Centrometal BioSolid 17, BioSolid 26, BioSolid 34 Technical Instructions

Page 1

The fuel to be used is only wood under 25% humidity content (wood dried min. 1 year). The outlet temperature always has to be over 60°C. This can be reached by obligatory connection of the 3-way thermic valve ESBE VTC 512, VTC 531 or Laddomat 21, which blocks the boiler temperature fall under the 60°C level if the boiler is connected to the central heating system through an appropriate number of the CAS accumulation tanks or manual 4-way mixing valve if the boiler is connected direct to the central heating system.

IMPORTANT !

During the process of refilling the fuel the main switch of the boiler and the button ‘’START/STOP’’have to be turned on.

NOTE:

www.centrometal.hr e-mail: [email protected]

Centrometal d.o.o. Glavna 12, 40306 Macinec, Croatia

central tel: +385 40 372 600, fax: +385 40 372 611 servce tel: +385 40 372 622, fax: +385 40 372 621

Centrometal d.o.o. shall not be responsible for possible incorrect data caused by printing errors or error made in transcription and all figures and diagrams are for explanatory purposes only and relevant adjustment have to be made at the spot. In any case, it reserves the right to modify its products as deemed to be required and useful without any prior notification.

TUCPlus-10_1/2010-eng

BioSolid

TECHNICAL INSTRUCTIONS

for installation, use and maintenance of hot water boiler and installation of additional equipment

HEATING TECHNIQUE

Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia, tel: +385 40 372 600, fax: +385 40 372 611

HEATING TECHNIQUE

Page 2

Technical data

BioSolid 26

(mm)

max.

330x150x150

BioSolid 17 BioSolid 34

max.

500x150x150

max.

500x150x150

TYPE

Fuel size

3 16 72

180 0,026 0,620

2,5

wood logs

12-20

530x255

250

670

596

1050 1070

840

1050

390

430

150

165

340

675

915

450

850

227

(kW)

(Pa) (lit.) (°C)

(kg/s)

(kW)

(mbar)

(h)

(%)

(l)

(mm)

(l)

(lit./kW)

(W)

(°/bar)

(V~) (Hz)

(W) (mm) (mm) (mm) (mm) (mm) (mm)

(kg)

(kg) (bar) (bar)

(°C)

(mm)

(R) (R) (R)

(R) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

underpressure

by EN 303-5 point 4.2.5

10-15°C, 2 bar

230

150

2,5 5,5

5/4" 1/2" 3/4" 1/2"

3 18 98

180 0,034 0,669

12-20

103

530x255

117

736

596

1150 1140

840

1150

489

534

165

340

775

1015

610

950

227

3 14 54

180 0,017 0,476

12-20

370x255

670

436

1050 1085

680

1050

288

318

165

340

505

915

450

850

275

Nominal heat output Boiler class Required chimney underpressure Water amount in boiler Exhaust gas temperature at nominal heat output Exhaust mass flow at nominal heat output Standby heat losses Boiler resistance on water side at nominal output Combustion period at nominal output Fuel type Fuel moisture content

Firebox volume Wood feeding opening AxB Combustion chamber volume Combustion chamber type Required minimum accumulation next to boiler Electrical power input Temp. and press. of water from water supply line into heat exchanger Supply voltage Frequency Current type Fan power

Boiler body mass Total mass - (boiler with casing and accessories) Max. operating overpressure Test pressure Max. operating temperature Uptake tube – external diameter

Dimensions of the boiler body

Dimensions in total

Total depth Total width Total height

Lenght Width Height

(D) (E) (F)

(A) (B) (C)

Flow and return pipe (male thread) Charge/discharge (female thread) Heat exchanger connector (male thread) Connector of exchanger sensor (female thread) H1 H2 H3 H4 H5 H6 L1

Other dimensions

Boiler connections

Technical instructions BioSolid Technical instructions BioSolid

12.0. ERRORS AND POSSIBLE CAUSES

ERROR

E1-1 - short circuit of the boiler sensor

E2-1 - short circuit of flue gas sensor E2-2 - flue gas sensor interrupted

E3-1 - short circuit of the heating accumulation tank sensor

E3-2 - heating accumulation tank sensor interrupted

E1-2 - boiler sensor interrupted

WHAT TO DO

Replace the boiler sensor

Replace the flue gas sensor

Replace the heating

accumulation tank sensor

Errors and possible causes

Page 3

Dimensions and basic parts of the boiler

LEGEND:

KR - Digital boiler regulation GV - Upper boiler door for cleaning VL - Door of the combustion chamber DV - Lower boiler door PL - PInlet line DM - Chimney connection VT - Fan PV - Outlet line PP - Filling / draining GR - Scraper for cleaning

