Powercorn - Model 75 kW - Heating Systems for Grain as Fuel- Brochure

Grain-fuel boiler englisch POWERCORN Installation instructions PC-A-00-00-00-01-IAEN EN-B31-008-V08-1011 POWERCORN Installation Instructions 2 Information on this documentation BS-B-00-00-00-01-IAEN Please read through this documentation carefully. It is intended as a reference document and contains important information on the design, safety, operation, maintenance and care of your heating system. We are always looking to improve our products and documentation. Any ideas and suggestions you may have will be gratefully received. GUNTAMATIC Heiztechnik GmbH a Georg Fischer Group Company Bruck 7 A-4722 PEUERBACH Tel: 0043 (0) 7276 / 2441-0 Fax: 0043 (0) 7276 / 3031 E-mail: info@guntamatic.com It is important that you pay particular attention to the safety issues highlighted in the text by these symbols. The entire contents of this document are the property of GUNTAMATIC and therefore protected by copyright. Reproduction of any kind, communication to third parties by any means or use for purposes other than those intended without the written consent of the owner is prohibited. Subject to printing errors and technical amendments. POWERCORN Installation Instructions 3 Installation instructions PC-C-00-00-00-01-IAEN Page 1 Introduction..........................................................4 1.1 Safety instructions 4 1.2 Guarantee and warranty 4 1.3 Commissioning 4 1.4 Site requirements 4 1.4.1 Fire safety (minimum fire safety requirements) 5 1.4.2 Boiler room requirements 7 1.4.3 Flue requirements 8 1.4.4 Fuel store requirements 9 2 Installation and assembly .................................11 2.1 Delivery 11 2.2 Carrying to installation site 11 2.3 Positioning and aligning the boiler 11 2.4 Plumbing connections 12 2.5 Filling and bleeding the system 15 2.6 Connecting the flue 16 2.7 Energy saving draught regulator with pressure-surge compensator 17 2.8 Installing the fuel outfeed system 18 2.8.1 FLEX system 18 2.8.2 BOX system 21 3 Electrical connections.......................................22 3.1 Electrical connections to the heating system 22 3.2 Wiring requirements 23 3.3 Electrical connections 24 4 Final checks/Commissioning............................27 5 Standards/Regulations......................................28 6 Plumbing diagrams...................................... 29-45 7 Electrical wiring diagram ..................................46 7.1 Control panel 46 7.2 Wall controller set MK261 47 7.3 Boiler circuit board 48 8 Technical data....................................................50 8.1 POWERCORN 30 50 8.2 POWERCORN 50 51 8.3 POWERCORN 75 52 8.4 FLEX outfeed system 53 8.3 BOX outfeed system 54 POWERCORN Installation Instructions 4 1 Introduction BS-01-00-00-00-01-IAEN 1.1 Safety instructions BS-01-01-00-00-01-IAEN GUNTAMATIC heating systems represent state-of-the-art technology and meet all applicable safety regulations. Incorrect installation can endanger life and limb. Heating boilers are combustion systems and are potentially dangerous if handled incorrectly. Installation, commissioning and servicing must, therefore, only be carried out by adequately qualified technicians observing all regulations and the manufacturer's instructions. 1.2 Guarantee and warranty BS-01-02-00-00-01-IAEN The manufacturer's guarantee is subject to correct installation and commissioning of the heating system. Defects and damage caused by incorrect installation, commissioning or operation are not covered by the guarantee. To ensure that the system functions as intended, the manufacturer's instructions must be followed. Furthermore, only genuine replacement parts or parts explicitly approved by the manufacturer may be fitted to the system. 1.3 Commissioning BS-01-03-00-00-01-IAEN Commissioning of the boiler must be carried out by an authorised GUNTAMATIC specialist or other qualified persons. They will check whether the system has been installed according to the plans, adjust the system settings as required and explain to the system operator how to use the heating system. 1.4 Site requirements BS-01-04-00-00-01-IAEN When establishing the site requirements, it is absolutely essential to take account of the locally applicable planning, building and implementation regulations and the dimensional specifications in the fitting guidelines, installation examples and technical data. Compliance with the locally applicable regulations and the correct implementation of the measures required on site are solely the responsibility of the system owner and are a requirement of the manufacturer's guarantee. GUNTAMATIC provides no guarantee of any kind for any type of site work. Without making any claims as to completeness or non-applicability of official requirements, we recommend the following specifications based on the Austrian Guidelines pr TRVB H 118: POWERCORN Installation Instructions 5 1.4.1 Fire safety BS-01-04-01-00-01-IAEN If the installation site is not subject to any other fire safety requirements, the GUNTAMATIC minimum fire safety requirements must always be observed. If the installation site is subject to stricter requirements than the minimum fire safety requirements specified here, then the stricter requirements must always be observed without exception. Caution: Compliance with the GUNTAMATIC minimum fire safety requirements is subject only to verification by the operator. The operator alone is responsible for strict compliance. Verification during commissioning is not provided for. Caution: National regulations must also be complied with. National regulations Austria: F90/T30 State legislation of the federal states Technical Directive on Preventative Fire Safety pr TRVB H118 Germany: No requirements for systems up to 50 kW Standard boiler regulations (M-FeuVO) Hessen and Saarland – in these states §16 FeuVO Hessen applies Switzerland: Fire safety regulations (www.vkf.ch) France: Relevant fire safety authority Italy: Relevant fire safety authority POWERCORN Installation Instructions 6 Minimum fire safety requirements BS-01-04-01-01-01-IAEN BS-01-04-01-02-01-IAEN Boiler room Floor of concrete construction, either bare or tiled. All materials for floor, walls and ceiling must be fire-resistant to F60 rating. If a fabric hopper is installed in the boiler room (not allowed in all countries), the floor walls and ceiling must be F90-rated. The boiler room door must be a Class T30 fire door which opens in the direction of escape and is self-closing. Connecting doors to the fuel storeroom must also be Class T30 fire doors, self-closing and lockable. There must be no direct connection to rooms in which flammable gases or liquids are stored (e.g. garage). BS-01-04-01-03-01-IAEN Fuel storeroom The same minimum fire safety requirements apply as for the boiler room. Storeroom doors/hatches: Storeroom doors/hatches must be fire safe to Class T30, self-closing and lockable. There must be a warning sign carrying the message "Do not enter when feeder system is running" attached to the storeroom door/hatch. Fireproof collars: If the storeroom is not situated directly adjacent to the boiler room, a fireproof collar must be fitted to the extraction and air return pipes at their wall exit points from the boiler room. If the outfeed auger goes directly into the boiler room, it is factory fitted with a special fire safety lining. No additional fireproof collars are required on the air pipes. If the outfeed auger is sited entirely inside the storeroom (i.e. if the outfeed auger does not extend out of the storeroom), fireproof collars must similarly be fitted to the extraction and air return pipes at their wall exit points from the storeroom. Manual fire extinguisher: If 50 m³ of fuel or more can be stored, a manually operated fire extinguishing facility must be installed. It must be protected against freezing and connected to a pressurised water pipe (DN20 conduit). The discharge point must be located directly above where the fuel outfeed channel exits the storeroom. The fire extinguishing facility must be identified by a sign carrying the inscription "Fuel storeroom fire extinguisher". Filler pipes: Filler pipes through rooms where there is a fire risk must be provided with Class F90 cladding. POWERCORN Installation Instructions 7 1.4.2 Boiler room requirements BS-01-04-02-00-01-IAEN PH-01-04-02-01-01-IAEN Combustion air supply The pressure in the boiler room must not be less than 3 Pa (0.3 mm H2O). The air vents for boiler rooms must have a clear, net cross-sectional area of at least 200 cm² and must not be sealable. With combustion boiler systems with a fuel heat output upwards of 50 kW, the net, clear cross-sectional area must be increased to at least 5 cm² per kW rated output according to the combustion air requirement of the boiler system. The air supply ducting must connect directly to the outside and if the ducting passes through other rooms, it must be jacketed to Class F90. On the outside of the building, air vents must be covered by a protective grille with a mesh size of > 5 mm. The supply of combustion air should, if possible, enter at floor level in order to prevent cooling of the boiler room. BS-01-04-02-02-01-IAEN Electrical installation The lighting and the electrical wiring in the