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Summary of Contents for THERMOSTAHL BIOPLEX MCL-BIO
- Page 1 BIOMASS-SOLID FUEL RETORT BOILER BIOPLEX MCL-BIO INSTALLATION AND SERVICE MANUAL VERSION: UPDATE: 10.10.2013...
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Page 2: Table Of Contents
Contents GENERAL INFORMATION ....................3 1.1. Proper use of the appliance ....................3 1.2. Safety warnings ......................3 1.3. Data label ........................3 1.4. Document information ..................... 3 TECHNICAL FEATURES AND DIMENSIONS ............... 4 2.1. Technical features ......................4 2.2. Function principle ...................... -
Page 3: General Information
The appliance is designed for use in pumped hot water central heating systems. Any other use is considered improper and is prohibited. THERMOSTAHL declines any responsibility for damages or injuries caused by improper use; in this case the risk is completely at the user’s responsibility. -
Page 4: Technical Features And Dimensions
TECHNICAL FEATURES AND DIMENSIONS 2. TECHNICAL FEATURES AND DIMENSIONS 2.1. Technical features BIOPLEX boiler is a steel solid fuel boiler, with cylindrical heat exchanger consisted of fire tubes. The furnace system BIOFIRE made of steel plates. The furnace plate and grates that come in contact with fire are made of special refractory cast iron. -
Page 5: Function Principle
TECHNICAL FEATURES AND DIMENSIONS 2.2. Function principle 2.2.1. Boiler The function of the BIOPLEX boiler is based on natural gas evacuation through the chimney. The fuel is positioned on the grate. The combustion takes place in the fire chamber. During the combustion the flame comes in contact with the side walls of the fire chamber, which are surrounded by water. -
Page 6: Dimensions
TECHNICAL FEATURES AND DIMENSIONS 2.3. Dimensions DIMENSIONS Feeding door Type inch MCL-BIO 20 350x480 1470 1280 1380 1½” 1” ¾” 1½” MCL-BIO 28 350x480 1470 1280 1380 1” ¾” 1½” ¾” MCL-BIO 36 350x480 1470 1280 1380 1060 1” MCL-BIO 45 350x480 1470 1280... - Page 7 TECHNICAL FEATURES AND DIMENSIONS BOILER TECHNICAL DATA Fire Max. Pellet Silo Nominal Output* chamber wood Weight consumption** volume Boiler type length length kcal/h kg/h MCL-BIO 20 20.000 2,0-3,0 MCL-BIO 28 28.000 3,0-4,0 MCL-BIO 36 36.000 4,0-5,0 MCL-BIO 45 45.000 5,0-6,5 MCL-BIO 53 53.000 6,0-7,0...
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Page 8: Fuel
TECHNICAL FEATURES AND DIMENSIONS 2.4. Fuel The BIOPLEX series is designed for automatic function with solid fuel of biogenic or fossil nature, with granulation up to 30 mm and humidity up to 20%. The boiler is also able to be used on wood or other solid fuels with manual feeding, without any modification. -
Page 9: Boiler Mounting
BOILER MOUNTING 3. BOILER MOUNTING 3.1. Transportation and delivery The boiler is delivered on wood pallet, well positioned with metal plates. Remove them carefully by unscrewinf the screws holding them in place. The loading and unloading of the boiler must be performed with a forklift or a crane. A special hook is provided on the upper part of the boiler for lifting. -
Page 10: Boiler Room
BOILER MOUNTING 3.2. Boiler room 3.2.1. General requirements The boiler must be installed in a special and separate room. This room must be chosen so that it offers easy access for fuel transport, air supply and exhaust gas evacuation. The doors of the boiler room must be metallic, open outwards, and have at least 0,9 m width. -
Page 11: Chimney
BOILER MOUNTING 3.3. Chimney The chimney installation must supply sufficient draught, air tightness and protection against condensation. The appropriate chimney installation is very important for the boiler’s efficient and safe function! The chimney must be positioned if possible in the interior of the building. It must be vertical, with no changes in the direction. - Page 12 BOILER MOUNTING Fig 4. Chimney connection...