KA - Heat exchanger connection - draining to the sewage TO - Thermal safety valve sensor connection TV - Heat exchanger connection - thermal safety valve connection point DO - Lower opening for flue gas chamber cleaning / opening for the secondary air OZ - Air opening lid OD - Place for the temperature sensor of flue gases SV - Microswitch ZP - Zipper IP - Base protection

Technical instructions BioSolid Technical instructions BioSolid

Grate

Metal sheet for grate

Figure 10. Metal sheets for grate

Grate

Metal sheet for grate

BioSolid 26 / 34 :

BioSolid 17:

Boiler cleaning and maintenance

Grate

Metal sheet for grate

C=F

DM OC

PV PP

DM OC

BioSolid 26 i BioSolid 34 BioSolid 17

Page 4

General, boiler description, delivery, additional equipment

1.0. GENERAL

1.1. BOILER DESCRIPTION

1.2. DELIVERY OF BioSolid BOILER

1.3. OBLIGATORY ADDITIONAL EQUIPMENT OF BOILER BioSolid INSTALLED TO CLOSED CENTRAL HEATING SYSTEM

-Thermal shut off valve (such as CALEFFI 543 513)- 1 piece

Technical instructions BioSolid Technical instructions BioSolid

Hot water boiler BioSolid have modern design, is made of proofed high-quality materials, welded by state-of-the art technology and meets all requirements for connection to central heating system.

Steel boilers BioSolid, with an rated thermal output 17, 26, and 34 kW are constructed for wood firing. They are intended for heating of small and middle sized premises. Widely sized combustion chamber enables the firing with wood pieces of 500 mm for boilers 26 and 34 kW and 330 mm for boilers 17 kW. One filling period lasts min. 2 hours, with the possibility of prolonging it to the whole day, if the heating requirement is decreased. The functioning of the boiler is steered by the built-in digital regulation system. The boiler must be connected to the central heating system through an appropriate number of the CAS water accumulators or directly to the central heating system. Boiler cleaning is very simply and can be done from the

front and back side.

The boiler BioSolid (covered by the casing with an thermal insulation and with builtin the digital boiler regulation), sensor for accumulation tank and scraper for cleaning (scraper, zipper), base protection.

Detail A

Figure 9. Openings for cleaning flue gas chamber

openings for cleaning flue gas chamber

Boiler cleaning and maintenance

Page 5

2.0. BOILER POSITIONING AND ASSEMBLY

min. 1000 mm

min.

500

min. 1000 mm*

min. 1500 mm

min. 700 mm*

Figure 1. Minimum distance from the room walls

Boiler positioning and assembly

min. 1000 mm**

* - If the boiler is installed in the heating system via the accumulation ** - If the boiler is directly installed on the heating system

Technical instructions BioSolid Technical instructions BioSolid

The boiler's body is covered by the casing with an thermal insulation on wooden box and packed in a protective PVC foil. Before placing boiler body onto its location in the boiler room, it should be removed from palette. Boiler positioning and assembly and building in of additional equipment must be performed by a qualified person. We recommend that boiler is placed on a concrete base with height of 50 to 100 mm above the floor. Boiler room must be frost-proof and well ventilated. Boiler has to be positioned so that it can be properly connected to the chimney (see point 4.0) and simultaneously, enabling tending of boiler and additional equipment, control during operation, and cleaning and maintenance (see Figure 1).

WARNING! Flammable items must not be placed on the boiler and within the minimum distances shown in Figure 1.

Figure 8. Extraction turbulators

BioSolid 26

BioSolid 34

Boiler cleaning and maintenance

5.Cleaning of the fan box:

- unscrew two M8 nuts and remove the fan box lid.

- remove ash and impurities from the fan box.

- place back the fan box lid on two M8 screws and tighten them with two M8 nuts to

get good air tightness during operation.

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Technical instructions BioSolid Technical instructions BioSolid

11.0. BOILER CLEANING AND MAINTENANCE

Boiler cleaning and maintenance

Protective gloves must be used (see Figure 7). Ash remaining in boiler after solid fuel firing should be disposed into metal containers with a cover. First, main switch at boiler control unit has to be turned off. Combustion chamber have to be clean on daily basis with scraper for cleaning. If the metal sheet, which that lie on the grid, are clipped or removed at cleaning, they need be put back (see Figure 10). Flue gas chamber should be cleaned as required. Fan box should be cleaned as required. Fan blades should be cleaned as required. Flue ducts should be cleaned as required. Ash tray in the lower boiler part should be cleaned as required. Checking of all control and safety elements once per year by authorised serviceman / fitter is recommended.

1. Cleaning a flue ducts

- open the upper boiler door (see Point 8.0 and Figure 5.3)

- take out turbulators from the flue ducts (only for BioSolid 26 and 34) (see Figure 8.)

