BiSolid Saver A Installation, Operation And Maintenance Manual

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

BiSolid Saver

31.1.2013 г. 09:12

OM-BSSV00/08/2012/EN

MANUAL

FOR INSTALLATION, OPERATION AND MAINTENANCE OF HOT
WATER SOLID FUEL BOILER FROM SERIES BISOLD SAVER

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CONTENT page.

1. IMPORTANT INFORMATION ABOUT THE SYSTEM OPERATION 3

1.1. SAFETY INSTRUCTIONS 3

1.2. PURPOSE OF THE BOILER 4

1.3. FUEL 4

1.4. BOILER DESCRIPTION 5

1.5. BOILER OVERALL DIMENSIONS 6

1.6. BOILER SCHEMATIC CROSS-SECTION VIEW 7

1.7. BOILERS TECHNICAL DATA 8

2. INTRODUCTION 17

2.1. BOILER GENERAL REQUIREMENTS 17

2.2. ENSURING PEOPLE AND EQUIPMENT SAFETY 18

3. OPERATION INSTRUCTIONS 19

3.1. OPERATION OF BOILER FROM BISOLID SAVER SERIES 19

3.2. SAFE OPERATION OF THE BOILER 19

4. BOILER INITIALIZATION FOR OPERATION 21

4.1. BOILER CHECKS BEFORE OPERATION START 21

4.2. FILLING AND DRAINING THE HEATING SYSTEM 21

5. BOILER OPERATION AND CONTROL WITH WOOD LOGS 22

5.1. BOILER FIRING 22

5.2. CONDENSATION AND TARS 23

5.3. BOILER SWITCH OFF 24

5.4. BOILER SHORT-TERM SWITCH OFF 24

5.5. BOILER LONG-TERM SWITCH OFF 24

5.6. BOILER HANDLING 25

5.7. BOILER CLEANING AND MAINTENANCE 25

5.8. BOILER REPAIR 26

5.9. WARRANTY AND WARRANTY CONDITIONS 27

5.10. BOILER PACKAGE KIT AT DELIVERY 27

6. BOILER OPERATION AND CONTROL WITH WOOD PELLETS 29

6.1. BOILER FIRING 29

6.2. BOILER SWITCH OFF 32

6.3. BOILER HANDLING 32

6.4. BOILER CLEANING AND MAINTENANCE 32

6.5. BOILER REPAIR 32

6.6. BOILER CONTROL PANEL 32

6.7. BOILER WITH PELLET BURNER WIRING DIAGRAM 34

6.8. CONTROL PANEL WITH CONNECTORS FOR PELLET BURNER 35

7. BOILER INSTALLATION INSTRUCTIONS 38

7.1. BOILER INSTALLATION – COMMON INFORMATION 38

7.2. CHOOSING SUITABLE BOILER SIZE 38

7.3. POSITIONING IN THE BOILER ROOM 38

7.4. CONNECTING THE BOILER TO THE HEATING SYSTEM 39

7.5. INSTALLATION OF THE HEATING OUTPUT REGULATOR 40

7.6. INSTALLATION OF THE THERMO-MANOMETER GAUGE 40

7.7. BOILER STRUCTURE – COVER PANELS INSTALLATION 40

7.8. EXPANSION TANKS (BUFFERS) INSTALLATION AND OPERATION 42

7.9. TRANSPORTATION AND STORAGE 44

7.10. BOILER INSTALLATION TO FLUE OUTLET PIPES 44

7.11. BOILER JOINING TO CHIMNEY 45

8. TROUBLESHOOTING 46

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1. IMPORTANT INFORMATION ABOUT SYSTEM
OPERATION

Dear BISOLID SAVER hot water boiler owners,
We would like to congratulate you for your new ecological boiler system. By purchasing this

quality product from the manufacturer you have chosen a system that ensures higher comfort
level and optimized fuel consumption in environmentally protecting way and natural resource
saving. Your hot water boiler is manufactured under strict ISO 9001 standards.

On the next pages we have introduced specific information and important advices about the
system operation, its functions and methods of maintenance. Please pay special attention to
this manual. Good knowledge of this document content will give you the pleasure of long-term
and trouble-free operation of the system.

We wish you all the best with Your Bisolid Saver boiler.

1.1. SAFETY INSTRUCTIONS

The hot water boiler from series BiSolid Saver and its accessories correspond to all applicable
directions for safety techniques. Your hot water boiler and all of its accessories operate under
variable electricity 220-230 V. Improper electrical installation or repair may endanger user’s life
from electrical shock. Installation works must be performed only by qualified technicians.

This manual is intended for authorized service specialists only. It is important to know that:

 Works on the heating installation should be performed only by technicians who had

acquired such rights by law.

 Works on the electrical installation should be performed by qualified electricians only.
 Initial operation start up including installation visual checks, adjustments and starting

must be performed by the manufacturer authorized personal.

Legal provisions

While operating with the appliance please observe:

 Legal provisions for safety technique.
 Legal provisions for environment protection.
 Provisions for proper installation.
 Applicable provisions of European community.

Safety instructions

Please observe these safety instructions in order to prevent the people from
risks and harms, as well as damage to properties and environment.

Safety instructions explanation.
Please exude attention to the following symbols in this manual:

Danger

This symbol warns for harmful risks or danger to people.

Warning

This symbol warns for risks of damage to properties and environment.

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Direction

Information marked with this symbol contains additional data.

Works or activities for setting the appliance in proper technical working order

Warning

Repairs of constructional elements which functions are related to the technical
safety may compromise the safely operation of the installation. Damaged or
faulty elements must be replaced with genuine spare parts provided by the
manufacturer.

Warning

After carefully reading of the installation and operation manual, you will acquire
all necessary information about design, controls and safety operation of the
boiler. After unpacking the boiler please check its completeness and delivered
elements. Check whether boiler size corresponds to the desired designation.

The hot water boiler BiSolid Saver has possibility for installation of additional safety valve –
type DBV1, which is designed for draining excess heated water, so the boiler temperature
does not exceed 95 oC.

If any failures or troubles occur the boiler must be led out from operation and removing of the
faults/troubles must be provided by specialized company. For proper functioning, safe and
long-term operation of the appliance, a regular check ups and prophylaxis must be performed,
at least once per year. Such technical care guarantees your investment.

Repairs should be performed only with genuine spare parts. In case of faults or troubles
caused by unqualified installation, non-compliance with the requirements or the operation
manual, the manufacturer company is not responsible and does not provide warranty for the
product.

1.2. PURPOSE OF THE BOILER

The steel made hot water boiler from series BiSolid Saver is a heating source suitable for
heating of dwellings, single-family houses, production workshops and another similar objects
with heating losses up to 25-40 kW. The heating system can be designed as opened type or
with expansion tank (buffer), with gravity or forced circulation of the heating water, with
maximum overpressure of 200 kPa.

The optimum functionality of the appliance depends either on the professionally designed
heating installation or its precise handling.

1.3. FUEL

The boiler BiSolid Saver is designed mainly for firing dry wood, with maximum water content of
20%, i.e. cut from round timber with diameter up to 100 mm and length up to 400 mm,
chopped firewood with or without bark. The boiler manufacturer recommends placing the fuel
cross-wide in the combustion chamber, so staged combustion and deposition of the fuel are

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achieved. If the fired wood shape does not meet the requirements, the handling personal
should more often attend and control the boiler.

The boilers from series BiSolid Saver are able to utilize wood pellets according to standard EN
14961-2, category ENplus-A1 with the following characteristics:

Table 1. Wood pellets main parameters

Parameter Dimension

Value

Diameter mm 6;8
Length mm 3.5-40
Water content % 10
Ash content % 0.7
Mechanical durability % 97.5
Caloricity MJ/kg 16.5
Bulk density kg/m3 600

Wood pellets must be stored in dry premises, so they can be transported without problems
and also in order to achieve trouble-free operation with optimum combustion and maximum
efficiency.

Warning

Boilers from series BiSolid Saver W, BiSolid Saver С and BiSolid Saver А are
not designed for firing any type of coal.

