Hoval BioLyt 50 Manual

Figure: BioLyt (100-160)
Subject to modi cations | EN
Technical information
Installation instructions
4 214 852 / 01 - 06/19
Hoval products may only be installed and com-
missioned by appropriately qualied experts.
These instructions are intended exclusively for the spe-
cialist. Electrical installations may only be carried out
by a qualied electrician.
BioLyt (50-160)
Wood pellet boiler
These instructions are applicable to the fol-
lowing types:
42-BioLyt (50) 49 kW
42-BioLyt (70) 69 kW
42-BioLyt (75) 73 kW
42-BioLyt (100) 99 kW
42-BioLyt (130) 130 kW
42-BioLyt (150) 149 kW
42-BioLyt (160) 156 kW

1. Important notes
1.1 Safety instructions ..............................................................................................................................................................4
1.2 Explanation of the symbols ................................................................................................................................................4
1.2.1 Warnings ..........................................................................................................................................................................4
1.2.2 Warning symbols...............................................................................................................................................................4
1.3 On delivery...........................................................................................................................................................................4
1.4 Warranty...............................................................................................................................................................................4
1.5 Manuals................................................................................................................................................................................5
1.6 Approvals and identification...............................................................................................................................................5
1.7 Standards and directives ....................................................................................................................................................5
1.7.1 Germany §........................................................................................................................................................................5
1.7.2 Switzerland § ....................................................................................................................................................................5
1.7.3 Austria § ...........................................................................................................................................................................6
1.7.4 United Kingdom § .............................................................................................................................................................6
1.7.5 Europe §...........................................................................................................................................................................6
2. General assembly
2.1 Characteristics of the boiler room......................................................................................................................................8
2.2 Installation and set-up.........................................................................................................................................................8
2.3 List of the screw packets (BioLyt 50-160) ..........................................................................................................................9
3. Assembly BioLyt (50-75)
3.1 Changing the door attachment side BioLyt (50-75)..........................................................................................................10
3.2 Burner BioLyt (50-75) ........................................................................................................................................................10
3.3 Mounting the ash rotor BioLyt (50-75)..............................................................................................................................11
3.4 Water-side and flue-gas side connection BioLyt (50-75) .................................................................................................11
3.5 Fitting the thermal insulation BioLyt (50-75)....................................................................................................................12
3.6 Fitting the burner BioLyt (50-75).......................................................................................................................................13
3.7 Fitting the pellet hopper BioLyt (50-75) ............................................................................................................................14
3.8 Fitting the probes, sensors and cables BioLyt (50-75) ....................................................................................................16
3.9 Fitting the casing BioLyt (50-75).......................................................................................................................................18
3.10 Fitting the ash box and miscellaneous BioLyt (50-75).....................................................................................................20
4. Assembly BioLyt (100-160)
4.1 Changing the door attachment side BioLyt (100-160)......................................................................................................22
4.2 Water-side and flue-gas side connection BioLyt (100-160) .............................................................................................22
4.3 Fitting the thermal insulation BioLyt (100-160) ................................................................................................................23
4.4 Fitting the burner BioLyt (100-160) ...................................................................................................................................24
4.5 Fitting the pellet hopper BioLyt (100-160) ........................................................................................................................26
4.6 Fitting the probes, sensors and cables BioLyt (100-160) ................................................................................................28
4.7 Fitting the casing BioLyt (100-160) ...................................................................................................................................30
4.8 Fitting the ash box and miscellaneous BioLyt (100-160).................................................................................................32
4.8.1 Safety precaution for installation in line with EMC requirements......................................................................................33
5. Technical information
5.1 Brief technical description................................................................................................................................................35
5.2 Technical data....................................................................................................................................................................36
5.3 Dimensions BioLyt (50-75) ................................................................................................................................................37
5.4 Dimensions BioLyt (100) ...................................................................................................................................................38
5.5 Dimensions BioLyt (130-160) ............................................................................................................................................39
5.6 Space requirement ............................................................................................................................................................40
6. Installation
6.1 Water connections.............................................................................................................................................................42
6.1.1 General provisions..........................................................................................................................................................42
6.1.2 Safety equipment............................................................................................................................................................42
6.1.3 Return maintenance........................................................................................................................................................42
6.1.4 Insulation of the heat distribution system.........................................................................................................................42
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TABLE OF CONTENTS

