Veto Spring Agitator. User Manual Installation, Operation and Service

Transcription

1 VSA EN1.0 Veto Spring Agitator User Manual Installation, Operation and Service Retailer: Keep this manual.

2 1

3 Contents 1. Introduction Contact information Type plate and delivery information Warranty Deficiencies in delivery and return of warranty parts Processing of warranty matters Product markings Product documentation Version history Document conventions Symbols Other document conventions General safety and warnings Fire safety Product description Operating principle Product variants Product accessories Technical data Emissions Installation Preparations for installation Inspecting and preparing installation site Inspecting chimney and venting system Inspecting combustion air supply Installing main switch Required tools for installation Checking the device Installing burner head to the boiler ( kw) Installing the burner head cover ( kw) Installing the main components of the spring agitator system Installing the feeding screw to the chain coupling Installing gearbox and electric motor Building the silo

4 5.6. Installing base plates and feeding chutes Installing the stirrer disc and springs Installing the burner equipment Installing combustion blower to the burner head Installing moving grate Installing the electric motor Installing the water tank Installing the water level control sensor Installing BVTS backfire control system Testing BVTS backfire control system Retrofitting BVTS backfire control system Installing the temperature sensor Installing the flue gas/flame control sensor Installing the control unit Commissioning Before taking the burner into use Initial settings for the burner Operation Fuels Chips and sawdust Pellets Briquets Fuel moisture Forbidden use of fuels Burner control Lighting the burner manually Lighting the burner automatically Setting combustion manually Shutting down the burner manually Fire-fighting equipment Taking the burner out of use Taking the burner back in use Emergency situations Fire in the boiler room Fire in the silo Backfire

5 Actions after backfire Service Servicing the burner Tightening the pipe joints Removing ash from inside the burner Cleaning the burner head air holes Replacing burner head gaskets Servicing the blower Servicing the gearbox Servicing the feeding screw Servicing the silo and the feeding chute Cleaning the silo Servicing the backfire prevention system Testing the safety devices Troubleshooting Burning device has stopped Burning device has stopped and cooled down Efficiency of the device weakened Smoke coming into the silo Adjusting the burner does not succeed Device components and spare parts Disposal of the burner

6 5

7 1. Introduction You have made a good choice in purchasing Veto spring agitator. The burner together with a Veto boiler offers a pure, economic, efficient, and near-emission-free way of burning renewable energy sources approved by the manufacturer. By avoiding using fossil fuels, you can considerably diminish the burden on the environment and prevent global warming. This manual is for using Veto spring agitator. To gain the best possible benefit of the device, read this manual before installing, connecting or using the device. If all the instructions are followed, the device provides a long-lasting, economic, and faultless performance. Only use this manual with the device it was delivered with. The instructions, descriptions and technical information are based on the latest knowledge on the structure of the burner at the moment this instruction manual is created. We constantly develop our products further, and we therefore reserve the right to make any alterations without prior notice. Improper use of the product can result in serious injury. To avoid injury, read and carefully follow all instructions provided in this manual before installing, operating, or servicing the device. The instructions provided in this manual are recommendations. Laws and regulations of local authorities override our recommendations Contact information 6

8 1.2. Type plate and delivery information Write down the information from the type plate for easy reference. You need the information when, for example, ordering spare parts or claiming warranty. Table 1 Type plate and delivery information Type Manufacturing year Serial number Delivery date Figure 1 Type plate location 1 1 Type plate 7

9 1.3. Warranty The manufacturer Veljekset Ala-Talkkari Oy grants a warranty for the products that it manufactures and markets. The user is liable for damage resulting from use of the equipment for any purpose other than that for which it was designed. The warranty period is one year from the date of delivery (EU countries: The device has a warranty that complies with the legislation in the country of use). The warranty for parts changed under the warranty continues until the end of the original warranty period. The prerequisite for warranty is observation of the installation, use, service and safety instructions for the device. Continuation of the warranty for the device requires the use of original spare parts or those approved by the manufacturer. Service and any repairs performed during the warranty period must be assigned to a service company approved by the manufacturer. Compensation for service during warranty period can also be claimed if: The service visit is unnecessary (the reason is not covered by the warranty). The manufacturer s instructions concerning installation, use and care have not been observed. Corrective measures were not taken immediately upon observation of the fault. The warranty covers: Manufacturing and raw material defects in products manufactured by Veljekset Ala- Talkkari Oy. The warranty does not cover: Defects or damage caused by: o Natural wear (spring agitator springs, feeding screw, grates, blades, feet, etc.) o Misuse of the product or use in violation of the instructions o Neglect of service in accordance with the instruction manual o Change work or repairs made without the manufacturer's consent o Other manufacturers control devices or programs o Safety equipment that deviates from that delivered or is installed contrary to the instructions o External factors Breakage of parts preventing overloading Indirect costs or down time, or the resulting financial losses Work or travel costs unless separately agreed in advance with the manufacturer 8

