INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR INSTALLATION, OPERATION AND MAINTENANCE OF PELLET BOILER OF SERIES BISOLID

MANUAL FOR INSTALLATION, OPERATION AND MAINTENANCE OF PELLET BOILER OF SERIES BISOLID 20 July 2017

CONTENT page. 1. IMPORTANT INFORMATION ABOUT THE PELLET BOILER OPERATION... 3 1.1. SAFETY INSTRUCTIONS... 3 2. PELLET BOILER BISOLID DESIGNATION... 5 3. DESCRIPTION OF PELLET BOILER FROM SERIES BISOLID... 6 3.1. MAIN INFORMATION ON THE PELLET BURNER BISOLID GP XX_B HC>... 7 3.2. MAIN INFORMATION ON THE FUEL HOPPER... 9 4. BISOLID PELLET BOILER S TECHNICAL DATA... 11 5. MOUNTING AND INSTALLATION OF PELLET BOILER BISOLID... 24 5.1. REQUIREMENTS FOR INSTALLATION OF PELLET BOILER BISOLID... 24 5.2. REQUIREMENTS FOR INSTALLATION OF PELLET BURNER BISOLID GP XX_B HC> TO BOILER BISOLID... 24 5.3. MOUNTING OF HOT WATER PELLET BOILER BISOLID... 25 5.3.1. POSITIONING OF THE BOILER... 25 5.4. METHODIC FOR INSTALLATION OF BOILER... 26 5.4.1. CONNECTION TO A CHIMNEY... 26 5.4.2. CONNECTING TO THE HEATING INSTALLATION... 27 5.4.3. INSTALLATION OF PELLET BURNER FROM SERIES BISOLID GP XX_B HC>... 27 5.4.4. MOUNTING THE FIRE-CLAY MADE DIRECTING BRICKS... 28 5.4.5. POSITIONING/CHECK OF THE ASH CLEANING SECTION COVER... 29 5.4.6. MOUNTING OF THE COVER PLATE IN FRONT OF THE FLUE GAS OUTLET... 29 5.4.7. MOUNTING OF THE BOILER S HORIZONTAL COVERS... 31 5.4.8. MOUNTING OF THE COVER OVER THE BOILER S CONVECTION TRACT... 31 5.4.9. MOUNTING OF THE COVER OVER THE BOILER S COMBUSTION CHAMBER... 32 5.4.10. CONNECTING THE PELLET BURNER TO THE BOILER... 32 5.4.11. MOUNTING OF THE FUEL TRANSPORT AUGER TO THE BURNER... 33 5.4.12. FILLING UP THE FUEL TRANSPORT AUGER... 34 5.4.13. CONNECTING OF THE BOILER TO THE MAIN POWER SUPPLY... 34 5.4.14. EXEMPLAR HYDRAULIC DIAGRAM... 34 6. INITIALIZATION OF THE SYSTEM TO OPERATION... 36 6.1. MAIN REQUIREMENTS ABOUT THE USED FUEL... 36 6.2. INITIALIZATION TO OPERATION OF THE BOILER BISOLID... 37 6.2.1. GENERAL CONDITIONS... 37 6.2.2. POWERING OF THE PELLET BOILER FROM SERIES BISOLID... 37 6.2.3. SWITCHING OF THE SYSTEM ON... 38 6.2.4. PARAMETERS FOR BOILER OPERATION ADJUSTMENT... 38 6.2.5. PARAMETERS FOR ADJUSTMENT OF PELLET BURNER BISOLID GP XX_B HC>... 39 6.2.6. NOMINAL OPERATION MODE OF THE BOILER... 39 6.3. ADJUSTMENT OF THE BOILER HEATING OUTPUT... 40 6.4. DECREASING THE BOILER HEATING OUTPUT... 40 6.5. INCREASING THE BOILER HEATING OUTPUT... 40 6.6. ADJUSTMENT OF THE COMBUSTION PROCESS... 40 6.7. SWITCHING THE BOILER OPERATION OFF... 41 6.8. EMERGENCY BOILER SHUT DOWN... 41 6.9. SERVICING AND MAINTENANCE OF THE PELLET BOILER BISOLID... 42 6.10. WARRANTY AND WARRANTY CONDITIONS... 44 6.11. ACTIONS AFTER EXPIRY OF THE BOILER LIFE CYCLE... 45 7. TROUBLESHOOTING... 46 8. WIRING DIAGRAM OF PELLET BOILER BISOLID IN A SYSTEM WITH PELLET BURNER BISOLID GP XX_B HC>... 49 2

1. IMPORTANT INFORMATION ABOUT THE PELLET BOILER OPERATION Dear Bisolid pellet boiler owners, We would like to congratulate you for your new pellet boiler. 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 and natural resource saving way. Your pellet 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 longterm and trouble-free operation of the pellet boiler. 1.1. SAFETY INSTRUCTIONS The hot water pellet boiler from series Bisolid and its accessories correspond to all applicable directions for safety techniques. Your pellet boiler and all of its accessories operate under variable electricity 230 VAC. 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 techniques. Legal provisions for environment protection. Provisions for proper installation. Applicable provisions of the European community. SAFETY INSTRUCTIONS Danger 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 pay attention to the following symbols in this manual: 3

Danger This symbol warns the user about health risks. Warning This symbol warns the user about possible risks and harms to properties and environment. Information This symbol presents text with additional information for the user. WORKS OR ACTIVITIES FOR SETTING THE APPLIANCE IN PROPER TECHNICAL WORKING ORDER 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. After carefully reading of the installation and operation manual, you will acquire all necessary information about design, controls and safety operation of the pellet boiler. After unpacking the pellet boiler please check its completeness and delivered elements. Check whether the pellet boiler size corresponds to the desired designation. If any failures or troubles occur the pellet 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 pellet boiler, 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. The current manual for operation, installation and maintenance uses notation of pellet boiler Bisolid includes the model of pellet boilers modification Bisolid 18 (18kW), Bisolid 25 (25kW) и Bisolid 30 (30kW). 4

