POWERCHIP-V10-Installation & Assembly Instructions

Woodchip boiler

POWERCHIP/POWERCORN 50 Special

Installation and assembly instructions

V10 Nov 2009

POWERCHIP Installation Instructions

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Information about these installation and assembly instructions

These instructions are intended for the technical staff of the installer. They provide the necessary information regarding assembly and installation.

The Appendix contains fitting guidelines, plumbing diagrams and electrical wiring diagrams that will assist the installation and service engineers when installing and servicing the system.

We are always looking to improve our products and documentation. Any ideas and suggestions you may have will be gratefully received.

GUNTAMATIC Heiztechnik GmbHa Georg Fischer Group CompanyBruck 7A-4722 PEUERBACH

Tel: 0043 (0) 7276 / 2441-0

Fax: 0043 (0) 7276 / 3031

E-mail: [email protected]

TRECO Ltd6 Millennium PlaceTiverton Business Park Tiverton EX16 6SB, UK

Tel: 0845 1309012

Fax: 01884 250799


Information that you should always take note of in your own interests is identified by the symbols shown on the left.

The entire contents of this document are the property of GUNTAMATIC and therefore protected by copyright. Reproduction of any kind, communication to third parties by any means or use for purposes other than those intended without the written consent of the owner is prohibited.

Subject to printing errors and technical amendments.


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Contents Page1 Introduction..........................................................4

1.1 Safety instructions 41.2 Guarantee 41.3 Site requirements 4

1.3.1 Boiler room requirements 51.3.2 Fuel storeroom requirements 61.3.3 Flue requirements 7

2 Installation and assembly ...................................82.1 Delivery 82.2 Carrying to installation site 82.3 Positioning and aligning the boiler 82.4 Installing the automatic ash extraction system 92.5 Installing Powerchip, fuel agitator and outfeed 92.6 Dimensions table for fuel agitator and outfeed 132.7 Wall opening and constructing the inspection hatch 142.8 Connecting the flue 152.9 Energy-saving flue draught regulator and pressure-

surge compensator 162.10 Plumbing connections 172.11 Filling and bleeding the system 202.12 Electrical connections to the system 212.13 Wiring requirements for the system 232.14 Electrical connections 242.15 Final checks 262.16 Commissioning 26

3 Standards and regulations................................27

4 Plumbing diagrams............................................284.1 Plumbing diagrams for Powerchip 20/50 29-354.2 Plumbing diagrams for Powerchip 75/100 36-414.3 Diagrams for systems supplying multiple

properties 42-444.4 Boiler cascade system with sequential boiler control 45

5 Electrical wiring diagram ..................................465.1 Control panel and 400V router module 465.2 Boiler circuit board 475.3 Wall controller set MK261 48

6 Technical data....................................................496.1 Technical data for Powerchip 20/50 496.2 Technical data for Powerchip 75/100 506.3 Technical data for Powercorn 50 Special 51

Who is responsible for what?

Letters in brackets indicate who is responsible.O = Operator of system E = Electrician H = Heating installer F = Flue technician G = GUNTAMATIC authorised installer


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1 Introduction

1.1 Safety instructionsGUNTAMATIC heating systems represent state-of-the-art technology and meet all applicable safety regulations. The boiler and fuel supply system are electrically operated. Incorrect installation can endanger life and limb. Heating boilers are combustion systems and are potentially dangerous if handled incorrectly. Installation, commissioning and servicing must, therefore, only be carried out by adequately qualified technicians observing all regulations and the manufacturer's instructions.

1.2 GuaranteeThe manufacturer's guarantee is subject to correct installation and commissioning of the heating system. Defects and damage caused by incorrect installation, commissioning or operation are not covered by the guarantee. To ensure that the system functions as intended, the manufacturer's instructions must be followed. Furthermore, only genuine replacement parts or parts explicitly approved by the manufacturer may be fitted to the system.

1.3 Site requirementsWhen establishing the site requirements, it is absolutely essential to take account of the locally applicable planning, building and implementation regulations and the dimensional specifications in the fitting guidelines, installation examples and technical data. Compliance with the locally applicable regulations and the correct implementation of the measures required on site are solely the responsibility of the system owner and are a requirement of the manufacturer's guarantee. GUNTAMATIC provides no guarantee of any kind for any type of site work. Without making any claims as to completeness or non-applicability of official requirements, we recommend the following specifications based on the Austrian Guidelines pr TRVB H 118:


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1.3.1 Boiler room requirementsConcrete floor, bare or tiled, all materials for floor, walls and ceiling must be fire-resistant to F30 rating. The boiler room door must be a Class T30 fire door which opens in the direction of escape and is self-closing. Connecting doors to the fuel storeroom must also be Class T30 fire doors, self-closing and lockable. The pressure in the boiler room must not be less than 3 Pa (0.3 mm H2O). The air vents for boiler rooms must have a clear, net cross-sectional area of at least 200 cm and must not be sealable. When installing combustion boiler systems with a fuel heat output upwards of 50 kW, the net, clear cross-sectional area must be increased to at least 5 cm per kW rated output according to the combustion air requirement of the boiler system. The air supply ducting must connect directly to the outside and if the ducting passes through other rooms, it must be jacketed to Class F90. On the outside of the building, air vents must be covered by a protective grille with a mesh size of > 5 mm. The lighting and the electrical wiring in the boiler room must be permanently installed. There must be a clearly marked emergency off switch in an easily accessible position outside the boiler room, close to the boiler-room door. A hand-held fire extinguisher (6kg gross weight, EN3) must be mounted outside the boiler room near the boiler-room door. The boiler room, pipes carrying water and any district heating pipes must be protected against freezing. There mustbe no direct connection to rooms in which flammable gases or liquids are stored (e.g. garage).

Clear access opening for offloading with packingPH20/30, PH40/50 at least 80 x 170 cm (W x H)PH75, PH100 (PC50 Special) at least 100 x 190(170) cm (W x H)Dimensions refer to boiler with grate cleaner motor and stoker removed.

Clear access opening for offloading w/o packingPH20/30, PH40/50 at least 75 x 170 cm (W x H)PH75, PH100 (PC50 Special) at least 86(83) x 180(170) cm (W x H)

Dimensions refer to boiler with casing, stoker, flue connecting pipe, ash boxes and ash door removed.

Minimum room size PH20/30, PH40/50 at least 230(240) x 240 cm (W x L)PH75, PH100, PC50 Special at least 230(240) x 270 cm (W x L)

Dimensions in brackets refer to systems with automatic ash extraction system.

Minimum room height PH20/30, PH40/50, PC50 Special at least 225 cmwith heat exchanger cover removed at least 210 cm

PH75, PH100 at least 240 cmwith heat exchanger cover removed at least 230 cm


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1.3.2 Fuel storeroom requirementsThe same site requirements apply as for the boiler room. Due to the risk of injury when the system is in operation, storeroom doors must be lockable and kept locked. There must be a warning sign carrying the message "Do not enter when feeder system is running" attached to the storeroom door. If 50m of fuel or more can be stored, a manually operated fire extinguishing facility must be installed. It must be protected against freezing and connected to a pressurised water pipe (DN20 conduit). The discharge point must be located directly above where the fuel outfeed channel exits the storeroom. The fire extinguishing facility must be identified by a sign carrying the inscription "Fuel storeroom fire extinguisher". If the fuel storeroom is filled by a tanker truck using a compressed-air delivery system, the filler pipes must be earthed. With this method of filling, make sure the storeroom is dust-sealed. Electrical equipment is prohibited in the fuel storeroom. For storerooms in the services area, it is possible to dispense with F90 jacketing of the fuel store. The fuel must be stored separately (wooden boarding) from other materials and the fire containment zone must be less than 500m. If there is also a fire wall dividing off a living area, an automatic fire extinguishing facility is required. There must be a lockable F90-class inspection hatch above the fuel outfeed channel.

(See Section 2.7, "Fuel outfeed channel inspection hatch")

Fuel auger The drive motor and the necessary electrics must be installed outside the storeroom.

Structural requirements The enclosing walls must be capable of withstanding the possible static loads created by the fuel and when filling the fuel store. The following wall thicknesses have proven effective in practice:

Concrete, 10 cm, reinforced

Masonry/brick, 12 cm, plastered/rendered on both sides

Timber stud walling made with 12cm studs spaced at 62.5 cm, boarded on both sides with wooden materials 15-20 mm thick

Doors/boarding Above-ground fuel stores must be accessible by a door with a cross-sectional area of at least 1.80 m opening to the outside. The inside of the door opening must be covered with boarding so that the fuel cannot run out if the door is opened by mistake.