1.4. BOILER DESCRIPTION

The boiler is a welded construction from steel plates and pipes. The inside space is separated
by the combustion chamber water baffle, combustion chamber and heat-exchanger, through
which the flue gasses are led to the flue pipe. Under the combustion chamber and the fuel
loading tank is situated a two-component grill, which can be easily controlled with a lever on
the boiler side. The primary air is supplied through a regulating valve on the ash cleaning and
fuel feeding door. Heating output regulation is performed either manually or automatically by
temperature regulator (TRV), which is standard supplied with the boiler, as part of its delivery
kit. Water inlet and outlet are secured with muffs 1

1/2"

. The flue pipe is situated on the boiler

back. The initial firing flap is controlled from top of the boiler.
The steel made hot water boilers from series BiSolid Saver are offered in three product groups

(modifications):

BiSolid Saver W

Wood logs boiler – standard (factory) prepared with hinges for
installation of second additional door with pellet burner. When
equipped with second door and burner the boiler becomes combined –
double door.

BiSolid Saver С

Wood logs boiler – standard (factory) equipped with second additional
door with pellet burner – double door.

BiSolid Saver А

Combined boiler for wood logs and wood pellets – standard equipped
with constantly installed and applied pellet burner, which can be also
used for initial firing of the dry wood. The burner should not be
removed when the appliance operates with dry wood.

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Information about all product groups (modifications) is presented in this manual for operation,
installation and maintenance.

1.5. BOILER OVERALL DIMENSIONS

Overall dimensions of the boiler BiSolid Saver are presented in Figure 1 and Table 2.

Figure 1. Overall dimensions of boiler BiSolid Saver

60 G

D

F

A

C 100160

B

7

8

4

5

3

2

1

E

9

6

1 – Fuel feeding door
2 – Secondary air flap
3 – Soot cleaning door
4 – Grill lever
5 – Ash cleaning door
6 – Pipes to DBV1 – not standard part of
the boiler delivery kit

7 – DBV1 – two-way cooling safety valve
– not standard part of the boiler delivery kit
8 – TRV – temperature valve regulating
the boiler heating output
9 – Heat-exchanger cover with initial firing
flap

Table 2. Overall dimensions of boiler BiSolid Saver

BiSolid

Parameter Notation Dimension

Saver 25 Saver 40

Boiler height A mm 900 1100
Boiler length B mm 920 920
Boiler width C mm 720 720
Heating water outlet flange height D mm 1030 1030
Flue pipe axis height E mm 905 890
Heating water inlet flange height F mm 215 215
Heating water outlet distance G mm 290 340
Inlet and outlet muff - 1 ½” 1 ½”
Flue pipe diameter (outer)_ mm 130 160

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1.6. BOILER SCHEMATIC CROSS-SECTION VIEW

Schematic cross-section view of boiler BiSolid Saver is presented in Figure 2.

Figure 2. Schematic cross-section view of boiler BiSolid Saver

1.Fuel hopper cover panel 2.Middle cover panel

3.Rear cover panel with flap 4.Flap with handle

5.Second flue gas pass (turbolators position) 6.Rear section

7.Hot water outlet 8.Flue pipe Ф150 mm

9.Isolation cover 10.Fireclay bricks

11.Cold water inlet 12.Draining muff

13.Cleaning cover 14.Bushes for legs

15.Bottom isolation 16.Moving grill

17.Ash tray 18.Grill handle

19.Flipping grill 20.Rotation axle shaft

21.Combustion chamber door 22.Air inlet flap (for dry wood)

23.Front cover panel 24.Dry wood hopper

25.Thermo-manometer gauge

The steel turbolators are optionally offered for every boiler from series BiSolid Saver W,
BiSolid Saver C and BiSolid Saver A and can be used in all operation modes.

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Direction

Turbolators are recommended for usage in the second flue gas pass of the
boiler.

1.7. BOILERS TECHNICAL DATA

The boilers from series BiSolid Saver W are specialized for firing dry wood. The higher
efficiency compared to competitor boilers is achieved due to the steel made three pass
construction of the heat-exchanger finishing with two sets of steel tubes (larger heat
exchanging area). The boilers are suitable for heating of one or double floor or small company
buildings, as well as for heating of domestic water.

Outer view of hot water boiler from series BiSolid Saver W is showed in Figure 3.

Figure 3. Outer view of boiler BiSolid Saver W

Standard equipment of the boilers from series BiSolid Saver W is presented in Figure 4.

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Figure 4. Standard equipment of the boilers from series BiSolid Saver W

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The main advantages of the boilers from series BiSolid Saver W are:

• The reliable, compact, and simple construction of the boiler provides wood logs firing
(with length up to 400 mm) at high efficiency, which guarantees economic operation
and low cost for heating.

• Possibility for firing certain types of agro-wastes – wood residues from forest and
agricultural industries (branches from fruit trees and others, brushwood, corn cob,
sunflower cakes, vines), industrial wood residues and wastes (barks, shavings),
building construction wood wastes and wood briquettes.

• The fuel feeding space, respectively its capacity is increased, which guarantees long
operation time between two consecutive re-fuels.

• Standard equipped with temperature valve for automatic regulation of the fresh firing­air flow rate, which ensures maximum fuel utilization, economic operation, as well as
possibility for adjustment within a wide range of heating output.

• Extremely comfortable for installation, operation and maintenance.

• The boiler complies with the European ecology directives and requirements.

• Developed and designed for easy and quick installation of pellet burner BiSolid GP.

Technical data for hot water boiler from series BiSolid Saver W firing dry wood are presented
in Table 3.

Table 3. Technical data for hot water boiler from series BiSolid Saver W

Description

Dimension Saver W 25 Saver W 40

Fuel - Wood Wood
Nominal heating output kW 25 40
Operating pressure bar 2 2
Efficiency % 86 86
Operating draught Pa 20-30 20-30
Fuel consumption rate at maximum heating output

kg/h 6.70 10.60
Water temperature operation range °C 70-90 70-90
Minimum inlet water temperature °C 65 65

Boiler water volume l 70 100
Fuel hopper volume l 79 106

Boiler weight kg 237 285
Boiler length mm 920 920
Boiler height mm 900 1100
Boiler wide mm 720 720

Maximum height of fuel filling in the hopper -

¾

¾

The boilers from series BiSolid Saver С are standard equipped with additional front door,
wood pellet burner and control board. Switching from dry wood to pellets and reverse is easy
and quickly (for less than a minute). The burners from series BiSolid GP utilize wood pellets
with diameter ∅ 6-8 mm and category according to standard EN 14961-2 - ENplus-A1.

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The higher efficiency compared to competitor boilers is achieved due to the steel made three
pass construction of the heat-exchanger, finishing with two sets of steel tubes (larger heat
exchanging area).

Outer view of hot water boiler from series BiSolid Saver С is presented in Figure 5.

Figure 5. Outer view of boiler BiSolid Saver С

Standard equipment of the boilers from series BiSolid Saver С is presented in Figure 6.

Figure 6. Standard equipment of the boilers from series BiSolid Saver С

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The main advantages of the boilers from series BiSolid Saver C are:

• Possibility for utilization of certain types agro wastes – wood residues from forest and
agricultural industries (branches from fruit trees and others, brushwood, corn cob,
sunflower cakes, vines), industrial wood residues and wastes (barks, shavings),
building construction wood wastes and wood briquettes.

• The fuel feeding space, respectively its capacity is increased which guarantees long
operation time between two consecutive re-fuels.

• Standard equipped with temperature valve for automatic regulation of the firing-air flow
rate, which ensures maximum fuel utilization, economic operation, as well as possibility
for adjustment within a wide range of heating output.

• Extremely comfortable for installation, operation and maintenance.

• The pellet burners from series BiSolid GP are fully automated – ignition, flame control,

combustion chamber blowing. Also equipped with intuitive LCD display for easy
operation.

• Automatic adjustment of fresh air and fuel feed rates according to the selected
operating temperature, which feature provides high efficiency of the appliance at
minimum fuel consumption.

