Tifell Biofell 30 BV, Biofell 50 BV Installation And Maintenance Manual
Installation and Maintenance
Guide
Cascade installation
of modulating oil-fired
condensing boilers
Biofell 30 BV
Biofell 50 BV
Page 2 of 20 601130040 [Revision 1502.00] [subject to changes with no previous notice] Biofell Cascade
1 Set Measurements .............................................................................................................................................................. 3
2 Power Connections ............................................................................................................................................................ 3
2.1 Basic Hydraulics ................................................................................................................................................................................ 4
2.2 Filling the System .............................................................................................................................................................................. 5
2.2.1 General Notes ........................................................................................................................................................................... 5
2.2.2 Water Features .......................................................................................................................................................................... 5
3 Combustion Waste Disposal ............................................................................................................................................. 6
3.1 Single Exhaust Pipes......................................................................................................................................................................... 6
3.2 Evacuation Manifold .......................................................................................................................................................................... 7
3.3 Drainage of Condensate.................................................................................................................................................................... 8
4 Fuel Installation .................................................................................................................................................................. 9
5 Temperature Control .......................................................................................................................................................... 9
5.1 Heat Demand ...................................................................................................................................................................................... 9
5.1.1 Heating and DHW Controlled by Biofell’s Cascade System ...................................................................................................... 9
5.1.2 Heating and DHW Controlled by an External Device (0-10 v) ................................................................................................... 9
5.2 Module Ignition Sequence ................................................................................................................................................................ 9
6 Electric Wiring .................................................................................................................................................................... 9
6.1 Wiring diagram ................................................................................................................................................................................. 10
7 Settings ............................................................................................................................................................................. 12
7.1 Configuring All Modules ................................................................................................................................................................. 12
7.2 Configuring Module 1 [master] ....................................................................................................................................................... 14
8 Temperature Display ........................................................................................................................................................ 15
9 System Parameters .......................................................................................................................................................... 15
9.1 Operation Levels .............................................................................................................................................................................. 16
9.2 LPB Parameters ............................................................................................................................................................................... 16
9.3 Configuration Parameters ............................................................................................................................................................... 16
9.4 Boiler Parameters ............................................................................................................................................................................ 16
9.5 DHW Parameters .............................................................................................................................................................................. 16
9.6 CCP/CCB Heating Parameters ........................................................................................................................................................ 16
9.7 Maintenance Parameters................................................................................................................................................................. 17
10 Alarm Codes ..................................................................................................................................................................... 17
11 Settings Tab ...................................................................................................................................................................... 18
12 Monitoring and Maintenance Plan .................................................................................................................................. 18
Thank you for choosing a Tifell boiler. Within the Tifell range of products you have chosen one Biofell model. This is a boiler capable of providing the right comfort level for your
home, together with an adequate, diesel-powered hydraulic system delivering a balanced and economical supply of domestic hot water.
This document is an integral and essential part of the product, and shall therefore be delivered with it to the user. Read the warnings and advice contained in this manual, as
they provide important information about the product’s safe installation, use and maintenance.
The installation of this boiler must be carried out by qualified personnel in accordance with current standards and following the manufacturer's instructions.
Both commissi oning and maintenance of these boilers should be performed by Ti fell’s Official Technical Assi stance Service.
Current Spanish regulations on thermal installations in buildings, Royal Decree 1027/2007 of July 20, hold the owner or user responsible for the installation and maintenance of
machinery and equipment, regardless of whether there exists a legal warranty on them by the manufacturer or seller. They also demand a mandatory annual inspection. Breach
of this requirement may hold the owner or user liable for any damage to third parties, without prejudice to any administrative penalties applicable.
Improper installation of these boilers can cause damage to people, animals and objects. The manufacturer disclaims all responsibility in this regard.
Biofell Cascade 601130040 [Revision 1502.00] [subject to changes with no previous notice] Page 3 of 20
1 Set Measurements
129,50
110
780,2
84,5 310 119
749,5
110
K
2.028,5
643
28
64 515 64
535,5 60 292124,5
749,5
84,5 60 292124,5
15,70
780,2
84,5 129,5
533,5 60 292124,5
95
60
50
50
60
1.823 [Biofell 50] / 1.880 [Biofell 30]
K
84,5 60 292124,5
95
60
50
50
60
643
524119
35
813 [Biofell 50 ] / 870 [Biofell 30]
K
J
D
F
A
B
J
D
F
A
B
A
Fuel inlet 3/8”M
B Fuel return 3/8”M
D Heating return 3/4”M
F Way of heating 3/4”M
J Condensate outlet 20 mm
K Flue 80 mm
Figure 1
2 Power Connections
Up to 16 sets of Biofell BV [30] [50] thermal units (modules) may be installed.
If the heating circuit is old, or likely to contain or generate sludge or impurities that can clog the modules’ heating bodies, a plate heat exchanger must be
installed to separate the heating circuit from the modules.
In case of not using a plate heat exchanger, it is imperative to install a balanced needle, and a sludge filter and/or decanter, on return
modules. This obligation is doubly justified when the gage height at installation exceeds a 2-bar pressure.
Before hydraulically connecting the modules to the insta llation, a sweep of the entire hydraulic circuit should be performed.