Damp-proofing The fuel must be protected against rain and contact with water or damp floors/walls. The storeroom must remain dry all year round. If there is a risk of temporarily damp walls, fitting a back-ventilated facing to the walls and lining them with wooden material may be required.


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1.3.3 Flue requirementsThe flue must be matched to the system in order to ensure economical and trouble-free operation.

Important

The system must only be connected to the flue if the flue meets the legal requirements and the technical specifications. The flue must be matched to the boiler output and dimensioned in accordance with DIN 4705. In order to be able to accurately dimension the flue, the calculations must be based on the flue gas figures. When designing new flues, high thermal insulation chimneys (DIN 18160 T1 heat transmission resistance group I) or suitable fireclay flues that are insusceptible to damp and have general building regulation approval should be used. It is advisable to involve those responsible for approving the flue system early on in the planning phase.

Figures for flue dimensioning calculations

Rated output

TypeFlue gas

temp.CO2 Mass flow rate

Required draught

PH 20/30 180C 12.5% 0.025 kg 15 pascals

PH 40/50 190C 13.0% 0.040 kg 15 pascals

PC 50S 185C 12.5% 0.040 kg 15 pascals

PH 75 180C 12.5% 0.065 kg 15 pascals

PH 100 195C 12.5% 0.082 kg 20 pascals

Sub-maximum output

TypeFlue gas

temp.CO2 Mass flow rate

Required draught

PH 20/30 130C 9.5% 0.010 kg 10 pascals

PH 40/50 145C 10.0% 0.015 kg 10 pascals

PC 50S 140C 9.5% 0.015 kg 10 pascals

PH 75 140C 9.5% 0.020 kg 10 pascals

PH 100 150C 10.5% 0.025 kg 12 pascals

The flue must be thermally insulated or insusceptible to damp as the flue gas

temperature can be below 105ÄC.


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2 Installation and assembly

2.1 Delivery (O)The boiler system is delivered packed in a wooden crate. Please check that the delivery is complete and in perfect condition.

Defects Please make a note of any deficiencies directly on the delivery note and contact the supplier or our Customer Service.

2.2 Carrying to installation site (H)The system is delivered on a wooden pallet and can be lifted and carried to the installation site using a pallet truck.

The system's boiler body can be dismantled into two parts. If that is necessary, a person authorised by GUNTAMATIC must be consulted.

2.3 Positioning and aligning the boiler (H)Keep to the minimum wall clearances specified by the system planner and manufacturer. If important details are missing, please refer to the planning documentation or ask our Technical Support. Position the system as close as possible to the flue to avoid having a long flue connecting pipe. The system must be accessible from the left or right side. There must be sufficient clearance for opening the fuel box door.

Clearance on left at least 40 cm (preferably 70 cm)

Clearance on right at least 40 cm

Clearance at back at least 50 cm (with auto ash extraction system, at least 60 cm)

Clearance at front at least 80 cm

Important → The appliance feet must be screwed in to a length of 35 mm.

Fig. 1


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2.4 Installing the automatic ash extraction system (H)The optional automatic ash extraction system is fitted as described in the separate installation instructions. They are supplied with the automatic ash extraction system.

2.5 Installing Powerchip, fuel agitator and outfeed (H)1.) Erect the boiler in the boiler room with the required wall

clearance as per Fig. 2/Section 2.3, setting the adjustable feet (Fig. 1) so that the boiler is tilted slightly upwards at the rear so that the air inside the boiler can escape when the system is filled.

2.) When erecting the boiler make sure that the fuel auger is fitted on the right of the boiler and can only be turned approx. 90 forwards or backwards (Fig. 3).

3.) The storeroom should not be significantly lower down than the boiler room. The maximum possible inclination angles for the outfeed auger are shown in Fig. 3. With the optional fuel chute extension (Fig. 4, Art. no. PH030-9-200-0) inclinations of up to 23 can be achieved. In such cases, the storeroom must be adapted to the slope of the agitator.

4.) With the stoker unit removed, insert the inlet seal (A, Fig. 9) between the stoker unit and boiler flange and secure with four M08x30 hexagon-head bolts, spring washers and nuts. Unscrew the foot (B, Fig. 9) on the stoker unit to take the weight of the stoker unit. Connect the electrical leads for the ignition fan, fill level switch, fire safety motor, stoker sensor, drive motor G1 and drive motor A1.

5.) Place the drive unit (C, Fig. 9) on the stoker unit and turn it towards the storeroom. The drive unit ball should form an airtight seal with the rubber seal (D, Fig. 9) of the stoker unit.

6.) Pre-assemble the required conveyor trough sections (0.22 m, 0.55 m, 1.10 m, 2.20 m or 2.97 m) on the floor. Always fit the 0.50 m trough section supplied (E, Fig. 9) in the area where the auger passes through the wall. Screw the individual trough sections firmly together using M08x30 hexagon-head bolts, washers and nuts (joins should be flush on the inside). Join the individual auger sections together so that the auger slope is even and continuous (F, Fig. 9). Then connect the pre-assembled outfeed auger to the drive unit (C, Fig. 9).

7.) Connect the agitator (G, Fig. 9) to the outfeed auger, making sure that the auger slope is even and continuous (F, Fig. 9). Then screw the auger trough sections firmly together.

Fig. 4

Fig. 2

Fig. 3


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8.) Fit the spring arms to the agitator. The agitator rotates clockwise (Fig. 5). Fit the longest arms opposite one another. The spring arms (I, Fig. 9) must be 15-20 mm above the outfeed auger at the point where they pass over it. Do not tighten the bolts (H, Fig. 9) on the springarms. The agitator feet (J, Fig. 9) must be adjusted so that the longest arm is 3-4 cm clear of the floor at its lowest point (K, Fig. 9).

9.) Screw the drive unit to the stoker unit using the fixing screws (L) (M10x100 and M10x140 mm) making sure it forms an airtight seal.

Always ensure the drive unit is fitted vertically (at 90 to the floor, see Fig. 6).

10.) Place the agitator centrally in the storeroom so that the spring arms clear the storeroom walls by a few centimetres. Firmly secure the agitator to the storeroom floor using masonry screws and wall plugs.

11.) Using the legs supplied, support the outfeed auger in the storeroom at the mid-point of the auger and where it exits the storeroom (Fig. 7) – the legs should not be more than 120 cm apart.

Position the feet so that they cannot move lengthways.The legs should rest against the flanges/support brackets of the auger. Place sound insulating material underneath to prevent noise transmission. Adjust the legs vertically so that the auger is resting firmly on them. Firmly secure the legs to the storeroom floor using masonry screws and wall plugs.

12.) Seal the hole in the wall (H, Fig. 9, dimensions H 700 x W 450 mm) around the outfeed auger with mineral wool and cover the gap on both sides of the wall with the cover plates supplied. If necessary, break out the perforations in the cover plates.

13.) Screw the galvanised mounting brackets supplied to the boiler base (Fig. 8) using the M8x16 hexagon-head bolts and slide the base insert and insulation (N, Fig. 9) under the boiler base.

14.) If the boiler is to be run on woodchips, a sloping storeroom floor is not absolutely imperative. If it is to run on grain or pellets, a sloping storeroom floor must be constructed.

Use planed timber boards (larch) or blockboard panels 3 cm thick

Rest the boards/panels on the lip of the outfeed auger. A supporting substructure as shown in Fig. 11 should be constructed at the rear of the agitator.

15.) The boarding (V, Fig. 7) over the inspection hatch must be provided on site and prevents uncontrolled spillage of the fuel into the boiler room. A sloping board 3 cm thick must be fitted at an angle of approx. 20, 20 cm above the outfeed auger, 20 cm from the storeroom wall and overlapping the inspection hatch opening by at

Fig. 5

Fig. 6

Fig. 8

Fig. 7


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least 10 cm on each side 3. The structure must be adequately fixed and adequately supported underneath.

Important → The auger drive unit must form a 100% airtight seal with the fuel chute. The rubber seal must completely seal the ball joint. Fix the drive unit securely with the screws supplied.

16.) Because of the sprinkler system, the temperature monitor on the outfeed auger is not required for storerooms with a capacity of no more than 50 m. If the storeroom capacity is larger than 50 m, the temperature monitor as well as the sprinkler unit must be connected to the outfeed channel near to where it passes through the wall. If 50m of fuel or more can be stored, a manually operated fire extinguishing facility must be installed. It must be protected against freezing and connected to a pressurised water pipe (DN20 conduit). The discharge point must be located directly above where the fuel outfeed channel exits the storeroom. The fire extinguishing facility must be identified by a sign carrying the inscription "Fuel storeroom fire extinguisher".

