SOLARFOCUS octoplus User manual

l
DR-0030-DE
Read carefully before operating.
Pellet boiler octoplus
Installation manual for qualified personnel
DR-6019-EN / v27-202107

For your safety
2 Installation manual octoplus
About this manual........................................................2
1For your safety.........................................................3
2Product information................................................4
2.1 Scope of delivery ..............................................4
2.2 Sectional drawing..............................................4
2.3 Technical specifications....................................5
2.4 Dimensions........................................................6
2.5 Installation dimensions.....................................7
3Prior to assembly....................................................8
3.1 Installation room................................................8
3.2 Chimney connection.........................................8
3.3 Room sealed operation (RS)...........................9
3.4 Washers used - overview.................................9
4Installation..............................................................10
4.1 Assemble the boiler........................................10
4.2 Establishing the room-sealed connection.....28
4.3 Connecting the pellet hose.............................28
4.4 Flue gas pipe: Make a hole for emission
measurement..................................................30
5Hydraulic connection...........................................31
5.1 Make-up water requirements.........................31
5.2 Connections - overview..................................32
5.3 Boiler safety group (BSG)..............................32
5.4 Thermal overload protection..........................32
5.5 Expansion tank................................................32
5.6 Return flow boosting (RFB)........................... 32
5.7 Additional differential charging circuit Art.6152
......................................................................... 32
5.8 Operating the octoplus without a solar system33
5.8.1 Leave the cover caps on the solar coil connections 33
5.8.2 Circulation pump for optimum tank usage (in the case
of low return temperature) ......................................33
6Electrical connection........................................... 34
6.1 Connections to the boiler power element..... 34
6.2 Power supply.................................................. 35
6.3 Connections required for installation............. 35
6.4 Connecting the control to the internet........... 35
6.5 Connecting the heating circuit pump (X9, X10)
......................................................................... 35
6.6 Electrical fusing............................................... 35
6.7 Types of sensors - overview.......................... 36
7Initial commissioning .......................................... 36
7.1 Commissioning log......................................... 37
7.2 Customer service order form......................... 39
8Plant schematic.................................................... 40
8.1 octoplus, with DHW tank and solar system.... 40
8.2 octoplus, with fresh water module andsolar
system............................................................. 40
8.3 octoplus, with biomass boiler, buffer tank, DHW
tank, solar system .......................................... 41
8.4 octoplus, with biomass boiler, buffer tank,fresh
water module, solar system........................... 41
About this manual
The language of the original manual is German. Ver-
sions of this manual in all other languages are trans-
lations of the original.
Function of the manual
The manual is a constituent part of the product and
enables safe and efficient handling of the product.
Compliance with all the safety instructions specified
is a basic prerequisite for safe working.
Storing the manual
Keep the manual for the entire life of the product.
You must pass the manual on to the new owner
when the product is dismantled andreused. If the
manual is lost or destroyed, request a new copy from
the manufacturer.
Symbols and labelling
Precondition for an action
Instruction
Result of an action
Numbering of figures
The numbering can befound below the figures, for
example: Fig. 6-3
6-3 stands for the unique identification of the figure
and is used in the text if thefigure is referenced. The
number 6 stands for the main section of the manual
where the figure can be found, the number 3 for the
serial number of the figure within the main section of
the manual.
Service-Hotline
- Email: [e-mail]
- Austria, and international: [phone]
- Germany: [phone]
- Switzerland: [phone]