boiler room must be permanently installed. There must be a clearly marked emergency off switch in an easily accessible position outside the boiler room, close to the boiler-room door. BS-01-04-02-03-01-IAEN Fire extinguisher A hand-held fire extinguisher (6kg gross weight, EN3) must be mounted outside the boiler room near the boiler-room door. BS-01-04-02-04-01-IAEN Protection against freezing The boiler room, pipes carrying water and any district heating pipes must be protected against freezing. PC-01-04-02-05-01-IAEN Minimum room size PC30 at least 230 (240) x 240 cm (W x L) PC50, PC75 at least 230 (240) x 270 cm (W x L) (Dimensions in brackets refer to systems with automatic ash extraction system.) PC-01-04-02-06-01-IAEN Minimum room height PC30, PC50 at least 225 cm (with heat exchanger cover removed at least 210 cm) PC75 at least 240 cm (with heat exchanger cover removed at least 230 cm) PC-01-04-02-07-01-IAEN Clear access opening PC 30 at least 80 x 170 cm (W x H) PC 50, PC75 at least 100 x 190 cm (W x H) (Dimensions refer to boiler with stoker and grate cleaner motor removed.) Boiler dimensions PC-01-04-02-08-01-IAEN Without packing PC 30 at least 75 x 165 cm (W x H) PC 50 at least 90 x 165 cm (W x H) PC 75 at least 90 x 180 cm (W x H) (Dimensions refer to boiler with casing, stoker, flue connecting pipe and ash box removed.) POWERCORN Installation Instructions 8 1.4.3 Flue requirements BS-01-04-03-00-01-IAEN The flue must be matched to the system in order to ensure economical and trouble-free operation. BS-01-04-03-01-01-IAEN Important BS-01-04-03-02-01-IAEN The system must only be connected to the flue if the flue meets the legal requirements and the technical specifications. The flue must be matched to the boiler output and dimensioned in accordance with DIN 4705. In order to be able to accurately dimension the flue, the calculations must be based on the flue gas figures. When designing new flues, high thermal insulation chimneys (DIN 18160 T1 heat transmission resistance group I) or suitable fireclay flues that are insusceptible to damp and have general building regulation approval should be used. It is advisable to involve those responsible for approving the flue system early on in the planning phase. BS-01-04-03-03-01-IAEN Flue height The minimum flue height is 5 - 10 m depending on boiler output. The flue must terminate at least 0.5 m above the highest part of the building. In the case of flat rooves, the flue must terminate at least 1.5 m above the surface of the roof. Flue dimensioning data Dimension the flue for rated output. PC-01-04-03-05-01-IAEN (Averaged figures with used heat exchanger) Rated output Sub-maximum output Type Flue gas temp. CO2 Mass flow rate Required draught PC30 160 °C 11.0 % 0.025 kg/s 15 pascals PC50 180 °C 11.0 % 0.030 kg/s 15 pascals PC75 180 °C 11.0 % 0.065 kg/s 15 pascals Type Flue gas temp. CO2 Mass flow rate Required draught PC30 100 °C 9.0 % 0.010 kg/s 10 pascals PC50 110 °C 9.0 % 0.011 kg/s 10 pascals PC75 110 °C 9.0 % 0.020 kg/s 10 pascals Use heat-insulated fireclay flues that are insensitive to damp. The flue gas temperature can be less than 105°C. POWERCORN Installation Instructions 9 1.4.4 Fuel store requirements BS-01-04-04-00-01-IAEN BS-01-04-04-01-01-IAEN Access doors/hatches Above-ground fuel stores must be provided with a door or hatch that opens outwards. So that the fuel cannot run out if the fuel store is opened by mistake, the inside of the access door/hatch opening must be covered with boarding (which must be removable from the outside). Due to the risk of injury when the system is in operation, access doors/hatches must be lockable and kept locked when the system is in operation. There must be a warning sign carrying the message "Do not enter when feeder system is running" attached to the access door/hatch. Electrical equipment FLEX system BS-01-04-04-02-01-IAEN Electrical equipment is prohibited in the fuel storeroom. BOX system Electrical equipment is permitted in the room in which the system is installed. Light bulbs must not be fitted in close proximity to the fabric hopper. BS-01-04-04-03-01-IAEN Filler set The filler pipes must be earthed. FLEX system At least 2 filler pipes must be installed. Minimum separation 0.5 m. BS-01-04-04-04-01-IAEN Installation in cold areas If installed in cold areas, vacuum pipes and outfeed unit must be adequately insulated (frost-proof). Risk of condensation formation Structural requirements FLEX system BS-01-04-04-05-01-IAEN The enclosing walls must be capable of withstanding the possible static loads created by the fuel and the pressure when filling the fuel store. BOX system It is imperative that the load-bearing capacity of the base is adequately dimensioned as, when the hopper is completely full, heavy loads act on the points on which the unit rests. BS-01-04-04-06-01-IAEN Erecting BOX system Indoor installation: The fabric hopper must always be installed separately from the boiler in a different room. In some countries, the fabric hopper may be installed in the same room as the boiler if a minimum separation of 1 m between the fabric hopper and the boiler can be maintained and the fuel heat output remains below 50 kW. National legislation must also be observed Outdoor installation: If erected outdoors, no F90 lining is required if the minimum distances for fire flashover are maintained. The fabric hopper must be protected against rain, damp and UV light. POWERCORN Installation Instructions 10 BS-01-04-04-07-01-IAEN Wall penetration If there is an auger conveyor passing through the storeroom wall, the gap in the wall must be filled with mineral wool and sealed by means of the non-contact (sound insulation) finishing plates provided. BS-01-04-04-08-01-IAEN Filling the fuel store When pressure-filling the fuel store from a tanker truck, the air pumped in must be drawn out of the fuel store. Extraction is the responsibility of the supplier. BS-01-04-04-09-01-IAEN Damp-proofing The fuel must be protected against contact with water or damp floors/walls. The storeroom must remain dry all year round. If there is a risk of temporarily damp walls, fitting a back-ventilated facing to the walls and lining them with wooden material may be required. POWERCORN Installation Instructions 11 2 Installation and assembly BS-02-00-00-00-01-IAEN 2.1 Delivery BS-02-01-00-00-01-IAEN The boiler system is delivered packed in a wooden crate wrapped in foil. Please check that the delivery is complete according to the delivery note and in perfect condition. Deficiencies Please make a note of the deficiencies identified directly on the delivery note and contact the supplier, heating installer or our Customer Service. 2.2 Carrying to installation site BS-02-02-00-00-01-IAEN The system is delivered on a wooden pallet and can be lifted and carried to the installation site using a pallet truck. Carrying in dismantled The boiler body can be dismantled into parts for carrying in. If that is done, a person authorised by GUNTAMATIC must be consulted. 2.3 Positioning and aligning the boiler PH-02-03-00-00-01-IAEN Keep to the minimum wall clearances specified by the system planner and manufacturer. If important details are missing, please refer to the planning documentation or ask our Technical Support. Position the system as close as possible to the flue to avoid having a long flue connecting pipe. The system must be accessible from the left or right side. Clearance on left at least 40 cm (preferably 70 cm) Clearance on right at least 40 cm Clearance at front at least 80 cm (leave space for fuel box door to open) Clearance at back at least 50 cm (with auto ash extraction system, at least 60 cm) Floor clearance Set the clearance between the boiler base and the floor to the required minimum of 35 mm by unscrewing the adjustable feet on the boiler base. Set the boiler at a slant Unscrew the rear adjustable feet slightly further so that the boiler is slightly higher at the rear. That will allow the air inside the boiler to escape easily when the system is filled. POWERCORN Installation Instructions 12 2.4 Plumbing connections PC-02-04-00-00-01-IAEN Powercorn 30/50 A ? Sensor for temp. relief valve, ½" B ? Heating return, 1¼" C ? Temperature-relief heat exchanger, ¾" D ? Boiler sensor, safety temp. limiter (STL) E ? External thermostat/drain, ½" F ? Heating flow, 1¼" Powercorn 75 A ? Sensor for temp. relief valve, ½" B ? Heating flow, 2" C ? Temperature-relief heat exchanger, ¾" D ? External thermostat, ½" E ? Drain F ? Heating return, 2" POWERCORN Installation Instructions 13 PC-02-04-00-01-01-IAEN Temperature-relief heat exchanger The maximum permissible boiler operating temperature is 110°C. In order to prevent the maximum allowable operating temperature being exceeded, connection of a temperature-relief valve (Fig. 15, Fig. 16) conforming to Austrian standard ÖNORM 8131 and DIN 4751 and with a response temperature of 95°C is required. The supply pressure must be at least 2 bar but no more than 6 bar. Powercorn 30/50 A ? Cold water supply for temp.-relief heat exchanger B ? Sensor for temp. relief valve, ½" C ? Temp. relief valve, 95°C Powercorn 75 A ? Cold water supply for temp.