6.1.5 Additional installation information....................................................................................................................................42
6.1.6 Hydraulic integration .......................................................................................................................................................43
6.2 Flue connection and dimensioning ..................................................................................................................................44
6.2.1 General information ........................................................................................................................................................44
6.2.2 Connecting 2 Hoval BioLyt (50-160) to a common chimney .............................................................................................44
6.3 Electrical connection.........................................................................................................................................................45
6.3.1 General information ........................................................................................................................................................45
6.3.2 Terminal plate with automatic firing device ......................................................................................................................46
7. Commissioning
7.1 Water quality......................................................................................................................................................................47
7.2 Filling up the heating system, the calorifier (if fitted) and hot water buffer storage tank..............................................48
7.3 Commissioning..................................................................................................................................................................48
7.4 Installation inspection.......................................................................................................................................................48
8. Maintenance
8.1 Cleaning the boiler ............................................................................................................................................................49
8.2 Annual inspection by a service engineer .........................................................................................................................49
8.2.1 Heating system ...............................................................................................................................................................49
8.2.2 Boiler ..............................................................................................................................................................................49
8.3 Safety temperature limiter - Reset ....................................................................................................................................50
3
4 214 852 / 01
TABLE OF CONTENTS

1. Important notes
1.1 Safety instructions
The system may only be placed in operation
if all the relevant standards and safety regula
-
tions have been complied with.
WARNING
The heat generator can only be de-energised
by disconnection from the mains (e.g. all-po-
le switch).
WARNING
All electrical power supply circuits must be
switched o󰀨 before accessing the terminals.
1.2 Explanation of the symbols
1.2.1 Warnings
!
DANGER
... indicates a situation of immediate danger
which will lead to serious or fatal injuries if
not avoided.
!
WARNING
... indicates a situation of possible danger
which can lead to serious or fatal injuries if
not avoided.
!
CAUTION
... indicates a situation of possible danger
which can lead to minor or slight injuries if
not avoided.
NOTICE
... indicates a situation of possible danger
which can lead to damage to property if not
avoided.
1.2.2 Warning symbols
The following warning signs are combined for the war-
ning notes with signal words CAUTION, WARNING and
DANGER.
!
General warning of a danger zone.
“Warning: dangerous electrical voltage” as a
warning for accident prevention.
Ensures that people do not come into contact
with electrical voltage. The danger sign with
the black lighting symbol warns against the
danger of electrical voltage.
Information:
Provides important information.
§
Provides important information. Refers to
standards and directives.
1.3 On delivery
Carry out a visual inspection immediately on receiving the
boiler. If any damage is found, take the necessary steps
as dened in the delivery contract. The respective risk
carrier bears the cost of repairs.
1.4 Warranty
The warranty does not cover defects attributable to:
• Failure to comply with these instructions
• Failure to comply with the operating instructions
• Incorrect installation
• Impermissible modications
• Incorrect handling
• Contaminated operating materials (pellets, water, com-
bustion air)
• Unsuitable chemical additives to the heating water
• Damage caused by the application of force
• Corrosion by halogen compounds (e.g. paints, adhesi-
ves, solvents)
• Corrosion caused by not observing the required water
quality
44 214 852 / 01
IMPORTANT NOTES