Page 4 of 20 601130040 [Revision 1502.00] [subject to changes with no previous notice] Biofell Cascade
2.1 Basic Hydraulics
15
1616
DHW OUTPUT
GENERATOR CONDENSA TION
FLUE CONDENSATI ON
FILLING
THE
SYSTEM
MIXED CIRC UIT´ S
FLOW
MIXED
CIRCUIT´S
RETURN
COLD WATER INLET
Module 1Module 2
Module nModule 3
S
ACS
M B3
S
CAL
M B 1X
TA
CAL
M H3
0-10v
M H3
S
E
M B9
B
CAL
QX1 N
B
ACS
Q3 N
VM
CAL
Y2 Y1
Figure 2
Figure 3
Biofell Cascade 601130040 [Revision 1502.00] [subject to changes with no previous notice] Page 5 of 20
Figure 4
2.2 Filling the System
2.2.1 General Notes
To prevent lime scale damage to the DHW exchanger, the feed water hardness should not exceed 15°fH. In any case it is advisable to
check the water used, and install the appropriate device for its treatment.
To fill up the system, clean tap water must be used only. If adding antifreeze chemicals, a hydraulic breaker must be installed in the filling
system, to allow separation between the heating circuit and the water circuit.
After making the hydraulic connections, complete the installation as follows:
Check that the pump is not blocked.
Check that the automatic air vent is loose to allow gas evacuation.
Open the DHW’s main circuit input.
Unscrew the pump cap to remove any air bubbles, and close it when water comes out of it.
Open the traps on any devices connected to the circuit, and control the process of removing any air. When water comes out, close radiator straps.
Check the gauge so that installation pressure reaches a value of about 1.5 bar.
If after performing the operations indicated, a decrease in pressure is detected, open the fill again until the gauge pressure reaches 1.5 bar.
Ensure that the fill is securely closed.
2.2.2 Water Features
To ensure that the device should work properly, take into account the following basic rules:
Make sure there are no leaks, and closing any large or evident ones.
If there is an automatic filling system, a counter should be available to determine the size of any leaks.
To fill the system soft water should be used to reduce the total hardness. Furthermore, water must be treated to keep the pH value within corrosion-
preventing limits.
For new installations or boiler replacements, installations must be effectively filtered or screened to protect the boiler from impurities and air.
Ensure that no water come out of the system during maintenance operations, even though the amount seem insignificant: for example, it is
recommended that the system incorporate cutting keys allowing filter cleaning.
Before connecting the boiler, the system’s water should always be tested to check if the values shown advice emptying the system, using existing
waters or performing a chemical cleaning (if the system is particularly dirty or clogged) before filling it with treated water.
Water treatment
Page 6 of 20 601130040 [Revision 1502.00] [subject to changes with no previous notice] Biofell Cascade
To preserve the primary circuit heat exchanger and ensure optimum heat transfer, the features of the water flowing through the boiler’s primary condensate
exchanger must remain constant over time. Preparatory work such as the system’s cleaning and maintenance, checking water features, and installing
filtration systems are essential to achieve this goal.
The choice of water treatment should be made according to the water features, the system type, and the limits of purity required.
Oxygen
Inevitably a certain amount of oxygen will infiltrate the system, both in the filling phase and during operation (system refills, or using materials without
oxygen barrier). Oxygen reacts with steel, causing corrosion and sludge formation. The heat exchanger is made of stainless steel to avoid corrosion, but
sludge may accumulate on hot parts, including the exchanger. As a consequence, the boiler’s power is reduced, and the primary exchanger’s active parts
may obstruct, which in turn may damage the boiler.
To limit this consequence one can resort to:
Mechanical systems: a suitable combination of traps and water softener reduces the amount of oxygen present in the system.
Chemical systems: additives that allow oxygen to remain dissolved in water.
Hardness
Depending on the mains water hardness, its calcium content varies. Calcium sticks to hot parts, including the primary heat exchanger. This may reduce the
boiler’s capacity, and obstruct the primary exchanger’s active parts, which can seriously damage the boiler.
If the mains water does not comply with the values shown in the following table, then it must be treated to soften it. Additives can be used to keep the lime
dissolved. Water hardness should be controlled regularly, and the following values recorded:
A
cidit
y
6,6 < pH < 8,5
Conductivity 400 ÷ 600 μS/cm (a 25°C)
Chlorides < 125 mg/l
Iron < 0,5 mg/l
Coppe
r
< 0,1 mg/l
When the above values are exceeded, applying a chemical treatment is necessary.
Remember that the choice of a water treatment should be made according to the water features, the system type, and the limits of purity
required.
3 Combustion Waste Disposal
3.1 Single Exhaust Pipes
The installation of exhaust ducts for combustion products must be performed by qualified personnel, and must comply with the requirements of the national
and local laws and regulations. The Biofell boilers are pressurized, so the evacuation of combustion products is via a sealed 80 mm-diameter outlet duct,
while the air is taken in from the room where the boiler is installed.
All accessories used in the evacuation of combustion products must be supplied by Tifell.
The maximum flue length (L) that can be installed is:
Flue’s maximal length D=80
Models Maximum length
Biofell 30
15.00 m
Biofell 50
7.00 m
When setting up the flue, one must consider the equivalent lengths of the fittings listed in the following table in any case maximum length be exceeded.
Equivalent lengths of accessories
Accessory
V
ertical Horizontal
1,000 mm linear section 1.00 m 1.50 m
90º bend 1.50 m 2.50 m
45º bend 1.75 m 1.00 m
It is recommended to place the vent pipe slightly inclined (2 to 3 %) upwards, thus preventing its blowing out condensate produced in the duct. Do not turn
the flue more than four times in the whole length of the discharge.
If the flue is completely vertical, and its length grea ter than 3 m, a condensation-collecti ng siphon should be connec ted to a drain on the
duct’s base.
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