Guntamatic BIOCOM Installation Instructions Manual
Pellet boiler englisch
BIOCOM
Installation instructions
BC-A-00-00-00-01-IAEN
EN-B31-007-V10-0711
BIOCOM Installation Instructions
2
Information on this documentation
BS-B-00-00-00-01-IAEN
Please read through this documentation carefully.
It is intended as a reference document and contains important
information on the design, safety, operation, maintenance and
care of your heating system.
We are always looking to improve our products and
documentation. Any ideas and suggestions you may have will
be gratefully received.
GUNTAMATIC Heiztechnik GmbH
a Georg Fischer Group Company
Bruck 7
A-4722 PEUERBACH
Tel: 0043 (0) 7276 / 2441-0
Fax: 0043 (0) 7276 / 3031
E-mail: info@guntamatic.com
It is important that you pay particular
attention to the safety issues highlighted in
the text by these symbols.
The entire contents of this document are the property of
GUNTAMATIC and therefore protected by copyright.
Reproduction of any kind, communication to third parties by
any means or use for purposes other than those intended
without the written consent of the owner is prohibited.
Subject to printing errors and technical amendments.
BIOCOM Installation Instructions
3
Installation instructions
BC-C-00-00-00-01-IAEN
Page
1 Introduction..........................................................4
1.1 Safety instructions 4
1.2 Guarantee 4
1.3 Commissioning 4
1.4 Site requirements 4
1.4.1 Fire safety
(minimum fire safety requirements)
5
1.4.2 Boiler room requirements 7
1.4.3 Flue requirements 8
1.4.4 Fuel store requirements 9
2 Installation and assembly .................................11
2.1 Delivery 11
2.2 Carrying to installation site 11
2.3 Positioning and aligning the boiler 11
2.4 Plumbing connections 12
2.5 Filling and bleeding the system 15
2.6 Connecting the flue 16
2.7 Energy saving draught regulator with pressure-surge
compensator 17
2.8 Installing the fuel outfeed system 18
2.8.1 FLEX system 18
2.8.2 BOX system 21
3 Electrical connections.......................................22
3.1 Electrical connections to the heating system 22
3.2 Wiring requirements 23
3.3 Electrical connections 24
4 Final checks/Commissioning............................27
5 Standards/Regulations......................................28
6 Plumbing diagrams...................................... 29-45
7 Electrical wiring diagram ..................................46
7.1 Control panel 46
7.2 Wall controller set MK261 47
7.3 Boiler circuit board 48
8 Technical data....................................................49
8.1 BIOCOM 30-100 49-50
8.2 FLEX outfeed system 51
8.3 BOX outfeed system 51
BIOCOM Installation Instructions
4
1 Introduction
BS-01-00-00-00-01-IAEN
1.1 Safety instructions
BS-01-01-00-00-01-IAEN
GUNTAMATIC heating systems represent state-of-the-art
technology and meet all applicable safety regulations.
Incorrect installation can endanger life and limb. Heating
boilers are combustion systems and are potentially dangerous
if handled incorrectly. Installation, commissioning and
servicing must, therefore, only be carried out by adequately
qualified technicians observing all regulations and the
manufacturer's instructions.
1.2 Guarantee and warranty
BS-01-02-00-00-01-IAEN
The manufacturer's guarantee is subject to correct installation
and commissioning of the heating system. Defects and
damage caused by incorrect installation, commissioning or
operation are not covered by the guarantee. To ensure that
the system functions as intended, the manufacturer's
instructions must be followed. Furthermore, only genuine
replacement parts or parts explicitly approved by the
manufacturer may be fitted to the system.
1.3 Commissioning
BS-01-03-00-00-01-IAEN
Commissioning of the boiler must be carried out by an
authorised GUNTAMATIC specialist or other qualified
persons. They will check whether the system has been
installed according to the plans, adjust the system settings as
required and explain to the system operator how to use the
heating system.
