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Guntamatic
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PRO 250

Guntamatic PRO Series, PRO 250 Operating Instructions Manual

Woodchip boiler
PRO
Operating Instructions/System Log Book PRO-A-00-00-00-01-BADE
DE-B30-012-V02-1013-V3.0
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Information on this documentation
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 Bruck 7 A-4722 PEUERBACH
Tel: 0043 (0) 7276 / 2441-0 Fax: 0043 (0) 7276 / 3031 E-mail: office@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.
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Contents 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 PRO 11
4 Safety systems ................................................... 12
5 Description of control panel ............................. 14
6 Overview of menu and levels ............................ 15
6.0 Information level 16
6.1 House level 17
6.1.1 Boiler enabling 17
6.1.2 Programme 17
6.1.3 User level 18
6.1.3.1 User menu 18
6.1.3.2 Thermal Store Pump HP0 menu 19
6.1.3.3 Network System menu 19
6.1.3.4 Heating Circuit menu 19
6.1.3.5 Hot Water menu 20 Supplementary Hot Water menu 20
6.1.3.6 Feeder Pump menu 20 Charging Pump menu 20
6.1.3.7 Boiler cascade menu 21
6.1.4 Service level 21
6.1.4.1 Service menu Reset Data 22
6.1.4.2 Service menu Commissioning 22
6.1.4.3 Service menu HP0 Parameters 23
6.1.4.4 Service menu System Settings 24
6.1.4.5 Service menu Network System Parameters 25
6.1.4.6 Service menu Heating Circuit Parameters 25
6.1.4.7 Service menu Hot Water Parameters 26
Service menu Supplementary Hot Water Parameters26
6.1.4.8 Service menu Feeder Pump Parameters 26
Service menu Charging Pump Parameters 26
6.1.4.9 Service menu Return Mixer Valve Parameters 26
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Contents Page
7 User settings ................................ ...................... 27
7.1 Activating a heating programme 27
7.2 Deactivating a heating programme 28
7.3 Programming heating times 29
7.3.1 Programming en bloc 29
7.4 Changing the heating characteristic 30
7.5 Changing the hot water temperature 31
7.6 Analogue room stat 32
7.7 Digital room controller 32
8 Operating the heating system .......................... 33
8.1 Starting up/Shutting down the system 33
8.2 Heating system checks 33
8.3 Fuel quality 34
8.4 Fuels 35
8.4.1 Woodchips 35
8.4.2 Pellets 36
8.5 Filling/refilling the fuel store 37
8.6 Combustion air supply 38
8.7 Emptying the ash 39
9 Cleaning/Care ..................................................... 40
9.1 Cleaning the fuel store 41
9.2 Interim cleaning 41
9.3 Complete cleaning 42
9.4 Cleaning at end of heating season 42
10 Rectifying faults ................................................. 43
11 Information messages/Fault codes .................. 44
12 Replacing fuses ................................................. 46
13 Log book ............................................................. 47
13.1 Weekly visual inspection 48
13.2 Monthly checks 48
13.3 Servicing 48
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1 Introduction PRO-01-00-00-00-02-BADE
You have made an excellent choice with the purchase of your GUNTAMATIC boiler.
It is a product of many years' 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
The PRO is a modern biomass boiler. The fuel is fed to the boiler from a fuel storeroom by an auger-type conveyor with fuel agitator.
1.2 Type approval
The boiler is designed in accordance with Class 3 to EN 303-5 and the agreement of the Austrian Federal States according to Art. 15a BVG relating to safety measures for small combustion heating systems and energy saving. The original type approval certificates are available for inspection at the manufacturer's offices.
1.3 Further information
The documentation consists of the following documents:
Installation instructions  Planning and installation instructions  Wiring diagram  Operating instructions
If you have any questions, please consult our Customer Support.
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2 Important notes PRO-02-00-00-00-01-BADE
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
The boiler is designed for heating central heating water and for use as a central heating boiler.
2.2 Operating the heating system
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
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 a drastic
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.
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2.4 Safety instructions
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
Mains plug
Repair work
In an emergency: In the event of electric shock, disconnect
the power supply immediately.
Administer first aid. Call the duty doctor.
Fault rectification
Unauthorised modifications
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 completely 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
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Servicing work
Emptying ash
Boiler cleaning
Flue gas fan
Gaskets
In an emergency: Take the person affected into the
open air immediately. Call the duty doctor.
Air supply
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.
