Guntamatic BIOSTAR BOX User manual

Pelletfiring
englisch
BIOSTAR Complete
Operating instructions
EN-B30-003-V21-0322

2
Information on this documentation BS-01
Please read through this documentation carefull .
It is intended as a reference document and contains important
information on the design, safet , operation, maintenance and care
of our heating s stem.
We are alwa s looking to improve our products and
documentation. An ideas and suggestions ou ma have will be
gratefull received.
GUNTAMATIC Heiztechnik GmbH
Bruck 7
A-4722 PEUERBACH
Tel: [phone] / 2441-0
Fax: [phone] / 3031
Email: [e-mail]
It is important that ou pa particular attention to
the safet issues highlighted in the text b these
s mbols.
The entire contents of this document are the propert of
GUNTAMATIC and therefore protected b cop right.
Reproduction of an kind, communication to third parties b an
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.

3
Contents 03
page
1 Introduction ................................................................................ 5
2 Important notes .......................................................................... 6
2.1 Intended use ................................................................................................... 6
2.2 operate the heating s stem ............................................................................. 6
2.3 gurantee and liabilit ....................................................................................... 7
2.4 Securit instructions ........................................................................................ 7
2.5 Securit notes on the heatings stem ............................................................. 11
3 S stem components ................................................................ 12
4 Safet S stems ........................................................................ 13
5 control panel description ........................................................ 14
6 Overview of Menu and Levels ................................................. 15
6.0 Houselevel ................................................................................................... 16
6.1 Programme selection ................................................................................. 17
6.2 Customer level ............................................................................................ 17
6.2.1 Customer menu ......................................................................................... 18
6.2.2 Heating circuit ............................................................................................ 19
6.2.3 Hot water .................................................................................................... 20
6.2.4 HP0 ............................................................................................................ 20
6.2.5 Pipeline ...................................................................................................... 21
6.2.6 APP ............................................................................................................ 21
6.2.7 Servicelevel .............................................................................................. 22
6.2.7.1 Resetdata ................................................................................................ 22
6.2.7.2 Beginning Service ................................................................................... 23
6.2.7.3 Parameter Heating circuit ....................................................................... 24
6.2.7.4 Parameter Hot water ............................................................................... 24
6.2.7.5 Parameter HP0 ....................................................................................... 25
6.2.7.6 Parameter trunk blink .............................................................................. 26
6.2.7.7 Parameter Reflux mixer .......................................................................... 26
6.2.7.8 S stem settings ....................................................................................... 27
7 User settings ............................................................................ 29
7.1 Heating On / Off ......................................................................................... 29
7.2 Heatingprogramme how to programme .......................................................... 30
7.3 Roomtemperature adapt .......................................................................... 31
7.4 Warmwatertemperature adapt ................................................................. 32
7.5 Roomcontroller use ................................................................................. 33

4
Contents
page
8 Operating the heating s stem ................................................. 34
8.1 Controlling of heatingcirculation s stem ....................................................... 34
8.2 Fuel ............................................................................................................... 35
8.3 Fill storeroom ................................................................................................ 36
8.4 Empt ing the ash .......................................................................................... 37
9 Cleaning/ care .......................................................................... 38
9.1 Interim cleaning ............................................................................................. 39
9.2 General cleaning ........................................................................................... 40
10 Error/ Fault messages ............................................................. 41
11 Fault clearance ......................................................................... 42
12 Replacing fuses ....................................................................... 43
13 S stem log book ...................................................................... 44
14 Parameter changes .................................................................. 44
15 Heatingcirculation attitudes .................................................... 44
16 Declaration of conformit ........................................................ 46

5
1 INTRODUCTION BS-01
You have made a good choice with GUNTAMATIC.
We suppl ou with a product based on man ears of boiler-
making experience, and it is our most urgent wish that ou alwa s
enjo our heating s stem.
The following instructions should be of use to ou during operation
and maintenance. Please remember that even the best furnace
cannot do without care and maintenance. Therefore, read this
operating manual carefull and have the initial start-up carried out
b a GUNTAMATIC-authorized specialist. Above all, follow the
safet instructions in Chapter 2.
Short description The BIOSTAR furnace is a modern boiler. The discharge takes
place from a storage room b means of a suction s stem.
T pe approval The firing is designed according to class 5 according to EN 303-5,
as well as the agreement of the federal states according to Art. 15a
BVG on protective measures for small firing s stems and saving of
energ . The original t pe test certificates are available from the
manufacturer.
Further Information
The documentation consists of the following documents:
 Planning Document
 Installation instructions
 Operating instructions
If ou have an questions, please consult our Customer Support.