10 Deficiencies in delivery and return of warranty parts Deficiencies in delivery must be reported within seven (7) days of the delivery. Broken warranty parts must be returned to the plant for a warranty inspection (include a warranty report). A part to replace the broken part can be delivered prior to warranty processing. An invoice for returned warranty parts that do not meet the terms of the warranty can be sent after warranty processing. The client can be charged for parts that are not returned upon request Processing of warranty matters The retailer is the primary contact channel in warranty matters and problem situations. The retailer handles processing of the matters with the manufacturer. The retailer must be provided with the following information: brand, model and purchasing date for the device and the serial number of the device from the type plate. Warranty compensation is subject to determination of the cause of the damage and agreement with the manufacturer concerning the repair prior to initiating any repair work. 9

11 1.4. Product markings The installer is in charge of pasting a compilation sticker in the immediate vicinity of the entrance to the overhaul space under the silo and another compilation sticker where the silo is filled up with fuel. Pay attention to the warning and information stickers: they help you to avoid risks. Figure 2 Product marking locations

12 Table 2 Product markings on the device Item Product marking Risk of carbon monoxide poisoning and fire Leaving covers or hatches open leads to immediate risk of fire when device is in operation. Close covers and hatches airtight.ventilate properly before entering fuel bin. Always work in pairs. When entering fuel bin have a person outside fuel bin to secure your safety. Hazardous voltage will cause severe injury or death. Turn off power. Wait 15 min before service. Although control unit is dead, supply voltage from frequency converter remains. Read manual before using device. Failure to follow instructions could result in death, serious injury or damaged device. Moving parts can crush and cut. Blower impeller rotates. Keep fingers away from rotating impeller. Switch off control unit before servicing. Moving parts can crush and cut. Feeding screw under lid starts rotating without warning. Switch off power before opening lid. Bin lid may suddenly close due to strong wind or weakened gas springs. During maintenance ensure lid stays open in all conditions. Risk of burn and fire Device is hot and remains hot after switch-off. Do not cover burner head. Keep it clean. Be cautious in boiler room. Moving parts can crush and cut. Burner runs intermittently and starts without warning. Even when device is switched off springs may have potential energy. Do not enter fuel bin while power is on. Hot water in boiler When pressure rises hot water may discharge through relief valve. Be careful near relief valve s downpipe. Do not let cold water inside hot boiler. Inhalation hazard Air born particulates Dust mask required during sweeping boiler and working in silo. Protect device from dust. Do not step on motor. Motor surface is slippery. Motor may get damaged. 11

13 Item Product marking 1 Hazardous voltage will cause severe injury or death. Turn off power. Wait 15 min before service. Although control unit is dead, supply voltage from frequency converter remains. 2 Moving parts can crush and cut. Blower impeller rotates. Keep fingers away from rotating impeller. Switch off control unit before servicing. 3 Risk of burn and fire Device is hot and remains hot after switch-off. Do not cover burner head. Keep it clean. Be cautious in boiler room. 4 Moving parts can crush and cut. Burner runs intermittently and starts without warning. Even when device is switched off springs may have potential energy. Do not enter fuel bin while power is on. 5 Moving parts can crush and cut. Feeding screw under lid starts rotating without warning. Switch off power before opening lid. 12

14 Item Product marking 6 Do not step on motor. Motor surface is slippery. Motor may get damaged. 13 Installation sticker 13

15 1.5. Product documentation Table 3 Related product documentation Manual name Boilers Veto Stoker Boiler 30, 60, 75, 80, 100, 120, 150, 220kW Veto Stoker Boiler 300, 400, 500, 700, 990kW Control unit A T Log-1 and A T Log-2 Control Unit User Manual Lambda 5S control unit Burners Veto Spring Agitator User Manual Other TA control Unit Data Sheet Ash Screw Data Sheet Rotary Feeder Data Sheet Veto Burner Head 160, 240, 360, 480, 640, 800, 990 kw User Manual Veto Air Boiler Transport and Storage Veto Spring Agitator Transport and Storage Veto Burner Head 160, 240, 360, 480, 640, 800, 990 kw Transport and Storage Other manufacturers documentation Boiler Thermostat User Manual BVTS User Manual Dry-boil Protection Centre User Manual GSM Alarm AT Log User Manual GSM Alarm Lambda User Manual Identification VSB EN1.0 ATL EN _LAMBDA 5S GB_v8 VSA EN1.0 TAC EN1.0 ASD EN1.0 RFD EN1.0 VBR EN1.0 VAIR2V GB SBT US1.0 VST US1.0 VBT US /B-07/01 IC.PI.500.E B4081 D17016Ds GSM_AT LOG_v1 GSM_LAMBDA 5_v Version history Table 4 Document version history Version Date Changes EN First version 14

16 1.7. Document conventions Symbols Table 5 Symbols used in this document Symbol Explanation Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates special information to the reader, but not related to personal injury Other document conventions Table 6 Document conventions Item Convention Example Display texts Written in capital letters. Can FLAME MONITORING ALARM! be alarm messages, display instructions or setting parameters. Italics Indicates a reference within this document. Refer to Document conventions. 15