For your safety
Installation manual octoplus 3
1 For your safety
Make sure that you read this manual before
commissioning the product. Compliance with the in-
structions in this manual, particularly the safety in-
structions, is vital for safe operation.
Safety information
Do not use or store combustible materials in the vi-
cinity of the boiler.
When opening the boiler door, ensure that noflue
gas orflying sparks escape. Never leave the boiler
door open and unattended.
The boiler must be switched off before filling the
storage room!
Never open thecombustion chamber door during
operation.
Only touch the designated operating elements
(handles) while the boiler is in operation. Other
components (combustion chamber door, flue gas
pipe, …) can become very hot – danger of burns!
In the event of damage to the insulation, switch off
the power supply immediately and have the insula-
tion repaired.
Protect live parts against moisture.
Do not allow unauthorised persons, children or ani-
mals to enter the boilerroom. Persons who are un-
familiar with the boiler or have received no instruc-
tion in its use must not be allowed to operate it.
Use onlyfuel which meets the prescribed quality
standards.
Do not use auxiliarymaterials to ignite the pre-
scribed fuel.
Have maintenance work performed regularly (con-
tact the SOLARFOCUS GmbH Service Department
or an authorisedcustomer service partner).
If visible damage is ascertained (e.g. leakage of wa-
ter, thermal deformation, traces of smoke or scorch-
ing, mechanical damage etc.), operation must not
be continued or the boiler started up again. The
system may only be operated if it is in perfect tech-
nical condition.
If the system is out of operation for lengthy periods,
it must be ensured that all parts bearing water are
fully protected against frost.
The system operator is responsible for setting the
parameters in the customer menu of the boiler con-
trol. As-delivered condition is always the factory set-
ting, which must be adjusted by the system opera-
tor to meet the individual requirements. The manu-
facturer cannot be held liable for damage resulting
from incorrect adjustment.
The boiler must be operated exclusively in accord-
ance with the planning and installation specifica-
tions and with the relevant regulations, laws and
product-specific instructions. The manufacturer ac-
cepts no liabilityfor damage and the consequences
of damage resulting from incorrect installation, op-
eration or use of the boiler or from failure to perform
maintenance and cleaning correctlyand punctually.
The operator/owner of the system is under obliga-
tion to observe the applicable regional guidelines,
directives and laws pertaining to the operation of
wood- and pellet-fired combustion systems.
The modification or disabling of safety equipment is
strictly prohibited.
The fire, building and electrical engineering require-
ments and the safety regulations must be complied
with in addition to the instructions in the operation
manual and the legal requirements applicable in the
country of use!
Incorrect cleaning and maintenance or failure to
perform cleaning and maintenance can lead to seri-
ous malfunctions during combustion and thus
cause accidents! Before maintenance work on the
boiler: Switch the boiler off and allow it tocool
down!
All checks (service operations), cleaning processes
and other events must be entered in an inspection
log in accordance with TRVB H 118.
Accident prevention regulations
In addition to the instructions contained in this man-
ual, the local accident prevention regulations and the
national industrial safety regulations also apply. In
the event of damage to the insulation, switch off the
power supply immediately and have the insulation
repaired. Protect live parts against moisture and
damp.
Qualification of personnel
The work procedures described must be carried out
by qualified specialist personnel. Work on electrical
components must be performed by trained electri-
cians and in accordance with the relevant laws and
directives.

Product information
4 Installation manual octoplus
2 Product information
2.1 Scope of delivery
Pos.
Quan-
tity
Designation
1
1
Ash container
2
1
Operating unit touch display page 22,
Fig. 4-37
3
1
Operation manual DR-6023
4
1
Transparent bag with 3 x corrugated
hose connectors
5
1
Transparent bag with external sensor,
boiler flow contact sensor
6
1
Transparent bag with temperature sen-
sor, overtemperature reset, flue gas
temperature sensor, magnetic holder
back plate
7
2
Stainless steel combustion grate
8
1
Feeder unit (including rotary valve) 
page 14, Fig. 4-14
9
1
Electrical power element page 17, Fig.
4-21
10
1
Flange gasket between burner unit and
tank page 11, Fig. 4-4
11
2
Threaded plug page 17, Fig. 4-23
12
1
Cable duct L=1000 mm, incl. 4 x plas-
terboard dowels page 17, Fig. 4-22
Pos.
Quan-
tity
Designation
13
3
Adhesive mount cable tie page 23, Fig.
4-39
14
6
Loose cable temperature sensor red, or
with metal shield
15
1
Assembly instructions DR-6019
16
1
Leather glove
17
1
Frame parts kit
18
1
Suction turbine housing (including
noise reduction) page 25, Fig. 4-44
19
1
ID fan page 18, Fig. 4-24
20
Fire clay bricks page 11, Fig. 4-4
21
1
Screwdriver Torx20
22
1
Screw set
23
1
Tank insulation (two-piece jacket,
cover, etc.) page 13, Fig. 4-9
24
4
Adjustable feet page 11, Fig. 4-3
25
1
Cladding door page 22, Fig. 4-36
26
Various covers (sheet metal parts for
cladding)
Not included in the scope of delivery: Solar pump set ♦ pellets hose ♦ flue pipe parts and connection materials
2.2 Sectional drawing
1
Suction turbine
2
Filling level sensor
3
Touch display
4
Lambda sensor
5
Electrical power element
6
Intermediate pellet store
7
Heat exchanger cleaning active (auger)
8
ID fan
9
Flue gas pipe
10
Ignition device (glow pencil)
11
Screw feeder with rotary valve
12
Solar coil
13
Ash roller
14
Ash container
3
1
11
10
13
12
7
4
8
5
9
6
2
14

