SAS GRO-ECO Operator's manual

1
`
BOILER
Z A K Ł A D M E T A L O W O
-
K O T L A R S K I
28-100 Busko-Zdrój, Owczary, ul. Przemysłowa 3
Phone: [phone], Fax: [phone]
TECHNICAL - START - UP DOCUMENTATION
of water boilers for heating installations
SAS GRO-ECO type
adopted for black coal of pea coal granulation 5÷
÷÷
÷25 mm
SAS
GRO
-
EC
O

2
INDEX
page
Conformity Declaration
3-4
1.
Introduction
5
2.
Use of boiler
5
3.
Boiler’s construction description
5
4.
Technical dat
a
7
5.
Fuel
7
6.
Boiler’s assembly guidelines
7
6.1 Requirements for boiler-room 8
6.2 Boiler arrangement 8
6.3 Connecting boiler to a chimney 8
6.4 Connecting boiler to heating installation 9
6.5 Connecting boiler to electrical installation 10
7.
Operation and exploitation guidelines
10
7.1 Filling with water 10
7.2 Firing up and functioning of a boiler 10
7.2.1 Firing up and functioning of a boiler in automatic
mode 11
Table
-
(Technical
-
operation parameters)
13-14
Boilers construc
tion scheme
15-16
7.3 Cleaning the boiler 17
7.4 End of heating season 17
7.5 Terms of safe exploitation 17
7.6 States of improper boiler’s functioning 18
8.
Protection means
20
9.
Terms of delivery
20
10.
Recycling
21
11.
Terms of w
arranty
21
Service
rep
air
s
23
Warranty c
ard
24

3

4

5
Dear buyer and user of boiler of SAS GRO-ECO type, this technical start-up
documentation contains all necessary information required for energy-saving, safe
and longstanding exploitation of your boiler.
We kindly ask you to get familiar with documentation content prior to
assembling and starting the exploitation of a boiler. Hereby documentation shall be
kept for future use and for warranty.
SAS GRO-ECO type boilers with fuel bunker and screw feeder are designated
for water installations of the central heating systems, open type with gravitational
or forced water circulation, protected according to presently being in force, both
domestic or the union detailed regulations (e.g. PN-91/B-02413 – Boilers of
SAS GRO-ECO type installed in accordance to hereby documentation
recommendations are not subject to the commissioning led by the Branch Office of
Technical Inspection).
Boilers are specifically recommended for the flats heating in single-family homes,
pavilions, etc., where calculated feeding water temperature does not exceed 85°C,
and working pressure does not exceed 1,5 bar. Required gases draught
pressure after a boiler is 0,30 - 0,55 mbar (depending on boiler’s power). These
boilers may also work in hot water installations utilizing a heat exchanger. Boiler’s
selection for building heating should be based on heat balance, according to
regulations in force, both domestic and the union (e.g. PN-B-02025:2001).
Heating boiler of SAS GRO-ECO type, is low temperature automated boiler
for heating installations, with water body, made of plates and steel pipes of welded
construction.
Boiler SAS GRO-ECO, is a construction designed for high effective, a back coal
of pea coal grade fuel, combustion. Its granulation is 5 – 25 mm (energetic pea
coal, washed, 31.2 type). Basic components of a boiler are illustrated on the
drawing (p. 15-16).
The water jacket it is a cuboids shape structure with double walls, separated by water
partitions. The combustion chamber is placed under the high-efficient convection heat
exchanger. The boiler functions based on the set composed of:
screw fuel feeder driven by motoreducer
1. INTRODUCTION
2. USE OF BOILER
3. BOILER CONSTRUCTION DESCRIPTION

