Pellet Boiler BIOSTAR FLEX/BOX/W Operating Instructions
Contents
1. Vorlauftemperatur C 5 0 5 Au entemperatur C BIOSTAR Operating instructions 7 5 Changing the required hot water temperature BS 07 05 00 00 01 BADE formation Status Kesseltemperatur Betrieb Programm NORMAL Leistung 0 Aussentemperatur 25 25 C ft Hausebene Programm NORMAL Programm ABSENKEN BIS WARMWASSER NACHLADEN Programm HANDBETRIEB ROSTREINIGUNG Kundenebene Ob Kundenebene 1 a O o 6 o Kundenmen Heizkreis 0 Helzkreis 1 Heizkreis 2 Warmwasser O Kundenebene Warmwasser O Oll ol N v Betrieb Pumpe AUTO Uhrenprogramm WW O Uhrenprg WW Sommer 0 WW Solltemp O 55 WW Vorrang 0 Ne c in Kundenebene Warmwasser O WW Solltemp 0 WW Solllemp 0 55 55 C Warmwasser Solllemperatur You can change the required hot water temperature on the Hot Water menu The example set out below illustrates programming the required temperature for DHW cylinder O 1 gt Press the House level button ZS 2 Press the User level button 3 Press the DHW cylinder 0 button EJ 4 Press the DHW required temp 0 button 5 Use the and buttons to set the required temperature 6 To save the setting press the ok bu2. eesses 6 2 1 Intended use 6 2 2 Operating the heating system 6 2 3 Guarantee and liability 6 2 4 Safety instructions 7 System components 11 3 1 Cutaway diagram of Biostar FLEX 11 3 2 Cutaway diagram of Biostar W 12 Safety SVSLOMS cie io tee ceo etosoc ee oco toco ivo nee tuee ts 13 Description of control panel 14 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 Programme Parameters 22 6 4 5 Service menu Hot Water Parameters 23 6 4 6 Servicemenu HPO Parameters 23 6 4 7 Service menu System Settings 24 User settings a een een 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 Contents 10 11 12 13 Page ni dpi the heating system 31 Starting up Shutting down the system 31 gt H
3. User menu gt User settings Heating Circuit O menu gt Timer controlled pump heating circuit modulating control Heating Circuit 1 menu gt Timer controlled mixer valve heating circuit Heating Circuit 2 menu gt Timer controlled mixer valve heating circuit DHW 0 menu Thermal store menu Thermal store settings Detail View menu Boiler data and operating modes are shown Date Time menu Thermal store timings and charging programme settings Facility for querying operating modes sensor readings and switch conditions on Detail View menu Facility for viewing setting date and time on Date Time menu 17 BIOSTAR Operating instructions 6 3 1 Heating Circuit menu User BS 06 03 01 00 01 BADE The Heating Circuit menu allows you to enter the settings for the various heating circuits ot Kundenebene 1 Helzkreis 1 8 D Lm Heating circuit control status Oil Unrenprogramm 1 Facility for setting heating and low temperature times 9 WE S cts Facility for setting daytime required temperature 10 il ooo emn es Facility for setting night time required temperature 11 ae ad Facility for setting room effect thermostat function ot Kundenebene 1 Helzkreis 1 12 DG Facility for setting heating characteristic 13 idi ae Changeover from low temperature mode to night time set temperature 14 KL Outside temperature mode cut off for heating circuits 8 Options Auto Heating circuit is switched ON OFF according to deman
4. BS 06 03 03 00 01 BADE 6 3 4 22 23 6 3 5 6 3 6 The Thermal Store HPO menu allows you to enter settings for thermal store management ot Kundenebene Pufferspeicher Status of special output HPO HPO AUTO a sia Facility for setting thermal store charging programme Ladeprogramm m i i Facility for setting thermal store charging times Facility for setting the thermal store required temperature effective for thermal store top sensor T3 Facility for setting the thermal store minimum temperature effective for thermal store top sensor T3 19 Options Auto Thermal store pump is switched ON OFF according to demand and timer programme Off The thermal store pump is switched off Constant The thermal store pump runs continuously 20 Options Full The thermal store is fully charged Charging switches off when the required thermal store temperature at T3 is reached and also the required thermal store temperature minus the parameter TSbtm Boff 10 C is reached at T2 Part The thermal store is partially charged Charging switches off when the required thermal store temperature is reached at T3 2 parameter TS top B off 21 Thermal store only charged during charging times enabled in Thermal store timer programme User menu ot Kundenebene Kundenmen et Asche entleert Aschewarnung Kesselfreigabe m3 Zaehler gt 0 setzen Einstellung m3 Z hler ot Kundenebene Kundenmen
5. Fill level switch open with Fill level below limit Check connection vacuum outfeed Replenish pellets Automatic terminals 28 30 FO9 No response from Hall effect Drive motor G1 jammed Fuel chute overfilled drive sensor G1 within time param F12 Reset button unit jammed connection Tsafe G1 faulty test programme STL tripped Caution Boiler or pump malfunction High temperature STL Press STL check fuses tripped Reset button STL test F16 Param O2 sensor comp or Oxygen sensor readings Oxygen sensor dirty or adjusted setting above the limits above limits Check Reset button defective carry out oxygen of param mV top or mV btm F19 sensor test clean sensor If TKS2 sends no signals during Ash box full or auto Ash box full objects in the cleaning cleaning mech jammed R b ash auger de ashing motor F20 eset button jammed or TKS2 defective Fault ns Fault F05 via oxygen sensor Flue gas error due to O2 Oxygen sensor reading due to prior O2 sensor off 2 G1 sensor off incorrect connection faulty off Oxygen sensor test Reset button check flue draught FGT too F21 en Fill level not reached within the Fill level not reached No fuel fill level sensor time Outfeed max Check vacuum system defective vacuum pipes F22 Reset button clogged vacuum system not air tight vacuum unit defective outfeed motor jammed fault memory Notifi Ash box not emptied within set Empty ash box Ash box not
6. message on the display FO before resuming operation by means of the Quit button BS 02 04 00 05 01 BADE do not make any unplanned changes to the settings or any modifications to the heating System Loss of guarantee entitlement BIOSTAR Operating instructions Servici ng wo rk BS 02 04 00 06 01 BADE oervice the boiler regularly or make use of our Customer Service Em ptyi ng as h BS 02 04 00 07 01 BADE Glowing embers can cause fires Only remove the ash from the boiler or store it in non combustible containers Boiler cleaning BS 02 04 00 08 01 BADE Caution Touching hot components can cause skin burns A The boiler must only be cleaned when it is cold flue gas temperature lt 50 C Flue gas fan BS 02 04 00 09 01 BADE Risk of injury from rotating parts The fan must only be removed when it is disconnected from the power supply unnluaaed Gaskets BS 02 04 00 10 01 BADE Risk of gas poisoning It is possible that flue gas could escape if gaskets are damaged Have defective gaskets replaced by an authorised technician In an emergency Take the person affected into the open air immediately Call the duty doctor Air supply BS 02 04 00 11 01 BADE Danger Risk of suffocation A Inadequate air supply can be fatal Make sure there is an adequate supply of air Note If there is more than one boiler in the same room a greater supply of fresh air must be provided B
7. u Schnecke f llen Sauganiage f llen Modus Eco ideal T O Austragung Sperrzeit A n Deutsch BS 06 03 04 00 01 BADE Depending on the system configuration the menus may contain different items Menu option Ash emptied Press YES to confirm after emptying ash box Maximum time in hours until ash warning is triggered oh Ash warning deactivated Enable burner Setting OFF Burner does not start up controller remains active Facility for resetting the fuel gauge Sets counter to 0 Facility for setting average pellet size For manually switching on drive motor G1 Only possible in OFF mode For manual vacuum filling of fuel hopper Do not interrupt process Fuel filling lock out time Force filling still possible Facility for setting operating mode Menu language setting 22 Higher setting the fuel gauge counts down faster 23 Options ECO optimum High output High dust High clinker Detail View menu User Date Time menu User Economy mode setting factory setting Setting necessitates more frequent cleaning only use temporarily Setting for low quality pellets with high dust content Setting for if high levels of clinker form in the fire box BS 06 03 05 00 01 BADE All possible system operating statuses sensor readings and switch conditions can be queried in Detail View No settings can be made on this menu Its primary purpose is to aid telephone dia
