condensating point. The choice and the construction of the chimney should be performed by an authorized person. Minimal distance between boiler and the chimney is 500 mm. The flue gas tube has to have an inclination of 30-45° to the chimney (Figure 3.). In order to unable entering of the condensate from the chimney into the boiler, 10 mm of the flue gas tube length has to be inserted deaper inside the chimney. It is obligatory to insulate the chimney connection tube with a mineral stone wool of 30-50 mm thickness. All installation works must be made in accordance with valid national and European standards.

H - Useful chimney height

Figure 3. - Possible connecting of the BioTec Plus boiler to the chimney

Possible way of connecting to the chimney of the BioTec Plus 25-35 boiler (recommendation)

Possible way of connecting to the chimney of the Bio-Tec-L boiler (Only BioTec Plus 45 because of position of the fan)

Technical instructions BioTec Plus

Page 20

100

110

5 10 15

6 7 8 9

An example of the chimney selection:

- boiler output: 25 kW

- Fuel: wood logs, wood pellets

- required useful chimney height: H=8 m

- required inner chimney diameter: 18 cm

- boiler output: 35 kW

- Fuel: wood logs, wood pellets

- required useful chimney height: H=8 m

- required inner chimney diameter: 20 cm

- boiler output: 45 kW

- Fuel: wood logs, wood pellets

- required useful chimney height: H=8 m

- required inner chimney diameter: 22 cm

Figure 5. - Dimensioning of the chimney for BioTec Plus boilers

Useful chimney height - from flue gas tube connection

to the top of chimney

Inner chimney diameter - interior chimney diameter.

Nominal thermal output of the boiler (kW)

Useful height of the chimney (m)

Inner diameter of the chimney (cm)

At connecting a boiler to the chimney, flue gas tubes and elbows must not pass behind the fan since in that case the cleaning and maintenance will not be possible. An example of incorrect position of flue gas tubes and elbows in relation to the fan is presented at the Figure 4.

Figure 4. Incorrect connecting the boiler to the chimney - not possible cleaning of the fan

BioTec Plus 45

BioTec Plus 25 / 35

Fan

Flue gas elbow

Flue gas tube

Technical instructions BioTec Plus

Page 21

Boiler room must be equipped with an opening for supply of fresh air which is dimensioned in accordance with boiler thermal output (minimum opening area according to below shown equation). Such opening must be protected with a net or grate. All installation works have to be performed in accordance with valid national and European standards. Boiler must not operate in flammable and explosive environment.

4.1. FRESH AIR OPENING

Q - boiler output in kW

A - opening area in cm

A = 6,02 Q

Equation for calculate opening area:

Technical instructions BioTec Plus

Page 22

5.0. CONNECTION TO THE CENTRAL HEATING SYSTEM

All installation works must be made in accordance with valid national and European standards. Boiler BioTec Plus can be built to closed and open central heating system. In both cases boiler must be fired with wood logs or wood pellets. Installation has to be made in according to technical standards, by a professional who will be responsible for proper boiler operation. The main flow pipe from the boiler to the central heating system must not pass above the top back casing cover (PD), otherwise the removal of the turbulators and cleaning of flue gas tubes is impossible (see Figure 6). Before connecting boiler to central heating system, the system has to be flushed to remove impurities remaining after system installation. It prevents boiler overheating, noise within the system, disturbances at a pump and mixing valve. Boiler should always be connected to central heating system by connectors, never by welding. Figure 1. shows minimum distances required for boiler cleaning and maintenance.

Figure 6. Examples of main flow contructions

PD - Top back casing cover PL - Main flow

Recommended Recommended

Technical instructions BioTec Plus

Page 23

Scheme 1a. - Basic scheme for boiler instalation on closed central heating system with return flow protection with thermic valve (group) (electrical connections and sensor are not drawn, for details see general schemes)

bar

Scheme 1b. - Basic scheme for boiler instalation on open central heating system with return flow

protection with thermic valve (group) (electrical connecetions and sensors are not drawn, for details see general schemes)

above the highest heating body

1 - Boiler BioTec Plus

2 - Accumulation tank «CAS»

3 - Boiler pump

4 - Return flow protection by 3-way mixing valve with actuator (protection valve) or by 3-way thermic valve (like Esbe LTC, VTC..., 60°C)

5 - Expansion vessel for closed heating systems (approx. 10% of the total volume of installation)

6 - Open expansion vessel for open heating systems (OPC) (approx. 7% of total volume of installation)

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Technical instructions BioTec Plus

Page 24

5.1. CONNECTION TO THE OPEN CENTRAL HEATING SYSTEM

If the boiler is aimed to be integrated into an open central heating system, one of possible way how to connect the boiler to the system is shown on Scheme 1b. In case of BioTec Plus boilers, the

boiler pump obligatory has to be connected to the boiler control unit, in order to make turning on and off of the pump depending on the temperature of the water in the boiler, to avoid boiler

condensation. Connection to an open central heating system requires the implementation of an open expansion vessel (OPC) above the level of the highest heating body (radiator). If the expansion vessel is situated inside the non heated room, it has to be insulated. The volume of the open expansion vessel is about 7% of the volume of entire heating installation. The boiler has to be connected with one or more CAS water accumulators, depending on its nominal power. It is recommended to connect minimum 50 liters water accumulation to each 1 kW boiler nominal power (i.e. for the 45 kW boiler minimal water accumulation should be 2250 liters) and always check the local regulation about the needed minimum volume. The boiler should not be used without being connected to the water accumulation tank with needed min. volume. It must be connected to the CAS water accumulator obligatory through an 3-way mixing valve with actuator (protection valve) or 3-way thermic valve (like ESBE VTC 512, VTC 531 (60°C), LTC 261, LTC 271 (60°C)).

5.2. CONNECTION TO THE CLOSED CENTRAL HEATING SYSTEM

In closed heating system (as in example shown in Scheme 1a) it is obligatory to build in certified safety valve with opening pressure of 2,5 bar, minimum seat diameter of 15 mm, minimum inlet connection of 1/2", minimum exit connection of 3/4" and a membrane expansion vessel. Safety valve and expansion vessel must be built in accordance with professional rules and any valve must not be located between safety valve and expansion vessel and boiler. The closed heating

system must have the installed expansion vessel of larger volume (vessel volume must be approx. 10% of the heating installation volume). In all boiler types the heating pump must be

connected to boiler control unit so that the heating pump switching on and off would depend on water temperature in the boiler. The boiler has to be connected with one or more CAS water accumulators, depending of its power. It is recommended to connect 50 liters water accumulation to each 1 kW boiler power (i.e. for the 45 kW boiler minimal water accumulation should be 2250 liters). The functioning of boiler control unit is shown in Technical manual ''Digital boiler control unit BioTec Plus''. The boiler should not be used without being connected to the water accumulator. It must be connected to the CAS water accumulator obligatory through an 3-way mixing valve with actuator (protection valve) or 3-way thermic valve (like ESBE VTC 512, VTC 531 (60°C), LTC 261, LTC 271 (60°C)).

Technical instructions BioTec Plus

Page 25

5.2.1. BOILER THERMAL PROTECTION

According to European EN standards, boiler thermal protection must be installed in closed heating system. Boiler is factory prepared for installation of thermal protection. Heat exchanger is factory installed on left side of the boiler (wood), and thermal safety valve (7) should be installed according to Scheme 2. On right side of the boiler (wood pellet) is also factory installed heat exchanger with factory installed thermal safety valve. In case of any damage of boiler installed in the closed heating system due to its overheating, and boiler or system are not equipped with any thermal protection at all, or do not have properly installed thermal protection, guarantee will not be applied.

IMPORTANT:

Thermal protection must be connected to the water supply installation of the premises supplied from the public water supply line and not from hydrophor. Namely, in case of failure of power supply, boiler could be overheated, and then hydrophor is not able to ensure required water supply.

THERMAL PROTECTION: Left side of the boiler (wood):

Thermal protection for left side of the boiler BioTec Plus consists of a heat exchanger which is factory built in boiler, and thermal safety valve (7) (such as CALEFFI 543 513) (see Scheme 1).

Thermical valve (7) is installed into prepared connector (male thread 3/4") in the upper part of left lateral side of the boiler casing.

Right side of the boiler (wood pellets):

Thermal protection for right side of the boiler BioTec Plus consists of a heat exchanger which is factory built in boiler, and thermal safety valve (11) which is also factory built in boiler.

INSTALLATION (according to Scheme 2.): Left side of the boiler (wood):

- screw the thermal safety valve sensor (6) (outer thread1/2") into the sleeve joint (2) (inner thread1/2").

- fix the connection (4) (inner thread 3/4") of the thermal safety valve to the city plumbing cold water inlet and the connection (5) (inner thread 3/4") to the connection point of the heat exchanger (1) (outer thread1/2") - the arrow shows the direction.

