Guntamatic BIOSTAR 12 User manual

Pelletfirung englisch
BIOSTAR 12 / 15 / 23 kW
Planing and Installation BS-01
EN-B31-003-V10-0515

2
Information on this documentation BS-01
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
Bruck 7
A-4722 PEUERBACH
Tel: [phone] / 2441-0
Fax: [phone] / 3031
Email: [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.

3
CONTENTS BS-01
Page
1 Introduction ............................................................................4
1.1 Safety instructions 4
1.2 Gurantee and liability 4
1.3 Taking in Service 4
1.4 Site requirements 4
2 PLANING .................................................................................5
2.1 Fire safety 5
2.2 Minimum fire safety requirements 6
2.3 Boiler room requirements 7
2.4 Flue requirements 9
2.5 Flue draught and pressure- surge compensator 10
2.6 Fuel storage 11
2.7 Examples for Planing 13
2.8 Heatingcirculation rule 15
3 CONSTRUCTION ..................................................................16
3.1 Delivery 16
3.2 Carrying to installaion site 16
3.3 Positioning and aligning the boiler 16
3.4 Hydraulic Integration 17
3.5 Filling and bleeding the system 19
3.6 Flue connection 20
3.7 Construction holding 21
3.7.1 System FLEX 21
3.7.2 System BOX 25
3.7.3 System Weekbox 26
4 ELECTRICAL CONNECTIONS .............................................28
4.1 Heating system electrical connections 30
5 FINAL CHECKS.....................................................................31
6 STANDARDS / REGULATIONS............................................32
7 Electrical wiring diagramme................................................33
8 TECHNICHAL DATA.............................................................
37
8.1 Biostar 12 / 15 / 23 FLEX / BOX 37
8.2 Biostar 12 / 15 / 23 W 38
8.3 Feed SYSTEM FLEX 39

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1 INTRODUCTION BS-01
1.1 SAFETY INSTRUCTIONS
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 GURANTEE AND LIABILITY
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 COMISSIONING
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
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:

5
2 Planning 01
2.1 Fire safety BS-01
The fire security instroductions are obligatory needed
on the construction place
The Compliance from counties ore states fire security
law is obligatory and stands higher then the
GUNTAMATIC fire security instruction
Austria State legislation of the federal states
Technical Directive on Preventative Fire Safety (pr TRVB H118)
Germany Standard boiler regulations (M-FeuVO)
Hessen and Saarland – in these states §16 FeuVO Hessen applies
Switzerland Fire safety regulations (www.vkf.ch)
any other exporting countries Any fire safety office
You have to follow you specific country fire safety
rules obligatory. Your country safety rules are higher
then our GUNTAMATIC minimum rules.
If there are no specific fire security rules in your
country, you have to follow the GUNTAMATIC
introductions

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2.2 Minimum fire safety requirements BC-01
Boiler room Floor of concrete construction, either bare or tiled. All materials
for floor, walls and ceiling must be fire-resistant to F60/REI60
rating.
Boiler rooms door: The Boiler room’s door also might close
single handed and it has to be possible to close off the door.
Connecting doors to the fuel storeroom must also be Class
T30/EI
2
30-C fire doors, self-closing and lockable. There must
be no direct connection to rooms in which flammable gases or
liquids are stored.
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/EI
2
30-C, 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.
> 50 m³ HLE - 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/REI90 cladding.

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2.3 Boiler room requirements BC-01
Minimum room height
BC 30 / 40 / 50 ideal solution H 225 cm
1)
possible H 210 cm
BC 75 / 100 ideal solution H 240 cm
1)
possible H 230 cm
1)
= minimum height on upscrewed heat exchanger
Minimum room size
BC 30 / 40/50 B 240 cm x
2)
T 230 cm (
3)
T 240 cm)
BC 75 / 100 B 270 cm x
2)
T 230 cm (
3)
T 240 cm)
2)
T = The room with boiler’s bodies front seeing from behind
3)
= Minimum size from the automatic ash suction system
Clear access opening
BC 30 / 40 / 50
4)
ideal B 120 cm x H 205 cm
5)
possible B 80 cm x H 170 cm
6)
possible B 75 cm x H 165 cm
BC 75 / 100
4)
ideal B 180 cm x H 210 cm
5)
possible B 100 cm x H 190 cm
6)
possible B 90 cm x H 180 cm
4)
= Contribution of ready mounted boiler on transportwood
5)
= Contribution without Stoker, cleaning impulse and Transportwood
6)
= Measures with aditional to Point
5)
unrigged
Combustion air supply The pressure in the boiler room must not be less than 3 Pa
(0.3 mm H
2
O). 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/REI90. 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.
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.
The line connector 230 VAC, 50 Hz, 13 A is needed.
Fire extinguisher A hand-held fire extinguisher (6kg gross weight, EN3) must be
mounted outside the boiler room near the boiler-room door.
Protection against freezing The boiler room, pipes carrying water and any district heating
pipes must be protected against freezing.

