instruction booklet - hetas

INSTRUCTION BOOKLET BIOTEC 25 AND BIOTEC 40

Version BIOTECHTS122013

3

USER MANUAL FOR INDEPENDENT PELLET FIRED BOILERS

SUPPLEMENTARY INSTALLATION INSTRUCTIONS FOR THE UK MARKET TO BE READ IN CONJUNCTION WITH THOSE IN THE INSTRUCTION BOOKLET

READ THE INSTRUCTION BOOKLET AND THESE SUPPLEMENTARY INSTRUC-TIONS CAREFULLY BEFORE INSTALLATION

These instructions together with those in the instruction booklet cover the basic principles to en-sure the satisfactory installation of the boiler, although detail may need slight modification to suit particular local site conditions.

In all cases the installation must comply with current Building Regulations, Local Authority

Byelaws and other specifications or regulations as they affect the installation of the boiler.

It should be noted that the Building Regulations requirements may be met by adopting the relevant recommendations given in British Standards BS 8303, BS EN 15287-1:2007 as an alternative means to achieve an equivalent level of performance to that obtained following

the guidance given in Approved Document J.

Should any conflict apply between these instructions and the original manufacturers in-

structions then the most stringent advice must apply.

Please note that it is a legal requirement under England and Wales Building Regulations that the installation of the boiler is either carried out under Local Authority Building Control approval or is installed by a Competent Person registered with a Government approved Competent Persons Scheme. HETAS Ltd operate such a Scheme and a listing of their Reg-

istered Competent Persons can be found on their website at www.hetas.co.uk.

Use of the boiler

The manufacturer is not responsible for damages resulting from incorrect use. The operational parameters and adjust-

ments can only be modified with the approval of Strebel ltd. The use of parameters and adjustments outside the approved

range can cause damage or faults to the Boiler ,accessories and or the system. If the flue gas system is designed incorrectly

or heavily polluted or if the boiler is not cleaned regularly or the water supply fails, the manufacturer is not liable for dam-

age caused by such failures.

This manual contains very important stipulations as prepared by Hetas ,It is very im-

portant that this manual is fully studied before installation commences and all instruc-

tions are adhered to.

http://www.hetas.co.uk

4

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 offence to emit smoke from a chimney of a building, from a furnace or

from any fixed boiler if located in a designated smoke control area. It is also an offence to acquire an

"unauthorised fuel" for use within a smoke control area unless it is used in an "exempt" appliance

("exempted" from the controls which generally apply in the smoke control area).

The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise

smokeless 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. Therefore 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 details of Clean Air Act requirements”

THE BIOTEC 25 & 40 BOILERS have been recommended as suitable for use in smoke control areas

when burning Wood pellet with a moisture content of less then 8% STREBEL recommends pellets

with a diameter of 6 to 8 mm and length of 10 to 30 mm to DIN ENplus A1 as referred

to in EN 14961-2 A1

Current standards and certification should be checked when considering RHI applications.

CLEAN AIR ACT

Wood Pellets

Wood pellets are produced by an increasing number of suppliers in this country, However,

there may be a difference in the size and standard offered by the various suppliers.

STREBEL recommends pellets with a diameter of 6 to 8 mm and length of 10 to 30 mm to

DIN ENplus A1 as referred to in EN 14961-2 A1

5

INDEX

Possible Injury

Text showing this symbol give safety infor-

mation where applicable

Possible hand injuries

Working on parts marked with this symbol

can cause hand injuries. Wear Gloves.

Fire hazard

Text passages with this symbol give infor-

mation about fire hazards.

Additional information or advice

Adhere to local and national regulations

concerning positioning, installation, oper-

ation and disposal of the boiler.

Danger of frost

Frost forming in the system pipes during

cold weather can cause severe damages.

Text passages with this symbol contain

information relating to frost prevention.

Signs and symbols

Risk of electric shock

Sections marked with this symbol are only to be

carried out by an electrician. Text showing this sym-

bol give information about electrical matters.

Surfaces with high temperatures

Touching hot surfaces can cause burns. Surfaces

marked with this symbol may only be touched

when the system is fully cooled down. Text pas-

sages with this symbol hold information relating

to hot boiler parts.

DANGER

Safety information……………………………………………………………………...………..……………………………...……………...6

Technical data……….....................................................................................................................................7

Technical information, Service Clearances……………………..………...…………………....……………………………..…....8

Construction and function.............................................................. ........................................................... 9

Hydraulic Schemes……………............................................................................................................10,11 &12

Boiler features............................................................................................................................................13

Installation, Flue, Electrical……………………………………………………………………………………..……….….….14,15 & 16

Electrical &Connections……………………………………..…………………………………………………………………….…...16 &17

Commissioning.,………………………................................................................................................................18

Thermal valve………………………………………………………………………………………………………………………………….……18

Operational phases………………………………………………....…………………………....…………………………………………....19

Boiler controller............................................................................................................................20, 21 & 22

Control parameters ……………….....................................................................................................23, 24 & 25

Maintenance………………………………………………………………………………………………………………………………………….26

Possible faults………………………………............................................................................................................ 27

Fuel………………………………………………....…………………………....….......................................................................28

Relocating and boiler disposal.................................................................................................................... 29

Guarantee ...................................................................................................................... ............................29

SUPPLEMENTARY OPERATING INSTRUCTIONS FOR THE UK MARKET………………………..30

Clean Air Act Stipulation.………………………………………………………………………………………….4

Hetas Stipulation……………………………….………………………………………………….……………….3

6

Special care must be taken when installing the boil-er such that the requirements of the Health and

Safety at Work Act are met.

Handling

Adequate facilities must be available for loading, unload-

ing and site handling.

Basics

The boiler must be installed by a competent profession-

al. The Biotec is manufactured according to current

safety standards. If safety rules are ignored, injury or

even death of the user could result. Damage to the boil-

er and accessories can result if the manual and safety

instruction are not adhered to.. The specialist responsi-

ble for the installation must explain the proper handling

of the boiler to the user. Only use the boiler if it is in-

stalled properly. Always follow the instructions of this

manual. Any boiler failure must be repaired as soon as

possible.