1.5 Manuals
All instructions relevant to your system can be found in
the Hoval system manual - please keep all manuals!
In exceptional cases, the instructions can be found with
the components!
Further sources of information:
• Hoval catalogue
• Standards, regulations
1.6 Approvals and identification
Wood pellet boilers of the type series BioLyt (50-160) are
designed and approved for use as heat generators for
hot water heating systems with ow temperatures of up
to 80°C. They comply with the requirements of the Euro-
pean standard for solid fuel boilers EN 303-5. The boilers
have been tested by TÜV SÜD (Technical Inspectorate
South Germany) (Munich).
The type label with the technical data is attached to one
of the casing side panels. The label includes the serial
number identifying the boiler.
1.7 Standards and directives
1.7.1 Germany §
EnEV Energy conservation ordinance in
the current version.
1.BimSchV 1st Act for the implementation of the
applicable Federal Immission Pro-
tection Act, in the current version.
TRD 721 Safety valves for steam boilers of
group II (also applies to heat gene-
rators with safety temperatures be-
low 100°C).
TRD 414 Wood-red combustion systems on
steam boilers.
DIN 4702 Part 4 Heating boilers in general; heating
boilers for wood and other biomass.
DIN 4807 Expansion tanks.
DIN 4753 Part 1 Caloriers for drinking and process
water.
DIN 1988 Part 2 Technical rules for drinking water in-
stallations (DVGW).
VDI 2035 Guidelines for the prevention of cor-
rosion and scale formation in water
heating systems.
DIN V 18160 Planning and design of waste gas
systems.
DIN 4795 Secondary air devices for domestic
chimneys.
Local building regu-
lations
The relevant local building regulations
must be observed when installing
or modifying a combustion system
(combustion and waste gas systems).
FeuV Ordinance for ring installations and
boiler rooms - passed as a result of
the building regulations for the cor-
responding federal state.
VDI 3464 Storage of wood pellets (safety as-
pects).
1.7.2 Switzerland §
• Hydraulic regulations and those pertaining to instru-
mentation and control.
• Cantonal and local re prevention authority regulations
as well as state-specic regulations.
• Fire protection regulations of the VKF.
• SVGW (Swiss Association of Gas and Water Experts)
directives and guidelines for the use of gas.
• SWKI BT-102-01 guidelines on water composition for
heating, steam, cooling and air conditioning systems.
• SWKI 91-1 guidelines on boiler room ventilation.
• SWKI 93-1 safety guidelines for the installation of hea-
ting systems.
• Observe the SIA recommendations No. 384/4 Flue sys-
tems for heating systems in buildings, calculation of
cross-sections.
• Procal/FKR guidelines Ready-to-connect electrical
connections on heating boilers and burners.
• Technical bulletin - Procal Corrosion by halogen com-
pounds.
• The LRV regulations must be adhered to.
5
4 214 852 / 01
IMPORTANT NOTES

1.7.3 Austria §
ÖNORM H5151-1 Design of hot water central heating
systems with or without water heating.
ÖNORM H5170 Heating systems - Requirements with
respect to building and safety techno-
logy, re and environmental protection.
ÖNORM H5190 Heating systems – Sound insulation
measures.
ÖNORM H5195
Part 1 and 2
Heat transfer media for building ser-
vices systems.
Prevention of damage by corrosion
and the formation of scale in closed
hot water heating systems.
Frost protection in heating systems
and other systems containing heat
transfer media.
TRVB H118 Automatic wood-fuelled combustion
systems (re protection).
ÖNORM M7137 Wood pellets: Requirements for the
storage of wood pellets by the end user.
1.7.4 United Kingdom §
“The Clean Air Act 1993 and Smoke Control Areas”.
Under the Clean Air Act local authorities may declare the
whole or part of the district of the authority to be a smoke
control area. It is an o󰀨ence to emit smoke from a chim-
ney of a building, from a furnace or from any xed boiler
if located in a designated smoke control area. It is also an
o󰀨ence to acquire an “unauthorised fuel” for use within a
smoke control area unless it is used in an “exempt” appli-
ance (“exempted” from the controls which generally apply
in the smoke control area).
The Secretary of State for Environment, Food and Ru-
ral A󰀨airs has powers under the Act to authorise smoke-
less fuels or exempt appliances for use in smoke control
areas in England. In Scotland and Wales this power rests
with Ministers in the devolved administrations for those
countries. Separate legislation, the Clean Air (Northern
Ireland) Order 1981, applies in Northern Ireland. There-
fore it is a requirement that fuels burnt or obtained for
use in smoke control areas have been “authorised” in
Regulations and that appliances used to burn solid fuel
in those areas (other than “authorised” fuels) have been
exempted by an Order made and signed by the Secretary
of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air
Act can be found here: http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the
Clean Air Act 1993 including designation and supervision
of smoke control areas and you can contact them for de-
tails of Clean Air Act requirements.
1.7.5 Europe §
EN 303-5 Boilers for solid fuels with a heat out-
put of up to 300 kW.
EN 1443 Waste gas systems, general require-
ments.
EN 14868 Corrosion protection – Guidelines for
water circulation systems.
EN 12828 Heating systems in buildings - Design
of hot water heating systems.
EN ISO 17225-2 Fuel wood pellets (A1).
EN 13384-1 Waste gas systems – Procedures for
heat and flow calculations.
Waste gas systems with a fireplace.
and further regulations and standards issued by CEN,
CEN ELEC, DIN, VDE, TRD and the legislative body. The
regulations of the local building authorities, insurance
companies and chimney sweeps must also be taken into
account. Approval by the authorities may be required.
64 214 852 / 01
IMPORTANT NOTES