8. 4 Safety instructions Power switch Mains plug Hepair work Fault rectification Unauthorised modifications BIOSTAR Operating 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 BS 02 04 00 01 01 BADE The power switch must remain switched on at all times and may only be switched off when the system is not in operation BS 02 04 00 02 01 BADE 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 BS 02 04 00 03 01 BADE 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 In an emergency In the event of electric shock disconnect the power supply immediately Administer first aid Call the duty doctor BS 02 04 00 04 01 BADE If faults occur the causes must first be eliminated on the basis of the information
9. BOSCH The oxygen sensor heater is switched on off according to operating mode The oxygen sensor heater is permanently switched on Oxygen sensor heater does not switch off until boiler has been in OFF mode for more than 50 h Data querying via Windows hyper terminal display Data querying via online recorder only usable at factory GSM module Data querying information messages and boiler control via GSM module 7 User Settings BIOSTAR Operating instructions 7 1 Activating a heating programme Information Status Di Kesseltemperatur Co Betrieb o Programm O Leistung M Aussentemperaiur 25 25 C ft Hausebene Programm AUS b Programm AUS O Programm NORMAL Programm WARMWASSER ae Programm HEIZEN Programm ABSENKEN ft Hausebene Programm NORMAL Programm AUS O Programm NORMAL Programm WARMWASSER x Programm HEIZEN Programm ABSENKEN O Information Status Kesseltemperatur Betrieb Programm NORMAL Leistung 0 Ausseniemperatur 25 25 C BS 07 01 00 00 01 BADE To set tne NORMAL programme proceed as set out below step by step 1 Press the House level button EM The programme currently selected Off is shown in the header 2 Press the Normal button ON The new programme selected Normal is now shown in the header 3 Press the Info button To 4 The Normal programme is now shown on the Status information screen After activating the N
10. F Betrieb HKO Pumpe Serviceebene Inbetriebnahme HKPO Freigabe 38 C f Vorlauft 0 max F Helzkurve 0 F Uhrenprogramm 0 F Raumger t HKO Serviceebene Inbetriebnahme F Betrieb HK1 Mischer HKP1Freigabe F Vorlauft 1 max F Heizkurve 1 F Uhrenprogramm 1 Serviceebene Inbetriebnahme F Raumger t HK1 RFF f Betrieb HK2 Mischer F HKP2Freigabe 38 C F X Vorlauft 2 max 75 C F Helzkurve 2 1 3 Serviceebene Inbetriebnahme F Uhrenprogramm 2 F Raumger t HK2 RFF F HKR 1 vom Nein F HKR2vor Nein F Betrieb HPO Pufferpumpe Serviceebene Inbetriebnahme F At Saugl nge 15m F Erstbef llung F Schnecke f llen F Kundenparameter speichern BIOSTAR Operating instructions BS 06 04 03 00 01 BADE All system components present can be programmed and activated from the service menu Commissioning For setting boiler type For setting boiler output stated on rating plate Setting for outfeed system type For activating heating circuit controller O For activating DHW cylinder O For setting the DHW charging time for NORMAL programme For setting the DHW charging time for HOT WATER programme For setting required hot water temperature For setting hot water priority For activating Heating Circuit O Pump heating circuit modulating control without thermal store Enabling temperature for Heating circuit O For setting maximum flow temperature for heating circuit O
11. and off times for every day of the week To activate programming en bloc press the same weekday button twice in succession all days are then highlighted and can be programmed collectively to the same times 2 7 4 28 Information Status Wi Kesseltemperatur Betrieb Programm NORMAL Leistung 0 Ausseniemperatur 25 25 C ft Hausebene Programm NORMAL Programm ABSENKEN BIS WARMWASSER NACHLADEN Programm HANDBETRIEB ROSTREINIGUNG Kundenebene Of Kundenebene A Kundenmen Heizkreis 0 Heizkreis 1 Heizkreis 2 Warmwasser 0 Ob Kundenebene 1 Helzkreis 1 7 Heizkurve 1 amp Nacht aus AT Mid AT Abschallung Ob Kundenebene Helzkreis 1 Helzkurve 1 Heizkurve 1 0 6 0 6 1 2 1 4 gt Heizk rper 0 5 0 7 gt Fussbodenh Heating characteristic graph BIOSTAR Operating instructions Changing the heating characteristic BS 07 04 00 00 01 BADE The heating circuits charging pumps can only be called into action during the times enabled in the timer programme The example set out below illustrates programming the heating characteristic for heating circuit 1 1 Press the House level button Ao 2 Press the User level button 3 Press the Heating circuit 1 button EN 4 Press the Heating characteristic 1 button 5 Use the and buttons to set the heating characteristic 6 To save the setting press the OR button
12. hard e No additives or binding agents e he ideal length is 20 mm The price should always be a secondary consideration after the quality criteria If the required quality criteria are not met problems with combustion or conveying increased wear and pellet consumption can result Therefore you should not accept quality standards that do not meet the above requirements Calorific value 4 9 kWh ka Bulk weight 2650 kg m Pellet size length Pellet diameter Water content 8 10 96 Ash content BS 08 05 00 00 01 BADE As a general rule wood pellets should be stored in absolutely dry storerooms Those rooms can be fitted with pressure filling and air extraction pipes Type A 110 DIN14309 G4 1 2 or be provided with a filling hatch and must be fire rated to Class F90 The fire door must be protected by removable wooden boards The wall opposite the pressure filing pipe is to be protected by a blast guard Alternatively the pellets can be stored in fabric hoppers or plastic outdoor tanks Note If pellets come into contact with water they swell up and disintegrate Therefore the storeroom must be absolutely dry 33 8 6 34 BIOSTAR Operating instructions Filling refilling the fuel store Vacuum systems Boiler mounted hopper BS 08 06 00 01 01 BADE Caution The heating system must be set to Off mode at least one hour before the fuel store is filled N On no account must the fuel store be filled whi
13. 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 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 BS 05 00 00 04 01 BADE 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 Never use sharp objects such as ball point pens or the like to operate the touch screen 6 Overview of menu and levels menu structure Fault screen QUUD UNA a eu ONE q ais BERG ME i Information l i MEE inc PEE A q Status info sia aaa I MK Controllero EE lo MN MEM NUNT Ca MEN T Off MK Controller 1 i MG li NN UPS EE ON MM EM i Normal 1 MK Controller 2 T MEN JL NNI E mM CNN BORNE NEED 1 E Hotwater Thermal store info 1 EEUU EP oH NS 4 ERO E i Heating E rl co det To 4 A Po Low A r en Information level en EEE mA To E RECHARGEHW Ez SEATS ec Manual Grate cleaning I User Level I Li Service level i Parameters menu House level A BIOSTAR Operating instructions Service level BS 06 00 00 00 01 BADE v I Li Boiler parameters e Menus shown with a dashed border only a
14. outside temperature Figure in brackets average temperature Information Boiler Shows boiler data Shows boiler temperature Shows CO2 level Shows efficiency Shows time in hours until ash warning is triggered Shows fuel gauge Fuel quantity Information Controller O Heating circuit controller 0 HCC 0 Shows domestic hot water temperature and operating mode for cylinder O Shows operating mode for heating circuit O pump heating circuit Shows boiler temperature Shows operating mode for heating circuit 1 mixer heating circuit Shows flow temperature Shows operating mode for heating circuit 2 mixer heating circuit Shows flow temperature Information Controller 1 Only shown if Heating circuit controller 1 is present Information Controller 2 Only shown if Heating circuit controller 2 is present Information Thermal store Shows thermal store temperature at top Shows thermal store temperature at bottom Shows thermal store pump HPO operating mode Shows thermal store charging programme Only shown if one or more heating circuit controllers are activated Only shown if a thermal store is integrated in the system 6 2 6 3 gt oe i ai 2 x u u u No House level user ft Hausebene Programm AUS b Programm AUS O Programm NORMAL Programm WARMWASSER E Programm HEIZEN Programm ABSENKEN ft Hausebene Programm AUS O Programm ABSENKEN BIS WARMWASSER N