-relief heat exchanger B ? Sensor for temp. relief valve, ½" C ? Temp. relief valve, 95°C POWERCORN Installation Instructions 14 PH-02-04-00-02-01-IAEN Thermal store Installing a thermal store is not necessary as the boiler is operated by a modulating control system and the system can be quickly shut down. However, if the required continuous heat output in the summer months is below 10 kW for systems up to 50 kW, or 22 kW for systems upwards of 50 kW, combination with a thermal store is necessary for reasons of efficiency. PC-02-04-00-03-01-IAEN Return boost The boiler return temperature must be at least 55°C and must be held at the required level by a bypass pump between the boiler flow and return pipes. If a thermal store is connected, the boiler return temperature must similarly be at least 55 °C, which must be ensured by a return boost (cross-over valve) set as shown in the plumbing diagram. If this requirement is not complied with, there is an increased risk of corrosion and guarantee entitlement will be lost as a result.Connect the return boost set precisely as specified in our plumbing diagrams. Important The dimensioning of the return boost pump (set) is designed for the arrangements shown in GUNTAMATIC plumbing diagrams. If additional components such as heat meters are incorporated in the system plumbing, or if the overall thermal store pipe run (flow and return) is more than 30 m, re-dimensioning of the boiler charging pump (HP0) may be necessary. SY-02-04-00-04-01-IAEN Expansion vessel The boiler operates in a sealed heating system and must be provided with an expansion vessel for pressure compensation. To calculate the expansion volume, the volume of the system when cold must be known. Please select the expansion vessel on the basis of the manufacturer's specifications. The expansion volume of the system is calculated as follows: System volume x Expansion factor x Additional allowance factor • Expansion factor for wood-fuel boilers = 0.03 • Additional allowance factor = 3.0 for systems under 30 kW • Additional allowance factor = 2.0 for 30-150 kW systems • Additional allowance factor = 1.5 for systems over 150 kW Example calculation: 2500 litres x 0.03 x 3 = 225 litres BS-02-04-00-05-01-IAEN Plastic piping If plastic piping for underfloor heating or district heating pipes are connected, they must be protected against excessive temperatures by using a limiting thermostat for the circulation pumps. BS-02-04-00-06-01-IAEN Pump selection The choice of pump must be made by the installer or building technology planner on the basis of the friction data, the pipe cross-sectional area and the required delivery pressure for the piping system planned. POWERCORN Installation Instructions 15 2.5 Filling and bleeding the system BS-02-05-00-00-01-IAEN The system is filled with water from the domestic supply. Please note the guidelines on "Corrosion and boiler protection in heating and domestic water systems". Water quality The water quality of hot water systems with flow temperatures of max. 100°C is subject to VDI 2035. According to VDI 2035 Part 1, "Avoiding damage to hot water systems", which comply with EN12828, the first-fill and replenishment water, must be conditioned (preferably softened) if the following overall hardness limits [°dH] according to total heat output (kW) are exceeded: • < 50kW: with circulating flow heaters, if °dH > 16.8 • 50 to 200 kW: if °dH > 11.2 • 200 to 500 kW: if °dH > 8.4 • > 500kW: if °dH > 0.11 Water heater If a water heater is also used in addition to the GUNTAMATIC boiler, it should be filled according to the installation instructions for it. Filling the system • Match the pressure of the system when cold to the air charge pressure of the expansion vessel • Check the operating pressure on the pressure gauge Bleeding the system • Switch off and bleed circulation pumps. • Bleed boiler by opening the bleed valve on the boiler and allowing air to escape until water runs out. • Bleed radiator heating system (if present) by opening the bleed valve on every radiator and allowing air to escape until water runs out. • Bleed underfloor heating system (if present) by opening each heating circuit and flushing through thoroughly until there are no more air bubbles in the heating circuit pipes. • Important: perform sequence in the correct order Start bleeding in the cellar or on the ground floor and finish in the attic. • Check the system operating pressure on the pressure gauge and add more water if necessary. • Restart circulation pumps. Only systems that have been properly bled guarantee effective conveyance of heat. POWERCORN Installation Instructions 16 2.6 Connecting the flue BS-02-06-00-00-01-IAEN PC-02-06-00-01-01-IAEN The boiler is connected to the flue by means of a flue connecting pipe which must be gas-tight and insulated between the heating boiler and the chimney (insulation thickness 50 mm). Flue connecting pipe The following diameters should be used: • PC 30 dia. = 150 mm • PC 50, PC 75 dia. = 180 mm Flue connecting pipes longer than 4 m or with more than 3 bends: • PC 30 dia. = 160 mm • PC 50 dia. = 200 mm • PC 75 dia. = 220 mm The hole in the wall for connecting the flue pipe must be lined with a built-in double-skinned lining tube or fireproof material. The flue connecting pipe must rise upwards from the boiler to the flue at an angle of at least 6° and be connected with gas-tight joints. An inspection cover must be provided for cleaning the flue connecting pipe. PH-02-06-00-02-01-IAEN A ? Flue connecting pipe insulation (50 mm) B ? Testing point for flue draught (Distance from boiler = at least 3 x dia. of flue connecting pipe) C ? Alternatively: Flue draught regulator in flue connecting pipe (As close as possible to junction with the flue) D ? Flue connecting pipe, min. gradient 6° H ? Flue draught regulator/pressure-surge compensator in flue (Preferred fitting arrangement) BS-02-06-00-03-01-IAEN Note • The flue connecting pipe musty be gas-tight • An energy-saving flue draught regulator with pressure-surge compensator (Class RE) must be fitted • Insulate the flue connecting pipe • Do not brick in the flue connecting pipe (noise transmission) • The flue connecting pipe must not extend into the flue POWERCORN Installation Instructions 17 2.7 Energy-saving flue draught regulator and pressure-surge compensator BS-02-07-00-00-01-IAEN Purpose • To ventilate the flue when the system is not in operation • To compensate for pressure surges • To regulate and limit the flue draught Fitting requirement The energy-saving flue draught regulator must be fitted in accordance with the local regulations, preferably in the flue approx. 0.5 m below the point where the flue connecting pipe joins or alternatively in the flue connecting pipe close to its junction with the flue. Flue draught setting: • Adjusting the flue draught is only of any use at outside temperatures below +5°C. • The system must have been in operation for at least an hour • Ensure there is sufficient demand for heat for the boiler to be run at rated output for at least 15 minutes • Measure the flue draught between the boiler and the flue draught regulator (distance of measuring point from boiler ideally 3 x flue diameter from connection between boiler and flue connecting pipe). Flue draught The flue draught should not differ by more than +/- 3 pascals from the figure specified in the flue dimensioning data. If the flue draught cannot be reduced to the required figure, either a larger draught regulator should be fitted or an additional flue baffle fitted between the flue and the draught regulator. Too much flue draught May cause the flue gas temperature to increase and accelerate combustion as a result. Poor boiler output adjustability, increased dust discharge and malfunctions can result. Too little flue draught Performance problems, incomplete combustion and malfunctions when operating below rated output can result. Fitting an energy-saving flue draught regulator/pressure-surge compensator (Class RE) is absolutely imperative. POWERCORN Installation Instructions 18 2.8 Fuel outfeed installation BS-02-08-00-00-01-IAEN 2.8.1 FLEX system BS-02-08-01-00-01-IAEN Important ? Ensure the inlet opening is on the correct side. A ? Conveying direction B ? Inlet opening always this side C ? Direction of rotation D ? Scraper E ? Floor mounting plate F ? Check dimension 56 mm Fig. A Installing the outfeed auger (Fig. A) 1. Feed the drive unit (1) of the fuel outfeed auger through the hole (W 330mm x H 250mm) in the storeroom wall. 2. Depending on the auger length, join auger sections complete with conveyor trough (2) to the drive unit (1) from the storeroom end. Important: join the auger sections together so that the auger slope continues evenly. Afterwards securely fix the auger trough flange joint using the M8x30 bolts supplied (3) and locking washers. Make sure that the auger troughs are joined together so as to be perfectly flush on the inside. Screw the flange plate (4) and bearing on the end of the outfeed auger (if not pre-fitted). 3. Slightly unscrew the grub screws (5) on the bearing and attempt to push the auger towards the drive unit as far as it will go. Then re-tighten the grub screws. 4. After assembly: rotate the auger to check that is running true (maximum allowable auger run-out in the centre is 3 mm). 