Product information
Installation manual octoplus 5
2.3 Technical specifications
octoplus
10
15
15.5
22
Output
[kW]
2.9 –9.9
2.9 –14.9
4.6 –15.5
6.6 - 22
Energy efficiency class
A+
Dimensions
Width
[cm]
88
97
Depth with fan
[cm]
146
159
Height
[cm]
188
Minimum room height
[cm]
201
Tank installation dimensions
[cm]
>75
>80
Tilted height
[cm]
177
186
Tank diameter without insulation
[cm]
70
79
Weight
Tank weight
[kg]
150
190
Total boiler weight (tank including
attachments)
[kg]
348
377
Water side
Tank volume
[l]
550
800
Maximum operating pressure
[bar]
3
Solar coil area
[m²]
1.8
2.4
Solar coil content
[l]
11.9
15.9
Fuel
Fuel
Wood pellets acc. to EN17225-2, ENplus-A1
Capacity of intermediate pellet
store
[l]
49
Flue gas side
Flue gas pipe diameter
[cm]
13
Height to centre of flue pipe
[cm]
38
39
Flue gas mass flow full load
[g/s]
5.5
8.4
8.6
11
Flue gas mass flow partial load
[g/s]
2.5
2.5
2.6
3.8
Max. flue gas temperature (full
load/partial load) [1]
[°C]
140 / 100
Minimum draught requirement [2]
[Pa]
5
Emissions according to test re-
port
Flue gas values [3] from test re-
port: Test institute / test report no.
Austria /10-
UW-Wels-EX-
053-2
Austria /10-UW-
Wels-EX-053-1
Austria /14-UW-
Wels-EX-70
Austria /14-UW-
Wels-EX-70
Date of the test report
21/06/2010
21/06/2010
21/08/2015
10/09/2014
CO full load
[mg/m³]
70
40
38
17
CO partial load
[mg/m³]
165
165
161
125
NOx full load
[mg/m³]
103
101
102
103
NOx partial load
[mg/m³]
104
104
104
105
Org. C full load
[mg/m³]
<1
2
3
Org. C partial load
[mg/m³]
2.7
2.6
3
Dust content full load
[mg/m³]
16
19
19
18
Dust content partial load
[mg/m³]
15
15
15
20
[1]
The maximum flue gas temperature can be adjusted electronically
[2]
A draught stabiliser must be fitted if the specified draught of 15 Pa is exceeded (attention: In the case of a boiler with room-sealed oper-
ation, use a room-sealed draught stabiliser)
[3]
Flue gas values in mg/m³ are based on 13% O2 of the volume flow
Thermal overload protection and return flow boosting are not requiredfor the octoplus heating boilers.

Product information
6 Installation manual octoplus
2.4 Dimensions
octoplus 10, 15
octoplus 15.5, 22

Product information
Installation manual octoplus 7
2.5 Installation dimensions
octoplus 10, 15 / octoplus 15.5, 22
2-1
2-2
** Access to the rear side of the boiler must be provided (at least 45 cm on the left or right).
* When the solar pump assembly is fitted onto the octoplus, the distance to the wall must be made larger.
Minimum required room height: 201 cm (valid for all octoplus sizes).

