THERMOSTAHL BIOPLEX MCL-BIO Manual

BIOMASS-SOLID FUEL RETORT BOILER
BIOPLEX MCL-BIO
INSTALLATION AND SERVICE MANUAL
VERSION:
2.1
UPDATE:
10.10.2013

Contents
1. 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
2. TECHNICAL FEATURES AND DIMENSIONS .......................................................................4
2.1. Technical features ...........................................................................................................4
2.2. Function principle............................................................................................................ 5
2.2.1. Boiler...................................................................................................................... 5
2.2.2. Furnace...................................................................................................................5
2.3. Dimensions .................................................................................................................... 6
2.4. Fuel...............................................................................................................................8
3. BOILER MOUNTING .........................................................................................................9
3.1. Transportation and delivery ..............................................................................................9
3.2. Boiler room .................................................................................................................. 10
3.2.1. General requirements ............................................................................................. 10
3.2.2. Boiler room dimensions........................................................................................... 10
3.3. Chimney ...................................................................................................................... 11
4. INSTALLATION ..............................................................................................................13
4.1. Hydraulic connections .................................................................................................... 13
4.2. Safety features ............................................................................................................. 13
4.3. Overheating serpentine.................................................................................................. 14
4.4. Return temperature protection........................................................................................ 14
4.5. Filling the system .......................................................................................................... 15
4.6. Automatic ignition system .............................................................................................. 15
4.7. Connection diagrams ..................................................................................................... 16
4.7.1. Open expansion vessel connection............................................................................ 16
4.7.2. Closed expansion vessel connection.......................................................................... 17
5. ELECTRICAL CONNECTIONS...........................................................................................18
5.1. General instructions ...................................................................................................... 18
5.2. Control panel functions .................................................................................................. 18
5.3. Wiring diagram ............................................................................................................. 19
6. BOILER START-UP .........................................................................................................20
6.1. Initial lighting checks..................................................................................................... 20
6.2. Start-up....................................................................................................................... 20
6.3. Checks to carry after initial start-up ................................................................................ 20
6.4. Fuel loading.................................................................................................................. 21
6.5. Combustion regulation ................................................................................................... 21
6.6. Chimney damper adjustment.......................................................................................... 22
7. SERVICE AND MAINTENANCE ........................................................................................23
7.1. Cleaning ...................................................................................................................... 23
7.1.1. Cleaning the boiler ................................................................................................. 23
7.1.2. Cleaning the chimney box ....................................................................................... 24
7.1.3. Cleaning the furnace............................................................................................... 24
7.2. Maintenance intervals .................................................................................................... 24
7.2.1. Daily maintenance.................................................................................................. 24
7.2.2. Weekly maintenance............................................................................................... 24
7.2.3. Monthly maintenance.............................................................................................. 24
7.3. Basic service procedures ................................................................................................ 25
7.3.1. Service after overheating ........................................................................................ 25
7.3.2. Service after feeder blockage................................................................................... 25
7.3.3. Service after motor bolt breakage ............................................................................ 27
7.3.4. Service after power blackout.................................................................................... 27
7.3.5. Replacement of the ignition element ......................................................................... 27
7.4. Maintenance after long stop ........................................................................................... 28
7.4.1. Maintenance of the boiler ........................................................................................ 28
7.4.2. Maintenance of the furnace...................................................................................... 29
8. TROUBLESHOOTING ......................................................................................................30
9. WARRANTY....................................................................................................................31