2. PELLET BOILER BISOLID DESIGNATION Type designation of boiler series: Bisolid 18 Example Bisolid 18 Boiler trade name Nominal heating output*, kw * Similar to other models of hot water boilers Bisolid 25 and Bisolid 30. The pellet boilers from series Bisolid are designated to utilize wood pellets as the boiler has a steel made construction. These boilers are used for local heating systems and also for heating of domestic water. The boiler utilizes wood pellets, as described below, as the generated heat is accumulated by the heat exchanging surfaces of the boiler body and is transferred to the heat carrier in the heating system. The hot water pellet boiler from series Bisolid standard delivery kit includes: Heat exchanger 1 unit. Automated pellet burner with manually mechanically cleaning from series Bisolid GP xx_b hc> 1kit. Ash container (tray) 1pc. Boiler s bottom cover panel (between the second and third pass). Fire-clay made bricks 2 pcs. Flap 1pc. Door handle 1pc. Cleaning kit (scraper 1pc, hook 1pc). Electrical connector for room thermostat 1pc. Power supply cable 1pc. Nut and washer M10 2 pcs. Manual for installation, operation and maintenance of the boiler 1pc. The pellet boiler from series Bisolid is designated to utilize wood pellets with diameter Ø 6-8mm, from class A1 according to standard EN ISO 17225-2:2014. Boiler s advantages: Compact and simple steel structure that allows dynamic operation, easy installation and operation - plug & play. Compact control, interface panel and exported in the back end of the boiler connectors. Ability to work with a room thermostat (weekly programmable). Meets the most stringent European requirements and standards (EN 303-5:2012). High efficiency and low emissions. Ability to providing domestic hot water (DHW). Minimum operating costs. The boilers are available in two versions for left or right side burner adjustment. 5

3. DESCRIPTION OF PELLET BOILER FROM SERIES BISOLID The steel made hot water pellet boiler from series Bisolid is designated for heating of local installations with natural or forced water circulation performed with or without circulations pump. The heat exchanger unit is module of the system designated for automatic utilization of pellets and for heating of the circulations water. The cleaning of the ash from the burning process can be performed manually through the combustion chamber s lower front door, by taking out the ash-tray and gathering its content in proper for the purpose containers. The combustion process organization and the heat exchanging with the boiler body internal surfaces ensures high efficiency. The operation of the system: hot water pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> depend on the chimney draught. The chimney draught depends on the chimney condition and on the flue gas temperature. The hot water boiler s Bisolid heat exchanger construction complies with the resistance requirements for such type of appliances: EN 303-5:2012 - "Heating boilers. Part 5: Heating boilers for solid fuels, manually and automatically stoked, nominal heat output of up to 500 kw. Terminology, requirements, testing and marking. Figure 3.1. External view of steel made hot water pellet boiler from series Bisolid. The boiler consists of the following components/modules: The main module of the hot water boiler is the boiler body (heat exchanger), as the automated burner from series Bisolid GP xx_b hc> is mounted on its side. The heat exchanger is offered in two versions: so called left and right mounting. The automated pellet burner with manually mechanically cleaning can be mounted only on the left or only on the right side of the boiler body. The heat exchanger unit construction is made of steel plates. The combustion chamber is designed in the front lower part of the heat exchanger, as the ash container is below it. The heat exchanger is with compact size related to the achieved heating output, because it has three pass design, which provides optimal heat exchanging and high efficiency. 6

Fire clay made components mounted in the combustion chamber, which ensure optimal burning process and complete fuel combustion. The ash-tray is positioned at the bottom of the combustion chamber. The ash residues are gathered in it providing easy cleaning. The water inlet and outlet muffs are positioned at the boiler s back side and are inner threaded with size G1½, as through them the appliance can be connected to the heating system. The flue outlet (with external diameter Φ149 mm) is positioned centrally in the top rear side of the boiler and serves for extraction of the flue gasses to the chimney. The steel made heat exchanger, its cover and doors are isolated with mineral wool, which limits the heating losses to the local environment. Manometer, positioned on the boiler body s front panel, indicates the circulations water pressure in the heat exchanger. External decoration side cover panels made of steel plates and painted with high quality color coating materials. 3.1. MAIN INFORMATION ON THE PELLET BURNER BISOLID GP XX_B HC> The pellet burner with manually cleaning from series Bisolid GP xx_b hc> is mounted horizontally and laterally ("left" or "right" installation) of the hot water boiler from series Bisolid and it is a separate (standalone) module. The kit of the pellet burner with manually cleaning from series Bisolid GP xx_b includes: Main module 1pc. Fuel transport auger 1 pc. Flexible pipe 1 pc. with brackets 2 pcs. Manual for installation, maintenance and operation of pellet burner from series Bisolid GP xx_b hc> 1 pc. The main module of automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> consists of the following components: Combustion chamber, that provides conditions for optimal burning process and is made of high quality fire-proof steel. Fire-grate of the combustion chamber, that can be easily removed and provides availability for easy cleaning of the ash. Air distribution tract, that provides equal firing air distribution and cooling of the burner s components. Electrical heating element, used for initial fuel firing and positioned under the combustion chamber s fire-grate. Fresh (firing) air fan, equipped with sensor for determining the rotation velocity and providing availability for adjustment. Photo-sensor for monitoring of the burning process, positioned sideways for easier cleaning. Emergency temperature sensor for prevention of the so called back fire in the pellets inlet pipe. Control module, for monitoring and controlling of the burner operation. Fuel transport auger connector, used for powering the auger. Interface panel, equipped with display and keyboard for easy adjustment. Linkages handle for manually mechanical cleaning of the grate in the combustion chamber of the burner. The pellet burner kit includes electrical powered external auger used for transportation of the fuel from the hopper to the burner. The auger consists of compact size motor-gear equipped 7

with integrated overheating protection, pipe in which the fuel is transported to the flexible pipe drop zone. The flexible pipe made of special transparent thermo-resistant inflammable material (it melts but does not separate toxic substances) that connects the auger and the burner s main module. The main advantages of the pellet burner from series Bisolid GP xx_b hc> are: The pellet burner s are fully automated ignition, flame control, combustion chamber blowing. It is 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. Automatic modulation of the burning process decreasing the number of stops and ignitions, respectively fuel and electricity consumption. Manually mechanical cleaning of the fire-grate, through leverage without opening the boiler and without interruption of the operation. Circulations pump control according to heat carrier (water) temperature. Quiet operation and low electric power consumption. Protection from back-fire and from heat carrier (water) freezing. Circulations pump protection against blocking. Possibility for control of extractor (flue gas) fan. Possibility for operation with room thermostat and week programmer. The actual and detailed information on the construction and technical data of the pellet burner with manually cleaning from series Bisolid GP xx_b hc> is given in its manual for operation. Figure 3.2. External view of automated pellet burner with manually cleaning from series Bisolid GP xx_b hc>. 8

Figure 3.3. Arrangement of the main modules of the pellet burner (side view). External auger for fuel transport from hopper to the main burner s module Flexible pipe Pipe for pellets feeding Main module 3.2. MAIN INFORMATION ON THE FUEL HOPPER The pellet hopper is the reservoir of the pellet kit that provides conditions for compact storing of the fuel, needed for long-term operation of the system and optimal conditions for operation of the burner s transport auger. In case the hopper is build/constructed at the customer s site then its construction must provide free (gravity) fuel flow to the auger s intake zone, easy refueling, cleaning and enough capacity for longer operation of the system. The manufacture company produces sectional (assembled) pellets hoppers, made of galvanized steel plates, with capacity: 250, 450 и 650 kg. 9