- with scraper clean a dirt which are stuck on the wall of flue ducts

- bring back turbulators to the flue duct (only for BioSolid 26 and 34) (see Figure 8.)

- close upper boiler door (see Point 8.0 and Figure 5.3, Figure 5.4)

2. Cleaning a combustion chamber:

- combustion chamber can be cleaned through door of the combustion chamber and the lower boiler door with cleaning set (delivered with boiler)

- take care to clean thoroughly its lateral sides to ensure as better heat exchange and maximum boiler utilisation rate as possible.

3. Cleaning flue gas chamber:

- flue gas chamber can be clean through side openings (see page3 and Figure 9.)

- remove the cover

- remove the dirts which are stuck during the boiler operation i boiler cleaning

- bring cover back

4. Cleaning of fan blades:

- unscrew four M8 nuts by which the fan flange is fixed to the boiler.

- pull out the fan with the flange along the flange holder and turn it to the left to access the fan blade.

- then, remove all deposits of ash and impurities from the blade.

- put the fan together with the flange back on four M8 screws and tighten them with four M8 nuts to get good air tightness during operation.

2.1. BASE PROTECTION MOUNTING

Base protection (Page 3, IP) coming with the boiler and it is necessary set in the provided place after boiler positioning (see Figure 1.1.).

Figure 1.1. Base protection mounting

base protection

Base protection mounting

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Technical instructions BioSolid Technical instructions BioSolid

Figure 8. Primary and secondary air setup

Secondary air

Primary air

Secondary air

Manual primary air regulator:

Manual secondary air regulator

10.1. PRIMARY / SECONDARY AIR SETUP

Primary air setup

For the regulation primary or secondary air use MANUAL PRIMARY / SECONDARY AIR REGULATOR, (see Figure 8). It is recommended to use the boiler to the factory defaults. For a possible change in the setting of primary and secondary air is necessary to remove the screw M5 (Figure 8).

Factory defaultFactory default

Screw M5 Screw M5

4.0. CONNECTION TO CHIMNEY

3.0. MAKE UP AIR OPENING

Make up air opening, connection to chimney

Q - boiler output in kW

A - opening area in cm

A = 6,02 Q

Each boiler room must be equipped with an opening for supply of make up air which is dimensioned in accordance with boiler output (minimum opening area according to the below shown equation). Such opening must be protected with a net or grate. All installation works have to be performed in accordance with valid national and European standards. Boiler must not operate in flammable and explosive environment.

Properly dimensioned and built chimney is a precondition for safe boiler operation and heating efficiency. A chimney must be thermally insulated, gas-tight and smooth. Cleaning door must be made in the lower part of a chimney. Chimney made of bricks must include 3 layers with central insulation layer made of mineral wool. Thickness of thermal insulation should be min. 30 mm of chimneys is built against to interior wall, and min. 50 mm if it is built on the outer side. Internal dimensions of

the chimney light diameter depend on chimney height and boiler output and they have to be selected in accordance with diagram shown in Figure 3. The

chimney usable height is the measure from connection spot of smoke pipe to the chimney top. As these boilers can be fired with solid fuel, chimney has to be selected according to the solid fuel diagram. Fuel gas temperature at the chimney exist must be min. 30°C higher than condensation temperature of combustion gases. Selection and building of a chimney must be made by a professional. Required maximum distance from boiler to chimney is 1000 mm, and minimum distance is 500 mm. Uptake tube must be installed at an angle (min. 5°) with a gradient from chimney to boiler (Figure 2). In order to prevent condensate from chimney to enter the boiler, uptake tube must be placed 10 mm deeper into chimney. Connecting uptake tube between boiler and chimney must be thermally insulated with a mineral wool layer having thickness of 30 to 50 mm. All installation works must be made in accordance with valid national and European standards.

Page 8

Technical instructions BioSolid Technical instructions BioSolid

FUEL REFILLING PHASE:

- After the regulation starts to display the lack of fuel , the fuel should be refilled (if it is necessary to continue the heating process)-BEFORE REFILLING, press START button. (see Point 6.1.1).

- open the boiler door of combustion chamber (see point 8.0. and Figure 5.)

- align glow with poker

- insert fuel (recommended to fill the full firebox) (see Figure 6.)

- close the upper boiler door (see point 8.0. and Figure 5.)

TURNING OFF DIGITAL REGULATION:

- If we dont continues with heating proces, after the control indicator-no fuel switches on , wait until the boiler is cooled down below 65°C and until there is no glow in the chamber. Only then the main switch on the boiler digital regulation may be turned off (see 6.1.1.).