6
grateless, self-cleaning furnace in the from on the cast iron retort of goblet
shape
fan blowing the air into the chamber – retort
electronic temperature controller.
The fuel for combustion process is transported by means of a screw feeder from the
fuel hopper placed by the side of boiler.
All processes leading to fuel combustion together with the air delivered by blow-in
fan take place in the iron cast retort. Above the coal burner an iron cast deflector in
placed. The deflector radiator plate deflecting heat radiation onto a glow in order to
make combustible gases be burner completely and distribute fumes into the heat
exchanger uniformly. The cinder which has been formed in the final phase of
combustion process in moving towards the rim of the retort, and then drop down into
an ash pan chamber. For easier maintenance the chamber is provided with a drawer
pullout type.
Due to its efficiency, the combustion chamber burns such a quantity of fuel, which is
necessary to obtain the temperature set on the controller. The controller constantly
measures the temperature of water boiler. Depending on the results, it controls fuel
feeder and ventilator. At the same time the controller operates a circulation pump
(provided a heating installation is equipped with such pump). Detailed design,
functioning and operation description of the controller is attached to this controller
manual.
The boiler’s advantage, is a simple operation relaying on periodic coal bunker
refueling (the fuel bunker) and cinder removing from the ash drawer with no
requirement to stop the boiler. Once boiler is fired up, it does not call for further
service, and its operation may be practically continuous in the entire heating season.
Boiler may be also use beyond heating season in the configuration with hot utility
water boiler.
Tree- duct gas channel construction renders full utilization of gasses heat. In addition,
the upper part of combustion chamber is closed with a water jacket.
Gases are transferred into a chimney trough the smoke conduit situated at the back
of a boiler. The smoke conduit is equipped with smoke throttle, with in case in to high
chimney draught allows for its throttling. On the smoke conduit sidewall there is
washout whole. Combustion chamber door, and ash box door are placed on the
boiler’s front. For periodic cleaning operations and also for firing up a boiler, the retort
may be accessed through furnance door.
In the upper part of boiler, under the cover, there is a flap of upper washout hole
cover. It renders easy access to perform cleaning operation of the heat exchanger
cassettes. Lateral washout door are used for dust removing if accumulated.
To the upper part of the heat exchanger a hot water connector is welded. To the
lower part of it, on the back wall, a return water connector is welded. Blowdown
connection is placed on the boiler’s lateral wall.
The entire constructions is wrapped with insulation material, a mineral wool, which
fills the space between a head exchanger and boiler’s casing.

7
Basic energetic parameters are structured in the table (p. 13-14) and on the drawing
(p. 15-16).
Flawless exploitation of boiler and screw feeder depends on appropriate fuel
application or adjusting the exploitation system to the fuel type already available.
Proper selection of fuel type and grade results not only in fuel saving (efficient fuel
combustion), but also boiler servicing is less time consuming.
For boilers SAS GRO-ECO type, a back coal of pea coal grade fuel is applied.
Its granulation is 5 – 25 mm (energetic pea coal, washed, 31.2 type). The coal of
fine coal grade and coal of thicker than given granulation
*
should not be applied. This
type of fuel may hinder feeder operation.
Basic parameters of the coal for SAS GRO-ECO type boilers are placed:
Granulation 5 - 25 mm
Humidity to 25 %
Ash content to 10 %
Ash melting temperature > 1150°C
Low coal swelling coal should not tend to stick when burner
Volatile particles content 30 – 40 %
It is recommended to use coal which is prone to agglomeration (coking), although it is
good caloric properties, higher losses of the coal in ash may occur.
Besides that, some of highly coking coals may cause the tip of screw feeder burn off.
Note: fuel bunker should be supplied with a coal free of water, without
excessive volume of the fine fractions and foreign bodies.
Boiler’s assembling should be performed by qualified and authorized personnel
(qualified person upon adequate training and authorized for performing maintenance
and repair works). The fitter’s obligation is to get familiar with the product, its
functioning and protection systems functionality.
*
In particular, during the loading or fuel refueling, attention should be paid if lumps of coal, pieces of wood,
stones or other unwanted objects are present, as feeder gear may be blocked once affected (it may be blocked
once affected (it may load to cut the motoreducer)
4. TECHNICAL DATA
5. FUEL
6. BOILER ASSEMBLY GUIDELINES