The ash should only be removed from the
boiler or stored 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.
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Flue draught regulator
Safety clearances
Entering the fuel storeroom
Filling the storeroom
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: 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: Combustible gases in storeroom!
When filling the fuel storeroom from a
tanker truck or using a pressure-filling
system, it is imperative that the boiler is
shut down.
If this rule is ignored, flammable and
poisonous gases can be drawn into the
storeroom.
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Protection against freezing
Emergency fire extinguishing system
Fire extinguisher
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.
Note: Contact our Customer Service.
If the emergency fire extinguishing system
has been triggered, it is always due to a fault
in the heating system.
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3 System components PRO-03-00-00-00-01-BADE
3.1 Cutaway diagram of PRO
1.) Stepped grate – primary air
2.) Domed swirl chamber
3.) Photosensor
4.) Inspection cover
5.) Helix baffles
6.) Heat exchanger
7.) Flue draught fan
8.) Automatic cleaning mechanism
9.) Flue pipe
10.) Oxygen sensor
11.) Flue gas sensor
12.) Grate motor
13.) Ash collecting device
14.) Menu-based touch-screen controller
15.) LED status indicator
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4 Safety systems PRO-04-00-00-00-01-BADE
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 10°C above specified temperature
The drive motor stops the fuel feed system and the flue draught fan shuts down.
Safety level 2 Boiler temperature over 95°C
All heating pumps and the cylinder charging pump are switched on to carry heat away from the boiler.
Safety level 3 Boiler temperature over 100°C
The STL (safety temperature limiter) trips and switches all boiler control functions off while the 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 The controller, the flue draught fan and all 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.
Outer casing door open
The drive motors stop feeding the boiler with fuel The flue draught fan switches to maximum extraction speed If the outer casing door is closed again within 60 seconds,
combustion is continued
On the stoker duct The stoker duct and feeder box are designed to be completely
air-tight as far as the fire safety flap. That means that any burn-back is extinguished by lack of air. The fire safety flap is tested and approved as a burn-back prevention device. A positioner motor opens and closes the flap. Fuel delivery does not start until the flap is completely open. If the event of a fault or a power failure, the flap closes automatically of its own accord. When the boiler is in operation, the controller prevents burn-back into the stoker auger by replenishing the fuel. In addition, a sensor monitors the temperature in the vicinity of the stoker auger. In that way, burning fuel is continually pushed back out of the auger duct. This burn-back prevention system always functions unless the electricity supply to the boiler system is cut off.
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On the fuel store outfeed unit Required in all countries
In addition, between the end of the fuel outfeed unit and the burn-back prevention device there is a sprinkler unit that is used instead of the temperature monitor with fuel stores with a capacity not exceeding 50 m³ and is triggered at 55°C. When the sprinkler is triggered, the sloping outfeed auger enclosure – which also serves as a burn-back inhibiting device – is completely flooded. The quantity of water required to do so is at least 20 litres. If the temperature drops back below 55°C, the flooding is stopped.
Overfill prevention
The overfill prevention function is triggered by the fill level sensor in the fuel chute or the contact switch on the overfill prevention cover. If the fill level sensor trips, the auger A1 stops and the auger G1 continues running. If the sensor remains on for longer than 10min, the overfill fault is generated. If the overfill prevention cover switch trips, the auger A1 is stopped after 3 seconds and the overfill fault registered immediately.
Fuel stores > 50 m³ Requirement in Austria
A temperature monitor connected to a warning device must be installed in the fuel storeroom at the point where the fuel conveyor exits the fuel store and enters the boiler room. A visual and audible warning device must be triggered when the temperature exceeds 70°C.
Manually operated fire extinguishing facility
This fire extinguishing facility is for the purpose of combating a fire seated in the fuel storeroom in the area of the outfeed unit and is manually actuated. It consists of conduit piping with a minimum size of DN 20 and is to be fitted in the fuel storeroom immediately above the fuel conveyor close to its exit point through the wall or ceiling and positioned so as to obtain the maximum possible fire extinguishing effect. The conduit piping is to be connected directly to a pressurised water supply and provided with a stop tap located in the boiler room. That tap must be identified by a sign carrying the inscription "Fuel storeroom fire extinguisher". The design of the fire extinguishing facility must be such that it cannot be damaged by the delivery of fuel into the fuel store or by the fuel outfeed equipment.
Note: The sprinkler system must be connected
on all systems regardless of local
regulations.