GENERAL INFORMATION
3
1. GENERAL INFORMATION
1.1. Proper use of the appliance
Before you make use of this appliance make sure you have read and fully understood the
instructions included in this manual.
The installation and use of the appliance must be performed according to the instructions
indicated in this manual in combination with the current national safety regulations.
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.
To ensure an efficient and flawless function of the appliance, it is strongly recommended that
you have performed an annual service by a qualified technician.
1.2. Safety warnings
All installation and maintenance procedures must be carried out by professional and authorized
personnel, in compliance with the indications in the present manual and national regulations.
Any failure to correctly install this appliance could cause damage or injuries!
Do not make modifications to parts of the appliance, unless you have contacted the company
and an authorized service contractor.
Only original accessories and spare parts must be used to ensure correct and safe function.
Make sure you respect the cleaning and maintenance procedures on the corresponding
intervals. Failure to do so can cause malfunction to the appliance and possible damages.
The boiler is design to function on the fuels indicated in the corresponding paragraph. Any
other fuel is prohibited. Do not use explosive or flammable substances! Do not store such
substances inside the boiler room.
The working pressure varies according to the model. Make sure you use the appropriate water
pressure. Working in a pressure higher than the one indicated in this manual is
strictly prohibited and dangerous!
1.3. Data label
The data label of the appliance is placed on the boiler’s side cover, on the external part. Make
sure that it is properly placed and readable.
On the label it is indicated the serial number and the manufacturing year of the appliance.
1.4. Document information
This document is an integral and indispensable part of the product and must be retained in
good condition by the user. Keep it in a safe place for future reference.
If the appliance is sold or transferred to another person, this manual has to always follow the
appliance and handed to the new user or installer.

TECHNICAL FEATURES AND DIMENSIONS
4
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.
The boiler body is made of cold rolled steel St 37.2 STAS 500/2-80~S235 JR SR EN 10025/90
according to DIN 17100. The boiler is designed so that all the parts in contact with exhaust
gases are water cooled. The boiler body parts are assembled by welding. Weldings are
performed according to standards 288-1 and 288-3 according to DIN 50120, 50121-50145, SR
EN 1011.1/2001, by means of electric arc welding (MIG-MAG).
DESCIPTION OF BOILER COMPONENTS
Steel boiler body with cylindrical heat exchanger
Removable rear smoke box with inspection cleaning door
Upper door for cleaning the heat exchanger
Middle door for ignition and fuel loading, equipped with an inspection flange, which can also
be used for a burner mounting
Lower door for ash removal
Ash box positioned on the lower part of the fire chamber
Cast iron catalyst positioned above the furnace
Rockwool body insulation of 50 mm thickness
Electrostatically painted external covers
Control panel for electromechanical operation
Safety heat exchanger (optional)
DESCIPTION OF FURNACE COMPONENTS
Steel furnace body
Feeding auger welded to solid axis
Combustion air fan
Feeding motoreducer
Transmission system with chain wheels
Transmission system protection cover
Cast iron combustion plate
Cast iron grates for manual wood feeding
Ignition element (optional)
Fuel silo with protection frame and shuttering lid

TECHNICAL FEATURES AND DIMENSIONS
5
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. The fire chamber is
of big volume in order to receive big
dimension logs and to ensure a long
autonomy.
The combustion air is supplied by the fan
and distributed through an air distributor,
positioned below the fuel grate. The
combustion is regulated through the fan,
controlled by the control panel.
Fig 1. Boiler function
The exhaust gases are guided through the heat exchanger to the smoke box, and afterwards
evacuated to the chimney. The smoke box is equipped with an inspection and cleaning door,
which also actions as an explosion relief.
The doors have an insulation cord to ensure air-tight closing. Each door is equipped with a
screwed handle, which must always be well tightened during the combustion. The flange on
the middle door has a rotating clamp, for secondary air adjustment and flame inspection. If
necessary, this flange can be removed, and a burner can be placed in its position.
2.2.2. Furnace
The BIOPLEX boiler is equipped with the innovative biomass furnace BIOFIRE. The system is
consisted of two axes (BI-AX): The lower axis is the main one, feeding fuel to the furnace,
while the upper is the secondary, transporting the fuel from the silo to the main axis. Between
the two axes there is a safety DROPBOX device. This device has a metal flap that automatically
closes with a spring when the feeding stops. This way the danger of blockage and backfire is
eliminated. The motoreducer is mounted on the lower axis, and the transmission is realized
through chain wheels. A metal protection cover is places around the transmission system.
The combustion air is supplied by the fan mounted on the furnace. In case the optional ignition
system is installed, there is a 500W ignition element
mounted in the air pipe, close to the furnace plate.
Legend
1
Silo flange
2
Fuel box
3
Upper feeding axis
4
Transmission chain
5
Motor
6
Reducer
7
Support leg
8
Fan
9
Boiler flange
10
Lowe feeding axis
11
Mixing chamber
12
Fuel DROPBOX
13
Cast iron plate
14
Lower feeding axis