- fix the tube connected to the sewage outlet at the connecting point (3) (outer thread1/2").

Right side of the boiler (wood pellets):

- fix the connection (9) (inner thread 3/4") to the city plumbing cold water inlet.

- fix the tube connected to the sewage outlet at the connecting point (10) (outer thread1/2").

Technical instructions BioTec Plus

Page 26

Scheme 2. - Thermal protection in an closed heating system

1 - Heat exchanger connection (to thermal safety valve) (left side of the boiler - wood) 2 - Connection for the thermal safety valve sensor (left side of the boiler - wood) 3 - Heat exchanger connection (to the sewerage) (left side of the boiler - wood) 4 - Thermal safety valve connection (cold water inlet HV) 5 - Thermal exchanger connection (to the boiler) (to the boiler) 6 - Thermal safety valve-sensor 7 - Thermal safety valve 8 - Dirt filter (recommended) 9 - Heat exchanger connection (right side of the boiler - wood pellet) 10 - Heat exchanger connection (to the sewerage) (right side of the boiler - wood pellets) 11 - Factory inbuil thermal safety valve (right side of the boiler - wood pellets)

bar

Safety air vent group

Main flow

Sewerage flow

Return flow

Filling / draining

Sewerage flow

Technical instructions BioTec Plus

Page 27

Scheme 3. - General scheme of closed central heating system with 2 or more accumulation tanks.

5.3. GENERAL CONNECTION SCHEMES

All general schemes hereafter will be shown with one accumulation tank, but they can be performed with two or more accumulation tanks (buffer tanks). Pay attention to electrical and sensors connections on general schemes!

bar

S10

S12

S13 S14

Terminal Block

P1 P2

Conn

cted t

o th

e boile

ele

onics

1 - Boiler "BioTec Plus" 2 - "CAS" accumulation tank (buffer tank) 3 - Return flow protection (3-way mixing valve with actuator (protection valve) or 3-way thermic valve (60°C), VTC 512, VTC 531, LTC 261, LTC 271) 4 - Safety airvent unit 5 - Expansion vessel for closed systems (min. 10% of the total volume of installation) 6 - Thermal safety valve

P1 - PumpP1 (boiler pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - Return flow temperature sensor D - Outer temperature sensor E - Flue gas sensor

* *

Not included in delivery of boiler BioTec Plus (need additional order)

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Each heating scheme with BioTec Plus has option of installing up to 4 pcs CM2K-B modules (additional heating circuits management, DHW preparation and recirculation).

Page 28

Scheme 4. - General scheme of closed central heating system with 1 accumulation tank, boiler return flow protection with 3 - way mixing valve with electric actuator.

NOTE:

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

- Return flow protection (3) can be also performed by 3-way thermic valve ((60°C), VTC 512, VTC 531, LTC 261, LTC 271).

S10

S12

S13 S14

Terminal Block

P1 P2

bar

Not included in delivery of boiler BioTec Plus (need additional order)

1 - Boiler "BioTec Plus". 2 - "CAS" accumulation tank (buffer tank). 3 - Return flow protection (3-way mixing valve with actuator (protection valve) 4 - Expansion vessel for closed systems (min. 10% of the total volume of installation) 5 - Safety airvent unit 6 - Thermal safety valve

* *

P1 - Pump P1 (boiler pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - Return flow temperature sensor D - Outer temperature sensor E - Flue gas sensor

ected t

o t

e boile

ele

ron

ics

Mixing valve

actuator

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Technical instructions BioTec Plus

Page 29

bar

3P1

S10

S12

S13 S14

P1 P2

Scheme 5.- General scheme of closed central heating system with 1 accumulation tank and

in front behin accumulation tankDHW preparation / d .

NAPOMENA:

- According to this scheme is possible to perform version for open central heating system (see point 6.0, Connection to the central heating system).

P1 - Pump P1 (boiler pump) P2 - Pump P2 (DHW pump) P3 - 3-way diverter valve P3 A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C

DHW sensor (domestic hot water) D - Outer temperature sensor E - Flue gas sensor F - Main flow sensor J - Return flow temperature sensor

* * *

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

IMPORTANT! This way of connecting DHW tank is neccesary if in some part of the year we only want to use pellets for heat DHW tank.

1 - Boiler "BioTec Plus". 2 - "CAS" accumulation tank (buffer tank). 3 - Return flow protection (3-way mixing valve with actuator 4 - Expansion vessel for closed systems (min. 10% of the total volume of installation) 5 - Sanitary water tank (SKB-Digi/LKB-Digi/TB/STEB) 6 - Safety airvent unit 7 - Thermal safety valve

* *

onnec

ed to th

e b

oil

er el

ctro

nics

Not included in delivery of boiler BioTec Plus (need additional order)

Terminal Block

Mixing valve

acturator

Technical instructions BioTec Plus

Page 30

Scheme 6. - General scheme of closed central heating system with 1 accumulation tank, heating system behind accumulation tank, 1 heating circuit with 3-way mixing valve with actuator (or without actuator), and DHW preparation.

S10

S12

S13 S14

Terminal Block

P1 P2

T T

bar

1 - Boiler "BioTec Plus". 2 - "CAS" accumulation tank (buffer tank). 3 - Return flow protection (3-way mixing valve with actuator (protection valve) or 3-way thermic valve (60°C), VTC 512, VTC 531, LTC 261, LTC 271) 4 - Expansion vessel for closed systems (min. 10% of the total volume of installation) 5 - Sanitary water tank (SKB-Digi/LKB-Digi/TB/STEB) 6 - Safety airvent unit 7 - Thermal safety valve

P1 - Pump P1 (boiler pump) P2 - Pump P2 (DHW pump) P3 - Pump P3 (heating pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C

DHW sensor (domestic hot water) D - Outer temperature sensor E - Flue gas sensor F - Main flow sensor G - 3-way mixing valve with actuator or manual 3-way mixing valve H

- Room corrector (CSK)

I - Heating circuit

J - Return flow temperature sensor

Mixing valve

acturator

* *

Conn

cted t

o th

e boile

ele

onics

Not included in delivery of boiler BioTec Plus (need additional order)

NOTE:

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

- Actuator can be installed only on position „G” or position „3” and noway on any other positions.

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Can be used only if it’s on position „G” installed actuator

***

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Page 31

bar

3P1

S10

S12

S13 S14

Terminal Block

P1 P2

Mixing valve

actuator

Scheme 7. - General scheme of closed central heating system with 1 accumulation tank, heating

system in front of accumulation tank, 1 heating circuit with 3-way mixing valve with actuator, room corrector, and DHW preparing.

ecte

d t

o t

e bo

electron

ics

Not included in delivery of boiler BioTec Plus (need additional order)

NOTE:

According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

1 - Boiler "BioTec Plus ". 2 - "CAS" accumulation tank (buffer tank). 3 - Return flow protection 4 - Expansion vessel for closed systems (min. 10% of the total volume of installation) 5 - Sanitary water tank (SKB-Digi/LKB-Digi/TB/STEB) 6 - Safety airvent unit 7 - Thermal safety valve

* *

P1 - Pump P1 (boiler pump) P2 - Pump P2 (DHW pump) P3 - Pump P3 (heating pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C

DHW sensor (domestic hot water) D

Outer temperature sensor E - Flue gas sensor F - Main flow sensor G - 3-way mixing valve with actuator H

- Room corrector (CSK)

I - Heating circuit

J - Return flow temperature sensor

* * *

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Page 32

Scheme 8. - General scheme of closed central heating system with 1 accumulation tank, heating system behind accumulation tank, 2 heating circuit with 3-way mixing valve (one with actuator, other manually operated).

NOTE:

- According to this scheme is possible to preform version with heating system in front accumulation tank.

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

- Actuator can be installed only on position „J” or position „3” and noway on any other positions.

S10

S12

S13 S14

Terminal Block

P1 P2

bar

T T

CIRCUIT 1 CIRCUIT 2

Conn

cted t

o th

e b

oil

nic

Mixing valve

actuator

* *

P1 - Pump P1 (boiler pump) P2 - Pump P2 (heating pump circuit 2) P3 - Pump P3 (heating pump circuit 1) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - Return flow temperature sensor D

Outer temperature sensor E - Flue gas sensor F - Main flow temperature sensor G - Room thermostat H

- Room corrector (CSK)

I - Heating circuit

3-way mixing valve with actuator or manual 3-way mixing valve

K -

Manual 3-way mixing valve

* * *

* *

Not included in delivery of boiler BioTec Plus (need additional order)

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Can be used only if it’s on position „J” installed actuator

***

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Page 33

S10

S12

S13 S14

Terminal Block

P1 P2

bar

T TT T

G G

H1 H2

I I

J J

Managed with CM2K-B module

CM2K-B

T T

CIRCUIT 1

Not included in delivery of boiler BioTec Plus or CM2K-B module (need additional order)

Included in basic delivery of CM2K-B module

NOTE:

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system). It's possible to expand system of heating circuit lead by CM2K-B module with installing additional CM2K-B modules (max. 3 pcs) in serial connection.