6
2 IMPORTANT NOTES BS-01
Your boiler has been designed and produced in accordance with
the latest technical advances and all applicable safet regulations.
Nevertheless incorrect operation, the use of unapproved fuels or
the failure to carr out necessar maintenance and repairs can
result in personal injur or damage to propert . You will avoid
dangerous situations b onl using the boiler for the purpose for
which it was designed and b operating, cleaning and maintaining
it correctl . Onl start up the heating s stem when it is in perfectl
safe working order.
2.1 INTENDED USE BS-01
The boiler is designed for heating central heating water and for
use as a central heating boiler.
Do not use the boiler to burn rubbish!
Burning rubbish will cause extensive corrosion
and consequentl to a substantial reduction in the
service life of the boiler.
2.2 OPERATE THE HEATING SYSTEM BS-01
The heating s stem ma onl be operated and cleaned b
demonstrabl trained persons (as per check list). Children,
unauthorised persons or persons
Even if the opposite is requested, servicing and
repair work ma onl be carried out b
authorised specialists.

7
2.3 GURANTEE AND LIABILITY BS-01
Gurantee and liabilit claims for personal injur and/ or propert
damage are inadmissible if the are attributable to one or more
of the following causes:
 use of the boiler for purposes other than that intended
 failure to follow the instructions, guidance and safet
precautions given in the documentation
 incorrect commissioning, operation, maintenance or repair
of the boiler
 operation of the boiler when safet s stems are
inoperative
 unauthorised modifications
2.4 SAFETY INSTRUCTIONS PC-01
To prevent accidents, small children should not be allowed into
the boiler room or fuel storeroom. Please follow the safet
instructions below. B doing so, ou will protect ourself and
prevent damage to our heating s stem.
Power switch
The power switch must remain switched on at
all times and ma onl switched off when the
s stem is not in operation
Mains plug
Risk of fatal injur from electric shock!
The mains power suppl is brought to the boiler
via the plug marked Mains. That plug and other
components of the s stem remain live even
when the Power switch on the control panel is
switched off.
Repair work
Repair work ma onl be carried out b
authorised technichians!
Touching live electrical components can cause
fatal injur !
Even when the Power switch is „OFF“ some
components of the s stem are still live.
Therefore, when carr ing out repair work it is
imperative that the power suppl to the heating
s stem is disconnected b means of the „mains
plug“ or a circuit breaker
In an
emergen :
In the event of an electric shock, disconnect the power suppl
immediatl . Administer first aid and call the dut doctor
Fault rectification:
If faults occur, the causes must first be
eliminated on the basis of the information
message on the displa (F0…) before resuming
operation b means of the “Quit” button.

8
Modifications
Do not make an unplanned changes to the
settings or an modifications to the heating
s stem.
Loss of guarantee entitkement!
Servicing work
Service the boiler regularl or make use of our
Costumer Service.
Empt ing ash
Glowing embers can cause fires!
Onl remove the ash from the boiler or store it
in non combustible containers.
Boiler cleaning
Touching hot components can cause skin burns!
The boiler must onl be cleaned when it is cold
(flue gas temperature < 50 °C)
Flue gas fan
Risk of injur from rotating parts!
The fan must onl be removed when it is
disconnected from the power suppl
(unplugged)
Gaskets
Risk of gas poisoning.
It is possible that flue gas could escape if
gaskets are damaged.
Have defective gaskets replaced b an
authorised technician.
In an
emergenc :
Take the person affected into the open air immediatel . Call the
dut doctor!
Air suppl
Risk of suffocation!
Inadequate air suppl can be fatal.
Make sure there is an adequate suppl of air.
Note: If there is more than one boiler in the same room, a greater
suppl of frehs air must be provided.
Flue draught regulator:
Risk of detonation!
A flue regulator with a pressure surge
compensator is an essential requirement!