SAFETY INFORMATION

Fire Cement Some types of fire cement are caustic and should not be allowed to come into contact with the skin. In case of contact wash immediately with plenty of

water.

Metal Parts When installing or servicing this boiler care should be

taken to avoid the possibility of personal injury.

IMPORTANT WARNING This boiler must not be installed into a chimney

that serves any other heating appliance.

There must not be an extractor fan fitted in the same room as the boiler as this can cause the

boiler to emit fumes into the room.

Combustible material should not be located where

the heat dissipating through the walls of fireplaces

or flues could ignite it. Therefore when installing

the boiler in the presence of combustible materials

due account must be taken of the guidance on

the separation of combustible material given in

Building Regulations Approved Document J and

also in these boiler instructions.

Fire hazard

DANGER

Hand Injury

Asbestos This boiler contains no asbestos. If there is a possi-

bility of disturbing any asbestos in the course of the installation then please seek specialist guidance

and use appropriate protective equipment.

Every person intending to operate the boiler is

advised to carefully read this manual especially

the safety information. Persons intending to

clean the boiler or perform other maintenance

must read this Instruction Booklet otherwise the

warranty is invalid.

DANGER

During boiler operation, carbon monoxide can emit

through the boiler doors if they are opened . Only

leave the boiler doors open as long as necessary.

Insufficient ventilation during boiler operation can

cause death. Closing the ventilation openings of the

boiler room or the boiler is prohibited. Please adhere

to BS 6798 & BS5440:2 Wood requires one and a half

times the ventilation needed for gas .

Carbon monoxide

CO Alarms:-Building regulations require that whenever a new or replacement fixed solid fuel or wood/biomass appliance is installed in a dwelling a carbon monoxide alarm must be fitted in the same room as the appliance. Further guidance on the installation of the carbon monoxide alarm is available in BS EN 50292:2002 and from the alarm manufactur-er’s instructions. Provision of an alarm must not be considered a substitute for either in-stalling the appliance correctly or ensuring regular servicing and maintenance of the ap-

pliance and chimney system.

Please observe other advice contained

within specific areas of this Manual

Hand Injury

7

MAXIMUM BOILER TEMPERATURE

MINIMUM BOILER TEMPERATURE

°C

°C

90

70

90

70

FLUE TEMPERATURE MAXIMUM OUTPUT °C 135 140

FLUE TEMPERATURE MINIMUM OUTPUT °C 95 95

FLUE EXHAUST GAS FLOW RATE MAX OUTPUT Kg/Sec 0.0176 0.0280

FLUE EXHAUST GAS FLOW RATE MIN OUTPUT Kg/Sec 0.0079 0.0140

EFFICIENCY % 91 85

BOILER WATER CONTENT LTR 74 118

HYDRAULIC RESISTANCE DELTA T 10 C mbar 7 7

NOMINAL OUTPUT KW 25 40

MINIMUM OUTPUT KW 8 13

HYDRAULIC RESISTANCE DELTA T 20 C mbar 2 2

BOILER WEIGHT Kg 340 459

BOILER CLASS EN303-5 3 3

MAXIMUM OPERATING PRESSURE BAR 2.5 2.5

MAXIMUM TEST PRESSURE BAR 5 5

MAXIMUM CHIMNEY (DRAUGHT) NEGATIVE

PRESSURE

PA

ii

12 15

FLOW & RETURN CONNECTION SIZE INCH 1 1¼

FLUE CONNECTION DIAMETER m m

i

130 i 130 i

MAXIMUM CAPACITY OF THE STANDARD PELLET

HOPPER

Kg 120 170

ELECTRICAL SUPPLY/AMPERAGE 230V 50HZ

MAX 1 AMP

230V 50HZ

MAX 1 AMP

WATTAGE DURING NORMAL OPERATION W 100 123

WATTAGE DURING IGNITION PHASE W 300 323

Biotec 25 Biotec 40

Data subject to change without notice.

TECHNICAL DATA

i. It will be necessary to fit an adapter in the Flue pipe connection to increase the Flue diameter to the required

minimum Flue diameter of 150 mm (as previously stipulated) to comply with U.K. regulations

ii A Draught stabiliser (by others) should be fitted to the flue to maintain the required flue draught.

STREBEL recommends pellets with a diameter of 6 to 8 mm and length of 10 to 30 mm to

DIN ENplus A1 as referred to in EN 14961-2 A1

8

TECHNICAL INFORMATION

SIDE VIEW

C

G

B

R1

R3

R1

F

A E

R2

D

H

Biotec TOTAL WIDTH WITH

HOPPER

TOTAL

DEPTH

B

HEIGHT

C

FLUE

SPIGOT

D

BOILER

BODY WIDTH

E

RETURN

HEIGHT

F

FLOW

HEIGHT

G

FLUE

HEIGHT

HR

TOTAL

WIDTH

A

25 1226 (200LTR HOPPER) 870 1610 130 500 269 1132 1304 1380

40 1560 (300LTR HOPPER) 1104 1660 130 708 254 1301 1311 1608

It will be necessary to fit an adapter in the Flue pipe con-

nection to increase the Flue diameter to the required mini-

mum Flue diameter of 150 mm (as previously stipulated)

to comply with U.K. regulations

BIOTEC R1 R2 R3

Flow & Return Vent Drain

25 1” ½” ¾”

40 1¼” ½” ¾”

Service & Fill Clearances

PLAN

500mm

700mm 700mm

STREBEL

700mm

500mm

Dimensions

9

CONSTRUCTION & FUNCTION

13

16

11 12

9

12

7

8

1

14

6

15

3

2

Boiler Construction

Legend:

1.) Combustion chamber

2.) Heat exchanger

3.) Pellet silo

4.) Pellet screw

5.) Gear motor

6.) Heat exchanger top

7.) Air supply

8.) Combustion Fan

9.) Burner-door

10.) Flue connection

11.) Flue exhaust probe

12.) Boiler-controller

13.) Exhaust/flue pipe

14.) Ash drawer

15.) Heat exchanger cleaning system

16.) Ignition system

Function

The pellets are conveyed from the silo (3) to the burn-

er (1) via the pellet screw (4).

