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Summary of Contents for Guntamatic Powerchip 50 Special
- Page 1 Woodchip boiler englisch POWERCHIP /POWERCORN 50 Special Operating Instructions/System Log Book PH-A-00-00-00-01-BAEN EN-B30-009-V10b-0711-V3.0...
- Page 2 We are always looking to improve our products and documentation. Any ideas and suggestions you may have will be gratefully received. GUNTAMATIC Heiztechnik GmbH a Georg Fischer Group Company Bruck 7 A-4722 PEUERBACH Tel: 0043 (0) 7276 / 2441-0 Fax: 0043 (0) 7276 / 3031 E-mail: info@guntamatic.com...
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Page 3: Table Of Contents
POWERCHIP Operating Instructions Contents Page PH-C-00-00-00-01-BAEN Introduction............5 Brief description Type approval Further information Important notes............6 Intended use Operating the heating system Guarantee and liability Safety instructions System components..........11 Cutaway diagram of POWERCHIP Safety systems...........12 Control panel description........14 Overview of menu and levels......15 Information level House level User level... - Page 4 POWERCHIP Operating Instructions Contents Page Operating the heating system......34 Starting up/Shutting down the system Heating system checks Fuel quality Fuels 8.4.1 Woodchips 8.4.2 Pellets 8.4.3 Grain fuel 8.4.4 Miscanthus Fuel storage Filling/refilling the fuel store Combustion air setting Emptying the ash Cleaning/care .............42 Cleaning the fuel store Interim cleaning...
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Page 5: Introduction
Even the best boiler cannot operate effectively without proper care and maintenance, so please read through these instructions carefully and have your appliance commissioned by an engineer authorised by GUNTAMATIC. Most importantly, you should follow the safety instructions in Section 2. -
Page 6: Important Notes
POWERCHIP Operating Instructions Important notes BS-02-00-00-00-01-BAEN Your boiler has been designed and produced in accordance with the latest technical advances and all applicable safety regulations. Nevertheless incorrect operation, the use of unapproved fuels or the failure to carry out necessary maintenance and repairs can result in personal injury or damage to property. -
Page 7: Safety Instructions
POWERCHIP Operating Instructions Safety instructions BS-02-04-00-00-01-BAEN To prevent accidents, small children should not be allowed into the boiler room or the fuel storeroom. Please follow the safety instructions below. By doing so, you will protect yourself and prevent damage to your heating system. Power switch BS-02-04-00-01-01-BAEN The power switch must remain switched on at... - Page 8 POWERCHIP Operating Instructions Servicing work BS-02-04-00-06-01-BAEN Service the boiler regularly or make use of Note: our Customer Service. Emptying ash BS-02-04-00-07-01-BAEN Danger: Glowing embers can cause fires. Only remove the ash from the boiler or store it in non-combustible containers. Boiler cleaning BS-02-04-00-08-01-BAEN Caution:...
- Page 9 POWERCHIP Operating Instructions Flue draught regulator BS-02-04-00-12-01-BAEN Danger: Risk of detonation. A flue draught regulator with a pressure surge compensator is an essential requirement. Safety clearances BS-02-04-00-13-01-BAEN Danger: Fire risk. Do not store any flammable items in the close vicinity of the boiler. Follow the local regulations.
- Page 10 POWERCHIP Operating Instructions Protection against freezing BS-02-04-00-16-01-BAEN Note: Anti-freeze function. The system can only perform its freezing prevention function if sufficient fuel is available and there are no faults. Emergency fire extinguishing system PH-02-04-00-03-01-BAEN Note: Contact our Customer Service. If the emergency fire extinguishing system has been triggered, it is always due to a fault in the heating system.
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Page 11: Cutaway Diagram Of Powerchip
POWERCHIP Operating Instructions System components BS-03-00-00-00-01-BAEN Cutaway diagram of POWERCHIP PH-03-01-00-00-01-BAEN Firebox door Stepped grate – primary air Combustion chamber Fuel spout Swirl jet – secondary air Reaction tube Inspection cover Helix baffles Tube-type heat exchanger 10.) Flue draught fan 11.) Heat exchanger cleaning mechanism 12.) Flue pipe 13.) Oxygen sensor... -
Page 12: Safety Systems
POWERCHIP Operating Instructions Safety systems BS-04-00-00-00-01-BAEN To prevent the boiler overheating, the controller reduces the heat output in certain situations. If the boiler still threatens to overheat, the controller responds according to a set of defined safety levels. Safety level 1 BS-04-00-00-01-01-BAEN 15°... - Page 13 POWERCHIP Operating Instructions burn-back into the stoker auger by replenishing the fuel. In addition, a sensor monitors the temperature in the vicinity of the stoker auger. In that way, burning fuel is continually pushed back out of the auger duct. This burn-back prevention system always functions unless the electricity supply to the boiler system is cut off.