Fig. 9 Installation of boiler, fuel auger and agitator

Fig. 10 Installation of safety systems


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Fig. 11 Installation of sloping floor, emergency off switch, air vents, fire extinguisher, wall opening, safety systems

Sloping floors made of wood or concrete must be provided on site. If made of wood, the sloping floor should be constructed of timber boards (larch) or blockboard panels 3 cm thick. The substructure of 10 x 10 cm battens should be as shown in Fig. 11. The posts must stand on concrete or metal plates. The clearance between the agitator arms and the sloping floor must be 15 - 20 mm. With concrete sloping floors, the auger channel clearance should be 2-3 cm.

Fig. 11

O Fire extinguisher (6 kg) adjacent to boiler room door

P Emergency off switch outside boiler room

Q Air vent, at least 200 cm, or 5 cm per kW if output is 50 kW or more

R Sloping floor made of wood or concrete

S Storeroom ventilation only required for woodchips

T Supports for outfeed auger

U Supports for sloping wooden floor


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2.6 Dimensions table for fuel agitator and outfeed

Important The overall length of the outfeed auger including agitator must not exceed 7 m. The wall exit section (WS) must always be fitted where the auger passes through the wall.

Agitator dia. AS WS RWS GL Remarks1.5 m agitator 730 mm 550 mm 750 mm 2030 mm Basic2.0 m agitator 730 mm 550 mm 1000 mm 2280 mm Basic2.5 m agitator 730 mm 550 mm 1250 mm 2530 mm Basic Trough Length3.0 m agitator 730 mm 550 mm 1500 mm 2780 mm Basic TS1 220 mm3.5 m agitator 730 mm 550 mm 1750 mm 3030 mm Basic TS2 550 mm4.0 m agitator 730 mm 550 mm 2000 mm 3280 mm Basic TS3 1100 mm4.5 m agitator 730 mm 550 mm 2250 mm 3530 mm Basic TS4 2200 mm5.0 m agitator 730 mm 550 mm 2500 mm 3780 mm Basic TS5 2970 mm

Important Always fit the longest agitator arms opposite one another. The securing screws (W) on the agitator spring arms must not be fully tightened. Fit the agitator arms so that they clear the outfeed auger by approx. 15-20 mm.

Agitator arm 250 cm 225 cm 197 cm 172 cm 147 cm 120 cm 92 cm 64 cm1.5 m agitator 4 off2.0 m agitator 2 off 2 off2.5 m agitator 2 off 2 off3.0 m agitator 2 off 2 off3.5 m agitator 2 off 1 off 1 off4.0 m agitator 2 off 1 off 1 off4.5 m agitator 2 off 1 off 1 off5.0 m agitator 1 off 1 off 1 off 1 off

Fig. 12


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2.7 Wall opening and constructing the inspection hatch (H)

Wall opening The table of dimensions below details the measurements for positioning the wall opening. The dimensions refer to the standard agitator outfeed system specifications, i.e. outfeed unit + 0.55 m trough and agitator.

Agitator Dimension A Dimension B1.5 m 500 mm 370 mm2.0 m 500 mm 410 mm2.5 m 500 mm 440 mm3.0 m 500 mm 470 mm3.5 m 500 mm 500 mm4.0 m 500 mm 530 mm4.5 m 500 mm 540 mm5.0 m 500 mm 550 mm

Inspection hatch construction The construction of the inspection hatch and the associated wall lining should be carried out as described below and will enable access to the storeroom for the purposes of removing any objects that may be jammed in the auger before the enclosed section of the auger trough. The hatch canopy constructed as per Fig. 7 prevents the stored fuel spilling out when the inspection hatch is opened.

1.) Pack the gap at the sides and below the outfeed auger (A) with mineral wool (B).

2.) Fit the cover plates supplied (C) on the inside and outside.

3.) Fix the top edge of the lining (D) in the wall flush with the cover plates.

4.) Cut a section of mineral wool (E) to size to fit the hatch opening.

5.) Insert the mineral wool (E) between the cover plate (F) and the inspection hatch rear panel (G) as shown in Fig. 14 using the hexagon-head bolts supplied.

6.) Fit the inspection hatch cover (H) and secure with wing nuts.

Fig. 13

Fig. 14

Fig. 15

A

B

C

B

D

E

H

F

G

Wall opening

Width 450 mmHeight 700 mm


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2.8 Connecting the flue (H)

The boiler is connected to the flue by means of a flue connecting pipe which must be gas-tight and insulatedbetween the heating boiler and the flue (insulation thickness 50 mm).

Flue connecting pipe The following diameters should be used:

Powerchip 20/30 dia. = 150 mm


Powercorn 50 Special dia. = 180 mm

Powerchip 75 dia. = 180 mm

Powerchip 100 dia. = 180 mm

Flue connecting pipes longer than 4 m or with more than 3 bends:



Powercorn 50 Special dia. = 200 mm

Powerchip 75 dia. = 220 mm - 250 mm

Powerchip 100 dia. = 220 mm 250 mm

The hole in the wall for connecting the flue pipe must be lined with a built-in double-skinned lining tube or fireproof material. The flue connecting pipe must rise upwards from the boiler to the flue at an angle of at least 6 and be connected with gas-tight joints. An inspection cover must be provided for cleaning the flue connecting pipe.

A → Flue connecting pipe insulation (50 mm)

B → Testing point:distance from boiler3x flue tube diameter

C → Option of fitting in flue pipe forenergy saving draught regulator with pressure-surge compensator(observe local regulations)

D → Flue connecting pipe, min. gradient 6

E → Option of fitting in flue forenergy saving draught regulator with pressure-surge compensator(observe local regulations) Fig. 16

Flue caps and hoods Must be made of non-combustible materials and must not reduce the cross-sectional area of the flue, decrease the flue draught or obstruct the cleaning of the flue. The flue gas should be able to exit vertically from the flue outlet without hindrance. The method of fixing must be capable of withstanding strong gusts of wind.


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2.9 Energy-saving flue draught regulator and pressure-surge compensator (F)

Purpose of the energy-saving flue draught regulator

To ventilate the flue when the system is not in operation

To compensate for pressure surges

To regulate and limit the flue draught

Fitting The energy-saving flue draught regulator must be fitted in accordance with the local regulations either in the flue approx. 0.5 m below the point where the flue connecting pipe joins or in the flue connecting pipe close to its junction with the flue.

Adjusting the flue draught regulator to the required flue draught

Adjusting the flue draught is only of any use at outside temperatures below +5C.

The system must have been in operation for at least an hour.

Ensure there is sufficient demand for heat for the boiler to be run at rated output for at least 15 minutes.

Measure the flue draught between the boiler and the flue draught regulator (distance of measuring point from boiler ideally 3 x flue diameter).

Flue draught The flue draught should not differ by more than +/- 3 pascals from the figure specified in the flue dimensioning data (see Section 1.3.3). If the flue draught cannot be reduced to the required figure, either a larger draught regulator should be fitted or an additional flue baffle fitted between the flue and the draught regulator.

Too much flue draught May cause the flue gas temperature to increase and accelerate combustion as a result. Poor boiler output adjustability, increased dust discharge and malfunctions can result.

Too little flue draught Performance problems, incomplete combustion and malfunctions when operating below rated output can result.

Fitting an energy-saving flue draught regulator/pressure-surge compensator

(Class RE) is absolutely imperative.


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2.10 Plumbing connections (H)

Boiler plumbing connections

Powerchip 30/50 and Powercorn 50 Special

A → Sensor for temp. relief valve, "

B → Temperature-relief heat exchanger

C → Heating return, 1"

D → Boiler sensor, safety temperature limiter (STL)

E → External thermostat, "

F → Heating flow, 1"

Fig. 17

Powerchip 75/100

A → Sensor for temp. relief valve, "

B → Heating flow, 2"

C → Temperature-relief heat exchanger

D → External thermostat, "

E → Drain

F → Heating return, 2"

Fig. 18


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Temperature-relief heat exchanger The maximum permissible operating temperature of the boiler is 110C. In order to prevent the maximum allowable operating temperature being exceeded, connection of a temperature-relief valve (Fig. 19, Fig. 20) conforming to Austrian standard NORM 8131 and DIN 4751 and with a response temperature of 95C is required. The supply pressure must be at least 2 bar but no more than 6 bar.

Powerchip 30/50 and Powercorn 50 Special

A → Cold water supply fortemperature-relief heat exchanger

B → Sensor for temp. relief valve, "

C → Temp. relief valve, 95C

Fig. 19

Powerchip 75/100

A → Cold water supply fortemperature-relief heat exchanger

B → Sensor for temp. relief valve, "

C → Temp. relief valve, 95C

Fig. 20


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Return boost The boiler return temperature must be at least 55C and must be held at the required level by a bypass pump between the boiler flow and return pipes. If a thermal store is connected, the boiler return temperature must similarly be at least 55 C, which must be ensured by a return boost (cross-over valve) set as shown in the plumbing diagram. If this requirement is not complied with, there is an increased risk of corrosion and guarantee entitlement will be lost as a result. Connect the return boost set precisely as specified in our plumbing diagrams.