1.4 Site requirements
BS-01-04-00-00-01-IAEN
When establishing the site requirements, it is absolutely
essential to take account of the locally applicable planning,
building and implementation regulations and the dimensional
specifications in the fitting guidelines, installation examples
and technical data. Compliance with the locally applicable
regulations and the correct implementation of the measures
required on site are solely the responsibility of the system
owner and are a requirement of the manufacturer's guarantee.
GUNTAMATIC provides no guarantee of any kind for any type
of site work. Without making any claims as to completeness or
non-applicability of official requirements, we recommend the
following specifications based on the Austrian Guidelines pr
TRVB H 118:
BIOCOM Installation Instructions
5
1.4.1 Fire safety
BS-01-04-01-00-01-IAEN
If the installation site is not subject to any other fire safety
requirements, the GUNTAMATIC minimum fire safety
requirements must always be observed. If the installation site
is subject to stricter requirements than the minimum fire safety
requirements specified here, then the stricter requirements
must always be observed without exception.
Caution: Compliance with the GUNTAMATIC minimum fire safety
requirements is subject only to verification by the operator.
The operator alone is responsible for strict compliance.
Verification during commissioning is not provided for.
Caution: National regulations must also be complied with.
National regulations Austria: F90/T30
State legislation of the federal states
Technical Directive on Preventative Fire Safety pr TRVB H118
Germany: No requirements for systems up to 50 kW
Standard boiler regulations (M-FeuVO)
Hessen and Saarland – in these states §16 FeuVO Hessen
applies
Switzerland:
Fire safety regulations (www.vkf.ch)
France:
Relevant fire safety authority
Italy:
Relevant fire safety authority
BIOCOM Installation Instructions
6
Minimum fire safety requirements
BS-01-04-01-01-01-IAEN
BS-01-04-01-02-01-IAEN
Boiler room Floor of concrete construction, either bare or tiled. All
materials for floor, walls and ceiling must be fire-resistant to
F60 rating. If a fabric hopper is installed in the boiler room (not
allowed in all countries), the floor walls and ceiling must be
F90-rated. The boiler room door must be a Class T30 fire door
which opens in the direction of escape and is self-closing.
Connecting doors to the fuel storeroom must also be Class
T30 fire doors, self-closing and lockable. There must be no
direct connection to rooms in which flammable gases or
liquids are stored (e.g. garage).
BS-01-04-01-03-01-IAEN
Fuel storeroom The same minimum fire safety requirements apply as for the
boiler room.
Storeroom doors/hatches: Storeroom doors/hatches must
be fire safe to Class T30, self-closing and lockable. There
must be a warning sign carrying the message "Do not enter
when feeder system is running" attached to the storeroom
door/hatch.
Fireproof collars: If the storeroom is not situated directly
adjacent to the boiler room, a fireproof collar must be fitted to
the extraction and air return pipes at their wall exit points from
the boiler room. If the outfeed auger goes directly into the
boiler room, it is factory fitted with a special fire safety lining.
No additional fireproof collars are required on the air pipes. If
the outfeed auger is sited entirely inside the storeroom (i.e. if
the outfeed auger does not extend out of the storeroom),
fireproof collars must similarly be fitted to the extraction and
air return pipes at their wall exit points from the storeroom.
Manual fire extinguisher: If 50 m³ of fuel or more can be
stored, a manually operated fire extinguishing facility must be
installed. It must be protected against freezing and connected
to a pressurised water pipe (DN20 conduit). The discharge
point must be located directly above where the fuel outfeed
channel exits the storeroom. The fire extinguishing facility
must be identified by a sign carrying the inscription "Fuel
storeroom fire extinguisher".
Filler pipes: Filler pipes through rooms where there is a fire
risk must be provided with Class F90 cladding.
BIOCOM Installation Instructions
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1.4.2 Boiler room requirements
BS-01-04-02-00-01-IAEN
PH-01-04-02-01-01-IAEN
Combustion air supply The pressure in the boiler room must not be less than 3 Pa
(0.3 mm H2O). The air vents for boiler rooms must have a
clear, net cross-sectional area of at least 200 cm² and must
not be sealable. With combustion boiler systems with a fuel
heat output upwards of 50 kW, the net, clear cross-sectional
area must be increased to at least 5 cm² per kW rated output
according to the combustion air requirement of the boiler
system. The air supply ducting must connect directly to the
outside and if the ducting passes through other rooms, it must
be jacketed to Class F90. On the outside of the building, air
vents must be covered by a protective grille with a mesh size
of > 5 mm. The supply of combustion air should, if possible,
enter at floor level in order to prevent cooling of the boiler
room.