- Actuator can be installed only on position „G” or position „3” and noway on any other positions.

* *

F - CM2K -B module (can be expanded to max. 4 units connected in series) G - 3-way mixing valve with actuator or manual 3-way mixing valve H1 - Room corrector 2 (CSK) H2 - Room corrector 3 (CSK) I - Heating circuit J - Main flow temperature sensor in circuit CM2K. (must be installed with

3-way mixing valve with actuator)

K - Heating pump (managed by CM2K-B) L - Return flow temperature sensor

* * **

P1 - Pump P1 (boiler pump) P2 - Pump P2 (DHW pump) P3 - Pump P3 (heating pump circuit 1) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - DHW sensor (domestic hot water) D - Outer temperature sensor E - Flue gas sensor L - Main flow temperature sensor H

- Room corrector 1 (CSK)

* * *

Scheme 9. - General scheme of closed central heating system with 1 accumulation tank, heating system behind accumulation tank, 3 heating circuit with 3-way mixing valve and DHW preparing.

nec

d t

o t

e bo

Mixing valve

actuator

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

***

Can be used only if it’s on position „G” installed actuator

****

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Page 34

Sch

me 10. - G

eneral sc

e o

f c

osed ce

ral heat

ing sys

m wi

h 1 ac

cumulati

on t

ank

, hyd

osso

r b

d a

ion ta

nk, 2 heat

ng circ

s wi

th 3

way m

ixi

ng va

ve w

uato

r m

anage

d b

y C

-B mo

e, DH

W p

pari

ng.

F - CM2K -B module (can be expanded to max. 4 units connected in series) G - 3-way mixing valve with actuator or manual 3-way mixing valve H1 - Room corrector 1 (CSK) (1x room corrector CSK included in basic boiler delivery) H2 - Room corrector 2 (CSK) I - Heating circuit J - Main flow temperature sensor in circuit CM2K (must be installed with

3-way mixing valve with actuator)

K - Heating pump (managed by CM2K-B) L - Return flow temperature sensor

bar

T TT T

K K

G G

H1 H2

I I

J J

CM2K-B

S10

S12

S13 S14

Terminal Block

P1 P2

Not included in delivery of boiler BioTec Plus or CM2K-B module (need additional order)

Included in basic delivery of CM2K-B module

NOTE:

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

- It's possible to expand system of heating circuit lead by CM2K-B module with installing additional CM2K-B modules (max. 3 pcs) in serial connection.

Managed with CM2K-B module

ted t

o th

e bo

ile

ron

P1 - Pump P1 (boiler pump) P2 - Pump P2 (DHW pump) P3 - Pump P3 (hydraulic crossover pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - DHW sensor (domestic hot water) D - Outer temperature sensor E - Flue gas sensor M - Hydraulic crossover sensor (delivered as flow temperature sensor)

* * *

* *

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

***

Can be used only if it’s on position „3” installed actuator

***

Technical instructions BioTec Plus

Page 35

S10

S12

S13 S14

Terminal Block

P1 P2

bar

T TT T

K K

G G

H1 H2

I I

J J

CM2K-B

T T

CIRCUIT 1

Not included in delivery of boiler BioTec Plus or CM2K-B module (need additional order)

Included in basic delivery of CM2K-B module

NOTE:

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

- It's possible to expand system of heating circuit lead by CM2K-B module with installing additional CM2K-B modules (max. 3 pcs) in serial connection.

- Actuator can be installed only on position „G” or position „3” and noway on any other positions.

cte

d t

o t

he bo

Managed with CM2K-B module

1 - Boiler "BioTec Plus". 2 - "CAS" accumulation tank (buffer tank). 3 - Return flow protection (3-way mixing valve with actuator (protection valve) or 3-way thermic valve (60°C), VTC 512, VTC 531, LTC 261, LTC 271) 4 - Expansion vessel for closed systems (min. 10% of the total volume of installation) 5 - Hydraulic crossover 6 - Safety airvent unit 7 - Thermal safety valve

* *

* * *

P1 - Pump P1 (boiler pump) P2 - Pump P2 (hydraulic crossover pump) P3 - Pump P3 (heating circuit 1 pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - Return flow temperature sensor D - Outer temperature sensor E - Flue gas sensor H -

Room corrector 1 (CSK) L - Main flow temperature sensor (circuit 1) M - Hydraulic crossover sensor (delivered as flow temperature sensor)

* * *

F - CM2K -B module (can be expanded to max. 4 units connected in series) G - 3-way mixing valve with actuator or manual 3-way mixing valve H1 - Room corrector 2 (CSK) (1x room corrector CSK included in basic boiler delivery) H2 - Room corrector 3 (CSK) I - Heating circuit J - Main flow temperature sensor in circuit CM2K (must be installed with

3-way mixing valve with actuator)

K - Heating pump (managed by CM2K-B)

Mixing valve

actuator

Sche

e 1

1. - G

eneral sch

eme o

f close

d centr

al hea

ing s

yst

em with 1 a

umulat

on ta

, h

ossover behind accum

n tank, 3 hea

ing c

ircu

its w

ith 3

ay m

ixing valve with

ctuat

or (

1 di

ect he

g ci

rcuit an

d 2 c

uit

s mana

d b

y C

K-B mo

e).

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

***

Can be used only if it’s on position „G” installed actuator

****

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Page 36

Scheme 12. - General scheme of closed central heating system with 1 accumulation tank, custom heating system

S10

S12

S13 S14

Terminal Block

P1 P2

bar

NOTE:

- According to this scheme is possible to preform version for open central heating system (see point 6.0, Connection to the central heating system).

* *

P1 - Pump P1 (boiler pump) A - Accumulation tank sensor (upper) B - Accumulation tank sensor (lower) C - Return flow temperature sensor D - Outer temperature sensor E - Flue gas sensor

ect

ed t

o th

e b

Custom heating system (only with 3-way mixing

valve with actuator) -

heating system in front

accumulation tank

Custom heating system -

heating system behind

accumulation tank

Not included in delivery of boiler BioTec Plus (need additional order)

BioTec Plus

05:08

OFF

0.0%

xx°C

x%xx°C

xx°C

xx °C

25.0°C

20.0-0.0°C

20.0°C

-°C

xx°C

Can be used only if it’s on position „3” installed actuator

Technical instructions BioTec Plus

Page 37

6.1. BOILER CONTROL

The boiler is controlled with electronic control unit, built in the upper part of the boiler, below upper casing. Control unit controls boiler functioning, one heat circuit through 3 way mixing valve with actuator and outer temp. sensor and DHW tank. On the front boiler panel are main switch, for switching on/off the boiler control unit, safety thermostat and touch screen of control unit.

6.0. BOILER REGULATION

Figure 7. Boiler electronic

Boiler electronic position

Control unit display

Main switch

STB Safety thermostat

Boiler electronic position

Technical instructions BioTec Plus

Page 38

CAUTION:

When connecting any electrical part be sure to unplug the boiler at the main switch and disconnect the power supply.

S13

S10

S11

S12

S14

S1 - Sanitary water / hydraulic crossover sensor* S2 - Accumulation tank 1 sensor (up) S3 - Accumulation tank 2 sensor (down) S4 - Flue gas sensor S5 - Outer sensor S6 - Main flow sensor / hydraulic crossover sensor* S7 - Return flow sensor S8 - Not used S9 - Room thermostat S10 - Alarm output 1 (Additional equipment) S11 - Alarm output 2 (Additional equipment) S12 - Not used S13 - Not used S14 - Room corrector

Terminal Block & Strip Connector

7.0. ELECTRIC CONNECTION

All electrical works must be performed by a certified professional in accordance with valid national and European standards.

A device for switching of all power supply poles must be installed in electrical installation in accordance with the national regulations on electrical installations.

*If the configuration contains hydraulic crossover, delivered main flow temperature sensor or sanitary water sensor becomes hydraulic crossover sensor, depending on other elements of the configuration. When configuration contains hydraulic crossover along DHW tank or heating circuit, then hydraulic crossover temp. sensor must be connected to connector S6, in other cases hydraulic crossover temp. sensor must be connected to the connector S1.