• The combustion chamber is made of fire resistance steel, which guarantees reliable
and long-term operation.

• Automatic modulation of the burning process decreasing the number of stops and
ignitions, respectively fuel and electricity consumption.

• Possibility for wide range regulation of the heat carrier (water) temperature.

• Possibility for operation with room thermostat and weekly programmer.

• Circulations pump control according to heat carrier (water) temperature.

• Possibility for control of extractor fan.

• Quiet operation and low electric power consumption.

• Protection from back-fire and from heat carrier (water) freezing.

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Table 4 presents technical data for operation of hot water boiler from series BiSolid Saver C

and wood pellet burner from series BiSolid GP.

Table 4. Technical data for operation of hot water boiler from series BiSolid Saver C and wood

pellet burner from series BiSolid GP.

Description Dimension

Saver C 25

Saver C 40

Fuel - Wood Pellets Wood Pellets
Wood pellets category according to EN
14961-2

- ENplus-A1

ENplus-A1

Nominal heating output kW 25 25 40 35
Working pressure bar 2 2 2 2
Fuel consumption at nominal output kg/h 6.7 5.8 10.6 8.0
Chimney draught Ра 20-25 20-25 20-25 20-25
Efficiency % 86 91 86 91
Boiler water volume l 70 70 100 100
Fuel hopper volume l 79 79 106 106
Boiler weight kg 253 253 301 301
Boiler length mm 1260 1260 1260 1260
Boiler height mm 900 900 1100 1100
Boiler wide mm 720 720 720 720

Up to this moment the boilers from series BiSolid Saver A have no analogue on the Bulgarian
market. They are equipped with constantly installed pellet burner BiSolid and according to the
consumer’s needs and without any additional reconstruction they can either utilize wood logs
or wood pellets with diameter ∅ 6-8 mm and category according to standard EN 14961-2 ­ENplus-A1.

The pellet burners BiSolid GP are suitable and applicable only for hot water boilers BiSolid
and they provide possibility for ignition of the filled in the boiler wood logs.

The higher efficiency compared to competitor boilers is achieved due to the steel made three
pass construction of the heat-exchanger finishing with two sets of steel tubes (larger heat
exchanging area).

Reliable, compact, and simple construction of the boiler provides wood logs firing (with length
up to 400 mm) at high efficiency, which guarantees economic operation and low cost for
heating.

Outer view of hot water boiler from series BiSolid Saver А is presented in Figure 7.

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Figure 7. Outer view of hot water boiler BiSolid Saver А

Standard equipment of the boilers from series BiSolid Saver A is presented in Figure 8.

Figure 8. Standard equipment of the boilers from series BiSolid Saver A

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The main advantages of the boilers from series BiSolid Saver А are:

• The pellet burners from series BiSolid GP are fully automated – ignition, flame control,
combustion chamber blowing. Also equipped with intuitive LCD display for easy
operation.

• Automatic adjustment of fresh air and fuel feed rates according to the selected
operating temperature, which feature provides high efficiency of the appliance at
minimum fuel consumption.

• The combustion chamber is made of fire resistance steel, which guarantees reliable
and long-term operation.

• Automatic modulation of the burning process, decreasing the number of stops and
ignitions, respectively fuel and electricity consumption.

• Possibility for wide range regulation of the heat carrier (water) temperature.

• Possibility for operation with room thermostat and weekly programmer.

• Circulations pump control according to heat carrier (water) temperature.

• Possibility for control of extractor fan.

• Self operation optimization depending on the building inertia (heating losses).

• Quiet operation and low electric power consumption.

• Protection from back-fire and heat carrier (water) freezing.

Warning

Boilers from series BiSolid Saver W, BiSolid Saver С and BiSolid Saver А are
not designed for firing any type of coal.

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Table 5 presents technical data for operation of hot water boiler from series BiSolid Saver A
and wood pellet burner from series BiSolid GP.

Table 5. Technical data for operation of hot water boiler from series BiSolid Saver A and wood

pellet burner from series BiSolid GP.

Description Dimension

Saver А 25

Saver А 40

Fuel - Wood Pellets Wood

Pellets
Wood pellets category according to EN
14961-2

- ENplus-A1

ENplus-A1

Nominal heating output kW 25 25 40 35
Working pressure bar 2 2 2 2
Fuel consumption at nominal output kg/h 6.7 5.8 10.6 8.0
Chimney draught Ра 20-25 20-25 20-25 20-25
Efficiency % 86 91 86 91
Boiler water volume l 70 70 100 100
Fuel hopper volume l 79 79 106 106
Boiler weight kg 253 253 301 301
Boiler length mm 1260 1260 1260 1260
Boiler height mm 900 900 1100 1100
Boiler wide mm 720 720 720 720

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2. INTRODUCTION

2.1. BOILER GENERAL REQUIREMENTS

The boiler and its accompanying equipment must be installed and used in accordance to the
designed heating installation, all applicable legal norms, technical standards and manufacturer
instructions. The boiler should be used only for the subscribed purposes.

The boiler must be installed only for the purposes for which is designed. If the boiler is
delivered and installed to the customer by the same person, then the whole accompanying
documentation must be provided as well (especially the user manual book). The boiler’s
genuine package should be kept until its initial operation start up, in case the boiler should be
transported again.

After installation the boiler operation must be initiated by service organization, authorized by
the manufacturer.

The boiler corresponds to the applicable EU legal provisions. If the boiler should be used in
countries outside the EU, all deviations from local laws and legal provisions must be identified
and corrected.

In case of faults in the boiler please contact a service organization authorized by the
manufacturer. Every incompetent intervention might damage the boiler (and possibly the
accompanying equipment).

The service technician initializing the boiler start up for first time must show the customer all of
its main components, different boiler systems and how to control the boiler. The technician
must present the boiler’s safety elements and signalization, and respectively the relevant user
reaction. If the boiler is delivered and installed to the customer by the same person, then he
must ensure that boiler’s genuine package is kept, in case the boiler should be transported
again.

Please check the delivery of the boiler’s standard accompanying equipment.
Please check if the delivered model and type of the boiler corresponds to the usage

requirements.
If you are not sure how to manage the boiler, please carefully read the relevant instructions in

this manual for operation and installation, and respectively continue as prescribed.
Please never take/stick off or damage the marks and signs on the boiler. Please keep the

boiler genuine package until its initialization to operation, in case the boiler should be
transported again.

If doing a boiler repair, you must always use genuine spare parts only!
It is forbidden to make any changes to the internal installation of the boiler or to change
anything in any way.

At the end of the boiler’s life cycle, it should be packed together with its parts and disposed in
an environmentally safe way.

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The manufacture company is not responsible for damage or harms caused by non-compliance
with:

 Terms and conditions stated in this manual for operation and installation.
 Applicable standards and legal provisions.
 Procedures for installation and operation.
 Terms and conditions presented in the product warranty card.

Situations which are possible to occur in real-time practice and precaution measures that
should be taken:

 Switch off the boiler if there are any flammable or explosive vapors in the boiler room,

that may mix with the ambient air which is fed for firing in the boiler (for example from
paint while painting, spraying or laying molten substances, gas leakage, etc.).

 If it is necessary to drain the water out of the boiler or from the entire system, as the

water should not be dangerously hot.

 If there is any leakage from the boiler’s heat-exchanger or when the heat-exchanger is

choked up, do not try to start the boiler until normal operation conditions are recovered.

2.2. ENSURING PEOPLE AND EQUIPMENT SAFETY

The boiler and all of its parts are in compliance with the safety requirements of the relevant EU
legal regulations.

In order to install and operate the boiler in real-time conditions and in compliance with its
usage designation (stated below only as usage), is necessary also to observe the additional
requirements, as most important of them (those that should not be missed) are presented in
the relevant regulation documents. In addition to the above mentioned documents for the
usage of the boiler it is also necessary to comply with this operation and installation manual
and the product accompanying documentation supplied by the manufacture company.