Figure 3.4. Sectional (assembled) sheet metal pellets hopper with 250kg capacity. Figure 3.5. Sheet metal pellets hopper with capacity of 300 l. 10

4. BISOLID PELLET BOILER S TECHNICAL DATA The technical heating data for hot water pellet boiler from series Bisolid are presented in Table 4.1. Table 4.1. Technical heating data for hot water pellet boiler from series Bisolid. PARAMETER DIMENSION VALUE Pellet boiler model - Bisolid 18 Bisolid 25 Bisolid 30 Nominal heat output kw 18 25 30 Heating output adjustment range kw 7.5-18 7.5 25 9-30 Used fuel Wood pellets Suitable wood pellets class according to standard EN ISO 17225-2:2014 - A1 Required air quantity to achieve effective burning process kg/h 27 30 45 50 57-64 m 3 /h 24 27 39 44 50-56 Flue gas mass flow rate g/s 9.4 15.6 19.8 Energy efficiency class according to regulation - (ЕU) 2015/1187 Efficiency at nominal operation mode 92.4 91.5 91.0 Excess air ratio coefficient λ 1.5 1.7 Flue gas temperature at ºC 160 170 180 nominal operation mode Residues from the burning process Ash The quantity depends on the fuel s ash content The technical data for hot water pellet boiler from series Bisolid are presented in Table 4.2. 11

Table 4.2. Technical data for hot water pellet boiler from series Bisolid. PARAMETER DIMENSION VALUE Hot water pellet boiler model - Bisolid 18 Bisolid 25 Bisolid 30 Boiler weight kg 192 212 222 Boiler water volume dm³ 44 50 60 W1- Length of boiler body 580 580 580 Overall W Length dimensions of with pellet 954 954 954 the system: burner mm W х D х H D - Depth 770 770 770 H -Height 885 965 1044 Boiler class - 5 Operation water overpressure in the boiler bar 2.5 Boiler test overpressure bar 4 Recommended operation water temperature in the boiler ºC 80 Minimum boiler inlet water temperature ºC 60 Chimney draught * Pa 12-15* Connection Inlet/outlet water pipes G 1½ Flue outlet mm 149 Power supply voltage - L1, N, PE, 50Hz; 230VАС; Electrical consumption (with ignition) W <100 +1100 System electrical protection - IP20 * If the chimney draught operation parameters are lower than the above presented values it is necessary to install flue gas extraction fan. The selection, installation and connection to the flue gas extraction fan have to be made by the technically trained and qualified person. The technical parameters of hot water solid fuel boilers series Bisolid according to the delegated Regulation (EU) 2015/1187 are presented in Table 4.3. 12

Table 4.3 Technical parameters of hot water solid fuel boilers series Bisolid according to the delegated Regulation (EU) 2015/1187. Model identifier: Hot water pellet boiler Bisolid 18. Stoking mode: Automatic: it is recommended that the boiler be operated with a hot water storag e tank of a volume of at least 360 litre (**) Condensing boiler: no Solid fuel cogeneration boiler: no Combination boiler: no Fuel Preferred fuel (only one): Other suitable fuel(s): Log wood, moisture content 25 % no no Chipped wood, moisture content 15-35 % no no Chipped wood, moisture content > 35 % no no Compressed wood in the form of pellets or briquettes yes no Sawdust, moisture content 50 % no no Other woody biomass no no Non-woody biomass no no Bituminous coal no no Brown coal (including briquettes) no no Coke no no Anthracite no no Blended fossil fuel briquettes no no Other fossil fuel no no Blended biomass (30-70 %) and fossil fuel briquettes no no Other blend of biomass and fossil fuel no no Characteristics when operating with the preferred fuel: Seasonal space heating energy efficiency ƞ s [%]: 87 13

Energy efficiency index EEI: А+ Item Symbol Value Unit Item Symbol Value Unit Useful heat output At rated heat output P n (***) 18 kw At rated heat output Useful efficiecny ƞ n 92,4 % At [30 %/50%] of rated heat output, if applicable Р р 11 kw At [30 %/50%] of rated heat output, if applicable ƞ p 92,6 % For solid fuel cogeneration boilers: Electrical efficiency Auxiliary electricity consumption At rated heat output el max 0,156 kw At rated heat output Ƞ el,n - % At [30 %/50%] of rated heat output, if applicable el min 0,134 kw Of incorporated secondary emission abatement equipment, if applicable - kw In standby mode P SB 0,0048 kw Contact details Ekoterm Proekt EAD / ZMM Haskovo AD 6300, Haskovo 67 Saedinenie Blvd. (*) Tank volume = 45 Pr (1 2,7/Pr) or 300 litres whichever is higher, with Pr indicated in kw (**) Tank volume = 20 Pr with Pr indicated in kw (***) For the preferred fuel Pn equals Pr 14

Model identifier: Hot water pellet boiler Bisolid 25. Stoking mode: Automatic: it is recommended that the boiler be operated with a hot water storag e tank of a volume of at least 500 litre (**) Condensing boiler: no Solid fuel cogeneration boiler: no Combination boiler: no Fuel Preferred fuel (only one): Other suitable fuel(s): Log wood, moisture content 25 % no no Chipped wood, moisture content 15-35 % no no Chipped wood, moisture content > 35 % no no Compressed wood in the form of pellets or briquettes yes no Sawdust, moisture content 50 % no no Other woody biomass no no Non-woody biomass no no Bituminous coal no no Brown coal (including briquettes) no no Coke no no Anthracite no no Blended fossil fuel briquettes no no Other fossil fuel no no Blended biomass (30-70 %) and fossil fuel briquettes no no Other blend of biomass and fossil fuel no no Characteristics when operating with the preferred fuel: Seasonal space heating energy efficiency ƞ s [%]: 89 Energy efficiency index EEI: А+ 15