N L N L N L N L L

N N L

Red

Black

White

Power supply

230 V

Pump P1

Pump P2

Pump

Mixing valve

actuator

Fan

RPM

Counter

Technical instructions BioTec Plus

Page 39

1 2 3 4

T O 4

1 2 2 21 13 3 34 4 45 56 6

T O 1 T O 2 T O 3

1 2 3 4

P OW 1

L LL t L t L t L t L t L t L t L t L t L t L tN N N N N N N N NL p Lp

BI O T E C - OUTPUTS

F1 - 3 ,15 A F 2 - 5 00 m A F 3 - 3,1 5A

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

N L P E N O Z

Supply

230V

Secondary air

motor device

Primary air

motor device

Mixing valve

motor device

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

Technical instructions BioTec Plus

Page 40

Red

Black

White

Black

Blue

Brown

P 2

P 3

2 1

2P C RNI

MUŠK I

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

Heating

pump

Heating

pump

Buffer tank

pump

Flue gas fan with

RPM counter

Technical instructions BioTec Plus

Page 41

1 1 1

2 2 2

3 3

4 4

H AL 1 A i 2 A i 3 A i 1 T C 1

UT P 1 U TP 2

+5 V

SI G GND

GND

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

Boiler door

microswitch

Boiler sensor Thermocouple

Coded key

for boiler

power

Technical instructions BioTec Plus

Page 42

UT P

US B

BI O T E C - di sp l

U TP CABLE

UT P CABLE

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

SIG

GND

1 2

+5V

GND

SIG

S1 S 2 S3 S 4 S5 S 6 S7 S8 S 9 S 10 S11 S12

U TP 1 UT P 2

BI O T E C - SENSORS

1 2

+5 V

GND

SIG

S13

1 2

+5 V

GND

SIG

S14

1 2 3

S K

U TP CABLE

3 2

+5V

GND

SIG

FUEL LEVEL SENSOR

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

DHW sensor

S 9 - room thermostat

S10 - output for alarms

S11 - output for alarms

Buffer

tank sensor

Buffer

tank sensor

Flue gas

sensor

Outer

sensor

Boiler flow

sensor

Boiler

return sensor

Room corrector

SENSORS

Technical instructions BioTec Plus

Page 43

RS 4 85

B G

LA MB D A PROBE

L -

L+

T fg . S

DI / AO

S T

N F

23 0 V

UT P 2

UT P 1

WHITE

GREY

BLACK

U TP CABEL

4P C RNI

MUŠK I

L1N L2

PE N L

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

Lambda

probe

Feeding

system motor

device

Technical instructions BioTec Plus

Page 44

F1 - 3 ,15 A F 2 - 5 00 m A F3 - 3 ,15 A

1 2 3 4

T O 4

1 2 2 21 13 3 34 4 45 56 6

T O 1 T O 2 T O 3

1 2 3 4

P OW 1

L LL t L t L t L t Lt L t L t L t L t L t L tN N N N N N N N NL p L p

PE L TE C -

1 2 3

L t NL t

T O 5

4P C RNI

ŽEN SK I

L1 NL2

2P C RNI

ŽENS K I

2 1

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

Motor for

grate cleaning

Feeder screw

motor device

RSE rotation valve

motor device

Electric heater

Electric magnet

Technical instructions BioTec Plus

Page 45

1 1 1

2 2 2

3 3

4 4

H AL 1 A i 2 A i 3 A i 1 R o 1

UT P 1 U TP 2

PE L TE C - ul a zi

+5 V

SI G GND

+12 V REL 1 REL 2

GND

2P C RNI

ŽENS K I

2 1

2P CR NI

MUŠK I

2 1

2P SI V I

MUŠK I

2P SI V I

ŽEN SK I

2 1

ELECTRIC SCHEME - BOILER CONTROL UNIT

BioTec Plus

Project:

Date:

Drawing n.:

Function: Lacation:

Init.:

Rev.:

Total pages:

Page:

Grate

microswitch

Photocell

Pressure switch

Boiler sensor

Technical instructions BioTec Plus

Page 46

7.1. BOILER SENSORS AND PROBES

6 8

- Boiler temperature sensor (NTC 5K) (left side of the boiler; fuel: wood)

- Boiler temperature sensor (NTC 5K) (right side of the boiler; fuel: wood pellets)

- Combustion chamber temperature sensor (thermo couple)

- Flue gas sensor (PT1000)

- Fan RPM sensor

- Lambda probe

- Outer temperature sensor (NTC 5K)

- Main / return flow temperature sensor (NTC 5K)

- Domestic hot water (DHW) temperature sensor (NTC 5K)

- Pressure switch

- Photocell

- Fuel level sensor (wood pellets)

* - Installed on heating installation

Technical instructions BioTec Plus

Page 47

Temperature

(°C)

Resis.

( W )

Temperature

(°C)

Resis.

( W )

-30

885 225 1.866

-25 904 230 1.886

-20 923 235 1.905

-15 942 240 1.924

-10 962 245 1.943

-5 981 250 1.963 0 1.000 255 1.982 5 1.019 260 2.001

10 1.039 265 2.020 15 1.058 270 2.040 20 1.077 275 2.059 25 1.096 280 2.078 30 1.116 285 2.097 35 1.135 290 2.117 40 1.154 295 2.136 45 1.173 300 2.155 50 1.193 305 2.174 55 1.212 310 2.194 60 1.231 315 2.213 65 1.250 320 2.232 70 1.270 325 2.251 75 1.289 330 2.271 80 1.308 335 2.290 85 1.327 340 2.309 90 1.347 345 2.328

95 1.366 350 2.348 100 1.385 355 2.367 105 1.404 360 2.386 110 1.424 365 2.405 115 1.443 370 2.425 120 1.462 375 2.444 125 1.481 380 2.463 130 1.501 385 2.482 135 1.520 390 2.502 140 1.539 395 2.521 145 1.558 400 2.540 150 1.578 155 1.597 160 1.616 165 1.635 170 1.655 175 1.674 180 1.693 185 1.712 190 1.732 195 1.751 200 1.770 205 1.789 210 1.809 215 1.828 220 1.847

-20

-15

-10

-5 0 5

10 15 20 25 30 34 40 45 50 55

Temperature

(°C)

48.534

36.465

27.665

21.158

16.325

12.694

9.950

7.854

6.245

5.000

4.028

3.266

2.663

2.184

1.801

1.493

Resistance

( )

60 65 70 75 80 85 90

95 100 105 110 115 120 125 130

1,244

1.041 876

740,7 629,0 536,2 458,8 394,3 340,0 294,3 255,6 222,7 190,7 170,8 150,5

RESISTANCE LIST NTC 5k/25°C SENSOR

(measuring field from -20 - +130 °C)

RESISTANCE LIST NTC Pt1000 SENSOR

(measuring field -30 - +400 °C)

Technical instructions BioTec Plus

Page 48

If you smell flue gas:

- shut down the heating system

- Ventilate the boiler room

- Close all doors leading to the living space

8.0. BOILER US E

Boiler must not be used in flammable and explosive environment. It must not be used by children or disabled persons (either physically or mentally), as well as by

person without knowledge or experience, unless they are under control or trained by s person responsible for their safety. Children must be supervised in the vicinity of the product. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. Protective gloves are obligatory. Check whether boiler and equipment are installed and connected in accordance with these Technical instructions. Check whether chimney meets requirements of point 4.0 therein. Check whether boiler room meets all requirements therein. Check if fuel fulfils all requirements therein. Check whether the boiler and the entire heating system are filled with water and vented.

Note:

Before every use check if the boiler doors and cover door are closed.

Flue gas can lead to life-threating poisoning!

Technical instructions BioTec Plus

Page 49

8.1.1. BUTTON S

Button ’’START’’/’’STOP’’

Button ’’ON / OFF’’ options: on / off boiler operation’’

Button ’’DISPLAY SELECTION’’ options: main menu / work

Button ’’BOILER OPERATION DISPLAY’’ options: graphic / numeric

Button ’’ENTER’’

Button ’’BACK’’

Button’’PREVIOUS SCREEN’’

Button ’’NEXT SCREEN’’

Button ’’OK’’

Navigation buttons: ’’LEFT’’, ’’RIGHT’’, ’’UP’’, ’’DOWN’’

Button ’’DELETE’’

Button ’’FACTORY SETTINGS’’

Button ’’INFORMATION’’

Button ’’COPY’’ Button ’’PASTE’’

8.1. BOILER CONTROL UNIT USE

Technical instructions BioTec Plus

Page 50

The pump has a request for work (next to the pump symbol bright yellow square when the consumer given the demand for work the pump, the pump does not work if you have not met all the conditions for work, for example. low temp. in the boiler, otherwise the pump normally works)

Pump (when pump is working symbol is rotating, otherwise idle)

70°C

50°C

Accumulation tank with current temperature at top of the tank and at the bottom of the tank.