NOTE:

During the process of refilling the fuel the main switch of the boiler and the button ‘’START/STOP’’have to be turned on.

Boiler use

Connection to chimney, selection of a chimney

5 10 15

6 7 8 9

2530

Figure 3. Chimney dimensioning for boilers BioSolid

Useful chimney height (m)

Boiler nominal output (kW)

Light chimney diameter (cm)

An example of selection of a chimney:

- Boiler heat output: 34 kW

- Fuel: wood

- Required usable chimney height: H = 8 m

- Required chimney light diameter: 20 cm

- Usable chimney height - chimney height from connection spot of smoke pipe to the chimney top.

- Light chimney diameter - interior chimney diameter.

min. 500 mm max. 1000 mm

10mm

Figure 2. Possible ways of connections of boilers BioSolid to chimney

Thermal insulation

Opening for cleaning

Thermal insulation

Opening for cleaning

RECOMMENDATION

Page 9

Technical instructions BioSolid Technical instructions BioSolid

Boiler use

Check if the pump of heating system is connected to boiler control unit BioSolid. Check whether boiler control unit BioSolid is connected to power supply.Fuel with max. 25% moisture content may be used. Check if the fresh air access to the boiler room is available (Point 3.0) Check if globe valves toward heating bodies are open.

Check if the safety elements are properly connected and are functioning perfectly:

- closed central heating systems should have safety valve of max. 2,5 bar, thermal safety valve and expansion vessel of min. volume which is not less then 10% of the total water quantity in the system.

- open central heating systems should have an open expansion vessel of min. volume which is not less then 7% of the total water quantity in the system situated enough over the level of the highest radiator in the system and insulated, if it is mounted outside of heated space.

Check if the mobile elements of the boiler are properly positioned:

- sheet metal protecting cover (ZL-Figure 5.2.) have to be fixed to the carriers in the combustion chamber.

- air damper check if it is able to move.

- primary/secondary air door cover.

- firing has to be performed according to the instructions described in this manual If you are sure that energy from boiler will be consumed, made firing up for one filling of the firebox.

IGNITION PHASE AND FIRST FUEL CHARGING:

- Open boiler door of the combustion chamber (and close bottom if they open) (see point 8.0. and figure 5).

- Put small pieces of wood (chips), crumpled paper then again small pieces of wood (chips) to the combustion chamber (Figure 6.), on grate trought the door of the combustion chamber (Figure 6.). To all this put smaller logs (max. 25% moisture) to max. height 1/2 firebox.

- Close boiler door of the combustion chamber (see point 8.0. and Figure 5.).

- Turn the MAIN SWITCH on.

- Push the button ’’START / STOP’’ (the LED diode light).

- Open the lower boiler door (see point 8.0. and Figure 5.), little back-door behind the lower boiler door and ignite paper.

- Couple minutes after small pieces of wood (chips) starts burning, close the little back door and lower boiler door (see point 8.0. and Figure 5.).

- Check whether heating system pump turn on/off at approx. 65°C.

- After about a half hour refill firebox with wood logs (max. 25% moisture).

Installation of boiler to the central heating installation

5.0. BOILER INSTALLATION TO CENTRAL HEATING SYSTEM

5.1. BOILER INSTALLATION TO CLOSED HEATING SYSTEM

In closed heating system (as in example shown in Scheme 1a and 1b) it is obligatory to build in certified safety valve with opening pressure of 2,5 bar, minimum seat diameter of 15 mm, minimum inlet connection of 1/2", minimum exit connection of 3/4" and a membrane expansion vessel. Safety valve and expansion vessel must be built in accordance with professional rules and any valve must not be located between safety valve and expansion vessel and boiler. In all boiler types the heating pump must be connected to digital boiler regulation BioSolid according to electric diagram relevant for specific boiler use (point 7 in these instructions) so that the heating pump switching on and off would depend on water temperature in the boiler. If boiler is connected to the heating system under Diagram 1b it is recommended that the environment temperature control is made by a 4-ways manual mixing valve.

All installation works must be made in accordance with valid national and European standards. Boiler BioSolid can be built to closed and open central heating systems. In both cases boiler can be fired with solid fuel. Installation has to be made, in according to technical standards, by a professional who will be responsible for proper boiler operation. Before connecting boiler to central heating system, the system has to be flushed to remove impurities remaining after system installation. It prevents boiler

overheating, noise within the system, disturbances at a pump and mixing valve. Boiler should always be connected to central heating system by connectors, never by welding. Figure 1. shows safe distances required for boiler cleaning and maintenance.

Page 10

Technical instructions BioSolid Technical instructions BioSolid

Protective gloves are obligatory!

Figure 7. Protective gloves

Figure 6. Fuel supply method

Note: For opening the boiler doors see point 8.0. and Figure 5.