74 214 852 / 01
NOTES

2. General assembly
2.1 Characteristics of the boiler room
The architectural and ventilation requirements for boiler
rooms are dened in the building regulations applicable
to the relevant installation site.
Ensure an adequate supply of fresh air to the boiler room
to make sure that there is an unobstructed ow of the
combustion air required for the operation of all combus-
tion devices in the boiler room and so that there is no
shortage of oxygen for operating personnel. Ensure that
the air intake cannot be closed or blocked.
The minimum required free cross section for the supply
air opening depends on the current local regulations in
each case.
2.2 Installation and set-up
The boiler is delivered in several packages:
- Boiler body
- Pellet hopper/burner/accessories
- Control
- Casing and insulation
- Ash box
Installation:
For overall unit dimensions, see page 40
The ash discharge motor (rear side of the boiler) should
be disassembled if there is a risk of damaging it during
installation.
Set-up:
Place the boiler body at the desired installation point, ob-
serving the minimum clearance dimensions to the walls
(see chapter 5.6). The boiler door with the integrated
burner mechanism can be mounted optionally on the right
or on the left hand side.
Sound insulation:
The following measures are possible for sound insulation:
• Make boiler room walls, ceiling and oor as thick as
possible, install a silencer in the intake air opening,
provide carriers and brackets for the pipes with noise
insulation.
• If there are living areas above or below the boiler room,
install rubber vibration dampers under the base rails of
the boiler and connect pipes exibly using expansion
joints.
• Connect circulating pumps to the piping network using
expansion joints.
2.3 List of the screw packets (BioLyt 50-160)
Marking Art. no. Designation Number Content
A6023998 Attachment set A Installation casing/control
2
10 56
4 4 4 4
Self-tapping screw with recessed head ST4.8x50 Serrated washer A 3.7 Self-tapping screw (recessed) ST3.5x9.5 Washer Ø6.4/12.5x1.6 Hex. nuts M6 Hex. nuts M8 Washer A D8.4/16x1.6
B6024024 Attachment set B Mounting, burner mechanism
4 4 4
Washer A D 10.5/20x2 Circlips B10 Hex. nuts M10
C6024028 Attachment set C Installation protecting plate
4 8 8 2 4
Self-tapping screw with recessed head ST4.8x16-C-H Washer D 5.3/15x1.2 Serrated washer A10.5 Speed nut C-clips Ø4.8/3.0-3.9 Hex. nuts M5
D6023999 Attachment set D Mounting, boiler insulation
18 26
2
2x4 m
Insulation clips D3/38 Tension springs Strap fasteners Packing strapping 12.7x0.75 black
F6024025 Attachment set F Fitting the pellet hopper
4 8 4 2
Hex screw M8x20 Washer Ø8.4/16.0x1.6 Hex. nuts M8 Hex screw M8x70
84 214 852 / 01
GENERAL ASSEMBLY

2.3 List of the screw packets (BioLyt 50-160)
Marking Art. no. Designation Number Content
A6023998 Attachment set A Installation casing/control
2
10 56
4 4 4 4
Self-tapping screw with recessed head ST4.8x50 Serrated washer A 3.7 Self-tapping screw (recessed) ST3.5x9.5 Washer Ø6.4/12.5x1.6 Hex. nuts M6 Hex. nuts M8 Washer A D8.4/16x1.6
B6024024 Attachment set B Mounting, burner mechanism
4 4 4
Washer A D 10.5/20x2 Circlips B10 Hex. nuts M10
C6024028 Attachment set C Installation protecting plate
4 8 8 2 4
Self-tapping screw with recessed head ST4.8x16-C-H Washer D 5.3/15x1.2 Serrated washer A10.5 Speed nut C-clips Ø4.8/3.0-3.9 Hex. nuts M5
D6023999 Attachment set D Mounting, boiler insulation
18 26
2
2x4 m
Insulation clips D3/38 Tension springs Strap fasteners Packing strapping 12.7x0.75 black
F6024025 Attachment set F Fitting the pellet hopper
4 8 4 2
Hex screw M8x20 Washer Ø8.4/16.0x1.6 Hex. nuts M8 Hex screw M8x70
94 214 852 / 01
GENERAL ASSEMBLY