TECHNICAL FEATURES AND DIMENSIONS
6
2.3. Dimensions
DIMENSIONS
Type
Feeding
door
A
A1
A2
B
H
H1
E
C
T3
T1-
T2
T5
T6
mm
mm
mm
inch
MCL-BIO 20
350x480
630
670
1470
560
1280
1380
960
860
195
1½”
1”
¾”
MCL-BIO 28
350x480
630
670
1470
660
1280
1380
960
960
195
1½”
1”
¾”
MCL-BIO 36
350x480
630
670
1470
760
1280
1380
960
1060
195
1½”
1”
¾”
MCL-BIO 45
350x480
630
670
1470
860
1280
1380
960
1160
195
1½”
1”
¾”
MCL-BIO 53
350x480
630
670
1470
960
1280
1380
960
1260
245
2”
1”
¾”
MCL-BIO 60
350x480
630
670
1470
1060
1280
1380
960
1360
245
2”
1”
¾”
MCL-BIO 70
600x360
910
810
1700
860
1600
1720
1240
1280
245
2”
1 ¼”
¾”
MCL-BIO 80
600x360
910
810
1700
980
1600
1720
1240
1380
245
2”
1 ¼”
¾”
MCL-BIO 90
600x360
910
810
1700
1100
1600
1720
1240
1480
245
2”
1 ¼”
¾”
MCL-BIO 100
600x360
910
810
1700
1200
1600
1720
1240
1580
295
2 ½”
1 ¼”
¾”
MCL-BIO 120
600x360
910
810
1700
1330
1600
1720
1240
1680
295
2 ½”
1 ½”
¾”
MCL-BIO 140
600x360
910
810
1700
1580
1600
1720
1240
1750
295
2 ½”
1 ½”
¾”
MCL-BIO 160
600x360
910
810
1700
1830
1600
1720
1240
2000
295
2 ½”
1 ½”
¾”
MCL-BIO 180
600x360
910
810
1700
1830
1600
1720
1240
2300
295
2 ½”
1 ½”
¾”
MCL-BIO 200
500x810
1100
1000
2050
1350
2000
2160
1500
1950
345
3”
2”
2x¾”
MCL-BIO 250
500x810
1100
1000
2050
1600
2000
2160
1500
2200
345
3”
2”
2x¾”
MCL-BIO 300
500x810
1100
1000
2050
1850
2000
2160
1500
2450
395
4”
2”
2x¾”
MCL-BIO 350
500x810
1100
1000
2050
1850
2000
2160
1500
2450
395
4”
2 ½”
2x¾”
MCL-BIO 400
500x810
1100
1000
2050
2100
2000
2160
1500
2650
395
4”
2 ½”
2x¾”
MCL-BIO 450
500x810
1100
1000
2050
2100
2000
2160
1500
2650
395
4”
2 ½”
2x¾”
MCL-BIO 500
1230x520
1540
1440
2400
1600
2400
2650
1750
2300
445
5”
2 ½”
2x¾”
MCL-BIO 550
1230x520
1540
1440
2400
1600
2400
2650
1750
2300
445
5”
2 ½”
2x¾”
MCL-BIO 600
1230x520
1540
1440
2400
1800
2400
2650
1750
25700
445
5”
2 ½”
2x¾”
MCL-BIO 650
1230x520
1540
1440
2400
1800
2400
2650
1750
25700
445
5”
2 ½”
2x¾”
MCL-BIO 700
1230x520
1540
1440
2400
2150
2400
2650
1750
2820
495
6”
2 ½”
2x¾”
MCL-BIO 800
1230x520
1540
1440
2400
2400
2400
2650
1750
3070
495
6”
3”
2x¾”
MCL-BIO 900
1230x520
1640
1540
2400
2600
2870
2650
1750
3350
495
6”
3”
2x¾”