Important → The dimensioning of the return boost pump (set) is designed for the arrangements shown in GUNTAMATIC plumbing diagrams. If additional components such as heat meters are incorporated in the system plumbing, or if the overall thermal store pipe run (flow and return) is more than 30 m, re-dimensioning of the boiler charging pump (HP0) may be necessary.

Thermal store A thermal store is not absolutely essential as the boiler is operated by a modulating control system and the system can be quickly shut down. However, if the required continuous heat output in the summer months, and specifically in systems that incorporate a solar panel system, is below 10 kW for 30 kW systems, 15 kW for 50 kW systems or 22 kW for 75 or 100 kW systems, combination with a thermal store is necessary for reasons of efficiency.

Expansion vessel The boiler operates in a sealed heating system and must be provided with an expansion vessel for pressure compensation. To calculate the expansion volume, the volume of the system when cold must be known. Please select the expansion vessel on the basis of the manufacturer's specifications. The expansion volume of the system is calculated as follows:

System volume x Expansion factor x Additional allowance factor Expansion factor for wood-fuel boilers = 0.03

Additional allowance factor = 3.0 for systems under 30 kW Additional allowance factor = 2.0 for 30-150 kW systems Additional allowance factor = 1.5 for systems over 150 kW

Example calculation: 1500 litres x 0.03 x 3 = 135 litres

Plastic piping If plastic piping for underfloor heating or district heating pipes are connected, they must be protected against excessive temperatures by using a limiting thermostat for the circulation pumps.

Pump selection The choice of pump must be made by the installer or building technology planner on the basis of the friction data, the pipe cross-sectional area and the required delivery pressure for the piping system planned.


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2.11 Filling and bleeding the system (H)The system is filled with water from the domestic supply. Please note the guidelines on "Corrosion and boiler protection in heating and domestic water systems".

Water quality The requirements are as follows:

Overall hardness→ < 1 fH

pH level → max. 8.3 - 9.0

Oxygen → < 0.1 mg/l

Water heater If a water heater is also used in addition to the GUNTAMATIC boiler, it should be filled according to the installation instructions for it.

Filling the system Proceed as follows when filling the system:

Match the pressure of the system when cold to the air charge pressure of the expansion vessel

Check the operating pressure on the pressure gauge

Bleeding the system Proceed as follows when bleeding the system:

Switch off and bleed circulation pumps.

Bleed boiler by opening the bleed valve in the boiler flow pipe and allowing air to escape until water runs out.

Bleed radiator heating system (if present) by opening the bleed valve on every radiator and allowing air to escape until water runs out.

Bleed underfloor heating system (if present) by opening each heating circuit and flushing through thoroughly until there are no more air bubbles in the heating circuit pipes.

Important: perform sequence in the correct order!

Start bleeding in the cellar or on the ground floor and finish in the attic.

Check the system operating pressure on the pressure gauge and add more water if necessary.

Restart circulation pumps.

Only systems that have been properly bled guarantee effective conveyance of heat.


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2.12 Boiler electrical connections

Electrical wiring diagram See Section 5

Mains power supply 400V, 50Hz, 13A fuse

Required connections on site

Power supply, 5-core (3L/N/PE)

Power surge conductor (lightning conductor recommended)

Phase sequence detector relay (recommended for backup power supply)

Emergency off switch

Standard boiler specifications

1 Boiler control panel

1 Router module excluding heating circuits (400V AC)

1 Boiler circuit board excluding heating circuits (230V AC)

1 Fault signal output on boiler PCB (24V AC)

1 Safety temperature limiter

1 Boiler sensor (KVT20 Ω)

1 Stoker sensor (PT1000 Ω)

1 RGT sensor (non-replaceable resistor Ω)

1 Oxygen sensor (12V DC)

1 Fire safety flap (24V DC)

1 Flue draught fan (230V AC)

1 Grate cleaner motor (230V AC)

1 Stoker drive motor G1 (400V AC)

1 Outfeed drive motor A1 (400 VAC)

1 Outfeed drive motor A2 (400 VAC) for feeder auger

1 Ignition fan (230V AC)

1 TKS 1 firebox door switch (230V AC)

1 TKS 2 outfeed monitor switch (230V AC)

1 TKS fill level switch (firebox monitor)

1 Boiler enabling switch (emergency off)

1 Boiler charging pump output HP0 (230V AC)


22

Optional outside-temperature based heating circuit controller

The outside-temperature based heating circuit controller set MK261 is offered as an option and is installed as a compact wall controller connected via CAN bus. Operation and configuration is via the boiler control panel.

Wall controller set MK261 The wall controller set MK261 can be used to control a DHW cylinder, a pumped heating circuit, 2 mixed heating circuits, one supplementary function (HWP or EXTERNAL) and a district heating pipe. If the supplementary and district heating functions are not used, heating circuit 0 can be operated as a mixed circuit.

Maximum configuration Max. 3 MK261 wall controller sets per heating system

1 Outside sensor with housing (KVT20 Ω) per heating system

Max. 2 DHW cylinder sensors per wall controller (KVT20 Ω)

2 thermal store sensors per thermal store installed (KVT20 Ω)

Max. 3 flow temperature sensors per wall controller (KVT20 Ω)

Max. 3 mixer valve motors per wall controller

Max. 1 RFF analogue room stat per heating circuit

Max. 3 RS digital room controllers per heating system

Resistances for KVT20 and PT1000

Temperature in C KVT20 in kΩ Temperature

in C PT1000 in kΩ

-20C 1.383 -10C 0.961-16C 1.434 0C 1.000-8C 1.537 10C 1.039-4C 1.590 20C 1.0780C 1.644 30C 1.117

10C 1.783 40C 1.15520C 1.928 50C 1.19430C 2.078 60C 1.23240C 2.234 70C 1.27150C 2.395 80C 1.30960C 2.563 100C 1.38570C 2.735 125C 1.48080C 2.914 150C 1.573

Optional automatic ash extraction system

3-core supply (230VAC)

1 TKS ash bin cover switch

1 Ash bin temperature sensor (PT1000 Ω)


23

7 0 1NEP 00 1 1 0 1 40 1E P2 0 1 3 0 1N NEP 5 01 6 0 1

DAQ

EP9 0 1NE P 8 01 0 1 1 1 1 1N 2 1 1 3 1 1

12

81

301

29

127

PE

12

5P

E1

26

E P4 1 1E PN N 5 11

118

11

912

01

21

12

2P

E1

241

23

117

116

CAN - BCES H+L HS H - +L H-

HKR 0 230VAC

TPM 400VAC

BCE

HKR 1 230VAC

S H L-

CAN - BCEHS HH + - L + S H

HKR 2 230VAC

S H - L +H

CAN - BCEL- +H

CAN - Bus CAN - Bus CAN - Bus

RG 2

RG 1

RG 0

CAN - BCEHS H - L +

RS (HKR 0)

CA

N -

Bus

RG 4

RG 5

RG 3

-

CA

N -

Bu s

HS H L +

RS (HKR 1)

CAN - BCE RG 7

RG 8

RG 6

-

CA

N -

Bus

HS H L +

CAN - BCE

RS (HKR 2)

CA

N -

Bus

CA

N -

Bus

2.13 Wiring requirements for the system

Important Low-power leads and CAN bus connecting cables must not be routed along a shared conduit with the mains power!

Sensor 2 x 1mm

Analogue room stat RFF 2 x 1mm

Digital room controller RS 2 x 2 x 0.5 mm twisted pair, shielded

CAN bus connecting cable 2 x 2 x 0.5 mm twisted pair, shielded

Key:TPM → Router module (400VAC)BCE → Display and control unitHKR → Heating circuit controller (230V AC)RG → Analogue room statRS → Digital room controller

Important Whenever possible, always wire the CAN bus "in line", i.e. from the display and control unit to heating circuit controller 0 then from there to heating circuit controller 1, and so on. If wired in a star pattern, the overall length of the CAN bus must not exceed 100 metres. Wire the CAN bus +/- and H/L connections with twisted-pair cable in each case.


24

2.14 Electrical connections (E)The electrical connections to the boiler system on site may only be made by an approved electrical installer observing all the applicable regulations. In addition, it is essential that electrical system components are protected against damage from heat radiation.