The ignition system (16) automatically ignites the pel-

lets during start-up or after an operating pause.

The fan (8) supplies the burner with primary and sec-

ondary air.

The air ducts in the combustion chamber supply the

correct amount of air for primary and secondary com-

bustion .

See page 19 for operational phases.

10

DRAIN OFF COCK

ISOLATING VALVE SAFETY

PUMP

PRESSURE GAUGE

TEMPERATURE GAUGE

AUTO AIR VENT

HEAT STORE

STREBEL

Fill

DHW

THERMAL VALVE COLD WATER

SUPPLY TO REGULATIONS

See your quotation for items

that are supplied. Positions &

orientation below are for ease

of illustration

HYDRAULIC SCHEME

AUTOMATIC 3 PORT MIXING

VALVE for maintained return

temperature

EXPANSION VESSEL

SEALED SYSTEM

The installer must fit a cold water supply (1/2“

connection) and comply fully with regulations in

force

A certified safety valve not exceeding 2.5 bar

must be installed in the heating system. The

safety valve sizing should be to current regula-

tions. Do not install other valves between the

safety valve and boiler. The water return temper-

ature must not fall below 60 °C to prevent the

build up of condensate inside the boiler.

11

HYDRAULIC SCHEME

DRAIN OFF COCK

ISOLATING VALVE



temperature

SAFETY

PUMP

PRESSURE GAUGE

TEMPERATURE GAUGE of

AUTO AIR VENT

LOW LOSS HEADER

EXPANSION VESSEL




of illustration

DHW Fill

Use

STREBEL

SEALED SYSTEM



force THERMAL VALVE COLD WATER









12

DRAIN OFF COCK

ISOLATING VALVE



temperature

SAFETY

VALVE

PUMP

PRESSURE GAUGE

TEMPERATURE GAUGE

AUTO AIR VENT

LOW LOSS HEADER

EXPANSION VESSEL




of illustration

DHW Fill

THERMAL VALVE COLD WATER


STREBEL

SEALED SYSTEM

Maximum system resistance 22Kpa

3 Port diverting valve

with actuator All & con-

trol by others.



force








13

Boiler features

General information

The Biotec Boiler has a modern design and is made

of high quality material. The boiler tests were carried

out conforming to EN 303-5, therefore the boiler ful-

fils all requirements for the connection to a central

heating system. The maximum permitted system

pressure is 2.5 bar.

The Boiler can be sited in areas as described in this

manual .The Boiler is a free standing Boiler and is not

suitable for siting in the living space such as a

Lounge, Bedroom, Office etc..

This boiler is suitable for central heating system of

family-homes, small businesses or workshops. The

automatic operation is very user-friendly, because the

only action during operation is re-filling the pellet silo

depending on the usage. The Biotec includes the silo

and pellet screw with the silo on the right hand side.

The silo can be mounted on the left hand side on ap-

plication and at extra cost .

STREBEL

Wood pellets are an excellent renewable fuel they

are cylindrical in shape with a low ash-percentage

after combustion which accounts for about 1 %. The

caloric value of pellets is approx. 18000 kJ/kg,

which means that 2 kg pellets is roughly equivalent

to 1 ltr of light heating oil.

The storing qualities and the high energy value of

pellets make them the ideal replacement for oil or

gas.

Conformity declaration

The company STREBEL confirms according to EN45014:1998

that the Biotec boiler complies with the following stand-

ards:

EC-guidelines:

MD 98/37/EC : PED 97/23/EC : LVD 2006/95/EC:

EMC2004/108/EC

General standards:

EN 303-5:1999; EN 60204-1:2006; EN 60335-1:2002;

EN 50165:1997+A1; EN 61000-6-3:2001; EN ISO 12100-

1:2003; EN ISO 12100-2:2003; EN 1050:1997

Other standards and technical specifications:

EN 287-1:2004, EN 288-3:1992; EN 10204:2004; EN ISO

7000:2004.

Testing method conformity: Module B1

Limit of Emission combustion products (class) 3

Certificates: EC Control Type –Certificate Nr. 0745/350/09

Responsible laboratory: TÜV Thüringen e.V. Service-Centre

South Germany, Industry.13, D-98544 in the town Zella

Mehlis

We hereby declare that the stated products were produced

under safety and specific guidelines and standards. All

working conditions & terms of use comply with this manual.

If this product is changed by others and changes are unap-

proved by Strebel the above confirmation loses its validity.

BOILER FEATURES BOILER PERFORMANCE

Refer to page 7 for details of the boiler’s per-

formance and technical data

HETAS Ltd Approval

This appliance has obtained HETAS Ltd approval for burning compressed wood pellets as specified in the main instruction manual. Approval does not cover the use of other fuels either alone or mixed with the recommended fuel, nor does it cover in-

structions for the use of other fuels

HETAS MCS APPROVAL

for the specific model numbers as follows:

Biotec 25 HTSMCS1301/01

Biotec 40 HTSMCS1301/02

THE BIOTEC 25 & 40 BOILERS have been rec-

ommended as suitable for use in smoke control areas

when burning Wood pellet with a moisture content

of less then 8% STREBEL recommends pellets with

a diameter of 6 to 8 mm and length of 10 to 30 mm

to DIN ENplus A1 as referred to in EN 14961-2 A1

SMOKE CONTROL APPROVAL

This appliance has obtained

14

DANGER

INSTALLATION

Because the boiler runs at high efficiencies, the temperature of the flue gases is at times lower than conventional solid fuel appliances. Although it is not classed as a condensing appliance, the low flue gas temperature results in condensation occurring within the flue. Any chimney flue sys-tem must therefore be able to withstand the ef-fects of condensate and operate under wet condi-tions (designation letter W). In addition it should be soot fire resistant and able to withstand the corrosive effects of flue products generated by solid fuels (designation G and 3 respectively). If installation is into an existing masonry chimney then it will require re-lining with a liner meeting the specification described above. Existing con-crete or clay lined chimneys are not suitable for this boiler and must be lined as described above. All installations must be in accordance with Build-

ing Regulations Approved Document J.