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Page 14: Control Panel Description
POWERCHIP Operating Instructions Control panel description BS-05-00-00-00-01-BAEN The appliance has a large touch-screen control panel with a menu-based interface. All setting and query options are shown on the display. All settings can be entered by pressing the "buttons" on the touch screen. Any system messages are displayed on the screen. -
Page 15: Overview Of Menu And Levels
Detail View Changes to the settings on the Service and • • • • DHW2 Parameters Date/Time Parameters levels may only be made with the agreement of GUNTAMATIC. HP0 parameters System settings Layout of touch-screen display BS-06-00-00-01-01-BAEN Header Scroll bar... -
Page 16: Information Level
POWERCHIP Operating Instructions Information level (user) PH-06-01-00-00-01-BAEN You use the "DOWN" and "UP" buttons to navigate through the Information Level menu. Fault screen → highest priority Plain-language fault messages are displayed showing date and time of occurrence Fault is acknowledged by pressing "Quit" button Information level →... -
Page 17: House Level
POWERCHIP Operating Instructions (user) House level PH-06-02-00-00-01-BAEN All heating programmes and menus are listed and described below: Heating and hot water switched off → Anti-freeze function active Heating and hot water on as per timer programme Hot water as per timer programme DHW summer →... -
Page 18: Heating Circuit Menu
POWERCHIP Operating Instructions menu (User) 6.3.1 Heating Circuit BS-06-03-01-00-01-BAEN The Heating Circuit menu allows you to enter the settings for the various heating circuits. Heating circuit control status Facility for setting heating and low-temperature times Facility for setting daytime required temperature Facility for setting night-time required temperature Facility for setting room effect/thermostat function Facility for setting heating characteristic... -
Page 19: Heating Circuit Menu
POWERCHIP Operating Instructions 6.3.3 Heating Circuit menu (User) BS-06-03-03-00-01-BAEN The Thermal Store HP0 menu allows you to enter settings for thermal store management. Status of special output HP0 Facility for setting thermal store charging programme Facility for setting thermal store charging times Facility for setting the thermal store required temperature →... -
Page 20: User Menu
Detail View. No settings can be made on this menu. Its primary purpose is to aid telephone diagnosis of possible fault causes and to assist the GUNTAMATIC engineer with fault rectification. menu (User) 6.3.7 Date/Time... -
Page 21: Service Level
(Expert) BS-06-04-00-00-01-BAEN CODE entry required. Changes to the settings on the Service Level may only be made with the agreement of GUNTAMATIC or an authorised GUNTAMATIC engineer. Service menu Reset data → Caution: All system settings may be lost. Service menu Fault screen →... -
Page 22: Service Menu Begin Service
POWERCHIP Operating Instructions Service menu (Expert) 6.4.3 Begin Service BS-06-04-03-00-01-BAEN All system components present can be programmed and activated from the service menu Commissioning. For setting boiler type For setting boiler output → stated on rating plate For setting outfeed system type For activating feed auger →... - Page 23 POWERCHIP Operating Instructions Assignment of thermal store sensor Manual filling of outfeed auger → A1 + G1 For saving user parameters after system configuration Options Heating circuit controller is not activated → No Heating circuit controller is activated → external heating circuit controller (wall controller) →...