3. Assembly BioLyt (50-75)
3.1 Changing the door attachment side
BioLyt (50-75)
BioLyt (50)
1. Remove top clamping sleeve (1) and take o󰀨 the door.
2. Remove the bottom clamping sleeve (2), t on the op-
posite side, re-install the door and ret the top clam-
ping sleeve (1).
3. Change palm grips (3).
31
2
Fig. 01
BioLyt (70,75)
4. Tighten all palm grips (1).
5. Remove screws (2) for the swivel arm top and bot-
tom.
6. Swivel the arm (3) to the other side.
7. Ret screws (2) for the swivel arm top and bottom.
1
2
3
Fig. 02
Figure, delivery state
(Boiler door swivel-mounted to the right)
3.2 Burner BioLyt (50-75)
The gap between the burner tube and the combustion
chamber insulation is to be lled with the stu󰀩ng wool (1)
provided (Fig. 03).
1
Fig. 03
Fit the baffle plate (Fig. 04) and secure in position
(Fig. 05).
Fig. 04
Fig. 05
Remove the transport locking devices (wooden elements)
from the combustion chamber.
10 4 214 852 / 01
ASSEMBLY BIOLYT (50-75)

3.3 Mounting the ash rotor BioLyt (50-75)
The ash rotor is xed to the screw pipe of the ash screw.
Fig. 06
Rotor attachment points
(2x thread M8)
Screw the rotor in place with the screws M8x16 and circlips
(non-corroding) provided (Fig. 06).
NOTICE
• No longer screws are to be used.
• Alignment: The rotary axis of the rotor bla-
de must be located on the right adjacent to
the ash discharge screw (screws provided
with the rotor).
• The correct functioning of the rotor must be
checked when the boiler is commissioned
by Hoval Service.
3.4 Water-side and flue-gas side connecti-
on BioLyt (50-75)
• The boiler can be connected up before tting the casing
• A return temperature control system is required (see
hydraulic schematics for the individual system)
• A temperature-controlled safety drain valve must be in-
stalled (position of the immersion sleeve (1, Fig. 07 and
Fig. 08).
!
WARNING
•
A combined draught-explosion damper
between boiler and ue is mandatory.
•
it must be positioned in such a way that
no-one will be injured in the event of de-
agration.
• the combination draught-explosion damper
must be positioned within the boiler room.
BioLyt (50)
1
Fig. 07
BioLyt (70,75)
1
Fig. 08
114 214 852 / 01
ASSEMBLY BIOLYT (50-75)

3.5 Fitting the thermal insulation
BioLyt (50-75)
Attachment set D 8. Attach the insulation mat (1) on the pins provided on
the burner ange and secure with iso-clips (Fig. 09).
9. Attach the insulation mat (2, 2a) on the pins welded
to the rear wall of the boiler and secure with the iso- clips (Fig. 09) provided.
10. Place the insulation mat (3) around the base of the
water jacket (black sides outwards) and secure with tension springs (3a).
11. Place the insulation mat (4) around the top of the
water jacket (black sides outwards and starting at Pos. 5) and secure with tension springs (3a), two plastic straps (4a) and strap fasteners (4b, Fig. 10, Fig. 11). Do not overtighten the straps (reduced in- sulating value)
The remaining insulation mats are tted prior to installation of the casing
Fig. 09 Fig. 10
1
2 2a
4
3
3a
Fig. 11
4a 4b
D
5
3.6 Fitting the burner BioLyt (50-75) Attachment set B 12. Close the combustion chamber door (tighten the
palm grips).
13. Install burner mechanism (7).
Do not forget the gasket.
14. Insert the fan heater (8) into the ignition tube.
8
12 4 214 852 / 01
ASSEMBLY BIOLYT (50-75)