TECHNICAL FEATURES AND DIMENSIONS
7
*Nominal output is obtained with good quality wood pellet.
**Pellet consumption is calculated as average, based on pellet with calorific power 4.800
kcal/kg and external temperature 0oC.
FURNACE TECHNICAL DATA
Furnace type
BIOFIRE I
BIOFIRE II
BIOFIRE III
BIOFIRE IV
Boiler range
MCL-BIO 20-60
MCL-BIO 70-90
MCL-BIO 100-200
MCL-BIO 250-500
MCL-BIO 550-900
Fan
Type
RV-12RK
RV-06
RV-05
RV-25 RK
RV-21 RK
Power
W
80
80
85
230
250
Air debit
m3/h
240
350
400
580
900
Pressure
Pa
310
300
300
520
550
Voltage
V/Hz
230/50
230/50
230/50
230/50
Noise level
dB
<60
<60
<60
<60
Protection
IP 20
IP 20
IP 20
IP 20
Motor
Type
EWM 30-50/300
EWM 30-50/300
MAF 071 AR2-0
MAF 071 AR2-0
Power
W
180
180
370
370
Voltage
V/Hz
230/50
230/50
380/50
380/50
Protection
IP 54
IP 54
IP 54
IP 54
Silo volume
lit
370
600
950
1.500
Weight
kg
200
250
320
450
BOILER TECHNICAL DATA
Boiler type
Nominal Output*
Pmax
Fire
chamber
length
Pellet
consumption**
Max.
wood
length
Silo
volume
Weight
kcal/h
kW
bar
mm
kg/h
mm
lit
kg
MCL-BIO 20
20.000
23
3
450
2,0-3,0
400
370
380
MCL-BIO 28
28.000
32
3
550
3,0-4,0
500
370
420
MCL-BIO 36
36.000
41
3
650
4,0-5,0
600
370
460
MCL-BIO 45
45.000
52
3
750
5,0-6,5
700
370
500
MCL-BIO 53
53.000
61
3
850
6,0-7,0
800
370
550
MCL-BIO 60
60.000
69
3
950
7,0-8,5
900
370
600
MCL-BIO 70
70.000
81
3
700
7,5-9,5
650
600
750
MCL-BIO 80
80.000
93
3
820
7,5-9,5
750
600
880
MCL-BIO 90
90.000
104
3
920
8,5-10,0
850
600
930
MCL-BIO 100
100.000
116
3
1080
10,0-11,8
950
600
1000
MCL-BIO 120
120.000
139
3
1200
11,5-14,0
1100
600
1070
MCL-BIO 140
140.000
162
3
1450
12,5-16,0
1350
600
1220
MCL-BIO 160
160.000
186
3
1650
14,0-19,0
1550
600
1470
MCL-BIO 180
180.000
209
3
1650
14,0-19,0
1550
600
1680
MCL-BIO 200
200.000
232
3
1200
20,0-28,0
1100
950
1790
MCL-BIO 250
250.000
291
3
1450
24,0-33,0
1350
950
2010
MCL-BIO 300
300.000
348
3
1700
28,0-39,0
1600
950
2230
MCL-BIO 350
350.000
406
3
1700
33,0-45,0
1600
950
2230
MCL-BIO 400
400.000
464
3
1950
38,0-50,0
1850
950
2750
MCL-BIO 450
450.000
522
3
1950
43,0-55,0
1850
950
2980
MCL-BIO 500
500.000
580
3
1450
85,0-110,0
1350
2000
3500
MCL-BIO 550
550.000
638
3
1450
85,0-110,0
1350
2000
3800
MCL-BIO 600
600.000
696
3
1700
110,0-140,0
1600
2000
4200
MCL-BIO 650
650.000
754
3
1700
110,0-140,0
1600
2000
4700
MCL-BIO 700
700.000
812
3
1935
130,0-165,0
1800
3000
5200
MCL-BIO 800
800.000
928
3
2000
145,0-180,0
1900
3000
5650
MCL-BIO 900
900.000
1.044
3
2300
160,0-210,0
2200
3000
6150