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Installation site You have to plan the furnace in the near of the chimney to avoid a long
flue pipe. The firing has to be accesible from the left and right side. The
reloading hast to be kept free..
BIOSTAR FLEX BIOSTAR W
A→LEFT distance ideal 70 cm minimum
possible 15 cm
B→Line Connector 230 VAC 13A
C→installation variant energy-saving damper with explosion damper in the flue
c a. 50 cm under the flue – please follow the local laws
D→installation variant energy-saving damper with explosion damper in the flue
c a. 50 cm under the flue – please follow the local laws
E→flue
wet non- sensitive chamotte-flue advised
F→BEHIND distance
ideal 70 cm minimum
possible 50 cm
G→Drain
H→Combustion air supply
I→RIGHT distance ideal 70 cm minimum
possible 25 cm at Type FLEX
possible 15 cm at Type W
J→fire extinguisher
6 kg filling weight EN3
K→FRONT distance ideal 100 cm minimum
possible 70 cm
L→escape switcher (emergency stop)
M→fireproof door
T30 / EI
2
30-C lockable and self depended

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2.4 FLUE REQUIREMENTS BS-01
Use heat-insulated fireclay flues that are
insensitive to damp.
The flue gas temperature can be less than
100°C.
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.
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 diameter The flue hast to adjust on the fire power. The following dates
are approximate values and could be used for planning. We
recommend calculating the flue by a professional.
BIOSTAR 12 / 15
BIOSTAR 23
eff. High above 6 m D = 140 mm
eff. High below 6 m D = 160 mm
eff. High above 6 m D = 160 mm
eff. High below 6 m D = 180 mm
Flue dimensioning data Dimension the flue for rated output!
(Averaged figures with used heat exchanger)
Rated output:
Type Exhaust
gas CO
2
massflow Flue
draught
BS 12 160°C 13,6% 0,010 kg/s 10 Pascal
BS 15 175°C 14,3% 0,012 kg/s 10 Pascal
BS 23 180°C 13,1% 0,016 kg/s 15 Pascal
Teillast:
Type Exhaust
gas CO
2
Massenstrom Flue
draught
BS 12 105°C 9,9% 0,003 kg/s 2 Pascal
BS 15 105°C 9,9% 0,003 kg/s 2 Pascal
BS 23 101°C 10,0% 0,006 kg/s 2 Pascal

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2.5 Flue draught regulator and pressure-surge compensator BS-01
Fitting an energy-saving flue draught
regulator/pressure-surge compensator
(Class RE) is absolutely imperative.
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.
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).
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.

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2.6 FUEL STORAGE BS-01
Please note:
the specific national rules for your fuel store
(for example. ÖNORM M7137, VDI 3464,.. .) are strictly
adhered blindly
Jahresbedarfsschätzung The fuel store should be able to pick up the stock for a year .
The fuel store volume is circa 2/3 when the fuel supply is
active. The storeroom should be recantugular and wider then
3,5 m. So narrower the store room is, so less storeroom is
available.
→per 1 kW/Year ca. 0,65 m³ = ca. 450 kg Pellets
wet protection The fuil is to protect from wet floors or walls. The storeroom
has to be dry during the whole year. In case of temporary
wettnes walls, we advice you to install a ventilated facin on the
wall. You also have to clad the walls with derived timber
product.
Cold area Suction pipes and order units in the cold areas might be
isolated freezeproof.
Danger of condensation!
filling set There has to mounted two filling stuts
minimum distance 0,5 m – maximum distance 1,5 m.
Location The fuil will delivered in an pump truck. The storeroom ort he
filling conections has to be ordered, that they are reachable
form a tube which has a maximum length from 30 m. On the
second filling connection the Transport air will be aspirated the
transport air.
Statics With Flex store systems on the floor and the containment walls
must have the static requirement withstand by the stored fuel
and the pressure during filling. In Box store systems requires
particicular attention to the sustainability to the substed, as at
full filling in the Box acting on the individual support points.
BOX placement The box must be installed basically separated from the boiler in
another room. In some countries, the fabric tank could be set
up in the room where the furnance if there is a minimum
distance of 2 m between the BOX and the boiler could be
maintained and the thermal output does not reach 50 Kw.
Therefore observe the regulations in force addition! For
outdoor positioning, no F90/ REI90 trim is required , if the
minimum distances were respected. The fabric tank must be
protected against rain, wetness and UV Light.
FLEX wall breakthrough Breadth 33 cm / High 25 cm (for FLEX propulsive unit)