8
Prior to boiler’s assembling it is strictly necessary to get familiarized with
the content of hereby Technical-Start-Up Documentation.
6.1. REQUIREMENTS FOR BOILER-ROOM
The boiler room, where the heating boiler for central heating installation shall be
installed, must conform the requirements of detailed regulations being in force, at the
country of destination (e.g. PN-87/B-02411).
In particular, the following requirements shall be fulfilled:
the boiler rooms should be located as centrally as possible to rooms
which are covered with heating system, and the boiler itself should be placed
as close as possible to chimney (chimneys),
boiler rooms entrance door should be opened on the outside, and be made of
inflammable materials,
the boiler room should have air blow-out ventilation, a channel with section no
less than 50% of the chimney section, but not less than 21 x 21 cm, with the exit
at the back part boiler’s room, (lack of such ventilation or obstruction may cause:
smoking, inability to get higher temperature),
the boiler room should have blow- out ventilation under room’s ceiling with
section no less than 25% of the chimney section, but not less than 14 x 14
cm (the purpose of this system is to carry out harmful gases).
NOTE: Employing of mechanical blow-out ventilation is unacceptable.
The boiler room should be provided with day and artificial lighting.
6.2. BOILER ARRANGEMENT
Special foundation for boiler is not required, however it is recommended to put it on
concrete platform 2 cm high, but it may be also practiced to put it directly on
the fire-proof floor.
The surface under a boiler should be precisely leveled, also floor (ceiling) strength
must be sufficient to afford the boilers weight.
A boiler should be positioned in such a way, that service of a furnace, an ash pan,
hopper and cleaning operations are easy and safe. Boilers should be distant from the
wall no less than 1m.
6.3. CONNECTING BOILER TO THE CHIMNEY
Chimney channel and connection should be performed according to the
requirements of detailed regulations being currently in force in the country of
destination (e.g. Ministry of Infrastructure Decree, as of 1 April 2002 Journal of acts
no. 75).
The boiler should be connected directly to the funnel by means of a smoke
connector e.g. steel pipe (proper for temp. >400°C) with diameter ensuring tight
mounting on the smoke conduit outlet. Area of chimney – smoke conduit
connection should be precisely sealed.
The chimney’s height and section, as well as accurateness of its construction
shall ensure obtaining required chimney draught of min. 0.30 – 0.55 mbar.
Too weak draught may also cause or help in carbon black forming, which is then

9
settling down on the boiler’s convection channels. If the draught is too strong, it will
cause excessive air to draw into the retort from the outside, enlarging heat losses and
will be also affecting the dust quantity to be blowout the cinders. A smoke conduit is
provided with sprocket, which in case that chimney draught is to strong, enables its
throttling.
Selection of the chimney’s height and section comparing to boiler power should be
based on detailed regulations being in force in the country of destination.
Assuming that is not possible to achieve such parameters for chimney, and chimney
draught problems and experienced, resulting in improper boiler performance, the
gases blow-out fan, or chimney base together with built-in fan may be applied, for
supporting and stabilizing the draught.
It is important for the chimney to has its beginning at the level of boiler room floor, for
the reason that gases leaving the boiler are able to be repelled. It is also important,
that in the bottom part of chimney, there is washout whole with tight closing.
In order to avoid the air back possibly appearing in the chimney, its height should be
above a crest of roof not less than 1.5. Chimney’s utility (permeability) should be
checked and confirmed by authorized chimney-sweeper at least once a year.
PRIOR TO BOILER COMMISSIONING THE CHIMNEY SHOULD BE BASKED!
For boiler to be used, it is not required to apply flue insert, however in year
round exploitation – it is recommended to provide heating to the hot utility
water container.
6.4. CONNECTING BOILER TO HEATING INSTALLATION
The boiler should be connected to heat in installation with screw connectors.
Protecting measures for water heating installations of opened type should be
according to detailed regulations being in force in the country of destination (e.g.PN-
91/B-02413).
Volume of pressure vessel should be equal at least 4% volume o water in the entire
heating installation.
NOTE: Ascending and descending safety pipe as well as circulation pipe
must not be equipped with any valves. In addition, those pipes and the
pressure vessel should be protected against freezing.
Boilers of SAS GRO-ECO type may work with gravitational or forced water
circulation. If installation is provided with circulation pump, than on feeding/return pipe
the differential valve should be installed. When blackout or pump malfunction occurs,
this valve will open and the system start work running by gravitation.
NOTE: It is recommended to connect the boiler to heating system
provided with three- or four-pass valve. The main advantage of such
connection is boiler protection function against low temperature corrosion,
preventing it from premature wear.
If not satisfactory to comply with manufacturer’s recommendations in reference to
maintaining given heating water temperature ranges occurs (table TECHNICAL –
EXPLOITATION PARAMETERS p. 13-14, point 13, it concerns in particular
long-lasting return water temperature below 55°C), then the boiler should

