Biotec. Ökotec 25. Installation and user manual. Bedienungsanleitung. Produktinformation

Biotec Ökotec 25 Installation and user manual AufstellungsProduct information und Bedienungsanleitung Produktinformation

Safety information Safety information Basics The boiler must be installed by a competent professional. The Biotec is produced according to current safety requirements. Incorrect use can cause accidents, injury or even death of the user, if the rules for safe use are ignored. This can also cause damages to the boiler or to other items next to the boiler. The specialist responsible for the implementation must explain the proper handling of the boiler to the user. Only use the boiler if it is installed properly. Always follow the instructions of this manual. Every boiler failure must be fixed as soon as possible. Use of the boiler The manufacturer is not responsible for damages resulting from an inappropriate use. In this case, the user is responsible. The operation parameters can only be modified in the range prescribed in this manual. The use of parameters outside the range can cause damages or errors in the system. Prescribed fuel This boiler is designed for the combustion of wood pellets. The use of other fuels is prohibited. Wood pellets are cylindrical and made from wood scraps without additives or chemical binders. The pellets must have specifical dimensions and a low moisture level. STREBEL recommends pellets with a diameter of 6 to 8 mm and a lenght of 10 to 30 mm. Quality and form are prescribed throughste standards ÖNORM 7135 and DIN 51731. Only use pellets that comply with ÖNORM, DIN or equal regional stadards. More informations in chapter 3. Risk of electric shock Works with parts marked with this symbol are only to be carried out by an electrician. Text passages with this symbol hold information about electric connections. Caution Working on parts marked with this symbol can cause injury or material damage. Text passages with this symbol hold information about safety precautions. Possible hand injuries Working on parts marked with this symbol can cause hand injuries. Fire hazard Flammable items may not be positioned near the boiler. Text passages with this symbol hold information about fire prevention. Danger of frost Frost forming in the system pipes after a longer period of downtime during the cold season can cause severe damages. Text passages with this symbol hold information about frost prevention. Additional notices Follow regional prescriptions on positioning, installation, operation and disposal of the boiler. Every person with the intend of operating the boiler is prescribed to carefully read this manual. This applies especially for the safety informations. Even persons intending to clean the boiler or perform other maintenance must read this manual. Otherwise, the guaranty expires. This manual is to be stored safely. Possible risks Carbon monoxyde During boiler operation, carbon monoxyde can issue through the boiler doors. Only leave them open as long as necessary. Insufficient vent during operation is critical. Closing the vent of the boiler room or the boiler is prohibited. Signs and symbols Surfaces with high temperatures Touching such surfaces can cause burns. Surfaces marked with this symbol may only be touched when the system is cooled down. Text passages with this symbol hold information about hot boiler parts. 2

Contents 1 Boiler features... 4 2 Technical data... 5 3 Fuel... 7 4 Construction and funtion... 8 5 Installation... 9 6 Boiler controller... 18 7 Phases of operation... 22 8 Maintenance... 23 9 Possible malfunctions... 24 10 First start-up... 25 11 Disposal of the boiler... 26 Terminal connections... 27 3

1 Boiler features 1.1 General information The boiler Biotec has a modern design and is made of high quality material. The boiler testings were carried out conform to EN 303-5, so the boiler fulfi lls all requirements for the connection to the central heating system. The maximum permitted system pressure is 2.5 bar. This boiler is suitable as central heating system for single- or multi-family-homes, small businesses or workshops. The automatic operation shows to be very user-friedly, because the only action during operation is re-filling the pellet silo every day to every couple of days, depending on the current output. The Biotec includes the silo and pellet screw. The basic design of the boiler features the silo on its right side. On request and for additional charge, the silo can be mounted on the left side resp. a bigger silo can be installed. Pellets make an excellent fuel. Wood pellets are zylindrical and made from wood sraps. The ash-percentage after the combustion is especially low with pellets and accounts for about 1 %. The caloric value of pellets is approx. 18000 kj/kg, wich means that 2 kg pellets comply to 1 l light heating oil. The storing qualities and the high energy value of pellets make them the ideal replacement for oil or gas. Additionally, they are produced from wood, a regional renewable source. Boiler features 1.2 Conformity declaration The company STREBEL confirms according to EN45014:1998 that the boiler Biotec complies with the following standards: EC-guidelines: MD 98/37/EC PED 97/23/EC LVD 2006/95/EC EMC 2004/108/EC Harmonized standards: EN 303-5:1999; EN 60204-1:2006; EN 60335-1:2002; EN 50165:1997+A1; EN 61000-6-3:2001; EN ISO 12100-1:2003; EN ISO 12100-2:2003; EN 1050:1997 Other standards and technical spezifications: EN 287-1:2004, EN 288-3:1992; EN 10204:2004; EN ISO 7000:2004. Used method for testing conformity: Modul B1 Grenzwert der Emission der Verbrennungsprodukte (Klasse) 3 Certificates: EC Control Type Certifikate Nr. 0745/350/09 Responsible laboratory: TÜV Thüringen e.v. Service-Center Südthüringen, Industriestr.13, D-98544 Zella-Mehlis We hereby declare that the mentioned products were produced under safety- and norm prescriptions, guidelines and standards. All working conditions and terms of use comply with this manual. In case the product is changed in a way we are not informed of, this confirmation loses its validity. 4