TECHNICAL FEATURES AND DIMENSIONS
8
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.
This means different types of biomass fuels, such as pellet, agropellet, olive husks, fruit
kernels, cereals, granulated carbon. When the fuel used has characteristics that significantly
vary from nominal (i.e. carbon, cereals, agricultural residues), it is recommended that they are
used in combination with pellet or agropellet at a 50:50 ratio. If you want to use solely carbon
as fuel, please contact the manufacturer.
The fuel with the best quality, concidering calorific power, ash content, humidity and
standartization, is wood pellet. The less quality of the fuel, the more fuel supply must be
provided to achieve the nominal power and of course the most the consumption and the ash
remains.
The nominal characteristics of the boiler are calculated for use on wood pellet!
Fuel type
Calorific
power
Max
diameter
Max
humidity
Ash
content
kWh/kg
mm
%
%
Pellet
4,8
6 –8
<10
<1
Agropellet
4 –4,2
6 –10
<10
<5
Coal
5,3 –6,5
3 –25
<15
4 –8
Lignite
1,6 –3,8
3 –25
<20
<10
Cereals (oat)
4,2
3 –6
10 –13
0,6
Wood chips
4,3
5 –25
<20
4 - 6
Barks
2,6
5 –25
<20
8 - 10
Wood
4 –4,3
-
<20
4 - 8
Wood briquette
5,2
-
<10
<4
Table 1. Characteristics of different types of fuels
Every type of biomass fuel contains a significant amount of humidity, which highly affects its
combustion behaviour and calorific value. Boiler output, efficiency and autonomy will
significantly diminish as the humidity increases. The nominal data presented in this manual are
calculated for humidity content 10%. Maximum allowable humidity content is 20%. If the fuel
has bigger humidity, the combustion will be highly imperfect, causing problems to the furnace
and the feeder.
For proper and efficient function and a long lifespan, it is strictly recommended that only dry
wood is used, with a humidity content of 20%. Practically, this means at least one year dry
wood.
In order for the feeding and combustion system to function properly the
maximum allowed humidity of the fuel is 20%!
It is prohibited the use of explosive, inflammable materials, plastic, domestic
residues, etc.
The boiler is provided with a flange for mounting a burner for use with oil or gas as an
alternative fuel. However, this option is an emergency alternative, and it is not recommended
that boiler is on stable function on oil or gas. The efficiency will be very low on such fuels.
If a burner is mounted, remove it before you use solid fuel again.
It is prohibited to manually feed solid fuel in the boiler simultaneously with the
burner function!

BOILER MOUNTING
9
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.
The boiler is very heavy. Do not try to lift by hands or other unsuitable
equipment. Danger of injury! Perform all moves with extreme attention and care.
Remove the boiler packaging with attention. Keep the packaging material away from
chidren since it can be dangerous. After having unpacked everything, make sure that the
appliacne is intact and undamaged. In case of doubt do not use the appliance and inform the
supplier.
The BIOPLEX boiler is delivered with the following equipment already fitted and mounted:
Boiler steel body
Rockwool insulation mounted on the boiler body and tightened with plastic tapes
Metal covers mounted on the boiler body
Turbinators positioned inside the fire tubes
Cast iron catalyst for the biomass combustion
Cast iron grates for wood combustion
Control panel and electrical connections
The furnace system BIOFIRE is already preassembled and mounted on the boiler side flange. It
consists of:
BIOFIRE furnace steel body
Fuel silo with lid, shutter, inspection window
Feeder with screw
Fan
Motoreducer
Transmission system with chain wheels
Protection cover of the mechanism
Cast iron combustion plate
The following accessories are positioned inside the boiler body. Remove them carefully by
opening the middle door.
Cleaning tools
Safety kit
Drainage valve
In the documentation folder you will find:
Technical manual
Warranty leaflet
Declaration of conformity