BS-01-04-02-02-01-IAEN
Electrical installation The lighting and the electrical wiring in the boiler room must
be permanently installed. There must be a clearly marked
emergency off switch in an easily accessible position outside
the boiler room, close to the boiler-room door.
BS-01-04-02-03-01-IAEN
Fire extinguisher A hand-held fire extinguisher (6kg gross weight, EN3) must be
mounted outside the boiler room near the boiler-room door.
BS-01-04-02-04-01-IAEN
Protection against freezing The boiler room, pipes carrying water and any district heating
pipes must be protected against freezing.
BC-01-04-02-05-01-IAEN
Minimum room size PH 30, BC 40, PH 50 at least 230(240) x 240 cm (W x L)
BC 75, BC 100 at least 230(240) x 270 cm (W x L)
(Dimensions in brackets refer to systems with automatic ash extraction
system.)
BC-01-04-02-06-01-IAEN
Minimum room height BC 30, BC 40, BC 50 at least 225 cm
(with heat exchanger cover removed at least 210 cm)
BC 75, BC 100 at least 240 cm
(with heat exchanger cover removed at least 230 cm)
BC-01-04-02-07-01-IAEN
Clear access opening BC 30, BC 40, BC 50 at least 80 x 170 cm (W x H)
BC 75, BC 100 at least 100 x 190 cm (W x H)
(Dimensions refer to boiler with grate cleaner motor and stoker removed.)
Boiler dimensions
BC-01-04-02-08-01-IAEN
Without ISO BC 30, BC 40, BC 50 at least 75 x 165 cm (W x H)
BC 75, BC 100 at least 90 x 180 cm (W x H)
(Dimensions refer to boiler with casing, stoker, flue connecting pipe and ash
box removed.)
BIOCOM Installation Instructions
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1.4.3 Flue requirements
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The flue must be matched to the system in order to ensure
economical and trouble-free operation.
BS-01-04-03-01-01-IAEN
Important
BS-01-04-03-02-01-IAEN
The system must only be connected to the flue if the flue
meets the legal requirements and the technical specifications.
The flue must be matched to the boiler output and
dimensioned in accordance with DIN 4705. In order to be able
to accurately dimension the flue, the calculations must be
based on the flue gas figures. When designing new flues, high
thermal insulation chimneys (DIN 18160 T1 heat transmission
resistance group I) or suitable fireclay flues that are
insusceptible to damp and have general building regulation
approval should be used. It is advisable to involve those
responsible for approving the flue system early on in the
planning phase.
BS-01-04-03-03-01-IAEN
Flue height The minimum flue height is 5 - 10 m depending on boiler
output. The flue must terminate at least 0.5 m above the
highest part of the building. In the case of flat rooves, the flue
must terminate at least 1.5 m above the surface of the roof.
Flue dimensioning data Dimension the flue for rated output.!
BC-01-04-03-05-01-IAEN
(Averaged figures with used heat exchanger)
Rated output
Sub-maximum output
Type
Flue gas
temp.
CO2 Mass flow rate
Required
draught
BC30
160 °C 12,5 % 0.024 kg/s 15 pascals
BC40
170 °C 13,0 % 0.030 kg/s 15 pascals
BC50
170 °C 13,0 % 0.030 kg/s 15 pascals
BC75
190 °C 13,0 % 0.042 kg/s 15 pascals
BC100
190 °C 13,0 % 0.055 kg/s 15 pascals
Type
Flue gas
temp.
CO2 Mass flow rate
Required
draught
BC30
100 °C 9,5 % 0.010 kg/s 10 pascals
BC40
105 °C 10,0 % 0.012 kg/s 10 pascals
BC50
115 °C 10,0 % 0.009 kg/s 10 pascals
BC75
120 °C 10,0 % 0.013 kg/s 12 pascals
BC100
120 °C 10,0 % 0.017 kg/s 12 pascals
Use heat
-
insulated fireclay flues that are
insensitive to damp.
