Guntamatic BIOSTAR FLEX User manual

Pellet Boiler
BIOSTAR FLEX/BOX/W
Installation Instructions BS-A-00-00-00-01-IADE
DE-B31-003-V07-0511 (Taurus)
UK Distributor
Treco Ltd
Pyramid House
Tiverton Business Park
Tiverton, Devon EX16 6TG
www.treco.co.uk
[email protected]
0845 130 9012/ 01884 250 970

BIOSTAR Installation instructions
2
Information on this documentation BS-B-00-00-00-01-IADE
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: [phone] / 2441-0
Fax: [phone] / 3031
E-mail: [e-mail]
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.

BIOSTAR Installation instructions
3
Contents BS-C-00-00-00-01-IADE Page
1 Introduction..........................................................4
1.1 Safety instructions 4
1.2 Guarantee 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 14
2.6 Connecting the flue 15
2.7 Energy saving draught regulator and pressure-surge
compensator 16
2.8 Fuel outfeed installation 17
2.8.1 FLEX system 17
2.8.2 BOX system 21
2.8.3 Boiler-mounted hopper system 21
3 Electrical connections.......................................23
3.1 Electrical connections to the heating system 23
3.2 Wiring requirements 24
3.3 Electrical connections 25
4 Final checks/Commissioning ...........................27
5 Standards/Regulations......................................28
6 Plumbing diagrams...................................... 29-34
7 Electrical wiring diagram ..................................35
7.1 Control panel 35
7.2 Wall controller set MK261 36
7.3 Boiler circuit board 37
8 Technical data....................................................40
8.1 BIOSTAR FLEX/W 40-41
8.2 FLEX outfeed system 42
8.3 BOX outfeed system 43

BIOSTAR Installation instructions
4
1 Introduction BS-01-00-00-00-01-IADE
1.1 Safety instructions BS-01-01-00-00-01-IADE
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-IADE
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-IADE
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-IADE
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:

BIOSTAR Installation instructions
5
1.4.1 Fire safety BS-01-04-01-00-01-IADE
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

BIOSTAR Installation instructions
6
Minimum fire safety requirements BS-01-04-01-01-01-IADE
BS-01-04-01-02-01-IADE
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-IADE
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.

BIOSTAR Installation instructions
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1.4.2 Boiler room requirements BS-01-04-02-00-01-IADE
BS-01-04-02-01-01-E
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 100 cm² for the
Biostar 12/15 and at least 150 cm² for the Biostar 23 and must
not be sealable. 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-IADE
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-IADE
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-IADE
Protection against freezing The boiler room, pipes carrying water and any district heating
pipes must be protected against freezing.
BS-01-04-02-05-01-IADE
Minimum room size Biostar FLEX at least 148 x 193 cm (W x L)
Biostar W at least 194 x 193 cm (W x L)
BS-01-04-02-06-01-IADE
Minimum room height Biostar FLEX at least 200 cm
Biostar W at least 180 cm
BS-01-04-02-07-01-IADE
Clear access opening Biostar FLEX/W at least 70 x 150 cm (W x H)
BS-01-04-02-08-01-IADE
Boiler dimensions
With packing Biostar FLEX at least 106 x 83 x 195 cm (L x W x H)
Biostar W at least 163 x 83 x 157 cm (L x W x H)
Without packing Biostar FLEX at least 64 x 68 x 150 cm (L x W x H)
Biostar W at least 64 x 68 x 150 cm (L x W x H)
Boiler-mounted hopper at least 101 x 61 x 150 cm (L x W x H)

BIOSTAR Installation instructions
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1.4.3 Flue requirements BS-01-04-03-00-01-IADE
The flue must be matched to the system in order to ensure
economical and trouble-free operation.
BS-01-04-03-01-01-IADE
Important
BS-01-04-03-02-01-IADE
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-IADE
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.
BS-01-04-03-04-01-IADE
Flue diameter The flue must be matched to the boiler output. The following
details are guide figures and can be used for planning
purposes. However, we recommend that the flue dimensions
are calculated precisely by an expert.
BIOSTAR 12/15 eff. flue height over 6 m D=140 mm
eff. flue height under 6 m D=160 mm
BIOSTAR 23 eff. flue height over 6 m D=160 mm
eff. flue height under 6 m D=180 mm
Flue dimensioning data Dimension the flue for rated output.! BS-01-04-03-05-01-IADE
(Averaged figures with used heat exchanger)
Rated output
Sub-maximum output
Type
Flue gas
temp.
CO2
Mass flow rate
Required
draught
Biostar 12
160°C
13,6%
0.010 kg/s
10 pascals
Biostar 15
175°C
14,3%
0.012 kg/s
10 pascals
Biostar 23
180°C
13,1%
0.016 kg/s
15 pascals
Type
Flue gas
temp.
CO2
Mass flow rate
Required
draught
Biostar 12
105°C
9,9%
0.003 kg/s
5 pascals
Biostar 15
105°C
9,9%
0.003 kg/s
5 pascals
Biostar 23
101°C
10,0%
0.006 kg/s
7 pascals
Use heat-insulated fireclay flues that are
insensitive to damp.
The flue gas temperature can be less
than 105°C.