BOILER MOUNTING
10
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.
The boiler installation is prohibited in rooms with extensive dust, dangerous
gases, and moist spaces.
For the correct boiler function it is necessary that the boiler room has openings for natural
ventilation and combustion air supply. It is recommended that two different openings are used
for this purpose, positioned on opposite walls and diagonally to ensure good air circulation. The
total surface of the openings must be at least 1/12 of the boiler room surface. Forced
ventilation is prohibited in the boiler room.
The boiler room must be provided with a drainage channel. All safety devices must be
connected to this channel.
The boiler room must have an appropriate fire extinguishing system, according to the
regulations in force. In case that the building is designed with a fire alarm system, a smoke
detector must be positioned on top of every boiler.
The fuel storage is prohibited in the boiler room. If so, the storage must be separated from the
boiler with a non-flammable wall, and proper distanced from the boiler.
3.2.2. Boiler room dimensions
The boiler must be placed on a horizontal plane, with
adequate mechanical resistance to support the boiler’s
weight. The boiler must be positioned in the room in such
a way so that it is easily accessible from all the sides. The
following dimensions are recommended (see Fig 2)
Distance from the front wall (N):
For boilers up to 100 kW –minimum 1,5 m
For boilers bigger than 100 kW –minimum 2 m
Distance from the rear wall (L):
Appropriate distance for maintenance access. Minimum
0,6 m.
Distance from side walls (M):
For boiler up to 300 KW –minimum 0,6 m
For boilers bigger than 300 kW –minimum 1 m
Boiler room height (H):
For boilers up to 70 kW –minimum 2 m
For boilers 70 to 230 kW –minimum 2,4 m
For boiler 230 to 400 kW –minimum 3 m
For boiler bigger than 400 kW –minimum 3,5 m
Distance between two boilers (P) must be at least 1m.
Fig 2. Boiler room dimensions

BOILER MOUNTING
11
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. The cross-section of the chimney can be round or
rectangular. If the chimney is installed in the exterior, it must be insulated.
The horizontal part connecting the boiler’s chimney pipe with the vertical chimney must have
maximum length 2 m. If this distance is bigger, it is recommended to have a 15-30oinclination
upwards. The connection with the boiler’s chimney pipe must be air-tight.
The chimney must be equipped with a cleaning door at its base. Also cleaning doors are
recommended where there are changes in direction and ash can be accumulated. Tactical
cleaning is recommended (every 3 months) for efficient boiler function.
A chimney terminal must be installed at the end of the chimney for protection against weather
effects and foreign objects entrance. In areas with strong winds a special anti-downdraught
terminal is recommended.
The chimney height must exceed the roofline by at least 1 m. If there are other obstacles
positioned on the roof, the chimney height must exceed them by at least 1 m. If there are
multiple chimneys, minimum distance between them is 0,3m.
Each boiler should be connected to an independent chimney. Connection of multiple boilers to
the same chimney is not recommended.
Fig 3. Chimney distances

BOILER MOUNTING
12
Fig 4. Chimney connection

INSTALLATION
13
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 90oC and maximum pressure 3 bar
for boilers up to 500 kW, and 4 bar for bigger boilers.
When connected with a closed expansion vessel, its volume must be chosen double to a similar
installation on liquid or gas fuel.
If a connection pipe is not used, it must be sealed before water fill!
Legend
T1
Outlet
T2
Return
T3
Chimney pipe
T4
Discharge valve connection
T5
Safety kit connection
T6
Additional safety connection
4.2. Safety features
The boiler equipment includes a safety kit, which shall be connected to the corresponding
connection pipe T5. The kit consists of a safety valve, an air relief valve and a
thermomanometer. Bigger boilers are equipped with two or more safety valves.
Additional safety equipment can be mounted at the
connection pipe T6. This can be a dual safety valve
(pressure and temperature) or a cooling valve.
Alternatively this pipe can be used for connection
with the expansion vessel.
Fig 5. Boiler safety kit