17 2. General safety and warnings These general safety instructions help you to avoid dangerous situations when installing, operating or servicing the device. Important safety instructions are also presented in the beginning of each section. Do not make any alterations to the original device design. Any alterations to the device may result in serious hazard to people, property or environment. Installation and service of the device shall be performed only by an authorized professional installer following all the requirements of the authority having jurisdiction over the installation. Incorrect installation, operation, and service of this device could result in severe personal injury, death, or substantial property damage from fire, carbon monoxide poisoning, soot or explosion. Hazardous voltage! Although the control unit is dead, a normal supply voltage from the frequency converter remains. Refer to the frequency converter manual. Do not use the boiler room for general storage due to fire hazard. The burner must only be used together with a Veto boiler device and a control unit. Risk of burn! The lids are always hotter than the rest of the burner surface. Also some of the pipes are hot. Always be cautious in the boiler room. When servicing or checking the blower, ensure that it is not rotating. Switch off the control unit with the main switch or with the miniature circuit breaker F1 by setting the switch to down position. The device may only be operated by a person acquainted with the device and the related instructions in this manual. Risk of burn and fire! The burner head remains hot for a long time after the heating has been switched off. The burner head must not be covered and it must be kept clean. 16

18 Ashes or fuel may contain constituents causing allergic reactions. Use appropriate protective equipment when handling ashes or fuel. Use clothes and gloves made of non-flammable materials when servicing the device. Do not wear clothes that may melt or readily catch fire when working in the boiler room Fire safety Risk of carbon monoxide poisoning and fire! Always close the covers and hatches airtight. Leaving the covers or hatches open leads to immediate risk of fire when the device is in operation. Excessive fuel in the bin prevents the cover from closing air-tight. Risk of carbon monoxide poisoning and fire! Always check that the feed and service doors of the boiler are completely shut when in use. Risk of fire! Fuel that remains on the floor may catch fire from a spark, and fire may spread to the structure of the building. Risk of burn! Do not try to extinguish fire with water. Make sure that the container of the back fire control system is filled with water. Get and maintain suitable firefighting equipment and skills. Place sufficient manual fire extinguishing equipment near the boiler room. Risk of carbon monoxide poisoning and fire! Never collect ash in a plastic or cardboard box. Do not leave the collected ash indoors, even when collected in a container made of incombustible material, because the ash may produce gases containing carbon monoxide. 17

19 3. Product description Veto spring agitator is designed to be used with a Veto stoker boiler and a control unit. Only solid fuels approved by the manufacturer, such as, chips, pellets, and briquets should be used as a heating source. The Veto spring agitator delivery includes: Feeding chutes Feeding screws Rotary feeder Burner head Combustion air blower Water tank Main distribution board Base plate Gearbox holder Gearboxes Electric motors Stirrer disc Springs Top plate Bolts and nuts needed for installation 18

20 Figure 3 Veto spring agitator main components Boiler 2 Gearbox and electric motor 3 Capacitive sensor 4 Feeding screw 5 Springs 6 Mounting plate 1x1 m 7 Top plate 8 Wall protective board 9 Spring agitator base 10 Stirrer disc 11 Spring agitator gearbox 12 Feeding chute 13 Rotary feeder 14 Burner head 3.1. Operating principle When the Veto spring agitator is in operation, the springs drive fuel from the silo to the silo feeding screw. The fuel drops down through the rotary feeder to the burner head feeding screw that drives the fuel to the burner head where the fuel burns at a high temperature with the help of air blown in by the combustion air blower. The boiler heats up. Fresh fuel brought in by the feeding screw pushes the remaining ash to the boiler s ash box. The control unit automatically controls the burner fire heating the boiler. 19

21 3.2. Product variants Burners: 40 kw, stationary grate 60 kw, stationary grate 80 kw, stationary or moving grate 120 kw, stationary or moving grate Silo extensions: Maximum silo base size 5x5 m Minimum silo base size 2.5x2.5 m Minimum silo height 70 cm Maximum silo size for chips 100 m 3 Maximum silo size for pellets 30 m 3 Maximum silo size for briquets 40 m 3 Feeding chute lengths: Silo screw feeding chute 100 mm 200 mm 300 mm 400 mm 500 mm 500 mm 600 mm 700 mm 800 mm 1000 mm 1500 mm Burner head feeding chute 800 mm 1000 mm 1500 mm 20

22 Product accessories Accessories that can be ordered separately: Burner heads 160, 240, 360, 480, 640, 800, and 990 kw Feeding screws 125, 160, 200 mm and 2 x Ø160 mm (depending on the burner) Moving grate 80 and 120 kw Water level control sensor for water tank Support plate Lambda 5S control unit Lighting automation Veto XL control unit kw burner heads always include a moving grate. 21

23 4. Technical data Table 7 Feed settings for Veto spring agitator (feeding screw Ø 125 mm) Operating condition Pause condition Burner power kw Heat value kw/kg Moisture % Blower setting Fuel Wood chips min 40 s Wood pellets min 30 s Wood chips min 40 s Briquets Wood chips min 40 s Wood pellets min 30 s Briquets Wood chips min 40 s Wood pellets min 30 s Briquets Wood chips min 40 s Wood pellets min 30 s Briquets Space for customized settings Wood chips Wood pellets Briquets After-blow (s) Pulse (ms) Pause (s) Pulse (ms) Pause (min) 22