10
be connected to the heating installation equipped with three- or four-pass
valve protecting it against low temperature corrosion.
6.5. CONNECTING BOILER TO ELECTRICAL INSTALLATION
Boiler room should be equipped with electrical installation 230V/50Hz should
be according to detailed regulations being in force in the country of destination.
Electric socked should be earthed. Grounding functionality should be checked.
Cable extensions are forbidden. Faulty installation may cause the controller to be
destroyed or be unsafe for the user. Controller and other cooperating devices are
powered with 230 V, therefore all connections shell be made by qualified personnel
(certified electrician).
Electrical cables of powered devices should be placed away from boiler’s
parts, which tend to be hot during exploitation of boiler (cover of the upper
washout hole, smoke conduit, door)
7.1. FILING WITH WATER
Boiler and the entire installation water filling is to be performed using blowdown
connection.
This activity should be performed slowly allowing the air residing in the
installation to be removed.
It is accomplished when water is going out of overflow pipe. When filling the
heating system installation with water it is recommended to loose screw connection
at the place of boiler – installation assembly (on the hot water connector). Once
water is flowing out, tight the connection.
NOTE: Filling installation with water when boiler is in use, especially if it is
very hot is strictly forbidden, as boiler’s damage or fracture may be caused.
Once heating season is over do not get rid of water from heating installation and
boiler. When required, water may be let of through blowdown connection to a drain
once it is cooled down.
7.2. FIRING UP AND FUNCTIONING OF A BOILER
Firing up a fuel in boiler should be started when checked if heating installation is filled
with water, and water is not frozen. It should also be checked, if water is not
leaking through thread fittings on boiler. Do not forget to heat the chimney prior to the
firs startup.
Person operating the boiler should know that some of boiler’s areas are
hot, therefore protective gloves should be worn! The same applies to
protective goggles.
7. OPERATION AND EXPLOITATION GUIDELINES
BOILER ASSEMBLY GUIDELINES

11
7.2.1. FIRING UP AND FUNCTIONING OF A BOILER IN THE
AUTOMATIC MODE
The boiler works in the continuous mode – without shopping the fire, so firing out
operations are pretty seldom. Before the boiler is faired up, the hopper should be
supplied with fuel (fuel bunker) however, in such amount that the cover may be easily
closed. While loading the hopper, make sure that stones, metal elements, etc. are not
present in the bulk of fuel. Otherwise, screw feeder mechanism may be blocked.
Then the controller should be switched on MANUAL MODE
∗
∗∗
∗
for such a period, which
is sufficient for feeder to transport a part of fuel stored in the hopper into the iron cast
retort (3 – 6 min.).
On the coal layer, put using the opening of the door (furnace door, pos.2) pieces of
crimpled paper, and on the top of it put pieces of wood. Fire up a paper, close the
door and switch on ventilator. Once the batch is glowing uniformly, the controller to be
switched into AUTOMATIC MODE. When is this mode, set the temperature value on
the controller (temperature of water in boiler), define working time of feeder and
determine the delay between the feeder’s successive connections. The whole
procedure should be in line with the controller manuals (User Parameters
Configurations). The volume of air delivered with a fan should be according to coal
combustion intensity. During firing up phase, the boiler should be controlled until
feeding water reaches 45
o
C. This procedure is important, as varying fuel quality may
cause the boiler to burn out.
If the fire is out during up phase, the furnace should be cleaned and boiler’s channels
ventilated, and the whole starting procedure must be repeated.
Once boiler is put into operations, basically is works unattended and combustion
process is continuous. Further service is limited to refueling the fuel hopper and
emptying the ash box chamber.
During the loading of fuel refueling, attention should be paid if lumps of coal,
pieces of wood, stones or other unwanted objects are present, as feeder gear
may be blocked once affected (it may lead to cut the couple wedge of the motor
gear)!
Controller’s set points should be adjusted according to current outdoor temperatures
and quality of the fuel. When adjusting the set points, such considerations should be
taken into account:
combustion is not stopped due to too low volume of delivered fuel and too
long brakes between successive feedings,
feeder is not discarding glowing pieces of coal.
Red, smoking fire indicates that air admission is too low. Pale, white fire, indicates
that air admission is too high. Proper fire is when clean, yellow fire is observed.
Setting may be adjusted no more than 5 – 10 % in a single approach. It takes
approximately 20 – 30 min., until the effect of changes will be visible.
If we allow the retort to work with high excess of air in the longer time comparing to
volume of delivered fuel, it will result in the fire “moving down” into the bottom of the
retort, what in consequence may cause cast iron nozzles to be damaged.
Avoid also retort to work with too thick layer of fuel.
∗
In this mode, feeder and ventilator may be switched on independently