Item Symbol Value Unit Item Symbol Value Unit Useful heat output At rated heat output P n (***) 25 kw At rated heat output Useful efficiecny ƞ n 93,9 % At [30 %/50%] of rated heat output, if applicable Р р 18 kw At [30 %/50%] of rated heat output, if applicable ƞ p 94,1 % For solid fuel cogeneration boilers: Electrical efficiency Auxiliary electricity consumption At rated heat output el max 0,156 kw At rated heat output Ƞ el,n - % At [30 %/50%] of rated heat output, if applicable el min 0,134 kw Of incorporated secondary emission abatement equipment, if applicable - kw In standby mode P SB 0,0048 kw Contact details Ekoterm Proekt EAD / ZMM Haskovo AD 6300, Haskovo 67 Saedinenie Blvd. (*) Tank volume = 45 Pr (1 2,7/Pr) or 300 litres whichever is higher, with Pr indicated in kw (**) Tank volume = 20 Pr with Pr indicated in kw (***) For the preferred fuel Pn equals Pr 16

Model identifier: Hot water pellet boiler Bisolid 30. Stoking mode: Automatic: it is recommended that the boiler be operated with a hot water storag e tank of a volume of at least 600 litre (**) Condensing boiler: no Solid fuel cogeneration boiler: no Combination boiler: no Fuel Preferred fuel (only one): Other suitable fuel(s): Log wood, moisture content 25 % no no Chipped wood, moisture content 15-35 % no no Chipped wood, moisture content > 35 % no no Compressed wood in the form of pellets or briquettes yes no Sawdust, moisture content 50 % no no Other woody biomass no no Non-woody biomass no no Bituminous coal no no Brown coal (including briquettes) no no Coke no no Anthracite no no Blended fossil fuel briquettes no no Other fossil fuel no no Blended biomass (30-70 %) and fossil fuel briquettes no no Other blend of biomass and fossil fuel no no Characteristics when operating with the preferred fuel: Seasonal space heating energy efficiency ƞ s [%]: 86 Energy efficiency index EEI: А+ 17

Item Symbol Value Unit Item Symbol Value Unit Useful heat output At rated heat output P n (***) 30 kw At rated heat output Useful efficiecny ƞ n 91,7 % At [30 %/50%] of rated heat output, if applicable Р р 20 kw At [30 %/50%] of rated heat output, if applicable ƞ p 90,4 % For solid fuel cogeneration boilers: Electrical efficiency Auxiliary electricity consumption At rated heat output el max 0,156 kw At rated heat output Ƞ el,n - % At [30 %/50%] of rated heat output, if applicable el min 0,134 kw Of incorporated secondary emission abatement equipment, if applicable - - In standby mode P SB 0,0048 kw Contact details Ekoterm Proekt EAD / ZMM Haskovo AD 6300, Haskovo 67 Saedinenie Blvd. (*) Tank volume = 45 Pr (1 2,7/Pr) or 300 litres whichever is higher, with Pr indicated in kw (**) Tank volume = 20 Pr with Pr indicated in kw (***) For the preferred fuel Pn equals Pr With the adoption of the new standard for wood pellets (EN ISO 17225-2) in 2014 there are introduced a new classes for wood pellets used in domestic heating boilers (Table 4.4.). 18

Table 4.4. Standard for wood pellets EN ISO 17225-2:2014 Parameter Dimension Class A1 Class A2 Class B Length (L) mm 3,15 L 40 3,15 L 40 3,15 L 40 Diameter (D) mm 6±1 8±1 Moisture (М) % < 10 < 10 < 10 Ash (A), dry % < 0,7 < 1,2 < 2,0 Buck density (BD) kg/m 3 > 600 > 600 > 600 Mechanical durability (DU) % > 97.5 > 97.5 > 96.5 Net caloricity (Q) MJ/kg kwh/kg > 16,5 > 4.6 > 16,5 > 4.6 > 16,5 > 4.6 Chlorine Cl % < 0,02 < 0,02 < 0,03 Nitrogen (N) % < 0,3 < 0,5 < 1,0 Sulphur (S) % < 0,04 < 0,05 < 0,05 Arsenic (As) mg/kg < 1 < 1 < 1 Cadmium (Cd) mg/kg < 0.5 < 0.5 < 0.5 Chromium (Cr) mg/kg < 10 < 10 < 10 Copper (Cu) mg/kg < 10 < 10 < 10 Lead (Pb) mg/kg < 10 < 10 < 10 Mercury (Hg) mg/kg < 0.1 < 0.1 < 0.1 Nickel (Ni) mg/kg < 10 < 10 < 10 Zinc (Zn) mg/kg < 100 < 100 < 100 6±1 8±1 6±1 8±1 19

The hot water pellet boiler from series Bisolid overall dimensions are presented on the next figures. Figure 4.1. View of hot water pellet boiler from series Bisolid (overall sizes) front view. Figure 4.2. View of pellet boiler from series Bisolid - top view. 20

Figure 4.3. View of hot water pellet boiler from series Bisolid (overall and connection sizes) rear side view. 21

Figure 4.4. View of pellet boiler Bisolid. Boiler s top cover panel Boiler s convection tracts cover Boiler s combustion chamber cover Boiler s combustion chamber door cover panel Pellet burner mounting flange 22

Figure 4.5. Cross section view of the hot water pellet boiler from series Bisolid with presented direction of the flue gasses and main construction modules. Boiler s top cover panel Flue gas outlet to chimney Flue gas third pass of the boiler Flue gas second pass of the boiler Flue gas first pass of the boiler Bottom cover cap of the baffle separating the convection tracts and the combustion chamber of the boiler Combustion chamber of the boiler Combustion chamber door of the boiler Ash container (tray) 23

5. MOUNTING AND INSTALLATION OF PELLET BOILER BISOLID 5.1. REQUIREMENTS FOR INSTALLATION OF PELLET BOILER BISOLID When installing the hot water pellet boiler from series Bisolid is necessary to meet the following basic requirements: The room anticipated to install the boiler must provide a constant flow of fresh air needed for combustion and good ventilation. It is not allowed installation of the boiler in dwellings, including corridors. Connecting the hot water pellet boiler from series Bisolid to the heating installation must be performed only by authorized qualified technician. Installation and maintenance of equipment with solid fuel is carried out by specialized companies with the right to conduct such activities. The hot water pellet boiler from series Bisolid is connected to the heating system with CLOSED expansion vessel. In the event that the system is with closed expansion vessel, in it must be installed pressure valve that opens when exceeding the operating pressure of the boiler (0.25 MPa) and this valve must be certified in accordance with PED 97/23. Before the commissioning of the boiler there should be ensured complete filling with water/liquid circulation and venting of the heating system. Maintenance of the boiler should be performed only by adults who are familiar with the instructions for use of the equipment. The achieved heating output of the system: hot water pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> depends on: The heating output adjusted for the burner operation. The contamination level of the boiler s heat exchanging surfaces. The sealing level of the door and combustion chamber s covers (the sealing ropes condition). The chimney draught. The efficiency coefficient of the system: hot water pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> in nominal operation mode reaches 89% (depending on the specific system) it can be achieved by adjustment of the burner s operation parameters by the use of gas-analyzer (to be performed by an authorized servicing specialist). 5.2. REQUIREMENTS FOR INSTALLATION OF PELLET BURNER BISOLID GP XX_B HC> TO BOILER BISOLID The automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> has to be mounted to the heat exchanger unit of the hot water pellet boiler from series Bisolid. The boiler construction provides availability for left or right mounting of the burner, therefore the suitable combination should be chosen during the preliminary system installation project. During the mounting process a proper sealing between the modules/components must be ensured in order to prevent intake of unorganized air from the environment or exhaust of flue gasses. The following requirements must be also taken into account: Easy access for cleaning of the burner s fire-grate. Secured safe operation conditions and maintenance of the system reliability. Availability for adjustment and servicing of the system: heat exchanger of the pellet boiler from series Bisolid (for example when necessary to clean it), burner from series Bisolid GP xx_b hc> - for adjustment, necessity for maintenance and regulation, 24