Prior to assembly
8 Installation manual octoplus
3 Prior to assembly
3.1 Installation room
The installation location and thefuel storage room mustmeet the applicable regional regulations (with regard to:
structural requirements, ventilation, fire protection, safety equipment, environmental protection; in AT: ÖNORM
H5170 and TRVB H 118).
The installation room mustbe frost-proof and dry and have a level floor of sufficient load-bearing capacity(note
total weight of boiler 5).
Note the installation dimensions to ensure sufficient space is provided (including for service andmaintenance
work).
3.2 Chimney connection
The correct dimensioning of the chimney and the selection of the right chimney system are important preconditions
for correct functioning of the heating system. The chimneymust route off the gases reliablyat all times. The chim-
ney should be moisture-resistant, e.g. made from stainless steel. Adequate insulation of the chimney must be pro-
vided.
Cross-section and chimney height
The necessary cross-section depends on the nominal output of the heating system and the effective chimney
height (at least 6.5 m).We recommend that you have thechimney calculations performed byqualified personnel.
However, as a general rule of thumb:
Rated boiler
Chimney diameter
up to 25 kW
13 cm
up to and incl. 30 kW
13 to 15 cm
up to and incl. 40 kW
15 to 18 cm
up to and incl. 60 kW
20 cm
Draught requirement for boiler: 5 Pa
Important points regarding the chimney connector
The chimneymust be resistant to moisture (fire bricks or stainless steel)
Ensure that the chimney is adequately insulated.
The cross-section should correspond to the boilerflue pipe diameter. Consult your chimneysweep for the corre-
sponding calculation.
The effective height should be minimum 6.5 m.
The flue pipe mustrise and be insulated; avoid unnecessary bends; keep the flue pipe as short as possible.
Draught regulator required! We recommend the use of an explosion flap.
Maximum deviation between the diameter of the flue pipe and the diameter of the existing flue is one size larger or
smaller (always consult the manufacturer)
Supply and exhaust air
The following applies for Austria (in accordance with ÖN H 5170):
For the supplyair, 2 cm² per kW thermal output of the fuel, but allow at least 200 cm² free cross-section. (Fuel
heat capacity = boiler capacity / efficiency)
For the exhaust air, allow at least 180 cm² free cross-section up to 100 kW nominal heat and an additional 1 cm²
free cross-section for everyfurther kW.
The following applies for Germany(specimen firing ordinance):
For heating appliances with a nominal output of up to 35 kW, a combustion air opening of at least 150 cm² or 2 x
75 cm² routed directlyinto the open air must be provided.
Alternatively, a door/window leading outside and a room content of at least 4 m³/kW nominal heat output are suit-
able. If the installation room does not abut onto an outside wall, combustion airsupplyvia connecting rooms is
possible. Here, the combustion air is supplied via a sufficientlydimensioned adjacent room which abuts onto an
outside wall.
From 35 to 50 kW, provide a free aeration cross-section of at least 150 cm². From 50 kW upwards, for aeration
and ventilation, provide a minimum free cross-section of 150 m² for each, plus 2 cm² per KW in excess of 50 kW.
Calculate at least a further 20 % for wire mesh in the aeration cross-section.

Prior to assembly
Installation manual octoplus 9
3.3 Room sealed operation (RS)
In conventional boiler rooms, the necessarysupplyair openings lead to uncontrolled heat loss. This is prevented by
using boilers as room sealed appliances, as the combustion air is drawn in from outside in closed supply air lines.
In particularly efficient systems,the temperature of the combustion air supplied is increased by drawing it in near
the flue gas duct.
The standard intake line has a diameter of diam. 80mm and is 1 m long(can be extended to a maximum of 3m).
To extend the linefurther (an additional length of 8 m is possible), the diameter must be increased to diam. 100
mm.
SOLARFOCUS boilers of the octoplusseries are available in a version for operation as room-sealed appliances.
Establishing the room-sealed connection 28
3.4 Washers used - overview
Designation
DIN125 A-8-VZ
DIN125 A-10-VZ
DIN9021-5-VZ
DIN9021-6-VZ
DIN 6798 Form A
interior diam.
Ø (d)
8.4 mm
10.5 mm
5.3 mm
6.4 mm
4.3 mm
exterior diam.
Ø (d2)
16 mm
20 mm
15 mm
18 mm
8 mm