The flue gas temperature can be less
than 105°C.
BIOCOM Installation Instructions
9
1.4.4 Fuel store requirements
BS-01-04-04-00-01-IAEN
BS-01-04-04-01-01-IAEN
Access doors/hatches Above-ground fuel stores must be provided with a door or
hatch that opens outwards. So that the fuel cannot run out if
the fuel store is opened by mistake, the inside of the access
door/hatch opening must be covered with boarding (which
must be removable from the outside). Due to the risk of injury
when the system is in operation, access doors/hatches must
be lockable and kept locked when the system is in operation.
There must be a warning sign carrying the message "Do not
enter when feeder system is running" attached to the access
door/hatch.
Electrical equipment FLEX system
BS-01-04-04-02-01-IAEN
Electrical equipment is prohibited in the fuel storeroom.
BOX system
Electrical equipment is permitted in the room in which the
system is installed. Light bulbs must not be fitted in close
proximity to the fabric hopper.
BS-01-04-04-03-01-IAEN
Filler set The filler pipes must be earthed.
FLEX system
At least 2 filler pipes must be installed. Minimum separation
0.5 m.
BS-01-04-04-04-01-IAEN
Installation in cold areas If installed in cold areas, vacuum pipes and outfeed unit must
be adequately insulated (frost-proof).
Risk of condensation formation
Structural requirements FLEX system
BS-01-04-04-05-01-IAEN
The enclosing walls must be capable of withstanding the
possible static loads created by the fuel and the pressure
when filling the fuel store.
BOX system
It is imperative that the load-bearing capacity of the base is
adequately dimensioned as, when the hopper is completely
full, heavy loads act on the points on which the unit rests.
BS-01-04-04-06-01-IAEN
Erecting BOX system Indoor installation: The fabric hopper must always be
installed separately from the boiler in a different room. In
some countries, the fabric hopper may be installed in the
same room as the boiler if a minimum separation of 1 m
between the fabric hopper and the boiler can be maintained
and the fuel heat output remains below 50 kW.
National legislation must also be observed!
Outdoor installation: If erected outdoors, no F90 lining is
required if the minimum distances for fire flashover are
maintained. The fabric hopper must be protected against rain,
damp and UV light.
BIOCOM Installation Instructions
10
BS-01-04-04-07-01-IAEN
Wall penetration If there is an auger conveyor passing through the storeroom
wall, the gap in the wall must be filled with mineral wool and
sealed by means of the non-contact (sound insulation)
finishing plates provided.
BS-01-04-04-08-01-IAEN
Filling the fuel store When pressure-filling the fuel store from a tanker truck, the air
pumped in must be drawn out of the fuel store. Extraction is
the responsibility of the supplier.
BS-01-04-04-09-01-IAEN
Damp-proofing The fuel must be protected against contact with water or
damp floors/walls. The storeroom must remain dry all year
round. If there is a risk of temporarily damp walls, fitting a
back-ventilated facing to the walls and lining them with
wooden material may be required.
BIOCOM Installation Instructions
11
2 Installation and assembly
BS-02-00-00-00-01-IAEN
2.1 Delivery
BS-02-01-00-00-01-IAEN
The boiler system is delivered packed in a wooden crate
wrapped in foil. Please check that the delivery is complete
according to the delivery note and in perfect condition.
Deficiencies Please make a note of the deficiencies identified directly on
the delivery note and contact the supplier, heating installer or
our Customer Service.
2.2 Carrying to installation site
BS-02-02-00-00-01-IAEN
The system is delivered on a wooden pallet and can be lifted
and carried to the installation site using a pallet truck.
Carrying in dismantled The boiler body can be dismantled into parts for carrying in. If
that is done, a person authorised by GUNTAMATIC must be
consulted.