Any existing chimney must be clear of obstruction and have been swept clean immediately before installation of the lining system. Where the chim-ney is believed to have previously served an open fire installation it is possible that the higher flue gas temperature from a closed appliance may loosen deposits that were previously firmly adhered, with the consequent risk of flue block-age. It is therefore recommended that the chim-ney be swept a second time within a month of

regular use after installation.

If there is no existing chimney then any new sys-tem must be to the designation described above and in accordance with Building Regulations Ap-

proved Document J.

Insufficient flue draught or a badly designed flue

can cause a fire which can spread from the burner

on to the pellet feed screw and then spread to the

pellets in the silo. This must not happen however a

safety extinguishing valve is fitted as standard

NOTE this is not a substitute for a correct flue de-

sign. See Page18

Prescribed fuel

This boiler is designed for the combustion of

wood pellets. The use of other fuels is prohibited.

Wood pellets are cylindrical and made from wood

without additives or chemical binders. The pellets

must have specific dimensions ( as below) and a

low moisture level.

STREBEL recommends pellets with a diameter of

6 to 8 mm and length of 10 to 30 mm to DIN

ENplus A1 as referred to in EN 14961-2 A1

More information on page 28

The connection to the Boiler flue outlet must not

be reduced in diameter. It will be necessary to fit an

adapter in the Flue pipe connection to increase the Flue

diameter to the required minimum Flue diameter of 150

mm (as previously stipulated) to comply with U.K. regu-

lations

All joints in the connection between the Boiler and the chimney must be made gastight using fire ce-

ment and where necessary fire-proof rope infill.

The boilers have a flue gas connector that allows

connection to either a masonry chimney or a pre-

fabricated factory made insulated metal chimney

in accordance with the manufactures instructions.

NOTE: A chimney height of not less than 4.5 metres ( the outlet from the chimney should be above the roof of the building in accordance with the provisions of Building Regulations Approved Document )measured vertically from the outlet of the boiler to the top of the chimney should be satisfactory. Alter-natively the calculation procedure given in EN 13384-1 may be used as the basis for deciding whether a particular chimney design will provide suf-

ficient draught.

DANGER

Installation & connection to the chimney.

A chimney/flue specialist must be used to calcu-

late chimney sizing and positioning in accordance

with regulations in force. Part J of the Building reg-

ulations refers to additional provisions for applianc-

es burning solid fuel with a rated output of up to

50kw

In order for the boiler to perform satisfactorily the chimney height/design must be sufficient to ensure an adequate draught of approximately 15 Pa for the Biotec 40 and 12 pa for the Biotec 25 so as to

clear the products of combustion and prevent smoke problems into the room. A draught stabiliser should be fitted to the Flue to maintain stable draught condi-

tions.

15

If the boiler is to be installed on a combustible floor surface, it must be covered with a non-combustible material at least 12mm thick, in ac-cordance with Building Regulations Approved Document J, to a distance of 30 cm in front of the boiler and 15 cm to each side measuring from the

door of the combustion chamber.

The central heating system must be in accordance with BS EN 14336:2004: Heating Systems in Build-ings. Installation and commissioning of water based heating systems. BS EN 12828: 2003; Heat-ing Systems in Buildings. Design of water based heating systems. BS EN 12831: 2003; Heating Systems in Buildings. Method for calculation of the design heat load and BS 6880:1988 Parts 1 to 3, Code of Practice for low temperature hot water heating systems of output greater than 45kW

where appropriate.

The installation of any electrical services during the installation of this boiler and the associated heating system must be carried out by a regis-tered competent electrician and in accordance with the requirements of the latest issue of BS

7671.

Commissioning and handover Ensure all parts are fitted in accordance with the

instructions.

On completion of the installation allow a suitable period of time for any fire cement and mortar to dry out, before lighting the boiler. Once the boiler is under fire check all seals for soundness and that the boiler and water system are operating cor-rectly. Ensure that the flue is functioning correctly and that all products of combustion are vented

safely to atmosphere via the chimney terminal.

On completion of the installation and commission-ing ensure that the operating instructions for the boiler are left with the customer. Ensure to advise the customer on the correct use of the appliance and warn them to use only the recommended fuel

for the boiler.

Advise the user what to do should smoke or fumes be emitted from the boiler. The customer should be advised about restricting access to the

boiler by children, aged and/or infirm people.

Electrical connections

A draught stabiliser should be fitted in the chim-ney above the Boiler flue pipe connection. Fit-ting of a draught stabiliser will affect the require-ment for the permanent air supply into the room in which the boiler is fitted in accordance with Approved Document J (see also combustion air

supply).

Adequate provision e.g. easily accessible soot door or doors must be provided for sweeping the

chimney and connecting fluepipe.

Boiler Base The base should be able to accommodate the weight of the boiler and its chimney if the chimney is not independently supported. The weight of the boil-

er is indicated in this manual page 7.

INSTALLATION A single wall metal fluepipe is suitable for con-necting the boiler to the chimney but is not suita-ble for use as the complete chimney. The chim-ney and connecting fluepipe must have a mini-mum diameter of 150 mm .Any bend in the chimney or connecting fluepipe should not ex-

ceed 45°. 90° bends should not be used.

The boiler should be installed on a non-combustible Base of a size and construction that is in accordance with the provisions of the current

Building Regulations Approved Document J.

Fire hazard

Regulations Approved Document J. An open win-

dow is not appropriate for this purpose.