3.5 Fitting the thermal insulation
BioLyt (50-75)
Attachment set D 8. Attach the insulation mat (1) on the pins provided on
the burner ange and secure with iso-clips (Fig. 09).
9. Attach the insulation mat (2, 2a) on the pins welded
to the rear wall of the boiler and secure with the iso- clips (Fig. 09) provided.
10. Place the insulation mat (3) around the base of the
water jacket (black sides outwards) and secure with tension springs (3a).
11. Place the insulation mat (4) around the top of the
water jacket (black sides outwards and starting at Pos. 5) and secure with tension springs (3a), two plastic straps (4a) and strap fasteners (4b, Fig. 10, Fig. 11). Do not overtighten the straps (reduced in- sulating value)
The remaining insulation mats are tted prior to installation of the casing
Fig. 09 Fig. 10
3.6 Fitting the burner BioLyt (50-75) Attachment set B 12. Close the combustion chamber door (tighten the
palm grips).
13. Install burner mechanism (7).
Do not forget the gasket.
14. Insert the fan heater (8) into the ignition tube.
Fig. 12
4212946 32-BioLyt (50-75) / grma / 05.06.2014 M 1 : 10
8
7
B
134 214 852 / 01
ASSEMBLY BIOLYT (50-75)

3.7 Fitting the pellet hopper BioLyt (50-75) Attachment set A, F (Fig. 13) 15. Mount the attachment brackets (20, in the casing package) for the pellet hopper (in the casing package) from below on the boiler with nuts M8 plus U-washers
(A), brackets can be screwed on on the right and left. Slide the pellet hopper (21) into position before the nal tightening of the nuts.
16. Adjust the pellet hopper (21) with the connection tube (22) and screw in position (F). 17. Connect the connection tube (22) to the metering tube using a self-locking clip. Do not forget the gasket! 18. Screw the induced-draught fan (24) to the ue gas collector cover, do not forget the gasket. (4 pcs. - nut M8 with washer and circlip). Install blower sup-
port (24a).
19. Mount the cable duct (25, Fig. 14) on the side of the attachment bracket using M6 nut and washers (A). The cable duct must be mounted on the same side as
the automatic ring device.
20. Screw clamping plate with automatic ring device (26) on the side of the pellet hopper (unscrew the self-trapping screws, hook in the clamping plate, retighten
the screws).
The automatic ring device must be mounted on the burner swivel side. To change the combustion chamber door attachment side,
see chapter 3.1 for BioLyt (50-75).
21. Fit the metering screw (27, top screw) inside the metering tube and secure with hex socket screws M8x60 (with circlips, screws and spacers supplied with the
metering screw). Do not forget the gasket.
22. Mounting the pellet suction turbine (23, option). Mount the edge protection prole (23b) in the pellet hopper at position (23a). Place the suction system (23) on
the four M6 threaded bolts. Place a plastic insulating sleeve (23c) (collar downward) and a tall washer (23d) on each bolt and then secure the suction system with wing nuts (23e). Route the extension cable of the suction system to the rear along the centre of the hopper and between hopper and boiler downward to the automatic ring device. Establish a connection in accordance with the wiring diagram. When routing the cable ensure that it cannot touch the heating surface cleaner mechanism (HFR, Fig. 16, page 17). The sound attenuation cowl is placed later during the installation of the casing (53, Fig. 21, page 20).
20
23
14 4 214 852 / 01
ASSEMBLY BIOLYT (50-75)

Fig. 14
Fig. 13
A
24a
25
28a 28
20
24
F
26 21 27 22
20
23
23a
23b
23e
23d
23c
A
25
154 214 852 / 01
ASSEMBLY BIOLYT (50-75)

3.8 Fitting the probes, sensors and cables BioLyt (50-75) Pass all the cables needing to be routed from the automatic ring device to the top or rear side of the boiler through the cable duct (Fig. 14). Cable outlets are provided in the form of lateral openings at the corresponding points.
NOTICE
Route sensor cables and 230V cables sepa- rately.
Rear of the boiler (see also Fig. 16):
- Insert the ue gas temperature sensor (AGF) into the immersion sleeve on the ue gas connector
and secure with the capillary support spring.
- Route and connect the cables for the heating surface cleaner drive (HFR) (make sure the cables are
not trapped in the lever mechanism).
- Route and connect the cable for the ash discharge screw drive (AAT). - Insert the boiler temperature sensor (WF) from the automatic ring device into the immersion sleeve
and secure. The safety temperature limiter sensor (STB) will need to be installed into this immersion sleeve when proceeding with the installation of the casing.
- Mount the return temperature sensor (BRU) on the return line. - Install the lambda probe (see Fig. 15). - Insert the cable for the induced-draught fan (SZG) (SZG; incl. extension cable).
Front side of the boiler (see also Fig. 17):
- Route the cable of the lower ll level sensor (PBSu) in the pellet hopper to the automatic ring de-
vice.
- Introduce the combustion chamber temperature sensor (BRF) into the immersion sleeve and lock it. - Insert the feeder screw temperature sensor (ESF) into the immersion sleeve and x it in position
(cylinder screw M4x10).
- Plug the cables for the pressure fan (DG+DG-PWM) into the fan.
After all the cables have been routed, proceed to t and secure the plug-in connections according to the diagram on the automatic ring device.
The cables that lead from the burner mecha
-
nism to the clamping plate must be bundled
so that the burner can be swivelled open wi
-
thout di󰀩culty (see Fig. 41, page 46).
Lambda probe
Fig. 15
See also Fig. 40 and Fig. 41, chapter 6.3.2.
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ASSEMBLY BIOLYT (50-75)