Any intervention over the boiler’s operation from children and persons under the influence of
narcotic substances, psychiatric abnormalities and etc., must be prevented.

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3. OPERATION INSTRUCTIONS

3.1. OPERATION OF BOILER FROM BISOLID SAVER
SERIES

The boiler must be handled only by adult people, which have been already introduced to the
boiler operation and its proper handling. The people operating the boiler must strictly comply
with the manual and they have rights only to start the boiler operation, to adjust the
temperature on the heating output temperature regulator, to switch off boiler operation and to
provide regular checkouts during its operation. After initializing the boiler into operation the
service technician is obligated to introduce the user with the operation and maintenance of the
boiler. Attendance of children without supervision near the boiler is not allowed. Any
interventions or activities over the boiler construction which may endanger the life or health of
the handling or attending personal are strictly forbidden.

The boiler should be operated at maximum 90 oC water temperature and progress controlled.
Usage of flammable liquids for easier firing as well as any activities related to increase of the
boiler’s nominal heating output (overloading) are strictly forbidden. Positioning of flammable
objects on top or near the boiler is also not allowed. The ash should be taken out in fireproof
container with cover.

Danger

In case of danger from penetration of flammable vapors or gasses in the boiler
room or any activities that may lead to fire or explosion (gluing the flooring,
varnishing with flammable paints or others), the boiler must be led out of
operation before starting any of these activities.

3.2. SAFE OPERATION OF THE BOILER

All safety prescriptions must be observed when the boiler is operating. The boiler BiSolid
Saver must not be used for any other purposes except the ones introduced in this manual.

The surface of the boiler should be cleaned only with standard inflammable cleaners.
Positioning of objects made of flammable materials near the boiler or at unsafe distance is not
allowed.

It is not allowed to store flammable materials (wood, paper, oil and other flammables) in the
boiler room. The minimum allowed distance between the boiler’s outer parts and the flue and
any average or hard igniting materials (which dye out after firing without any additional heat
energy), should be not less that 100 mm.

The allowed distance from easy igniting materials (which continue to burn after removal of the
ignition source) must be minimum 200mm.

If the degree of flammability of the materials can not be proved, a minimum distance of 200
mm must be observed.

Removal of solid wastes, products from the burning process, out of the ash tray space should
be performed by the help of an ash box, situated in the middle of the boiler ash tray. The ash

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box (ash tray) must be emptied before it has been filled up. All activities with the ash box
should be performed by using a handle, situated in its front part. After removing the box from
the boiler the ash should be dumped in preliminary prepared fireproof container. When
handling or operating please use gloves as protective equipment.

Danger

When installing the boiler and elements for safety and control please do not
forget that all installation works must comply with the safety labor principles. If
two way safety valve or heat output temperature-regulator replacement is
necessary, please use the recommended devices. In case of using any other
type of devices you should ask the manufacturer company first. The heat output
temperature regulator must be checked by authorized specialist once per year.

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4. BOILER INITIALIZATION FOR OPERATION

4.1. BOILER CHECK-UPS BEFORE INITIALIZATION FOR
OPERATION

Before initializing the boiler for operation the service technician must check:

 If the installation complies with the project.
 Boiler must be filled with water, to be under pressure and to check the entire heating

system for leakages.

 Boiler connection to chimney – flue pipe connection lines must be approved by

authorized service technician.

 Heating regulators functionality.

Warning

The service technician must train the consumer how to operate and manage the
boiler and also to fill in exact start of operation date in the warranty card of the
product.

4.2. FILLING AND DRAINING THE HEATING SYSTEM

The system can be filled or drained with water only if the water corresponds to EN standards
values. The water must be clean, with no color, no suspended particulates, oils and chemically
aggressive and corrosive substances, and also it should not be acid (pH factor must be higher
than 7.0). At first place a comprehensive washing of the entire heating system should be
performed.

Warning

Water quantity in the system should not be decreased or drained except in the
cases when the boiler is being repaired or there is risk of freezing. An antifreeze
fluid can be added against freezing, with a volume of 15% from the total liquid
quantity (please see the anti-freezing fluid supplier usage instructions).

Warning
Not fulfilling the above mentioned requirement might result in clogging the heat­exchanger of the boiler. During the heating season the water volume in the
heating system must be kept constant. If refilling with water you must be careful
to not intake air into the system. The circulation water should never be drained
out from the boiler or the heating system, except if it is absolutely necessary, for
example when doing repairs and etc. Draining and refilling the system with
water increases the risk of corrosion and boiling stone (scale).

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5. BOILER OPERATION AND CONTROL WITH WOOD LOGS

5.1. BOILER FIRING

Before firing the boilers BiSolid Saver W and BiSolid Saver С, please check:

 Water quantity in the heating system.
 Sealing of the heat-exchanger cover.
 Condition of the soot door.

Open the firing flap by lifting and turning the tension rod. Put paper and small wood pieces
over the fire-grate through the fuel feeding door. After closing the fuel feeding door start firing
with burning paper through the ash tray space. After inflammation fill the hopper with wood
logs. After inflammation close the initial firing flap.

During the several first ignitions for checking the optimum flame condition is recommended to
perform control over the quality of burning. It includes tracking the smoke out of the chimney.
Indication for quality burning is the lack of excessive smoke from the chimney – in case it’s a
fact, it means that there is insufficient secondary air in the combustion chamber.

Danger

 Do not start the boiler if it’s not connected to a chimney.
 Before starting the boiler check its connection with the chimney.
 Check the chimney draught. If it is above the recommended values a

draught regulator has to be installed.

When operating hot water boilers from series BiSolid Saver W and BiSolid Saver С with wood
logs it is necessary to put the grills and ash box (ash tray) in their correct position, so the
reliable and safe operation of the appliance is secured.

Under the combustion chamber and the fuel hopper is situated two-component moving fire­grate, which can be easily operated by a lever located on the boiler side.

On figure 9 is presented the positioning of the ash tray and the fire-grates, when firing wood
logs with the boilers from series BiSolid Saver W and BiSolid Saver С.

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Figure 9. Positioning of the ash tray and the fire-grates, when firing wood logs

with the boilers from series BiSolid Saver W and BiSolid Saver С.

Warning

When the boilers from series BiSolid Saver W and BiSolid Saver C operate with
wood logs, with closed fuel feeding door, the ash tray lower side is turned
inwards and the grilles are down.

5.2. CONDENSATION AND TARS

At initial boiler start up a condensation forms over the boiler walls and leaks down in the
combustion chamber. Such condensation on the walls might cause doubt that the boiler
“leaks”. The condensation disappears after depositing of ash on the inside walls, which is
usually achieved after 2 to 4 ignitions. When operating at low heating output, low water
temperature in the boiler and low flue gas temperature, condensation forms on the inside
boiler walls, which leak into the combustion chamber. Because the flue gases condensation
point is 65 oC the condensation forms only when there is cooling of the gases in the middle
sections of the boiler walls, where the temperature is lower than 65 oC. If condensing affects
the combustion chamber it means that the used fuel is too wet. In such cases condensation
could leak in the combustion chamber even if the water temperature is higher than 65 oC.
Tar forms similar to condensation - low heating output, low temperatures and another reason
could be incorrect burning process adjustment (insufficient secondary air flow). The tar can be
removed by a scraper, supplied together with the boiler, but only if the tar is in soft condition.
This can be achieved at boiler water temperature around 90oC. Such operating temperature
quickly takes out the heating appliance from its nominal operating mode. Therefore as
optimum fuel are recommended soft types of wood which burn quickly.

Front fire-grate
position

Rear fire-grate
position

Ash tray
position

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Warning

If decide to install expansion tank (buffer) in order to extend the boiler life cycle
time, then before that you should eliminate the possibility to occur low
temperature corrosion in the fuel passage, by keeping the temperature in the
boiler above the point of condensation 65 oC. This can be achieved by a mixing
device. If the low temperature corrosion is not being limited the boiler corrodes
and the expansion tank in most cases reduces the boiler body life time, due to
pressure and dynamic loads over the boiler walls. Authorization to install
expansion tanks got only legally approved servicing companies.

