Guntamatic Biostar Flex, Biostar Box Operating Instructions Manual
Pellet boiler englisch
BIOSTAR
FLEX/BOX/W
Operating Instructions/System Log Book
BS-A-00-00-00-01-BAEN
EN-B30-003-V16-0411-V3.0
BIOSTAR Operating instructions
2
Information on this documentation
BS-B-00-00-00-01-BAEN
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.
BIOSTAR Operating instructions
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Contents
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Page
1 Introduction..........................................................5
1.1 Brief description 5
1.2 Type approval 5
1.3 Further information 5
2 Important notes....................................................6
2.1 Intended use 6
2.2 Operating the heating system 6
2.3 Guarantee and liability 6
2.4 Safety instructions 7
3 System components..........................................11
3.1 Cutaway diagram of Biostar FLEX 11
3.2 Cutaway diagram of Biostar W 12
4 Safety systems...................................................13
5 Description of control panel .............................14
6 Overview of menu and levels............................15
6.1 Information level 16
6.2 House level 17
6.3 User level 17
6.3.1 Heating Circuit
menu
18
6.3.2 Hot Water
menu
18
6.3.3 Thermal store
menu
19
6.3.4 User
menu
19
6.3.5 Detail View
menu
19
6.3.6 Date/Time
menu
19
6.4 Service level 20
6.4.1
Service menu
Reset Data 20
6.4.2
Service menu
Fault screen 20
6.4.3
Service menu
Commissioning 21
6.4.4
Service menu
Heating Circuit/
Screed Drying Prog. Parameters
22
6.4.5
Service menu
Hot Water Parameters 23
6.4.6
Service menu
HP0 Parameters 23
6.4.7
Service menu
System Settings 24
7 User settings ......................................................25
7.1 Activating a heating programme 25
7.2 Deactivating a heating programme 26
7.3 Setting a timer programme 27
7.3.1 Programming en bloc 27
7.4 Changing the heating characteristic 28
7.5 Changing the hot water temperature setting 29
7.6 Analogue room stat 30
7.7 Digital room controller 30
BIOSTAR Operating instructions
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Contents
Page
8 Operating the heating system...........................31
8.1 Starting up/Shutting down the system 31
8.2 Heating system checks 31
8.3 Fuel quality 32
8.4 Fuels 33
8.4.1 Pellets 33
8.5 Fuel storage 33
8.6 Filling/refilling the fuel store 34
8.7 Emptying the ash 35
9 Cleaning/care .....................................................36
9.1 Cleaning the fuel store 36
9.2 Interim cleaning 37
9.3 Complete cleaning 38
10 Rectifying faults.................................................39
11 Information messages/Fault codes ..................40
12 Replacing fuses .................................................41
13 Log book.............................................................42
BIOSTAR Operating instructions
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1 Introduction
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You have made an excellent choice with the purchase of your
GUNTAMATIC boiler.
It is a product of many year's experience in boiler-making and
it is our sincere wish that your heating system provides you
with many years of satisfaction.
These instructions are intended as a guide to operation and
maintenance. Even the best boiler cannot operate effectively
without proper care and maintenance, so please read through
these instructions carefully and have your appliance
commissioned by an engineer authorised by GUNTAMATIC.
Most importantly, you should follow the safety instructions in
Section 2.
1.1 Brief description
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The BIOSTAR is a modern biomass boiler available with
power outputs of 12, 15 or 23 kW. The fuel is fed either from a
boiler-mounted hopper by an auger-type conveyer or from a
separate fabric hopper or storeroom by an auger conveyor
and vacuum system.
1.2 Type approval
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The boiler is designed as a Class 3 appliance as defined by
the draft standard ÖNORM EN 303-5 (CEN/TC7/WG 1 – Doc.
N 36-D) of 15/12/1996 and the agreement of the [Austrian]
Federal States according to Art. 15a BVG, in accordance with
the Austrian fire safety regulations, safety systems, CE and on
safety measures for small combustion heating systems and
the combustion heating system approval regulations (LGBl.
33/1992) of the Federal State of Steiermark. The original type
approval certificates are available for inspection at the
manufacturer's offices.
1.3 Further information
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The documentation consists of the following documents:
• Planning Document
• Installation instructions
• Operating instructions
If you have any questions, please consult our Customer Support.
BIOSTAR Operating instructions
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2 Important notes
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Your boiler has been designed and produced in accordance
with the latest technical advances and all applicable safety
regulations. Nevertheless incorrect operation, the use of
unapproved fuels or the failure to carry out necessary
maintenance and repairs can result in personal injury or
damage to property. You will avoid dangerous situations by
only using the boiler for the purpose for which it was designed
and by operating, cleaning and maintaining it correctly. Only
start up the heating system when it is in perfectly safe working
order.
2.1 Intended use
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The boiler is designed for heating central heating water and
for use as a central heating boiler.
2.2 Operating the heating system
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The heating system may only be operated and cleaned by
demonstrably trained persons (as per check-list). Children,
unauthorised persons or persons with a mental impairment
may only enter the boiler room under the supervision of an
authorised person. When unsupervised, the boiler room/fuel
store must be locked and the key kept in a place where it is
inaccessible to such persons.