Fuel supply method, boiler use

10.0. BOILER USE

VL SV DV PZ DR

Boiler door of the combustion chamber Microswitch Lower boiler door Lever for opening / closing the boiler door of the combustion chamber Wood log

LEGEND:

bar

Installation of boiler BioSolid to closed heating system

Scheme 1a. An example of building in of accumulation tank into the central heating

system required under EN 303-5

Shema 1b. An example of building in of accumulation tank into the central heating system not required under EN 303-5

Closed heating system

6 7

8 9

-Obligatory installation of air self venting group (safety valve 2,5 bar)

-Room thermostat

-Manual 3-ways mixing valve

-Thermometer

-Thermostat valve-Temperature of return line min. 60°C

-Thermal protection of boiler

-Manual 4-ways mixing valve

-Accumulation tank (CAS)

-Closed-type expansion vessel

-P1 - Pump of the heating system

max

Page 11

Technical instructions BioSolid Technical instructions BioSolid

IGNITION PHASE AND FIRST FUEL CHARGING:

- Open boiler door of the combustion chamber (and close bottom if they open) (see point 8.0. and figure 5).

- Put small pieces of wood (chips), crumpled paper then again small pieces of wood (chips) to the combustion chamber (Figure 6.). To all this put smaller logs (max. 25% moisture) to max. height 1/2 firebox.

- Close boiler door of the combustion chamber (see point 8.0. and Figure 5.).

- Turn the MAIN SWITCH on.

- Push the button ’’START / STOP’’ (the LED diode light).

- Open the lower boiler door (see point 8.0. and Figure 5.), little back-door behind the lower boiler door and ignite paper.

- Couple minutes after small pieces of wood (chips) starts burning, close the little back door and lower boiler door (see point 8.0. and Figure 5.).

- Check whether heating system pump turn on/off at approx. 65°C.

- After about a half hour refill firebox with wood logs (max. 25% moisture).

FUEL REFILLING PHASE:

- After the regulation starts to display the lack of fuel , the fuel should be refilled (if it is necessary to continue the heating process)-BEFORE REFILLING, press START button ones, (see point 6.1.1).

- open the boiler door of combustion chamber (see point 8.0. and Figure 5.)

- align glow with poker

- insert fuel (recommended to fill the full firebox) (see Figure 6.)

TURNING OFF DIGITAL REGULATION:

NOTE:

During the process of refilling the fuel the main switch of the boiler and the button ‘’START/STOP’’have to be turned on.

Start up

5.1.1. BOILER THERMAL PROTECTION - BioSolid

Boiler thermal protection

According to European EN standards, boiler thermal protection must be installed in closed heating system. Boiler is factory prepared for installation of thermal protection. Heat exchanger is built into boiler at factory, and thermal safety valve 2 is installed according to scheme 2. In case of any damage of boiler installed in the closed heating system due to its overheating, and boiler or system are not equipped with any thermal protection at all, or do not have properly installed thermal protection, guarantee will not be applied.

IMPORTANT:

Thermal protection must be connected to the water supply installation of the premises supplied from the water supply line and not from hydrophor. Namely, in case of failure of power supply, boiler could be overheated, and then hydrophor is not able to ensure required water supply.

THERMAL FUSE:

Thermal fuse for boiler BioSolid consists of a heat exchanger which is factory built in boiler, and thermal valve 2 (such as CALEFFI 543 513) (see Scheme 2.).

Part 2 is installed into prepared connector (male thread 3/4") in the upper back side of boiler. INSTALLATION (under Scheme 2.)

- Thermal valve 2 is installed onto prepared connector (male thread 3/4") 6

- Connector 5 (female thread 3/4") of thermal valve should be connected to connector of heat exchanger factory built into boiler 6 (male thread 3/4").

- Thermal valve connector (female thread 3/4") should be connected to cold sanitary water supply.

- Connector of heat exchanger 7 should be connected sewage system.

- Tighten thermal valve sensor (male thread 1/2") into coupling 1 (female thread 1/2”)

bar

Scheme 2. Installation of thermal protection of boiler BioSolid installed in the closed heating system

FROM WATER SUPPLY SYSTEM CONNECTED TO MUNICIPAL WATER SUPPLY LINE

Safety valve 2.5 bar

Inlet into central heating system

Outlet from

central heating system

SEWAGE

* Position of thermal valve after installation:

(valve head downward)

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Technical instructions BioSolid Technical instructions BioSolid