24 When the fuel moisture percent exceeds 35%, the maximum power of the burner can diminish to half of what it is when using drier fuel. The maximum allowed moisture percent for wood chips is 30%. The values in the feed settings table are derived from 30-mm wood chips which means that the feeding screw feeds the fuel approximately 2.3 kg/rotation. If the chip size differs from that, the feed values should be calculated again. For example, for ChipMatic 40 kw: Operate the feeding chute with no fire for 10 min and weigh the wood chips used. With 30-mm wood chips (moisture 20%) the weight should be ca. 7 kg. For more information about the fuels, see 7.1 Fuels. The moisture content, piece size, thermal value, weight and other parameters of the fuel affect the efficiency of the burner so that using these values may produce different boiler outputs. Therefore, no reference values can be given as to the positions of the air-adjustment plate Emissions The flue gas emission values apply only when using recommended fuels. For flue gas emissions, the device is tested according to the European standard EN The noise emission of the device is approximately 85 db, depending on the used fuel type. 23

25 5. Installation Installation of the device shall be performed only by an authorized professional installer following all the requirements of the authority having jurisdiction over the installation. Incorrect installation of this device could result in severe personal injury, death, or substantial property damage from fire, carbon monoxide poisoning, soot or explosion. Failure to follow the installing instructions may lead to dangerous situations. Install the main switch according to the local laws and regulations. If there are no local regulations, it is recommended that the main switch is installed near the boiler room exit. Lift the device according to the instructions. Clean up the area where the silo is to be placed. An untidy space is a security risk when moving the heavy appliance to its installation space. When the device is operated manually during maintenance and installation, there should be no other persons near the device than the person servicing it. The installer is in charge of pasting a compilation sticker in the immediate vicinity of the entrance to the overhaul space under the silo and another compilation sticker where the silo is filled up with fuel. When installing, check the air-tightness of the joints and the condition of the cover sealing. 24

26 5.1. Preparations for installation Inspecting and preparing installation site Do not use the boiler room for general storage due to fire hazard. Install the device indoors. The device must have an own confined space. Drain the installation site. Minimum safety distances in the installation site should be according to the regulations. Plan where to place the water tank of the backfire prevention system. For connecting the backfire prevention system to the burner, get enough plastic hose with an inner diameter of 13 mm. The bottom of the water tank must be at least 50 cm higher than the feeding chute. Close tightly all boiler hatches Inspecting chimney and venting system For chimney and venting requirements, see the Veto stoker boiler manual Inspecting combustion air supply For combustion air supply requirements, see the Veto stoker boiler manual Installing main switch Install the main switch close to the boiler room door so that in case of emergency the switch is easy to access without entering the boiler room. 25

27 Required tools for installation 13 mm wrench 17 mm wrench 19 mm wrench Screwdriver Level Trolley jack Tape measure The burner delivery includes the bolts and nuts needed in burner installation. You need two set wrenches of each size. Table 8 Screw torque when installing spring agitator Diameter mm Strength class 8.8 Strength class Nm 34 Nm Nm 67 Nm Nm 117 Nm Nm 200 Nm 5.2. Checking the device Abbreviation BH FS MG L XL S A Explanation Burner head Feeding screw Moving grate Lambda 5S control unit Veto XL control unit Standard Accessory Table 9 Contents of the delivery Quantity Item Product FS Ø125/ FS Ø125/ FS Ø160/ FS Ø125/ number BH BH 160 BH 160 BH 240 Burner head 40 kw x Burner head 60 kw x Burner head 80 kw x Burner head 80 kw MG x Burner head 120 kw x Burner head 120 kw MG x Burner head 160 kw, Ø125 mm x

28 Quantity Item Product number FS Ø125/ BH FS Ø125/ BH 160 FS Ø160/ BH 160 FS Ø125/ BH 240 Burner head 240 kw, Ø125 mm x Burner head 160 kw, Ø160 mm x - Burner head 240 kw, Ø160 mm Burner head 360 kw Burner head 480 kw Burner head 640 kw Burner head 800 kw Burner head 990 kw Rotary feeder Ø125 mm Feeding screw Ø125 mm Burner head feeding screw Ø125 mm Rotary feeder Ø160 mm Feeding screw Ø160 mm Burner head feeding screw Ø160 mm Rotary feeder Ø200 mm Feeding screw Ø200 mm Burner head feeding screw Ø200 mm Rotary feeder 2 x Ø Feeding screw Ø160 mm Feeding screw Ø200 mm (OMF) Gearbox RMI Electric motor 1,5 kw Gearbox RMI Coupling cover Ø125 mm Coupling cover Ø160 mm Coupling cover Ø200 mm Feeding screw gasket plate Feeding screw gasket plate Feeding screw gasket plate Feeding chute 1500 mm, Ø125 mm Feeding chute 1000 mm, Ø125 mm Feeding chute 500 mm, Ø125 mm Feeding chute 1500 mm, Ø160 mm measure Feeding chute 1000 mm, Ø160 mm measure Feeding chute 500 mm, Ø160 mm Feeding chute 1500 mm, Ø200 mm measure Feeding chute 1000 mm, Ø200 mm measure Feeding chute 500 mm, Ø200 mm Feeding chute cover 1500 mm, Ø mm Feeding chute cover 1500 mm, Ø mm Feeding chute cover 1500 mm, Ø A mm Chain coupling Base plate Gearbox holder Gearbox washer Flange RMI Disc shaft Rubber gasket Chain coupling gasket holder Stirrer disc Top plate Spring