15. perfectly safe working order 2 1 Intended use BS 02 01 00 00 01 BADE The boiler is designed for heating central heating water and for use as a central heating boiler 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 2 2 Operating the heating system BS 02 02 00 00 01 BADE 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 Caution even if the opposite is requested servicing and repair work may only be carried out by authorised specialists 2 3 Guarantee and liability BS 02 08 00 00 01 BADE 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 e use of the boiler for purposes other than that intended e failure to follow the instructions guidance and safety precautions given in the documentation e incorrect commissioning operation maintenance or repair of the boiler e operation of the boiler when safety systems are inoperative e unauthorised modifications 2
16. 0 ED L p p Rew9 0000 0 1 D p Signature initials System operator L NNNM ETE CR CS CIC IC RC ECC romero 0 0 0 p E oom 0 01 pL Lu lll e 0 0 D p p lp m RS O O O O O O O m i LL lll pee 0 L m9 0 1 pl pese ft 1 D p e 0 00 1 DE Ll M9 00 1 Ll e 9 9000 1 45 BIOSTAR Operating instructions System operator Serviced by EE ooo romeo 0 0 L1 l come RS L Lu lll e 0 0 1 D p m A HO DNS HH T E E T m ee eee eee 1 3 T1 ITI TII sse 0 1 Ll wewelIIJIIIJITITIJIIJIJJIS mm LIT a a a a T mws 00 0 L p p Rew9 000 0 1 L Signature initials System operator L NNNM ETE CR CS CIC IC RC ECC romero 0 0 0 p E oom 0 01 pL Lu lll e 0 0 D p p lp m RS O O O O O O O m i LL lll pee 0 L m9 0 1 pl eee E D e 0 00 Ll ee 9M 00 Ll e e 90000 0 1 D p 46 BIOSTAR Operating instructions System operator Serviced by EE ooo romeo 0 0 L1 l come RS
17. 0 00 01 BADE Input TKS1 open door switch Ash box open Door switch defective F01 Automatic connector faulty ash box open Tipper grate unable to move Tipper grate unable to Ash chamber too full servo into position within 200 sec attain position Inspect motor defective faulty from activation grate Reset button connection F02 Boiler temperature too high Boiler temperature too Boiler or pump malfunction above parameter BTW high Check flue draught boiler sensor defective or and boiler sensor Reset button switch fault F04 Fault N Flue gas sensor gt in control Combustion fault Check No fuel fuel chute overfilled mode after time param X25 grate fuel chute and incorrect flue draught gt FGT 4 BT is less than pellets Reset button defective flue gas sensor param FGTb betw 30 and F05 100 Fault N Photo sensor via param FW Fire box overfilled Check via time param T bf grate fuel chute and No fuel fuel chute overfilled pellets BESEF DONON photo sensor not in position F06 Fault N Flue gas sensor gt in ignition Ignition not possible No fuel fuel hopper not filled mode no FGT increase after Check grate and pellet faulty ignition fan faulty time parameter X2 supply Reset button connection F07 Entry in With vacuum outfeed fill level Fill level sensor not Fill level sensor dusty or not below limit after conveyor reacting None defective running time RT G1 min F08 terminals 28 30
18. 3 If the temperature drops below the set temperature during the low temperature phase the boiler heats to the required night time temperature 14 The set outside temperature is exceeded during the heating phase the heating circuits are switched off 6 3 2 Hot Water menu User BS 06 03 02 00 01 BADE The Hot Water menu allows you to enter the settings for the various domestic hot water circuits ot Kundenebene Warmwasser O 15 E Betrieb Pumpe auto A Hot water circuit control status 16 Uhrenprogramm WW O Facility for setting hot water charging times 1 MIND LL NN Facility for setting summer hot water charging times 2o p Facility for setting required hot water temperature Facility for setting hot water priority 18 WX WW Vorrang 0 Nein 15 Options Auto Charging pump is switched ON OFF according to demand and timer programme Off The charging pump is switched off Constant The charging pump runs continuously 16 All charging times programmed in the DHW timer programme are active when the programme is set to Normal 17 All charging times programmed in the DHW summer timer programme are active when the programme is set to Hot Water 18 Options No During charging of DHW cylinder heating circuits can be enabled Yes During charging of DHW cylinder heating circuits cannot be enabled factory setting recommended 18 BIOSTAR Operating instructions 6 3 3 Heating Circuit menu User
19. ACHLADEN 6 Programm HANDBETRIEB E ROSTREINIGUNG Kundenebene ft Hausebene Programm AUS F Serviceebene JS Paramelermen BIOSTAR Operating instructions BS 06 02 00 00 01 BADE All heating programmes and menus are listed and described below Heating and hot water switched off Anti freeze function active Heating and hot water on as per timer programme Hot water as per timer programme DHW summer Heating mode switched off Heating mode Day and night hot water heating as per timer programme Low temperature mode Day and night hot water heating as per timer programme Low temperature mode until a specified time Hot water as per timer programme Hot water heating outside programmed charging times Max duration 90 min Constant heating to specified boiler temperature Set on User menu Manual opening of tipper grate for cleaning purposes Takes you to User level Takes you to Service level CODE required Takes you to Parameters level CODE required 3 Pressing the buttons takes you to the relevant programme level User level User ot Kundenebene E Kundenmen O Heizkreis 0 O Helzkeis 1 O Heizkreis 2 Warmwasser O ok Kundenebene CE Pufferspeicher Lo Detailanzeige KB Datum Uhrzeil 4 Setting options on User menu gt 6 7 BS 06 03 00 00 01 BADE Depending on the system configuration the menu levels and submenus may contain different items
20. HW2 NU T r USE AREE i uu ur d I Thermal store I Eo co SH Li i NENNT Detail View Date Time BS 06 00 00 01 01 BADE 15 6 1 Information level user 1 2 16 St rung Fehler F hler Raumger t HKO Unterbrechung am Do 04 11 um 11 17 Information ABSENKEN BIS Fr 5 11 2010 11 35 Information Status Kesseltemperatur 44 C Betrieb AUS Programm ABSENKEN Leistung 0 Aussentemperatur 0 26 C information Kessel Abgastemperatur CO2 Gehalt Wirkungsgrad Asche leeren in Brennstoffz hler Information Regler O Warmwasser 0 26 C AUS Heizkreis 0 44 C AUS Heizkreis 1 24 C AUS Heizkreis 2 25 C AUS Information Pufferspeicher Qt Puffer oben 04 Puffer unten Pufferpumpe Qt _Ladeprogramm BIOSTAR Operating instructions BS 06 01 00 00 01 BADE You use the DOWN B and up buttons to navigate through the Information Level menu Fault nighest priority Plain language fault messages are displayed showing date and time of occurrence Fault is acknowledged by pressing Quit button Information 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 Information Status shows boiler status Shows boiler temperature Shows boiler operating mode Shows selected programme Shows boiler output Shows
21. ILER SYSTEMS as required by the Austrian Technical Directive H118 on Preventative Fire Safety Please note a log book is not legally required in the UK however it is recommended that one be kept System Operator eek System installer ee Boiler system Mc c O rr a E a A Type EIERN a tase O RV RSS ENO RR RDI NR O RR TTET Wearmanulaciired caes RM Raia a a a ca via etus on aU pi Bed uhg oOUlDHlS desbusioetbetiri pia neus na ga od na GR e 42 12 1 12 2 BIOSTAR Operating instructions The following checks are to be carried out regularly on the automatic wood burning boiler system by the system operator when it is in operation Weekly visual inspection Once a week the entire boiler system including the fuel store is to be visually inspected Any deficiencies identified are to be rectified immediately Monthly checks The following monthly checks are to be carried out and if a log book is maintained should be recorded in the log book e Flue gas passages clean flue gas channels in boiler flue connecting pipe and smoke trap e Controller functioning properly e Fault indication warning system s functioning properly e Combustion air and flue draught fans functioning properly e Firebox in good order e Portable fire extinguisher ready for use e Correct storage of ash e No combustibles stored in boiler room e No accumulation of combustible deposits on roof e Fire safety closures fire door