transport auger for servicing and maintenance, fuel hopper for refueling and cleaning. 5.3. MOUNTING OF HOT WATER PELLET BOILER BISOLID The installation of hot water pellet boiler from series Bisolid requires preparation of and initial project in accordance with applicable standards and regulations: For the heating system - EN 303-5:2012 - "Heating boilers. Part 5: Heating boilers for solid fuels, manually and automatically stoked, nominal heat output of up to 500 kw. Terminology, requirements, testing and marking. For the chimney. Fire safety requirements. For the power supply - EN 60335-1/2006/A12012 - "Protection of domestic electrical appliances". 5.3.1. POSITIONING OF THE BOILER During the positioning of hot water pellet boiler from series Bisolid is needed to keep the following requirements: The minimum free space for manipulation in front of the boiler must at least 1000 mm. The minimum allowed distance between the boiler s rear side and a wall must be at least 400 mm. The minimum distance between the boiler s side, where the automated burner from series Bisolid GP xx_b hc> main module is mounted and a wall must be at least 500 mm, in order to ensure free access to the burner itself, as the fuel transport auger and hopper position has to be also taken in to account. The minimum distance between the boilers s opposite side, to which the automated burner from series Bisolid GP xx_b hc> main module is mounted and a wall must be at least 500 mm, in order to provide access to the heat exchanger covers and availability for its easy cleaning from the ash. The minimum free space over the hot water pellet boiler from series Bisolid must be at least 600 mm, in order to ensure free access to the heat exchanger s internal surfaces for ash deposits cleaning purposes. The minimum distance between the hot water boiler from series Bisolid and the pellets hopper must be at least 1000 mm, in order to ensure safe operation conditions and prevention of fire. The boiler must be positioned in a way that provides free access to the power supply socket box (230VAC/50Hz). Do not touch the hot connections for water or flue gas pipe during the boiler operation. If the boiler room has two boilers, is not allowed to put any fuel between them. We recommend maintaining a minimum distance of 800 mm between the boiler and fuel or to store fuel in a room different from the room in which the boiler is installed. 25

Do not put flammable materials over pellet boiler s top side or near it within the safety distance. The requirements for installation and operation of transport fuel auger from the fuel hopper to burner s main module are given in its manual for installation, operation and maintenance. 5.4. METHODIC FOR INSTALLATION OF BOILER After the hot water boiler from series Bisolid has been positioned it must be connected to the heating installation and to the chimney by observing the relevant requirements. For correct and reliable operation it is required to level the boiler horizontally, which will ensure its reliable air freeing. 5.4.1. CONNECTION TO A CHIMNEY After installation and ground leveling of the boiler it must be connected to a chimney, by observing the requirements for effective and reliable operation of the system. Figure 5.1. Rear side view of hot water pellet boiler from series Bisolid. Muff circulations water outlet Flue gas outlet pipe Muff circulations water inlet 26

5.4.2. CONNECTING TO THE HEATING INSTALLATION As next the hot water pellet boiler from series Bisolid must be connected to the heating installation by using proper fittings has to be performed according to the preliminary prepared technical project. 5.4.3. INSTALLATION OF PELLET BURNER FROM SERIES BISOLID GP XX_B HC> When installing the pellet burner with manually cleaning from series Bisolid GP xx_b hc> is it necessary to compiling the requirements set out in its manual. It also needs to use the seal of mineral wool, which are carefully placed on the coupling flange of the burner and used for insulation and reduce heat flow, which is transmitted by the boiler to the burner. Figure 5.2. View of the mounting flange for connecting the pellet burner to the hot water boiler. Side opening for mounting of the pellet burner Mounting screws for pellet burner from series Bisolid GP xx_b hc> to the boiler After mounting of the burner the screws have to be tightened equally, so the sealing between its flange and the boiler body is guaranteed. 27

Figure 5.3. View of mounted pellet burner from series Bisolid GP xx_b hc>. 5.4.4. MOUNTING THE FIRE-CLAY MADE DIRECTING BRICKS The fire clay bricks, delivered with the boiler kit, should be mounted in the heat exchanger s combustion chamber (during transportation of the system the bricks are packed and placed in the ash drawer inside the boiler s combustion chamber). Figure 5.4. Mounting of fire-clay components in the combustion chamber of the boiler. 28

5.4.5. POSITIONING/CHECK OF THE ASH CLEANING SECTION COVER Figure 5.5. The boiler s cover cap after its second flue pass is positioned correctly. Cover cap, closing the flue tract The correct positioning of the cover is very important with regards to the boiler s efficient and reliable operation. Therefore after the boiler installation its position has to be checked and also every time after cleaning of the ash. 5.4.6. MOUNTING OF THE COVER PLATE IN FRONT OF THE FLUE GAS OUTLET The cover panel has to be positioned by placing it on the special welded supports on the one side and in contact with the boiler body wall on the other. This cover plate serves to direct the flue gasses from the second to the third flue pass and also in case of emergency situations it should be opened in order to decrease the pressure pulsations (for example in case of high pressure of the flue gasses in the boiler s flue tract. This cover plate is operating under thermal loads, therefore it has symmetrical design. It is recommended to rotate the cover panel on every two to three operation weeks. 29

Figure 5.6. The directing cover panel is dismounted and the boiler flue outlet can be clearly seen. The directing cover panel is placed over the boiler s side, before its correct positioning Figure 5.7. Directing cover panel correct positioning. The directing cover panel is positioned correctly A hook for easier handling of the directing cover panel Element welded to the heat exchanger, which must brace the directing cover panel 30