2.3 Guarantee and liability
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Guarantee and liability claims for personal injury and/or
property damage are inadmissible if they are attributable to
one or more of the following causes:
• use of the boiler for purposes other than that intended
• failure to follow the instructions, guidance and safety
precautions given in the documentation
• incorrect commissioning, operation, maintenance or
repair of the boiler
• operation of the boiler when safety systems are
inoperative
• unauthorised modifications
Caution:
Do not use the boiler to burn rubbish!
Burning rubbish will cause extensive
corrosion and consequently to a
substantial reduction in the service life of
the boiler.
Caution: even if the opposite is requested, servicing
and repair work may only be carried out by
authorised specialists.
BIOSTAR Operating instructions
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2.4 Safety instructions
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To prevent accidents, small children should not be allowed
into the boiler room or the fuel storeroom. Please follow the
safety instructions below. By doing so, you will protect yourself
and prevent damage to your heating system.
Power switch
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Mains plug
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Repair work
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In an emergency: In the event of electric shock, disconnect
the power supply immediately.
Administer first aid. Call the duty doctor.
Fault rectification
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Unauthorised modifications
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Note: The power switch must remain switched on at
all times and may only be switched off when
the system is not in operation.
Danger: Risk of fatal injury from electric shock.
The mains power supply is brought to the
boiler via the plug marked Mains. That plug
and other components of the system remain
live even when the Power switch on the
control panel is switched off.
Danger: Repair work may only be carried out
by authorised technicians.
Touching live electrical components can
cause fatal injury.
Even when the Power switch is "OFF" some
components of the system are still live.
Therefore, when carrying out repair work it is
imperative that the power supply to the
heating system is disconnected by means of
the "mains plug" or a circuit breaker.
Note: If faults occur, the causes must first be
eliminated on the basis of the information
message on the display (F0...) before
resuming operation by means of the "Quit"
button.
Note: do not make any unplanned changes to the
settings or any modifications to the heating
system.
Loss of guarantee entitlement
BIOSTAR Operating instructions
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Servicing work
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Emptying ash
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Boiler cleaning
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Flue gas fan
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Gaskets
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In an emergency: Take the person affected into the open
air immediately. Call the duty doctor.
Air supply
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Note: If there is more than one boiler in the same room, a
greater supply of fresh air must be provided.
Note: Service the boiler regularly or make use of
our Customer Service.
Danger: Glowing embers can cause fires.
Only remove the ash from the boiler or store it
in non-combustible containers.
Caution: Touching hot components can
cause skin burns.
The boiler must only be cleaned when it is
cold (flue gas temperature < 50°C)
Danger: Risk of injury from rotating parts.
The fan must only be removed when it is
disconnected from the power supply
(unplugged).
Danger: Risk of gas poisoning.
It is possible that flue gas could escape if
gaskets are damaged.
Have defective gaskets replaced by an
authorised technician.
Danger: Risk of suffocation
Inadequate air supply can be fatal.
Make sure there is an adequate supply of air.
BIOSTAR Operating instructions
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Flue draught regulator
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Safety clearances
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Entering the storeroom
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Filling the storeroom
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Danger: Risk of detonation.
A flue draught regulator with a pressure surge
compensator is an essential requirement.
Danger: Fire risk.
Do not store any flammable items in the close
vicinity of the boiler.
Follow the local regulations.
Danger: Potentially fatal health risk!
As with all organic materials, stored pellets
can produce gases, which then collect in the
storeroom. Therefore, entering the storeroom
is only allowed when it is empty (max. 1/5 full)
and only after ventilating it thoroughly for at
least 2 hours beforehand.
Storerooms that contain more than the above
amount of fuel may only be entered by
authorised service engineers after prior
testing of the air quality inside the storeroom.
Danger: Risk of injury!
Only enter the store room when the
system is switched off. Always shut off
the power supply before entering.
Affix a sign to the storeroom door.
Keep the storeroom doors locked.
Danger: Risk of poisoning and fire!
When filling the fuel storeroom from a tanker
truck or using a pressure-filling system, it is
imperative that the boiler is shut down (OFF
mode).
If this rule is ignored, flammable and
poisonous gases can be drawn into the
storeroom.
BIOSTAR Operating instructions
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Protection against freezing
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Fire extinguisher
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Note: Anti-freeze function.
The system can only perform its freezing
prevention function if sufficient fuel is
available and there are no faults.
Note: Provide a fire extinguisher.
There must be a fire extinguisher placed
immediately outside the boiler room door.