29 Quantity Item Product number FS Ø125/ BH FS Ø125/ BH 160 FS Ø160/ BH 160 FS Ø125/ BH 240 Fastener bushing Water tank Key 9x14x90 mm Key 8x12x50 mm Key 11x18x100 mm A-T Log-2 control unit S S S S Lambda 5S control unit A A A A Veto XL control unit A A A A Gasket for blower Combustion blower RFE Combustion blower RFE Gasket for blower Combustion blower RFE Gasket for blower Combustion blower RFT Stand for blower Combustion blower CMA 531 1,5 kw Stand for blower CMA Burner head gasket Ø Burner head gasket Ø Burner head gasket Ø Burner head gasket 2 X Ø Gear shaft RMI Gear shaft OMF Temperature sensor pocket Screw M16x Washer M Screw M16x Lock screw Screw M10x Nyloc nut M Washer M Nyloc nut M Screw M8x Screw M10x Silicon sealing compound Main switch Substitute resistance Table 10 Contents of the delivery (continued) Quantity Item Product number FS Ø160/BH 240 FS Ø160/360 FS Ø200/480 Burner head 40 kw Burner head 60 kw Burner head 80 kw Burner head 80 kw MG Burner head 120 kw Burner head 120 kw MG Burner head 160 kw, Ø125 mm Burner head 240 kw, Ø125 mm Burner head 160 kw, Ø160 mm Burner head 240 kw, Ø160 mm x - - Burner head 360 kw x - Burner head 480 kw x 28

30 Quantity Item Product number FS Ø160/BH 240 FS Ø160/360 FS Ø200/480 Burner head 640 kw Burner head 800 kw Burner head 990 kw Rotary feeder Ø125 mm Feeding screw Ø125 mm Burner head feeding screw Ø125 mm Rotary feeder Ø160 mm Feeding screw Ø160 mm Burner head feeding screw Ø160 mm Rotary feeder Ø200 mm Feeding screw Ø200 mm Burner head feeding screw Ø200 mm Rotary feeder 2 x Ø Feeding screw Ø160 mm Feeding screw Ø200 mm (OMF) Gearbox RMI Electric motor 1,5 kw Gearbox RMI Coupling cover Ø125 mm Coupling cover Ø160 mm Coupling cover Ø200 mm Feeding screw gasket plate Feeding screw gasket plate Feeding screw gasket plate Feeding chute 1500 mm, Ø125 mm Feeding chute 1000 mm, Ø125 mm Feeding chute 500 mm, Ø125 mm Feeding chute 1500 mm, Ø160 mm measure Feeding chute 1000 mm, Ø160 mm measure Feeding chute 500 mm, Ø160 mm Feeding chute 1500 mm, Ø200 mm measure Feeding chute 1000 mm, Ø200 mm measure Feeding chute 500 mm, Ø200 mm Feeding chute cover 1500 mm, Ø125 mm Feeding chute cover 1500 mm, Ø160 mm Feeding chute cover 1500 mm, Ø200 mm 42871A Chain coupling Base plate Gearbox holder Gearbox washer Flange RMI Disc shaft Rubber gasket Chain coupling gasket holder Stirrer disc Top plate Spring Fastener bushing Water tank Key 9x14x90 mm Key 8x12x50 mm Key 11x18x100 mm A-T Log-2 control unit S S S Lambda 5S control unit A A A Veto XL control unit A A A 29

31 Quantity Item Product number FS Ø160/BH 240 FS Ø160/360 FS Ø200/480 Gasket for blower (L) 2(L) Combustion blower RFE (L) 2(L) Combustion blower RFE (XL) - Gasket for blower (XL) - Combustion blower RFE (L & XL) 1(L) 2(XL) Gasket for blower (L & XL) 1(L) 2(XL) Combustion blower RFT Stand for blower Combustion blower CMA 531 1,5 kw Stand for blower CMA Burner head gasket Ø Burner head gasket Ø Burner head gasket Ø Burner head gasket 2 x Ø Gear shaft RMI Gear shaft OMF Temperature sensor pocket Screw M16x Washer M Screw M16x Lock screw Screw M10x Nyloc nut M Washer M Nyloc nut M Screw M8x Screw M10x Silicon sealing compound Main switch Substitute resistance Table 11 Contents of the delivery (continued) Quantity Item Product number FS Ø200/640 FS 2xØ160/800 FS 2xØ160/900 Burner head 40 kw Burner head 60 kw Burner head 80 kw Burner head 80 kw MG Burner head 120 kw Burner head 120 kw MG Burner head 160 kw, Ø125 mm Burner head 240 kw, Ø125 mm Burner head 160 kw, Ø160 mm Burner head 240 kw, Ø160 mm Burner head 360 kw Burner head 480 kw Burner head 640 kw x - - Burner head 800 kw x Burner head 990 kw x Rotary feeder Ø125 mm Feeding screw Ø125 mm Burner head feeding screw Ø125 mm Rotary feeder Ø160 mm Feeding screw Ø160 mm

