VETO CLEANER 500 FLUE GAS CLEANER

As of serial number 3100 0001 VETO CLEANER 500 FLUE GAS CLEANER USER MANUAL SPARE PARTS LIST Manufacturer: ALA TALKKARI Veljekset Ala-Talkkari Oy FI-62130 HELLANMAA TEL. +358 6 433 6333 FAX +358 6 437 6363 Sales:

2 FOREWORD... 3 1. CLEANER INTRODUCTION... 4 1.1 General information on operation... 4 1.2 Cleaner components... 4 1.3 General safety instructions... 5 1.4 Warning and instruction labels... 6 1.5 Technical specifications... 6 2. INSTALLATION, CONNECTION AND START-UP... 7 2.1 Installation... 7 2.2 Electrical connections... 7 3. FLUE SUPPORT INSTALLATION... 8 3.1 Installing the flue support..... 8 4. OPERATION... 9 4.1 Frequency converter and sensors of the flue gas cleaner... 9 4.2 Operation when heating the boiler unit... 9 5. MAINTENANCE... 11 6. TROUBLESHOOTING... 12 7. DISPOSAL... 12 8. SPARE PARTS LISTS... 13 BACK PAGE EU Declaration of Conformity

3 FOREWORD You have purchased a VETO flue gas cleaner which, if properly used, will benefit you for many years to come. When purchasing the device, you have discussed its operation and functions with the vendor, and you have also had the chance to get to know the device. However, this initial introduction cannot replace a proper examination of the machine s operation or of this instruction manual. The purpose of this manual is to help you familiarise yourself with the structure, use and maintenance of the cleaner. This instruction manual assumes that you are used to or well guided in operating a boiler unit. Read this manual carefully before installing and using the machine. Attention symbol This attention symbol denotes safety instructions in this manual. Read and take careful note of these parts in order to prevent various kinds of accidents. Instructions, descriptions and technical data All instructions, descriptions and technical data in this manual are based on the latest information on the structure of the device at the moment of printing the manual. However, we are in the process of developing the product further. Therefore, we reserve the right to make changes to the product without prior notice. Type: Serial number: Year: Spare parts If you need to acquire spare parts for your machine, you must always provide the vendor or service personnel with the information on the type plate of the machine in order to receive the correct parts. Enter the information on the type plate in the above space in order to have it easily available when needed.

4 1. CLEANER INTRODUCTION 1.1 General information on operation The flue gas cleaner is intended for cleaning flue gas particles from airborne ash, soot and sparks. The flue gas cleaner comprises a flue gas suction extractor and a cyclone as well as automation technology that controls the suction extractor. In the context of this manual, the term suction extractor refers to the combination of an electric motor and a fan connected to it. The fan is located inside the blower hood (cover). The cyclone section of the cleaner separates impurities from flue gases by centrifugal action. As flue gas is sucked up through the middle, heavier particles are pushed to the outer section of the cyclone and led down into the ash container. The gas flow rate is adjusted by the control centre s adjustment automation. The control centre measures the vacuum in the combustion chamber and adjusts the revolutions of the suction extractor accordingly by means of a frequency converter. 1.2 Cleaner components Figure 1. Flue gas cleaner 1 Adjustment leg 2 Ash container 3 Rear hatches 4 Band 5 Flue gas suction extractor 6 Top cover 7 Ventilation cover 8 Electric motor 9 Upper curve pipe for flue/flue base 10 Smaller inspection hatch 11 Outlet cleaning hatch

5 1.3 General safety instructions These general safety instructions help avoid hazards when installing, using or servicing the machine. More essential safety instructions are given at the beginning of each chapter. Installation: Neglecting to observe the installation instructions may cause hazardous situations. Maintenance: Stop the boiler unit and let the cyclone cool down sufficiently before beginning maintenance work. Air leaks: - The air-tightness of joints and the condition of maintenance hatch seals must be checked in conjunction with installation and maintenance work. - Hatches and components must be properly closed and affixed before starting the device. Inadequate assembly causes hazardous situations. Operation: A boiler unit can only be used by persons who have familiarised themselves with the equipment and the instruction manual. Protective equipment: Ash contains impurities the inhalation of which should be avoided. Use proper protective equipment when working with ash. Note that hot coal may be mixed in with ash. Use non-melting hot work gloves and protective clothing when handling ash. Environment: The installation location and boiler room must be kept free of extraneous items and material.

6 1.4 Warning and instruction labels By observing the warning and instructions labels, you can avoid accidents. Figure 2. Warning and instruction label - Only a competent person may use the burner, boiler and cleaner. - Carbon monoxide is generated in the cleaner. Let the equipment ventilate after stopping it and before beginning maintenance work. - The surfaces under the cleaner hatches are hot after use. Let them cool down before handling. - The fan impellers present a serious hazard if the protective covers are opened without turning the maintenance switch to the 0 position. 1.5 Technical specifications VETO flue gas cleaner Width (mm) 1,100 Length (mm) 1,595 Height (mm) 1,915 +200 Operating voltage 400 Blower max capacity (m³ / h ) 2400 Power demand (kw) 1.5 Current demand (A) 3.7 Max noise level (db) 66 Weight (kg) 650 Combustion chamber s vacuum during 20 Pa heating Table 1. Technical specifications.