22. IOSTAR Operating instructions Flue draught regulator BS 02 04 00 12 01 BADE Risk of detonation A flue draught regulator with a pressure surge compensator is an essential requirement Safety clearances BS 02 04 00 13 01 BADE Fire risk Do not store any flammable items in the close vicinity of the boiler Follow the local regulations Enteri ng the storeroom BS 02 04 00 14 01 BADE 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 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 Fi lling the storeroom BS 02 04 00 15 01 BADE 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 10 Protection against freezing Fire extinguisher BIOSTA
23. L Lu lll e 0 0 HE D p lp m A HO DNS HH T E E T m ee eee eee Enc O Ha AS ER DE ER DE HR ER DR DR sse eee wewelIIJIIIJITITIJIIJIJJIS mm LIT a a a a T mws 00 0 L p p Rew9 000 0 1 L Signature initials System operator L NNNM ETE CR CS CIC IC RC ECC romero 0 0 0 p E oom 0 01 pL Lu lll e 0 0 D p p lp m RS O O O O O O O m i LL lll pee of m9 0 0 01 pl eee E D e 0 00 Ll ee M9 00 1 Ll e 9 9000 1 If you require more system log book pages please photocopy them 47 Treco GreenHeat UK Distributor Treco Ltd Pyramid House Tiverton Business Park Tiverton Devon EX16 6TG www treco co uk info treco co uk 0845 130 9012 01884 250 790 GUNTAMAT GUNTAMATIC Heiztechnik GmbH A 4722 PEUERBACH Bruck 7 Tel 0043 0 7276 2441 0 Fax 0043 0 7276 3031 E mail info guntamatic com
24. ORMAL heating programme check the selected programme on the Status information screen As soon as heat is called for and there is sufficient heat in the thermal store the heating circuits start up fully automatically 25 26 7 2 Deactivating a heating programme O Information Status E ca oO Q Kessellemperatur Betrieb Programm NORMAL Leistung 096 Ausseniemperalur 25 25 C ft Hausebene Programm NORMAL 5 Programm AUS O Programm NORMAL Programm WARMWASSER EI Programm HEIZEN Programm ABSENKEN ft Hausebene Programm AUS e 0 p Programm AUS Programm NORMAL Programm WARMWASSER Programm HEIZEN Programm ABSENKEN formation Status Kesseltemperatur Betrieb Programm Leistung Aussentemperatur BIOSTAR Operating instructions BS 07 02 00 00 01 BADE To set the NORMAL programme to OFF proceed as set out below step by step 1 gt Press the House level button emi The programme currently selected Normal is shown in the header 2 Press the Off button The new programme selected Off is now shown in the header 3 Press the Info button o 4 The Off programme is now shown on the Status information screen After deactivating the NORMAL heating programme check the selected programme on the Status information screen BIOSTAR Operating instructions 7 3 Setting a timer programme BS 07 03 00 00 01 BADE Inf
25. Pellet Boiler BIOSTAR FrLexBoxw Operating Instructions System Log Book ae DE B30 003 V 16 041 1 V3 0 Taurus UK Distributor Treco Ltd Pyramid House Tiverton Business Park Tiverton Devon EX16 6TG WWW treco co uk info treco co uk 0845 130 9012 01884 250970 Information on this documentation 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 BS C 00 00 00 01 BADE Pag e INtFOQUCH ON 5 1 1 Brief description 5 1 2 Type approval 5 1 3 Further information 5 Important notes
26. R Operating instructions BS 02 04 00 16 01 BADE Anti freeze function The system can only perform its freezing prevention function if sufficient fuel is available and there are no faults BS 02 04 00 17 01 BADE Provide a fire extinguisher There must be a fire extinguisher placed immediately outside the boiler room door BIOSTAR Operating instructions 3 System components 3 1 Cutaway diagram of BIOSTAR Flex BS 03 01 00 00 01 BADE E M x E Ash box door Cleaning grate Primary air Self cleaning grate Secondary air Swirl plate Burn back inhibiting fuel chute Expansion zone Automatic heat exchanger cleaning mechanism Grate cleaner motor Ignition fan Ceramic insulation Overall insulation Helix baffles Tube type heat exchanger Flue draught fan Flue gas sensor Oxygen sensor Control panel controller Sensor for fill level indicator Motor Drive gear Vacuum fan Fuel hopper Pellet auger Photosensor Rotary feeder oL a S SA a a Lll l4 lx oooNOOIP OD O MPP w oO MPM PD PP N 01 EO E CCLCOQOLUVCgICUAAg CCCCOUUSULSOEOOUCCE C QRC EO UY GSC C OCOOGYO CULTU CI BIOSTAR Operating instructions 3 2 Cutaway diagram of BIOSTAR W BS 03 02 00 00 01 BADE SONDA RON mE S Si Si IE E S Si si SONDA P OD O NNNNNNNO DA BON HO Ash box door Cleaning grate Primary air Self cleaning grate Secondary air Swirl plate Bu
27. Setting for heating characteristic for heating circuit O For setting heating times for heating circuit O For activating room stat or room controller for heating circuit O For activating heating circuit 1 Enabling temperature for Heating circuit 1 For setting maximum flow temperature for heating circuit 1 Setting for heating characteristic for heating circuit 1 For setting heating times for heating circuit 1 For activating room stat or room controller for heating circuit 1 For activating heating circuit 2 Enabling temperature for Heating circuit 2 For setting maximum flow temperature for heating circuit 2 Setting for heating characteristic for heating circuit 2 For setting heating times for heating circuit 2 For activating room stat or room controller for heating circuit 2 For activating heating circuit controller 1 external wall controller For activating heating circuit controller 2 external wall controller For activating special output HPO For setting vacuum pipe length Set single pipe length For first time filling of fuel hopper Do not interrupt process For starting drive motor G1 Fill stoker auger After completing system configuration save customer data 21 26 27 28 29 Options Options Options Options FLEX BOX B HOP None Pump Mixer None RFF RS Full RS HC None F pump BIOSTAR Operating instructions Vacuum outf
28. d and timer programme Off The heating circuit is switched off Constant The pump runs continuously with mixer valve heating circuits the mixer valve is not operated 9 Modulation to daytime required temperature is only possible in conjunction with a room stat or room controller raising or lowering the required temperature shifts the heating curve up or down accordingly 10 Modulation to night time required temperature is only possible in conjunction with a room stat or room controller in addition the outside temperature must be below that set in menu option Night OFF OT hysteresis 2 C 11 Options 0 No room effect programmed 2596 Modulation of room temperature based 2596 on room temperature and 7596 on outside temperature 50 Modulation of room temperature based 50 on room temperature and 50 on outside temperature 75 Modulation of room temperature based 75 on room temperature and 25 on outside temperature 100 Modulation of room temperature based 100 on room temperature T 1 C If the required room temperature is exceeded by 1 C the heating circuit pump is switched off T2 C If the required room temperature is exceeded by 2 C the heating circuit pump is switched off T3 C If the required room temperature is exceeded by 3 C the heating circuit pump is switched off 12 Ahigher heating characteristic figure produces a higher required flow temperature at the same outside temperature 1
29. e The amount of cleaning work required is heavily dependent on the quality of the fuel used and lower quality fuels may necessitate more cleaning work BS 08 01 00 04 01 BADE The system only needs to be shut down at the end of the heating season if faults occur or in order to refill the fuel store To do so set the system to the programme OFF and allow it to cool down for approx 120 minutes The system can then be shut down If the system is not used for extended periods summer also isolate it from the power supply by disconnecting the mains plug in order to prevent unnecessary lightning damage BS 08 02 00 01 01 BADE The operating pressure is normally between 1 bar and 2 5 bar If the system pressure is too low malfunctions may result If necessary top up the water in the heating system Note Completely draining and refilling the system or topping up a system filled with anti freeze or treated water must only be carried out by a heating engineer Topping up the heating system water e he heating system water must be cold when topping up make sure the heating system water temperature is below 40 C e Add water slowly until the required system pressure is indicated on the system pressure gauge e Bleed the heating system e Check the system pressure again and add more water if necessary BS 08 02 00 02 01 BADE Turn the red knob on the safety set check for leaks and correct operation in the event of malfunctio