9.0. START UP THE BOILER

Start up

Boiler must not be used in flammable and explosive environment. It must not be used by children or disabled persons (either physically or mentally), as well as by person without knowledge or experience, unless they are under control or trained by s person responsible for their safety. Children must be supervised in the vicinity of the product. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.Protective gloves are obligatory (Figure 7.). Check whether boiler and equipment are installed and connected in accordance with these Technical instructions including all points from 1.0 to this 9.0. Check whether chimney meets requirements of point 4.0 therein. Check whether boiler room meets all requirements therein. Check if fuel fulfils all requirements therein. Check whether the boiler and the entire heating system are filled with water and vented. Check whether safety elements have been correctly installed and in proper working order (see previous points of instructions). Check whether uptake duct is sealed and thermally insulated. Check if the pump of heating system is connected to boiler control unit BioSolid. Check whether boiler control unit BioSolid is connected to power supply. Check if the boiler is connected direct to the central heating system or throught one or more water accumulator/s, through the appropriate pump/s and 3-way thermic valve ESBE VTC 512, VTC 531 or Laddomat 21 according to this manual. Fuel with max. 25% moisture content may be used. Check if the fresh air access to the boiler room is available (Point 3.0) Check if globe valves toward heating bodies are open. Check if the safety

elements are properly connected and are functioning perfectly:

Check if the mobile elements of the boiler are properly positioned:

- sheet metal protecting cover (ZL-Figure 5.2.) have to be fixed to the carriers in the combustion chamber.

- air damper check if it is able to move.

- primary/secondary air door cover.

- metal sheet for grate set to providet place (see Figure 10).

- firing has to be performed according to the instructions described in this manual Remove all objects like documents/manuals eventually laying inside the boiler. If you are sure that energy from boiler will be consumed, made firing up for one filling of the firebox.

-Boiler BioSolid

-thermometer

2 3 4 5

-close tightly

-manual 3-ways mixing valve

-manual 4-ways mixing valve

-thermostat valve-ensures temperature in return pipe min. 60°C

-accumulation tank (CAS)

-room thermostat

-open expansion vessel OPC

-P1 - pump of the heating system

5.2. BOILER INSTALLATION TO OPEN HEATING SYSTEM

OPC

Example of installation of boiler BioSolid in an open heating system

Scheme 3a. An example when building in of accumulation tank into the central heating

system required under EN 303-5

ABOVE THE HIGHEST HEATING BODY

U kotlovnicu

Scheme 3b. An example when building in of accumulation tank into the central heating

system is not required under EN 303-5-5

ABOVE THE HIGHEST HEATING BODY

U kotlovnicu

Open heating system

If boiler is installed in an open central heating system, it is recommended that system is made according to Scheme 3a or 3b. In open system it is necessary to put an open expansion vessel above the height of the highest heating body. If expansion vessel is located in a room without heating, it should be insulated.

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Technical instructions BioSolid Technical instructions BioSolid

Figure 5.4. Use the zipper when closing boiler door of the combustion chamber

Detail A

Zipper

Boiler door opening method

Boiler control unit

6.0. CONTROL OF BOILER TEMPERATURE

6.1. BOILER CONTROL UNIT BioSolid

- ''0/1'' the main switch (power supply switch) has the function to turn on / off the regulator.

- Indication "START" (LED diode) shows the regulator functioning mode-turn on.

- ''START / STOP" button - turn on / turn off the fan.

- "+" button.

- "SET" button.

- "-" button.

- Indication (LED diode) "NO FUEL" indicates that the temperature of the flue gases is below the default value after defined elapsed time of fan work.

- Indication "FAN" (LED diode) indicates that the fan is turned on/off.

- Indication (LED diode) "Pump". indicates that the pump P1 is turned on/off.

- The LED display shows the measured temperatures, paramter settings and detection of possible errors.

- safety thermostat -turn of the supply of electricity to the boiler and turn of boiler control unit if temperature in boiler exceeds 110°C (+0°C / -9°C)

5 6 7

8 9

Pump of heating system P1 (see scheme 1 and 2) should be connected to boiler control unit BioSolid which control pump operation and protects boiler against subcooling.

Fi20

Fi10

Figure 4. Control panel of boiler control unit BioSolid

6.1.1. DESCRIPTION OF THE BUTTONS AND LABELS ON BOILER CONTROL UNIT

If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

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Technical instructions BioSolid Technical instructions BioSolid

Boiler door opening method

-Lower boiler door

1. Pull the handle of the lower boiler door RDV in the direction of the arrow UP (Figure 5.2).

2. Press the lower boiler door DV in the direction of the arrow right (Figure 5.2).

3. Press the handle of the lower boiler door RDV in the direction of the arrow DOWN (Figure

5.2.) that te the lower boiler door DV is closed.