All boiler system internal wiring is wired up at the factory ready for use. The work required on site by the electrical installer consists only of connecting the mains power and wiring up and connecting the system components such as thermal store, CAN bus, heating circuit pumps, mixer valve motors, etc.

Mains power supply A three-phase power supply is required (400V, 50Hz, 13A fuse). The mains power must be connected by means of the standard non-reversible power socket on the rear panel of the boiler. It must possible to isolate the system entirely from the mains without opening the switch panel cover.

Opening switch panel Before the switch panel is opened, the mains lead must be unplugged from the socket on the rear panel of the boiler. The system must not be live.

Undo switch panel securing screw

Lift up front right plastic panel section slightly, pull forwards at the bottom and unclip at the top.

The circuit boards with the associated connectors and fuses (see electrical wiring diagram) are located underneath it in an easily accessible position.

The appropriate cable ducts must be used when connecting electrical leads.

Feeder auger By using an additional transfer unit and a feeder auger, extended functionality can be achieved. Connection is to the router module as per the wiring diagram (feeder auger motor A2 and feeder auger overfill cover monitor TKS 3).

Boiler cascade system If multiple boilers (max. 4) are operated in a cascade system (sequential boiler system), all systems must be connected in line by means of a CAN bus. The CAN bus must be wired without connecting the + terminal.

Wall controller set MK261 The wall controller set MK261 must be connected to the power supply at terminal H35 and connected to the boiler or another wall controller via the CAN bus.


25

External burner request With wall controller set MK261, the supplementary output (terminal H25) can be used to request heat from an external boiler. The load on the output must not exceed 230V and 2.0A. With this configuration option, it is not possible to operate three mixed heating circuits. The district heating pipe function is available, however.

Connecting 2 DHW cylinders With wall controller set MK261, the supplementary output (terminal H25) can be used to run an additional DHW cylinder. With this configuration option, it is not possible to operatethree mixed heating circuits. The district heating pipe function is available, however.

3 mixed heating circuits With wall controller set MK261, the supplementary output (terminal H25) and the district heating pipe output (terminal H26) can be used to control heating circuit 0 using a mixer valve motor. The associated heating circuit pump is connected to terminal H33 (HKP 0). With this configuration option, the district heating pipe and supplementary functions are notavailable.

Analogue room stat The room stat should be connected to the MK261 wall controller set at terminals 1 and 2 (see electrical wiring diagram).

Digital room controller The room controller must be connected to the boiler or wall controller set MK 261 via CAN bus.

Emergency off switch According to prTRVB H 118, it must be possible to switch off the system using an emergency off switch fitted outside the boiler room near to the boiler room door. The burner must then shut down but the heating controller and all safety equipment must remain functional. Connected to the boiler enabling switch, terminals 22/23 on the boiler circuit board (see electrical wiring diagram).

Important → Repair work on the system must only be carried out when the system has been isolated completely from the power supply.

Automatic ash extraction system This is connected according to the installation and operating instructions supplied with the automatic ash extraction system.

Surge protection We recommend the installation of a power surge protector in the building's consumer unit.

Backup power supply On systems supplied by a backup power generator, a phase sequence detector relay should be fitted. Only use regulated electricity generators.

Earthing The entire system is to be joined to the earth circuit conductor via the connected piping system according to the regulations.


26

2.15 Final check (E, H) After completing installation of the system, check

again that all joints and pipes are properly tightened and not leaking.

Check that all covers are fitted and secured.

Check that the fitting of all connections (water, flue, electrical, ...) has been done correctly and then check that the conveying system is free of foreign objects.

Check that all required safety signs and instructions are attached and hand over all documentation (operating and installation instructions) for the system.

Check that all electrical connections have been properly wired before connecting the system to the power supply.

Clean the system and clear up the installation site.

Always leave the boiler room clean.

2.16 Commissioning (H)Commissioning must only be carried out by GUNTAMATIC or a qualified specialist. The precondition is that the flue technician, heating installer and electrician have cleared the system for operation. The authorised GUNTAMATIC specialist will carry out the following work during commissioning:

Check the entire system

Check the electrical functions

Adjust the programmer to the system

Commission the boiler

Explain to the user how the system functions and how to operate and clean it

Record the details of the customer and the system and complete the commissioning log

Important Any deficiencies identified must be recorded in writing and rectified within the following 4 weeks in order to maintain guarantee entitlement.

The fully completed commissioning checklist must be sent to GUNTAMATIC immediately as otherwise the

guarantee will be void.

Important These installation instructions should not be destroyed after commissioning but kept permanently with the system together with the operating instructions.


27

3 Standards and regulations

The boiler is designed as a Class 3 appliance as defined by the draft standard NORM EN 303-5 (CEN/TC7/WG 1 – Doc. N 36-D) of 15/12/1996 and the agreement of the [Austrian] Federal States according to Art. 15a BVG, in accordance with the Austrian fire safety regulations, safety systems, CE and on safety measures for small combustion heating systems and the combustion heating system approval regulations (LGB.33/1992) of the Austrian Federal State of Steiermark. The original design type approval certificates (BLT Wieselburg, IBS Linz) are available for inspection at the manufacturer's offices.

Austria NORM M 7550 Central heating boilers up to 100C – Terms,

requirements, tests, standard identification NORM M 7510 Part 1: Guidelines for the inspection of central

heating systems NORM M 7510 Part 2: Guidelines for the inspection of central

heating systems, guide figures NORM B 8130 Safety systems NORM B 8131 Sealed water-circulation heating systems, safety

requirements NORM B 8133 Safety requirements, domestic hot water systems NORM H 5195-1 Assessment and suitability of the heating water

(minimum requirements for the heating water) prTRVB H 118 Technical regulations, preventative fire safety for

automatic wood-burning systems HEATING OUTPUT: The heating output is to be selected (set) by the

engineer in accordance with the local heating system regulations so that the rated heat output does not exceed the heat requirement determined according to DIN 4701 or NORM M7500.

Germany DIN 4751-1 / Safety systems for heating systems with flow

temperatures up to 110C (120C in course of preparation) DIN 4751-2 / Water-circulation heating systems – sealed heating

systems with thermostatic safety systems and flow temperatures up to 120C – safety systems

DIN 4751-4 / Safety systems for domestic hot water systems with flow temperatures up to 120C; sealed water-circulation heating systems with static heads over 15 m or rated heat outputs over 350 kW

DIN 1988 Mains water piping systems on building plots, technical regulations for construction and operation

Switzerland Swiss Clean Air Regulations (LRV) Swiss Regulations on Small Combustion Heating Systems VKF Fire Safety Directive for Heating Systems SIA 384

United Kingdom BSEN 303-5 UK Building Regulations 2000 (Parts B, J, L,P)

Other standards and regulations may be applicable in other countries and must be complied with.


28

4 Plumbing diagrams

4.1 Powerchip 20/50

Diagram no.: PH-01-1 Outside temp. based controller, DHW cylinder ECO305

Diagram no.: PH-01-2 Outside temp. based controller, 2 ECO305 DHW cylinders

Diagram no.: PH-02-1 Outside temp. based controller, thermal store PSB, integrated solar panel system

Diagram no.: PH-03-1 Outside temp. based controller, DHW cylinder ECO305, thermal store PS

Diagram no.: PH-04-1 Outside temp. based controller, thermal store PSB

Diagram no.: PH-05-1 Outside temp. based controller, DHW cylinder ECO305, district heating pipe

Diagram no.: PH-06-1 Outside temp. based controller, DHW cylinder ECO305, thermal store PS, district heating pipe

4.2 Powerchip 75/100

Diagram no.: PH-07-1 Outside temp. based controller, DHW cylinder ECO305, thermal store PS

Diagram no.: PH-08-1 Outside temp. based controller, thermal store PSB, connected solar panel system

Diagram no.: PH-09-1 Outside temp. based controller, thermal store PSB

Diagram no.: PH-10-1 Outside temp. based controller, DHW cylinder ECO305

Diagram no.: PH-11-1 Outside temp. based controller, DHW cylinder ECO305, district heating pipe

Diagram no.: PH-12-1 Outside temp. based controller, DHW cylinder ECO305, thermal store PS, district heating pipe

4.3 Supplying multiple properties

Diagram no.: PH-13-1 District heating pipe supply via charging pump (LAP) for max. 3 properties

Diagram no.: PH-14-1 District heating pipe supply via feeder pump (ZUP) for max. 3 properties

Diagram no.: PH-15-1 District heating pipe supply via thermal store pump (PUP) for max. 3 properties

4.4 Boiler cascade system with sequential boiler control

Diagram no.: PH-16-1 Boiler cascade system with sequential boiler control for max. 4 boilers

Setting on HP0 menu: → HP0 mode = Feeder pump Heat from biomass 29

Diagram no. PH-01-1Electrical connections as per operating and installation instructions

With wall controller set MK261, the supplementary output (terminal H25) and the district heating pipe output (terminal H26) can be used to control heating circuit 0 using a mixer valve motor. The heating circuit pump is connected to output HKP 0 (terminal H33) and flow temperature sensor 0 to terminal H21/H22. With this configuration option, the district heating pipe and supplementary functions are not available.