Technical data 2 Technical data Pelletskessel Biotec 25 Biotec 25 S Biotec 40 Rated output kw 25 25 40 Minimum output kw 8 8 13 Flow-/Return temperature C 90/70 90/70 90/70 Flue gas temperature at rated output C 135-140 Minimum flue gas temperature C 95 95 95 Flue gas volume flow at rated output kg/s 0,0176-0,0280 Flue gas volume flow at min. output kg/s 0,0079-0,0140 Effi ciency % 88 91 85 Water volume l 70 74 118 Resistance on water side t=10 K/t=20 K hpa 7/2 7/2 7/2 Weight kg 320 340 459 Boiler class N 303-5 3 3 3 Maximum operating/testing pressure bar 2,5/5 2,5/5 2,5/5 Maximum flue draft Pa 12-15 Connection flow/return inch 1 1 5/4 Exhaust connection diameter mm Ø 130 130 130 Pellet silo volume l 200 500 400 Maximum volume of silo (extra charge) l 400 - - Electric connection 230 V ~ 50 Hz (max. 1 A) 230 V ~ 50 Hz (max. 1 A) 230 V ~ 50 Hz (max. 1 A) Power consumption ignition/fan/screw motor W 400/41/50 400/41/50 400/41/50 5

Technical data 2.1 Dimensions R HE F H DE D W2 W Boiler diameters (mm) Overall width (W) Depth (D) Height (H) Diameter exhaust conn. (DE) Boiler width (W2) Height return (R) Height flow (F) Centre exhaust conn. (HE) Biotec 25 1275 (200 L silo) 905 1435 130 500 269 1132 1130 Biotec 25 S 1443 (500 L silo) 905 1630 130 500 269 1132 1330 Biotec 40 1645 (400 l silo) 1070 1660 130 708 254 1301 1330 Connections (inch) R1 R2 R3 Biotec 25 1 1/2 3/4 Biotec 25 S 1 1/2 3/4 Biotec 40 5/4 1/2 3/4 Silo volume W. H. D. Pellet silo dimensions (mm) Lid halfheight Lid max height 200 Litre 765 1350 650-1990 400 Litre for Biotec 25 400 Litre for Biotec 40 935 1350 750 1715 2100 935 1625 750 1990 2375 500 Litre 935 1545 750 1910 2295 6

Fuel 3 Fuel 3.1 Required fuel-quality DIN 51731 Pellet-size HP5, made from by-products of wood and woodshavings, without additives. The energy value of 2 kg pellets complies with the energy of 1 l light heating oil (10 kwh). ÖNORM 7135 The Austrian standard comprises quality requirements of pellets, testing regulations, supervision of pellet production and labelling. DIN Plus Standard DIN Plus combines Standard DIN 51731 and Standard ÖNORM 7135. The certification procedure at the manufacturer s works is carried out by the responsible certifi ed DIN-inspector. The quality of the pellets is supervised and checked regularly. Standard DIN 51731 ÖNORM 7135 DIN Plus Length mm max. 50 max. 5 x diameter max. 5 x diameter Diameter mm 4-10 max. 10 max. 10 Chaloric value MJ/kg 17.5-19.5 min. 18 min. 18 Pellet density kg/m 3 1-1.4 min. 1.12 min. 1.12 Pellet bulk density kg/m 3 min. 650 min. 650 n.a. Water content % max. 12 max. 10 max. 10 Ash content % max. 1.5 max. 1.5 max. 0.5 Abraison of the pellets % n.a. max. 2.3 max. 2.3 Sulphur content % n.a. max. 0.04 max. 0.04 Nitrogen content % n.a. max. 0.3 max. 0.3 Chlorine content % n.a. max. 0.2 max. 0.2 7