12
When in the automatic mode, the controller measure water temperature in boiler, and
based on its value, controls fuel feeder and blow-in fan, making optimal setting for the
specific fuel type.
As far as weather condition are concerned, combustion intensity, regulation and
heating capacity of the boiler should be accommodated following changing
conditions. This is done by readjusting the temperature of water coming out of boiler
(when tree-way, or four-way valve is installed, the control functions is made by
changing the position of the gate valve).
At the same time, the controller operates the heating system circulation pump (if such
is provided).
Heat requirement in the heat installation is varying due to changing outdoor
conditions such as the day time and outdoor temperature. Temperature of water
coming out of boiler depends also on the building thermal characteristic, construction
materials used, especially those used for insulation.
During fire up phase smoke may be getting out of boiler into room or sweating of the
boiler may be observed. After boiler and fluke is warmed up, these effects should be
out. Boiler’s operation stoppage may be due to getting rid of fuel in the hopper, or
feeder blockage due to hard object, stones, etc. presence.

* when working at average load (50% of rated power)/ rated load ** if manufacturer recommendations regarding heating water temperature ranges are not observed, boiler must
be obligatory connected to central heating system e uipped with three- or four – ways valve, protecting against so called „ low temperatures corrosion”
No. Parameter Unit SAS GRO-ECO
1. Boiler power kW 17 23 29 36 42 48
2. Boiler heated surface m
2
1.5 2.0 2.5 3.0 3.5 4.0
3.
Boiler efficiency
%
81,7 ÷ 87,8
4. Fuel consumpcion* kg/h 1,1 1,9 2,5 3,0 3,6 4,1
5. Load chamber capacity
dm
3
kg
100
~75
120
~90
150
~110
180
~130
200
~150
240
~170
6. Boiler water capicity l 100 120 130 140 160 190
7. Boiler weight (without water) kg 430 560 600 640 680 740
8.
Re uired chimney draught
mbar
0,30
0,45
9. Exhaust temperature °C 90 ÷ 210
10.
Recommended heating water working
temp. °C 60 ÷ 80
11. Maximal allowable working temperature °C 85
12. Maximal allowable operating pressure bar 1,5
13.
Minimal return water temp.**
°C
55
14. Power supply V/Hz ~230 / 50
15.
Power consumption
W
to 180
16.
Dimensions
A
mm
1170 1200 1200 1200 1200 1280
A1 290 290 290 290 290 290
B 1090 1210 1210 1270 1270 1270
B1 450 530 530 600 600 600
H 1250 1430 1500 1500 1580 1580
H1 1140 1310 1380 1380 1480 1480
H2 870 980 1060 1040 1120 1120
C 380 430 430 430 430 500
D 200 220 240 240 240 240
17. Smoke conduit diameter mm Ø 180 Ø 180 Ø 200 Ø 200 Ø 220 Ø 220
18. Connector pipe diameter (supply/return) " G 1½ G 2
19. Min. chimney height m 6 7 8 9
20. Minimal chimney dimensions/diameter
cmxcm
mm
18x18
Ø 210
20x20
Ø 220
21x21
Ø 240
22x22
Ø 250
25x25
Ø 280
25x25
Ø 280
TECHNICAL AND OPERATING PARAMETERS OF SAS GRO-ECO BOILER