5.4.7. MOUNTING OF THE BOILER S HORIZONTAL COVERS Figure 5.8. Covers positioning of hot water pellet boiler from series Bisolid. 5.4.8. MOUNTING OF THE COVER OVER THE BOILER S CONVECTION TRACT This cover is equipped with protection plate, made of stainless steel. Figure 5.9. Directing cover over the boiler s convection tract. 31

5.4.9. MOUNTING OF THE COVER OVER THE BOILER S COMBUSTION CHAMBER This cover is equipped with isolating plane, designated for operation under high temperatures in the boiler s combustion chamber. Figure 5.10. Directing cover over the boiler s combustion chamber. The directing cover over the boiler s convection tract and directing cover over the boiler s combustion chamber are different and their positions must not be changed. 5.4.10. CONNECTING THE PELLET BURNER TO THE BOILER On the rear side of the boiler s side cover are installed connectors for connecting to: the power supply, the pellet burner with manually mechanically cleaning from series Bisolid GP xx_b hc> and room thermostat. Depending on right or left mounting of the burner the connectors are positioned on the adjacent side cover panel of the boiler. These connection s connectors are equipped with component that prevents from disconnecting and it must be released. 32

Figure 5.11. Description of electrical connectors mounted on the rear side of the boiler s cover. Switch START Room thermostat connector Communication connector Pellet burner connector Emergency thermostat Switch POWER Electrical fuse Power supply connector The manometer serves to indicate the pressure of the circulations water in the boiler s heat exchanger. The manometer is positioned at the top left corner of the heat exchanger s front panel. 5.4.11. MOUNTING OF THE FUEL TRANSPORT AUGER TO THE BURNER The fuel transport auger has to be mounted in accordance to the requirements presented in the manual for operation, installation and maintenance of pellet burner from series Bisolid GP xx_b hc>. 33

The tilting angle (between the auger s pipe axis and the horizontal plane) influences directly its production rate, i.e. the fuel feeding rate that it will provide at certain operation mode. Therefore if this angle is changed it will be necessary to re-adjust the burner in order to provide certain heating output. 5.4.12. FILLING UP THE FUEL TRANSPORT AUGER The fuel transport auger of pellet burner from series Bisolid GP xx_b hc> has to be connected to a standard power supply and the fuel hopper has to be filled with fuel. Then should you wait until the pellets start to drop from the auger s outlet. After that the auger has to be plugged off and then plugged in to the burner s main module, as the coupling is positioned on the burner s right side. After that the system can be switched on. The manufacture company reserves its right to make changes over the system s construction, without obligation to inform its customers. 5.4.13. CONNECTING OF THE BOILER TO THE MAIN POWER SUPPLY The power supplying of the system, consisting of hot water boiler from series Bisolid and pellet burner from series Bisolid GP xx_b hc>, should be performed by the power supply cable attached to the product s delivery kit. The connection to the main power supply must be implemented only from authorized electrical specialist. The manufacture company reserves its right to make changes over the presented modules construction, without obligation to inform its customers. At initial start of the pellet burner, and also after full depletion of fuel in the auger s volume, it must be refilled with fuel - this process is described in its pellet burner manual. This operation should also be explained and demonstrated to the end user. 5.4.14. EXEMPLAR HYDRAULIC DIAGRAM The schematic exemplar hydraulic diagram for connecting a hot water pellet boiler from series Bisolid to a heating installation with OPENED expansion tank is presented on the next figure. 34

Figure 5.12. The exemplar hydraulic diagram for connecting a hot water boiler from series Bisolid to a heating installation. The exemplar hydraulic diagram is for information only, and can not be used as practically implemented hydraulic scheme. Table 5.1 Description of the elements indicated in Figure 5.12. No. DESCRIPTION 1 Hot water boiler from series Bisolid 2 Relief valve 3 DHW boiler 4 Check valve 5 Circulation pump 1 6 Relief valve 7 Opened or closed expansion vessel 8 Ball valve 9 Three-way mixing valve 10 Circulation pump 2 No. DESCRIPTION 11 Ball valve 12 Water filter 13 Thermovalve TV 14 Check valve 15 Contact thermostat 16 Heat accumulator 17 Automatic machine for water refill 18 Tap for filling and draining 22 Automatic air eliminator with valve 23 Relief valve 24 Check valve The completion of the installation and implementation of adjustment of hot water pellet boiler from series Bisolid shall be recorded in the protocol for commissioning and adjustment where mandatory are filled in the fields with the necessary information. 35

6. INITIALIZATION OF THE SYSTEM TO OPERATION The system, consisting of hot water pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc>, must be initiated to operation only by specialized company, authorized for such activities. 6.1. MAIN REQUIREMENTS ABOUT THE USED FUEL During the initialization of hot water pellet boiler from series Bisolid is necessary to comply the following requirements to the used fuel. To ensure complete burning only dry fuel has to be used that complies with the requirements for reliable operation, presented in the pellet burner s manual book. The manufacture company recommends storing the fuel in dry and ventilated premises. Fuel storing near the system (boiler and burner) at distance less than 400 mm is strictly forbidden. The optimal recommended distance, recommended by the manufacture company, is at least 1000 mm. The preferably the fuel should be stored in a neighbor premise. All fire safety requirements must be observed during installation of the system, consisting of hot water pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> and storage of the fuel. It is recommended to place a fire-extinguisher at easy accessible and visible place. The heating systems with opened expansion tank allow direct contact between the heating (circulations) liquid and the surrounding atmosphere. During the heating season the water absorbs oxygen (through the contact surface between the water and the air), which increases the corrosive action of the circulations liquid over the steel surfaces, as water evaporation can also occur. For refilling only water complying with the circulations liquids requirements, according to standard EN15207-81, should be used. Constant water quantity in the heating system must be maintained during the heating season. When refilling the system with water air intake should be prevented. The water should be used only for its designation. It is recommended to check the water quantity in the heating installation on every 14 days. The system should be refilled with water only when the hot water boiler has been cooled. This is necessary in order to protect the steel made heat exchanger from thermal tensions and damage. In case the installation will not be used and there is risk of local freezing of the circulations water, it is recommended to drain the water out. Also the presence of water in the heating installation and the boiler protects the steel surfaces from contact with the oxygen, respectively from corrosion. 36