9
Safet clearances
Fire risk!
Do not store an flamable items in the close
vivinit of the boiler.
Follow the local regulations!
When heating
Attention Danger of deflagration!
When the boiler is running please don’t open
the boiler door or cleaning openings
Fill storage room
Attention poisoning and fire hazard!
The boiler must be switched off when
filling the storage room using a blower or
pump truck (Prog. OFF) !
Failure to do so can result in flammable and
toxic gases entering the storage room!
Enter storage room
Attention danger of death!
All biogenic substances can form
gases during storage.
Entering the storage room is therefore onl
permitted when the storage room is empt
(max. 1/5 remaining content) and after at least 2
hours of good ventilation.
Storage rooms with a higher filling level ma
onl be entered b authorized customer service
technicians after prior measurement of the air
qualit in the storage room.
Enter storage room
Attention risk of injur !
Onl enter the storage room when the
s stem is switched off! Alwa s disconnect
power before entering!
Put a sign on the storage room door!
Keep storage room doors locked!
Anti freeze function
Anti- freeze function
The s stem can onl perform its
freezing prevention function if sufficient fuel is
available and there are no faults.

10
Fire extinguisher
Provide a fire extinguisher!
There must be a fire extinguisher placed
immediatl outside the boiler room door!
Over temperature
Attention risk of injur !
If the boiler temperature exceeds 100 °C, the
boiler room must be vacated immediatel !
Under no circumstances ma boiler doors or
maintenance openings on the boiler be opened!
Plant remote access
Attention risk of injur !
If remote access to the s stem is activated, for
example using an app, GSM module, etc. ... all
t pes of work on the heating s stem ma onl be
carried out without exception when the heating
s stem is de-energized!

11
2.5 SECURITY ADVICES FOR THE HEATING SYSTEM BS-01
Warning of dangerous electric voltage
Warning of rotating components
Warning of hot surfaces
Warning of deflagration
grounding
Observe operating or installation instructions
Separate electric s stem from the mains
Pull angle plug aside
power Suppl
Do not use rigid cable for installations

12
3 SYSTEM COMPONENTS 04
1. Ash box door
2. Cleaning grate
3. Primar air
4. Self- cleaning grate
5. Secondar air
6. Swirl plate
7. Burn- bacl
8. Expansion zone
9. Automatic heat exchanger cleaning
10. Grate cleaner motor
11. Ignition fan
12. Ceramic insulation
13. Overall insulation
14. Helix baffels
15. Tube- t pe heat exchanger
16. Flue draught fan
17. Flue gas sensor
18. Lambdasond
19. Control unit
20. Sensor-filler level
21. Motor
22. Drive gear
23. suction fan
24. storing box
25. Pellet spiral
26. Sensor-burning monitioring
27. rotar valve

13
4 SAFETY SYSTEMS BS-01
To prevent the boiler overheating, the controller reduces the heat
output in certain situations. If the boiler still threatens to overheat,
the controller responds according to a set of defined safet levels.
Safet level 1 15°C above specified temperature
The drive motor Stops the fuel feed s stem and the flue draught
fan shuts down.
Safet level 2 Boiler temperature above 85°C
All heating pumps and the c linder charging pump are switched
on to carr heat awa from the boiler
Safet level 3 Boiler temperature above 100°C
The STL (safet temperature limiter) trips and switches all boiler
control functions off while the heating circulation pumps continue
to run. The s stem remains switched off even if the boiler
temperature drops back below 90°C. The s stem must not be
started up again until an faults have been rectified and the boiler
has been checked.
Power failure The controller, the flue draught fan and all circulation pumps
switch of due of electricit if there is a power cut. The glowing fuel
bed on the grate continues burn with the natural draught of the
flue. As this operating mode is not ideal, a larger amount of ash
collechts on the grate as well. As soon as the electricit suppl is
restored, the controller takes control of the heating s stem again.
Opening the ash box

the auger motor Stopps feeding in fuel;
 the suctionblower goes to 100 % extraction speed;
 After the firebox door is closed, normal operation is resumed
or re- ignition initiated