Warning

At boiler initial firing condensation appearance is possible. This should not
embarrass the user, because it is normal event – especially when firing wood
with higher water content. The boiler “dries” when it reaches normal operation
mode.

5.3. BOILER SWITCH OFF

We do not recommend to try accelerating the burning process in the boiler. The fuel must burn
completely by itself over the fire-grate.

5.4. BOILER SHORT-TERM SWITCH OFF

After switching off the boiler, clean it, take out all burned wastes, empty its ash-box, clean the
contact surfaces of the feeding door and the ash-box, and after that close boiler’s feeding and
ash-box doors.

5.5. BOILER LONG-TERM SWITCH OFF

When switching the boiler off for long period of time (at the end of the heating season), it must
be completely cleaned from all unburned accumulations (soot, ash and deposits). Otherwise
the accumulation of moisture in the unburned gasses leads to excessive boiler corrosion.

Warning

The boiler can be operated only by adult people who are well introduced with the
current manual for operation.
Switch off the boiler every time when there is any (even momentary) danger by the
presence of flammable or explosive vapors situated in the same room from which
the boiler intakes air for burning (for example painting paint, spraying or laying
molten substances, gas leakage, etc.).
Boiler initial firing with explosive substances is strictly forbidden.
Boiler overheating is forbidden.
The boiler and the chimney have to be completely cleaned at the end of the heating
season. Also grease all hinges, chimney flap mechanism and other moving parts.

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5.6. BOILER HANDLING

The air for burning (primary air) regulation can be performed by a regulating flap, positioned
on the fuel feeding door (or on the ash-tray cleaning door). When refilling the hopper with new
fuel, the fuel feeding door should be left slightly opened for a while, until the smoke from the
hopper drifts away. After that the door can be wide opened and the boiler can be refilled with
fuel. The fire-grate cleaning can be performed by moving the lever forward and backward in a
range of 10-15 cm, together with a slight lifting move. If you wish to perform full fire-grate
cleaning after the burning process, then the fire-grate has to be moved fully forward with the
help of the lever.

The boiler has to be used up to its nominal heating output. Overheating – half-opened ash
cleaning door, usage of charcoal and other types of coal decrease the boiler life-time, which is
not recommended by the manufacturer. The boiler and the heating system have to be
designed and dimensioned so there is no continues operation with water temperature below
65 oC – point of condensation. If the boiler works too long in such operation mode its life-time
decreases, forms high boiler and chimney contamination and tar, which results in low chimney
draught and efficiency. We recommend that during transition seasons (spring, autumn) the
boiler should be fired for short time at full heating output, in order to burn the deposits and to
dry the chimney.

Warning:

The manufacturer does not recommend burning of saw-dust or shavings under
any circumstances, because they drastically decrease the boilers life-time
cycle.

5.7. BOILER CLEANING AND MAINTENANCE

After continues operation of the boiler amounts of soot and ash accumulate to its walls, which
decrease its efficiency. The amount of soot and tar depend on its operation modes, type of
used fuel, chimney draught values and the outlet water temperature. Boiler cleaning has to be
performed occasionally according to the working conditions and needs, but at least once per
week.

After stopping its operation cleaning of the fire-grate from ashes must be performed, in
compliance with the instructions in part “Boiler handling”. The firing flap has to be adjusted in
top position and the heat-exchanger cover taken off. Cleaning of the heat-exchanger has to
be performed with the cleaning tools kit, supplied together with the boiler (steel scraper and
brush). The soot fallen under the heat-exchanger can be removed through the soot door. After
boiler cleaning the ash door has to be returned to its starting position.

During cleaning it is recommended to check the fire-clay bricks condition positioned in the
combustion chamber. Damaged bricks have to be replaced with new ones.

Warning

Note that closing of the firing flap should be done on time.

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Direction

The ash must be stored (the ash has to be taken out by using gloves) in
fireproof reliable containers and to be transported to opened spaces. Other
garbage or wastes should not be stored in these containers.

Maintenance of the boilers from series BiSolid Saver has to be performed daily, periodically or
early.

During the daily maintenance the user must clean the unburned residues in the combustion
chamber, to clean the ash gathered in the combustion chamber and to dump the ash-box
(ash-tray).

It is important that the user performs periodical maintenance of the appliances, in order to
achieve effective usage, prevention of possible problems with its operation and optimum boiler
life cycle. We recommend periodical check on every 3 months. Such checks have to be
performed by authorized service technicians and should include the following activities:

 Check boiler’s combustion chamber and flue pipe, including the chimney. They should

be cleaned if necessary.

 Check for leakages of incoming or outgoing water, in and out of the boiler, water pipe

links as well.

 Check valves, fittings and accessories.
 Check circulation pumps.
 Visual check of fire-grate.
 Perform operation control check for safety of the hydraulic system and the boiler.

The yearly maintenance (prophylaxis) of the boiler must be performed only by authorized
technicians, before the start of the heating season. Before calling the service technicians the
user has to provide already cleaned flue pipes and chimney. During the yearly prophylaxis the
authorized technicians perform the following checks and activities:

 Position of the combustion chamber shaft, isolation and isolation ropes.
 Boiler test at operating pressure for adjustment of the burning, by measuring flue gas

parameters if necessary.

 Check and clean the boiler’s fire-grate and surfaces from soot and ash.
 Test boiler connections for leakages.
 Check fittings including muffs, mixing valves, pressure valves for reliability.
 Test and if necessary clean the water filter.
 Check expansion tank (buffer) and clean it if necessary.
 Test pressure sensor. Clean or replace it if necessary.
 Perform operation control check for safety of the hydraulic system and the boiler.

5.8. BOILER REPAIR

The user may perform spare parts replacement by him/her-self, only according to the attached
list. Only installation or servicing company can perform larger scale repairs.

Boiler’s handling personal is authorized to perform only repair activities that do not
require special professional qualification and represent simple parts replacement as fire­grates, sealing ropes, fire-clay bricks, secondary air pipe and initial firing flap. All other failures
must be removed by authorized service.

Warning

Use only genuine spare parts when repairing the boiler.

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5.9. WARRANTY AND WARRANTY CONDITIONS

We pay attention to customers that initializing into operation and technical servicing of all hot
water boilers BiSolid Saver must be performed by specialized installation company. Otherwise
any eventual warranty claims will not be accepted. Warranty issues must be claimed just after
the defect has been discovered. The manufacturer reserves the right to make changes,
related to the product technical optimization. The warranty period is presented in the boiler’s
warranty card, which is its main belonging and is determined by the precise observation of the
instructions in the current manual for installation, operation and maintenance. The Buyer has
to issue a warranty claim in written form and present it to the Seller or authorized service
company.

5.10. BOILER PACKAGE KIT AT DELIVERY

All hot water boilers from series BiSolid Saver are delivered fully assembled and functionality
tested. The full accompanying delivery kit for the boilers BiSolid Saver W, BiSolid Saver C and
BiSolid Saver А are presented in Table 5.

Table 5. Package kit BiSolid Saver series

Saver W Saver C Saver A

Pos.

Description

(pcs) (pcs)

(pcs)
1 Hot water boiler Bisolid Saver 1 1 1
2 Wood pellet burner Bisolid GP 1 1
3 Wood pellet auger Bisolid 1 1
4 Door for pellet burner 1 1
5 Door for wood logs 1 1
6 Fire-grates 2 2 2
7 Fire-clay bricks 3 3 3
8 Ash-tray 1 1 1
9 Electrical control panel 1 1

10

TRV – thermo-mechanical heat output
regulator

1 1 1

11 Cleaning tool – scraper 1 1 1
12 Cleaning tool – brush 1 1 1
13 Cleaning tool - hook 1 1 1
14 Operation manual book 1 1 1
15 Warranty card 1 1 1

Offered spare parts, with order:

 Sealing rope for fuel feeding door.
 Fire-clay bricks.
 Cast iron fire-grates (2 pcs –the same).
 Sealing rope for ash cleaning door.