Figure 5. Boiler door opening method

VL SV DV PZ

GR RV

Boiler door of the combustion chamber Microswitch Lower boiler door Lever for opening / closing the boiler door of the combustion chamber Delimiter Handle of the boiler door of the combustion chamber

DVL DR

PGV GV RDV ZL

Holder of the boiler door of the combustion chamber Wood log Cover of the upper boiler door Upper boiler door Handle of the lower boiler door Sheet metal protecting cover

Setting the boiler operating parameter

6.1.2. VIEWING THE MEASURED TEMPERATURE

6.1.3. SETTING THE BOILER OPERATING PARAMETERS

6.1.3.1. BOILER SET TEMPERATURE

6.1.3.2. OTHER PARAMETERS OF THE BOILER OPERATION

For view the measured temperature using buttons ''-'' or ''+'':

-T urn on (1) the main switch (0/1)

- Holding down the button ‘’+’’ on the display is displayed ''_ _ 01''. When we relase the button ''+'' on the display is displayed flue gases temperature without label °C. Following holding down the button ''+'' on the display is displayed ''_ _ 02'', when we relase the button ''+'' on the display is displayed accumulation tank temperature without label °C. The boiler temperature with label °C is displayed on the display after the short review. Holding down the button ''-'' the preview goes reverse way.

Factory setting: 80°C Available setting: min. 70°C; max. 90°C. When is boiler installed directly on heating installation (no accumulation tank) (Figure 1b, 3b), adjust a boiler temperature max. 80°C. Changes procedure of the set temperature of the boiler:

- Turn on (1) the main switch (0/1)

- ''SET'' and ''-'' buttons press 3 seconds, displayed ''P-01'’

- Press the button ''SET'', displayed on the display ''t 80'’

- When we pressed the buttons ''+'' or ''-'' it is posible to change the set boiler temperature

- Press the button ''SET'', displayed on the display ''P-01'’

-Short press the button ''ON/OFF'' for input confirmation. On the display is displayed current temperature of the boiler (if the button for change temperature or ''ON/OFF'' button is not pressed within 60 second on the display is displayed current boiler temperature without input confirmation changes of set boiler temperature.

FP01 - difference of the boiler temperature at which is the fan again turn on (fan turn off when the boiler temperature is set and turn on when the boiler temperature value is lower then set difference), Factory setting: 5°C, set range 0-8°C. FP02 - elapsed time from the button ''START'' was pressed or from the boiler door was opened / closed or from the fan achieved set boiler temperature and turned off / turned on or from the fan achieved flue gas temperature (250°C) and turned off / turned on to beginning of comparing flue gas temperature with boiler temperature - when is flue gas temperature is lower then water temperature in the boiler, the fan turn off, and LED diode ''NO FUEL'’ turning on. Factory setting: 120 (minutes), set range 0-180 (minutes).

OPEN

CLOSED

DVL

Detail A

Figure 5.1

Figure 5.2

DOWN

Figure 5.3

Detail B

RDV

LEFT RIGHT

CLOSED OPEN

PGV

Nut M10

LEGEND:

DOWN

Page 15

Technical instructions BioSolid Technical instructions BioSolid

8.0. BOILER DOORS OPENING METHOD

Door opening method

Protective gloves are obligatory (Figure 7.)! BOILER DOORS OPENING METHOD:

- Boiler door of the combustion chamber

1. Pull the lever for opening / closing the boiler door of the combustion chamber PZ in the direction of arrow OPEN (Figure 5.2.).

2. Catch the handle of the boiler door of the combustion chamber and the door slightly open, leave them as a couple seconds to fan draw smoke through short circuit and open them up to the required height that the holder of the boiler door of the combustion chamber DVL can recline on the delimiter GR (Figure 5.1., detail A).

3. Easy take down boiler door of the combustion chamber VL so that the holder of the boiler door of the combustion chamber DVL hook to the delimiter GR (Figure 5.1., detail A).

- Upper boiler door

1. Remove the cover of the upper boiler door PGV in the direction of the arrow UP (Figure 5.3).

2. Remove the two nuts M10 and washers (Figure 5.3., Detail B) which are attached the upper boiler door GV.

3. Open the upper boiler door GV in the direction of arrow OPEN (Figure 5.3).

- allowed to open only at the stage of cleaning of the boiler and boiler parts.

- Lower boiler door

1. Pull the handle of the lower boiler door RDV in the direction of the arrow UP (Figure 5.2).

2. Open lower boiler door DV in the direction of arrow LEFT (Figure 5.2).

- allowed to open only at the stage of ignition phase of the boiler, cleaning of the boiler and boiler parts.

BOILER DOORS CLOSING METHOD:

- Boiler door of the combustion chamber

1. Catch with the right hand handle of the boiler door of the combustion chamber RV and boiler door of the combustion chamber VL pull up slightly, and with left hand and with zipper slip away (draw to yourself) holder of the boiler door of the combustion chamber DV (Figure 5.1.,Detail A, Figure 5.4, Detail A).