30. eating 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 Cleaning care uu2 2a22000a00000an00nnanunnnanunnnnnunnnnn 36 9 1 Cleaning the fuel store 36 9 2 Interim cleaning 37 9 3 Complete cleaning 38 Hecutying Taults dace cecniecncscncecucscedevectendeavetet 39 Information messages Fault codes 40 Replacing TUSES u 41 LOG DOONK iioi ioi eei doi osi ise coe c aor des casa cet 42 1 1 1 1 2 1 3 Introduction Brief description Type approval Further information BIOSTAR Operating instructions BS 01 00 00 00 01 BADE 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 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 separa
31. eed from a storeroom Vacuum outfeed from a fabric hopper Auger outfeed from a storeroom Auger outfeed from a boiler mounted hopper Heating circuit is deactivated The heating circuit pump will be controlled by the timer programme The heating circuit pump and the mixer valve will be controlled by the timer programme No room stat connected Analogue room stat is connected Digital room controller is connected facility for setting all heating circuits Digital room controller is connected facility for setting assigned heating circuit only Output HPO is deactivated Pump HPO is operated as a feeder pump only activate with heating circuit controller Th store pump Pump HPO is operated as thermal store charging pump Pump FSO Pump HPO is operated as a pump only activate without heating circuit controller Fault signal output 230 V AC 6 4 4 Service menu Heating Circuit Screed Drying Programme Parameters Expert ss 06 04 04 00 01 sa0E 22 27 28 30 fF Serviceebene Parameter HK1 Betrieb HK1 Raumger t HK1 Mischerlaufz Vorlauft min Vorlauft 1 max Mischer RFF 120 Sek 25 C soc T JF Serviceebene Parameter HK1 Kessel berh HKP1 Freigabe Parallelversch Estrichheizen VL Anstieg Anstieg nach Est VL Min Est VL Max Est Haltezeit Start Estricht A CAUTION 5 C 38 C 1 Tage 20 C 45 C 4 Tage Nein Options for setting the
32. emptied or cation emptying interval F23 Reset button counter not reset fault 40 12 Replacing fuses Heplacing fuses BIOSTAR Operating instructions BS 12 00 00 00 01 BADE 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 is disconnected by means of the mains plug or a circuit breaker Fuse function is indicated on the relevant electrical wiring diagrams in the installation instructions 1 Set the system to the programme OFF and allow it to cool down for at least 10 minutes 2 Switch the Power switch to 0 and unplug the mains plug on the back of the boiler to fully disconnect it from the power supply Unfasten the controller cover and remove it Locate the defective fuse with the aid of the wiring diagram in the installation instructions and replace it 5 Press in the fuse holder 2 3 mm using a medium sized screwdriver and turn it half a turn anticlockwise to release it The holder and fuse will then pop out a few mm Hemove the blown fuse and replace with a new one Insert the fuse holder press it in 2 3 mm and secure it in position by turning it half a turn clockwise 41 BIOSTAR Operating instructions LOG BOOK for AUTOMATIC WOOD BURNING BO
33. en checked BS 04 00 00 04 01 BADE 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 BS 04 00 00 05 01 BADE e he auger motor stops feeding in fuel e The flue draught fan switches to maximum extraction speed e After the firebox door is closed normal operation is resumed or re ignition initiated 13 5 14 BIOSTAR Operating instructions Control panel description Power switch 1 STL 2 Touch screen display 3 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 BS 05 00 00 01 01 BADE BS 05 00 00 02 01 BADE Normally remains permanently switched on The power switch may only be switched off when the system is not in operation Note The system must also be disconnected from the mains by unplugging the power lead when carrying out repairs or servicing work BS 05 00 00 03 01 BADE Excessive temperature approx 100 C trips the safety temperature
34. erfilled Flue draught is too great Wide demand fluctuations on the part of heating system components The amount of heat produced cannot be dissipated It may be that a heating pump has failed or has not started up Hopper misaligned Noise transmission Fan is dirty Fan or blades loose Noise created by bends or rigid connecting pipe junctions with chimney flue Fan bearing defective Check external mains plug and or power supply lead between circuit boards Check fuse in supply lead and on the control panel circuit board Eliminate leaks Consult flue installer Check flue Carry out complete cleaning Balance heating system and heating pumps Wait until boiler charging has finished or deactivate boiler priority Increase flue draught in chimney flue if necessary Carry out complete cleaning or consult engineer if necessary Re adjust flue draught regulator Stagger heating system component demand over time Ensure heat dissipation by switching on pumps opening mixer valves or turning on hot water taps The cause of the boiler overheating must be identified if it happens frequently a heating engineer should be called in Check fuses on the boiler circuit board Re align hopper If necessary place the adjustable feet of the boiler on rubber pads Clean fan Eliminate cause Fit insulators sleeves Order replacement motor 39 BIOSTAR Operating instructions 11 Information Fault messages B5 1100 0
35. f hler F F FW vorhanden JF Serviceebene Anlageneinst F FW kalib FW korr 0 kOhm F F Lambdasonde NGK F Lambdaheizung AUTO F Lambda Kalib fF Serviceebene Anlageneinst F Lam sonde korr 0 0 mV F Lam kenniinie 0 0 F PC benwachung Terminal F SU Logging F SD Daten fF Serviceebene Anlageneinst F CID Daten F F02 St rmeldung F12St rmeldung F F23 St rmeldung F Erstbef llung fF Serviceebene Anlageneinst F Saugzug TAKT Einschub Optimal Fl geltype D140 n F Getriebe G1 ABM F F Zeit ABS Pumpe 60 Sek JF Serviceebene Anlageneinst F HKP Zwangseinsch 85 C Restw Nutzung 65 C HKP Frost TV 3 C T V Funktion F F HKP Frost TA 3 C F F Options None NGK BOSCH Options Auto Constant Options Terminal DAQ Facility for setting special boiler and system parameters For setting system type stated on rating plate For setting boiler type stated on rating plate For setting outfeed system type Automatic de ashing On systems with integral ash box set to Off For setting heating circuit controller O For setting heating circuit controller 1 external wall controller For setting heating circuit controller 2 external wall controller Outside temperature sensor activation deactivation Fuel setting Setting 1 15 kW setting 2 23 kW For photo cell activation deactivation Combustion moni
36. gnosis of possible fault causes and to assist the GUNTAMATIC engineer with fault rectification BS 06 03 06 00 01 BADE 19 BIOSTAR Operating instructions 6 4 Service Level Expert BS 06 04 00 00 01 BADE CODE entry required Changes to the settings on the Service Level may only be made with the agreement of GUNTAMATIC or an authorised GUNTAMATIC engineer Serviceebene Reseldaten Service menu Reset data Caution All system settings may be lost ls es Service menu Fault screen Fault memory Tesiprogramm Service menu Test program Function test of all system components Service menu Commissioning Activation of all system components Service menu HCO Parameters Parameters for HCO o Inbetriebnahme 1 Parameter HKO fF Serviceebene 1 Q Parameter HK1 Service menu HC1 Parameters Parameters for HC1 1 Parameter HK2 Service menu HC2 Parameters Parameters for HC2 1 w remm p Service menu DHWO Parameters Parameters for DHW cylinder 0 Parameter HPO v Service menu HPO Parameters Parameters for HPO Ant stell i T ageneinstellungen Service menu System Settings System parameters 6 4 1 Service menu Reset Data Expert BS 06 04 01 00 01 BADE Caution If the service menu option Reset Data is incorrectly used reconfiguration of the entire system may be necessary fF Serviceebene Resetdaten F Kundenparameter laden For importing stored customer data if nece