2.3 Positioning and aligning the boiler
PH-02-03-00-00-01-IAEN
Keep to the minimum wall clearances specified by the system
planner and manufacturer. If important details are missing,
please refer to the planning documentation or ask our
Technical Support. Position the system as close as possible to
the flue to avoid having a long flue connecting pipe. The
system must be accessible from the left or right side.
Clearance on left at least 40 cm (preferably 70 cm)
Clearance on right at least 40 cm
Clearance at front at least 80 cm (leave space for fuel box door to open)
Clearance at back at least 50 cm (with auto ash extraction system, at least 60
cm)
Floor clearance Set the clearance between the boiler base and the floor to the
required minimum of 35 mm by unscrewing the adjustable feet
on the boiler base.
Set the boiler at a slant Unscrew the rear adjustable feet slightly further so that the
boiler is slightly higher at the rear. That will allow the air
inside the boiler to escape easily when the system is filled.
BIOCOM Installation Instructions
12
2.4 Plumbing connections
BC-02-04-00-00-01-IAEN
Biocom 30/40/50
A → Sensor for temp. relief valve, ½"
B → Heating return, 1¼"
C → Temperature-relief heat exchanger, ¾"
D → Boiler sensor, safety temperature
limiter (STL)
E → External thermostat/drain, ½"
F → Heating flow, 1¼"
Biocom 75/100
A → Sensor for temp. relief valve, ½"
B → Heating flow, 2"
C → Temperature-relief heat exchanger, ¾"
D → External thermostat, ½"
E → Drain
F → Heating return, 2"
BIOCOM Installation Instructions
13
BC-02-04-00-01-01-IAEN
Temperature-relief heat exchanger The maximum permissible boiler operating temperature is
110°C. In order to prevent the maximum allowable operating
temperature being exceeded, connection of a temperaturerelief valve conforming to Austrian standard ÖNORM 8131
and DIN 4751 and with a response temperature of 95°C is
required. The supply pressure must be at least 2 bar but no
more than 6 bar.
Biocom 30/40/50
A → Cold water supply for
Temperature-relief heat exchanger
B → Sensor for temp. relief valve, ½"
C → Temp. relief valve, 95°C
Biocom 75/100
A → Cold water supply for
Temperature-relief heat exchanger
B → Sensor for temp. relief valve, ½"
C → Temp. relief valve, 95°C
BIOCOM Installation Instructions
14
PH-02-04-00-02-01-IAEN
Thermal store Installing a thermal store is not necessary as the boiler is
operated by a modulating control system and the system can
be quickly shut down. However, if the required continuous
heat output in the summer months is below 10 kW for systems
up to 50 kW, or 22 kW for systems upwards of 50 kW,
combination with a thermal store is necessary for reasons of
efficiency.
BC-02-04-00-03-01-IAEN
Return boost The boiler return temperature must be at least 40°C in
systems up to 50 kW and 45°C for systems upwards of 50
kW, and must be held at the required level by a bypass pump
between the boiler flow and return pipes. If a thermal store is
connected, the boiler return temperature must be at least 55
°C, which must be ensured by a return boost set as shown in
the plumbing diagram. If this requirement is not complied with,
there is an increased risk of corrosion and guarantee
entitlement will be lost as a result. Connect the return boost
set precisely as specified in our plumbing diagrams.
Important The dimensioning of the return boost pump (set) is designed
for the arrangements shown in GUNTAMATIC plumbing
diagrams. If additional components such as heat meters are
incorporated in the system plumbing, or if the overall thermal
store pipe run (flow and return) is more than 30 m, redimensioning of the boiler charging pump (HP0) may be
necessary.
SY-02-04-00-04-01-IAEN
Expansion vessel
The boiler operates in a sealed heating system and must be
provided with an expansion vessel for pressure compensation.
To calculate the expansion volume, the volume of the system
when cold must be known. Please select the expansion vessel
on the basis of the manufacturer's specifications. The
expansion volume of the system is calculated as follows:
System volume x Expansion factor x Additional allowance
factor
• Expansion factor for wood-fuel boilers = 0.03
• Additional allowance factor = 3.0 for systems under 30 kW
• Additional allowance factor = 2.0 for 30-150 kW systems
• Additional allowance factor = 1.5 for systems over 150 kW
Example calculation: 2500 litres x 0.03 x 3 = 225 litres
BS-02-04-00-05-01-IAEN
Plastic piping
If plastic piping for underfloor heating or district heating pipes
are connected, they must be protected against excessive
temperatures by using a limiting thermostat for the circulation
pumps.