Plumbing diagram for Powerchip 20/50Outside-temperature based controller, ECO DHW cylinder1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits

GUNTAMATIC components1. Powerchip woodchip system2. Flue draught regulator RE15 with pressure surge

compensator Art. no.: H38-1553. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Branch control valve Not supplied9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Flow temp. sensor VF20 (VF0 for HK 0) Art. no.: S70-002

UK Agent:TRECO LtdTel. 0845 [email protected]

www.treco.co.uk

Settings on HP0 parameters menu: → HP0 mode = Feeder pump Heat from biomass 30


With wall controller set MK 261, the supplementary output (terminal H25) can be used to run an additional DHW cylinder. Connect supplementary cylinder sensor to terminals H15/H16. With this configuration option, it is not possible to operate three mixed heating circuits. The district heating pipe function is available, however.

Heating circuit 0 can be used with a fixed-setting controller for a low-temperature heating system or can be room-temperature controlled using an RFF 25 room stat for a radiator heating system.

Plumbing diagram for Powerchip 20/50Outside-temperature based controller, 2 ECO DHW cylinders1 Wall controller set MK 261 (HKR 0) → 2 DHW cylinders, 1 pumped heating circuit, 2 mixed heating circuits


compensator Art. no.: H38-1553. Outside temp. based wall controller set MK 261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Branch control valve Not supplied9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Cylinder sensor (ZSF 0) Art. no.: S70-00311. Flow temp. sensor VF20 (VF0 for HK 0)12. Flow temp. sensor VF20 (VF0 for HK 0) Art. no.: S70-002


www.treco.co.uk

Settings on HP0 parameters menu: → HP0 mode = Thermal store pump HP0 sensor = HCC 0 Heat from biomass 31



Plumbing diagram for Powerchip 20/50Outside-temperature based controller, thermal store PSB, connected solar panel system1 Wall controller set MK 261 (HKR 0) → 1 DHW cylinder in thermal store, 3 mixed heating circuits


compensator Art. no.: H38-1553. Outside temp. based wall controller set MK 261 Art. no.: S30-0304. Thermal store PSB As price list

Order 1 special sleeve, ", for sensor T2 As price listOrder thermal store lower heat exchanger flange As price list

5. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Return boost set RA60 Art. no.: H39-001

Alternatively: RA60 EnergieA Art. no.: H39-0039. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Ridged pipe heat exchanger for solar panel integration As price list11. 2 Thermal store sensors Art. no.: S70-00312. Flow temp. sensor VF20 (VF0 for HK 0) Art. no.: S70-002


www.treco.co.uk




Plumbing diagram for Powerchip 20/50Outside-temperature based controller, ECO DHW cylinder, PS thermal store1 Wall controller set MK 261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits


compensator Art. no.: H38-1553. Outside temp. based wall controller set MK 261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Return boost set RA60 Art. no.: H39-001

Alternatively: RA60 EnergieA Art. no.: H39-0039. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Thermal store PSB As price list11. 2 Thermal store sensors Art. no.: S70-003


www.treco.co.uk




Flue gas monitor (RGT) connected to terminals 22/23 (boiler enabling switch on boiler circuit board)

Single thermostat (ETH 100) closes above 65C

Plumbing diagram for Powerchip 20/50 with solid fuel boilerOutside-temperature based controller, thermal store PSB1 Wall controller set MK 261 (HKR 0) → 1 DHW cylinder in thermal store, 3 mixed heating circuits


compensator Art. no.: H38-1553. Outside temp. based wall controller set MK 261 Art. no.: S30-0304. Thermal store PSB As price list5. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Return boost set RA60 Art. no.: H39-001

Alternatively: RA60 EnergieA Art. no.: H39-0039. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Solid-fuel boiler As price list11. 2 Thermal store sensors Art. no.: S70-00312. Flue gas monitor (RGT), switching point 88C Art. no.: H00-80113. Single thermostat (ETH 100) Art. no.: S40-11014. Flow temp. sensor VF20 (VF0 for HK 0) Art. no.: S70-002


www.treco.co.uk



With wall controller set MK261, the supplementary output (terminal H25) and the district heating pipe output (terminal H26) can be used to control heating circuit 0 using a mixer valve motor. The heating circuit pump is connected to output HKP 0 (terminal H33) and flow temperature sensor 0 to terminal H21/H22. With this configuration option, the district heating pipe and supplementary functions are not available. With this configuration, the district heating pipe is supplied via the return boost set.

Plumbing diagram for Powerchip 20/50 with district heating pipeOutside-temperature based controller, ECO DHW cylinder1 Wall controller set MK 261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits


compensator Art. no.: H38-1553. Outside temp. based wall controller set MK 261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Return boost set RA60 Art. no.: H39-001

Alternatively: RA60 EnergieA Art. no.: H39-0039. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Flow equaliser Not supplied11. District heating pipe Not supplied


www.treco.co.uk




Plumbing diagram for Powerchip 20/50 with district heating pipeOutside-temperature based controller, ECO DHW cylinder, PS thermal store1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits


compensator Art. no.: H38-1553. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Return boost set RA60 Art. no.: H39-001

Alternatively: RA60 EnergieA Art. no.: H39-0039. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Thermal store PSB As price list11. District heating pipe Not supplied12. Thermal store sensor Art. no.: S70-003


www.treco.co.uk




Plumbing diagram for Powerchip 75/100Outside-temperature based controller, ECO DHW cylinder, PS thermal store1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits


compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation for 30m 1" thermal store piping (flow and return)

Grundfos UPS 32-100 or Wilo S30/10 Not suppliedin conjunction with thermostatic valve, 55C 2" Art. no.: H39-

204Alternatively: RA100 EnergieA Art. no.: H39-010

9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Thermal store PSB As price list


www.treco.co.uk




Plumbing diagram for Powerchip 75/100Outside-temperature based controller, thermal store PSB, connected solar panel system1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder in thermal store, 3 mixed heating circuits


compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. Thermal store PSB As price list

Order 1 special sleeve, ", for sensor T2 As price listOrder thermal store lower heat exchanger flange As price list

5. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation for 30m 1" thermal store piping (flow and return)

Grundfos UPS 32-100 or Wilo S30/10 Not suppliedin conjunction with thermostatic valve, 55C 2" Art. no.: H39-204Alternatively: RA100 EnergieA Art. no.: H39-010

9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Ridged pipe heat exchanger As price list11. 2 Thermal store sensors Art. no.: S70-003


www.treco.co.uk




Plumbing diagram for Powerchip 75/100Outside-temperature based controller, thermal store PSB1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder in thermal store, 3 mixed heating circuits


compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. Thermal store PSB As price list5. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation for 30m 1" thermal store piping (flow and return)


9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. 2 Thermal store sensors Art. no.: S70-003


www.treco.co.uk




Plumbing diagram for Powerchip 75/100Outside-temperature based controller, ECO DHW cylinder1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits



Grundfos UPS 32-100 or Wilo S30/10 Not supplied9. Fault indicator lamp Important: follow wiring diagram! Not supplied


www.treco.co.uk




Plumbing diagram for Powerchip 75/100 with district heating pipeOutside-temperature based controller, ECO DHW cylinder1 Wall controller set MK 261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits


compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Mixer valve positioner motor SM70 Art. no.: S50-5016. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation for 30m 1" overall piping (flow and return)


9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Flow equaliser Not supplied11. District heating pipe Not supplied


www.treco.co.uk




Plumbing diagram for Powerchip 75/100 with district heating pipeOutside-temperature based controller, ECO DHW cylinder, PS thermal store1 Wall controller set MK261 (HKR 0) → 1 DHW cylinder, 3 mixed heating circuits




9. Fault indicator lamp Important: follow wiring diagram! Not supplied10. Thermal store PSB As price list11. District heating pipe Not supplied


www.treco.co.uk

Settings on HP0 parameters menu: → HP0 mode = Thermal store pump Heat from biomass 42


Plumbing diagram for district heating pipe supply via charging pump (LAP) for max. 3 propertiesPOWERCHIP, POWERCORN or BIOCOM 75/100 kW boilerFor each property, one wall controller set MK261 → max. 1 thermal store, 1 pump circuit, 2 mixed circuits and 2 DHW cylinders per property