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Fuel store air sparging To avoid an high perilous Co² consentration you have to lift the
store and Broiler room.The opening for the lifting might
discharge into the atmosphere. There must be an air change
between the Storeroom and the ambient atmosphere. If the
natural thermal isnt´t enough you have to take technical
measures.
If the filling stubs (the openings) discharges not into the
atmosphere you have to lift it with another lifting opening. you
have to be careful, that there is no rainwater into the storeroom
from the filfting opening. The construction site from the
permeable to air storage container might have a port in to the
atmosphere. A ventilator shifts from 200cm² is enough.
Up to 30 t storage volume the requirement is prepossessed, if:
•The filling stub (opening) is leading into atmosphere for
minimum 2 caps with an air inlet
•The diameter from 2 ventilation pipes is per pipe
minimum 90 mm
•The ventilator shift from the exhaust port from both
Ventilation pipes from 2 m minimum 40 cm² and must be
higher then a lenghth from 2 me but minimum 60 cm ².
INFO: The whole ventilation shift from 2 caps from our
filling sets is 60 cm².
Over 30 t storage volume the requirements
•a combination between natural and manual lifting, based
on a Co² Sensor. If there is no natural lifting you have to
install forced ventilation- in case of a high Co²
Concentration ventilation is lifting automatically.
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). During 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.
Electric Installation At FLEX storesystems electroinstallations in the fuil aren´t
permissible.
At box level systems electroinstallations in the show room
aren´t allowed.
Filling couplings have to be grounded.

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2.7 EXAMPLES FOR PLANING BS-01
Example 1 Construction with Flex fuel supply next to the heating room.
The maximum length of agitator is 3m.
The maximum suction length is 25 m.
Minimum 2 fire security wristbands needed – please respect the minimum fire security rules!
Example 2 Machine with Flex fuel supply with annother building section.
The maximal length of extracting screw amounts 3 m.
The maximal suction length is 25 m.
Minimum 2 fire security wristbands needed – please respect the minimum fire security rules!
Example 3 Machine with Flex fuel supply with annother building section.
The maximal length of extracting screw amounts 3 m.
The maximal suction length is 25 m.
Minimum 2 fire security wristbands needed – please respect the minimum fire security rules!

14
Example 4 Consruction with BOX- fabric tank directly above the heating room.
The maximum Suction length is 25 m.
Minimum 2 fire security wristbands needed – please respect the minimum fire security rules!
Example 5 Construction with BOX- fabrictank in a other building section.
The maximum Suction length is 25 m.
Minimum 4 fire security wristbands needed – please respect the minimum fire security rules!
Example 6 Construction with outside location of Box with textil tank.
Construct the outside locatiob of box with an textlil tank. The box has to be so
located that the box is protected from wettnes, ran and UV light. The
suctionslughts have to so isolated in the cold area, that there is no way to
cultivation of condensation water.
Die maximale Sauglänge beträgt 25 m.
Minimum 2 fire security wristbands needed – please respect the minimum fire security rules!

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2.8 HEATING CIRCLE RULE BS-01
The heating circle rule is optional offered.
You can decide between a MKR set or a wall mounted MK 261 set.
● per construction 3 controlled by atmospheric condition rules
possible
● per construction could be actived just 1 MKR Set boiler
● pro Machine there are 3 remote control möglich;
● per heatingcircle one analogue room unit possible
Set-MKR Following functions could be activated:
Heatingcircle WW ●Warmwater-Memory
Heatingcirle 0 optional avalible ........ ●pump heating circulation
●aditional warmwater memory
Heatingcircle 1 optional avalible ....... ●Pumpheatingcirculation
●mixed heatingcirculation
Heatingcircle 2 optional avalible ....... ●Pumpheatingcirculation
●mixed heatingcirculation
wall mounted model set-MK261 Following funtions could be active:
Heatingcircle WW ●warmwater- memory
Heatingcircle 0 optional ................. ●pumpingheatingcircle
1)
●third mixed heatingcircle
Heatingcircle 1 optional ................. ●pumpingheatingcircle
●mixed heatingcircle
Heatingcircle 2 optional ................. ●pumpingheatingcircle
●mixed heatingcircle
Trunk link optional ......................... ●feederpump (ZUP)
●dumping device pump (PUP)
●cargo pump (LAP)
2)
●extension (ERW)
3)
●third mixed heatingcircle
adition optional .............................. ●aditional warmwater memory
4)
●third mixed heatingcircle
INFOBOX
1) the third mixed heatingcircle could be actived, if the functions trunk link and addition are not used.
2) through „ERW“ function a heating circle controller with trunk blink can be assigned an other heating circle controller
3) if the function „third mixed heatingcircle“ is activated, the trunk blink functions are not availible.
4) if the „third mixed heatingcircle“ is activated, the additional functions are not availibe.