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 Ash cleaning door – kit.
 Soot door with sealing for soot door.
 Initial firing flap with tension-rod.
 Heat-exchanger covers – kit.
 Sealing rope for heat-exchanger cover.

Special requirement for spare parts must be coordinated with the manufacturer.

Direction

When sending spare parts order, please point out the boiler type, its size,
factory number and year of production.

Spare parts and accessories for the boilers can be ordered to the service technician who
performed the installation or directly to the supplier.

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6. BOILER OPERATION AND CONTROL WITH WOOD
PELLETS

6.1. BOILER FIRING

Before firing the boiler from series BiSolid Saver С when utilizing wood logs please comply
with the instructions in part 5.1, presented in the current manual for operation.

When operating boilers from series BiSolid Saver С with wood pellets, the user has to use the
additional front door on which a pellet burner from series Bisolid GP can be installed. The
boilers from series BiSolid Saver C are equipped with control panel, so quickly and easily (for
less than a minute) you can switch from wood logs to wood pellets and contrariwise. The
burners from series BiSolid GP can burn wood pellets with diameter ∅ 6-8 mm and category
of wood pellets according to EN 14961-2 - ENplus-A1.

When operating boilers from series BiSolid Saver С and BiSolid Saver А with wood pellets, the
user must position the fire-grate and ash-box (ash-tray) correctly, in order to ensure reliable
and safe operation of the appliance.

Figure 10 and Figure 11 represent the correct positioning of the ash-tray and fire-grates for the
boilers BiSolid Saver С and BiSolid Saver А, when utilizing wood pellets.

Figure 10. Positioning of the ash-tray and fire-grates for the boilers BiSolid Saver С

and BiSolid Saver А, when utilizing wood pellets.

Front fire-grate
position

Ash-tray
position

Rear fire grate
position

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Figure 11. Positioning of the ash-tray and fire-grates for the boilers BiSolid Saver С and

BiSolid Saver А, when utilizing wood pellets (top view).

Warning

When boilers from series BiSolid Saver С and BiSolid Saver А operate with
wood pellets, the front fire-grate must be always lifted up, while the rear fire­grate must be down. The ash-tray must be positioned with its lower side
towards the pellet burner.

When operating boilers from series BiSolid Saver A with wood logs, the consumers use the
constantly installed pellet burner from series BiSolid GP for initial firing of the wood logs,
placed in the boiler’s hoper. In this case the burner must operate without changing the position
of fire-grates in the combustion chamber. After the wood logs ignition the pellet burner must be
switched off manually.

Fugure 12 represents the positioning of the ash-tray and fire-grates when operating with wood
logs, for boilers from series BiSolid Saver A equipped with constantly installed pellet burner.

Ash tray
position

Rear fire-grate
position

Front fire-grate
position

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Figure 12. Positioning of ash-tray and fire-grates for boilers from series BiSolid Saver A

operating with wood logs

Warning

When the boiler from series BiSolid Saver А, with constantly installed pellet
burner, is operating with wood logs, with closed boiler fuel feeding door, the fire­grates are down and the ash-tray is positioned with its lower side towards the
burner.

Warning

Switching from wood logs to wood pellets, for boilers BiSolid Saver А with
constantly installed pellet burner, can be performed manually by switching on
the pellet burner. In this case before starting the pellet burner the user must
change the position of the fire-grates in the combustion chamber, as described
in Figure 11.

Warning

When operating with wood pellets the user must be familiar in details with the
BiSolid GP manual for installation, operation and maintenance.

Warning

Hot water boiler from series BiSolid Saver А are not designated for burning
coal.

When operating with pellet burner you have to first turn on the main switch button, which
powers the burner control panel.

Warning

It is strongly recommended that starting of the pellet burner is done by the key
“Start” located on the electrical control panel (Please read the operation,
installation and maintenance manual of the pellet burner).

Front fire-grate
position

Rear fire-grate
position

Ash-tray
position

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6.2. BOILER SWITCH OFF

Switching off hot water boilers from series BiSolid Saver С and BiSolid Saver А operating with
wood logs must be performed in the appropriate way according to the instructions in parts 5.3,

5.4 and 5.5, presented in the current manual for operation. When operating with wood pellets
and pellet burner, its switching off must be performed according to the instructions presented
in the pellet burner BiSolid GP manual for operation.

Warning

Stopping the pellet burner is again performed by key “Start” positioned on the
electrical panel. Such stopping ensures burner normal switching off and
complete burning out of the remaining pellets. It is not allowed to stop the
burner through its main power supply switch.

6.3. BOILER HANDLING

When handling hot water boilers from series BiSolid Saver С and BiSolid Saver А operating
with wood logs, please observe the instructions in part 5.6 from the current manual for
operation. When operating with wood pellets handling of the pellet burner must be performed
according to the BiSolid GP burner series manual for operation.

6.4. BOILER CLEANING AND MAINTENANCE

When cleaning and maintaining hot water boilers from series BiSolid Saver С and BiSolid
Saver А operating with wood logs, please observe the instructions presented in part 5.7 from
the current manual for operation. When operating with wood pellets cleaning of the burner
must be performed in accordance to the BiSolid GP manual for operation.

6.5. BOILER REPAIR

Repairs of hot water boilers form series BiSolid Saver С and BiSolid Saver А operating with
wood logs must be performed according to the instructions presented in part 5.8 from the
current operation manual. When operating with wood pellets repair works must be performed
in accordance to the BiSolid GP manual for operation.

6.6. BOILER CONTROL PANEL

The electrical control panel of boilers BiSolid Saver С and BiSolid Saver А, operating with
pellet burners BiSolid GP, is presented in Figure 13.

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Figure 13. Electrical control panel of the boiler

Warning

All works and activities over the electrical wiring of the burner or adjustments,
where is necessary to remove its covers and other elements, that protect from
contact with the electrical parts, must be performed by authorized person.

Warning

The burner must be connected to the electrical installation of the relevant
appliance (boiler) by observing all safety techiques. The main power supply
cable must be used in complinace with the attached wiring diagram for
connecting to the main power supply and to burner’s control module.

START

ROOM THERMOSTAT

PELLET BURNER –
POWER SUPPLY

PELLET BURNER & BOILER
COMMUNICATION CABLE

FUSE, 10A

POWER – MAIN SWITCH

SAFETY THERMOSTAT

BOILER POWER SUPPLY
CABLE

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6.7. BOILER WITH PELLET BURNER WIRING DIAGRAM

Figure 14. Boiler with installed pellet burner – wiring diagram

Auger

1 2 3 4 5 6

1 2 3 4 5 6 1 2 3 4 5 6

6 5 4 3 2 1 6 5 4 3 2 1

Fresh air

Flue extractor ­optional

Pump

Ignition

Photo sensor

Start

Back fire

Room
thermostat

Pt 1000

H2O

1100 W

X1

X2

X3

X4

X5

F1
2A

F2
2A

F3
2A

F4
2A

F7
2A

F5
10A

F6
5A

Fan 1

Fan 2

Fan 3

Auger

Ignition

Pump

Cleaning

PE

Connector -

communication

N
220 V
Neutral

L
220 V
Phase

FS1
10A

Brown

Gray or blue

Safety thermostat
t – 950C

Connector –

pellet

burner

L1

N

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Warning

When operating with wood logs or wood pellets do not interrupt the boiler power
supply, because the circulation pump must operate until the boiler cools down.
In all wiring types the circulation pump must always operate when the boiler
looses heat for unloading purposes.

6.8. CONTROL PANEL WITH CONNECTORS FOR PELLET
BURNER

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Figure 15. Control panel with connectors for pellet burner wiring diagram

Pt 1000

Connector
Communication

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Warning
Connecting a room thermostat: Before connecting the room thermostat to the
connector (moving part) for ROOM THERMOSTAT (positioned on the back of
the boiler’s side cover panel), remove the factory installed bridge, located in the
connector. Use only room thermostat contact without external voltage! Please
see the wiring diagram!

Bushing installation, respectively water temperature sensor Pt1000 must be performed
according to the scheme presented in Figure 16.