32 Quantity Item Product number FS Ø200/640 FS 2xØ160/800 FS 2xØ160/900 Burner head feeding screw Ø160 mm Rotary feeder Ø200 mm Feeding screw Ø200 mm Burner head feeding screw Ø200 mm Rotary feeder 2 x Ø Feeding screw Ø160 mm Feeding screw Ø200 mm (OMF) Gearbox RMI Electric motor 1,5 kw Gearbox RMI Coupling cover Ø125 mm Coupling cover Ø160 mm Coupling cover Ø200 mm Feeding screw gasket plate Feeding screw gasket plate Feeding screw gasket plate Feeding chute 1500 mm, Ø125 mm Feeding chute 1000 mm, Ø125 mm Feeding chute 500 mm, Ø125 mm Feeding chute 1500 mm, Ø160 mm measure Feeding chute 1000 mm, Ø160 mm measure Feeding chute 500 mm, Ø160 mm Feeding chute 1500 mm, Ø200 mm measure Feeding chute 1000 mm, Ø200 mm measure Feeding chute 500 mm, Ø200 mm Feeding chute cover 1500 mm, Ø mm Feeding chute cover 1500 mm, Ø mm Feeding chute cover 1500 mm, Ø A mm Chain coupling Base plate Gearbox holder Gearbox washer Flange RMI Disc shaft Rubber gasket Chain coupling gasket holder Stirrer disc Top plate Spring Fastener bushing Water tank Key 9x14x90 mm Key 8x12x50 mm Key 11x18x100 mm A-T Log-2 control unit S - - Lambda 5S control unit A - - Veto XL control unit A S S Gasket for blower (L) - - Combustion blower RFE (L) - - Combustion blower RFE Gasket for blower Combustion blower RFE (L) 2(XL)

33 Quantity Item Product number FS Ø200/640 FS 2xØ160/800 FS 2xØ160/900 Gasket for blower (L) 2(XL) - - Combustion blower RFT Stand for blower Combustion blower CMA 531 1,5kW Stand for blower CMA Burner head gasket Ø Burner head gasket Ø Burner head gasket Ø Burner head gasket 2 X Ø Gear shaft RMI Gear shaft OMF Temperature sensor pocket Screw M16x Washer M Screw M16x Lock screw Screw M10x Nyloc nut M Washer M Nyloc nut M Screw M8x Screw M10x Silicon sealing compound Main switch Substitute resistance

34 5.3. Installing burner head to the boiler ( kw) 1. Close all boiler hatches tightly. 2. Seal the joint between the boiler and burner head with a gasket or ceramic wool if the gasket is not included in the delivery. 3. Test the size and suitability of the burner head cover before installing the burner head to the boiler. 4. Install the burner tightly to the boiler. Use M10 washer and M10 nut Installing the burner head cover ( kw) Before installing the burner head cover, the burner head must be installed to the boiler. 1. Install the cover of the burner head through the service door of the boiler. 2. Attach the cover to the support clamps located on the upper part of the burner head. 33

35 5.4. Installing the main components of the spring agitator system Figure 4 Layout of the spring agitator installation Boiler 2 Gearbox and electric motor 3 Capacitive sensor 4 Feeding screw 5 Springs 6 Mounting plate 1x1 m 7 Top plate 8 Wall protective board 9 Spring agitator base 10 Stirrer disc 11 Spring agitator gearbox 12 Feeding chute 13 Rotary feeder 14 Burner head 1. Install the boiler to its place according to the layout figure. 2. Install the burner head ( kw) to the boiler. 3. Install the feeding screw to the burner head feeding chute. Fasten the screw through the hatch. Rotate the gearbox motor connection to a suitable position to mount the feeding screw and the shaft with an M10x80 screw and a Nyloc nut. 34

36 Figure 5 Fastening the screw 4. Install the rotary feeder to the burner head. 5. Make a hole in the wall of the silo. The hole dimensions: Width 2 x screw diameter Height 3 x screw diameter 6. Install the feeding chutes starting from the top of the rotary feeder towards the gearbox of the silo. 7. Install the spring agitator gearbox to the feeding chutes. There is a chain coupling case attached to the gearbox. 8. Install the upper end of the rotary feeder and the gearbox to the correct angle. 35

37 Figure 6 Installation angle C A B A B C Installation angle Minimum height < 0 mm Minimum height of the silo wall The installation angle should not exceed 15. Do not build the base of the silo lower than the floor. Use lifting help when installing the gearbox. 9. Place a long water level to the machined surface of the gearbox. Measure the distance to the silo s floor (H) from both ends of the water level. The height should be the same from both ends. The water level should be aligned with the wall facing the boiler room before measuring the height (L). 36

38 Figure 7 Measuring the distance L L H H H L Distance to the silo s base Aligning of the system 10. Secure the height of the gearbox base by welding short welds on the bench legs. Bolt or weld the bench legs to the floor. 11. Install the rubber gasket and the chain coupling gasket holder. 12. Install the feeding screw through the silo to the chain coupling and the key. 37

39 Installing the feeding screw to the chain coupling The feeding screw is heavy. Never lift it without help. Make sure that the feeding screw is installed the right way around. The short shaft should be downwards and the long shaft upwards. Do not over-tighten the rubber gasket (7). The chain coupling is delivered installed to the gearbox shaft. Do not change its position. Figure 8 Installing the feeding screw to the chain coupling Chain coupling 2 Feeding screw 3 Taper lock 4 Fixing screw 5 Chain sprocket 6 Gearbox shaft 7 Rubber gasket 1. Push the feeding screw (2) against the chain coupling s taper lock (3) when installing the feeding screw. 2. Loosen the two fixing screws on the feeding screw side of the chain coupling. Leave the extractor screw on its place. 38