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3 CONSTRUCTION 01
3.1 Delivery BS-01
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.
3.2 Carrying to installation site BS-01
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.
3.3 Positioning and aligning the boiler BS-01
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 at back
ideal 70 cm mindestens
possible 50 cm
Clearance on left
ideal 70 cm mindestens
possible 15 cm
Clearance on right
ideal 70 cm mindestens
possible 25 cm at Type FLEX
possible 15 cm at Type W
Clearance at front
ideal 100 cm mindestens
possible 70 cm
Floor clearance
ideal 3,5 cm mindestens with screw feet triggered
possible 8 cm
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.

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3.4 HYDRAULIC INTEGRATION BS-01
BIOSTAR 12 / 15 / 23
A→Backrun 1"
B→advance 1“
Securitywarmexchanger The connection of an discharge thermic device after ÖNORM
8131 and DIN Norm 4751 not necaserry. A overheating of the
operating temperature, which is higher then 110 °degrees is not
possible. A overheating of operating temperature, which is
higher then 110° degrees is not possible. The non exceeding
maximum allowable operating temperature is ensured by a
software limininatatiob on the maximum boiler temperature to
80° C, by a mechanical safety shutdown (STL) of the furnance
above 95°(+/- 5 °C) an over temperature circuit of the pump.
Buffermemory The construction of an buffer memory isn´t necaserry, cause of
the Biostar could operated moduled- and it´s a construction
which turns quickly off. A buffermemory is just usefull when it´s
operated with a Solar panel or a solid fuel boiler.
That in the programme attituted programme „OFF“ the freeze
function could be maded sure, the building an E glow bar is
adviced with an attituded thermostat.
Return boost
The Biostar has a patended lowertemperature warm exchanger which
works in the counter. Cold water flows are kept away from the heat
exchanger surfaces are preheated by ascending hot water boiler. This
prevents the occurrence of condensation temperature of the heat
exchanger surfaces. This prevents the occurrence of condensation
temperatures at the heat exchanger surfaces. A return temperature
control is therefore installed only in combination with a buffer in order to
achieve the required return temperature of 38 °C.
Connection at glided mode
(Radiators) :
For modern connections (max. 1“ pipe) , which are builted in an
glided operating mode, a retutn flow increase isn´t necaserry.

18
Connection at low temperature construction (only mixer)
For low temperature systems (only floor or wall heaters),
which are operated exclusively with mixer and low flow
temperatures, it is necessary, a bypass pump between supply
and return (see system scheme in the Appendix) to install. It
shall be designed for a minimum flow rate of 600 l / h, as this
is necessary for optimal mixing in the heat exchanger.
Connection / Construction with buffermemory:
Build no return or fixed value valve to return high attitude one
but you are using a extrusion control-valve in the bypass line,
as well as in buffer operation, the boiler temperature is
controlled to slide between 50 ° C and 80 ° C. Failure to
observe this increased risk of corrosion and thus guarantee
and warranty performance loss. Connect the return
temperature control exactly to the specifications in our
connection diagrams on.
Sludge separator with magnetite Magnetite and the sludge separator in the Heatngwater could
become a problem for energysaver pumps. By installin a
prperly sized and applied sludge sperator with a magnet can
remided cost effenciently.
Either old pipes could be meant
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
•aditional factor (rated power < 30 kW) = 3
Example calculation: 500 Litre x 0,03 x 3 = 45 Litre
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.
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.
Danger of overheating Faulty operation, wrong fuil or disturbance could be load to
overheating. To avoid disturbance you have to install additional
fuse protections for maximum process water and fuses for
heating circulation temperatures.

19
3.5 Filling and bleeding the system BS-01
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: 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.
Construction flushing •Before charging you have to flush the system. When you do
this, it’s the best opportunity to clean magnetit and rust
sludge from the pipe system.
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.

20
3.6 FLUE CONNECTION BS-01
The connection on the flue occurs via an big exhaust gas pipe,
which is leaded gastight and the heatingcirculation has to be
isolated between the flue and the boiler.
Exhaustpipe →up 4 m length and maximum 3 sheets:
•BIOSTAR 12 / 15 / 23 Ø = 130 mm
→longer then 4 m or more then 3 sheets:
•BIOSTAR 12 / 15 / 23 Ø = 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.
A→Flue connecting pipe, min. gradient 6°
B→Isolation z.B. Rockwoll
C→Flue draught regulator/pressure-surge
compensator in flue
(Preferred fitting arrangement)
D→Alternatively: Flue draught regulator in
flue connecting pipe
(As close as possible to junction with the flue)
•The flue connecting pipe musty be gas-tight
•isolate the flue pipe
•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