GUNTAMATIC components1. Powerchip, Powercorn or Biocom 75/100 kW2. Flue draught regulator RE20 with pressure surge

compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Thermal store PSB As price list6. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation: Grundfos UPS 32-100

or Wilo Top-S30/10 Not suppliedin conjunction with thermostatic valve, 55C 2" Art. no.: H39-204Alternatively: RA100 EnergieA Art. no.: H39-010

9. Dimension charging pumps according to length of piping run e.g. Grundfos UPS 32-60 or Wilo 30/7 Not supplied

10. Fault indicator lamp Important: follow wiring diagram! Not supplied11. Mixer valve positioner motor SM70 Art. no.: S50-50112. Thermal store PS 2000/2 As price list13. District heating pipe Not supplied

max. 3 MK261 wall controller sets possible (HKR0, HKR1, HKR2)max. 3 RS100 room controllers possibleone RFF25 room stat per heating circuit possibleAlways connect outside sensor (AF) to HKR 0


www.treco.co.uk

Settings on HP0 parameters menu: → HP0 mode = Thermal store pump Heat from biomass 43


Plumbing diagram for district heating pipe supply via feeder pump (ZUP) for max. 3 propertiesPOWERCHIP, POWERCORN or BIOCOM 75/100 kW boilerFor each property, one wall controller set MK261 → max. 1 pump circuit, 2 mixed heating circuits and 2 DHW cylinders per property


compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Flow equaliser according to required output Not supplied6. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation: Grundfos UPS 32-100


9. Dimension feeder pumps according to length of piping run e.g. Grundfos UPS 32-60 or Wilo 30/7 Not supplied

10. Fault indicator lamp Important: follow wiring diagram! Not supplied11. Mixer valve positioner motor SM70 Art. no.: S50-50112. Thermal store PS 2000/2 As price list13. District heating pipe Not supplied



www.treco.co.uk

Setting on HP0 parameters menu: → HP0 mode = Feeder pump Heat from biomass 44


Plumbing diagram for district heating pipe supply via thermal store pump (PUP) for max. 3 propertiesPOWERCHIP, POWERCORN or BIOCOM 75/100 kW boilerFor each property, one wall controller set MK261 → max. 1 thermal store, 1 pump circuit, 2 mixed circuits and 2 DHW cylinders per property


compensator Art. no.: H38-1603. Outside temp. based wall controller set MK261 Art. no.: S30-0304. DHW cylinder ECO305 Art. no.: 048-5005. Thermal store PSB As price list6. Room stat RFF25 Art. no.: S70-0067. GSM module Art. no.: S15-0028. Recommendation: Grundfos UPS 32-100


9. Dimension pumps according to length of piping run e.g. Grundfos UPS 32-60 or Wilo 30/7 Not supplied

10. Fault indicator lamp Important: follow wiring diagram! Not supplied11. Mixer valve positioner motor SM70 Art. no.: S50-50112. District heating pipe Not supplied13. Flow equaliser Not supplied



www.treco.co.uk

Set output HP0 to thermal store pump for each system Heat from biomass 45


Plumbing diagram for boiler cascade system with sequential boiler controlPOWERCHIP, POWERCORN or BIOCOM boilerFor maximum of 4 boilers


compensator Art. no.: H38-1603. GSM module Art. no.: S15-0024. Recommendation: Grundfos UPS 32-100


5. Thermal store PS 2000/2 As price list6. Thermal store sensor Art. no.: S70-003

2 thermal store sensors required for each boilerConnect all boilers via CAN busmax. 3 MK261 wall controller sets per system possible (HKR0, HKR1, HKR2)max. 3 RS100 room controllers per system possibleone RFF25 room stat per heating circuit possibleAlways connect outside sensor (AF) to heating circuit controller 0 (HKR 0)

Important: The CAN bus must be wired without connecting the + terminal.Note: Only one boiler can be controlled/queried remotely via the GSM

module. However, faults are forwarded to the GSM module via the CAN bus.

Heating circuit installation:Diagram PH-13-1with charging pump (LAP)and thermal store

Diagram PH-14-1with feeder pump (ZUP) and without thermal store


www.treco.co.uk


46

TPM 400V

81 F

N O

FF O

7 1 F

1531 5 4

41 F

6 1 F 5 1 F

2 1 F

3 1 F

1 4 91511 5 2 1 5 0 1 4 51471 4 8 146

0 1 F

11 F

CAN-Bus (HKR, RS100)

7 0 1NE P 00 1 10 1 4 0 1E P2 0 1 3 0 1N NE P 5 0 1 6 0 1

NPE

L

Sic

he

rhei

tske

tte

G1

GSM

E P90 1NEP 80 1 0 1 1

A1

1 11N 2 1 1 31 1

1361401411431 4 4 1 4 2 1 3 8 1 3 7139

13

4N

13

5P

E1

2813

01

31

12

912

7P

E1

25

PE

12

6

E P

Re

lais

4 1 1E PN N

Re

lais

F2

0F

19

51 1

118

119

12

012

11

22P

E1

24

123

11

71

16

Pow

er I/

0

STB

116

- 127

Sta

ndar

d

KP -

I/O

SY-Bus

Net

z 40

0V 1

3A

BCE

A2N

etz

230V

TKS 3(230V)

Netz 230V

CAN

-Bus

(Bedien- u. Kontrolleinheit)

(Transportmodul 400V)

PE

N L1 L2 L3

(400

V)

(400

V)

(400

V)

GSM

5 Electrical wiring diagram (only use flexible cable and core sleeving for wiring)

5.1 Control panel and 400V router moduleKey:BCE = Display and control unitGSM = Remote control via mobile phoneSTB = Safety temperature limiterPower I/0 = Mains power switch (system On/Off)TPM 400V = 400V router module circuit boardNetz 400V 13A = 400V 13A power supply connectionNetz 230V = Boiler circuit board power supplyCAN-BUS = Cable connection betw. BCE and wall controller set MK261 or room controller RS100SY-BUS = Cable connection betw. BCE and boiler circuit boardHKR = Outside-temperature based heating circuit controllerRS100 = Digital room controllerG1 = Drive motor, 400V (stoker drive motor)A1 = Drive motor, 400V (fuel auger A1)A2 = Drive motor, 400V (feeder auger A2)TKS3 = Overfill cover monitor, feeder auger A2

DIP switchDefault setting:Both "OFF"

CAN MODULE addressDefault setting:Position "0"


47

RE

I

HP

0

+ (b

lack

)

M 1~

LINE

LOAD

SG

ZG

NF

N4

PEN

76

8P

EN

59

PE

PE

97

68

PE

N5

NPEL

N4

PEN

PE

N2

3P

E1

M 1~

PE

N2

3P

E1

66 4656

66

(whi

te)

(whi

te)

- (gr

ey)

4656

Lam

bda

BC

E

N

N

13

13

N

N

10

10

PE

PE

12

12

11

11

PE

PE

M 1~

N

N

PE

PE

14

14

15

15

N

N PE

PE

45

45

95162636 06 7585 5565

95

1 (6

-pol

)

16

3 (6

-pol

)

2636

2 (w

hite

)

06

BS

K

1 (b

lack

)

7585 5565M

24V=

2535 15 MK

R

2535 15

32

PE

17

17

16

16

19

19

18

18

M 1~

PE

PE

20

20

21

21

N

N

23

23

N

NPE

PE

PE

22

22

B

2724

PE

25PE

2628

2930

31

PE

64

64

Hal

l A1

849405 74

Stecker

(yel

low

/gre

en)

2 (b

lack

)

849405 74

(bla

ck)

N(g

reen

)

144454 2434

3533

3436

3837

9304

RG

T+

(gre

en)

14

1 (b

lack

) VC

C

4454

(whi

te)

-

2434

FZ

(red

)L1

9304

T1

32

2724

PE

25P

E26

2829

30

31

T2

TKS 1

TKS 2

3533

3436

3837

T3

STF

BCE

- TPM

400

V

(230V)

(230V)

(12V

) (24V

)

SY-Bus

Netz 230V

KP - I/O

L

Kesselplatine - I/O

(230V)

(230V)

(24V

~ 20

0 m

A)

SM

A

(230

V)

KFR

(230

V)

B

(230

V)