7 2. INSTALLATION, CONNECTION AND START-UP Safety instructions Clean the area where the cleaner will be installed thoroughly, and ensure that the floor is even and not susceptible to frost. An uneven and frost-susceptible floor causes leaks and structural damage. Moreover, neglecting to clear the area presents a safety risk when moving the heavy device to the installation location. When moving the cleaner, the forklift fork must be positioned under the base of the device. The base is even and can withstand lifting. 2.1 Installation The vacuum created by the flue gas suction extractor also affects the combustion chamber. Therefore, the joints all the way to the connection flue must be airtight. Level the cleaner with the adjustment legs. Secure the legs carefully after adjustment by welding or bolting them in place as they must withstand the weight of the flue in addition to the weight of the cleaner. 2.2 Electrical connections Safety instructions Electrical work relating to the cleaner requires authorisation to perform electrical installations, and the work must be conducted according to the figures on the control centre. In connection with the electrical work, a maintenance switch for turning off the suction extractor must always be installed in the cleaner. A pressure and vacuum transmitter must be installed on the outer surface of the boiler if the boiler is not included in the delivery.

8 3. FLUE SUPPORT INSTALLATION 3.1 Installing the flue support If the cleaner is included in the heating station delivery, install the flue support in the mountings included in the station s accessories. Attach the support bands of the flue, which is assembled on top of the cleaner, to the support. The delivery includes an installation diagram. Note! The maximum permissible length of flue pipe above the highest band is 4 metres. If the flue gas cleaner is connected to a flue mounted on a separate foundation, the connection must be made at a 30 angle via a pipe whose size is appropriate for the flue. A personnel lift or other approved lifting device must be used when assembling the flue. Assemble the flue according to the following manufacturer instructions. Figure 3. Installation diagram for flue support 1. Support bottom 2. Support top 3. Nut M16 DIN934 4. Screw M16x60 DIN 933 5. Screw M12x40 DIN 933 6. Reinforcement plate for the support 7. Adjustment leg, flue band 8. Support band fastening plate 9. Support fastening plate 10. Support mounting, fixed part of the heating station

9 4. OPERATION 4.1 Frequency converter and sensors of the flue gas cleaner Figure 4. Combustion chamber pressure and vacuum transmitters Figure 5. Frequency converter 1. Combustion chamber pressure transmitter 2. Combustion chamber vacuum transmitter 4.2 Operation when heating the boiler unit Before activating the heating: - Detach the transmitter vacuum pipe and reset it by pressing the ZERO button. (Do not reset during heating.) The button can be found under the transparent cover of the vacuum transmitter. Figure 2. - Open the cleaner s ventilation cover (component 7 in Figure 1) to the ventilation position. A suitable basic adjustment can be achieved by first twisting the cover closed and then opening it approx. 20 mm. When the burner is on standby, the flue gas suction extractor keeps the vacuum in the combustion chamber at approx. 5 Pa. Select the operating range using the jumpers under the transparent cover of the vacuum transmitter. The factory setting for the sensor operating range is ±50 Pa. In this case, the jumpers inside the transmitter are on pins M and ZC. Figure 2.

10 Figure 6. Vacuum transmitter General information on control The burner s central unit controls the operation of the cleaner by adjusting the vacuum by means of a frequency converter. The vacuum transmitter measures the vacuum in the combustion chamber via a silicone pipe. Heating The adjustment parameters of the frequency converter are preset at the factory. When the heating is switched on, the control centre activates the flue gas cleaner. The revolution speed of the flue gas suction extractor is adjusted according to the vacuum. When the vacuum is low, the revolution speed is high. Do not open the hatches when the burner is on as this will interfere with the automatic controls. The vacuum transmitter measures vacuum in the combustion chamber and converts it into 0 10 V voltage data. The frequency converter adjusts the revolution speed of the blower according to the voltage data it receives. The pressure transmitter, in turn, detects overpressure occurrences in the combustion chamber. At the factory setting, when combustion chamber overpressure exceeds 20 seconds, the transmitter sends a signal that stops the system.