BS-02-04-00-06-01-IAEN
Pump selection
The choice of pump must be made by the installer or building
technology planner on the basis of the friction data, the pipe
cross-sectional area and the required delivery pressure for the
piping system planned.
BIOCOM Installation Instructions
15
2.5 Filling and bleeding the system
BS-02-05-00-00-01-IAEN
The system is filled with water from the domestic supply.
Please note the guidelines on "Corrosion and boiler protection
in heating and domestic water systems".
Water quality The water quality of hot water systems with flow temperatures
of max. 100°C is subject to VDI 2035. According to VDI 2035
Part 1, "Avoiding damage to hot water systems", which
comply with EN12828, the first-fill and replenishment water,
must be conditioned (preferably softened) if the following
overall hardness limits [°dH] according to total heat output
(kW) are exceeded:
• < 50kW: with circulating flow heaters, if °dH > 16.8
• 50 to 200 kW: if °dH > 11.2
• 200 to 500 kW: if °dH > 8.4
• > 500kW: if °dH > 0.11
Water heater If a water heater is also used in addition to the GUNTAMATIC
boiler, it should be filled according to the installation
instructions for it.
Filling the system
• Match the pressure of the system when cold to the air
charge pressure of the expansion vessel
• Check the operating pressure on the pressure gauge
Bleeding the system
• Switch off and bleed circulation pumps.
• Bleed boiler by opening the bleed valve on the boiler
and allowing air to escape until water runs out.
• Bleed radiator heating system (if present) by opening
the bleed valve on every radiator and allowing air to
escape until water runs out.
• Bleed underfloor heating system (if present) by opening
each heating circuit and flushing through thoroughly
until there are no more air bubbles in the heating circuit
pipes.
• Important: perform sequence in the correct order!
Start bleeding in the cellar or on the ground floor and
finish in the attic.
• Check the system operating pressure on the pressure
gauge and add more water if necessary.
• Restart circulation pumps.
Only systems that have been properly bled
guarantee effective conveyance of heat.
BIOCOM Installation Instructions
16
2.6 Connecting the flue
BS-02-06-00-00-01-IAEN
BC-02-06-00-01-01-IAEN
The boiler is connected to the flue by means of a flue
connecting pipe which must be gas-tight and insulated
between the heating boiler and the chimney (insulation
thickness 50 mm).
Flue connecting pipe The following diameters should be used:
• BC 30, BC 40, BC 50 dia. = 150 mm
• BC 75, BC 100 dia. = 180 mm
Flue connecting pipes longer than 4 m or with more than 3
bends:
• BC 30, BC 40, BC 50 dia. = 160 mm
• BC 75, BC 100 dia. = 220 - 250 mm
The hole in the wall for connecting the flue pipe must be lined
with a built-in double-skinned lining tube or fireproof material.
The flue connecting pipe must rise upwards from the boiler to
the flue at an angle of at least 6° and be connected with gastight joints. An inspection cover must be provided for cleaning
the flue connecting pipe.
PH-02-06-00-02-01-IAEN
A → Flue connecting pipe insulation (50 mm)
B → Testing point for flue draught
(Distance from boiler = at least 3 x dia. of flue connecting pipe)
C → Alternatively: Flue draught regulator in flue
connecting pipe
(As close as possible to junction with the flue)
D → Flue connecting pipe, min. gradient 6°
H → Flue draught regulator/pressure-surge
compensator in flue
(Preferred fitting arrangement)
BS-02-06-00-03-01-IAEN
Note
• The flue connecting pipe musty be gas-tight
• An energy-saving flue draught regulator with pressure-
surge compensator (Class RE) must be fitted
• Insulate the flue connecting pipe
• Do not brick in the flue connecting pipe
(noise
transmission)
• The flue connecting pipe must not extend into the flue
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