* when working at average load (50% of rated power)/ rated load ** if manufacturer recommendations regarding heating water temperature ranges are not observed, boiler must
be obligatory connected to central heating system e uipped with three- or four – ways valve, protecting against so called „ low temperatures corrosion”
C* handle use to transport a boiler ( dimension 150 mm)
No. Parameter Unit SAS GRO-ECO
1. Boiler power kW 73 100 125 150 200 250 275
2. Boiler heated surface m
2
6.5 9.0 12.0 14.0 18.0 23.0
26.0
3.
Boiler efficiency
%
81,7 ÷ 87,8
4.
Fuel consumpcion*
kg/h
6
,
2
8
,
4
10,
5
12
,
6
16
,
8
21
,
0
23,5
5. Load chamber capacity
dm
3
kg
360
~260
460
~340
520
~380
580
~420
720
~540
860
~640
940
~700
6. Boiler water capicity l 310 430 490 540 620 690 720
7. Boiler weight (without water) kg 840 1370 1480 1830 2350 2850 3150
8.
Re uired chimney draught
mbar
0,55
9. Exhaust temperature °C 90 ÷ 210
10.
Recommended heating water working
temp. °C 60 ÷ 80
11. Maximal allowable working temperature °C 85
12. Maximal allowable operating pressure bar 1,5
13.
Minimal return water temp.**
°C
55
14. Power supply V/Hz ~230 / 50
15.
Power consumption
W
up to 280
up to 360
up to 900
16.
Dimensions
A
mm
1475 1820 1960 2100 2170 2420 2520
A1 310 420 470 500 570 720 720
B 1415 1750 1960 1960 1960 2350 2350
B1 740 820 940 940 940 1140 1140
H 1580 1730 1730 1800 1960 1960 1960
H1 1485 1610+c* 1610+c* 1675+c* 1800+c* 1800+c* 1800+c*
H2 1250 1360 1350 1420 1520 1515 1505
C 630 760 860 860 960 960 1060
D 250 300 300 350 350 440 440
17. Smoke conduit diameter mm 245x225 315x305 340x325 360x345 400x405 460x455 480x480
18. Connector pipe diameter (supply/return) " G 2½ G 3
19. Min. chimney height m 10 11 12 14
20. Minimal chimney dimensions/diameter
cmxcm
mm
26x26
Ø 320
28x28
Ø 360
29x29
Ø 380
32x32
Ø 400
32x32
Ø 400
34x34
Ø 420
34x34
Ø 420
TECHNICAL AND OPERATING PARAMETERS OF SAS GRO-ECO BOILER

1. boiler cover (body)
2. furnace door
3. ash box door
4. controller
5. insulation
6. upper washout hole cover
7. fuel storage bin
8. hot water connector pipe
9. smoke conduit
10. smoke throttle
11. smoke conduit cleaning hole
12. return water connector pipe
13. blowdown connection
14. lateral washout hole door
15. blowing fan
16. feeder drive mechanism
17. deflector
18. retort burner
19. water jacket
20. ash box
21. safety-valve
22. aeration canal lid of retort burner
23. connecting strip
24. feeder temperature sensor
25. revisory hole flap
26. heat exchanger baffles (quantity is
depend on boiler power)
BOILER CONSTRUCTION SCHEME OF SAS GRO-ECO TYPE ( 17- 48 kW)