11 When the burner is in power operation mode, the flue gas cleaner is programmed to keep the vacuum in the combustion chamber at approx. 20 Pa. In maintenance operation mode, the programmed combustion vacuum is approx. 5 Pa. In this mode, the cleaner blower spins at the default or, as necessary, higher speed. If the default revolution speed causes the pressure to decrease below 5 Pa, the speed will not be reduced from this level. 5. MAINTENANCE Safety instructions Stop the boiler unit, turn the maintenance switch to the 0 position and let the cyclone cool down sufficiently before beginning maintenance work. The cooling can be accelerated by turning the control centre s operation switch to the blower position. This mode must be kept engaged at least 30 minutes. Before arc welding, turn the maintenance switch to the 0 position. The location of the ground lead must be selected so that the current does not run through the motor bearings. Use a respirator. Weekly inspections Fan inspection and cleaning - The fan (blower component 5) must be inspected and the blades cleaned, as necessary, with pressurised air or by brushing them from both sides. To clean the fan, open hatch 10 (Figure 1). After this, open the screw-fastened hatch in the blower hood. The higher the moisture content of the fuel, the higher the likelihood of having to clean the fan more often. - Always clean the fan if you detect that the blower vibrates during operation. Ash removal - The amount of ash generated by different types of fuel varies. Therefore, there is variation in how frequently you need to empty the ash container. Open hatch 3 to remove the ash container. After you open the quick-release fastener, the container lowers slightly, after which it can be extracted and emptied. When reinstalling the container, ensure that the sealing surface of the container is free of ash and that the seal is firmly positioned against its mating surface. Note that you only need to shut down the system to empty the ash container. The ash container does not heat up to a hazardous level. However, protective gloves are necessary when handling the container.

12 Vacuum pipe cleaning - In conjunction with ash removal, the vacuum hose/pipe must also be cleaned. Detach the hose from the transmitter and blow through the hose in the direction of the combustion chamber. NOTE! Blowing in the direction of the vacuum transmitter may break the transmitter! Inspecting the ventilation cover The air that cools the fuel gas cleaner s motor flows through the ventilation cover. Periodically check that the cover is opened approx. 20 mm from the closed position. If the fan is unbalanced, the vibration may gradually close the cover. 6. TROUBLESHOOTING System stopped, overpressure Reason Fault Remedial measure Flue gas blower stopped - Blockage in vacuum (connection) pipe - Frequency converter displays an error message - Disconnect the hose and clean it along with the connection pipe - Do as the message indicates Blockage in boiler Airborne ash in the ash container Empty the ash container Blockage in flue gas blower Ash on the fan Clean according to instructions Maintenance hatch leaks (air) Hatch is open or seal is in poor condition Close or adjust the hatch. If necessary, replace the seal. Equipment runs at high power Reason Fault Remedial measure Frequency converter receives incorrect voltage data - Vacuum pipe is disconnected or blocked - Maintenance hatch is open or leaking - Other air leak into the combustion chamber - Equipment has not been cleaned - Disconnect the hose and clean it along with the connection pipe - Close hatch or prevent leak - Remove ashes, clean fan 7. DISPOSAL If correctly used and serviced, the cleaner will serve you well for a long time. In time, however, it will not be worthwhile to maintain the machine, which then needs to be appropriately disposed of. The simplest way to dispose of the machine is to deliver it to a specialised facility where it will be dismantled and its parts will be forwarded for further processing.

13 8. SPARE PARTS LISTS Flue gas cleaner Reference Name Qty Order No. 1. 2. Screw M16*35 din 933 1 72189 3. Spring 1 63052 4. Nut M8 din 934 1 73308 5. Cleaning hatch 1 43758 6. Cover plate, upper right 1 46678 7. Small inspection hatch 1 44515 8. Curve pipe cover plate 1 43792 9. Support frame 1 44587 10. Nut M10 din 934 1 73310 11. Curve pipe upper cover plate 1 43793 12. Washer M10 din 440 1 73134 13. Screw M10*30 din 933 1 72151 14. Screw M8*20 1 72130 15. Screw M10*60 din 933 1 72157 16. Support pipe mount 1 43785 17. Upper curve pipe/pipe connection 1 46675 18. Ventilation cover 1 43784 19. Top cover 1 43736-2 20. Blower 1 65055 21. Cover plate, upper left 1 46677 22. Band 1 68561 23. Leg 3 410601 24. Large inspection opening 1 44514 25. Ash container 1 45975 26. Screw M8*45 din 933 1 72136 27. Electric motor 1

Figure 7. Flue gas cleaner spare parts 14

15 Flue support Reference Name Qty Order No. 1. Support bottom section 1 44530 2. Support top section 1 44534 3. Nut M16 din 934 12 73316 4. Screw M16*60 din 931 12 721951 5. Screw M12*40 din 933 4 72170 6. Reinforcement plate for support 2 45221 7. Adjustment leg, pipe band 2 44900 8. Fastening plate of support band 2 44538 9. Fastening plate of support 2 44533 Figure 8. Flue support spare parts

16 EU DECLARATION OF CONFORMITY VELJEKSET ALA-TALKKARI OY FI-62130 HELLANMAA Tel. +358 6 433 6333 Fax +358 6 437 6363 declares that the product VETO CLEANER 500 Flue gas cleaner as of serial number 3100 0001 has been manufactured, to the appropriate extent, in accordance with the following directives: 2006/42/EC 2004/108/EC Hellanmaa, 20 August 2010 Place and date Antti Ala-Talkkari Managing Director