40 Figure 9 Position of the chain coupling and the installing screws Extractor screw 2 Fixing screw 3. Clean the feeding screw shaft of dirt. 4. Install the key to its place. 5. Turn the feeding screw so that the key and the keyway are parallel. Alternatively, rotate the gearbox shaft so that the feeding screw can be installed. The gearbox of a spring agitator with a silo or Veto 8 can be rotated from the gearboxes motor connection. The gearbox of a spring agitator without a silo can be rotated straight from the gearbox shaft. 6. Push the feeding screw gearbox shaft approximately 35 mm to the taper lock of the chain coupling. 7. Remove the extractor screw and tighten both fixing screws to 30 Nm torque. Tighten the screws again when the device has operated for half an hour. 39

41 Installing gearbox and electric motor 1. Install the gearbox to the upper end of the rotary feeder. a. Smear some vaseline to the screw shaft. Not to the keyway. b. Install a key to the shaft. c. Push the gearbox to its place. d. Turn the whole gearbox manually so that it is slotted into its place. Tighten the bolts. 2. Tighten the shaft of the feeding screw to the gearbox with a M16 screw and a gearbox washer to 115 Nm torque. If the feeding screw is short add fitting washers between the shaft and the gearbox washer. Figure 10 Fitting washers Feeding screw 2 Key 110 mm 3 Gearbox 4 Fitting washers Ø 30 mm 5 Gearbox washer Ø 65 mm 6 Screw M16x40 mm 3. Smear the shaft of the electric motor with vaseline. 4. Install the electric motor to its place. 40

42 5.5. Building the silo Build the silo according to the local laws and regulations. Maximum silo base size 5x5 m Minimum silo base size 2.5x2.5 m Minimum silo height 70 cm Recommended silo base materials: o Moisture-resistant plywood or o Sheet metal Recommended materials for the foundation of the silo base: o Lumber 2x5 or o Metal pipe 3x50x50 mm Recommended materials for the vertical supports: o Lumber 2x5 or o Metal pipe 3x50x50 mm Leave space under the silo base so that it is easy to overhaul the chain coupling. 1. Start to build the silo base around the gearbox. 2. When building the foundation for the silo base, leave a 1x1-meter space around the gearbox. The edges of the mounting plate should be supported by the joists. 3. Continue laying out the joists with 600x600-mm spacing. Do not lay joists nearer than 20 cm of the feeding chute. 4. Fit a vertical support to every junction of joists. 41

43 Figure 11 Building the silo base B A B A A B 800 mm 600 mm 5. Mount the mounting plate to its place. Align the groove in the mounting plate with the feeding chute. 42

44 Figure 12 Aligning the groove in the mounting plate 6. Attach the mounting plate with 10x60 mm torx screws. Use only ball-headed locking screws to bolt the base plates. 7. Mount the mounting plate on the gearbox. 8. Install wear plates around the silo s inner walls to prevent the springs to damage the silo. Use mm thick hard plywood approximately 250 mm upwards from the bottom of the silo. 9. Shorten the cover of the feeding screw so that the feeding screw s coarse threaded part does not show. Shorten only just after the bolts. 43

45 Figure 13 Shortening the cover B A A B Fine threaded part of the feeding screw with no cover Coarse threaded part of the feeding screw with cover If the feeding chute is not covered for over 1.5 m length, install a support plate. A support plate is included in the delivery only when the feeding chute is not covered for over 1.5 m length. 44

46 Figure 14 Support plate > 1500 mm A A Support plate 45

47 5.6. Installing base plates and feeding chutes Figure 15 Installing Ø125 feeding chute towards base plates Mounting plate 2 Laths 30x30 mm 3 Base plate 4 Foundation structure of the silo 5 Feeding chute The feeding chute should be under the base plates. Install 30x30 mm laths around the mounting plate. 46

48 Figure 16 Installing Ø160 feeding chute towards base plates A Groove Make grooves to the base plate for the feeding chute. Figure 17 Installing Ø160/200 feeding chute towards base plates Mounting plate 2 Base plate 3 Silo foundation 4 Feeding chute 47

49 5.7. Installing the stirrer disc and springs 1. Install the stirrer disc s shaft to the gearbox before installing the base plates of the silo s base. 2. Install the stirrer disc to the shaft. Ensure that the stirrer disc is the right way up. Rotate the stirrer disc before installing the springs to check the right rotation direction. 3. Check the length of the springs. The bevel of the spring ends should be 30x400 mm. Figure 18 Bevel of the spring ends mm 2 30 mm Table 12 Amount of spring sets Screw size mm Amount of spring sets Ø125 2 Ø160 3 Ø

50 Figure 19 Spring length L 4. The bushing of the spring is attached to the innermost spring. The two outer springs are pushed through the bushing before installing to the stirrer disc. The springs should slide freely inside the bushing (2). 49

51 Figure 20 Connecting springs 1 Lock screw 2 Bushing 3 Washer 4 Nut 5 Spring 5. Hand-tighten lightly both of the screws. Then properly tighten the screw in the round hole first, and the screw in the oblong hole second. The spring has to be parallel with the silo s base. Tighten the screws in accordance with the torque table. The narrower side of the bushing should be towards the rotation direction. 50