1. air intake dosage flap
2. ash box door
3. ash box
4. aeration canal lid of retort burner
5. retort burner
6. furnance door
7. boiler cover (body)
8. deflector
9. insulation
10. controller
11. smoke conduit cleaning hole
12. smoke conduit
13. smoke throttle
14. safety-valve
15. upper washout hole cover
16. hot water connector pipe
17. fuel storage bin
18. blowing fan
19. feeder drive mechanism
20. blowdown connection
21. lateral washout hole door
22. return water connector pipe
23. water jacket
BOILER CONSTRUCTION SCHEME OF SAS GRO-ECO TYPE (73 - 275 kW)

17
7.3. CLEANING THE BOILER
In order to use fuel in the safe manner, and to get declared boiler’s power
and heat efficiency, keeping adequate cleanliness of combustion chamber and
convection channels is indispensable.
Convection channels, where ashes are tend to gather should be cleaned
systematically, every 3÷7 days. For this purpose the boiler is provided with tools.
Convection channels cleaning is performed using washout wholes placed in the
upper part of boiler. Once cleaning operation is accomplished, whose holes should
be closed. Forming dust should be removed using door of side wall washout opening.
Failure to follow these recommendations may result in high heat losses, and render
difficult gases circulation in consequence make smoke coming out of boiler. In case
of using a fuel prone to sticking during combustion process, it may lead to
agglomeration and slug forming in the area of retort rim and combustion chamber
wall. In such a case, the obstacle should be pushed down into an ash drawer.
Systematic maintenance extends boilers life and its auxiliary equipment. Cleaning the
chimney duct is not less important.
NOTE: At least a month the quantity of slung in retort should be controlled. If
required, put out a boiler and clean retort-furnace.
7.4. END OF HEATING SEASON
Once heating season is finished, or when switching off the boiler is scheduled, the
controller should be then switched off and the glowing batch should be removed from
retort and push into ash box chamber.
Once boiler is out and cooled down, remove from the furnace all remains of
burned fuel and apply cleaning and conservation of the entire boiler. Pay special
attention to lubricate inner partitions of combustion chamber and all movable
elements with oil.
For the period of brake time, water should not be drained out of boiler and
installation. In the controller manual mode, switch on a feeder allowing it to slide the
glow into ash container.
If the boiler is not employed, once a week a feeder mechanism should be put to
work. This preserve the screw elements not to be blocked inside a pipe.
NOTE: it is not allowed to put out the fire with water when in the boiler’s room!
7.5. TERMS OF SAFE EXPLOITATION
In order to maintain safe operation of boiler following rules need to be exercised:
 keep the boiler in good technical condition and its installation, in
particular take care of the installation tightness, as well as keep sealed door
and washout openings,
 keep boiler room tidy, do not stack any objects not related to boiler’s operation,
 in the winter time do not apply brakes in heating process, preserving
water in installation against freezing. Especially, if the safety pipe is
frozen (overflow pipe) it may be very dangerous because of potential
damage of boiler,
 it is forbidden to fire up a boiler by use of petrol, kerosene, solvents,

18
explosion may occur causing he operator to be burned,
 in case of installation malfunction and lacking water in a boiler do not fill it in, if
boiler is hot, as it may cause its damage,
 all operations regarding boiler should be performed with special care and using
protective gloves,
 all defects of boiler should be immediately removed.
NOTE: The boiler should be regularly cleansed from soot and tarry residues
– any residue on the convection channels walls disrupts proper heat
transfer from the exchanger, lowering this way an efficiency of device and
increases fuel consumption.
7.6. STATES OF IMPROPER BOILER’S FUNCTIONING
Feeder design do not require complicated operation, or costly maintenance. However
its proper work (influencing efficiency and economy of combustion process) calls for
following some rules when feeder is operated and also some necessary activities
should be performed.
1. Furnace door should be periodically opened for checking the flame picture.
2. Periodically remove the slung if its amount is excessive.
3. Control fuel level in the hopper.
4. Check the hopper and shielding pipe against coal dust accumulation, if required
remove it.
5. Check if air nozzles are not damaged and air orifices are not blocked.
6. From time to time the feeder must be cleaned removing a dust and remains of coal
or ash.
7. Clean engines casing regularly using dry rag.
8. Do not use solvents for cleaning, as they may damage sealing ring and sealing
itself.
9. If boiler and feeder are withdrawn from exploitation process, every three months
the screw should be run for 15 minutes, this will prevent the screw to be blocked
inside a pipe.
PROBLEM
CAUSE/SYMPTOM REMEDY
Low heat
capacity of
device
gases channels obstructed clean the channels through
washout wholes
lack of fresh air delivered to
boiler room check blow-in ventilation, improve its permeability
burning inadequate fuel apply proper quality fuel (see
chapter 5.Fuel)
boiler power not up to heating
area
improper design and erection
of heating installation
improper functioning of
controller or fan
adjust controller’s settings up to
weather conditions or quality of
fuel, mainly feeder operation time
and fuel delivery pauses should be