Figure 16. Installation of water temperature sensor

Warning

Installation of the temperature sensor must be performed as shown on the
above presented scheme. This is operation related to people’s safety and must
be performed by qualified technical personal!

1. Direction for
removing cover panel

2. Direction for
removing cover panel

3. Direction for
removing cover panel

4. Position for
installation of sensor
Pt1000

5. Direction for
installation of cover
panel

6. Direction for
installation of cover
panel

7. Direction for
installation of cover
panel

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7. BOILER INSTALLATION INSTRUCTIONS

7.1. BOILER INSTALLATION – OVERAL INFORMATION

The hot water boilers from series BiSolid Saver must be installed only by specialized
company, authorized for such activities. Boiler installation must be performed in compliance
with the preliminary designed project and the acting legal provisions.

Use the existing network of authorized service organizations which comply with these
conditions and are able to take responsibility for all boiler installations, their initialization in
operation and warranty repairs.

Installation of the boiler must correspond to the acting prescriptions as well as to the operation
and installation manual. The manufacturer is not responsible for damages caused by
unqualified installation.

Warning

All problems (faults) with the boiler caused by clogging with dirt from the heating
system or faults caused by clogging are not covered by the product warranty.

7.2. CHOSING SUITABLE BOILER SIZE

The choice of suitable boiler size, i.e. its heating output is main condition for economic and
optimum operation of the appliance. The boiler has to be chosen with such size that
corresponds to the heating losses of the designated building site.

Choice of a boiler with too high nominal heating output (oversize) leads to increased
depositing of tar and condensation. Therefore it is not recommended to use boiler with heating
output higher that the heating losses of the building site.

7.3. POSITIONING IN THE BOILER ROOM

The hot water boilers from series BiSolid Saver can be positioned in rooms that comply with
the legal local provisions. The boiler room must have constant fresh air intake, needed for the
burning process. The air has to be clean, without halogen hydrocarbons, corrosive vapors and
should not be too wet and dusty. The room must be protected against freezing and with no
more than 80% relative humidity of the air.

The minimum allowed distance between boiler’s outer parts and flue pipes, and hard or
medium flammable materials is 100 mm. The minimum allowed distance between boiler’s
outer parts and flue pipes, and easy flammable materials is 200 mm.

Safe 200 mm distance must be kept in the cases when the flammability level of the material is
unknown. The same safety distance must be kept also for domestic objects, flammable
materials and fuels situated in the boiler room.

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The boiler must be steadily fixed over inflammable or heat-isolated foundation, which must
exceed the boiler contour with minimum of 300 mm in front and 100 mm in all other sides. For
easier handling and operation it is recommended that the foundation is inflammable and 100 –
150 mm high.

The boiler room must have ensured constant air flow for burning. Air consumption depends on
the boiler heating capacity, respectively 45-60 m3/h (200-300 cm2 opening for air intake
corresponds to such flow).

Danger

When the boiler operates do not touch any hot water pipe lines or flue pipes.

If there are two boilers in the room it is not allowed to position any fuel between them. It is
recommended to keep minimum distance of 800mm between the boiler and the fuel, or to
store the fuel in a premise different from the boiler room.

Danger

Do not put flammable materials over boiler’s top side or near it within the safety
distance.

7.4. CONNECTING THE BOILER TO THE HEATING SYSTEM

The BiSolid Saver boiler is designated for systems with natural gravity or forced circulation. To
reduce condensation of flue gases and to prolong boiler’s life time it is recommended to use
devices which do not allow the water temperature to decrease less than 65 oC (flue gases
point of condensation). For that purpose for example can be used a three-way, four-way
valves (DUOMIX) or thermostatic valve TSV.

Clean water has to be used as heat-carrier and it must comply with the standards. Its
hardness must not exceed the required values (Table 6).

Table 6. Boiler water parameters

Value Dimension Value

Hardness mmol/l 1
Ca2+ mmol/l 0.3

Total concentration of Fe + Mn mg/l (0.3)*

* - recommended value

As a passive boiler defense can be used liquids with low freezing point and anti-corrosion
action, for example FRITERM. In the cases when a two-way safety valve is connected to the
system, applying anti-freezing liquid is not recommended.

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7.5. INSTALLATION OF THE HEATING OUTPUT
REGULATOR

The heating output regulator or also temperature regulating valve (TRV) is mandatory part
from the necessary equipment to operate boilers from BiSolid Saver series and is delivered
together with the boiler, and also is included in the product price. Its installation usually is
performed by a specialized company, according to the applied from the TRV manufacturer
installation manual. TRV is installed in preliminary manufactured orifice with diameter 3/4“,
positioned on the upper right side of the boiler. It has to be connected to the primary air flap
tension-rod by a chain.

7.6. INSTALLATION OF THE THERMO-MANOMETER GAUGE

As special equipment, part of the boilers BiSolid Saver is also delivered a thermo-manometer
gauge – combined device for measuring water pressure and temperature. It is mandatory part
from the necessary equipment to operate the boiler. The thermo-manometer gauge is usually
installed by specialized company and is positioned on the hot water outlet muff, in a way that
will not prevent the fuel feeding door to open properly.

7.7. BOILER STRUCTURE - INSTALLATION OF COVER
PANELS

Before performing the boiler installation it is necessary to check:

1. Equipment:
a) Free equipment – covers with isolation kit.
b) Added equipment – cleaning tools kit – scraper and scratching brush (brush for pipes),
inlet muff, control lever end-caps, fastening material, installation and operation manual,
warranty card, TRV.

c) Integrated equipment – 2 pcs fire-grates, control lever, sealing and 3 pcs fire-clay bricks.
d) Special equipment – optional – combined temperature-pressure gauge with altimeter
(manotherm or thermometer), two-way safety valve DBV 1.

2. Remove the added steel plate inside the heating water lead-out muffs.

3. The initializing muff for supply of heating water must be positioned with direction towards
the floor. In case two-way safety valve DBV 1 is installed to the boiler, a T-profile part has to
be installed to the muff. A drain cock has to be screwed to it and the water supply should be
connected from the safety valve also.

4. End-caps have to be screwed at the end of the fire-grate control lever and at the initial
firing flap tension-bar.

5. Check the fire-clay bricks position.

6. Install the firing air regulator in accordance to the accompanying manufacturer manual.

7. Install the cover panels on the boiler, please see Figure 17.

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Figure 17. Cover panels installation on the boiler

1

3

2

6

4

5

a) Install cover panel for the hoper to fuel feeding door –position 1 fig.17 and screw them on

both sides with four bolts, by using the preliminary drilled orifices.
b) Installation of the heat-exchanger cover – position 2 fig.17 has to be performed in the same
way as described in paragraph (a).
c) The middle cover panel – position 3 fig.17. has to be inserted from its flat side under the

flange and then pulled towards the boiler ends (see fixing part of middle cover, fig.18).
d) Front cover panel – position 4 fig.17 has to be installed from its wider fixing side under the

low body brackets, then fix it with force to the boiler and then fix it to the upper brackets.
e) Installation of side cover panels – positions 4, 5 on fig.17 can be performed similar to

paragraph (d). When fixing the panels to the upper brackets try to precise, so their upper

side goes into the middle cover panel groove – position 3 on fig.17, and after that fix them

(please see the middle cover panel fixing part, fig.18).

Warning:

Before doing the final installation of the cover panels, it is recommended to lift
up each panel lower brackets, by using a bigger screwdriver. The brackets
should be corrected so there is a 2-3 mm gap between their lower edge and the
boiler body. This makes the cover panels installation easier.

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Figure 18. Fixing the middle cover panel

5, 6

3

7.8. EXPANSION TANKS (BUFFERS) OPERATION AND
INSTALLATION

The usage of expansion tanks (buffers) in systems for floor and central heating has a lot of
advantages, mainly because they limit the intake of air in the heating system. Increased
pressure has been monitored in some systems with expansion tanks, caused by incorrect
calculations. After years of boiler tests there has been introduced a common method for
calculation of expansion tanks sizes, with suitable maximum hydraulic difference which can
not damage the boiler body in cases of dynamic loads. For steel made boiler this difference is
defined at 50 kPa. For installation of expansion tanks to steel hot water boilers with capacity
up to 50 kW, the below introduced principles must be considered. In case any of the
principles is not considered the manufacturer will not cover warranty claims, for boilers that do
not function due to incorrectly designed, calculated or installed expansion tank.