5. Position the assembled outfeed auger so that the drive unit extends at least 420 mm (see Fig. B) out of the storeroom wall. 6. Screw the conveyor trough securely to the storeroom floor. Important: the conveyor trough must be aligned flush using the floor mounting plates (E) and screwed securely to the floor so that it is straight and has no sags or humps. POWERCORN Installation Instructions 19 7. Fill the gap (6) in the wall around the conveyor with mineral wool. Cover the hole on both sides of the wall with the masking plates supplied (7), fitting them so that they do not touch the conveyor. FLEX fuel outfeed system Fig. B Fitting the vacuum extraction and air return pipes (Fig. 9) 1. Connect the vacuum hoses (8) from the cyclonic separator (9) or fan to either of the vacuum hose connection spigots on the auger (routing the hoses so that the bends are as gradual as possible). Important: the minimum curvature radius for routing the hoses is 0.5 m. In addition, the hoses should not sag. An adequate number of fixings should be used. 2. The vacuum and air return pipes (8) must be secured to the cyclonic separator (9) and the drive unit (1) and made air-tight using the pipe clips supplied. Important: check for air-tightness the first time fuel is drawn in. Leaking joints can cause problems with filling. 3. Do not route the air hoses for the fuel delivery system outdoors or through cold rooms (possibility of condensation forming in the vacuum hoses). If necessary, insulate the vacuum hoses adequately. Important ? It is imperative that the vacuum and air return pipes are earthed. To do so, separate out the copper wire at the ends of the pipes joining the vacuum unit and the conveyor drive unit and connect them to the earthing connections on the vacuum unit and the outfeed unit. Important ? The fuel outfeed conveyor must be completely emptied (vacuumed out) every 3 years at least. POWERCORN Installation Instructions 20 Fitting the boarding in the FLEX system storeroom (Fig. 10) A ? Batten B ? Board trimmed by 3 cm C ? Supporting batten (10 x 10) D ? Wooden boards, planed, or blockboard (3 cm) E ? Square batten, 10 x 10 F ? Square batten, 10 x 10 L ? Reinforcing batten (C) required if L >/= 1500 mm Fig. C Viewed from conveyor drive unit facing towards storeroom Fit boarding in storeroom as follows: 1. Locate a length of roof batten in the slot in the auger to mark out the 35° slope. 2. Mark the height of the slope on the wall and screw square batten (F) (e.g. 10 cm x 10 cm) to the wall approx. 3 cm below the marked height of the slope. 3. Support horizontal batten with uprights every 1.5 m. If the distance between the auger and the wall is greater than 1.5 m, additional supporting battens (C) must be provided. 4. Planed timber boards or blockboard panels 3 cm thick (D) should be cut approx. 3 cm short so that when they are slotted into the auger a gap is left between the board and the wall. 5. Do not screw every board in place and instead screw a horizontal batten (A) to the wall across all the boards. 6. If the auger does not extend to the end of the storeroom, a 35° slope should also be constructed from the end wall to the conveyor. 7. If the conveyor sections do not reach up to the exit point through the wall, an additional substructure must be used up to the wall. POWERCORN Installation Instructions 21 Filler set The pellet store requires at least 2 filler pipes (for pressure-filling and air extraction). • Whenever possible, the filler pipes should be placed centrally in the shorter side of the storeroom. • Minimum distance from ceiling and walls 25 cm. • Required hole diameter in wall 130-150 mm. • Fill gap with (waterproof) expanding foam filler. • Ensure the filler pipes are fixed firmly in place. • The filler pipes must be earthed to the earthing conductor (1.5 mm2). A ? PVC pipe, 150 mm dia. B ? Filler set, straight C ? Steel pipe internal dia. 100 mm external dia. 108 mm D ? Filler set, 45° elbow E ? Light shaft Access doors/hatches Above-ground fuel stores must be provided with a door or hatch that opens outwards. So that the fuel cannot run out if the door/hatch is opened by mistake, the inside of the access door/hatch opening must be covered with boarding (which must be removable from the outside). Due to the risk of injury when the system is in operation, access doors/hatches must be lockable. There must be a warning sign carrying the message "Do not enter when feeder system is running" attached to the access door/hatch. The door/hatch opening must be provided with a (dust-proof) seal around its perimeter. A ? Seal B ? Fire door (hatch), Class T30 C ? U or Z-section framing D ? Wooden boards (at least 3 cm thick) 2.8.2 BOX system BS-02-08-02-00-01-IAEN The BOX fabric hopper system is installed as described in the separate installation instructions. They are supplied with the BOX system. POWERCORN Installation Instructions 22 3 Electrical connections BS-03-00-00-00-01-IAEN 3.1 Heating system electrical connections BC-03-01-00-00-01-IAEN Mains connection • 230V, 50Hz, 13A fuse (surge protector recommended) Standard specifications • 1 Boiler control panel (BCE) • 1 Boiler circuit board (230V AC) • 1 Safety temperature limiter (STL) • 1 Fault signal output (24V DC 200 mA – if freewheeling diode relay used) • 1 Boiler sensor (KVT20 ?) • 1 Flue gas temperature sensor (thermocouple) • 1 Stoker sensor (PT1000 ?) • 1 Oxygen sensor (12V DC) • 1 Flue draught fan (230V AC) • 1 Grate cleaner motor (230V AC) • 1 TKS 1 (firebox and ash box door switch, 24V DC) • 1 TKS fill level switch (firebox monitor) • 1 Stoker drive motor G1 (230V AC) • 1 Outfeed drive motor A1 (230 VAC) • 1 Outfeed fan A2 (230V AC) • 1 Fill level sensor (12V DC) • 1 Ignition fan (230V AC) • 1 Boiler enabling switch (emergency off) • 1 KLP output (230V AC) Optional equipment • 4 Pump outputs (230V AC) • 2 Mixer valve outputs (230V AC) • 1 Outside temperature sensor input (KVT20 ?) • 1 DHW cylinder sensor input (KVT20 ?) • 2 Flow temperature sensor inputs (KVT20 ?) Resistances Temperature in °C KVT20 in k? Temperature in °C PT1000 in k? -16°C 1.434 0 °C 1.000 -8°C 1.537 10 °C 1.039 0 °C 1.644 30 °C 1.117 10 °C 1.783 40 °C 1.155 20 °C 1.928 50 °C 1.194 30 °C 2.078 60 °C 1.232 40 °C 2.234 70 °C 1.271 50 °C 2.395 80 °C 1.309 60 °C 2.563 100 °C 1.385 70 °C 2.735 125 °C 1.480 POWERCORN Installation Instructions 23 RS (HKR 0)CAN - BusHKR 0 230VACHRG 2SH - L HCAN - BCE+ SH - L +CAN - BusRG 0RG 1 HCAN - BCESH L- +(Taurus)KPS Y-BUSSERVICEBCEDisplayE THERN. S D-CARD CAN CANCAN - Bus3.2 Wiring requirements BS-03-02-00-00-01-IAEN Surge protection Where CAN bus cables run between different buildings, the earthing conductors of the buildings must be connected to each other for potential equalisation purposes. If the earthing conductors cannot be interconnected, a 10 mm rustless ring earth must be laid along with the CAN bus cable in the ground. The earthing conductors and ring earth must then be connected to one another. Sensor 2 x 1 mm² Analogue room stat RFF 2 x 1 mm² CAN bus connecting cable 2 x 2 x 0.5 mm² twisted pair, shielded More outside-temp. based controllers can be connected via CAN bus Key: BCE ? Control panel KP ? Boiler PCB HKR ? Heating circuit controller RG ? Analogue room stat RS ? Digital room controller Wiring CAN bus in line Whenever possible, always wire the CAN bus "in line", i.e. from the display and control unit to heating circuit controller 0 then from there to heating circuit controller 1, and so on. If wired in a star pattern, the overall length of the CAN bus must not exceed 100 metres. Wire the CAN bus +/- and H/L connections with twisted-pair cable in each case. POWERCORN Installation Instructions 24 3.3 Electrical connections BS-03-03-00-00-01-IAEN The electrical connections to the boiler system on site may only be made by an approved electrical installer observing all the applicable regulations. In addition, it is essential that electrical system components are protected against damage from heat radiation. All boiler system internal wiring is wired up at the factory ready for use. The work required on site by the electrical installer consists only of connecting the mains power and wiring up and connecting the system components such as thermal store, CAN bus, heating circuit pumps, mixer valve motors, etc. BS-03-03-00-01-01-IAEN Mains power supply 230 V, 50 Hz, 13 A fuse The mains power must be connected by means of the standard non-reversible power socket on the rear panel of the boiler. It must possible to isolate the system entirely from the mains without opening the switch panel cover, e.g. by means of an automatic circuit-breaker. Correct polarity of the boiler's mains power connection must be ensured. The live (L) and neutral (N) phases must not be reversed as otherwise the short-circuit protection and safety system function cannot be guaranteed. PH-03-03-00-02-01-IAEN Opening switch panel Before the switch panel is opened, the boiler mains lead must be unplugged from the power supply. The system must not be live. • Undo switch panel securing screw. • Lift up front right panel section slightly, unclip and draw forwards to remove. • The circuit boards with the associated connectors and fuses (see electrical wiring diagram) are located underneath it in an easily accessible position. • The