5.2 Boiler circuit board (only use flexible cable and core sleeving for wiring)

Key:KP-I/0 = Boiler circuit boardSY-BUS = Cable connection betw. BCE and boiler circuit boardNetz 230V = Boiler circuit board power supplyLambda = Flue gas monitorBSK = Fire safety flapSMA = Fault indicator outputHall 1 = Grate cleaner motor monitorFZ = Fill level switch (fire box monitor)RGT = Non-replaceable flue gas temperature sensorT1 = Boiler temperature sensor inputT2 = Thermal store sensor inputT3 = Thermal store top sensor inputSTF = Stoker sensor input (stoker temperature monitor)TKS1 = Door switch (firebox door and ash box monitor)TKS2 = Cover switch (overfill cover monitor, feeder auger A1)BÅ = If unused jumper is standardKFR = Boiler enabling switch (emergency off)HP0 = Programmable output: thermal store pump or feeder pumpREI = Drive motor for stepped grate and grate cleaningSG = Flue draught fanZG = Ignition fanNF = Mains filter

Fuse assignment for boiler circuit boardF1 T 3.15A Oxygen sensor, BSK

F2 T 0.63A Power supply for electronics upline of mains transformer

F3 T 10A STB, ZG, REI, HP0

F4 T 2A STB, KFR, TKS1

F5 T 4A Line fuse: SG

F6 T 4A Line fuse: not used


48

1

1

2

2

12RG 0 (3, 6)

RG 2 (5, 8)

RG 1 (4, 7)

VF 2 (5, 8)

VF 1 (4, 7)

SF 0 (1, 2)

CAN - BCE

H2

H1

SH+L HSH -

H6

H4

H3

H5

H8

H7

H10

H9

OFF

ON

21

+L H-

(Wandgert Set MK261)

H32

H12

H11

H14

H13

H27 H29H28 PEN NPE PE NH31N H30PE NH33 H34 PENPE PEH35 N

AUF

AUF

ZU

M1~M1~ M1~M1~

HKP

2 (5, 8)

MI 1 (4, 7)

MI 2 (5, 8)

HK

P 1 (4, 7)

(230V)

(230V)

(230V)

(230V)

(230V)Netz

ZU

PEL N

M1~ M1~

HKP 0 (3, 6)

(230V)

(2 30V)S

LP 0 ( 1,2)

AF

CAN-Bus

(RS10

0)

CAN-Bus(HKR)(BCE)

CAN-Bus

HKR 0 (1, 2)H19

H17

H18

H15

H16

H20

T3

T2

ZSF 0 (1, 2)

H22

H21

VF 0 (3, 6)

H39 H38

SMA

(9,2

V= 2

0 m

A)

PE

H36

H37

(230V)FFR

FL 0 (1, 2)(230V)

ZU 0 (1, 2)

(230V)

M1~

PE

M1~

NPEH25 H26 N

MI 0 (3, 6)

(230V)

PEH25

M1~

H26N NPE

AUF

ZUB

5.3 Wall controller set MK261 (only use flexible cable and core sleeving for wiring)

Key:CAN-BUS = Cable connection betw. BCE, wall controller set MK261 and room controller RS100Netz 230V = Wall controller power supplyHKR 0 (1, 2) = Wall controller set MK261BCE = Display and control unitRS100 = Digital room controllerRG 0 (1, 2) = Analogue room stat inputAF = Outside sensor inputVF 0 (1, 2) = Flow temperature sensor inputSF = Cylinder sensor inputZSF = Supplementary cylinder sensor inputT2 = Thermal store sensor inputT3 = Thermal store top sensor inputSMA = Fault indicator outputFFR = District heating pipe enabling switchBÅ = If unused jumper is standardSLP 0 (1, 2) = Cylinder charging pump outputHKP 0 (1, 2) = Heating circuit pump outputMI 0 (1, 2) = Mixer valve motor outputFL 0 (1, 2) = Output for district heating pipe pumpZU 0 (1, 2) = Output usable for ext. burner or DHW cylinder (see Section 2.14 Electrical connections)FL+ZU = Programmable as third mixed heating circuit on wall controller (see Section 2.14 Electrical

connections)

Standard setting for S1:both DIP switches "ON"

Caution:Change to S2 setting only effective after switching mains power OFF and ON

Mixer valve alternative 0 (3, 6):only possible if district heating pipe 0 (1, 2) andsupplementary function 0 (1, 2) are not

Function of LEDsController on, CAN bus cable correctly connected:

LED → H5 (green) should light upLED → H6, H7 (orange) should flash

Mains power and fuse F1 are OK

LED → H1, H4 (green) should light upLED → H2, H3 (green) should flash

Fuse assignment for wall controllerF1 T 0.63A Power supply for electronics

F2 T 6.30A HKP 0, HKP 1, HKP 2, MI 0, MI 1, MI 2, SLP 0, FL 0, ZU 0

Terminal assignment on RFF25Connect contacts 1 and 2


49

6 Technical data6.1 Powerchip 20/30 and 40/50

Type POWERCHIP 20/30 POWERCHIP 40/50

Fuel

Woodchips G30Pellets 6mm

Grain fuel (supplementary equipment reqd.)



NORM M7133NORM M7135NORM M7139

Boiler outputWoodchips 7-30

Pellets 7-30Grain fuel 7-25

Woodchips 7-30Pellets 7-30

Grain fuel 7-25

kWkWkW

Required flue draughtBoiler temperatureReturn temperatureReturn boost

0.1560-80 (grain)>40 (grain 55)

Pump (RA60 with thermal store)

0.1560-80 (grain)>40 (grain 55)

mbarCC

Water capacityOperating pressure

128max. 3

147max. 3

litreslitres

Water system resistanceTemperature difference 20 K

Through-flow rate 1290Water temp. 38.5

Differential pressure 11.2

Through-flow rate 4257---


kg/hC




Through-flow rate 2128---


kg/hC

Ash pan, grateAsh pan, "heat exchanger"

6012

6012

litreslitres

ABCDEFG

Temp.-relief heat exch. sensorReturn, 1"

Temp.-relief heat exchangerSTL, boiler sensor

Drain, "Flow, 1"

Flue connecting pipe dia. 150

Temp.-relief heat exch. sensorReturn, 1"

Temp.-relief heat exchangerSTL, boiler sensor

Drain, "Flow, 1"

Flue connecting pipe dia. 150 mmOverall weight (w/o stoker unit)Weight of bottom boxWeight of heat exchangerWeight of stoker unitWeight of drive unit

5503401807555

5503401807555

kgkgkgkgkg

Temperature-relief heat exchanger Yes Yes

Power supply 400V/13A 400V/13A


50

6.2 Technical data Powerchip 75/100

Type POWERCHIP 75 POWERCHIP 100

Fuel






Boiler outputWoodchips 22-75

Pellets 22-75Grain fuel 21-70 (with additive)

Woodchips 22-100Pellets 22-100

Grain fuel 21-70 (with additive)

kWkWkW


0.1560-80 (grain 70-80)

>45 (grain 55)Pump (RA with thermal store)

0.2060-80 (grain 70-80)

>45 (grain 55)Pump (RA with thermal store)

mbarCC


256max. 3

256max. 3

litreslitres






kg/hC






kg/hC


8012

8012

litreslitres

ABCDEG

Flow, 2"Temp.-relief heat exchangerSupplementary sleeve, "

DrainReturn, 2"

Flue connecting pipe dia. 180

Flow, 2"Temp.-relief heat exchangerSupplementary sleeve, "

DrainReturn, 2"

Flue connecting pipe dia. 180 mmOverall weight (w/o stoker unit)Weight of bottom boxWeight of heat exchangerWeight of stoker unit

86543040575

86543040575

kgkgkgkg

temperature-relief heat exchanger Yes Yes

Power supply 400V/13A 400V/13A


51

6.3 Technical data Powercorn 50 Special

Type POWERCORN 50 Special Special with agitator

FuelWoodchips G30

Grain fuelPellets 6mm


Boiler outputWoodchips 12-50Grain fuel 12-40

Pellets 12-50

kWkWkW


0.1570-80>55C

Pump (RA60 with thermal store)

mbarCC


147max. 3

litresbar




kg/hC




kg/hC


8012

litreslitres

ABCDEFG

Temp.-relief heat exchangerSensor for temp.-relief heat exch.

Return, 1"STL, boiler sensor

Drain, "Flow, 1"

Flue connecting pipe dia. 180 mmOverall weight (w/o stoker unit)Weight of bottom boxWeight of heat exchangerWeight of stoker unitWeight of drive unit

6674102277555

kgkgkgkgkg

temperature-relief heat exchanger Yes

Power supply 400V/13A


52

GUNTAMATIC Heiztechnik GmbHA – 4722 PEUERBACH Bruck 7

Tel: 0043 (0) 7276 / 2441-0Fax: 0043 (0)7276 / 3031


6 Millennium Place Tiverton Business Park

TivertonDevon

EX16 6SBTel: 0845 [email protected]

Subject to printing errors and technical amendments.

www.treco.co.uk

Date post:	27-Nov-2014
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POWERCHIP-V10-Installation & Assembly Instructions

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