Construction and function 4. Construction and function 4.1 Construction 3 6 12 10 11 2 15 5 4 Construction of the boiler 14 13 1 7 8 9 Legend: 1 Burner 2 Heat exchanger w. turbulators 3 Pellet silo 4 Pellet screw 5 Gear motor 6 Case of heat exchanger 7 Case of burner 8 Fan 9 Combustion chamber door 4.2 Function The application box (14) houses the main switch for turning the boiler on and off. Boiler operation can be adjusted via pushbuttons on the controller panel (12). If the combustion process is started, the gear motor (5) of the pellet screw (4) starts to run. It conveys pellets from the silo (3) to the burner (1). Combustion takes place in the combustion chamber and can be inspected via the sight glass (15). The fan (8) provides primary and secundary air for combustion. The pellet ash falls into the ash drawer (13) through the openings of the combustion chamber floor. The turbulator-spirals within the heat exchanger tubes (2) can be moved up and down with the cleaning lever (11) to remove cloggings from the inside of the tubes. 10 Exhaust connection and exhaust probe 11 Cleaning lever 12 Controller panel Caution! The combustion chamber door (9) must be closed during boiler operation. The ash drawer and the combustion chamber may only be touched and cleaned when the boiler has cooled down. 13 Ash drawer 14 Application box 15 Sight glas 8

Installation 5 Installation The installation of the boiler and other system components must be carried out by qualified technicians. 5.1 Hydraulic scheme examples Pellet Pelletskessel boiler Biotec Biotec 25 25 RTH Power Netz 230 supply V / 230 50 Hz V/50 Hz B AB A Hydraulic Hydraulische compensator Weiche Return Rücklaufanhebung riser Regumat RTA 130 DN 25 HCP HKP TCP SLP CW KW DWP SF Speicher Tank RTH Raumthermostat SF Speicherfühler SLP Speicherladepumpe HKP Heizkreispumpe AG Ausdehnungsgefäss WW Warmwasser KW Kaltwasser HW Domestic Brauchwassermischer water mixer Hot Warmwasser water Safety Sicherheitsgruppe group cold Kaltwasser water Room thermostat Domestic water probe Tank charging pump Heating circuit pump Expansion vessel Hot water Cold water RTH DWP TCP HCP HW CW Connection scheme with domestic water tank 9

Installation RTH HCP HKP SLP TCP CP PF KW CW Pufferspeicher Compensator tank HW Brauchwassermischer Domestic water mixer Hot Warmwasser water DWP SF Tank Speicher Safety Sicherheitsgruppe group Kaltwasser cold water B AB A Return Rücklaufanhebung riser Regumat RTA 130 DN 25 RTH DWP CP TCP HCP HW CW Room thermostat Domestic water probe Compensator tank probe Tank charging pump Heating circuit pump Expansion vessel Hot water Cold water RTH Raumthermostat SF Speicherfühler PF Pufferfühler SLP Speicherladepumpe HKP Heizkreispumpe AG Ausdehnungsgefäss WW Warmwasser KW Kaltwasser Pellet boiler Biotec 25 Pelletskessel Biotec 25 Power Netz 230 supply V / 50 230 Hz V/50 Hz Connection scheme with domestic water tank and compensator tank 10

Installation RTH RTH Room thermostat Expansion vessel RTH Raumthermostat AG Ausdehnungsgefäss B AB A Rücklaufanhebung Return riser Regumat RTA 130 DN 25 Pellet Pelletskessel boiler Biotec Biotec 25 25 Netz Power 230 supply V / 50 230 Hz V/50 Hz Connection scheme with room thermostat 11

Installation AF OP Brauchwassermischer Domestic water mixer Hot Warmwasser water PF CP Tank-intank Speicher im system Speicher System HW A B AB Rücklaufanhebung Return riser Regumat RTA 130 DN 25 Ceta 106 Ceta RC FP OP CP MMO MCP HW CW Controller Room remote controller Flow probe Outside probe Compensator tank probe Mixer motor Mixer circuit pump Expansion vessel Hot water Cold water Ceta 106 Regelgerät Ceta RC Raumgerät VF Vorlauffühler AF Aussenfühler PF Pufferfühler MIMO Mischermotor MKP Mischerkreispumpe AG Ausdehnungsgefäss WW Warmwasser KW Kaltwasser Pellet boiler Biotec 25 Pelletskessel Biotec 25 Power Netz supply 230 V 230 / 50 V/50 Hz Hz 12 Ceta 106 Ceta 106 Ceta RC Ceta RC FP VF FP VF MCP MKP MCP MKP MIMO MIMO Safety Sicherheitsgruppe group cold Kaltwasser water Connection scheme with tank-in-tank system and 2 heating circuits CW Schemazeichnung, keine Gewähr auf Vollständigkeit