BIOSTAR Installation instructions
9
1.4.4 Fuel store requirements BS-01-04-04-00-01-IADE
BS-01-04-04-01-01-IADE
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-IADE
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-IADE
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-IADE
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-IADE
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-IADE
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.

BIOSTAR Installation instructions
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BS-01-04-04-07-01-IADE
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-IADE
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-IADE
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.

BIOSTAR Installation instructions
11
2 Installation and assembly BS-02-00-00-00-01-IADE
2.1 Delivery BS-02-01-00-00-01-IADE
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-IADE
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 BS-02-03-00-00-01-IADE
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 17 cm (from wall or installation)
Clearance on right at least 25 cm with FLEX system
at least 15 cm with boiler-mounted hopper system
Clearance at front at least 70 cm (leave space for fuel box door to open)
Clearance at rear at least 40 cm (from flue pipe)
Floor clearance Set the clearance between the boiler base and the floor to the
required minimum of 25 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.

BIOSTAR Installation instructions
12
2.4 Plumbing connections BS-02-04-00-00-01-IADE
Biostar 12/15/23 - FLEX/W
F→ Heating return, 1"
B→ Heating flow, 1"
C→ Boiler sensor/STL
D→ External thermostat, ½"
(if required)
E→ Safety valve
BS-02-04-00-01-01-IADE
Temperature-relief heat exchanger Connection of a temperature-relief valve is not required
according to the standards ÖNORM B 8131 and DIN 4751. It
is not possible for the maximum permissible operating
temperature of 110 °C to be exceeded. The system ensures
the maximum permissible operating temperature is not
exceeded by software-controlled limitation of the maximum
boiler temperature to 80 °C, a mechanical safety boiler cut-out
(STL) with a response temperature of 95 °C (+/- 5 °C) and by
a pump control mode for excessive temperatures.
BS-02-04-00-02-01-IADE
Thermal store Installing a thermal store is not necessary as the Biostar boiler
is operated by a modulating control system and can be quickly
shut down. Operation with a thermal store only serves a useful
purpose in combination with a solar panel system or a solid
fuel boiler.
BS-02-04-00-03-01-IADE
Return boost The Biostar has a patented low-temperature heat exchanger
that functions according to the contraflow principle. Cold water
is kept away from the heat-exchanger surfaces and preheated
by rising hot water from the boiler. That prevents
condensation temperatures from occurring on the heat-
exchanger surfaces. Therefore, a return boost circuit should
only be fitted in combination with a thermal store in order to
maintain the required return temperature of 38 °C.
Connection for operation in modulating mode (radiators):
With modern systems (max 1" pipes) that are set up for
operation in modulating mode, an external return boost is
therefore not necessary.

BIOSTAR Installation instructions
13
Connection with low-temperature systems (mixer valves
only):
With low-temperature systems (underfloor or warm-air
systems only) that are operated exclusively using mixer
valves and low flow temperatures, it is necessary to fit a
bypass pump between the flow and return pipes (see
plumbing diagram in the Appendix). It must be designed for a
minimum flow capacity of 600 l/h as that is required for
optimum mixing inside the heat exchanger.
Connection with systems with thermal store:
Do not install a return or fixed-setting valve to keep the return
temperature at a certain level, instead use a branch
regulating valve in the bypass pipe as, even when operating
with a thermal store, the boiler temperature is modulated
between 50°C and 80°C. 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.
Adjusting the return Restrict the bypass flow using the branch regulating valve so
that the return comes back 10°C colder than the flow.
BS-02-04-00-04-01-IADE
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 (rated output < 30 kW) = 3
Example calculation: 500 litres x 0.03 x 3 = 45 litres
BS-02-04-00-05-01-IADE
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-IADE
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.

BIOSTAR Installation instructions
14
2.5 Filling and bleeding the system BS-02-05-00-00-01-IADE
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.

BIOSTAR Installation instructions
15
2.6 Connecting the flue BS-02-06-00-00-01-IADE
BS-02-06-00-01-01-IADE
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:
Biostar 12/15/23 dia. = 130 mm
Flue connecting pipes longer than 4 m or with more than 3
bends:
Biostar 12/15/23 dia. = 150 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.
BS-02-06-00-02-01-IADE
A→At least 3 x flue connecting pipe diameter
B→Testing point for flue draught
C→Flue connecting pipe, min. gradient 6°
D→Alternatively: Flue draught regulator in flue
connecting pipe
(As close as possible to junction with the flue)
H→Flue draught regulator/pressure-surge
compensator in flue
(Preferred fitting arrangement)
BS-02-06-00-03-01-IADE
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

BIOSTAR Installation instructions
16
2.7 Energy-saving flue draught regulator and pressure-surge compensatorBS-02-07-00-00-01-IADE
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.

BIOSTAR Installation instructions
17
2.8 Fuel outfeed installation BS-02-08-00-00-01-IADE
2.8.1 FLEX system BS-02-08-01-00-01-IADE
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. 9)
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.

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18
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.

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19
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.

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20
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 pipeinternal dia. 100 mm
externaldia. 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)