3.8 Fitting the probes, sensors and cables BioLyt (50-75) Pass all the cables needing to be routed from the automatic ring device to the top or rear side of the boiler through the cable duct (Fig. 14). Cable outlets are provided in the form of lateral openings at the corresponding points.
NOTICE
Route sensor cables and 230V cables sepa- rately.
Rear of the boiler (see also Fig. 16):
- Insert the ue gas temperature sensor (AGF) into the immersion sleeve on the ue gas connector
and secure with the capillary support spring.
- Route and connect the cables for the heating surface cleaner drive (HFR) (make sure the cables are
not trapped in the lever mechanism).
- Route and connect the cable for the ash discharge screw drive (AAT). - Insert the boiler temperature sensor (WF) from the automatic ring device into the immersion sleeve
and secure. The safety temperature limiter sensor (STB) will need to be installed into this immersion sleeve when proceeding with the installation of the casing.
- Mount the return temperature sensor (BRU) on the return line. - Install the lambda probe (see Fig. 15). - Insert the cable for the induced-draught fan (SZG) (SZG; incl. extension cable).
Front side of the boiler (see also Fig. 17):
- Route the cable of the lower ll level sensor (PBSu) in the pellet hopper to the automatic ring de-
vice.
- Introduce the combustion chamber temperature sensor (BRF) into the immersion sleeve and lock it. - Insert the feeder screw temperature sensor (ESF) into the immersion sleeve and x it in position
(cylinder screw M4x10).
- Plug the cables for the pressure fan (DG+DG-PWM) into the fan.
After all the cables have been routed, proceed to t and secure the plug-in connections according to the diagram on the automatic ring device.
The cables that lead from the burner mecha- nism to the clamping plate must be bundled so that the burner can be swivelled open wi- thout di󰀩culty (see Fig. 41, page 46).
Fig. 15
AAT
Fig. 16
Fig. 17
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PBSu
AGF WF+STB HFR
SZG
ESF
BRF
DG+DG-PWM
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ASSEMBLY BIOLYT (50-75)

3.9 Fitting the casing BioLyt (50-75) Attachment set A, C
NOTICE
Before proceeding with the installation of the
casing, make sure that all the cables and
electrical connections to the automatic ring device have been tted.
23. Fit the thermal insulation mats (30, Fig. 20) and (28, 28a, Fig. 13). 24. Slide the side walls (31) into the plinth rails and hook into the slots of the attachment bracket
above.
25. Hook the controller box (32) on the right or left side wall (position depending on the automatic ring
device). Mount 2 special screws M4x8 with nuts M4 in the casing previously. Additionally secure the controller box with 2 self-tapping screws Ø 3.5 mm at the top. Route the temperature sensor for the safety temperature limiter (STB) to the back of the boiler and insert it into the immersion sleeve (with boiler and ow temperature sensors) and secure with the capillary support spring. Connect safety temperature limiter by tting at plug onto mounting tongues 1 and 2.
26. Loosely t protection plate (33a, Fig. 18 and Fig. 19) to the left and right top side wall (33, Fig. 18
and Fig. 20). Hook in the side walls. Position and adjust the protection plates and attach to the pellet hopper (serrated washer + washer must be used for the earth connection). Attach speed nuts (C-clips, 33b) (C).
27. Mount the top sections of the rear wall (34, 34a) using self-tapping screws (A). 28. Mount the middle section of the rear wall (35) using self-tapping screws (A). 29. Take o󰀨 sight glass. Mount the bottom section of the rear wall (36) using self-tapping screws (A).
Mount the ground cable (on the AAT cable) in the positions provided (on left or right side of the recess) using self-tapping screws. Fit the ash discharge motor cover (36a). Ret the sight glass.
30. Insert the rear cover (37). 31. Fit the front cover (38) (must be tted before installing the discharge hoses). 32. Insert the right and left burner cover at the bottom (39, 39a) on the screw heads provided and
press against the casing side panels at the top.
33. Hook in the front burner cover (40) at the side and screw to the protection plates (33a) at the top.
Hook in the front hood (40a) (pay attention to the slots).
34. Screw the cover plate (41, 41a) to the rear side walls (A). 35. Installation of no. 42, see chapter 3.10.
NOTICE
For 34, 34a, 35, 36 and 36a (Fig. 20), a ser-
rated washer must be used for one of the
self-tapping screws (Fig. 37, detail X) (earth connection).
Fig. 18
Fig. 19
4212946 32-BioLyt (50-75) / grma / 06.06.2014 M 1 : 1
33
33a
33b
NOTICE
Note: Insert cover (38) before mounting the suction hoses.
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ASSEMBLY BIOLYT (50-75)