Installation AF Ceta 106 Ceta 106 Ceta RC Ceta RC FP VF FP VF MCP MKP MKP MCP MIMO KW CW HW WW Safety Sicherheitsgruppe group cold Kaltwasser water FREWA FRIWA PF CP B AB A Rücklaufanhebung Return riser Regumat RTA 130 DN 25 MIMO Ceta 106 Ceta RC FP OP CP MMO MCP FREWA HW CW Ceta 106 Regelgerät Ceta RC Raumgerät VF Vorlauffühler AF Aussenfühler PF Pufferfühler MIMO Mischermotor MKP Mischerkreispumpe AG Ausdehnungsgefäss FRIWA Frischwassermodul WW Warmwasser KW Kaltwasser Cobtroller Room remote controller Flow probe Outside probe Compensator tank probe Mixer motor Mixer circuit pump Expansion vessel Fresh water module Hot water Cold water Pellet boiler Biotec 25 Pelletskessel Biotec 25 Power Netz supply 230 V 230 / 50 V/50 Hz Hz Connection scheme withcompensator tank, 2 heating circuits and freshwater-module 13 Schemazeichnung, keine Gewähr auf Vollständigkeit

Installation Brauchwassermischer Domestic water mixer Hot Warmwasser water HW Domestic water Brauchwasserexpansion Ausdehnungsgefäss vessel HW CP PF CW Combined Kombipufferspeicher compensator tank A B AB Rücklaufanhebung Return riser Regumat RTA 130 DN 25 Ceta 106 Ceta RC FP OP CP MMO MCP HW CW Ceta 106 Regelgerät Ceta RC Raumgerät VF Vorlauffühler Controller Room remote controller Flow probe Outside probe Compensator tank probe Mixer motor Mixer circuit pump Expansion vessel Hot water Cold water AF Aussenfühler PF Pufferfühler MIMO Mischermotor MKP Mischerkreispumpe AG Ausdehnungsgefäss WW Warmwasser KW Kaltwasser Pellet boiler Biotec 25 Pelletskessel Biotec 25 AF OP Power Netz supply 230 V / 230 50 Hz V/50 Hz 14 Ceta 106 Ceta 106 Ceta RC Ceta RC FP VF FP VF MCP MKP MKP MCP MIMO MIMO Safety Sicherheitsgruppe group cold Kaltwasser water Connection scheme with combined compensator tank and 2 heating circuits Schemazeichnung, keine Gewähr auf Vollständigkeit

Installation OP AF Ceta 106 HW Domestic Brauchwassermischer water mixer Hot Warmwasser water Ceta RC FP VF FP DP SF MCP MCP MKP SLP MIMO Ceta 106 Regelgerät Ceta RC Raumgerät KW CW Safety Sicherheitsgruppe group cold Kaltwasser water DW-tank Speicher Ceta 106 Ceta RC FP OP DP CP MMO MCP HW CW VF Vorlauffühler AF Aussenfühler Controller Room remote controller Flow probe Outside probe Domestic water tank probe Compensator tank probe Mixer motor Mixer circuit pump Expansion vessel Hot water Cold water SF Speicherfühler PF Pufferfühler MIMO Mischermotor MKP Mischerkreispumpe AG Ausdehnungsgefäss WW Warmwasser KW Kaltwasser CP PF B AB A Return Rücklaufanhebung riser Regumat RTA 130 DN 25 Pellet Pelletskessel boiler Biotec Biotec 25 25 Compensator Pufferspeicher tank Power Netz 230 supply V / 50 230 Hz V/50 Hz Connection scheme with combined compensator tank, 1 heating curcuit and DW-circuit 15

Installation 5.2 Installation place and chimney The boiler must be installed near a chimney. It is prohibited to close air vents. WARNING! 1.) The boiler must be placed on a solid and stable floor. 2.) The installation must be carried out by qualified technicians. 3.) The boiler room must be equipped with water- and grounded electrical connection. A waste water draw-off is advantageous. 4.) The boiler room must be vented in a sufficient way. 5.) Floor, walls, ceiling, door and equipment of the room must be made of non-flammable material. Additional notes: 1.) Humidity should be kept at a low level to avoid corrosion of metal parts. 2.) For the filling of the boiler we advise to use soft water. 3.) The circulation pump must not operate before the heating system is completely filled with water. The system must be bled. 4.) When connecting the boiler to the flue it is necessary to put the flue pipe inhorizontally or vertically. All connections must be sealed up properly. 5.) Before the first start-up, check the position of the chamotte bricks to make sure they fit correctly and were not shifted during transportation of the boiler. 6.) The chimney must be layed out according to diagram below. An insufficient flue draft holds a fire risk. In that case, the fire can spread from the burner on to the screw and the pellets in the silo. Rated output [kw] Rated output [kw] Chimney height [m] 16