Installation
10 Installation manual octoplus
4 Installation
4.1 Assemble the boiler
Lay all cables (temperature sensor, motor, lambda sensor, ...) in such a way that they do not touch the tank
raw body (where possible run above the insulation, or at a distance from the raw body).
Fig. 4-1
Dismantling the intermediate pel-
let store
Dismantle the intermediate pellet
store 1by loosening 2 x hex nuts
and washers 2.
Fig. 4-2
, Dismantling the burner
Dismantle the burner 1by loosen-
ing 4 x hex nuts and washers 2.

Installation
Installation manual octoplus 11
Fig. 4-3
Screw in adjustable feet
Insert disk-shaped insulation 1
under the tank.
Screw in 4 pcs adjustable feet 2
(SW24) and adjust tank level.
Fig. 4-4
, Installing the burner
Position fire clay brick 1into the
back of the burner unit 2.
Mount burner unit and flange gas-
ket 3onto the tank using 4 x hex
nuts DIN934-VZ/M12 and wash-
ers DIN125A-12-VZ 4.
Use fire clay bricks 5and 6(pay
attention to different shapes)
Fig. 4-5
Installing the burner cover
Bend the tabs 1in a vertical posi-
tion on both sides of the burner
unit.
Mount left and right covers 2, in-
cluding insulation.
Attach top cover 3and secure
with 4 x sheet metal screws
M4x10 4to the side panels.

Installation
12 Installation manual octoplus
Fig. 4-6
Installing the corrugated hose
connectors
Mount 3 x piece corrugated hose
connector 1with gasket 2and
cap nut 3.
Fig. 4-7
Mount tank temperature sensor
bottom
Insert 3 pcs temperature sensors
4into the bracket and secure with
screw DIN7985-VZ/M4x10.
Lay cables for the sensors on the
top of the tank.
- Top tank sensor, X30
- Centre tank sensor, X31
- Lower tank sensor, X32
Fig. 4-8
Mount retaining brackets
Loosen 4x hex nuts and washers
2, remove 2x retaining brackets 1.

Installation
Installation manual octoplus 13
Fig. 4-9
, mount tank insulation
Place insulation 1outside of the
tank base.
Insert two-part disk-shaped insu-
lation 2around the tank.
Fix insulation jacket sections by
hooking the plastic strips to the
tank.
Install upper Insulation 3
Fig. 4-10
Mount cover strips and rosettes
Mount 2x cover strips 1and 8x
rosettes 2on the tank.
Fig. 4-11
Installing the intermediate pellet
store
Mount the intermediate pellet
store 1to the burner with 2 pcs
hex bolts DIN933-VZ/M8x16 and
washers DIN125A-8-VZ 2.

Installation
14 Installation manual octoplus
Fig. 4-12
Prepare downpipe insert
Bend the finger of the downpipe
insert 1to an angle of ~80°.
Tip: use pliers
Fig. 4-13
Install downpipe insert and pipe
clamp
Position pipe clamp 1including
downpipe insert 2 to the down-
pipe bracket.
Check 3: The finger of the down-
pipe insert must be aligned (in
plan view) to the boiler back
panel.
Fig. 4-14
Installing the pellet feeder unit
Slide the pellet feeder unit 1into
the intermediate pellet store.
Connect the two connection spig-
ots with the pipe clamp 2.
Caution! Open filling chamber door
3and reach into the downpipe from
below: Check for correct seat /
orientation of the downpipe insert.
Check horizontal / vertical orien-
tation of the intermediate pellet
store, readjust if necessary.
Tighten up screws on the inter-
mediate pellet store console 4.