55°C

Domestic hot water tank with current temperature

Heating circuit

Room thermostat

Next to the room thermostat symbol bright blue circle (the room thermostat has requested for operating the pump, the pump does not work if you have not met all the conditions for its operation, for example. low temp. in the boiler, otherwise normally works)

8.1.2. SYMBOLS

Cleaning of ﬂue pass. (this symbol is located in left side-wood)

Pellets reﬃl (this symbol is located in left side-wood)

External control require burner operation (this symbol is visible only if external control is installed and conﬁgured)

Burner operation is not required by external control (this symbol is visible only if external control is installed and conﬁgured)

Technical instructions BioTec Plus

Page 51

8.1.3. MAIN SCREEN

19 2018

13 14

2221

1a - Boiler (Wood firing side) 1b - Boiler (Pellet firing side) 2 - Buffer tank 3 - Boiler pump P1 4 - 3 - way protection valve (thermic or with actuator) 5 - Boiler temperature (Wood firing side) 6 - Symbol of fan operation (simbol is rotate when fan working) 7 - Fan speed (rpm) 8 - Simbol and opening percentage of primary air actuator 9 - Simbol and opening percentage of secondary air actuator 10 - Glow option (if is enabled)

11 - Combustion chamber temperature 12 - Flue gas temperature 13 - The percentage of oxygen in the flue gases (lambda probe) 14 - Boiler side activity indicator 15 - Wood pellet tank 16 - Boiler temperature (Wood pellet firing side) 17 - Fuel level sensor (Wood pellets) 18 - Feeder screw 19 - Photocell 20 - Electric heater 21 - Outer temperature 22 - Errors and warnings 23 - Boiler working phase

Technical instructions BioTec Plus

Page 52

8.1.4. MAIN MENU

Button for change fuel (WOOD(w) / PELLETS(p))

Main menu on BioTec Plus boiler control unit is composed of two parts - changeable part (1a and 1b) and static part (2). By pressing button for change fuel (see image below) displayed parameter will be changed. Displaying parameters can be changed regardless of boiler working phase and which fuel are choosen as active for work.

1a - WOOD(w) menu (changeable menu) - menu for using parameters at wood firing (left side of the boiler) 1b - PELLETS(p) menu (changeable menu) - menu for using parameters at wood pellet firing (right side of the boiler) 2 - static part of main menu - this part of main menu is always same

Technical instructions BioTec Plus

Page 53

Using of BioTec Plus boiler are consist of using of left part of the boiler (fuel: wood) and using of right part of the boiler (fuel: wood pellets). On boiler control unit is necessary to choose which side of the boiler will be used (which fuel will be used). Below is shown procedure for choosing boiler side for work when is boiler turned off (working phase „OFF”).

PROCEDURE FOR CHOOSING BOILER SIDE FOR WORK (USED FUEL): Example: Selecting wood pellets for active fuel (right side of the boiler).

Left and right side of the boiler have indicators (A and B) which shows which of these two side are active (which fuel are choosen). Active side have green indicator, inactive side have red indicator (red „x”). On figure above is example for switching from left side of the boiler to the right side of the boiler (from wood to wood pellets). It’s necessary to press and hold for 3 seconds indicator on inactive boiler side (figure 1, indicator B). On display will be displayed message „Do you want choose wood pellets for active fuel?” (figure 2). Press „OK” button (figure 2). Now left side of the boiler have red inactive indicator, right side of the boiler have green indicator of activity (figure 3.).

8.1.5. CHOOSING BOILER SIDE (choosing fuel)

Technical instructions BioTec Plus

Maintenez ce bouton pour 3s!

A B

Page 54

8.1.6. TAKING OVER

Note: Option „Taking over” is possible only from left side of the boiler (fuel: wood) to right side of the boiler (fuel: wood pellets) (wood pellets taking over wood).

„Taking over” option is used for automatic switching operation from one fuel to another fuel. Automatic switch is possible only from wood to wood pellets. For use of „Taking over” option is neccesary to activate it (see „Activating „Taking over” option”).

„Taking over” option works on the way that when left part of the boiler (fuel: wood) runs out of the fuel, right side of the boiler (fuel: wood pellets) automatic take over work activity and right side of the boiler (fuel: wood pellets) continues with work.

ACTIVATING „TAKING OVER” OPTION

Activating „Taking over” option can be done on two ways: a) through main menu (menu: WOOD(w), „Taking over” submenu) b) through main screen by pressing boiler side status indicator

a) activating „Taking over” option through main menu

On main menu (menu: WOOD(w)) (see Point „8.1.4. Main menu”) choose submenu „4. Taking over”, select „Pellet On” and confirm it by pressing „Confirm” button.

Technical instructions BioTec Plus

Page 55

Hold this button for 3s!

a) activating „Taking over” option through main screen (boiler side activity indicator)

Press green activity indicator on right boiler side (fuel: wood) and hold it for 3 seconds. On display will be desplayed „Do you want to ENABLE „pellets take over?”. Confirm it by pressing „Confirm” button.

Hold this button for 3s!

Technical instructions BioTec Plus

Page 56

8.2. USE THE LEFT SIDE OF THE BOILER - FUEL: WOOD

8.2.1. IGNITION

Boiler must not be used in flammable and explosive environment. It must not be used by children or disabled persons (either physically or mentally), as well as by person without knowledge or experience, unless they are under control or trained by s person responsible for their safety. Children must be supervised in the vicinity of the product. Protective gloves must be used!

Protective gloves must be used!

NOTE:

Before ignition make sure that is left side of the boiler selected like active (see indicator „A” on figure below) (for procedure for choosing boiler side for work (used fuel) view point 8.0. „Boiler use” in this technical instructions).

IGNITION PHASE:

- Open upper and middle boiler doors (see pages 4 i 5 in this technical instructions”)

Follow these steps for succesfull igniton phase:

- press button for boiler start

- on display will be displayed window for boiler start

- press ”OK” button

Technical instructions BioTec Plus

Page 57

Primary and secondary wings seeking initial position. Please

wait and try again.

- if this message is shown on display than wait for primary and secondary air actuators

- primary and secondary air is ready for work when indicator stop blinking

Primary and secondary air indicators.

- on display is displayed message "IGNITION 1/3"

- cover the refractory stone with one row

of wood logs (be careful to not plug hole on refractory stone (detail A)

- cover the wood logs with fine chopped wood (use enough fine chopped wood to cover wood logs below)

- height of fine chopped wood layer must conform a approx. height of first row of wood logs

- cover the fine chopped wood with crumped paper (use enough crumpled paper to cover fine chopped wood) (detail B)

- place the wood logs on crumpled paper

- fill the fuel loading chamber with wood logs (detail C)

- close upper and lower doors

- leave middle door opened

- ignite the fire throuh middle boiler door (detail C)

- press enter button” “

Technical instructions BioTec Plus

Page 58

- on display is displayed message "IGNITION 3/3"

- close middle boiler door

- press ”enter” button

- on display is displayed message "IGNITION 2/3"

- on this step is neccessary to wait until flue gas temperature raise 50°C

- middle boiler door must be opened all time

- when is flue gas temperature higher than 50°C press ”enter“ button

Technical instructions BioTec Plus

Page 59

Additional:

During ignition phase is possible to see main display. It is neccessary to press button. Because ignition phase is on proces, display will be displayed current ignition step to (1). By pressing button we return to full preview of ignition phase.

Technical instructions BioTec Plus

Page 60

8.2.2. REFILLING

PHASE OF REFILLING FUEL LOADING CHAMBER:

For successful refilling of the fuel loading chamber follow the next steps:

When on display is displaying boiler operating phase „GLW2" that is mean the boiler have spent all the fuel and it’s remaining only glow in the fuel loading chamber.

In this step is neccessary to open upper boiler door and check if it glow quality good enough for firing continue and refilling wood loading chamber or it is necessary to go on ignition phase again.

When you open upper boiler door (see pages 4 i 5 in this technical instructions) than is displayed boiler operation phase „DOP0".

If you estimate that the glow is good enough for refilling wood load chamber with fuel it’s neccessary to folow next steps. If you estimate that the glow is not good enough for refilling wood load chamber follow steps in point „Procedure if glow is not enough good”. After glow checking is neccessary to close upper boiler door.

Protective gloves must be used!

Technical instructions BioTec Plus

GLW2

DOP0

Page 61

Press button „START / STOP“, on display will be displayed window with offered options „NEW LOADING“ and „OFF“. Press button „NEW LOADING“.

On display is displaying boiler operating phase „SP1".

Description of the refilling wood loading chamber:

- open upper boiler door (see pages 4 i 5 in this technical instructions).

- align the glow with scraper

- based on estimates of glow quality and amount of glow put more or less dry thin wood (depend about estimate) and after that fill the wood loading chamber with wood

- close upper boiler door (see pages 4 i 5 in this technical instructions)

ACTION:

NEW LOADING

OFF

GLW2

Technical instructions BioTec Plus

SP1

Page 62

Press button „START / STOP“, on display will be displayed window with offered options „NEW LOADING“ and „OFF“. Press button „OFF.