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Page 24: Service Menu Heating Circuit/Screed Drying Programme Parameters
POWERCHIP Operating Instructions Service menu (Expert) 6.4.4 Heating Circuit/Screed Drying Programme Parameters BS-06-04-04-00-01-BAEN Options for setting the heating circuit and screed drying parameters: Heating circuit operating status Room stat setting For setting mixer valve running time For setting minimum flow temperature For setting maximum flow temperature For setting boiler overcompensation →... -
Page 25: Service Menu Hp0 Parameters
POWERCHIP Operating Instructions 6.4.6 Service menu HP0 parameters (Expert) PH-06-04-06-00-01-BAEN Facility for setting the parameters for special output HP0 Operating status of special output HP0 Enabling temperature for special output HP0 For setting for thermal store top charging ON temperature For setting for thermal store top charging OFF temperature For setting for thermal store bottom charging OFF temperature Facility for setting district heating pipe temperature loss... -
Page 26: Service Menu Fp District Heating Pipe Parameters
POWERCHIP Operating Instructions Service menu (Expert) 6.4.7 District heating pipe parameters ZUP PH-06-04-08-00-01-BAEN Set the correct district heating pipe function according to the details in the plumbing diagrams. Operating status of district heating pipe function Facility for setting district heating pipe temperature loss Service menu (Expert) 6.4.8... -
Page 27: Service Menu System Settings
POWERCHIP Operating Instructions Service menu (Expert) 6.4.10 System settings PH-06-04-07-00-01-BAEN Facility for setting special boiler and system parameters For setting system type → stated on rating plate For setting boiler type → stated on rating plate Facility for setting fuel outfeed type For setting speed ratio of A1/G1 when fuel set to pellets For setting speed ratio of A1/G1 when fuel set to barley For setting speed ratio of A1/G1 when fuel set to triticale... -
Page 28: Activating A Heating Programme
POWERCHIP Operating Instructions User Settings BS-07-00-00-00-01-BAEN Activating a heating programme BS-07-01-00-00-01-BAEN To activate the "NORMAL" programme, proceed as set out below, step by step: 1) → Press the "House level" button The programme currently selected, "Off", is shown in the header 2) →... -
Page 29: Deactivating A Heating Programme
POWERCHIP Operating Instructions Deactivating a heating programme BS-07-02-00-00-01-BAEN To set the "NORMAL" programme to "OFF", proceed as set out below, step by step: 1) → Press the "House level" button The programme currently selected, "Normal", is shown in the header 2) →... -
Page 30: Setting A Timer Programme
POWERCHIP Operating Instructions Setting a timer programme BS-07-03-00-00-01-BAEN The heating circuits/charging pumps can only be called into action during the times enabled in the timer programme. The example set out below illustrates programming the timer programme for heating circuit 1: 1) →... -
Page 31: Changing The Heating Characteristic
POWERCHIP Operating Instructions Changing the heating characteristic BS-07-04-00-00-01-BAEN The heating circuits/charging pumps can only be called into action during the times enabled in the timer programme. The example set out below illustrates programming the heating characteristic for heating circuit 1: 1) →... -
Page 32: Changing The Required Hot Water Temperature
POWERCHIP Operating Instructions Changing the required hot water temperature BS-07-05-00-00-01-BAEN You can change the required hot water temperature on the Hot Water menu. The example set out below illustrates programming the required temperature for DHW cylinder 0: 1) → Press the "House level" button 2) →... -
Page 33: Analogue Room Stat
POWERCHIP Operating Instructions Analogue room stat BS-07-06-00-00-01-BAEN If your system is fitted with an outside-temperature based heating circuit controller, each heating circuit can be equipped with an analogue room stat if desired. The control knob on the room stat allows adjustment of the required room temperature preset on the Heating Circuit menu. -
Page 34: Operating The Heating System
Starting up/Shutting down the system BS-08-01-00-00-01-BAEN BS-08-01-00-01-01-BAEN Initial commissioning Initial commissioning and basic adjustment of the system may only be carried out by GUNTAMATIC engineers or authorised GUNTAMATIC agents. BS-08-01-00-02-01-BAEN Restarting Before starting up the system again in the autumn/winter, carry out the annual check of the control and safety systems to ensure they are safe and functional. -
Page 35: Fuel Quality
To ensure trouble-free heating with the boiler, the fuel must be of the right quality. PH-08-03-00-01-01-BAEN Your GUNTAMATIC heating system is designed for burning G30 woodchips with a max. moisture rating of W30, and pellets. With the optional lining for grain/miscanthus, the fuels barley, triticale and miscanthus can also be burned. -
Page 36: Fuels
POWERCHIP Operating Instructions Fuels BS-08-04-00-00-01-BAEN 8.4.1 Woodchips PH-08-04-01-00-01-BAEN Woodchips are made from waste wood from forestry work or from trees. After felling, chipping wood should be left to season for at least one summer in an airy and sunny location. In sunny spots, the wood can be left lying on the ground among needles so as to make use of the moisture-absorbing effect of the needles. -
Page 37: Pellets
POWERCHIP Operating Instructions 8.4.2 Pellets BS-08-04-01-00-01-BAEN There are a number of points to observe when ordering wood pellets in order to ensure that they are of perfect quality. Reliable and trouble-free operation of the boiler and the conveying systems can only be guaranteed with high-quality pellets. -