Installation Examples of correct chimney installation 5.3 Connection of the boiler parts Connect the electric wire of the pump to the power supply. (max. current 1 A). To prevent system freeze or if the boiler will not be used for a longer period of time, we advise to fill the system with a an antifreeze or to drain the system. Connection of the controller Connect the electric wire of the controller to the power supply. The installation of the electric accessories of the boiler needs a power supply with 230 V/50 Hz. Connection of the room thermostat A room thermostat can be connected to the controller. Before starting up the boiler, check the following: 1.) Water pressure in boiler and system. 2.) System must be bled. 3.) The wires of the boiler are installed correctly, undamaged and not touching surfaces that heat up during operation. 4.) The chamotte-bricks are correctly positioned in the burner. 5.) The pellet silo is properly clean. Installation scheme of the thermo-chamotte-bricks inside the burner. A certified safety valve (2.5 bar) and an expansion vessel must be installed in the heating system. Do not install other valves between the safety valve and the vessel. The return temperature must not fall below 60 C to prevent the build of condensate inside the boiler. 17

Boiler controller 6 Boiler controller 6.2 Basic display 6.1 Control panel The controller is used for regulating the pellet boiler operation. The design of the control panel is shown in the scheme below: 1 2 3 4 13 12 11 10 5 6 7 8 9 Legend The controller has an LCD display and 6 buttons on the right side of the display. Functions of the buttons Increase of parameter values Escape, boiler power off Browse menu go back Browse menu go forward Decrease of parameter values Enter, confi rm selected parameter 1 Time 2 Boiler operation 3 DW-tank temperature 4 Fan activated 5 Pump 6 Pellet screw 7 Ignition electrode 8 Boiler pump 9 Preset power output 10 Flue gas temperature 11 Current boiler temperature (desired) 12 Program 13 Boiler operation phase Inputs - Boiler probe (Pt 1000) - Flue gas probe (Pt 1000) - Domestic water probe (NTC, 10 kω) - Compensator tank probe (NTC, 10 kω) - Room thermostat - Input GSM controller Outputs - Ignition electrode (relay, 8A, NO) - Pellet screw (relay, 5A, NO) - Fan (PWM) In the line Boiler operation phase (13), information about the current phase of boiler operation (Boiler OFF, First ignition-phase, Combustion-phase, Cool-down phase, Room thermostat OFF, etc.) The symbol Boiler operation shows if the boiler is active or not. If the boiler is set to run in a pre-programmed operation mode, the display shows TIME. The symbols in the bottom line show the operational availability of the controller outputs resp. if the elemets (fan, pump, screw, ingniter, boiler pump) are active or not. If the symbol shows, that component is active. 18

Boiler controller 6.3 Start and stop of the boiler To start the boiler, activate the red main switch on the right side of the boiler. After activation, the boiler controller turns on and shows the basic display. To start boiler operation, press the enter button for about 2 seconds. The display shows ON and the boiler switches into the pre-pulse phase with maximum fan power. 6.5 Automatic operation To set the hours of operation for the automatic operation, press the button for about 2 seconds. The weekday can be selected by pressing or. To change the operating hours for the selected day, press the enter button. To switch to automatic operation, the enter button is again pressed for about 2 seconds. Then, the display shows TIMER PROGRAM BOILER. To shut down the boiler, the escape button is pressed for about 2 seconds until the display shows OFF. The boiler switches to the cool-down phase with decreased fan power. To deactivate the boiler, the escape button is again pressed for about 2 seconds. By deactivating the main switch, the boiler is powered down completely. 6.4 Setting of time and date For the setting of date and time the button about 2 seconds. is pressed for The display shows two rows of each two time-sets, the first is the start of operation, the second is the time for operation stop. In the example below, the boiler starts up at 06:00 am and deactivated at 04:00 pm. After a pause, operations starts again at 07:00 pm and stops at 10:00 pm. Then the boiler is deactivated until the next day. The operation times can be set individually for every day of the week. The values can be changed with the buttons and and confirmed with the enter button. After confirming, the selection shifts ahead one position. The current selection can be changed with the buttons and. With the enter button, the selection is confi rmed and shifts ahead one position. The seconds can not be set. When all positions are set, the user reaches the basic display. To escape the setting without making changes, press the escape button. After all four sets are confirmed, the display shows COPY. If this is confirmed with the enter button, the settings are copied to the next day. Pressing the escape button leads to the settings for the next weekday, without copying the changes. 19