19
changed (time for fuel burning off)
if controller does not work properly
Smoking chimney draught not sufficient check chimney’s permeability and
its parameters (see tab. height
and section to boiler’s power,
check if chimney end is not lower
than roof ridge
gases channels dirty clean up boiler through washout
holes
sealing rope indoor and
washout openings worn
replace a rope (to be replaced
regularly)
orifices leading the air to retort
blocked clean the retort, make orifices permeable
improper assembly of boiler
and chimney connection check accurateness
very low atmospheric pressure
improper position of smoke
throttle to current chimney
draught (it might occur smoke
from blowing fan or the lover
door
adjust sprocket position if it is
closed to much
Sudden
temperature
and pressure
rise
installation valves closed open the valves
pressure vessel frozen heat the pressure vessel
Water licking
out of boiler
so called boiler’s sweating",
this is natural process caused
by temperature difference in
boiler
during boiler’s start-up and after
each standby "heat the boiler" e.g.
burn it up to 70°C and keep that
temperature for several hours
Inappropriate
flame picture
on the
combustion
chamber
red, smoking fire indicating to
low air supply provide more air
Pale, white fire indicates to
high air supply provide less air
very shallow fire in retort
indicating, that percentage of
coal volume is too low
comparing to the amount of air
delivered
provide more coal or less air
reducing blow-in power
discarding glowing not
completely burned off pieces of
coal
reduce the set of fuel supply by 5
– 10% or increase blow in power.
Wait 20-30 minutes until such
changes come to effect, what
should be deflected in change of
fire state

20
In order to ensure the failure-free and safe operation (to maximum extent) the
controller of boiler is provided with many protection functions. If faulty status is
discovered, the alarm is launched (acoustic signal), and a message is shown on
display (depending on controller version).
THERMAL PROTECTION
The controller is equipped with safety temperature limiter, preserving the boiler against
overheating (boiling water in installation), if the controller is damaged. Temperature
limiter makes up mechanical protection measure, which is bimetallic sensor (placed
at the boiler water temperature sensor) cutting off power supply to blow-in fan and
fuel feeder, if temperature is higher than 90°C (pump still working).
TEMEPERATURE PROTECTION
The controller is equipped with additional temperature protection (electronic
one), for the case of bimetallic sensor is faulty. If temperature of 95°C is
exceeded, cutting off power supply to blow-in fan and fuel feeder is executed.
FUEL BUNKER PROTECTION
A controller is additionally protected against flames getting back into fuel
bunker (hopper). Boiler is provided with sensor measuring temperature around
hopper’s vicinity. If temperature raise is significant (flames back) an alarm is
launched and fuel is pushed out into combustion chamber.
SAFETY VALVE
Boiler is provided with safety valve being an additional protection against
pressure raise due to water freezing in part of installation, especially in the pressure
vessel.
Commercially delivered boilers are assembled and supplied with complete set
of tools for maintenance together with the technical-start-up documentation. Before
connecting a boiler to a heating installation, make check if all boiler’s components
are in good working condition, and that the boiler is fully equipped.
NOTE: Boilers need to be transported in the vertical position!
8. PROTECTION MEANS
9. TERMS OF DELIVERY