Wait until on display is displayed boiler operating phase „OFF”.

Go to the ignition phase like is described in point „IGNITION” in this technical instructions.

PROCEDURE IF GLOW IS NOT ENOUGH GOOD

If glow is not enough good for fuel refilling folow the next steps:

ACTION:

NEW LOADING

OFF

GLW2

Technical instructions BioTec Plus

Page 63

8.3. USE THE RIGHT SIDE OF THE BOILER - FUEL: WOOD PELLETS

Protective gloves must be used!

NOTE:

Before ignition make sure that is right side of the boiler selected like active (see indicator „A” on figure below) (for procedure for choosing boiler side for work (used fuel) view point 8.0. „Boiler use” in this technical instructions).

BOILER START:

For boiler start is neccesary to press ON / OFF button. After pressing ON / OFF button on display will be displayed window for boiler start confirmation. Press „OK” to confirm boiler start.

Technical instructions BioTec Plus

Page 64

BOILER STOP:

For boiler stop is neccesary to press ON / OFF button. After pressing ON / OFF button on display will be displayed window for boiler stop confirmation. Press „OK” to confirm boiler stop.

Technical instructions BioTec Plus

Page 65

8.3.1. REFFILING OF WOOD PELLETS

Wood pellet is manual filling on right upper side of the boiler (pellet part) (see figure below). It’s necessary to open casing cover using the handle.

IMPORTANT: At filling wood pellet tank it must be filled at least 2/3 of capacity for correct work of wood pellet level sensor!

Technical instructions BioTec Plus

Page 66

x.x.x. TEMPERATURE ADJUSTMENT 8.4. TEMPERATURE ADJUSTMENT

Temperature adjustment are performed seperately for left (fuel: wood) and right (fuel: wood pellets) side of the boiler. For adjustment left side of the boiler (fuel: wood) temperature it’s necessary to choose menu for wood firing (WOOD(w)). For adjustment right side of the boiler (fuel: wood pellets) temperature it’s necessary to choose menu for wood pellet firing (PELLETS(p)).

Fuel: Wood

SUBMENUS:

1. w.Boiler temperature

In this submenu is possible to adjust boiler working temperature.

- Factory adjusted: 85°C

- Adjustment range: 75°C - 90°C

2. w.Differential Boiler

In this submenu is possible to adjust differential for boiler working temperature.

- Factory adjusted: 5°C

- Adjustment range: 5°C - 7°C

3. Minimal buffer tank temperature

In this submenu is possible to adjust minimal buffer tank temperature.

- Factory adjusted: 20°C

- Adjustment range: 5°C - 85°C

This submenus depend about DHW configuration

TEMPERATURE ADJUSTMENT FOR WOOD FIRING

Technical instructions BioTec Plus

Page 67

4. DHW temperature (depend about DHW configuration)

In this submenu is possible to adjust domestic hot water temperature.

- Factory adjusted: 50°C

- Adjustment range: 40°C - 80°C

5. Differential of DHW (depend about DHW configuration)

In this submenu is possible to adjust differential of domestic hot water temperature.

- Factory adjusted: 5°C

- Adjustment range: 4°C - 40°C

6. Return flow temperature

In this submenu is possible to adjust return flow temperature.

- Factory adjusted: 60°C

- Adjustment range: 60°C - 70°C

Technical instructions BioTec Plus

Page 68

Fuel: Wood pellets

This submenus depend about DHW configuration

Submenus:

1. p.Maximal boiler temperature

In this submenu is possible to adjust maximal boiler working temperature.

- Factory adjusted: 80°C

- Adjustment range: 70°C - 90°C

2. p.Buffer tank temperature

In this submenu is possible to adjust buffer tank temperature.

- Factory adjusted: 80°C

- Adjustment range: 40°C - 85°C

3. p.Differential buffer tank temperature

In this submenu is possible to adjust differential for buffer tank temperature.

- Factory adjusted: 10°C

- Adjustment range: 5°C - 30°C

4. p.Differential stop buffer tank temperature

In this submenu is possible to adjust differential stop for buffer tank temperature.

- Factory adjusted: 5°C

- Adjustment range: 3°C - 30°C

TEMPERATURE ADJUSTMENT FOR WOOD PELLET FIRING

Technical instructions BioTec Plus

Page 69

5. Minimal buffer tank temperature

In this submenu is possible to adjust buffer tank temperature.

- Factory adjusted: 20°C

- Adjustment range: 5°C - 85°C

6. DHW temperature (depend about DHW configuration)

In this submenu is possible to adjust domestic hot water temperature.

- Factory adjusted: 50°C

- Adjustment range: 40°C - 80°C

7. Differential of DHW (depend about DHW configuration)

In this submenu is possible to adjust differential for domestic hot water temperature.

- Factory adjusted: 5°C

- Adjustment range: 4°C - 40°C

8. Return flow temperature

In this submenu is possible to adjust return flow temperature.

- Factory adjusted: 60°C

- Adjustment range: 60°C - 70°C

Technical instructions BioTec Plus

Page 70

9.0. CLEANING AND MAINTENANCE OF THE BOILER

Every millimeter of soot and dirt on the surfaces of the boiler surface means approx. 5% higher fuel consumption. Save fuel – clean the boiler on time!

PROTECTIVE GLOVES ARE OBLIGATORY!!!

DESCRIPTION OF MAINTENANCE

INTERVAL

Cleaning ash in firebox and under firebox (through middle and lower door - left part of the boiler) and ash tray emptying from right part of the boiler.

Before each ignition.

Flue gas tube cleaning. Before refilling of fuel / before ignition.

Checking correctness of security valve. Every 6 months.

Cleaning of flue gas chamber. At least once per year.

Cleaning and checking the flue installation sealing. At least once per year.

At least once per year.

Cleaning of area over heat exchanger pipes with turbulators.

Cleaning the blades and box of the fan. At least once per year.

Photocell cleaning. At least once per year.

Technical instructions BioTec Plus

Page 71

Cleaning / maintenance interval

Boiler type Description

Before each ignition

25, 35 and 45 kW

Cleaning ash in firebox and under firebox (through middle and lower door - left part of the boiler) and ash tray emptying from right part of the boiler.

Before every ignition is necessary to clean area below firebox and lower refractory stone (DS) (through middle and lower boiler door (DV)) and empty ashtray (PA) from the side of the right boier. Before cleaning is necessary to turn on option "cleaning". Fan will work at maximun speed to reduce the spread of dust to the room. When you finish cleaning, press the "STOP" button. If time of 30:00 minutes has expired cleaning option (fan) will automatically turn off.

1. Press button ”Cleaning“ on main screen

2. Press button ”OK“

3. Open front boiler door (VI).

4. Open middle boiler door

5. Open lower boiler door (DV).

6. Insert the ashtray to the middle gate (1) and clean up firebox with scraper and push the ash on the ashtray.

7. Insert the ashtray under lower door and use scraper to clean refractory stone(DS) and push ash on the astray.

8. Empty ashtray

9. Take out ash tray (PA) from right side of the boiler.

10. Empty ashtray (PA) and place it back.

11. After cleaning, the boiler is ready for ignition.

Cleaning / maintenance interval

Boiler power Description

Before refilling of fuel / before

ignition

25, 35 and 45 kW

Flue gas tubes cleaning

For flue gas tubes cleaning in necessary to pull lever (ZP) few times.

1 2

Technical instructions BioTec Plus

Page 72

Lateral opening for cleanign the

flue gas chamber (on left side of the boiler)

BioTec Plus

1 2 3

Checking the correctness of security valve

By briefly turning the cap of safety valve (C) check whether water coming out from the safety valve. If no water comes out after several repeated checks, then is necessary to replace the safety valve.

Cleaning / maintenance interval

Boiler power Description

Every 6 months

25, 35 and 45 kW

Check the correctness of security

valve

Cleaning / maintenance interval

Boiler power Description

At least once per year.

25, 35 and 45 kW

Cleaning of flue gas chamber.

1 - Switch off the boiler and disconnect from electric. power. 2 - Before cleaning flue gas chamber, pull lever (ZP) few times (see ”flue gas tubes cleaning“) 3 - Take out insulation cover, unscrew two screws which hold door of flue gas chamber. 4 - Insert ashtray and clean the flue gas chamber with scraper. 5 - Put the doors and insulation cover to original position.

Note: For the proper operation of the boiler it is IMPORTANT to hard tight the doors how it to seal perfectly!

Before this procedure be sure to disconnect boiler from electric. power!!!

Cleaning / maintenance interval

Boiler power

Description

At least once per year

25, 35 and 45 kW

Cleaning and checking the

flue installation sealing

Clean flue installation between the boiler and the chimney through the revision openings for cleaning or if not incorporated revision opened by removing the flue installation. After cleaning, inspect flue installation good sealing and seal it if the seal is not satisfactory.