appropriate cable ducts must be used when connecting electrical leads. POWERCORN Installation Instructions 25 PH-03-03-00-03-01-IAEN Outside-temperature based controller The MKR outside-temperature based heating circuit controller set is offered as an option and activated on the boiler circuit board if required. The MK261 wall controller set, on the other hand, can only be fitted externally and connected to the system via the CAN bus. Operation and configuration is via the boiler control panel. Set MKR The heating circuit controller can be used to control a DHW cylinder, a pumped heating circuit (HC0) and two mixed heating circuits (HC1, HC2). If heating circuit 0 is not used, the "supplementary" function can be used to operate a second DHW cylinder (HWP) or an external burner (EXTERNAL). Wall controller set MK261 The wall controller set MK261 must be connected to the power supply at terminal H35 and connected to the control panel via the CAN bus. The wall controller set can be used to control a DHW cylinder, a pumped heating circuit, 2 mixed heating circuits, one "supplementary function" (WWP or EXTERNAL) and a "district heating pipe" function (TSP/CP/FP). If the "supplementary" and "district heating" functions are not used, heating circuit 0 can be operated as a 3rd mixed circuit. Analogue room stat The room stat should be connected to the relevant heating circuit controller input at terminals 1 and 2 (see electrical wiring diagram). Digital room controller The room controller must be connected to the control panel (BCE) or wall controller set MK261 via CAN bus. 3rd mixed heating circuit Can only be activated on wall controller Heating circuit 0 can only be used as a mixed heating circuit if the "supplementary" and "district heating" functions are not activated. Mixer valve 0 (MI 0) is connected to output terminals H25 and H26 and heating circuit pump 0 (HKP 0) to terminal H33 on the wall controller. The "district heating pipe" and "supplementary" functions are then not available. 2. DHW cylinder Can be activated internally and/or on the wall controller. On the MKR controller set and on the MK261 wall controller set, an additional DHW cylinder (HWP) can be activated using the "supplementary" function. The district heating function on the wall controller set remains available but the 3rd mixed heating circuit cannot be connected. External burner request Can be activated internally and/or on the wall controller. On the MKR controller set and on the MK261 wall controller set, an external heating boiler (External) can be called for using the using the "supplementary" function. The load on the output must not exceed 230VAC and 2.0A. The district heating function on the wall controller set remains available but the 3rd mixed heating circuit cannot be connected. POWERCORN Installation Instructions 26 Boiler cascade Up to four heating boilers can be operated in a cascade system (sequential control system) and must be connected in-line via a CAN bus. The CAN bus lead must be wired without connecting the + terminal. Pay special attention to the section "Wiring requirements, Wiring CAN bus in line". BS-03-03-00-04-01-IAEN Emergency off switch According to prTRVB H 118, it must be possible to switch off the system using an emergency off switch fitted outside the boiler room near to the boiler room door. The burner must then shut down but the heating controller and all safety equipment must remain functional. Connected to the boiler enabling switch, terminals 22/23 on the boiler circuit board (see electrical wiring diagram). BS-03-03-00-05-01-IAEN Surge protection We recommend the installation of a power surge protector in the building's consumer unit. Pay special attention to the section "Wiring requirements, Surge protection". Earthing The entire system is to be joined to the earth circuit conductor via the connected piping system according to the regulations. When connecting the earth circuit conductor pay particular attention to keeping the connecting runs as short as possible. Emergency power supply Only use regulated generators. POWERCORN Installation Instructions 27 4 Final checks/Commissioning BS-04-00-00-00-01-IAEN Final checks • After completing installation of the system, check again that all joints and pipes are properly tightened and not leaking. • Check that all covers are fitted and secured. • Check that the fitting of all connections (water, flue, electrical, ...) has been done correctly. • Check that all required safety signs and instructions are attached and hand over all documentation (operating and installation instructions) for the system. • Check that all electrical connections have been properly wired before connecting the system to the power supply. • Clean the system and clear up the installation site. • Always leave the boiler room clean. Initial commissioning Commissioning must only be carried out by GUNTAMATIC or a qualified specialist. The precondition is that the flue technician, heating installer and electrician have cleared the system for operation. The authorised GUNTAMATIC specialist will carry out the following work during commissioning: • Check the entire system • Check the electrical functions • Adjust the programmer to the system • Commission the system • Explain to the user how the system functions and how to operate and clean it • Record the details of the customer and the system and complete the commissioning log Important ? Any deficiencies identified must be recorded in writing and rectified within the following 4 weeks in order to maintain guarantee entitlement. The fully completed commissioning checklist must be sent to GUNTAMATIC immediately as otherwise the guarantee will be void. Important ? These installation instructions should not be destroyed after commissioning but kept permanently with the system together with the operating instructions. POWERCORN Installation Instructions 28 5 Standards/Regulations BS-05-00-00-00-01-IAEN The boiler is designed as a Class 3 appliance as defined by the draft standard ÖNORM EN 303-5 (CEN/TC7/WG 1 – Doc. N 36-D) of 15/12/1996 and the agreement of the [Austrian] Federal States according to Art. 15a BVG, in accordance with the Austrian fire safety regulations, safety systems, CE and on safety measures for small combustion heating systems and the combustion heating system approval regulations (LGB.33/1992) of the Austrian Federal State of Steiermark. The original design approval certificates (BLT Wieselburg, IBS Linz) are available for inspection at the manufacturer's offices. When connecting the boiler, the following general, standard and safety regulations must be followed in addition to the local fire safety and building control requirements: • ÖNORM EN303-5 Boilers for solid fuels, manually and automatically stoked, with outputs up to 300 kW; terms, requirements, testing and identification; • ÖNORM H 5195-1 Assessment and suitability of the heating water (minimum requirements for the heating water); • ÖNORM M 7510 Guidelines for the inspection of central heating systems; • ÖNORM M 7550 Central heating boilers up to 100°C – Terms, requirements, tests, standard identification; • ÖNORM B 8130 Safety systems; • ÖNORM B 8131 Sealed water-circulation heating systems, safety requirements; • ÖNORM B 8133 Safety requirements, domestic hot water systems; • pr TRVB H 118 Technical Directive on Preventative Fire Safety • DIN 4751-1 / Safety systems for heating systems with flow temperatures up to 110°C (120°C in course of preparation); • DIN 4751-2 / Water-circulation heating systems – sealed heating systems with thermostatic safety systems and flow temperatures up to 120°C – safety systems; • DIN 4751-4 / Safety systems for domestic hot water systems with flow temperatures up to 120°C; sealed water-circulation heating systems with static heads over 15 m or rated heat outputs over 350 kW; • DIN 1988 Mains water piping systems on building plots, technical regulations for construction and operation; • DGVO §7(2) Technical requirements for systems for producing domestic hot water with a temperature not higher than 110°C which are stoked by hand with solid fuel; • HEATING OUTPUT: The heating output is to be selected (set) by the engineer in accordance with the local heating system regulations so that the rated heat output does not exceed the heat requirement determined according to DIN 4701 or ÖNORM M7500; • Swiss Clean Air Regulations (LRV) • Swiss Regulations on Small Combustion Heating Systems • VKF Fire Safety Directive for Heating Systems (Switzerland) • SIA 384 (Switzerland) POWERCORN Installation Instructions 29 6 Plumbing diagrams PC-06-00-00-00-01-IAEN Diagrams for boiler outputs up to 50 kW Diagram no.: PC-01-1 PC with high/low temperature system (2 mixed circuits) outside-temperature based controller, ECO DHW cylinder Diagram no.: PC-01-2 PC with high/low temperature system (3 mixed circuits) outside-temperature based controller (wall controller), ECO DHW cylinder Diagram no.: PC-02-1-1 PC with HT/LT system, PSF thermal store (inc. WSU) outside-temperature based controller, PSF thermal store, connected solar panel system Diagram no.: PC-03-1 PC with HT/LT system, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store Diagram no.: PC-04-1-1 PC combined with wood-burning