37. he radiators must not be fitted with thermostatic radiator valves valves must be fully turned on Note The room stat should not be fitted in a position where it will be exposed to warm sunshine or the heat from a stove Pull off the control knob from the front undo the fixing screw and remove the casing from the front Wire the room stat to terminals 1 and 2 BS 07 07 00 00 01 BADE An instruction manual is supplied with the room controller A maximum of 3 room controllers can be connected to the system Connection is established via the CAN bus 8 8 1 8 2 BIOSTAR Operating instructions Operating the heating system Starting up Shutting down the system Initial commissioning Restarting Day to day operation Shutting down the system Heating system checks Checking system pressure Pressure relief valve Expansion vessel Boiler room ventilation BS 08 01 00 01 01 BADE Initial commissioning and basic adjustment of the system may only be carried out by GUNTAMATIC engineers or authorised GUNTAMATIC agents BS 08 01 00 02 01 BADE Before starting up the system again in the autumn winter carry out the annual check of the control and safety systems to ensure they are safe and functional We recommend that you take out a maintenance contract so that the system operates safely and economically BS 08 01 00 03 01 BADE Clean the heating system precisely according to the instructions in the section Cleaning Car
38. heating circuit and screed drying parameters Heating circuit operating status Room stat setting For setting mixer valve running time For setting minimum flow temperature For setting maximum flow temperature For setting boiler overcompensation added to required temp required boiler temp Enabling temperature for Heating circuit 1 For setting heating characteristic parallel shift For activating screed drying programme Screed prog For setting the flow temperature increment Screed prog For setting time until next flow temperature increase Screed prog For setting minimum flow temperature Screed prog For setting maximum flow temperature Screed prog For setting holding time for maximum flow temperature Screed prog For starting the screed drying programme The screed drying parameters must be set in consultation with the floor layer Maintaining the specified temperatures is not possible in modulating control mode but only when using automatic mixer valves Maintenance of the specified temperatures cannot be 100 guaranteed due to various safety circuits and special boiler functions in exceptional cases the temperatures can be significantly exceeded If that is a problem in terms of damage to building work the screed drying function should be operated manually After activation of the screed drying programme the menu expands to reveal the screed programme parameters BIOSTAR Operating instruc
39. hopper can be opened by pulling on the catch The system detects that the hopper has been opened and shuts off the pellet auger sets the flue draught fan to full speed The hopper can be filled with pellets up to the edge of the seal Lock the hopper cover again and operation will be automatically resumed Once a year the hopper should be completely emptied and dust deposits completely vacuumed Out 8 7 Emptying the ash Procedure Hesetting the ash warning BIOSTAR Operating instructions BS 08 07 00 00 01 BADE The ash box has to be regularly emptied according to the amount of fuel used its quality and heat output The higher the dust content of the fuel the shorter the intervals at which the ash must be removed That is particularly the case with low quality fuels with a high dust content The accumulated ash obviously contains the residues of the fuel in concentrated form If you only use environmentally safe fuels the ash residue represents a high quality mineral fertiliser Danger Glowing embers can cause fires IN Only deposit or store the ash from the boiler in non combustible sites BS 08 07 00 01 01 BADE oet the system to Off mode and wait until the status display changes to Off mode Unfasten the ash box by lifting the handle upwards and pull the ash box out to the front The display on the control panel shows the message Ash box open F01 After emptying the ash box check the ash box gasket for wea
40. le the heating system is in operation BS 08 06 00 02 01 BADE When first filling the storeroom and every time it is refilled after being completely emptied do not immediately fill the store completely Instead the fuel auger should first be filled with pellets up to a depth of approx 10 cm over its entire length The fuel storeroom can then be filed up to the maximum permissible bulk storage height Note The fuel outfeed conveyor must be completely emptied vacuumed out every 3 years at least Emergency filling If automatic refilling of the fuel hopper should not be possible due to a fault on the fuel store outfeed system the fuel hopper can be refilled manually as an emergency measure Before you do so however first try to rectify the fault by consulting the section Rectifying faults or the section Information messages and fault codes in the operating instructions Procedure Set the system to the OFF programme and wait until it switches to OFF mode Then switch off the system on the control panel by setting the power switch to 0 Unscrew the top of the fuel hopper and fill it by hand this is best done from a sack of pellets Afterwards refit the hopper cover so that it is tightly sealed cancel the fault messages set the boiler to the heating programme and start up the system again Maximum bulk storage height Pellets max 2 5 m bulk storage height BS 08 06 00 03 01 BADE The boiler mounted
41. ns or leaks call in your installer or heating engineer BS 08 02 00 03 01 BADE If there are large pressure fluctuations between when the heating system is hot and cold check the charge pressure in the expansion vessel in the event of malfunctions or leaks call in your installer or heating engineer BS 08 02 00 04 01 BADE Check that the air supply vents ducts are clear 31 8 3 32 Fuel quality Ensuring fuel quality BIOSTAR Operating instructions To ensure trouble free heating with the boiler the fuel must be of the right quality Austria Always order pellets conforming to ONORM M 7135 Germany Always order pellets conforming to DIN 51731 Switzerland Always order pellets conforming to SN 166000 and carrying the Swisspellets mark Dust emission from the boiler flue is heavily dependent on the dust content of the fuel 8 4 Fuels 8 4 1 Pellets 8 5 Important quality criteria Fuel storage Properties BIOSTAR Operating instructions BS 08 04 01 00 01 BADE There are a number of points to observe when ordering wood pellets in order to ensure that they are of perfect quality Reliable and trouble free operation of the boiler and the conveying systems can only be guaranteed with high quality pellets Therefore we strongly advise that only quality assured products are used that are guaranteed as such by the manufacturer e lowest possible dust content e Surface should be shiny and very
42. o Yes and select OK to confirm Then select the desired heating programme e g NORMAL and start up the boiler The controller takes over control of the boiler again and switches to fully automatic operation 3 9 3 38 Complete cleaning BIOSTAR Operating instructions BS 09 03 00 00 01 BADE Depending on the load on the heating system complete cleaning may be required twice a year but should be carried out at least once a year Carry out the following steps for complete cleaning 1 10 Set the system to the programme OFF and allow it to cool down for at least 2 hours Carry out steps 2 8 of the interim cleaning procedure Before opening isolate the system from the mains Open the flue box 7 on the top of the boiler and remove the fan cover plate 8 by sliding it upwards Using an ash vacuum clean out all ash from the flue draught fan 10 between the heat exchanger tubes 9 and in the flue connecting pipe Risk of fire from glowing embers in the ash Check that the oxygen sensor 12 is firmly seated and if necessary remove it carefully clean it with a soft brush and refit it Make sure the oxygen sensor is firmly seated Remove the photo cell 13 and clean it with a soft cloth Remove the inspection cover 14 and check whether the inner surface of the chute is free of deposits If necessary scrape off using the chute cleaner 15 Afterwards refit