Connection to the central heating system

The boilers may be installed on either pumped open vented or sealed fully pumped systems. Where there is a combined hot water and heating system, a double-feed indirect cylinder to BS 1566 is necessary. Please ensure, if applicable, that a gravity heat leak radiator or towel rail is installed

to dissipate heat when the pump is off.

The clearance distances to combustible material beneath, surrounding or upon the Boiler Base and walls adjacent to the Boiler should comply with the guidance on the separation of combustible materi-al given in Building Regulations Approved Docu-

ment J and also in these boiler instructions.

Carbon monoxide

DANGER

Combustion air supply In order for the boiler to perform efficiently and safely there must be an adequate air supply into the room in which the boiler is installed to provide com-bustion air. The provision of air supply to the boiler

must be in accordance with current Building

16

1.) The boiler must be placed on a solid and stable

non combustable floor which is able to take its

weight.

2.) The installation must be carried out by qualified

technicians and the electrical supply and installa-

tion must be to regulations

3.) The boiler room must have a water supply

INSTALLATION

FIRE BRICKS

To prevent the system freezing when the boiler

is not to be used for a long period of time, we

advise draining the system.

OR

When the boiler is not producing heat, other

heaters should be in place to protect the Boiler

and system from frost where freezing could be

imminent

4) Servicing access should be fully considered

5) A waste water drain is advisable.

6.) The boiler room must have ventilation and a

Flue to current regulations

7) Floor, walls, ceiling, door and equipment of the

boiler room must be made of non-flammable ma-

terial.

8.) Humidity should be kept at a low level to avoid

corrosion of metal parts.

9) For filling the boiler we advise the use of soft

water.

10) The circulation pump must not operate before

the heating system is completely filled with water.

The system must be completely bled of air .

11) When connecting the boiler to the flue it is

necessary to make sure that all connections are

sealed properly.

Before starting up the boiler, check the fol-

lowing:

1.) The water pressure in the boiler and system

is adequate and the expansion vessel (where

used) is set

2.) The system is bled of air and fully vented

3.) The Boiler Control is set and the boiler wiring

is installed correctly and is undamaged and not

touching surfaces that heat up during operation.

4.) The combustion chamber bricks are correctly

positioned

5.) The pellet silo is clean and has a quantity of

pellets for first start up.

ELECTRICAL

Connect the pump to the Boiler control (max. 1 A).

Connection of the controller

Connect the controller to the power supply.

The installation of the electrical accessories of the

boiler need a power supply with 230 V/50 Hz.

Connection of the room thermostat

A room thermostat can be connected to the control-

ler.

Electrical Connection


REMINDERS

See page 18 For commissioning

17

DHW SENSOR NTC 10K

HEAT STORE PROBE NTC 10K

AUGER 230V 50HZ 50W

FAN 230V 50HZ 41W

IGNITION DEVICE 230V 50HZ 400W

BOILER RETURN LIFTING 230V 50HZ <400W

DHW PRIMARY PUMP 230V 50HZ <400W

HEATING PUMP 230V 50HZ <400W

ROOM STAT OR ON OFF CONTROL

POWER SUPPLY

230 V AC 50HZ 13 AMP

TERMINAL CONNECTIONS Risk of electric shock

18

If the boiler is not connected to a suitable flue system (not

enough height, wrong diameter of the chimney, dirt or heavily

polluted boiler), there is a possibility that fire can spread from

the burner into the silo.

Note all Flues must be to Building Regulations Ap-

proved Document J.

A part of the combustion air supply is led through the screw

channel and thus prevents backfire in the pellet silo. This air

current is present at all times during operation but if the flue

gas/chimney system is badly designed or heavily polluted, the

air supply may not be enough to stop the fire spreading up the

auger feed.

A thermal valve and a probe are mounted on the boiler ex

works. If a temperature of 95 °C or more is measured by the

inbuilt thermal valve (in the auger feed) it is activated and re-

leases water (from a pre charged vessel) extinguishing the fire

The installer must provide a water supply to the thermal valve

(1/2“ connection) and comply fully with regulations in force .

Fire Prevention of the Biotec

COMMISSIONING

THERMAL VALVE

Boiler auger showing the thermal valve

and probe

The commissioning of the Biotec boiler may only be car-

ried out by STREBEL or an experienced installer with the

approval of Strebel If the start-up is not carried out cor-

rectly, the boiler and the system can be damaged or

destroyed and be un-repairable.

Injury could result from non observation of this manual

and general health and safety rules

This manual lists many items that should be checked

before commissioning

Commissioning the Biotec Boiler

Precautions for the first commissioning

1.) Check if the red main switch is off

2.) Disconnect the boiler from the power supply.

3.) Check that the following parts are installed profession-

ally and working correctly

- All mechanical parts of the boiler including burner and

firebricks, fan, boiler pump and circuit pump/pumps and

safety valve. Check the Hydraulic scheme complies with

the examples shown on page 10, 11, & 12

4.) Check all electrical components, connections and de-

vices for correct installation IE gear motor, fan, controller

and display.

- protect all unused connections,

- check earthing

- check the power supply.


Actions required after thermal valve release

1.) Disconnect the boiler from the power supply.

2.) Remove the screw and gear motor.

3.) Remove wet or damp pellets from the silo and the screw

channel.

4.) Remove residual water and dry all system parts.

NOTE Moisture can cause electrical shorts.

5) Remount the screw and gear motor.

6 )Re fill the silo with dry pellets

7.) Connect to the power supply and test.

If wet or damp pellets are not removed completely the screw

and motor may jam. The manufacturer rejects responsibility

and the warranty expires if material damage occurs because

of such failures.

Thermal valve

probe

STRE-

Programming the Control should be carried out before

lighting the Boiler.

19

Operational phases

Ignition phase

If the flue gas temperature is above the temperature requir-

ing auto ignition of the pellets, the controller knows that the

combustion chamber holds enough ember temperature to

successfully continue combustion. In this case the ignition

device is not required . The dosage of pellets continues.