52 Figure 21 Installing springs Stirrer disc 2 Top plate 3 Spring set 4 Washer M16 5 Bolt M16x35 6 Screw M16x40 The spring can be shortened if necessary. 51

53 Figure 22 Spring sets A 2 spring sets B 3 spring sets C 4 spring sets The arrow represents the rotation direction of the springs. 6. Install the top plate on top of the stirrer disc. 7. Apply sealant to the open seams at the top end of the rotary feeder. Open bolt holes are sealed with a gasket which is bolted to the upper end of the rotary feeder. 52

54 Figure 23 Sealing the upper end of the rotary feeder A B Sealant Sealing plate 5.8. Installing the burner equipment Installing combustion blower to the burner head 1. Make sure that the gasket between the burner head and the combustion blower is on its place. 2. Fasten the combustion blower to the burner head using M6x16 screws. 3. Tighten the screws. 53

55 Figure 24 Installing the combustion blower 1 Nut M6 2 Washer M6 3 Blower 4 Screw M6x20 5 Gasket 6 Burner head 54

56 5.9. Installing moving grate The burner head with a moving grate is available as optional equipment. Figure 25 Moving grate equipment 1 Hex screw M8x20 2 Washer 3 Bearing 4 Limit switch 5 Gearbox mounting base 6 Gearbox 7 Electric motor 8 Control shaft 9 Screw for adjustment plate 10 Key 11 Fixing plate 12 Grate actuator 13 Moving grate glide 55

57 1. Install the feeding screw. 2. Install the burner head and the rotary feeder with gaskets in a straight line. Tighten the bolts. 3. Apply sealing compound on the sealing surface of the covers. 4. Install the covers. Tighten the bolts. 5. Fit together the gearbox mounting base (5), the gearbox (6) and the control shaft (8). 6. Turn the adjuster of the control shaft (8) to point in the direction of the silo. 7. Pull the grate actuator (12) to the maximum position. 8. Install the whole gearbox assembly on the burner head. Do not tighten the adjustment nuts. 9. Install the bearings (3) to the screw for adjustment plate (9). 10. Install the bearing assembly on the control shaft (8). 11. Attach the limit switch (4) and the fixing plate (11) to the limit switch bracket. 12. Adjust the moving grate glide (13) to press the limit switch down. 13. Tighten the nuts in the gearbox mounting base (5) and the limit switch (4). 14. Test the operation by rotating the gearbox shaft. 15. When the moving grate is correctly adjusted, install the electric motor (7) Installing the electric motor 1. Lubricate the motor shaft. 2. Connect the electric motor and the gearbox so that the motor s junction box is located upwards. 3. Install the electric motor with M6X18 screws. 4. Tighten the screws Installing the water tank 1. Attach the installing bracket for a water tank to a suitable place on the wall. The bottom of the water tank must be at least 50 cm higher than the feeding chute. 2. Install the water tank. 3. Connect the hose from the water tank tap to the feeding chute coupling which is closed with a beeswax plug. Open the tap and make sure that the tank lid has a 6-mm replacement-air hole. 56

58 Installing the water level control sensor The control sensor is available as optional equipment. The water level control sensor indicates when the water tank is empty, and stops the device. 1. Drill a hole with a diameter of 12 mm in the upper surface of the water tank. 2. Install a rubber gasket to the threaded part of the sensor. 3. Slide the sensor into the hole from the inside so that the gasket remains inside the water tank. Figure 26 Water level control sensor installed on the water tank 57

59 5.12. Installing BVTS backfire control system Before installation, read the instructions delivered with the temperature-controlled water valve (BVTS). Make sure that the text UP and the red marking on the sensor attached to the capillary tube are directed upwards when pushing the sensor into its installation space on the feeding chute. Tighten lightly. Install the BVTS sensor to the feeding chute lid approximately mm from the burner head flange. Figure 27 Installing BVTS sensor 1 BVTS sensor 2 Sensor pocket 3 Screw 4 Screw 5 Washer 6 Nut 58

60 1. Install the BVTS sensor (1) to a pocket (2). 2. Install the pocket with the sensor to the feeding chute lid so that the capillary sensor is towards the feeding. 3. Tighten the screw (4) by hand. 4. Secure the sensor to the lid with the screw (3). Figure 28 BVTS system connected to pressurized water supply network 1 Water tank 2 Water tank connection with a beeswax plug 3 BVTS connection 4 BVTS thermostat 5 Pipe from the water supply network 59

61 Figure 29 BVTS system connected Testing BVTS backfire control system The temperature limit is 90 C and it cannot be adjusted. To test the system, use hot water. 1. Fill the water tank in which the BVTS sensor is installed with hot water, water temperature being approximately 95 C. The valve should now open. 2. If the valve does not open, check the valve adjustment and the water temperature and test again. If the valve still does not open, it must be changed Retrofitting BVTS backfire control system If the BVTS system is retrofitted and there is no actual installation space for it on the feeding chute, attach the sensor to the feeding chute between the burner head and water connection by a clamping band. The sensor must be protected against the ambient air. 60

62 5.13. Installing the temperature sensor 1. Install the temperature sensor into its box. 2. Install the temperature sensor box under the feeding chute nuts of the burning device so that the bottom of the sensor box lies on the feeding pipe. Figure 30 Temperature sensor installed into its box Figure 31 Temperature sensor installed on the feeding chute 61