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5 Description of control panel PRO-05-00-00-00-01-BADE
The appliance has a large touch-screen control panel with a menu-based interface. All settings can be entered by pressing the "buttons" on the touch screen. Information messages and fault indications are displayed on the screen.
1-2 3
Power switch (1) Normally remains permanently switched on. The power switch
may only be switched off when the system is not in operation.
STL (2) The safety temperature limiter (STL) trips if the system
overheats → heating by the appliance is suspended. If the STL has tripped, identify and eliminate the cause and
then press in the STL button as far as it will go using a suitable object.
Touch-screen display (3) Pressing lightly with your fingertip on the relevant buttons on
the display opens the various programme levels and menus where you can make changes to the settings.
Note: When carrying out repairs or servicing work,
the system must also be fully isolated from
the mains by unplugging the power lead.
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.
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6 Overview of menu and levels PRO-06-00-00-00-01-BADE
Fault screen
Status info
Boiler info
MK Controller 0
info
MK Controller 1
info
MK Controller 2
info
Thermal store HP0
info
User Level
▲
Boiler enabling
Service level
Information level
Parameters menu
▼
Programme
▼
▼
User Level
Service level
CODE User menu
Programme level
Parameters menu
CODE Reset data
Heating circuit 0
▼
Boiler parameters
Fault list
Heating circuit 1
▲
Off
House level
Test program
Heating circuit 2
Normal Commissioning
Heating circuit 3
Hot water HC0 parameters
Heating circuit 4
Heating HC1 parameters
Heating circuit 5
Low HC2 parameters
Heating circuit 6
Low until HC3 parameters
Heating circuit 7
Recharge HW HC4 parameters
Heating circuit 8
Manual HC5 parameters
DHW 0
Grate cleaning HC6 parameters
DHW 1
HC7 parameters
DHW 2
Note:
Menus shown with a dashed border only appear if
activated on the Commissioning menu.
Changes to the settings on the Service and
Parameters levels may only be made with the agreement of GUNTAMATIC.
HC8 parameters
Th/store pump HP0
DHW0 Parameters
Boiler cascade
DHW1 Parameters
User menu
DHW2 Parameters
Detail View
HP0 parameters
Date/Time
System settings
Layout of touch-screen display
Header Scroll bar Scroll buttons
Symbols Select button
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6.0 Information level
The scroll buttons are used to navigate up or down through the menus. Touching the House button on the display opens the House Level menu.
1) Note: Only shown if the function Network System Controller or Heating Circuit Controller has been activated.
Only one of the functions Network System Controller or Heating Circuit Controller can be programmed. The two functions cannot be used simultaneously on the same boiler.
2) Only temperatures from the top and bottom thermal store sensors are shown on the Info Level. (If 5-sensor thermal store management is activated, the temperatures from the thermal store middle sensors are shown in Detail View.)
Fault screen → highest priority
Plain-English fault messages are displayed and saved
Fault is acknowledged by pressing Quit button
1)
Information level → Only shown if the programme "Low until" has been activated
Disappears after the set time has elapsed
Can be prematurely deactivated by pressing Quit button
Info Level – Status
Shows boiler temperature
Shows boiler operating mode
Shows selected programme
Shows boiler output
1)
Shows outside temperature → Figure in brackets = average temperature
Info Level – Boiler
Shows flue gas temperature
Shows CO2 level
Shows efficiency
Shows time in hours until ash warning is triggered
Shows fuel setting
1)
Info Level – Network system controller → (NSC)
Shows domestic hot water temperature and operating mode for cylinder 0
Shows operating mode for network system 0 → Pumped network system
Shows operating mode for network system 1 → Pumped or mixer-valve network system
Shows operating mode for network system 2 → Pumped or mixer-valve network system
1)
Info Level – Heating circuit controller 0 → (HCC 0)
Shows domestic hot water temperature and operating mode for cylinder 0
Shows operating mode for heating circuit 0 → Pumped heating circuit
Shows operating mode for heating circuit 1 → Pumped or mixer-valve heating circuit
Shows operating mode for heating circuit 2 → Pumped or mixer-valve heating circuit
1)
▼
Info Level – Heating circuit controller 1 → (HCC 1)
1)
▼
Info Level – Heating circuit controller 2 → (HCC 2)
2)
Information – Thermal store → (HP0)
Shows thermal store temperature at top
Shows thermal store temperature at bottom
Shows thermal store pump operating mode
Shows charging programme
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