Installation
Installation manual octoplus 15
Fig. 4-15
Mount retaining plates and frames
Screw 4x retaining plates 1to the
tank console using 2x hex bolts
DIN933-VZ/M6x20 2and washers
DIN9021-6-VZ 3.
Knock the adjustable feet 4into
the frame's shaped tube from be-
low, and screw the left and right
frame part to the retaining plates,
using hex bolts DIN933-
VZ/M6x20 and washers DIN9021-
6-VZ.
Use spacer plates 5as supple-
mentary shims for vertical orienta-
tion of the frame, if required.
Fig. 4-16
Installing the front burner cover
Bend tabs 1backwards.
Mount cover 2and insulation with
4 x self-tapping screws M4x10 3.
Fig. 4-17
Mount lower cover
Make sure that the cover is cor-
rectly positioned Fig. 4-18
Mount cover 1with 6x self-tap-
ping screws M4x10 2.

Installation
16 Installation manual octoplus
Fig. 4-18
Chamfer 1of the cover must
reach behind the flange 2of the
burner unit.
Fig. 4-19
Mount cross braces
Mount the upper cross brace 1
with 2 x hex bolts DIN933-
VZ/M5x12 and washers DIN9021-
5-VZ 2.
Mount the centre cross brace 3
with 2 x hex bolts DIN933-
VZ/M5x12 and washers DIN9021-
5-VZ 4.
Fig. 4-20
Connect the intermediate store
with the cross brace
Connect intermediate pellet store
to the cross brace using hex bolts
DIN933-VZ/M5x20 1and 2x
DIN125A-5-VZ 2.
Establishing the room-
sealed connection 28

Installation
Installation manual octoplus 17
Fig. 4-21
Mounting the electrical power ele-
ment
Mount power element 1with 4 x
screws DIN7985-VZ/M4x10 2.
Mount the terminal strip 3by
means of 2x screws DIN7985-
VZ/M3x10 and hex nuts DIN934-
VZ/M3 4.
Fig. 4-22
Mount the cable duct
Mount the cable duct 1with 4 x
plasterboard dowels 2.
Distance from the upper edge of the
insulation ~ 40 mm.
Fig. 4-23
Seal condensate drain
Screw in closing plug 1.

Increased condensate accu-
mulation may arise at low re-
turn temperature, e.g. screed
drying.
A boiler fill and drain valve provided
by the customer can be installed in-
stead of the closing plug.
4

Installation
18 Installation manual octoplus
Fig. 4-24
Connect electrical components
Connect both motors for heat ex-
changer cleaning 1to X24.
Connect lambda sensor 2to X45.
Connect ID fan 3to X19 and X47.
Place temperature sensor 4in the
flue pipe, connect to X34.
Fig. 4-25
Mount cable duct cover
Lay connector / cable for 230 volt
AC supply from X1 power ele-
ment to the boiler back in cable
duct.
Secure cable with enclosed
strain relief.
Press cover 1onto cable duct.

Installation
Installation manual octoplus 19
Fig. 4-26
Mount retaining brackets
Mount the 2 x retaining brackets 1
with 2 x hex nuts DIN934-VZ/M8
and washers DIN125A-8-VZ 2to
the threaded bolts.
Fig. 4-27
Flue chambers: Mount lower
cover
Mount lower flue chamber cover 1
with the lower 4 x screws
DIN7985-VZ/M5x10 and washers
DIN9021-5-VZ 2.
Fig. 4-28
Mount inspection hatch covers
Position insulation 1.
Mount cover 2with 4 x self-tap-
ping screws M4x10 3.

Installation
20 Installation manual octoplus
Fig. 4-29
Flue chambers: Mount upper
cover
Attach insulation 1
Turn screwed tabs 2at the bot-
tom of the cover downwards.
Mount cover with 4 x screws
DIN7985-VZ/M5x10 and washers
DIN9021-5-VZ 3.
Fig. 4-30
Mount overtemperature reset (but-
ton)
Screw switching unit 1behind the
cover from the front onto the hex
nut and cover cap 2.
Connect overtemperature reset
(button) to X20, attach protective
earth conductor to lug on the
power element.
Fig. 4-31
Mount the sensors for over-
temperature reset (button)
Insert sensor into the immersion
sleeve 1on the upper side of the
boiler.
Connect 3 x tank temperature
sensors, X30/X31/X32, 12