INSTALLATION
14
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.
Fig 6. Overheating serpentine connection
The valve can be connected on either side of the serpentine. Attention should be given to the
flow direction of the valve. The valve can be fitted on the cold water inlet or hot water outlet.
However, we recommend that the valve is fitted on the cold water inlet.
For the protection of the valve, a filter is recommended to be installed on the water line before
the valve.
On the opposite side of the serpentine, drainage must be connected.
The correct function of the discharge valve is crucial for the boiler’s safety.
Verify its function often and replace if defect.
4.4. Return temperature protection
For the correct function of the boiler and for protection against corrosion it is very important to
ensure steady temperature at the return of the boiler of at least 55oC.
This can be ensured by installing a recirculation pump between the boiler outlet and return
(see connection diagrams).
An alternative variation is by installing at the return of the boiler a three-way thermostatic
valve.

INSTALLATION
15
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. An additional manometer should be
installed on the cold water inlet to verify the cold pressure, at the lowest point of the
installation, at a point close to the boiler.
The whole installation must remain under nominal pressure for at least 10 minutes. During this
period, check that all the connections are tight and there are no water leakages. Make sure
that during this period no pressure drop appears.
After firing the boiler, make sure the network functions properly at working temperature and
pressure.
The hardness of the mains water supply affects the boiler’s life span. It is
recommended to use a water softener if water hardness exceeds 15of.
Do not fill the system at the working pressure! When the boiler will be heated,
the water pressure will raise. Filling pressure must be at least 1 bar lower than
working pressure!
4.6. Automatic ignition system
As an optional, the furnace can be provided with an automatic ignition system. This consists of
the following:
Ignition element 500W (2 pieces in bigger boilers)
Control panel Ecomax 800P (technical manual given with the control panel)
Exhaust temperature sensor
The ignition element is installed in a special inox tube casing, positioned under the furnace cast
iron plate. The cables are protected with a silicon layer, resistant to temperature up to 300oC.
All the electrical connections are prewired.
The controller is equipped with an exhaust temperature sensor. This must be installed on the
chimney, at a distance maximum 1m from the boiler.
If the boiler comes with the automatic ignition system, refer to the controller’s
manual for electrical connections and settings.

INSTALLATION
16
4.7. Connection diagrams
4.7.1. Open expansion vessel connection
Legend
1-9.
Separation valves
10,11.
Radiator valves
12.
Radiators
13-15.
Safety valves
16.
Filling valve
17.
Drainage valve
18.
Cold water valve
19-24.
One-way valves
B
Hot water boiler
VED
Open expansion vessel
PCI
Central heating pump
PRC
Recirculation pump
RP
Pressure reducer
F
Filter
A
Air relief valve
FD
Water softener

INSTALLATION
17
4.7.2. Closed expansion vessel connection
Legenda
1-9.
Separation valves
10,11.
Radiator valves
12.
Radiators
13-15.
Safety valves
16.
Filling valve
17.
Drainage valve
18.
Cold water valve
19-24.
One-way valves
B
Hot water boiler
VE
Closed expansion vessel
PCI
Central heating pump
PRC
Recirculation pump
RP
Pressure reducer
F
Filter
A
Air relief valve
FD
Water softener

BOILER START-UP
18
5. ELECTRICAL CONNECTIONS
5.1. General instructions
All electrical connection must be performed by an authorized professional, in conformity with
the local regulations and the indications of this manual. Connections must be done according
to norms EN 60529 and EN 60335-1, and protection norms IP 40 and IP 44.
All wiring must be waterproof insulated. Exposed cables should be protected within plastic
channel. 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.
5.2. Control panel functions
Fig 7. Control panel
The general switch ON/OFF interrupts the electrical supply to all the devices.
The furnace thermostat interrupts the fan and motor function when the preset boiler
temperature has been reached. It is recommended that this temperature is set between 70-
90oC. This temperature should never be set below 60oC.
The fan speed regulator regulates the fan rotating speed by means of a dimmer rheostat.
The pump thermostat starts the circulation pump function at the preset temperature. It is
recommended that this temperature is set around 45-55oC. The pump indication lamp follows
the function of pump.
The safety thermostat will interrupt the fan function if the boiler temperature reaches above
95oC. If so, it needs to be reset manually by unscrewing the plastic cover.
The ventilator and motor switches are used to activate or deactivate the corresponding
devices. The switch has an incorporated indication lamp that follows the function of the
devices.
The motor timer controls the motor function by means of ON/OFF time intervals. The first
timer T1 controls the TIME OFF interval, while the T2 the TIME ON interval.
If a burner is connected to the control panel, it can be connected in the place of the fan and
regulated by the fan thermostat.
Legend:
1.
Thermometer
2.
Furnace thermostat
3.
Safety thermostat
4.
Pump thermostat
5.
General ON/OFF switch
6.
Motor timer
7.
Fan speed regulator
8.
Pump indication lamp
9.
Motor switch
10.
Fan switch