If the flue gas temperature shows the temperature to be low

the controller knows that the combustion chamber has not

enough ember temperature to successfully continue combus-

tion.

First the fan is switched on to purge the combustion chamber

and vents before the ignition device is energised.

Second the pellet auger pushes enough pellets for light up

into the combustion chamber.

Third the ignition device is switched on

The Boiler now enters the warm up phase of operation.

Warm-up phase

The ignition device is switched off and the dosage of pellets is

reduced. The fan runs with increased speed (according to the

setting). in comparison to the combustion phase. The warm-

up phase has the purpose to “fan the fire” and let it spread

across the pellets in the combustion chamber. The duration of

the warm-up phase is fairly short. After this phase, the normal

run combustion phase starts.

In the case that the flue gas temperature does not rise be-

yond a pre programmed set temperature the controller rec-

ognises that the pellets can not be burning and the boiler

stops operation. The display shows “FAILED IGNITION“.

Combustion phase

During combustion phase, the pellet and air supply are regu-

lated based on the parameter settings. The controller aims for

the boiler to increase the temperature up to the „Maximum

boiler temperature“. when this is reached the boiler slowly

reduces its output to prevent repeated turning off and on .

The boiler shifts to pause mode when the temperature reach-

es the „Maximum boiler temperature“. On the top row the

display shows „Rated temp reached“. The boiler re starts op-

eration when the temperature of the boiler flow drops below

the set parameter “Maximum boiler temperature“. The de-

tected flue gas temperature determines if the boiler opera-

tion starts with the warm-up phase or the ignition phase as

described above

If a room thermostat or on off control (if used ) switches off,

it activates the setting that turns off the boiler and therefore

it sends the boiler into a phase of after-run., the boiler will

then quickly reach the required temperature and operation

will stop.

The pump will start if the boiler temperature rises beyond

the required temperature and also if the room thermostat

demands heat.

If the room thermostat /control does not call for heat the

pump runs for a period of 5 minutes after the boiler has

switched off then the pump stops until the room thermo-

stat/control calls for heat again.

OPERATIONAL PHASES

Programming the Control

Programming the Control should be carried out before

lighting the Boiler. Follow the logical steps shown on the

next pages.

The Boiler Commissioning must be carried out by a

trained engineer with the necessary approvals

20

1. IGNITION

Basic display

1

2

3

4

6 5 7 8 9

11

10

13

12

1. IGNITION

Boiler controller

Control panel

The controller is used for regulating the pellet boiler opera-

tion and should be set before commissioning

The design of the control panel is shown below:

The controller has an LCD display and 6

buttons on the right side of the display.

Functions of the buttons

Increase of parameter values

Escape, boiler power off

Browse menu – go back

Browse menu – go forward

Decrease the parameter values

Enter, confirm selected parameter

Inputs

- Boiler probe (Pt 1000)

- Flue gas probe (Pt 1000)

- Domestic water probe (NTC, 10 kΩ)

- Heat store probe (NTC, 10 kΩ)

- Room thermostat

- Input – GSM controller

Outputs -

Ignition system (relay,8A, NO)

- Pellet auger (relay, 5A, NO) -

Fan (PWM)

Legend

1 Time

2 Boiler operation

3 DHW temperature

4 Fan activated

5 Pump

6 Pellet auger

7 Ignition system

8 Boiler pump

9 Pre-set power output

10 Flue gas temperature

11 Current set boiler temperature

12 Program

13 Boiler operation phase

EXPLANATION OF THE DISPLAY (legend 13)

Boiler operational phase, information about the

current phase of boiler operation Boiler OFF,

First ignition-phase, Combustion-phase, Cool-

down phase, Room thermostat ,off etc.

The symbol „Boiler operation“ shows if the boil-

er is active or not.

If the boiler is set to run in a pre-programmed

operation mode, the display shows „TIME“.

The symbols in the bottom line show the opera-

tional availability of the controller outputs such

as fan, pump, auger, ignition , boiler pump and

whether they are active or not. If the symbol

shows, that component is active.

BOILER CONTROL

21

Start and stop of the boiler

To start the boiler, activate the red main switch on the

right side of the boiler. After activation, the boiler con-

troller turns on and shows the basic display. To start boil-

er operation, press the enter button for about 2 sec-

onds. The display shows “ON“ and the boiler switches

into the pre-pulse phase with maximum fan power.

To switch to automatic operation, the enter button is

again pressed for about 2 seconds. Then, the display

shows „TIMER PROGRAM BOILER“.

To shut down the boiler, the escape button is

pressed for about 2 seconds until the display shows

„OFF“. The boiler switches to the cool-down phase with

decreased fan power. To deactivate the boiler, the es-

cape button is again pressed for about 2seconds. By de-

activating (after a cooling down period) the main switch,

the boiler is powered down completely.

6.4 Setting of the time and date

For the setting of the date and time the button

is pressed for about 2 seconds.

The current selection can be changed with the

buttons and By pressing the

enter button the selection is confirmed. After

confirming the display now moves to the next ad-

justable position. (the seconds cannot be set) Con-

tinue as above to make the desired changes. When

all positions are set, the user returns to the basic

display. To escape the setting without making

changes, press the escape button.

Automatic operation

To set the hours of operation for the automatic

operation, press the button for about 2

seconds. The weekday can be selected by press-

ing or . To change the operating hours for

the selected day, press the enter button.

MONDAY

NO

YES

After all four sets of times are confirmed, the dis-

play shows „COPY“. If this is confirmed with the

enter button , the settings are copied to the

next day. Pressing the escape button leads to

the settings for the next weekday, without copy-

ing the changes.

MONDAY

TIMER PROGRAM

BOILER

The display shows two rows each with settable

times, the first is the start time , the second is the

stop time. In the example below, the boiler starts

at 06:00 am and is switched off at 04:00 pm. After

a pause the Boiler switches on again at 07:00 pm

and stops at 10:00 pm. Then the boiler is deac-

tivated until the next day. The operation times can

be set individually for every day of the week.