43. ormation Status Kesseltemperatur Betrieb Programm NORMAL Leistung 0 Ausseniemperalur 25 25 C ft Hausebene Programm NORMAL Programm ABSENKEN BIS WARMWASSER NACHLADEN Programm HANDBETRIEB ROSTREINIGUNG Kundenebene Ob Kundenebene 1 amp Kundenmen O Heizkreis 0 O Heizkreis 1 Nil 2 Warmwasser O ot Kundenebene 1 Helzkreis 1 Betrieb Pumpe Uhrenprogramm 1 Solltemperatur Tag Solltemperatur Nacht Raumeinfluss ot Kundenebene Helzkreis 1 Uhrenprogramm 1 Mo Di MI Do Fr Sa So EIN 1 04 00 AUS 1 21 00 EIN 2 AUS 2 EIN 3 AUS 3 7 3 1 Programming en bloc Dt Kundenebene Helzkreis 1 1 Uhrenprogramm 1 Mo D Mi Do F Sa So EIN 1 04 00 AUS 1 21 00 EIN 2 AUS 2 EIN 3 AUS 3 The heating circuits charging pumps can only be called into action during the times enabled in the timer programme The example set out below illustrates programming the timer programme for heating circuit 1 1 gt Press the House level button ES 2 Press the User level button 3 Press the Heating circuit 1 button ES 4 Press the Timer programme 1 button 5 Press the button for the day of the week to be set 6 Press the ON or OFF time to be altered 7 Use the and imn buttons to set the time 8 To save the setting press the ES BS 07 03 01 00 01 BADE En bloc programming can be used to programme the same on
44. ppear if activated on the Commissioning menu e Changes to the settings on the Service or Parameters levels may only be made with the agreement of GUNTAMATIC Layout of touch screen display Header Symbols 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 Scroll bar Informat un Status LI Kesseltemperatur Betrieb Programm Leistung Aussentemperatur 40 26 C HCO parameters 7 THE parameters 7 HGS parameters 7 HGS parameters 7 na parameters 7 HGS parameters 7 HGS parameters 7 HIG parameters 7 HGS parameters 7 DANO Paame C DWT Paama 7 BEAC HPO parameters Scroll buttons Select button 4 o a igs sate I Load H eating circuit 0 qoe ec M ase ianiacion 1 b H eating circuit 1 oett EL RER AIITEM I E H eating circuit 2 iss RES ee a iml I EN H eating circuit 3 pre i fy rei 1 CENE H eating circuit4 i ENSURE god assada en I NM H eating circuit 5 ESSI e p DA rS PER H eating circuit6 ESSES ni x EIS EHRE m Lo H eating circuit 7 IS nen PERL EEE ee TEN H eating circuit8 Po DAWO RP re To MEN DHW1 DER A T Po D
45. r and correct seating slide the ash box back in the boiler and lock it in position by pressing the ash box handle firmly downwards The message Ash box open F01 disappears again Ensure the ash box is properly sealed On the Programme menu set the system to the desired heating programme NORMAL HEATING etc and the system will start up again BS 08 07 00 02 01 BADE If the ash warning appears on the display it has to be reset on the User menu To do so go to the User menu and select the option Ash emptied change the setting to YES and press the OK button to confirm The ash warning has now been reset to the maximum number of hours before it is next triggered The time until the ash warning is issued is preset and can be adjusted to suit the fuel being used by selecting Ash Warning on the User menu on the User Level 35 9 9 1 36 Cleaning Care Cleaning Care Cleaning the fuel store BIOSTAR Operating instructions BS 09 00 00 01 01 BADE For safety reasons you must only carry out servicing and cleaning when the heating system is switched off and disconnected from the mains and has cooled down Servicing work inside the fuel storeroom must only be carried out under the supervision of a second person who must be outside the storeroom There is a risk that accumulation of carbon monoxide in the fuel storeroom could endanger your life In particular you should follow the safety instr
46. rn back inhibiting fuel chute Expansion zone Automatic heat exchanger cleaning mechanism Grate cleaner motor Ignition fan Ceramic insulation Overall insulation Helix baffles Tube type heat exchanger Flue draught fan Flue gas sensor Oxygen sensor Control panel controller Sensor for fill level indicator Motor Drive gear Fuel hopper Pellet auger Photosensor 12 4 Safety systems Safety level 1 Safety level 2 Safety level 3 Power failure Opening the ash box BIOSTAR Operating instructions 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 BS 04 00 00 01 01 BADE 15 C above specified temperature The drive motor stops the fuel feed system and the flue draught fan shuts down BS 04 00 00 02 01 BADE Boiler temperature above 85 C All heating pumps and the cylinder charging pump are switched on to carry heat away from the boiler BS 04 00 00 01 03 BADE 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 be
47. s self closing 12 3 Servicing The heating system must be serviced and inspected in accordance with the regional local and statutory regulations of the country of use We recommend that a maintenance contract is taken out providing for annual servicing by an authorised technician 43 BIOSTAR Operating instructions System operator Serviced by EE ooo romeo 0 0 L1 l come RS L Lu lll e 0 0 HE D p lp m A HO DNS HH T E E T m ee eee eee Enc O Ha AS ER DE ER DE HR ER DR DR CE 0 EEE RR pm O O O O O O O O O a aac E A a a S T mws 00 0 L p p Rew9 000 0 1 L Signature initials System operator L NNNM ETE CR CS CIC IC RC ECC romero 0 0 0 p E oom 0 01 pL Lu lll e 0 0 D p p lp m RS O O O O O O O m i O RO lll pee 00 1 D m9 0 l1 pl eee E D e 0 00 Ll ee M9 00 1 Ll e 9 9000 1 44 BIOSTAR Operating instructions System operator Serviced by EE ooo romeo 0 0 L1 l come RS L Lu lll e 0 0 HE D p lp m A HO DNS HH T E E T m ee eee eee Enc O Ha AS ER DE ER DE HR ER DR DR sse eee pee A O O O O O O O O w BR FRE BE DEREN a EEE PER N FR EEE 00
48. ssary Kundenparameter speichern For saving changes to system configuration in customer data 24 re Imports only the modified parameters of a new software version nnd For resetting duty hours counter is to O Servicezeit reset f For resetting service interval timer to O fF Serviceebene Resetdaten 25 Loads factory settings The system then has to be reconfigured F Steuerungsreset E Lambdskaibb reset For resetting calibration after replacing the oxygen sensor 24 After a change of software version only those parameters that have changed or been added in the new version are imported 25 Caution All system settings including hours of duty and service interval timer readings are lost after a controller reset the system is in the as delivered condition the system then has to be reconfigured 6 4 2 Service menu Fault Screen Expert BS 06 04 02 00 01 BADE fF Serviceebene Fehlerliste St rung stop F hler T1 Kesseltemperatur Unterbrechung Plain language fault messages are displayed showing date and time of am Fr 21 01 um 12 02 v occurrence 20 6 4 3 Service menu Commissioning Expert 26 28 27 28 27 28 29 fF Serviceebene Inbetriebnahme F Anlage Biostar F Type 15kW F Austragung FLEX F HKRO vorh F WW vorhanden 0 Serviceebene Inbetriebnahme F Uhrenprogramm WW 0 F Uhrenprg WW Sommer 0 F WW Solltemp O 55 C F WW Vorrang 0 Nein
49. te fabric hopper or storeroom by an auger conveyor and vacuum system BS 01 02 00 00 01 BADE The boiler is designed as a Class 3 appliance as defined by the draft standard NORM 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 BS 01 03 00 00 01 BADE The documentation consists of the following documents e Planning Document e Installation instructions e Operating instructions If you have any questions please consult our Customer Support BIOSTAR Operating instructions 2 m po rta nt n otes BS 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
50. terim cleaning BIOSTAR Operating instructions BS 09 02 00 00 01 BADE The ash box has to be emptied and interim boiler cleaning carried out at intervals depending on the amount of fuel used How often interim cleaning is required can vary from every 2 weeks to every 3 months The frequency of the cleaning work required is essentially dependent on the quality of the fuel A higher fuel dust content necessitates more frequent cleaning Carry out the following steps for interim cleaning 1 Set the system to the programme OFF and allow it to cool down for at least 1 hour Open the casing door 1 pull out the ash box 2 to the front and empty it Risk of fire from glowing embers in the ash Scrape off the ash above the swirl plate in the boiler burn out zone using the fire box poker 3 Introduce the fire box poker through the left ash box opening 4 On the House level menu start the programme Clean grate and allow the tipper grate 5 to swing down Do not carry out any cleaning operations while the tipper grate is moving Risk of injury from moving parts Use the cleaning tools supplied to clean the grate surface 5 and scrape deposits cleanly off the grate Also check the grate holes and clean them out if required Remove all remaining ash from the ash chamber 6 below the fire box Slide the ash box back into the ash chamber and seal it tightly On the User menu set the parameter Ash emptied t