BOILER START-UP
19
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:
GS
General ON/OFF switch
TS
Safety thermostat
TM
Furnace thermostat
TP
Pump thermostat
VT
Fan speed regulator
LP
Pump indication lamp
SM
Motor switch
SV
Fan switch
TR
Room thermostat
PE
Grounding
Unscrew the control panel back plate to have access to the connection terminals in the interior.
Connect the main electrical supply to the terminals 1,2,3 as indicated. The fan is connected to
the terminals 10,11,12 and the pump to the terminals 4,5,6.
The motor phase is connected to the terminal 9, while neutral and grounding together with the
fan’s at terminals 12 and 11 respectively.
Between the terminals 7,8 there is a jumper. If you want to connect a room thermostat,
remove the jumper and connect it to these two terminals.
Attention: The room thermostat must be a simple contact interruptor. It is not
allowed to connect a digital thermostat with an electrical signal output!

BOILER START-UP
20
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.
Make sure that the connection with the chimney is air-tight and the chimney installation is
properly made.
Check that the controller bulbs are well inserted and secured in the boiler’s case.
Make sure that the pressure in the network is correct.
Check that the boiler pump and the central heating pumps function properly.
Make sure that the connection with the expansion vessel is correct and the expansion
volume is sufficient for the boiler. No valves should be installed between the boiler and the
expansion vessel.
Make sure the boiler’s separation valves are open.
Make sure that there is sufficient air supply and natural ventilation in the boiler room.
Do not store inflammable materials or fuel close to the boiler! Before you light
the boiler make sure the boiler room is clear and safe.
6.2. Start-up
To correctly start up the BIOPLEX boiler follow the next steps:
Make sure the silo is full with fuel.
Make sure the chimney damper is positioned in horizontal position (completely open).
Open the middle door (feeding door) to have visual supervision of the feeding procedure.
Turn the control panel on from the general switch and activate only the motor from the
corresponding switch. Keep the fan deactivated during this step.
Set the first timer T1 to maximum and the second T2 to zero, in order to fill the furnace
with fuel. Fill it until the fuel level reaches the cast iron plate and covers a small part of it.
Stop the motor function from the motor switch.
Using sheets of thin paper or other ignition material, light the fuel placed in the furnace.
Wait several minutes until the flame stabilizes and covers the entire plate surface.
Close the middle door of the boiler. Turn on the fan by the corresponding switch. During this
step the motor must remain deactivated.
When the flame is fully developed, activate both the motor and the fan. Set the furnace
thermostat to the required temperature.
Follow the instructions given in the chapter Combustion Regulation to correctly regulate the
combustion.
It is prohibited to light the boiler with inflammable or explosive liquids.
6.3. Checks to carry after initial start-up
During the first start-up you need to carefully check the air-tightness of all the connections,
especially the doors and the connection with the chimney.
Check that the thermostats function properly and devices operate accordingly. Wait for the
boiler to reach the preset temperature and make sure the fan stops properly and the flame
falls down.
Check the temperature and pressure rise in the network. Make sure it is according to the
indications. Check if there is any water leakage in the network.
After burning of the fuel is completed, check the situation inside the boiler. If the walls are too
black, it means that there is insufficient air supply. If there is condensation forming on the