14
5 CONTROL PANEL DESCRIPTION BS-01
The appliance has a large touch- screen control panel with a meu-
based interface. All setting and quer options are shown on the
displa . All setting could be entered b pressing the “buttons” on
the touch screen. An s stem messages are displa ed on the
screen.
1 2 3 02
Power switch (1) Normall remains permanentl switched on. The power switch
ma onl be switched off when the s stem is not in operation.
The s stem must be disconnected from the
mains b unplugging the power lead when
carr ing out repairs or servicing work!
STB (2) Excessive temperature trips the safet temperature limiter (STB)
located under the cap (2) appliance operation is suspended; if the
STL has tripped, identif and eliminate the cause and then press
in the STL (button) with a thin object.
The s stem must not be started up again until
an faults have been rectified and the boiler has
been checked. If necessar , a heating engineer
must be called in.
Touch-Displa (3) Pressing lightl with our fingertip on the relevant buttons on the
displa opens the various program levels, menus and submenus.
All settings are made directl on the touch-screen displa .
Never use sharp objects such as ball-point pens
or the like to operate the touch screen

15
6 OVERVIEW OF MENU LEVELS BS-02
House level
Info level Prog. selection Customer level
▼
▼
▼
INFO-Error Boiler release Customer menu
INFO-Status OFF Heating circuit
INFO-Boiler NORMAL DHW
INFO-filter DHW DHW extra
INFO-Controller HEAT Buffer storage
INFO-Buffer REDUCE Pipeline
REDUCE TO… Detail displa .
BOOST DHW APP
MANUAL OPERATE Date-time
Grate cleaning Service level
exhaust. value
Menus shown with a dashed border onl appear if
activated on the Commissioning menu.

16
6.0 HOUSE LEVEL BS-01
About the selection buttons, ou switch to the different levels.
03
Info level
Program selection
see Chapter 6.1
Customer level
see Chapter 6.2
*) **) ***)
INFO
*) - Error messages, Temperatures, Scold and operational states, Buffer and
Heating circles could be requested.
**) - Programmes for boilers and heating circulations could be chosen;
- the boilers release could be broken;
***) - the attitudes for boilers, heating circulations could be changed
- the attitudes in the service area and the parameter menu could just
changed from authorised GUNTAMATIC staff.

17
6.2 COSTUMER LEVEL BS-02
Customer menu ...............................................................................................................
look at Chapter 6.2.1
* Heating circulaton .....................................................................................................
look at Chapter 6.2.2
* Warm water ..............................................................................................................
look at Chapter 6.2.3
Buffer storage..................................................................................................................
look at Chapter 6.2.4
* Loading pump ...........................................................................................................
look at Chapter 6.2.5
* Feed pump ................................................................................................................
look at Chapter 6.2.5
Detail screen .......................................................................... attitudes, condition and measurement of construction will be shown!
APP ...................................................................................................................................
look at Chapter 6.2.6
Date-time ................................................................................................... Date and time from the machine could be attituded!
Service level ......................................................................................................................
look at Chapter 6.2.7
back to house level .................................
look at chapter 6.0
INFO
* the selection buttons could just actived in connection with a heating circle;
6.1 PROGRAMMESELECTION BS-02
Boiler´s clearance ....................................... on Attitude „OFF“ the boiler didn´t start
* Program OUT ....................................... Heatingrun turned off
* Program NORMAL ................................ Heizung und WW-Bereitung eingeschaltet (nach Uhrenprogramm)
* Program WARM WATER ...................... heating turned off – WW- Bereitung eingeschaltet (after Watchpr. summer)
* Program HEATING ............................... Da and Night heatingrun (Warmwater with watchprogramme)
* Program LOWER .................................. Da and Night reduced mote (Warmwater with watchprogramme)
* Program LOWER TO ............................ Absenkbetrieb bis zu einem bestimmten Zeitpunkt
* RELOAD WARM WATER ..................... Duration maximal 90 Minutes
Program MANUAL....................................... Heatingservice on boilerstarget- or buffertargettrmperature
Grate cleaning ............................................. manual ON and OFF
Emissions measurement ............................. Programm for Emissionsmeasure
back to HOUSELEVEL ............................
look at Chapter 6.0
INFO
* the selection buttons wehre just shown,if a heatingcirculation is actived