The values can be changed with the buttons

and then confirmed with the enter button.

After confirming, the display now moves to the

next adjustable position.

BOILER CONTROL

22

CHANGEOVER

SUMMER WINTER

SUMMER

WINTER

POWER

4.) POWER:

The centre of the display shows the set power stage.

P1: Minimum output operation

P2: Intermediate output operation

P3: Maximum output operation

The bottom row shows the set values.

R= The operating duration of the auger

P= The Pause duration of the auger

V= The Fan-power during heating operation

5.) Switching between summer and winter-mode

In summer mode, the boiler only produces domestic

hot water.

BOILER TEMPERATURE

SET POINT

DHW TEMPERATURE

SET POINT

PARALLEL OPERATION

HWS PRIORITY

HOT WATER

HEATING ONLY

Operation parameters

The following parameters are relevant for boiler operation,

pellet combustion, and flue gas temperature. The parame-

ters are set by the technician before commissioning . The

operation parameters are displayed by pressing the button

in the basic display.

Press the buttons or to set the value for the select-

ed parameter.

Press the escape button to go back to the basic display.

Press the enter button to confirm the selection.

1.) Boiler temperature set value:

2.) DHW temperature set value:

3.) Domestic Hot Water setting

Parallel operation = both heating and hot water at the

same time to set point.

BOILER CONTROL

23

Setting parameters

Changes of parameters can be carried out by pressing the

buttons and together. Below is a list of parameters

with the factory settings.

The parameters can be changed by pressing or .

The setting is confirmed with the enter button then

the menu directs the user back to the basic display.

CONTROL PARAMETERS

24


The setting is confirmed with the enter button then

the menu directs the user back to the basic display.

Start on page 20

CONTROL PARAMETERS

25


The setting is confirmed with the enter button then the

menu directs the user back to the basic display.

The asterisk is displayed when DHW is present

Start on page 20

Temperature difference between heat store & boiler

Heat store probe adjustment

DHW temperature

CONTROL PARAMETERS

P2

26

Maintenance

Intervals of maintenance and cleaning

Maintenance work performed periodically is very important for a problem-free operation and the guarantee of a long life of

the boiler and other system components.

The maintenance period is affected by to the pellet quality and boiler usage . Soot and tar cling to the combustion chamber

walls, so their cleaning by hand.is very important

Before you start cleaning, turn off the boiler controller and deactivate the main switch. Let the boiler cool to a safe tempera-

ture that is not a burn or injury risk.

Interval

Every 3 days

Every 6

months

Clean the heat exchanger and com-

bustion chamber

Check and clean the flue exhaust

passes Check and clean the boiler

and flue gas probe

Clean all parts as stated

Move the lever of the heat exchanger cleaning system back

and forth 5 to 6 times. Remove the front refractory brick

and clean the combustion chamber with a vacuum cleaner.

Empty out the pellet silo and remove any wood dust with a

vacuum cleaner.

Carefully clean with slightly damp cloth.

The exhaust pipes can be removed and cleaned with the

cleaning tool when the system is cooled down.

As above & pull out the probes, remove soot and debris.

Clean the pellet silo

Clean the display

Components Action Required

When cleaning the combustion chamber with a vacuum

cleaner, the ash inside must be allowed to cool down to

prevent accidents.

When removing the front brick of the burner, there is a

risk of a burn injury Wait for the brick to fully cool down.

There is a risk of burns when cleaning the exhaust passes

because these surfaces can reach a temperature of up to

200 °C during operation. Wait until these parts cool down

fully before cleaning.

While cleaning, be aware that deadly carbon

monoxide can emit from an opened boiler door

or cover . Do not leave the boiler doors open

longer than necessary unless the Boiler is out of use

The ash quantity in the boiler depends on the pellet quality

and usage. High quality pellets leave less ash and reduce wood

dust in the pellet silo.

To prolong the live of the ignition system which ignites the pel-

lets, the ignition system and the air vent must be cleaned regu-

larly. Thoroughly clean the boiler system at the end of the

heating season to prolong its live and maintain its efficiency.

DANGER

MAINTENANCE

Once a year

Every month

Clearances for servicing are shown on page 8

27

System dirty

3) The refractory bricks in the combus-

tion chamber are misaligned

Possible faults

POSSIBLE FAULTS

28

Information kindly provided by Forever Fuels

Pellets, made from by-products of wood and wood shav-

ings, without additives. The energy value of 2 kg pellets

complies with the energy of 1 l light heating oil (10 kWh).

Comply DIN 51731

STREBEL recommends pellets with a diameter of 6

to 8 mm and length of 10 to 30 mm to DIN ENplus

A1 as referred in EN 14961-2 A1

Fuel PELLET INFORMATION

Strebel Biotec boilers require fuels complying to ENplus-A1

SP

EC

IA

LIS

T U

K

FU

EL

P

RO

VID

ER

29

Procedure for relocating the Biotec

1.) Stop the boiler operation.

2.) Wait until the pellets in the combustion chamber are burnt

up and the boiler has cooled down.

3.) Disconnect the boiler from power supply.

4.) Disconnect the boiler from the rest of the heating installation

and drain the water from the boiler.

5.) Remove the pellet silo.

6.) Remove the boiler shell.

7.) Remove the casing &insulation from the boiler body.

Reassemble the Biotec in its new location observing

the information with this manual

The boiler removal must be carried out by qualified techni-

cians. Otherwise personal injury or material damage can

RELOCATION AND BOILER DISPOSAL

Guarantee

12.1 Warranty Period

The product is guaranteed for two years.

12.2 The guarantee is valid, when

- the boiler is installed, mounted and commissioned by

STREBEL or a qualified installer,

- the boiler is installed complying with national and local

regulations

- the used pellet quality conforms with the standards stat-

ed in this manual.