Page 38: Miscanthus
POWERCHIP Operating Instructions 8.4.4 Miscanthus PH-08-04-02-00-01-BAEN The dried straw is harvested annually from the 3rd year on from April to May using a forage harvester. The crop should have a maximum moisture content of 20% when harvested. Miscanthus has to be stored dry. As the fusion point of miscanthus ash (clinker formation) is around 900°... -
Page 39: Filling/Refilling The Fuel Store
POWERCHIP Operating Instructions Filling/refilling the fuel store BS-08-06-00-00-01-BAEN BS-08-06-00-01-01-BAEN The heating system must be set to "Off" mode Caution: at least one hour before the fuel store is filled. On no account must the fuel store be filled while the heating system is in operation! First-time filling PH-08-06-00-01-01-BAEN When first filling the storeroom and every time it is refilled after... -
Page 40: Combustion Air Setting
POWERCHIP Operating Instructions Combustion air setting PH-08-07-00-00-01-BAEN After every change of fuel or after the boiler has not been used for an extended period, the combustion air setting should be checked/reset. The adjuster lever for the combustion air is located on the right above the right-hand ash box (see illustrations below). -
Page 41: Emptying The Ash
POWERCHIP Operating Instructions Emptying the ash PH-08-08-00-00-01-BAEN The ash boxes have to be emptied at intervals varying from every couple of days to 20 weeks depending on the amount of fuel used, its quality and heat output. The higher the ash content, the shorter the intervals at which the ash must be removed. -
Page 42: Cleaning/Care
In particular, you should follow the safety instructions in Section 2. BS-09-00-00-02-01-BAEN Cleaning The sophisticated cleaning system on a GUNTAMATIC heating system means that regular cleaning work is substantially reduced. All that is required is regular emptying of the ash. -
Page 43: Interim Cleaning
POWERCHIP Operating Instructions Interim cleaning PH-09-02-00-00-01-BAEN Interim cleaning must be carried out at intervals of between 1 week and 3 months depending on the fuel burned, the quantity of fuel used and how dirty the boiler is, and involves the following steps: 1. -
Page 44: Complete Cleaning
POWERCHIP Operating Instructions Complete cleaning PH-09-03-00-00-01-BAEN Depending on the load on the system, complete cleaning may be required twice a year but should be carried out at least once a year. All of the operations described in the section "Interim cleaning"... -
Page 45: Rectifying Faults
POWERCHIP Operating Instructions Rectifying faults PH-10-00-00-00-01-BAEN Fault Cause/Function Remedy Power supply disconnected Check external mains plug and/or power Control panel cannot be • • supply lead between circuit boards switched on Check fuse in supply lead and on the • Fuse blown control panel circuit board •... -
Page 46: Information/Fault Messages
POWERCHIP Operating Instructions Information/Fault messages PH-11-00-00-00-01-BAEN No. Category Origin Message Cancellation Possible causes Input TKS1 open longer than "t Firebox door or ash box Door switch defective, F01 Note safe" (door switch) open connector faulty, door or ash Automatic box open (F01) Combustion fault No fuel, incorrect air setting,... - Page 47 POWERCHIP Operating Instructions Param. "O2 sensor" or adjusted Oxygen sensor readings Oxygen sensor dirty or F19 Note setting above the limits of above limits. Test oxygen defective, carry out oxygen Reset button param. "mV top" or "mV btm" sensor sensor test, clean sensor (F19) Length of an oxygen sensor Oxygen sensor pause...
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Page 48: Replacing Fuses
POWERCHIP Operating Instructions Replacing fuses BS-12-00-00-00-01-BAEN Fuse function is indicated on the relevant electrical wiring diagrams in the installation instructions. Danger: Repair work may only be carried out by authorised technicians. Touching live electrical components can cause fatal injury. Even when the Power switch is "OFF" some components of the system are still live. -
Page 49: Log Book
POWERCHIP Operating Instructions System log book BS-13-00-00-00-01-BAEN LOG BOOK AUTOMATIC WOOD-BURNING BOILER SYSTEMS as required by the Austrian Technical Directive H118 on Preventative Fire Safety Please note: a log book is not legally required in the UK however it is recommended that one be kept. …………………………………………………………………….. -
Page 50: Weekly Visual Inspection
POWERCHIP Operating Instructions The following checks are to be carried out regularly on the automatic wood-burning boiler system by the system operator when it is in operation: 13.1 Weekly visual inspection: Once a week the entire boiler system including the fuel store is to be visually inspected. Any deficiencies identified are to be rectified immediately. - Page 51 POWERCHIP Operating Instructions Year: System operator: Serviced by: ……………………………. ……………………………………..........…………………………………………………………………………………………….. Monthly Remarks Check Flue gas passages Controller Warning system(s) Fans Firebox Portable fire extinguisher Ash storage Items stored in boiler room Deposits on roof Fire safety closures Smoke trap cleaning Signature/initials Year: System operator:...
- Page 52 POWERCHIP Operating Instructions BS-E-00-00-00-01-BAEN GUNTAMATIC Heiztechnik GmbH A – 4722 PEUERBACH Bruck 7 Tel: 0043 (0) 7276 / 2441-0 Fax: 0043 (0)7276 / 3031 E-mail: info@guntamatic.com...
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