BIOSTAR Operating instructions
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3 System components
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3.1 Cutaway diagram of BIOSTAR Flex
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1. Ash box door
2. Cleaning grate
3. Primary air
4. Self-cleaning grate
5. Secondary air
6. Swirl plate
7. Burn-back inhibiting fuel chute
8. Expansion zone
9. Automatic heat exchanger cleaning
mechanism
10. Grate cleaner motor
11. Ignition fan
12. Ceramic insulation
13. Overall insulation
14. Helix baffles
15. Tube-type heat exchanger
16. Flue draught fan
17. Flue gas sensor
18. Oxygen sensor
19. Control panel (controller)
20. Sensor for fill-level indicator
21. Motor
22. Drive gear
23. Vacuum fan
24. Fuel hopper
25. Pellet auger
26. Photosensor
27. Rotary feeder
BIOSTAR Operating instructions
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3.2 Cutaway diagram of BIOSTAR W
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1. Ash box door
2. Cleaning grate
3. Primary air
4. Self-cleaning grate
5. Secondary air
6. Swirl plate
7. Burn-back inhibiting fuel chute
8. Expansion zone
9. Automatic heat exchanger cleaning mechanism
10. Grate cleaner motor
11. Ignition fan
12. Ceramic insulation
13. Overall insulation
14. Helix baffles
15. Tube-type heat exchanger
16. Flue draught fan
17. Flue gas sensor
18. Oxygen sensor
19. Control panel (controller)
20. Sensor for fill-level indicator
21. Motor
22. Drive gear
23. ---
24. Fuel hopper
19
9
BIOSTAR Operating instructions
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4 Safety systems
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To prevent the boiler overheating, the controller reduces the
heat output in certain situations. If the boiler still threatens to
overheat, the controller responds according to a set of defined
safety levels.
Safety level 1
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15°C above specified temperature
The drive motor stops the fuel feed system and the flue
draught fan shuts down.
Safety level 2
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Boiler temperature above 85°C
All heating pumps and the cylinder charging pump are
switched on to carry heat away from the boiler.
Safety level 3
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Boiler temperature above 100°C
The STL (safety temperature limiter) trips and switches all
boiler control functions off while the heating circulation pumps
continue to run. The system remains switched off even if the
boiler temperature drops back below 90 °C. The system must
not be started up again until any faults have been rectified and
the boiler has been checked.
Power failure
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The controller, the flue draught fan and all circulation pumps
switch off due to lack of electricity if there is a power cut. The
glowing fuel bed on the grate continues burn with the natural
draught of the flue. As this operating mode is not ideal, a
larger amount of ash collects on the grate as well. As soon as
the electricity supply is restored, the controller takes control of
the heating system again.
Opening the ash box
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• The auger motor stops feeding in fuel
• The flue draught fan switches to maximum extraction speed
• After the firebox door is closed, normal operation is
resumed or re-ignition initiated
BIOSTAR Operating instructions
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5 Control panel description
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The appliance has a large touch-screen control panel with a
menu-based interface. All setting and query options are
shown on the display. All settings can be entered by pressing
the "buttons" on the touch screen. Any system messages are
displayed on the screen.
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1
2
3
Power switch (1)
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Normally remains permanently switched on. The power switch
may only be switched off when the system is not in operation.
STL (2)
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Excessive temperature (approx. 100°C) trips the safety
temperature limiter (STL) located under the cap (2); →
appliance operation is suspended; → if the STL has tripped,
identify and eliminate the cause and then press in the STL
(button) with a thin object.
Touch-screen display (3)
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Pressing lightly with your fingertip on the relevant buttons on
the display opens the various program levels, menus and
submenus. All settings are made directly on the touch-screen
display.
Note: The system must also be disconnected from
the mains by unplugging the power lead when
carrying out repairs or servicing work.
Note: The system must not be started up again until
any faults have been rectified and the boiler
has been checked. If necessary, a heating
engineer must be called in.
Note: Never use sharp objects such as ball-point
pens or the like to operate the touch screen.
BIOSTAR Operating instructions
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6 Overview of menu and levels
(menu structure)
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Fault screen
Information
Status info
Boiler info
MK Controller 0
info
Off
MK Controller 1
info
Normal
MK Controller 2
info
Hot water
Thermal store info
Heating
▲ Low
Information level
Low until
RECHARGE HW
Manual
User Level
Service level
▼
Grate cleaning
Parameters menu
▼
▼
User Level
Service level CODE User menu
Parameters menu CODE Reset data Heating circuit 0
Boiler parameters Fault list Heating circ uit 1
▲
Test program Heating circuit 2
House level
Commissioning Heating circuit 3
HC0 parameters Heating circuit 4
HC1 parameters Heating circuit 5
HC2 parameters Heating circuit 6
HC3 parameters Heating circuit 7
HC4 parameters Heating circuit 8
HC5 parameters DHW 0
HC6 parameters DHW 1
HC7 parameters DHW 2
HC8 parameters Thermal store
DHW0 Parameters Deta il View
DHW1 Parameters Date/Time
DHW2 Parameters
HP0 parameters
Note:
•
••
• Menus shown with a dashed border only appear if
activated on the Commissioning menu.
•
••
• Changes to the settings on the Service or
Parameters levels may only be made with the
agreement of GUNTAMATIC.
System settings
Layout of touch-screen display
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Header Scroll bar Scroll buttons
Symbols Select button
The header contains information about the level or menu selected. Operating statuses, sensor
readings and switch conditions can be queried in the Selection window. The various buttons
can be used to change and save settings or switch to different levels or menus, for example.
You switch between the levels and menus by touching the buttons directly on the display
screen.
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