51. the inspection cover and re insert the photo sensor in the Socket On the House level menu start the programme Clean grate and allow the tipper grate 5 to swing down Do not carry out any cleaning operations while the tipper grate is moving With the tipper grate open inspect the surface of the fire box and clean it with the chute cleaner if necessary Risk of injury from moving parts Check that the tipper grate 16 forms an air tight seal with the fire box opening Clean out all remaining ash from the ash chamber 17 on the left and right using the poker then refit the ash box and seal it tightly Then select the desired heating programme e g NORMAL The controller takes over control of the boiler again and switches to fully automatic operation BIOSTAR Operating instructions 10 Rectifying faults Fa CemeFmcion Remedy BS 10 00 00 00 01 BADE Control panel cannot be switched on Smoke escaping into boiler room Heat output too low Detonation Difficult to limit output Overheating Fault code F04 STL tripped Drive motor too noisy Fan too noisy Power supply disconnected Fuse blown Flue pipe leaking Flue draught regulator unfavourably positioned Flue not clear or not providing any draught Boiler very dirty Heating system inadequately balanced Boiler priority active Flue draught in chimney flue too low Detonation is only possible if the firebox is ov
52. tions 6 4 5 Service menu Hot water parameters Expert BS 06 04 05 00 01 BADE Facility for setting hot water parameters F Serviceebene Param WW 0 FT ww vorhanden 0 Hot water circuit operating mode 31 aoo Facility for setting hot water hysteresis Hot water cylinder recharging 7 00 Enabling temperature for cylinder charging pump gt ccP 0 amo orea For setting boiler overcompensation added to required temp required boiler temp 31 Ifthe temperature in the hot water cylinder falls 10 C hysteresis below the required temperature the hot water cylinder is heated up again the precondition is that the charging time is enabled in the timer programme on the Hot water menu 6 4 6 Service menu HPO parameters Expert BS 06 04 06 00 01 BADE Facility for setting the parameters for special output HPO fF Serviceebene Parameter HPO Betrieb HPO Pufferpumpe Operating status of special output HPO Freigabe ho soc Enabling temperature for output HPO 32 _ 77 o dis Setting for thermal store top boiler ON 33 fupe ou Setting for thermal store top boiler OFF 34 fe hes Setting for thermal store bottom boiler OFF fF Serviceebene Parameter HPO P Jom Pu Setting for temperature difference between boiler and bottom of thermal store 32 Function TS top B ON The boiler is started up when the thermal store temperature falls below the maximum temperature required by the heating circuit controller min
53. toring For activating photoresistor calibration For entering photoresistor compensation For setting oxygen sensor type For setting oxygen sensor heater For activating oxygen sensor calibration For entering oxygen sensor compensation For setting oxygen sensor characteristic only during Controller mode For activating monitoring mode Facility for data recording on SD memory cards Facility for reading data from SD memory cards For querying manufacturer code Setting for fault signal from tipper grate motor position monitor Setting for fault signal from speed monitor for drive motor G1 Setting for fault signal Empty ash box gt oh Deactivated For activating filling sequence only in OFF mode do not interrupt Setting for flue draught fan operation Motor operation setting only visible with outfeed type HX For selecting drive motor type For selecting flue draught fan blade type All pumps are activated once a week for the time set here Activates all heating circuits up to maximum flow temperature Pump HPO continues running until temperature at boiler is below set temperature If the outside temperature falls below HCP A F outside the heating circuit pumps start running HCP A F Flow is required flow temperature gt only in OFF mode Raises boiler temperature until STL trips in Controller mode No oxygen sensor or oxygen sensor is deactivated Oxygen sensor type fitted is NGK Oxygen sensor type fitted is
54. tton 29 7 6 Analogue room stat it 1 04 o Operating modes Installation site Connection 7 7 Digital room controller 30 BIOSTAR Operating instructions BS 07 06 00 00 01 BADE If your system is fitted with an outside temperature based heating circuit controller each heating circuit can be equipped with an analogue room stat if desired The control knob on the room stat allows adjustment of the required room temperature preset on the Heating Circuit menu Setting the control to a position in the positive range raises the room temperature by up to 3 C Setting it to a position in the negative range lower lowers the room temperature by up to 3 C Note This means that the room temperature shown in the Detail View will be inaccurate The room temperature shown will only match the actual temperature when the control knob is in the centre position Low Low temperature mode if during the low temperature phase the outside temperature falls below the temperature set in the parameter Night OFF OT the system heats to the room temperature set in the parameter Night time Required Temperature Normal Heating and low temperature modes on as per timer programme Heating Continuous heating to Required Daytime Temperature Fix the room stat on an internal wall at a height of approx 1m 1 5m The most effective room is the one that is most frequently occupied In that room t
55. uctions in Section 2 BS 09 00 00 02 01 BADE The sophisticated cleaning system on a GUNTAMATIC heating system means that regular cleaning work is substantially reduced All that is required is regular emptying of the ash The flue must be regularly swept At the same time the flue connecting pipe the flue gas box and the boiler heat exchanger should be cleared of fly ash Depending on how dirty the boiler becomes which is determined by the quality of the fuel burned interim cleaning may be required for which the precise procedure is described in the section Interim cleaning Depending on the load on the heating system complete cleaning for which the precise procedure is described in the section Complete cleaning may be required twice a year but should be carried out at least once a year If the heating system is subject to exceptionally high loads more extensive cleaning may be required BS 09 00 00 03 01 BADE If the casing panels or the controls become dirty they are best cleaned with a soft damp cloth Use only gentle solvent free cleaners to dampen the cloth On no account should solvents such as alcohol white spirit or thinners be used as they will attack the surface of the boiler BS 09 01 00 00 01 BADE The fuel outfeed auger and the fuel store must be completely emptied vacuumed out at least once every 3 years so as to prevent problems with the outfeed system due to dust accumulation 9 2 In
56. us the temperature set in the parameter TS top B ON Example Maximum temperature required by heating circuit controller 55 C Setting for TS top B ON 6 C The boiler starts up when the temperature at the thermal store top sensor T3 is 49 C 33 Function TS top B OFF The boiler is shut off when the temperature at the thermal store top sensor T3 reaches the thermal store required temperature plus the temperature set for the parameter TS top B OFF Example Required thermal store temperature 60 C Setting for TS top B OFF 5 C The boiler is shut off when the temperature at the thermal store top sensor T3 is 65 C 34 Function TS btm B OFF The boiler is shut off as soon as the temperature at the bottom of the thermal store T2 only differs from the temperature at the top of the thermal store T3 by the amount set for the parameter TS btm B OFF Example Temperature at top of thermal store T3 60 C Setting for parameter TS btm B off 10 C The boiler is shut off when the temperature at the thermal store bottom sensor T2 is 50 C 23 BIOSTAR Operating instructions 6 4 7 Service menu System settings Expert BS 06 04 07 00 01 BADE 24 35 36 37 35 36 37 JF Serviceebene Anlageneinst F Anlage Biostar Type 15kW F F Austragung FLEX F Kesselreinigung AUS F HKR 0 vorh Ja JF Serviceebene Anlageneinst F HKR 1 vor HKR 2 vorh Brennstoff F F Aussen
Download Pdf Manuals
Related Search