18
6.2.1 COSTUMERMENU BS-03
Ash empt ................................... after cleaning the Ash the choose the Menüpoint and confirm with „YES“ and „OK“
Ash warning ................................ hours to the new „Ashewarning“ after confirmation of the Function „Ash emptiing“
1)
* Freigabe HKR ....................... Setting of the long-distance line release on the external heating circuit controller.
m³ set Counter to 0...................... turns the m³ Counter to 0
Attitude m³ Counter ..................... influenced the numberspeed (high Value = quicker count)
fill the spiral ................................. manueal refill of Stokerchannel (stopps automaticall )
fill the suction construction .......... manual refilling of storing tank (is stopping automaticall )
Charge lock time ......................... no refilling with storingtank while the OFF time (excepted forcefilling)
2)
Mode ........................................... Combustion mode setting
Language .................................... attiude of countries specific language
** Boiler´s off time ..................... no heating operation during programmed blocking times
Filter ash emptied ........................ Select the menu after empt ing the filter ash and confirm with YES and OK.
Ash warning filter ......................... Hours until the next ash warning on the displa / the filter ash must be emptied.
3)
Filter operation ............................ Affects filter performance.
Clean filter ................................... Manual start of the filter cleaning – the boiler switches to run-on mode.
back to the Costumerlevel .......................
see Chapter 6.2
INFO
* The button is onl visible when programming trunk line operation = LAP.
** The button is onl visible if the HP0 output is programmed to None or Z-pump.
1) Auto ........................ The pipeline pump is controlled full automaticall .
Off ........................... The pipeline pump is switched off.
Permanent .............. The pipeline pump runs continuousl .
2) No ............................ Default setting
ECO-ideal................ Saving mode
Normal .................... Attitude needs more cleaning (attitude just shortl )
a lot of slag ............. Setting for heav slag formation in the combustion chamber
3) optimal .................... 2-stage operation - highest performance of the filter
reduced ................... 1-stage operation - reduced filter performance
disabled .................. Filter disabled - no filter performance

19
6.2.2 HEATING CIRCUIT BS-03
4)
Operation pump .......................... Affects the operating status of the heating circuit
5)
* Weather ................................ Automatic or manual activation of multiple clock programs
** Clock program ....................... Setting the heating and setback phases for the NORMAL heating program
* Clock program (cold) ............. Setting the heating and setback phases for the NORMAL heating program
* Clock program (mild) ............. Setting the heating and setback phases for the NORMAL heating program
* Clock program (warm) ........... Setting the heating and setback phases for the NORMAL heating program
6)
Target temperature da ............... A room unit is required to control the set room temperature
7)
Target temperature night ............. A room unit is required to control the set room temperature
8)
*** Room influence ..................... 0% - 100% influences the flow temperature / T1°C - T3°C influences the heating circuit pump
9)
Heating curve .............................. Affects the flow temperature – (higher set value = higher flow temperature)
10)
Night off AT ................................. Affects the heating circuit during the setback phase
11)
* AT-Limits cold/mild ................ Switching threshold for changing between the COLD and MILD clock programs
11)
* AT-Limits mild/warm ............. Switching threshold for changing between the MILD and WARM clock programs
12)
AT-Shutdown .............................. Affects the heating circuit during the heating phase
back to the costumer level .......................
look at Chapter 6.2
INFO
* The menu button is onl visible if **Multiple clock program** is activated in the commissioning menu.
** When the multiple clock program is activated, this menu button is not visible.
*** The menu button is onl visible if the room device/room station is activated in the commissioning menu.
4) Auto ........................ When the NORMAL heating program is activated, the heating circuit is switched ON and OFF full automaticall
according to the heating and setback times set in the clock program. If the outside temperature exceeds the value set
in the OT switch-off parameter, the heating circuit switches off.
Off ........................... The heating circuit is switched off.
Permanent .............. The heating circuit pump runs continuousl (no mixer control).
5) Auto ........................ Automatic changeover between the multiple clock programs COLD, MILD and WARM depending on the outside
temperature. You can set the outside temperature switching threshold for automatic changing of the multiple timer
programs in the OT limit COLD/MILD and MILD/WARM menus.
Cold ......................... Onl heating mode according to the COLD timer program.
Mild ......................... Onl heating mode according to the MILD timer program.
Warm ....................... Onl heating according to the WARM timer program.
6) Control to the DAY SET TEMPERATURE is onl possible during the heating phase of the heating circuit and requires a room device/room
station assigned to the heating circuit. This automaticall adjusts the heating curve so that the desired room temperature can be reached
in an weather.
- Without a room unit, heating can onl be operated according to a preset heating curve without taking the room temperature into
account. Increasing the target da temperature onl causes the preset heating curve to be shifted "up".
- If the outside temperature exceeds the value set in the OT switch-off parameter, the heating circuit switches off.
7) Control to the NIGHT-TIME TARGET TEMPERATURE is onl possible in the lowering phase of the heating circuit after the outside
temperature has fallen below the value set in the Night from AT menu and requires a room device/room station assigned to the heating
circuit. This automaticall adjusts the heating curve so that the desired room temperature is achieved.
- Without a room unit, onl reduced heating operation according to the preset heating curve is possible without taking the room
temperature into account. Increasing the night-time target temperature onl causes the preset heating curve to be shifted "up".
- If the outside temperature exceeds the value set in the Night off AT parameter, the heating circuit switches off again.
8) 0% – 100% .............. When the outside temperature is high (plus degrees) and the room temperature is too low, increasing the room
influence enables the desired room temperature to be reached more quickl .
T1C° - T3°C ............. If the set room temperature is exceeded b the set value, the heating circuit pump is switched off.
9) A higher heating curve causes a higher flow temperature at the same outside temperature.
10) If the outside temperature set in the Night off AT parameter is not reached during the lowering phase, the heating circuit switches on.
Attention: No frost protection function until the outside temperature set in the Night off AT menu is undershot.
11) Setting of the switching threshold for changing between the clock programs COLD/MILD and MILD/WARM.
Attention: The change between the weather-dependent clock programs depends on the average temperature of the previous da
and ma take place with a time dela until one da later.
12) If the set outside temperature is exceeded during the heating phase, the heating circuit switches off.