6.2. INITIALIZATION TO OPERATION OF THE BOILER BISOLID 6.2.1. GENERAL CONDITIONS There are the following general conditions which must be observed during the initialization of pellet boiler from series Bisolid in operation: The hot water pellet boiler servicing/handling must be performed by observing the requirements presented in the operation and maintenance manual. Any intervention over the system operation that might endanger the health of the servicing personal is strictly forbidden. During operation of the system it must be periodically checked by the servicing personal/customer. The user must not perform any repairs over the system s modules. If a problem occurs during operation ask for servicing assistance from the relevant retail company; Operation with heating output over the boiler s nominal output is not allowed. The ash residues left from the burning process have to be gathered in fire proof container equipped with covers and after cooling to ambient temperature it has to be dumped at proper for the purpose places. The ash remaining from wood pellets utilization can be also used for soil fertilization. The system, consisting of hot water boiler from series Bisolid and pellet burner with manually cleaning from series Bisolid GP xx_b hc> is controlled by a module, positioned on the burner. It is equipped with display and keyboard which serve for adjustment of the system operation parameters. More information is presented in the pellet burner from series Bisolid GP xx_b hc> manual book. Components of the interface control panel and their functions (see Figure 5.11): Switch START serves to submit START/STOP signal to the main module of the pellet burner with manually cleaning from series Bisolid GP xx_b hc>, which performs the relevant function through the burner s controller. Room thermostat connector serves to connect a programmable room thermostat that can control the system s operation. Such thermostat is optional equipment and is not delivered with the system s standard kit. Communication connector connector for connecting the pellet burner controller to the boiler. Pellet burner connector serves to connect the burner cable to the boiler. Emergency thermostat serves to protect the hot water pellet boiler from overheating. It is factory adjusted to stop the pellet burner from series Bisolid GP xx_b hc> power supply, in case the circulations water temperature is exceeded above the limit (adjusted in the factory to 95 o C). Switch POWER serves for central switching of the hot water boiler from series Bisolid and of the pellet burner from series Bisolid GP xx_b hc>. Electrical fuse central fuse positioned on the boiler s control panel. Power supply used to connect the central power supply cable and to provide electric power to the system. 6.2.2. POWERING OF THE PELLET BOILER FROM SERIES BISOLID The pellet boiler must be connected to the electric installation by observing the safety technique rules and requirements. The boiler is standard delivered with a power cable equipped with coupling used for connecting the boiler. 37

The fuel hopper must be filled with wood pellets, in order the feeding device to transport them to the burner zone. 6.2.3. SWITCHING OF THE SYSTEM ON System s switching on can be performed by the switch POWER, positioned on the hot water pellet boiler from series Bisolid. At operation assignment, defined by the assigned circulations water temperature in the boiler (and by assignment from room thermostat if connected), the automated pellet burner with manually cleaning from series Bisolid GP xx_b hc> activates and transits to automatic stand by mode pressing the switch START starts it. In case the START was preliminary switched on, the pellet burner starts immediately. If the system has been operated (or is in the so called hot reserve ), but the power supply (electricity) has been interrupted, it starts automatically when the power supply recovers. At initial start of the burner and insufficient chimney draught (for example when the chimney height is not enough and if it is dirty) there is possibility for excessive smoking from the boiler covers zone, positioned over the combustion chamber and the convective zone, or/and from the combustion door sealing. Therefore it is recommended to check the door proper closing, its sealing, the covers and also the chimney condition. The same situation may occur during transition seasons autumn and spring, when the natural chimney draught is low, due to the high environment temperature. If the ignition pellets doze is not adjusted correctly a smoking through the boiler s unsealed parts might occur. In such case it is necessary to adjust the ignition (primary) pellets doze of the burner to be performed by servicing technician. During the fuel ignition mode a module activates electric heating element (heater), positioned under the burner s tilted fire-grate. This component heats the fuel until it fires and the flame indicates by the photo-sensor of the burner. Detail information about the burner s construction and operation is presented in the pellet burner Bisolid GP xx_b hc> manual. The automated pellet burner from series Bisolid GP xx_b hc> operates with preliminary assigned algorithm, installed in the burner s control module. The burner s controller parameters adjustment must be performed only by trained servicing technician. 6.2.4. PARAMETERS FOR BOILER OPERATION ADJUSTMENT The hot water pellet boiler from series Bisolid operation mode is determined directly by the burner s control module settings, defining the assigned circulations water temperature in the boiler. The boiler s inlet water temperature has to be also taken in to account, as it influences the system operation, its reliability and efficiency. 38

The manufacture company guarantees efficient and reliable operation of the system: hot water pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc>, ONLY within the system s operation range, presented in Table 4.2 from this manual. 6.2.5. PARAMETERS FOR ADJUSTMENT OF PELLET BURNER BISOLID GP XX_B HC> The parameters defining the operation mode and the heating output of the burner and respectively of the boiler are presented in the operation and installation manual of the pellet burner with manually cleaning from series Bisolid GP xx_b hc>. The meaning, functions and how to change these parameters must be explained to the end user, in order to provide flexible and optimal usage of the appliance. In case that the hot water pellet boiler model is Bisolid 18, then the pellet burner from series Bisolid GP 25_B hc> has to be adjusted not to exceed the nominal heating output of the boiler. NOTES: The heating output levels and adjustment procedures are presented in the pellet burner from series Bisolid GP xx_b hc> manual book. The parameters used for adjustment of the automated pellet burner operation are presented in its manual book these parameters must be changed only by trained servicing technician. The heating output adjustment of the system: hot water pellet boiler from series Bisolid and pellet burner from series Bisolid GP xx_b hc>, can be performed by initial adjustment of the burner s operation parameters has to be performed by authorized servicing technician. The manufacture company reserves its right to change the automated pellet burner from series Bisolid GP xx_b hc> settings without obligation to inform its customers. 6.2.6. NOMINAL OPERATION MODE OF THE BOILER After completing the process to start the pellet burner with manually cleaning from series Bisolid GP xx_b hc> (the pellets are successfully fired) and the hot water boiler from series Bisolid has heated the circulations water in the installation, and the installation has been equal-tempered, it can be stated that the system is in nominal operation mode. The final adjustments of the modules operation should be performed in such mode. The so called hot test of the appliance and the heating installation should be performed in nominal heating output mode, according to the acting regulations. NOTES: If a circulations pump is used for transferring the heat energy from the hot water pellet boiler to the heating installation, the reverse (cooled) water temperature should not be 39