Boiler controller 6.6 Operation parameters The following parameters are relevant for boiler operation, pellet combustion, and fl ue gas temperature. The parameters are set by the technician before the fi rst start-up (see 6.7). The operation parameters are displayed by pressing the button in the basic display. Press the buttons or to set the value for the selected parameter. Press the escape button to go back to the basic display. Press the enter button to confirm the selection. 4.) POWER: The large position in the middle shows the set power stage. The row below shows the set values of the Operating duration of screw (R), the Pausing duration of screw (P) and the - Fan-power during heating operation (V). 1.) Boiler temperature rated value: P1: Minimum output operation P2: Intermediate output operation P3: Maximum output operation 2.) Tank temperature rated value: 5.) Switching between summer- and winter-mode 3.) DOMESTIC WATER: In summer-mode, the boiler only produces heat for domestic water. 20

Boiler controller 6.7 Setting parameters Changes of particular parameters can be done by pressing the buttons and at the same time. Below, a list of the parameters with the factory settings in brackets (value Biotec 25/ value Biotec 40). The parameters can be altered by pressing or. The setting is confirmed with the enter button and the menu directs the user back to the basic display. S1: Duration of start-up fan (30 s/30s) S2: Fan-power (100 %/100 %) S3: Duration of screw start-up dose (30 s/30 s) S4: Fan-power during start-up (30 %/30 %) S5: Delayed start of ignition (60 s/60 s) S6: Duration of start-up ignition (60 s/60 s) S7: Fan-power during ignition (80 %/80 %) S8: Duration of second ignition (600 s/600 s) S9: Duration of stabilisation (200 s/200 s) S10: Operating duration of screw during stabilisation (1,5 s/1,5 s) S11: Pausing duration of screw during stabilisation (10,0 s/10,0 s) S12: Fan-power during stabilisation (90 %/90 %) S13: Stabilisation delay (300 s/300 s) S14: Operating duration of screw P1 (2,5 s/4,0 s) S15: Pausing duration of screw P1 (10,0 s/10,0 s) S16: Fan-power during heating operation P1 (40 %/55 %) S17: Operating duration of screw P2 (3,0 s/4,5 s) S18: Pausing duration of screw P2 (10,0 s/10,0 s) S19: Fan-power during heating operation P2 (45 %/60 %) S20: Operating duration of screw P3 (3,0 s/5,0 s) S21: Pausing duration of screw P3 (10,0 s/10,0 s) S22: Fan-power during heating operation P3 (46 %/62 %) S23: Duration of cool-down phase (240 s/240 s) S24: Power of fan during cool-down phase (50 %/50 %) S25: Boiler delay with room thermostat OFF (0 s/0 s) S26: Max. flue gas temp. for ignition (100 C/100 C) S27: Min. flue gas temp. (7,0 C/7,0 C) S28: Min. Abgastemperatur (50 C/50 C) S29: Max. decrease of flue gas temp. (20 C/min / 20 C/min) S30: Duration of disregarded flue gas temp. in partial load operation (30 min./30 min) S31: Minimum operation (5 C/5 C) S32: Factor of boiler rated value for modulation (10 x/10 x) S33: Fan-power reduction permitted (5 %/5 %) S34: Hysteresis (5,0 C/5,0 C) S35: Turn-on temp. for return increase pump (55 C/55 C) S36: Diff. between turn-on and -off temp. (10 C/10 C) S37: Pump overrun with RT OFF (0 s/0 s) S38: Difference boiler to tank (5,0 C/5,0 C) S39: Boiler probe adjustment (0,0 C/0,0 C) S40: Flue gas probe adjustment (0,0 C/0,0 C) S41: Compensator tank probe adjustment (0,0 C/0,0 C) S42: Domestic water probe adjustment (0,0 C/0,0 C) 21