1. The expansion tank water supply pipe must be as shortest as possible, without shut-off
devices and with availability for expansion. The expansion tank has to be positioned
without possibility for heating from sun light.

2. Every heating system must be equipped with minimum one reliable safety valve,
installed on the boiler outlet pipe line, and also with pressure-gauge.

3. If a safety valve is installed it is necessary to perform additional check for its working­order, which can be controlled by checking the overpressure value 180 kPa, at which
point it actually opens. In case the safety valve opening pressure is higher, a new
adjustment must be performed.

4. Installation and adjustment of the safety valve, as well as installation, with accompanying
checks and correction of the gas volume in the expansion tank, must be performed only
by an authorized for such activity company. Before filling the heating system with water it
is necessary to ensure that the gas pressure in the expansion tank is higher than the
system hydrostatic height.

5. The heating source must be equipped with safety device, by the means of the European
norms. For the solid fuel boilers with heat capacity up to 50 kW is necessary to install a
draught regulator. The maximum allowed operation temperature is limited to 95

o

C.

6. The expansion tank and its water supply pipe must be secured against water freezing.

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7. The overpressure in the expansion tank can be adjusted by exhausting until reaching the
value for hydraulic pressure of the system in cold condition. The exhausting has to be
performed by the valve, located on top of the expansion tank and the overpressure can
be measured with pressure-gauge in the hydraulic system. If adding water in the system
the pressure has to be regulated with maximum 10 kPa higher than the hydrostatic
height value of the system.

8. After filling the system with water it is recommended to mark the corrected hydrostatic
height value on the pressure-gauge with dashes and also the maximum pressure in the
system after reaching water temperature of 90 oC.

9. If during operation values reach hydraulic difference between the marked dashes and
exceed minimum or maximum pressure, it is necessary to re-check the system, to air­free it, add water when the system is in cold condition and eventually to correct the gas
pressure in the expansion tank, in compliance with the manufacture company directions.

10. In boilers which use expansion tanks the hydrostatic height value must be maximum 12
m.

11. Outer control checks of the expansion tanks and water inlet pressure must be performed
at least once per year.

12. Individual project must be designed for every heating system.

13. If optimum expansion tank is chosen then should not be measured more than 60 kPa
hydraulic pressure and within 10 to 90

o

C water temperature in the system. This
hydraulic difference can be checked by performing heat test in which the water in the
system has to be heated by starting from cold condition. If the measured hydraulic
difference is higher than 60 kPa this means that you have made wrong choice of
expansion tank and there is a risk of damaging the boiler.

Calculation of expansion tank volume:

Expansion tank volume: O = 1,3 . V . (P1+B)/B

B - hydraulic difference, with defined value at 50 kPa for steel made boilers
P1 - hydrostatic pressure in absolute value (kPa)
V - Increased water volume in the system…... V=G.v, (dm3)
1,3 – safety coefficient
G - mass of the water in the heating system, (kg)
v - water volume increase at defined temperature difference (dm3/kg)

t /°C/ 60 80 90
v /dm/kg/ 0.0224 0.0355 0.0431

The real hydraulic difference value can be higher than the calculated with maximum 10 kPa, in
case of calculated limiting values and increased gas pressure in the expansion tank, according
to point 7.

Example:
Mass of the water in the heating system G = 180 kg
Hydrostatic height of the water in the heating system 9.5 m
Hydrostatic pressure absolute value P1 = 195 kPa
Temperature difference in the system t = 80 °C
Change in the volume with t = 80 °C v = 0.0355 dm

3

/kg

Safety valve corresponding overpressure 180 kPa

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Hydraulic difference 50 kPa
Increased volume in the entire system:

V = G.v
V = 180 . 0.0355 = 6.39 dm

3

Expansion tank minimum needed volume:
O =1.3 . 6.39 (195 + 50)/50 = 40.7 dm

3

According to the calculated volume for the expansion tank is defined the real volume closest to
the manufactured volumes O =50 dm

3

Warning:

Revision control overview check must be performed to the integrated expansion
tank and hydraulic test must be performed on every nine years.

7.9. TRANSPORTATION AND STORAGE

The boilers for expedition are offered by the manufacturer on a wooden pallet and secured
against moving with cap bolts. The boilers should not be transported in position different from
their base (normal operating position).

It is necessary to ensure at least the minimum conditions for preservation of the boilers during
their storage and transportation.

During transportation and storage the boilers packages and cover panels should not be
pressed.

Danger

The boilers should not be moved or transported without using forklifts, transport
carts or other wheel based transport utilities.

Package liquidation:
The package can be liquidated with the assistance of waste disposal posts or municipal waste

depot.
Appliance liquidation after life-cycle expiration:

The product liquidation (the boiler) can be liquidated with the assistance of waste disposal
posts or municipal waste depot.

7.10. BOILER INSTALLATION TO FLUE OUTLET PIPES

The flue gas outlet pipes can be fixed to the boiler flue by rivets with 5 mm diameter. The
shortest possible variation for outgoing of the flue pipes has to be chosen considered from the
boiler to the chimney, under angle and upwards.

The flue pipe must be led to the chimney and to be stably fixed to the boiler flue, so there is no
accidentally or movement by hand. The flue pipe line should not be longer that 1,5 m and if
possible additional knee joints should not be used. All flue pipe line parts must be

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manufactured my inflammable materials. Flue lines for solid fuel are very well adjusted pipes,
which are installed in the same direction as the flue gasses.

7.11. BOILER JOINING TO CHIMNEY

It is mandatory that all boilers in central heating systems are individually connected to a
chimney, with appropriate chimney draught, which is main condition for optimum operation of
the boiler.

The chimney draught has an important effect over the boiler heating output, its efficiency and
life cycle length.

Recommended chimney heights are presented in Table 7.

Table 7. Recommended chimney heights

Chimney section area Dimension SAVER 25 SAVER 40

15x15 cm m - ­15x20 cm m 7.5 ­15x30 cm m 6.5 8.5
Diameter 20 cm m 7.5 9.0
Diameter 25 cm m 6.5 7.5

The presented values are tentative. The chimney draught depends on its section area, height,
inner wall roughness and also the difference between flue gas and outside temperatures. Most
recommended are the isolated chimneys or those with chimney insert. Actual chimney draught
can be measured by authorized installation and servicing company.

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8. TROUBLESHOOTING

Failure

Reason

Solution

Unsealed soot doors

Fasten all soot door nuts, if
necessary replace doors sealing.

Unsealed heat-exchanger
cover and fuel feeding door

Check sealing ropes, correct
sealing ropes positioning, if
necessary replace sealing ropes.

Insufficient chimney draught

Perform chimney draught checks
and take correction measures.

The used fuel is with low
caloricity.

Use the prescribed fuel type with
normal caloricity, especially in low
outside temperatures.

The boiler can not
reach its nominal
heating output

Caused by improper pellet
burner operation

Read: BiSolid GP pellet burner
operation manual.

Unsealed fuel feeding and ash­cleaning doors

Check sealing ropes, correct
sealing ropes positioning, if
necessary replace sealing ropes.

Boiler’s heating output
can not be regulated

Too high chimney draught

Half-close the valve in the chimney
body, if necessary perform
chimney draught checks and take
correction measures.

High hydraulic resistance in the
heating system, especially in
the standalone system

Perform system cleaning with
rinse, if necessary install
circulation pump.

High water temperature
in the boiler and in the
same time low water
temperature in the
radiators. Water in the
boiler boils.

Too high chimney draught

Decrease chimney draught by
using draught regulator

In all other cases removing of eventual failures must be performed by the manufacturer or
authorized servicing company.

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