boiler, PSF thermal store outside-temperature based controller, wood-burning boiler, PSF thermal store Diagram no.: PC-05-1 PC with HT/LT system, district heating pipe, no thermal store outside-temperature based controller, ECO DHW cylinder Diagram no.: PC-06-1 PC with HT/LT system, district heating pipe, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store Diagrams for boiler outputs upwards of 50 kW Diagram no.: PC-07-1-1 PC with high/low temperature system, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store Diagram no.: PC-08-1-1 PC with HT/LT system, PSF thermal store (inc. WSU) outside-temperature based controller, PSF thermal store, connected solar panel system Diagram no.: PC-10-1 PC with high/low temperature system outside-temperature based controller, ECO DHW cylinder Diagram no.: PC-11-1-1 PC with HT/LT system, district heating pipe, no thermal store outside-temperature based controller, ECO DHW cylinder Diagram no.: PC-12-1-1 PC with HT/LT system, district heating pipe, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store Diagrams for systems supplying multiple properties (max. 3 properties) Diagram no.: PH-13-2 Properties supplied via district heating pipe function CP (charging pump) per property – 1 outside-temp. based controller, 1 ECO DHW cylinder 1 PS thermal store Diagram no.: PH-14-2 Properties supplied via district heating pipe function FP (feeder pump) per property – 1 outside-temp. based controller, 1 ECO DHW cylinder Diagram no.: PH-15-2 Properties supplied via district heating pipe function TSP (thermal store pump) per property – 1 outside-temp. based controller, 1 ECO DHW cylinder 1 PS thermal store Diagram for sequential boiler control system (cascade system) Diagram no.: PH-16-2 Sequential boiler control system (boiler cascade system) for max. 4 boilers Setting on HP0 menu: ? HP0 mode = Feeder pump Heat from biomass 30 KWHPO123Netz 230 V>55°C8M M5HKP0 HKP15HKP2 SLP0230V79AFFühlerleitungenVF1 VF2RG06 6RG16RG2SF 04WW Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-01-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Branch control valve Not supplied 9. Fault indicator lamp Important: follow wiring diagram Not supplied Diagrams for boiler outputs up to 50 kW POWERCORN with high/low temperature system (2 mixed heating circuits) outside-temperature based controller, ECO DHW cylinder Settings on HP0 parameters menu: ? HP0 mode = Feeder pump Heat from biomass 31 KW12Netz 230 V97MHKP0VF0RG0MVF2HKP2MHKP1VF1HPO>55°C8SF 05 5 5SLP09AFCAN-Bus6Netz 230 V3RG16RG264WW Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-01-2 Electrical connections as per operating and installation instructions • With wall controller set MK261, the supplementary output (terminal H25) and the district heating pipe output (terminal H26) can be used to control heating circuit 0 using a mixer valve motor. The heating circuit pump is connected to output HKP 0 (terminal H33) and flow temperature sensor 0 to terminal H21/H22. With this configuration option, the district heating pipe and supplementary functions are not available. Diagrams for boiler outputs up to 50 kW POWERCORN with high/low temperature system (3 mixed heating circuits) outside-temperature based controller (wall controller), ECO DHW cylinder GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based wall controller set MK261 Art. no.: S30-030 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Branch control valve Not supplied 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Flow temp. sensor VF20 (VF0 for HK 0) Art. no.: S70-002 Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 32 HP0213Netz 230 V>55°C89AF7 230VFühlerleitungen4WW11T2M5Option10M510 OptionHKP2HKP1HKP0VF112VF2Netz 230 V11T3SFKWRG2RG1RG06 6 6 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-02-1-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs up to 50 kW POWERCORN with high/low temperature system, PSF thermal store (inc. water supply unit) outside-temperature based controller, thermal store PSF, connected solar panel system GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. Thermal store PSF As price list 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA60 Art. no.: H39-001 Alternatively: RA60 EnergieA Art. no.: H39-003 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Option: 12-hole flange and ridged pipe heat exchanger 11. Thermal store sensor Art. no.: S70-003 12. Option: Secondary return unit Art. no.: 045-250 Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 33 KWT2123Netz 230 V79AF5M>55°CHP08 HKP0 HKP15MHKP2 SLP0Puffer HP0VF1Fühlerleitungen230VRG06RG16VF210T36RG2SF 0WW4 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-03-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs up to 50 kW POWERCORN with high/low temperature system, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA60 Art. no.: H39-001 Alternatively: RA60 EnergieA Art. no.: H39-003 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Thermal store PSB As price list 11. Thermal store sensor Art. no.: S70-003 Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 34 > 88°CRGTRauc hr ohr Fes ts tof fk es sel> 50°CKLP82Netz 230 V2112Fühler T2-F, T3-F, T5-F13>55°CNetz 230 VHP08M5M5HKP1HKP0 HKP2Option13Option13T2-FT211T3-FT5-FT310Netz 230 V11Fühlerleitungen230V9AF7VF1 VF26RG1RG06RG26WWKW4SF Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-04-1-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system. • Flue gas monitor (RGT) connected to terminals 22/23 (boiler enabling switch on boiler circuit board) Diagrams for boiler outputs up to 50 kW POWERCORN combined with wood-burning boiler, PSF thermal store (inc. water supply unit) outside-temperature based controller, wood-burning boiler, thermal store PSF GUNTAMATIC components 1. POWERCORN boiler and solid fuel boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. Thermal store PSF As price list 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA60 Art. no.: H39-001 Alternatively: RA60 EnergieA Art. no.: H39-003 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Option: Secondary return unit Art. no.: 045-250 11. Thermal store sensor Art. no.: S70-003 12. Flue gas monitor (RGT), switching point 88C° Art. no.: H00-801 13. Option: 12-hole flange and ridged pipe heat exchanger Settings on HP0 parameters menu: ? HP0 mode = Feeder pump Heat from biomass 35 KW1110123Netz 230 V79AF>55°CHP08M M5HKP0 HKP15HKP2 SLP0Fühlerleitungen230VVF1 VF2RG06RG16RG26SF 0WW4 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-05-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs up to 50 kW POWERCORN with high/low temperature system, district heating pipe, no thermal store outside-temperature based controller, ECO DHW cylinder GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA60 Art. no.: H39-001 Alternatively: RA60 EnergieA Art. no.: H39-003 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Flow equaliser Not supplied 11. District heating pipe Not supplied Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 36 11T2KWFühlerleitungen123Netz 230 V79AFM>55°CHP085HKP0 HKP1M5SLP0HKP2Puffer HP0VF1230VRG06RG16VF210T3RG26SF 0WW4 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-06-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs up to 50 kW POWERCORN with high/low temperature system, district heating pipe, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA60 Art. no.: H39-001 Alternatively: RA60 EnergieA Art. no.: H39-003 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Thermal store PSB As price list 11. District heating pipe Not supplied 12. Thermal store sensor Art. no.: S70-003 Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 37 21>55°CNetz 230 V93Netz 230 VM8HP0Fühlerleitungen230VAF75MHKP0 HKP1VF15MHKP2VF2SLP01111T2Puffer HP0T310KWSF 0WW4RG06RG16RG26 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-07-1-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs upwards of 50 kW POWERCORN with high/low temperature system, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Thermal store PSB As price list 11. Thermal store sensor Art. no.: S70-003 Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 38 12>55°C39Netz 230 VAF7230VFühlerleitungenWW 411T2MNetz 230 VM8HP05M5HKP1HKP0VF1HKP212VF2Option10Option1011T3SFNetz 230 VRG1RG06 6RG26KW Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-08-1-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs upwards of 50 kW POWERCORN with high/low temperature system, PSF thermal store (inc. water supply unit) outside-temperature based controller, thermal store PSF, connected solar panel system GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. Thermal store PSF As price list 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Option: 12-hole flange and ridged pipe heat exchanger 11. Thermal store sensor Art. no.: S70-003 12. Option: Secondary return unit Art. no.: 045-250 Settings on HP0 parameters menu: ? HP0 mode = Feeder pump Heat from biomass 39 KWSF 0>55°C123HP08HKP255MHKP0 HKP1MSLP0Netz 230 V9AF230VFühlerleitungen7VF2VF16 6 6RG0 RG1 RG2WW4 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-10-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs upwards of 50 kW POWERCORN with high/low temperature system outside-temperature based controller, ECO DHW cylinder GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Recommended pump Wilo EAS/6-3 P Art. no.: H39-101 9. Fault indicator lamp Important: follow wiring diagram Not supplied Settings on HP0 parameters menu: ? HP0 mode = Feeder pump Heat from biomass 40 12>55°C3SF 0Netz 230 VM1011KWHKP08HP0 M5M5HKP1 HKP2 SLP04WWNetz 230 V9AF7230VFühlerleitungen666VF1 VF2RG0 RG1 RG2 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-11-1-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs upwards of 50 kW POWERCORN with high/low temperature system, district heating pipe, no thermal store outside-temperature based controller, ECO DHW cylinder GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Flow equaliser Not supplied 11. District heating pipe Not supplied Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump HP0 sensor = Boiler Heat from biomass 41 21>55°C3Netz 230 V98Netz 230 VMHP0FühlerleitungenAF7230V1011MHKP0 HKP15VF15MSLP0HKP2VF2T2Puffer HP0T3KWSF 0WW46RG0 RG16RG26 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PC-12-1-1 Electrical connections as per operating and installation instructions • Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or Heating circuit 0 can be room-temperature controlled using an RFF25 room stat for a radiator heating system Diagrams for boiler outputs upwards of 50 kW POWERCORN with high/low temperature system, district heating pipe, PS thermal store outside-temperature based controller, ECO DHW cylinder, PS thermal store GUNTAMATIC components 1. POWERCORN boiler 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based controller set MKR Art. no.: S30-031 4. DHW cylinder ECO305 Art. no.: 048-500 5. Mixer valve positioner motor SM70 Art. no.: S50-501 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Fault indicator lamp Important: follow wiring diagram Not supplied 10. Thermal store PSB As price list 11. District heating pipe Not supplied Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump Heat from biomass 42 Netz12CAN-Bus7HeizraumT3Puffer HP08HP012>55°C10Einstellung im Menü Parameter HP0: Betrieb HP0 = PufferpumpeT2Puffer 15T2-1RG63Netz 230 VHKR 2LAP9CAN-Bus*Puffer 2T3-2HKP6510T2-29LAPHKP31313Fernleitung 2 auf LAP einstellenHaus 2Fernleitung 1 auf LAP einstellenWW411SF 1MKW6RG8MRG7VF8HKP8 SLP2SF 2M11 4WWVF7HKP7MKWRG56VF5RG4VF4HKP5HKP4 SLP1RG03Netz 230 VAF HKR 0CAN-Bus**Puffer 0T3-05HKP0T2-0RG33Netz 230 VHKR 19LAPCAN-Bus*T3-1101013Haus 1Fernleitung 0 auf LAP einstellenHaus 06RG2RG1WWVF2411SF 0MHKP2 SLP0VF1MHKP1KW Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PH-13-2 Electrical connections as per operating and installation instructions System supplying a maximum of 3 properties (suitable for POWERCHIP, BIOCOM and POWERCORN) District heating pipe function CP (charging pump) Per property – 1 outside-temperature based controller, 1 ECO DHW cylinder, 1 PS thermal store GUNTAMATIC components 1. Powerchip, Powercorn or Biocom 75/100 kW 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based wall controller set MK261 Art. no.: S30-030 4. DHW cylinder ECO305 Art. no.: 048-500 5. Thermal store PSB As price list 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Dimension charging pumps according to length of piping run e.g. Grundfos UPS 32-60 or Wilo 30/7 Not supplied 10. Fault indicator lamp Important: follow wiring diagram Not supplied 11. Mixer valve positioner motor SM70 Art. no.: S50-501 12. Thermal store PS 2000/2PS As price list 13. District heating pipe Not supplied max. 3 MK261 wall controller sets possible (HKR0, HKR1, HKR2) max. 3 RS100 room controllers possible one RFF25 room stat per heating circuit possible Always connect outside sensor (AF) to HKR 0 Settings on HP0 parameters menu: ? HP0 mode = Thermal store pump Heat from biomass 43 CAN-Bus max. 100 m127HeizraumT3Puffer HP01210Netz>55°C8HP0T2Haus 1HKP35RG63Netz 230 VZUP9CAN-Bus**10HKP65HKR 2ZUP91313 Fernleitung 2 auf ZUP einstellenHaus 2Fernleitung 1 auf ZUP einstellenVF4 VF5SLP1SF 1M4KW6HKP4MRG7 RG811HKP5SLP2SF 2M4WWVF7HKP7M11HKP8VF8KW6RG4 RG5WWRG0Netz 230 V 3CAN-Bus**10HKP05RG33Netz 230 VZUP9CAN-Bus**10HKR 1AF HKR 013 Fernleitung 0 auf ZUP einstellenHaus 06RG1 RG2SLP0SF 0M4WWVF1HKP1M11HKP2VF2KW Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PH-14-2 Electrical connections as per operating and installation instructions System supplying a maximum of 3 properties (suitable for POWERCHIP, BIOCOM and POWERCORN) District heating pipe function FP (feeder pump) Per property – 1 outside-temperature based controller, 1 ECO DHW cylinder GUNTAMATIC components 1. Powerchip, Powercorn or Biocom 75/100 kW 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based wall controller set MK261 Art. no.: S30-030 4. DHW cylinder ECO305 Art. no.: 048-500 5. Flow equaliser according to required output Not supplied 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Dimension feeder pumps according to length of piping run e.g. Grundfos UPS 32-60 or Wilo 30/7 Not supplied 10. Fault indicator lamp Important: follow wiring diagram Not supplied 11. Mixer valve positioner motor SM70 Art. no.: S50-501 12. Thermal store PS 2000/2PS As price list 13. District heating pipe Not supplied max. 3 MK261 wall controller sets possible (HKR0, HKR1, HKR2) max. 3 RS100 room controllers possible one RFF25 room stat per heating circuit possible Always connect outside sensor (AF) to HKR 0 Setting on HP0 parameters menu: ? HP0 mode = Feeder pump Heat from biomass 44 Netz21CAN-Bus max. 100 m7Heizraum13108>55°CHP0PUPRG3HKP3HKP6RG6Netz 230 V 3CAN-Bus10HKR 1*T3-15Puffer 1T2-1Netz 230 V 39PUPCAN-Bus10HKR 2*T3-25Puffer 2T2-29PUP1212 Fernleitung 2 auf PUP einstellenHaus 2Fernleitung 1 auf PUP einstellenHaus 16RG4 RG5VF4 VF5WWSLP14SF 1RG0HKP010HKR 0**AF6KWHKP4 HKP511MMWWSLP2SF 24VF8VF7HKP7 HKP8MM11RG7 RG8KW5Puffer 0T3-0T2-093CAN-Bus Netz 230 V12 Fernleitung 0 auf PUP einstellenHaus 06WWSLP04SF 0RG1 RG2VF1 VF2HKP1 HKP2MM11KW Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PH-15-2 Electrical connections as per operating and installation instructions System supplying a maximum of 3 properties (suitable for POWERCHIP, BIOCOM and POWERCORN) District heating pipe function TSP(thermal store pump) Per property – 1 outside-temperature based controller, 1 ECO DHW cylinder, 1 PS thermal store GUNTAMATIC components 1. Powerchip, Powercorn or Biocom 75/100 kW 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. Outside temp. based wall controller set MK261 Art. no.: S30-030 4. DHW cylinder ECO305 Art. no.: 048-500 5. Thermal store PSB As price list 6. Room stat RFF25 Art. no.: S70-006 7. GSM module Art. no.: S15-002 8. Return boost set RA100 EnergieA Art. no.: H39-010 9. Dimension pumps according to length of piping run e.g. Grundfos UPS 32-60 or Wilo 30/7 Not supplied 10. Fault indicator lamp Important: follow wiring diagram Not supplied 11. Mixer valve positioner motor SM70 Art. no.: S50-501 12. District heating pipe Not supplied 13. Flow equaliser Not supplied max. 3 MK261 wall controller sets possible (HKR0, HKR1, HKR2) max. 3 RS100 room controllers possible one RFF25 room stat per heating circuit possible Always connect outside sensor (AF) to HKR 0 Set output HP0 to thermal store pump for each system Heat from biomass 45 44MNetz 230 V>55°C1212HP0MNetz 230 VHP0>55°CT26MNetz 230 VNetzCAN-BusNetz3Kessel A>55°C42 1CAN- Bus12HP0NetzCAN-BusNetzKessel CMNetz 230 VKessel B4HP05Puffer HP0>55°CKessel DT36 Tel. 07276 / 2441-0 info@guntamatic.com www.guntamatic.com Diagram no. PH-16-2 Electrical connections as per operating and installation instructions Sequential boiler control system (boiler cascade system) for maximum of 4 boilers (suitable for POWERCHIP, BIOCOM and POWERCORN) GUNTAMATIC components 1. Powerchip, Powercorn or Biocom 75/100 kW 2. Flue draught regulator RE (size to suit flue diameter) As price list 3. GSM module Art. no.: S15-002 4. Return boost set RA100 EnergieA Art. no.: H39-010 5. Thermal store PS 2000/2PS As price list 6. Thermal store sensor Art. no.: S70-003 2 thermal store sensors required for each boiler Connect all boilers via CAN bus max. 3 MK261 wall controller sets per system possible (HKR0, HKR1, HKR2) max. 3 RS100 room controllers per system possible one RFF25 room stat per heating circuit possible Always connect outside sensor (AF) to heating circuit controller 0 (HKR 0) Important: The CAN bus must be wired without connecting the + terminal. Note: Only one boiler can be controlled/queried remotely via the GSM module. However, faults are forwarded to the GSM module via the CAN bus. Heating circuit installation: Diagram PH-13-2 with charging pump (LAP) and thermal store Diagram PH-14-2 with feeder pump (ZUP) and without thermal store POWERCORN Installation Instructions 46 7 Electrical wiring diagram BS-07-00-00-00-01-IAEN 7.1 Control panel (use only flexible cables for wiring) TH-07-01-00-00-01-IAEN BCE = Display and control unit (touch screen) Service = Connection socket SY-BUS = Connection socket/cable connection betw. BCE and boiler PCB Ethern. = Connection socket (inactive) SD-Card = Slot for SD memory card CAN = Connection socket for CAN bus CAN-Bus = Cable connection between BCE and digital room controller or wall controller GSM = Facility for connecting a GSM module Visu. = Facility for connecting a graphical boiler interface KP = Cable connection to boiler circuit