2. Take down lower boiler door of the combustion chamber VL to heights in which freely released holder of the boiler door of the combustion chamber DV can not hook the delimiter GR, let off the holder of the boiler door of the combustion chamber DV and close the boiler door of the combustion chamber VL.

3. Catch with the left hand the handle of the boiler door of the combustion chamber RV, press down the boiler door of the combustion chamber VL and close them with lever for opening / closing the boiler door of the combustion chamber PZ in the direction of arrow CLOSED (Figure 5.2)..

-Upper boiler door

1. Close the upper boiler door GV boiler in the direction of arrow CLOSED (Figure 5.3).

2. Mounting the two nuts M10 and washers (Figure 5.3., Detail B) to attach the upper boiler door GV.

3. Put the lid of the upper boiler door PGV in the direction of arrow DOWN (Figure 5.3.).

6.1.3.3. RESETTING THE BOILER CONTROL UNIT TO FACTORY SETTING

6.1.4. RELAY TEST

Other parameters of the boiler operation, resetting to factory setting, relay test

FP03 - Select operation (1) with or (0) without tempertaure sensor of heating accumulation tank, factory setting on (1).

- turn off (0) the main switch (0/1).

- holding down button ''SET'' and main switch (0/1) turn on (1). On the display is displayed ''pin''.

- press the button ''SET''. On the display is displayed 4 lines-down, and left line flashing. Pressing on the buttons ''+'' or ''-'' we enter numbers, and pressing on the button ''SET'' we confirm each digit, and move to the next digit.After confirming the last digit on the display is displayed ''FP01''. Pin is 1234.

- press the button ''SET'' on the display is displayed value FP01.

- pressing on the buttons ''+'' or ''-'' is posible to change the value Fp01. Values flashing when they are not factory.

- press the button ''SET'', on the display is displayed FP02.

- pressing on the buttons ''+'' or ''-'' is possible to change the value Fp02. Values flashing when they are not factory.

- press the button ''SET'', on the display is displayed FP03.

- pressing on the buttons ''+'' or ''-'' is posible to change the value Fp03. Values flashing when they are not factory.

- press the button ''SET'', on the display is displayed FP01 and so goes to the circle.

- Short press the button ''ON/OFF'' for input confirmation. On the display is displayed current temperature of the boiler (if the button for change temperature or ''ON/OFF'' button is not pressed 60 seconds on the display is displayed current boiler temperature, without input confirmation changes.

- turn off (0) the main switch (0/1)

- holding down button ''+'' and main switch (0/1) turn on (1). On the display is displayed ''FS'' and a few second is displayed current boiler temperature.

- turn off (0) the main switch (0/1)

- holding down button ''ON/OFF'' and main switch (0/1) turn on (1). Fan starts to work, light LED diode ''FAN'', on the display is displayed tESt. By pressing the buttons ''+'' or ''-'' we select pump relay, light diode ''PUMP'' and so goes to the circle (if the buttons is not pressed within 60 seconds the relay test be over automatically and on the display is displayed current boiler temperature.

Page 16

Connection to electrical installations

Technical instructions BioSolid Technical instructions BioSolid

7.0. CONNECTING BOILER TO ELECTRICAL INSTALLATIONS

All electrical works must be performed by a certified professional in accordance with valid national and European standards. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. A device for switching of all power supply poles must be installed in electrical installation in accordance with the national regulations on electrical installations. Pump of heating system should be connected to boiler control unit BioSolid (5-bit connector on the back side of boiler)

6.1.5. ELECTRIC POWER SUPPLY INTERRUPTION

6.1.6. POSSIBLE ERRORS

Power suply interruption, posibile errors

If the electric power supply is interrupted while the boiler is operating (ON) after the supply is re-established the boiler continues its operation. If druing the operation phase of the boiler (ON) the main switch (0/1) has been turned to off (0), after the new activation of the main switch (1) the boiler will work like the electric power supply is re-established - the boiler continues its operation.

By errors on the display is dispayed label of the errors: E1-1 - short circuit of the boiler sensor E1-2 - boiler sensor interrupted Fan operation disabled, pump works normally

E2-1 - short circuit of flue gas sensor E2-2 - flue gas sensor interrupted Fan operation disabled, pump works normaly

E3-1 - short circuit of the heating accumulation tank sensor E3-2 - sensor of heating accumulation tank interrupted Fan and pump works normally, reading the temperature of heating accumulation tank impossibile

Figure 4. - Connecting pump and accumulation tank temperature sensor

L1 L2 N

SENSOR

CAS

PUMP