12.3 The guarantee is invalid, if

- the boiler heating system and-flue gas system is

designed incorrectly,

- the installation and commissioning was not carried out

by an approved person,

- the repair and maintenance was not carried out

by an approved person,

The Warranty does not cover:

- Damages caused by weather (natural disasters, earth-

quakes, flood, fire, electric lightening etc.)

- damages to electric leads,

- use of parts from other manufacturers,

- damages caused by faulty system parts such as circuit

pumps, expansion vessels etc.

11.2 Disposal

The listed below steel parts of the boiler can be deliv-

ered to a recycling centre:

- Boiler body,, boiler shell, pellet silo, screw, gear mo-

tor and burner.

The electrical parts as well as glass parts, mineral wool

and plastic

Parts are separated and delivered to a recycling centre.

The boiler parts must not be disposed of in a domestic

waste .

GUARANTEE

Disposal of the boiler

30

USER MANUAL FOR INDEPENDENT PELLET FIRED BOILERS

SUPPLEMENTARY OPERATING INSTRUCTIONS FOR THE UK MARKET

TO BE READ IN CONJUNCTION WITH THOSE IN THE INSTRUCTION BOOKLET

WARNING NOTE

Properly installed, operated and maintained this Boiler will not emit fumes into the dwelling. Occasional fumes from de ashing and re fuelling may occur. However, persistent fume emission is potentially danger-ous and must not be tolerated. If fume emission does persist, then the following immediate action should be taken:

(a) Open doors and windows to ventilate the room and then leave the premises.

(b) Let the fire go out.

(c) Check for flue or chimney blockage and clean if required

(d) Do not attempt to relight the fire until the cause of the fume emission has been identified and corrected. If necessary seek expert advice.

The most common cause of fume emission is a flueway or chimney blockage. For your own safety these

must be kept clean at all times.

General

Before lighting the boiler check with the installer that the installation work and commissioning checks described above have been carried out correctly and that the chimney has been swept clean, is sound and free from any obstructions. As part of the boilers’ commissioning and handover the installer should

have shown you how to operate the boiler correctly.

Do not light the boiler if there is a possibility that any part of the heating system may be frozen

Please make sure that the ash-pit door, Boiler flue and combustion chamber doors, the hopper lid/

charging door and flue cleaning doors are firmly closed at all times whilst the boiler is in operation.

CO Alarm

Your installer should have fitted a CO alarm in the same room as the appliance. If the alarm sounds un-

expectedly, follow the instructions given under “Warning Note” above.

Boiler Access

Access to the boiler should be restricted for children, aged and/or infirm persons by way of a lockable

door to the room in which the boiler is installed.

Chimney cleaning The chimney should be swept at least twice a year. It is important that the flue connection and chimney are swept prior to lighting up after a prolonged shutdown period. Where the chimney is believed to have a served an open fire installation it is possible that the higher flue gas temperature from a flue sealed appli-ance may loosen deposits that were previously firmly adhered, with the consequent risk of flue blockage. It is therefore recommended that the chimney be swept a second time within a month of regular use after

installation.

READ THE INSTRUCTION BOOK AND THESE INSTRUCTIONS CAREFULLY BEFORE USING THE BOILER

31

It is not possible to sweep the Chimney accessing it through the boiler so the installer will have provided alternative means, such as a soot door. After sweeping the chimney the boiler flue outlet and the flue pipe

connecting the boiler to the chimney must be cleaned with a flue brush.

Periods of Prolonged Non-Use

If the boiler is to be left unused for a prolonged period of time then it should be given a thorough clean to remove ash and unburned fuel residues. Empty the hopper of unburned fuel. To enable a good flow of air through the appliance to reduce condensation and to avoid door seals becoming stuck and subsequently damaged, leave the filling hatch and combustion chamber doors slightly ajar. These actions will reduce the possibility of unnecessary damage and corrosion. Protect the Boiler from frost, seek advice from your

installer relating to frost protection.

Extractor fan There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to

emit smoke and fumes into the room

Aerosol sprays

Do not use or store an aerosol spray or inflammables on or near the boiler when it is alight.

Use of operating tools

Always use the operating tools provided when handling parts likely to be hot when the boiler is in use.

Chimney Fires

If the chimney is thoroughly and regularly swept, chimney fires should not occur. However, if a chimney fire does occur turn off the boiler immediately and isolate the mains electricity supply, and tightly close the doors of the boiler. This should cause the chimney fire to go out. If the chimney fire does not go out when the above action is taken then the fire brigade should be called immediately. Do not relight the boiler until

the chimney and flue-way have been cleaned and examined by a professional.

Permanent air vent

The boiler requires a permanent and adequate air supply in order for it to operate safely and efficiently.

In accordance with current Building Regulations the installer may have fitted a permanent air supply vent into the room in which the boiler is installed to provide combustion air. This air vent should not under any

circumstances be shut off or sealed.

USER OPERATING INSTRUCTIONS

Please read the important notices given above before referring to the main instruction book for detailed

operating instructions.

Frequency of cleaning ash and residues from combustion chamber and ash-box

The owner is required to regularly carry out this cleaning operation and the frequency will depend on the heating load. When first put to use the boiler should be checked on a daily basis and experience will show how often this will eventually be required. Remember also that during the main heating season the clean-ing interval will shorten as the load on the boiler will be higher. Do not let ash or clinker build up on the un-

derside of the grate as this will cause damage to the boiler

Recommended fuels The boiler is designed to burn only specialised either compressed wood pellets or wood chips which are detailed in the main instruction book. Under no circumstances should you attempt to burn any other type

of fuel.

Spare Parts For information on obtaining spare parts for the boiler, please contact Strebel directly. Details can be

found at the back of the instruction booklet.

USER MANUAL FOR INDEPENDENT PELLET FIRED BOILERS Page 2

32

Strebel will not be liable for Typographical and printing errors, changes in construction and

dimensions which are stated throughout this manual.

instruction booklet - hetas

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