Operation phases 7 Operation phases 7.1 Ignition phase If the fl ue gas temperature rises beyond the limit for triggering ignition, the controller registers that the burner room holds enough ember to successfully continue combustion. In this case, the ignition electrode is deactivted. The dosage of pellets continues. The pump is activated if the boiler temperature rises beyond the required temperature and if the room thermostat is activated. If the room thermostat is not activated, the pump runs for a period of time (5 minutes) after deactivation. After that period, the pump stops until the room thermostat is activated again. If the fl ue gas temperature falls below the limit for triggering ignition, the boiler switches to ignition phase. In this phase the fan is activated to clean the burner room, especially the vents below the ignition electrode. After that, the pellet screw starts working. It despenses the starting amount of pellets for ignition. When the duration of screw start-up dose is over, the ignition electrode is activated. After a successful igntion, the flue gas temperature rises and the boiler switches to warm-up phase. 7.2 Warm-up phase The ignition electrode is deactivated and the dosage of pellets reduced. The fan is running with increased speed in comparison to combustion phase (according to the setting). The warm-up phase has the purpose to fan the fi re and let it spread across the pellets in the burner. The duration of the warm-up phase is temporary. After this phase, the combustion phase starts. In the case that the fl ue gas temperature does not rise beyond the set point, the controller registeres that the pellets can not be ignited and the boiler stops operation. The display shows Failed ignition. 7.3 Combustion phase During combustion phase, the pellet and air supply are regulated based on the parameter settings. The controller aims for the boiler to increase the temperature up to the Maximum boiler temperature. After that is done, the boiler slowly reduces its output to prevent repeated turing off and on of the burner. The boiler shifts to pause mode when the temperature reaches the Maximum boiler temperature. On the top row the display shows Rated temp. reached. The boiler continues operation when the temperature of the flow water drops below the parameter Maximum boiler temperature. The current fl ue gas temperature determines if the boiler operation starts with the warm-up phase or ignition. If a room thermostat is used, it is possible to activate the setting that turns off the boiler resp. sends it into a phase of afterrun if the room thermostat is turned off. If the afterrun-function is used, the boiler will quickly reach the required temperature and stops operation. 22

Maintenance 8 Maintenance 8.1. Intervals of maintenance and cleaning The maintenance work performed periodically is very important for a problem-free operation und guarantee a long life of the boiler and other system components. The maintenance periods relate to the pellet quality and boiler output. Soot and tar cling to the burner room walls, so the burner room must be cleaned periodically by hand. Before you start the cleaning, turn off the boiler controller and deactivate the main switch. Interval Components Application Every 3 days Clean heat exchanger and burner room Move the lever of the heat exchanger cleaning system back and forth 5 to 6 times. Remove the front chamotte brick and clean the burner room with a vacuum cleaner. Every month Clean pellet silo Empty out the pellet silo and remove the wood dust with a vacuum cleaner. Every 6 months Once a year Clean display Check and clean exhaust passes Check and clean boiler and flue gas probe Clean all parts mentioned above Carefully clean with slightly damp cloth. The exhaust pipes can be removed and cleaned with the cleaning tool when the system is cooled down. Pull out the probes, remove soot and lime. When cleaning the burner room with a vacuum cleaner, the ash inside must be cooled down to prevent accidents. When removing the front brick of the burner, there is a risk of burn when handling it shortly after deactivation of the boiler because it may still be hot. Allow the boiler to cool down an adequate period of time until the bricks can be touched safely. There is a risk of burns when cleaning the exhaust passes because these surfaces can reach a temperature of up to 200 C during operation. Wait until these parts cool down before cleaning. While cleaning, mind that there is a choking hazard due to carbon monoxyde passing out if the boiler is in operation. In this case, carbon monoxyde extits the opened boiler doors. Do not leave the boiler doors open longer than necessary. The ash mass in the burner room depends on the pellet quality. High quality pellets case less ash in the burner room and less wood dust in the pellet silo. To prolong the livetime of the ignition electrode which ignites teh pellets, the electrode itself and the air vent must be cleaned regularly. Thoroughly clean the system at the end of the heating season to prolong its livetime and raise its efficiency. 23

Possible malfunctions 9 Possible malfunctions Malfunction/error Possible cause Solution The boiler is working but does not reach the set temperature. The boiler is wet. The flue gas is escaping insufficiently. The boiler does not start operation. The boiler reaches set temperature but the radiators stay cold. The fan does not work. Failed pellet ignition. Blocked screw. 1.) Boiler is polluted. 2.) Not enough fuel in burner. 3.) The chamotte bricks in the burner room are not placed correctly. Flue gas condensation. Defects in the boiler. 1.) Clean the boiler. 2.) Set the screw to longer running time. 3.) Place the bricks correctly. Flue gas pipes or heat exchangers are dirty. Clean the parts. The chimney opening is too small. No power supply or blackout. The circuit pump is not working (this pump is not delivered with the boiler). No potential on the circuit pump. 1.) Blown fuse. 2.) Foreign substance in the fan. 1.) No power supply or blackout. 2.) Ignition electrode error. 3.) Burner is dirty. 4.) Pellet silo is empty. 5.) Ignition not callibrated correctly. 6.) Fan error. 7.) Screw error. 8.) Flue gas probe error. 1.) No power supply or blackout. 2.) Foreign substance in the screw. 3.) Pellets are damp. 4.) Gear motor of the screw is defective. The radiator power is too high or the boiler output is to low. Meaning: replace the boiler with an other that has a higher output or adjust the number of radiators to the boiler output. Weld leaking parts on the boiler. This is carried out by customer service or an installler. Adjust chimney diameter to the boiler output. 1.) Check electric connections. 2.) Check fuse in domestic electrical installation. De-block the circuit pump by opening the cover and turn shaft with a screw driver. Check fuse of circuit pump. 1.) Replace fuse. 2.) Check if fan can be turned without resistance. 1.) Check fuse. 2.) Replace ignition electrode. 3.) Clean burner room. 4.) Refill pellet silo. 5.) Callibrate ignition. 6.) Fix malfunction of fan. 7.) Fix malfunction of gear motor or screw. 8.) Replace probe. 1.) Check fuse. 2.) Clean pellet silo and screw channel. 3.) Use dry pellets or pellets of higher quality. 4.) Replace gear motor. 24