20
6.2.3 WARM WATER BS-03
13)
Operation pump .......................... Setting the SLP pump operating mode.
Clock program WW ..................... Setting the hot water charging times for the NORMAL program.
Clock program WW summer........ Setting the hot water charging times for the WARM WATER program.
WW target temperature ............... Setting the target hot water temperature.
14)
WW priorit ................................. Affects the heating circuits during hot water charging.
WW reload .................................. Enables one-off hot water charging outside of the programmed charging times.
back to the costumerlevel ........................
look at Chapter 6.2
INFO
13) Auto ........................ Automatic hot water loading according to the timer program WW or WW summer.
Off ........................... The hot water circuit is switched off.
Permanent .............. The hot water pump (SLP) runs continuousl
14) No ............................ The heating circuits remain in operation during hot water loading.
Yes .......................... The heating circuits are switched off during hot water charging.
6.2.4 HP0 Z-PUMP / BUFFER STORAGE / PUMP BS-02
15)
* Operation pump ................. Setting the HP0 pump operating mode.
** Boiler target ....................... Adjustment of the desired boiler temperature.
*** Clock program ................... Influences the boiler release when the pump is set.
16)
**** Loading program ................ Affects the loading status of the buffer.
**** Clock program. buffer......... Affects the boiler release.
**** Buffer target ....................... Affects the target buffer temperature.
17)
**** Buffer min .......................... Affects the minimum buffer temperature.
back to the costumerlevel ........................
look at Chapter 6.2
INFO
* The HP0 menu is onl visible after activation in the commissioning menu.
** The button is onl visible if the Z-pump or pump function is activated in the commissioning menu.
*** The button is onl visible if output HP0 is activated as a pump.
**** Die Menübuttons sind nur bei aktiviertem Pufferspeicher sichtbar.
15) Auto ............................. The pump is controlled automaticall .
Off ................................ The pump is switched off.
Permanent................... The pump runs constantl .
16) Full ............................... The buffer is charged until the target buffer temperature plus excess [Po charging OFF (full)] is reached at the
buffer sensor at the top. In addition, the buffer target temperature difference of minus 10°C (Pu charging OFF) must
be reached at the bottom buffer sensor so that buffer charging is ended with the status full.
Part .............................. The buffer is charged until the target buffer temperature plus 10°C increase [Po charging OFF (full)] is reached at the
top of the buffer sensor.
17) If the buffer temperature falls below the set min. buffer temperature at the top of the buffer sensor, the buffer is full or partiall loaded again
full automaticall according to the set loading program to the set buffer target temperature.