lower than 60 o C, because there is possibility for overcooling of the flue gasses, respectively for water vapors condensation as a product from the fuel combustion. Continues operation of the appliance below its minimum heating output is not recommended, as presented in Table 4.1, because such operation modes are inefficient and not economic. If necessary to operate the system for longer time, especially the hot water boiler from series Bisolid, in heating output mode lower than the minimum, it is recommended to install and connect a heat accumulator (buffer), in order to ensure its efficient, economic and reliable operation. During the initial start up of the hot water boiler from series Bisolid, water vapours condensation over the heat exchanger internal surfaces might occur. This one-time (single time) process does not cause troubles to the appliance operation. 6.3. ADJUSTMENT OF THE BOILER HEATING OUTPUT The pellet boiler Bisolid heating output adjustment can be performed by adjusting the heating output level of the pellet burner from series Bisolid GP xx_b hc>. For detail information read the burner s manual book. In case that the used wood pellets type has to be changed (for example the change of class of pellets) it might be necessary to change the burner s heating output level. 6.4. DECREASING THE BOILER HEATING OUTPUT It can be performed by decreasing the burner s heating output level. For detail information read the burner s manual book. Do not decrease the pellet burner s heating output below the system s minimum heating output, because such modes decrease its efficiency and reliability. 6.5. INCREASING THE BOILER HEATING OUTPUT It can be performed by increasing the burner s heating output level. For detail information read the burner s manual book. Do not increase the burner s heating output above the system s nominal output, because in such modes its efficiency and reliability are decreased and there is possibility for excessive heat loading of its modules and components, which might lead to emergency situations and thermal deformations. 6.6. ADJUSTMENT OF THE COMBUSTION PROCESS The pellet burner with manually cleaning from series Bisolid GP xx_b hc> is factory adjusted to optimal operation parameters and it is not necessary to re-adjust it. The burning process adjustment has to be performed by trained and authorized servicing technician. The burning process, from the pellet burner, adjustment must provide flue gas parameters that comply with the requirements of standard EN 303-5:2012 and with the system operation data. 40

6.7. SWITCHING THE BOILER OPERATION OFF The system operation can be stopped by stopping the pellet burner from series Bisolid GP xx_b hc>. Detailed information is presented in the pellet burner with manually cleaning from series Bisolid GP xx_b hc> manual book. Another method to stop the system operation is by using the switch START, positioned on the interface panel of the hot water boiler from series Bisolid. To restore the system operation presses this switch again. It is forbidden to stop the appliance by the switch POWER during operation! The recommended stopping by the switch START or by the burner display module provides controlled and safe stopping. After stop command the fans operation ensure readiness for next starting and preserve the photo-sensor from damage. The stopping mode of the pellet burner with manual cleaning from series Bisolid GP xx_b hc> is presented in details in its operation and installation manual book. In case the system should be stopped entire cleaning of the heat exchanger s walls and the burner s combustion zone from the ash should be performed, because the ash has corrosive influence over the steel surfaces, which decreases the appliance life. At the end of the heating season not only cleaning but also prophylaxis has to be performed by specialized servicing company. Observance of these procedures ensures long life of the system s modules and their reliable operation. 6.8. EMERGENCY BOILER SHUT DOWN During operation of the system some of the modules (hot water boiler or pellet burner) might transit to emergency mode. Some emergencies might be indicated by the relevant module sensors which should perform automatic prevention procedures. In case of emergency situation overheating of the hot water boiler from series Bisolid its emergency thermostat activates, positioned on the boiler s interface panel. The cause for the emergency must be identified and the relevant measures taken. The thermostat must be switched back manually, by unscrewing its protection cover cap and pressing its button, after that the cover cap must be screwed again. The pellet burner from series Bisolid GP xx_b hc must be reset to by switching off and then back on the button POWER, positioned on the boiler s interface panel. In case of emergency situation with the automated pellet burner from series Bisolid GP xx_b hc> it transits to emergency mode, that stops its operation, followed by indication on the display panel. In such cases the indicated trouble code has to be checked in the burner s manual book and the relevant corrective measures should be taken, as described in its manual book. 41

In case of emergency situation that is not presented in the automated pellet burner from series Bisolid GP xx_b hc> manual, neither in this manual, should you ask for assistance by the retail company which services and maintains the system. 6.9. SERVICING AND MAINTENANCE OF THE PELLET BOILER BISOLID It is necessary the user to know in details presented manuals for installation, operation and maintenance of the pellet boiler from series Bisolid and automated pellet burner with manually cleaning from series Bisolid GP xx_b hc>. The end user has to have information on operating modes of the system, its adjustment and control and the methodic for servicing of system s modules as follows: How to load hopper with pellets - fuel is filled into a hopper from which the fuel transport auger takes and transfer them to the burner s main module. How to clean the boiler form the ash. Method of cleaning the ash, located on the grate - after system shutdown and cooling of the boiler and burner to safe temperatures of their surfaces, should open the door of the combustion chamber, to remove the grate, to clean the ash and grate, back them into place, and then close the door of the combustion chamber. Ash must be cleaned with personal protective equipment - sleeves, gloves and appropriate clothing. It is recommended the end user periodically (at least once every 72 hours of operation) to exclude pellet burner from series Bisolid GP xx_b hc> as it is described in its manual to wait enough time (it is recommended to wait about 30 minutes) until the boiler to cool to the safe temperatures on its surface and then to clean the internal heat exchanger surfaces of the ash, to export outside the boiler ash collected in the container, located at the bottom of the heat exchanger, then in reverse order to close the door and covers of the boiler, to clean the burner and then to switch on it in the manner described in its manual. The combustion chamber door closes by the use of a handle. It is recommended not to use too much force in order to preserve the sealing rope elasticity. To open the door turn the handle clockwise (lift the handle up to open it). Figure 6.1. Cleaning of the ash from the hot water boiler walls. 42

Figure 6.2. Cleaning of the ash from the hot water boiler. Open the combustion chamber door and take out the ash container, positioned at the bottom of the hot water boiler. The ash has to be gathered in fire-proof containers (or other proper containers), then place the ash tray back to its original position and close the door. The boiler covers have to be placed back too. The regular cleaning of the hot water pellet boiler heat exchanging surfaces and the pellet burner burning zone provide reliable and economic operation of the appliances and conditions for long-term usage of the system s modules. The cleaning of pellet burner from series Bisolid GP xx_b hc> should be performed as needed and operating working conditions from once a week to once a day. The number and frequency of cleaning of the pellet burner depend largely on the quality of the used wood pellets. The fuel is necessary to meet the requirements of standard EN ISO 17225-2:2014, class ENplus-A1. The pellet burner from series Bisolid GP xx_b hc> is cleaned in the following cases: During the operation of the pellet burner: - The pellet burner can be cleaned and at its operation. In this way of cleaning is discarded small dose unburned fuel, but the advantage is that there is no need any waiting time, i.e., cleaning can be done immediately on the customer request. The burner is programmed to continue working after this type of cleaning. Cleaning of the pellet burner without interrupting the operation of the device: - When a device does not operate assigned to it by the program, for example daily or weekly thermostat. - When a device does not operate and is in standby mode due to the achieved temperature. When the pellet burner is switch off: 43