Cleaning and checking the flue installation sealing

Before this procedure be sure to disconnect boiler from electric. power!!!

Technical instructions BioTec Plus

Page 73

Cleaning / maintenance interval

Boiler power Description

At least once per year

25, 35 and 45 kW

Cleaning of area over heat

exchanger pipes with turbulators

Metal vacuum cleaner

1 - Switch off the boiler and disconnect from electric. power. 2 - Take out last upper cover side. 3 - Open the flue gas chamber. 4 - Use the metal vacuum cleaner to clean dust and ash in flue gas chamber.

Before this procedure be sure to disconnect boiler from electric. power!!!

Metal tube

Technical instructions BioTec Plus

Page 74

Cleaning / maintenance interval

Boiler power Description

At least once per year

25, 35 and 45 kW

Cleaning the blades and box of

the fan

1. Switch off the boiler and disconnect from electric. power.

2. Unscrew nuts (A) shown in Image 1.

3. Relase screws (B) shown in Image 2.

4. Pull out fan with flange to the end od rail, then open it to left side (see Image 2. and Image 3.).

BioTec Plus 25, 35

BioTec Plus 45

1. Switch off the boiler and disconnect from electric. power.

2. Unscrew nuts (A) shown in Image 1.

3. Relase screws (B) shown in Image 2.

4. Pull out fan with flange to the end od rail, then open it to left side (see Image 2. and Image 3.).

Before this procedure be sure to disconnect boiler from electric. power!!!

1. 2.

Technical instructions BioTec Plus

Page 75

Cleaning / maintenance interval

Boiler type

Description

At least once a year

(or if you have problems

with the ignition)

25, 35 and 45 kW

Photocell cleaning

Dirty photocell which can result error in ignition or flame dissapear error

Valid photocell

Carefully remove the photocell from the box and then gently with a cotton swab clean the body and lens of photocell. After cleaning, carefully return photocell to work position.

57mm

The photocell should not be set too deep or too shallow in the box. So, limiter determines the proper depth of photocell position. Make sure the limiter is set to black mark. Black mark should be barely visible (see image below).

Limiter

Screw

Mark

The limiter must be set so that the black mark is barely visible like is shown below (partially covered by hose clamps)

Technical instructions BioTec Plus

Page 76

1 2 3 4 5 6

Error / Warning / Information code Error / Warning / Information name Date and time of error / warning / information occurrence Number of errors / warnings / informations „OK” button Buttons for scrolling through errors / warning / informations

Minimized window on main display

By pressing „OK” button error window will be minimized and showned on main display.

10.1 ERRORS/WARNINGS/INFORMATIONS ON THE MAIN SCREEN

All errors/warnings are recorded in history (see point 10.2.History)

3 4

When the error/warning still present, error/warning name and code

is painted red, and when error/warning is resolved, text turns green

10.0. MALFUNCTIONS

Technical instructions BioTec Plus

Page 77

10.2. HISTORY

By pressing on „History” button will be opened menu for choosing history list. It can be choosen between error list and warning list. Informations history are placed with error list.

Written is:

- time of occurrence errors / warnings / informations

- error / warning / information code

- description of the error / warning / information.

The first press on the field error/warning/information field is indicated, in addition to see and date generated errors/warnings/information. The second press on the selected error/ warning/information, prints a detailed description of the error/warnings/information and corrective action errors/warnings/information. If for some error/warning/information there is no description on current software version, on the screen will be displayed ”empty“.

Errors list

Warnings list

Technical instructions BioTec Plus

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10.3. ERROR LIST

MUTUAL ERRORS (WOOD / WOOD PELLETS):

E11

Memory error

Possible causes: Call service man!

ERROR

NAME DESCRIPTION

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes:Interruption on el. connections between

sensor and boiler, connection to the boiler, cold connection or DHW sensor is invalid.

DHW sensor error

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Interruption on el. connections between

sensor and boiler, cold connection or buﬀer tank sensor (up) is invalid.

Buﬀer tank sensor error (Up)

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Interruption on el. connections between

sensor and boiler, cold connection or buﬀer tank sensor (down) is invalid.

Buﬀer tank sensor error (Down)

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Interruption on el. connections between

sensor and boiler, cold connection or invalid ﬂue gas sensor.

Flue gas sensor error

Boiler status: Boiler work normally, problem appears on work of CM2K regulator if is installed. Possible causes: Interruption on el. connections between sensor and boiler (CM2K), cold connection or invalid outside temperature sensor.

Outside temperature sensor error

Possible causes: Interruption on el. connections between sensor and boiler, cold connection or invalid main ﬂow sensor.

Main ﬂow sensor error

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Interruption on el. connections between

sensor and boiler, connection to the boiler, cold connection or invalid return ﬂow sensor.

Return ﬂow sensor error

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Interruption on el. connections between

sensor and boiler, connection to the boiler, cold connection or invalid sensor.

Boiler sensor error (Wood)

Unknown boiler power

Boiler status: Boiler immediate go to phase OFF. Possible causes: Key for power loading is not installed or

recognized, cold connection or invalid key.

E10

Fan error

Boiler status: Boiler immediate go to phase OFF. Possible causes: Invalid fan or rpm counter (integrated in

fan housing) or safety thermostat is interrupt el. supply to fan because of too high temperature in the boiler.

Technical instructions BioTec Plus

Page 79

E13

Communication error with sensor board

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Call service man!

E14

Lambda probe error

a) Error occurs in the phase of "OFF" The problem is with el. heater which is integrated into the lambda probe b) Error occurs in all phases except "OFF” The problem is with the communication system within the lambda(Cables, connectors, el. boards, software)

E16

Communication error with CM2K module (1st and 2nd circuit)

Boiler status: Boiler work normally. Possible causes:Interruption in el. connections between

boiler and CM2K (between two CM2K’s), connection on boiler and CM2K (or two adjecent CM2K’s) or CM2K module is invalid.

E17

Sensor reg. 1. circuit

Boiler status: Pump of 1+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 1+ heating circuit (on regulator CM2K).

E18

Corrector reg. 1. circuit

Boiler status: Pump of 1+ heating circuit work in intervention mode by heating curve. Boiler work normally. Possible causes: Error on room corrector of 1+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E19

Sensor reg. 2. circuit

Boiler status: Pump of 2+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 2+ heating circuit (on regulator CM2K).

E20

Corrector reg. 2. circuit

Boiler status: Pump of 2+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 2+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E24

Boiler status: Boiler work normally. Possible causes: Interruption on el. connections between

room corrector and boiler, connection to the boiler or room corrector is invalid.

Room corrector

E22

Flue gas temperature too high

Boiler status: Boiler goes to phase „OFF”. Possible causes: Flue gas tubes are dirty (wood side),

invalid ﬂue gas sensor, bad sealing, open middle boiler door (wood side).

E12

Communication error with motherboard

Boiler status: Boiler immediate go to phase OFF. Possible causes: Call service man!

E26

Boiler status: Boiler work normally. Intervention mode: Boiler work to content heating demand

but boler has reduced possibilities. Possible causes: Interruption on el. connections between ﬁrebox sensor and boiler or bad connection to the boiler.

Firebox sensor disconnected

Technical instructions BioTec Plus

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E27

Boiler status: Boiler work normally. Possible causes: Interruption on el. connections between

room corrector and boiler, connection to the boiler or hydraulic crossover sensor is invalid.

Hydraulic crossover sensor error

E16_1

Boiler status: Boiler work normally. Possible causes:Interruption in el. connections between

boiler and CM2K (between two CM2K’s), connection on boiler and CM2K (or two adjecent CM2K’s) or CM2K module is invalid.

Communication error with CM2K module (3rd and 4th circuit)

E17_1

Sensor reg. 3. circuit

Boiler status: Pump of 3+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 3+ heating circuit (on regulator CM2K).

E18_1

Corrector reg. 3. circuit

Boiler status: Pump of 3+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 3+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E19_1

Sensor reg. 4. circuit

Boiler status: Pump of 4+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 4+ heating circuit (on regulator CM2K).

E20_1

Corrector reg. 4. circuit

Boiler status: Pump of 4+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 4+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E16_2

Boiler status: Boiler work normally. Possible causes:Interruption in el. connections between

boiler and CM2K (between two CM2K’s), connection on boiler and CM2K (or two adjecent CM2K’s) or CM2K module is invalid.

Communication error with CM2K module (5rd and 6th circuit)

E17_2

Sensor reg. 5. circuit

Boiler status: Pump of 5+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 5+ heating circuit (on regulator CM2K).

E19_2

Sensor reg. 6. circuit

Boiler status: Pump of 6+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 6+ heating circuit (on regulator CM2K).