3.9 Fitting the casing BioLyt (50-75) Attachment set A, C
NOTICE
Before proceeding with the installation of the casing, make sure that all the cables and electrical connections to the automatic ring device have been tted.
23. Fit the thermal insulation mats (30, Fig. 20) and (28, 28a, Fig. 13). 24. Slide the side walls (31) into the plinth rails and hook into the slots of the attachment bracket
above.
25. Hook the controller box (32) on the right or left side wall (position depending on the automatic ring
device). Mount 2 special screws M4x8 with nuts M4 in the casing previously. Additionally secure the controller box with 2 self-tapping screws Ø 3.5 mm at the top. Route the temperature sensor for the safety temperature limiter (STB) to the back of the boiler and insert it into the immersion sleeve (with boiler and ow temperature sensors) and secure with the capillary support spring. Connect safety temperature limiter by tting at plug onto mounting tongues 1 and 2.
26. Loosely t protection plate (33a, Fig. 18 and Fig. 19) to the left and right top side wall (33, Fig. 18
and Fig. 20). Hook in the side walls. Position and adjust the protection plates and attach to the pellet hopper (serrated washer + washer must be used for the earth connection). Attach speed nuts (C-clips, 33b) (C).
27. Mount the top sections of the rear wall (34, 34a) using self-tapping screws (A). 28. Mount the middle section of the rear wall (35) using self-tapping screws (A). 29. Take o󰀨 sight glass. Mount the bottom section of the rear wall (36) using self-tapping screws (A).
Mount the ground cable (on the AAT cable) in the positions provided (on left or right side of the recess) using self-tapping screws. Fit the ash discharge motor cover (36a). Ret the sight glass.
30. Insert the rear cover (37). 31. Fit the front cover (38) (must be tted before installing the discharge hoses). 32. Insert the right and left burner cover at the bottom (39, 39a) on the screw heads provided and
press against the casing side panels at the top.
33. Hook in the front burner cover (40) at the side and screw to the protection plates (33a) at the top.
Hook in the front hood (40a) (pay attention to the slots).
34. Screw the cover plate (41, 41a) to the rear side walls (A). 35. Installation of no. 42, see chapter 3.10.
NOTICE
For 34, 34a, 35, 36 and 36a (Fig. 20), a ser- rated washer must be used for one of the self-tapping screws (Fig. 37, detail X) (earth connection).
Fig. 20
30
3231
34a 34 35 36 36a
373841
33
39a
40a 39 3342
X
X
X
X
40
33a
X
41a
NOTICE
Note: Insert cover (38) before mounting the
suction hoses.
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ASSEMBLY BIOLYT (50-75)

3.10 Fitting the ash box and miscellaneous BioLyt (50-75)
36. Slide the ash box (50) into the screw pipe (do not forget the O-ring 50a, Fig. 21); the height of the rollers can be
adjusted by means of the nuts provided on the sides.
The ash box (50) must be aligned using the adjustable roller supports, as otherwise the connection to the
boiler will not be airtight. Ash box should be raised slightly at the wheels (a few mm); it will then be pressed
optimally against the gasket (50a) when the threaded rod (51) is tightened.
37. Lock the ash box (50) in position using the threaded rod (51); remove the nut beforehand (only serves as a trans-
port protection).
38. Hook the small front plate (52) to the side walls.
39. A󰀩x the adhesive type label.
Fig. 21
50
52
50a
51
53
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