board (SY bus) Caution: It is imperative that the vacuum pipes are earthed on the vacuum pump and the outfeed auger. POWERCORN Installation Instructions 47 7.2 Wall controller set MK261 (use only flexible cables for wiring) PH-07-02-00-00-01-IAEN RG 0-8 = Analogue room stat input for HC 0-8 Connector: H1/H2 – H3/H4 - H5/H6 AF = Connect only if not connected on boiler PCB Connector: H7/H8 VF 1, 2, 4, 5, 7, 8 = Flow sensor input for heating circuit 1, 2, 4, 5, 7, 8 Connector: H9/H10 - H11/H12 SF 0-3 = Cylinder sensor input for DHW cylinder 0, 1, 2 Connector: H13/H14 ZSF 0-2 = Supplementary cylinder sensor input Connector: H15/H16 T2 = Thermal store bottom sensor input Connector: H17/H18 T3 = Thermal store top sensor input Connector: H19/H20 VF 0, 3, 6 = Flow temperature sensor input for heating circuits 0, 3, 6 Connector: H21/H22 ZU 0, 1, 2 = Output programmable as ext. burner or DHW cylinder Connector: H25/PE/N FL 0, 1, 2 = Output for district heating pipe pump Connector: H26/PE/N HKP 0-8 = Output for heating circuit pump 0-8 Connector: H27/PE/N (H28, H33) Mi 1, 2, 4, 5, 7, 8 = Output for mixer valve 1, 2, 4, 5, 7, 8 Connector: H29/PE/N/H30, H31/PE/N/H32 SLP 0-3 = Output for cylinder charging pump 0, 1, 2 Connector: H34/PE/N Netz = Power supply input (230VAC) Connector: H35/PE/N FFR = District heating pipe enabling switch Connector: H36/PE/H37 SMA = Output for fault signal (9.2V= 20mA) Connector: H38/H39 RS = Output for digital room controller Connector: CAN-BCE Standard setting for S1: both DIP switches "ON" Caution: Change to S2 setting only effective after switching mains power OFF and ON Function of LEDs Controller on, CAN bus cable correctly connected: LED ? H5 (green) should light up LED ? H6, H7 (orange) should flash Mains power and fuse F1 are OK LED ? H1, H4 (green) should light up LED ? H2, H3 (green) should flash Fuse assignment for wall controller F1 T 0.63A Power supply for electronics F2 T 6.30A HKP 0, HKP 1, HKP 2, MI 1, MI 2, SLP 0 Connection on room stat Connect contacts 1 and 2 Mixer valve alternative (0, 3, 6): Only possible if output FL and output ZU are not required. POWERCORN Installation Instructions 48 7.3 Boiler circuit board (use only flexible cables for wiring) PC-07-03-00-00-01-IAEN RG 0 (1, 2) = Analogue room stat input for HC 0 (1, 2) Connector: H1/H2 (H3/H4, H5/H6) AF = Outside sensor input Connector: H7/H8 VF 2 (1) = Flow temperature sensor input for heating circuit 2 (1) Connector: H9/H10 (H11/H12) SF 0 = Cylinder sensor input for DHW cylinder 0 Connector: H13/H14 ZSF 0 = Supplementary cylinder sensor input (output HK 0 as DHW) Connector: H15/H16 T1 = Boiler sensor input Connector: 39/40 T2 = Thermal store bottom sensor input Connector: 31/32 T3 = Thermal store top sensor input Connector: 33/34 STF = Stoker sensor input (stoker temperature monitor) Connector: 37/38 RGT = Flue gas temp. sensor input (ensure correct polarity) Connector: 41/42 FZ = Fill level switch input (fire box monitor) Connector: 43/44 Hall REI = Hall-effect sensor input from drive motor REI Connector: 45/46/47 Hall G1 = Hall-effect sensor input from drive motor G1 Connector: 48/49/50 SMA = Output for fault signal (24V DC 200mA) Connector: 52/53 Lambda = Oxygen sensor input Connector: 63/64/65/66 TKS 1 = Input for door switch 1 (firebox door/ash box) Connector: 26/PE/27 FÜS = Fill-level sensor input Connector: 28/29/30 ZG = Ignition fan output (1=Fan, 2=Igniter) Connector: 1/PE/N/2 SG = Flue draught fan output Connector: 3/PE/N Netz = Power supply input (230VAC) Connector: 4/PE/N Power I/O = Power switch input/output Connector: 6/7 STB = STL input/output Connector: 8/PE/9 G1 = Output for stoker drive motor Connector: 13/PE/N REI = Output for drive motor for stepped grate and grate cleaner Connector: 14/PE/N A1 = Output for fuel outfeed drive motor Connector: 15/PE/N HP 0 = Programmable special output Connector: 20/PE/N A2 = Output for vacuum pump Connector: 21/PE/N KFR = Boiler enabling switch input Connector: 22/PE/23 HKP 2 (1, 0) = Output for heating circuit pump 2 (1, 0) Connector: H27/PE/N H28, H33 ZU 0 = Programmable as 2nd DHW cylinder or ext. burner Connector: H33/PE/N Mi 2 (1) = Output for mixer valve 2 (1) Connector: H29/PE/N/H30, H31/PE/N/H32) SLP 0 = Output for cylinder charging pump 0 Connector: H34/PE/N Fuse assignment for boiler PCB F1 T 4A REI F2 T 4A A1 F3 T 2A STB, Power, KFR F4 T 6.3A HKP 0, HKP 1, HKP 2, SLP 0, Mi 1, Mi 2 F5 T 10A HP 0, A2, ZG F6 T 4A G1, SG Connection on room stat Connect contacts 1 and 2 POWERCORN Installation Instructions 49 Notes BS-D-00-00-00-01-IAEN POWERCORN Installation Instructions 50 8 Technical data BS-08-00-00-00-01-IAEN 8.1 POWERCORN 30 PC-08-01-00-00-01-IAEN Type Powercorn 30 Fuel Grain fuel Pellets, 6mm ÖNORM M7135 Boiler output Grain fuel 7-25 Pellets 7-30 kW kW Required flue draught Boiler temperature Return temperature Return boost 0,15 70 – 80 > 55 ? Feeder pump if thermal store connected mbar °C °C Water capacity Operating pressure 128 max. 3 litres bar Water system resistance Temperature difference 20 K Through-flow rate 1070 Water temperature 34.4 Differential pressure 10.2 kg/h °C Water system resistance Temperature difference 10 K Through-flow rate 2140 Water temperature 38.7 Differential pressure 16.4 kg/h °C "Large" ash pan "Small" ash pan 60 12 litres litres A B C D E F G Temp.-relief heat exchanger sensor Return connection, 1 ¼" Temp.-relief heat exchanger connection, ¾" STB, boiler sensor Drain, ½" Flow connection, 1 ¼" Flue connecting pipe dia. 150 mm Inches Inches Inches Inches mm Overall weight w/o stoker unit Weight of bottom box Weight of heat exchanger Weight of stoker unit Weight of drive unit Weight per m of outfeed auger 562 340 192 70 26 40 kg kg kg kg kg kg Temperature-relief heat exchanger Yes Power supply 230V 13A POWERCORN Installation Instructions 51 8.2 POWERCORN 50 PC-08-02-00-00-01-IAEN Type Powercorn 50 Fuel Grain fuel Pellets, 6mm ÖNORM M7135 Boiler output Grain fuel 12-40 Pellets 12-50 kW kW Required flue draught Boiler temperature Return temperature Return boost 0,15 70 – 80 > 55 ? Feeder pump if thermal store connected mbar °C °C Water capacity Operating pressure 147 max. 3 litres bar Water system resistance Temperature difference 20 K Through-flow rate 1840 Water temperature 25.2 Differential pressure 4.7 kg/h °C Water system resistance Temperature difference 10 K Through-flow rate 3690 Water temperature 26.0 Differential pressure 18.7 kg/h °C "Large" ash pan "Small" ash pan 80 12 litres litres A B C D E F G Temp.-relief heat exchanger sensor Return connection, 1 ¼" Temp.-relief heat exchanger connection, ¾" STB, boiler sensor Drain, ½" Flow connection, 1 ¼" Flue connecting pipe dia. 180 mm Inches Inches Inches Inches mm Overall weight w/o stoker unit Weight of bottom box Weight of heat exchanger Weight of stoker unit Weight of drive unit Weight per m of outfeed auger 562 340 192 70 26 40 kg kg kg kg kg kg Temperature-relief heat exchanger Yes Power supply 230V 13A POWERCORN Installation Instructions 52 8.3 POWERCORN 75 PC-08-03-00-00-01-IAEN Type Powercorn 75 Fuel Grain fuel Pellets, 6mm ÖNORM M7135 Boiler output Grain fuel 21-70 (with additive) Pellets 22-75 kW kW Required flue draught Boiler temperature Return temperature Return boost 0.15 70 – 80 > 55 ? Feeder pump if thermal store connected mbar °C °C Water capacity Operating pressure 256 max. 3 litres bar Water system resistance Temperature difference 20 K Through-flow rate 3000 Water temperature 24.2 Differential pressure 1.1 kg/h °C Water system resistance Temperature difference 10 K Through-flow rate 6000 Water temperature 24.2 Differential pressure 3.1 kg/h °C "Large" ash pan "Small" ash pan 80 12 litres litres A B C D E G Flow connection, 2" Temp.-relief heat exchanger connection, ¾" Additional connection, ½" Drain, ½" Return connection, 2" Flue connecting pipe dia. 180 mm Inches Inches Inches Inches Inches mm Overall weight w/o stoker unit Weight of bottom box Weight of heat exchanger Weight of stoker unit Weight of drive unit Weight per m of outfeed auger 890 430 405 70 26 40 kg kg kg kg kg kg Temperature-relief heat exchanger Yes Power supply 230V 13A POWERCORN Installation Instructions 53 8.4 FLEX system outfeed BC-08-03-00-00-01-IAEN Wall opening for auger: Width 330 mm Height 250 mm Dimension A > Auger length Dimension B > Storeroom internal clear length FLEX 1.0 m 1080 mm – 1559 mm FLEX 1.5 m 1560 mm – 2039 mm FLEX 2.0 m 2040 mm – 2519 mm FLEX 2.5 m 2520 mm – 2999 mm FLEX 3.0 m 3000 mm – - 3479 mm FLEX 3.5 m 3480 mm – 3959 mm FLEX 4.0 m 3960 mm – 4439 mm FLEX 4.5 m 4440 mm – 4919 mm FLEX 5.0 m 4920 mm - . POWERCORN Installation Instructions 54 8.5 BOX system outfeed BC-08-04-00-00-01-IAEN Dimension A - B Dimension C (variable) Hopper capacity in m³ Hopper capacity in t BOX 7.5 210 cm x 210 cm 180 cm - 250 cm 5.0 m³ to 7.5 m³ 3.0 t to 4.7 t BOX 8.3 170 cm x 290 cm 180 cm - 250 cm 6.1 m³ to 8.3 m³ 4.0 t to 5.4 t BOX 11 250 cm x 250 cm 180 cm - 250 cm 8.3 m³ to 11 m³ 5.0 t to 6.7 t BOX 14 290 cm x 290 cm 180 cm - 250 cm 10.2 m³ to 14.1 m³ 6.5 t to 9.1 t POWERCORN Installation Instructions 55 POWERCORN Installation Instructions 56 BS-E-00-00-00-01-BAEN GUNTAMATIC Heiztechnik GmbH A – 4722 PEUERBACH Bruck 7 Tel: 0043 (0) 7276 / 2441-0 Fax: 0043 (0)7276 / 3031 E-mail: info@guntamatic.com