E18_2

Corrector reg. 5. circuit

Boiler status: Pump of 5+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 5+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

Technical instructions BioTec Plus

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E20_2

Corrector reg. 6. circuit

Boiler status: Pump of 6+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 6+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E16_3

Boiler status: Boiler work normally. Possible causes:Interruption in el. connections between

boiler and CM2K (between two CM2K’s), connection on boiler and CM2K (or two adjecent CM2K’s) or CM2K module is invalid.

Communication error with CM2K module (7rd and 8th circuit)

E17_3

Sensor reg. 7. circuit

Boiler status: Pump of 7+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 7+ heating circuit (on regulator CM2K).

E18_3

Corrector reg. 7. circuit

Boiler status: Pump of 7+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 7+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E19_3

Sensor reg. 8. circuit

Boiler status: Pump of 8+ heating circuit doesn't work. Boiler work normally. Possible causes: Error on ﬂow temperature sensor of 8+ heating circuit (on regulator CM2K).

E20_3

Corrector reg. 8. circuit

Boiler status: Pump of 8+ heating circuit work in intervention mode by heating curve. Boiler work normally.

Possible causes:

Error on room corrector of 8+ heating circuit (CM2K regulator), bad corrector connection to the CM2K or room corrector failure.

E28

Communication error with CMGSM

Boiler status: Boiler work normally. Possible causes: Interruption in el. connections between

boiler and CMGSM or invalid CMGSM module.

E29

Communication error with motherboard 2

Boiler status: Boiler goes to phase „OFF”. Possible causes: Call service man!

Technical instructions BioTec Plus

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WOOD FIRING ERRORS:

ERROR

NAME DESCRIPTION

Ew21

Firebox sensor

Boiler status: Boiler work normally. Intervention mode: Boiler work to content heating demand

but boiler has reduced possibilities.

Possible causes: Invalid ﬁrebox sensor.

WOOD PELLETS FIRING ERRORS:

Ep31

Photocell error

Ep32

Safety pressure switch

Ep33

No ﬂame in ignition phase

Ep34

Flame disappeared working phase

Ep35

Error grate cleaner

Ep36

Fuel level

Ep37

Flame disappeared at ignition stage

ERROR

NAME DESCRIPTION

Boiler status: Boiler go to phase OFF after ending phase S0 (retry start is allowed). Possible cause: Invalid photocell (sending information that ﬂame exist in phase S0).

Boiler status: Boiler immediate go to phase OFF. Possible causes: Firebox resistance is too high in phases

S2, S3, S4, (S5). It’s open any door or opening on boiler. Interruption in el. connection between safety pressure switch and boiler, connection to the boiler, cold connection or invalid safety pressure switch. Interruption or bad sealing of safety pressure switch pipe.

Boiler status: Boiler immediate go to phase OFF.

Boiler status: Boiler go to phases S7, C0 and OFF.

Boiler status: Boiler immediate go to phase OFF.

Ep38

Flame disappeared stabilization stage

Ep39

Fuel sensor

Boiler status: Boiler immediate go to phase OFF.

Ep40

Error ﬂap not closed

Boiler status: Boiler work normally. Possible causes: Check if the ﬂap is blocked with pellets , if

the sensor is soiled with dust , if the sensor is about 1 mm distant from the ﬂap , if the sensor reacts on the ﬂap ( the LED lamp is switching on the sensor ).

Technical instructions BioTec Plus

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Ep41

No pellets

Ep42

Mole or screw not working

Ep43

Communication error with CMVAC

Ep45

Wood in ﬁrebox or incorrect adjustment of pellet side.

Ep46

Upper door opened wood side

Ep44

Boiler sensor error (pellet)

Boiler status: Boiler work normally. Possible causes: Check the pellet level in the big

tank/room , check if the ﬂexible tubes are blocked, check if the turbine net is full with dust.

Boiler status: Boiler work normally. Possible causes: Check the electric connections on the

mole/feeder screw, check the ﬁlthiness of the mole/feeder screw.

Boiler status: Boiler work normally. Possible causes:Check the UTP cable and its connections

with the electric boards.

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Interruption on el. connections between

sensor and boiler, connection to the boiler, cold connection or invalid sensor.

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Existing of larger quantity of wood in

ﬁrebox (wood side) during burner work (wood pellet side) or incorrect adjustment of pellet side.

Boiler status: Boiler go to phases S7, C0 and OFF. Possible causes: Upper boiler door are opened (wood

side) during burner work (wood pellet side) after warning time Wp15 expire, invalid microswitch - upper boiler door (wood side).

Ep47

Screw reﬁll

Boiler status: Boiler work normally. Possible causes: No pellets in CPSP-BP tank for reﬁlling,

problem with feeder screw in CPSP-BP, interruption on el. connection between boiler and feeder screw, connection to the boiler.

Technical instructions BioTec Plus

Page 84

10.4. WARNING LIST

MUTUAL WARNINGS (WOOD / WOOD PELLETS):

Factory settings loaded.

WARNING

NAME DESCRIPTION

Appear always when fan decrease rotating speed or if turning ”OFF“ itself because of high ﬂue gas temperature.

The boiler operates without using the lambda probe.

The boiler operates without using the ﬂue gas sensor.

It can occur only if the conﬁguration contain ”Protection valve”. The boiler will resume normal work (the cause should be removed because boiler condensation will occur and ﬂue passes will clog up). The problem may be with 3way mixing valve (protection valve) / motor drive / sensor of return ﬂow temperature.

The temperature accumulation tank is lower than the desired which allow pump work.

Factory setting loaded

W10

W12

Fan protection

Intervention work (Lambda sensor)

Intervention work (Flue gas sensor)

Low return temperature

Low buﬀer temperature

WOOD FIRING WARNINGS:

WARNING

NAME DESCRIPTION

Boiler working (wood side), upper boiler door is opened and ﬂue gas temperature is too high. It’s necessary to close upper boiler door.

The boiler operates without using the RPM (rotates per minute) sensor.

Bad ignition, too damp wood, non-closed middle or lower door, non-closed side covers for cleaning or rear top cover for cleaning), impassable ﬂue pipe from the fan to the chimney, blocked passes for the primary or secondary air between the upper and middle boiler door. Check and close the insuﬃciently sealed openings and if necessary ﬁll and start the boiler again, if you don’t help these actions, call an authorized service to check primary / secondary openings.

Ww2

Ww7

Ww8

Flue gas temperature high. Close the upper door!

Intervention work (RPM sensor)

Ignition error

The boiler operates without using the ﬁrebox sensor.

Intervention work (Firebox sensor)

Technical instructions BioTec Plus

Page 85

WOOD PELLETS FIRING WARNINGS:

WARNING

NAME DESCRIPTION

Boiler status: Boiler will be work for a while, if pellet tank don’t be reﬁlled with pellets will be shown „E22 Fuel level” what’s mean that is no enough fuel for continue of boiler work. Possible causes: Low fuel level in pellet tank, enough for short time.

Wp13

Fuel level

Upper boiler door are opened (wood side) during burner work (wood pellet side), if time counter expire then will be showned error Ep46.

Wp15

Upper door opened wood side

Too high ﬂue gas temperature with the open upper boiler door. Close the uper door and restart the boiler (load fuel if is necessary).

No fuel.

Ww9

Ww11

Fan is OFF, ﬂue gas temperature is to high. Close the upper door!

Out of fuel

Technical instructions BioTec Plus

Page 86

10.5. INFORMATION LIST

MUTUAL INFORMATIONS (WOOD / WOOD PELLETS):

INFO.

NAME

Power up (Power down)

WOOD FIRING INFORMATIONS:

INFO.

NAME

Iw1

Oﬀ during ignition

Iw2

Ignition automaticly proceeded

Iw3

Bad ignition

Iw4

Oﬀ during stabilization

Iw6

Glow after power up

Iw7

Oﬀ after power up

WOOD PELLETS FIRING INFORMATIONS:

INFO.

NAME

Ip8

Reﬁll

Ip9

Flame disappeared in ignition phase

Ip9_1

Retry ignition

Ip10

No ﬂame in stabilization stage

Ip10_1

Retry ignition

Ip11

Pellet supply tube temperature too high

Ip12

Flame disappeared working phase

Ip12_1

Retry ignition

Technical instructions BioTec Plus

Page 87

Technical instructions BioTec Plus

Page 88

HEATING TECHNIQUE

www.centrometal.hr e-mail: [email protected]

Centrometal d.o.o. Glavna 12, 40306 Macinec, Croatia

central tel: +385 40 372 600, fax: +385 40 372 611 service tel: +385 40 372 622, fax: +385 40 372 621

Company assumes no responsibility for possible inaccuracies in this book originated typographical errors or rewriting, all the pictures and diagrams are principal and it is necessary to adjust each actual situation on the field, in any case the company reserves the right to enter their own products such modifications as considered necessary.