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Page 13: Installation
INSTALLATION 4. INSTALLATION 4.1. Hydraulic connections The boiler is intended for connection with an open expansion vessel network. The boiler can be connected also with closed expansion vessel, if it is equipped with an overheating serpentine (optional). The boiler is intended for maximum working temperature 90 C and maximum pressure 3 bar for boilers up to 500 kW, and 4 bar for bigger boilers. -
Page 14: Overheating Serpentine
INSTALLATION 4.3. Overheating serpentine As an optional, the boiler can be equipped with an overheating protection serpentine. This is incorporated in the boiler body, surrounding the fire chamber. For the function of the safety serpentine, a discharge valve must be installed. The bulb of the valve must be mounted on the boiler’s hot water delivery, at maximum distance 1m from the boiler. -
Page 15: Filling The System
INSTALLATION 4.5. Filling the system After completing all the hydraulic connections, the circuit may be filled with water. After filling the system, open the radiators air valves to get rid of the air in the installation. Verify that the installation pressure is according to the technical feature of the boiler. The pressure must be verified through the boiler’s manometer. -
Page 16: Connection Diagrams
INSTALLATION 4.7. Connection diagrams 4.7.1. Open expansion vessel connection Legend 1-9. Separation valves 10,11. Radiator valves Radiators 13-15. Safety valves Filling valve Drainage valve Cold water valve 19-24. One-way valves Hot water boiler Open expansion vessel Central heating pump Recirculation pump Pressure reducer Filter Air relief valve... -
Page 17: Closed Expansion Vessel Connection
INSTALLATION 4.7.2. Closed expansion vessel connection Legenda 1-9. Separation valves 10,11. Radiator valves Radiators 13-15. Safety valves Filling valve Drainage valve Cold water valve 19-24. One-way valves Hot water boiler Closed expansion vessel Central heating pump Recirculation pump Pressure reducer Filter Air relief valve Water softener... -
Page 18: Electrical Connections
The main electrical supply of the boiler must be connected to an independent safety of max 16A. The boiler room lighting must be on a separate circuit. THERMOSTAHL is not responsible for accidents or malfunctions caused by wrong or bad electrical connections. -
Page 19: Wiring Diagram
BOILER START-UP The control panel offers the possibility to connect with a room thermostat. When the room thermostat contact opens, the furnace function stops. 5.3. Wiring diagram Fig 8. Control panel wiring diagram Legend: General ON/OFF switch Safety thermostat Furnace thermostat Pump thermostat Fan speed regulator Pump indication lamp... -
Page 20: Boiler Start-Up
BOILER START-UP 6. BOILER START-UP 6.1. Initial lighting checks Before you start the boiler, make the following checks: Check that all the hydraulic connections and make sure they are tight. Make sure there is no leakage or moisture on the pipes or other equipment. ... -
Page 21: Fuel Loading
BOILER START-UP boiler walls, it means that the pump operation starts at a low temperature or the fuel has too big humidity content. Make sure you set the pump according to the indications and you install a return temperature protection system as indicated. 6.4. -
Page 22: Chimney Damper Adjustment
BOILER START-UP speed. The combination of these two will result to the optimum air delivery in order to accomplish perfect combustion. GENERAL SUGGESTIONS The flame needs to have reasonable dimensions and fill up the fire chamber as told. The flame must not be too red (too low air supply). ... -
Page 23: Service And Maintenance
SERVICE AND MAINTENANCE 7. SERVICE AND MAINTENANCE 7.1. Cleaning 7.1.1. Cleaning the boiler Solid fuel boiler require regular cleaning in order to function properly and efficient. Cleaning must be effected at least once a week. The boiler is equipped with three cleaning tools appropriate for the cleaning procedure of the boiler, as shown in Fig 11. -
Page 24: Cleaning The Chimney Box
SERVICE AND MAINTENANCE 7.1.2. Cleaning the chimney box To ensure efficient and safe function of the boiler, you must clean the chimney box from ash residues at least every 3 months. The ash box is equipped with a cleaning door for this purpose, as shown in Fig 14. -
Page 25: Basic Service Procedures
SERVICE AND MAINTENANCE 7.3. Basic service procedures 7.3.1. Service after overheating If overheating occurs, the safety valves of the boiler must open. If the boiler is equipped with an overheating protection coil, cold water will enter the coil to protect the boiler. Make sure the boiler pump is working. - Page 26 SERVICE AND MAINTENANCE Remove the whole feeder together with the bearings and supporting disk (see Fig 16). Fig 16. Removing the upper axis When putting back together, it is absolutely necessary to put the rubber gasket at its position! REMOVING THE LOWER AXIS ...
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Page 27: Service After Motor Bolt Breakage
SERVICE AND MAINTENANCE 7.3.3. Service after motor bolt breakage The connection between the motoreducer and the lower axis is realized through a protection bolt. This is designed in such a way so that it breaks in case of feeder blockage, to protect the motor from burning. If this bolt breaks, follow these steps to replace it: ... -
Page 28: Maintenance After Long Stop
SERVICE AND MAINTENANCE Fig 19. Removing the ignition element 7.4. Maintenance after long stop 7.4.1. Maintenance of the boiler It is necessary to perform a general maintenance and cleaning of the boiler after the heating season. Clean thoroughly all the surfaces of the boiler as described in the corresponding paragraph. -
Page 29: Maintenance Of The Furnace
SERVICE AND MAINTENANCE 7.4.2. Maintenance of the furnace It is necessary to perform a general maintenance and cleaning of the furnace after the heating season. The maintenance of the furnace should only be done when the boiler is stopped, cool and the power deactivated. -
Page 30: Troubleshooting
WARRANTY 8. TROUBLESHOOTING Problem Cause Solution - no electrical supply to the lamp The lamps of the - the control panel is not connected - check/replace the lamp control panel do not to electricity - connect to electricity light - lamp defect - check/replace the cables - electric cable defect - check/replace the fan, check the... -
Page 31: Warranty
WARRANTY 9. WARRANTY 1. Warranty duration is 3 years for all boiler parts under pressure, 1 year for other electro-mechanical equipment. The warranty period starts from the date of installation, but no longer than 120 days from the day of purchase. 2. - Page 32 THERMOSTAHL ROMANIA SISTEME TERMICE S.R.L. DRUMUL OSIEI 57-59, sector 6 Bucharest 062395, Romania www.thermostahl.ro...
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