Possible malfunctions, First start-up 9.1 Fire prevention of the silo In the case that the boiler is not connected to a suitable flue gas system (not enough height, wrong diameter of the chimney, decreased diameter because of dirt or heavily polluted boiler), there is a possibility that fire spreads from the burner into the silo. Thermal valve Probe A part of the combustion air supply is led through the screw channel and thus prevents backfi re in the pellet silo. This air current is present at all times during operation. If the fl ue gas system is badly designed or heavily polluted, the air supply may not be enough to stop a backfire. In this case, the thermal valve is activated which releases tempering water if a temperature of 95 C or more is measured. The fi re is extinguished that way. The thermal valve and the probe are mounted on the boiler ex factory. The buyer is obligated to provide a water supply to the thermal valve (1/2 connection) and to comply with the prescriptions regarding dimension and quality of the fl ue gas system. If the flue gas system is designed incorrectly or heavily polluted or if the boiler is not cleaned regularly, the manufactorer is not liable for fire caused by such failures. Scheme of thermal valve 10 First start-up The first start-up of the boiler Biotec may only be carried out by a professional of the company STREBEL or an experienced installer. If the start-up is not carried out correctly, the boiler and the system can be damaged or destroyed or injury and material damage can occur. 9.2 Measures after thermal valve release 1.) Disconnect boiler from power supply. 2.) Remove screw and gear motor. 3.) Clean out damp pellets from the silo and the screw channel. 4.) Mount screw and gear motor. 5.) Remove residual water and dry damp system parts. Moisture can cause electrical shorts. 6.) Connect to power supply. If the damp pellets are not removed completely, screw and motor may jam. The manufactorer rejects responsibility and the guaranty expires if material damage occurs because of such failures. 10.1 Precautions for the fisr start-up 1.) Disconnect boiler from power supply. 2.) Check if the red main switch on the boiler side is activated. 3.) Check if the following parts are installed professionally and working. - All mechanical parts of the boiler, - burner and chamotte bricks, - fan, - circuit pump, - safety valve. 4.) Check of all electrical connections: - Correct installation of all electric components (gear motor, fan, controller, display), - Protection of unused connections, - ground, - power supply. 25

Disposal of the boiler, Guaranty 11 Disposal of the boiler 11.1 Removal The boiler removal must be carried out by qualified technicians. Otherwise, injury or material damage can occur. Procedure of the removal 1.) Stop boiler operation. 2.) Wait until the pellets in the burner room are burnt up and the boiler is cooled down. 3.) Disconnect the boiler from power supply. 4.) Disconnect the boiler from the rest of the heating installation with a turncock and drain the water from the boiler. 5.) Remove pellet silo. 6.) Remove boiler shell. 7.) Remove mineral wool insulation from the boiler body. 11.2 Disposal The steel parts of the boiler are delivered to a recycling centre: - Boiler body, - boiler shell, - pellet silo, - screw, - gear motor, - burner. The electrical parts as well as glas parts, mineral wool and plastic parts are seperately delivered to the recycling centre. The boiler parts must not be disposed in the domestic waste bin. 26

Terminal connections COMPENSATOR TANK PROBE NTC10K DOMESTIC WATER TANK NTC10K SCREW 230 VAC, 50 Hz, 50 W FAN 230 VAC, 50 Hz, 41 W IGNITION 230 VAC, 400 W ROOM THERMOSTAT RETURN RISER 230 VAC, < 500 W TANK CHARGER PUMP 230 VAC, < 500 W CIRCUIT PUMP 230 VAC, <500 W POWER SUPPLY 230 VAC, 50 Hz 3 x 1,5 mm 2 27

STREBEL customer service: Teleph. +43 (0)2622 23555 70-72,93,94 Fax +43 (0)2622 84344 kundendienst@strebel.at Strebelwerk GmbH A - 2700 Wiener Neustadt, Wiener Strasse 118 Teleph. +43 (0)2622 235 55-0 Fax +43 (0)2622 253 46 verkauf@strebel.at www.strebel.at