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“ FI-NSP” BOILERS ON SOLID FUEL – PELLETS ASSEMBLING, OPERATION AND MAINTENANCE INSTRUCTIONS

BOILER’S TECHNICAL BOOK

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ATTENTION! STRICTLY RESPECT!

To protect against acid condense and to avoid the formation of tars

attacking the boiler’s body, it is mandatory to correctly assemble one of the

following equipment: 4 way valve or thermostatic mixing valve or

thermostatic control recirculation pump, (according to the fig.

”Installation scheme”, pg. 25-28.)

The boiler operating temperature must be in the range 70 – 90 °C,

while the minimal return temperature 60°C.

Use light color pellets as fuel (with minimum residues content) with

the maximum humidity of 12% and quality dry wood with the

maximum humidity of 25%.

When sizing the central heating boiler, you must take into account

the correct calculation of the heat needs, do not oversize the boiler!

The inobservance of the requirements above entails the

warranty loss!

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Dear beneficiary,

Thank you for choosing FI-NSP BOILER ON SOLID FUEL – PELLETS, an innovating and modern product, with special qualities and performances. This product provides maximum satisfaction if you use the boiler according to the recommendations of this manual. We guarantee you its long term use if the boiler’s putting into service is made by the authorized personnel of S.C. TERMOFARC S.R.L.

The company provides you warranty and long term post warranty.

Many of us have the experience of heating up using fire wood or wood scrap briquettes in the hot water boilers. It’s been a while since a new solid fuel appeared, the so-called pellets, an ecological fuel manufactured in a similar way as the wood scrap briquettes, by pressing wood wastes (wood scrap and wood chips),without any high pressure binders. The pellets have a cylindrical shape, with a diameter of 6 – 10 mm and up to50 mm long, with a calorific efficiency of 4.8 - 5 kWh/kg. Pellets are supplied in plastic bags of 15, 20, or 25 kg. Yet, in other countries, they are transported in cisterns out of which the pellets are directly fed to tanks.

The benefit of such pellets is that they are ecological and that they may be used for heating in central heating stations with automatic feeding.

Due to these reasons, our company executed this product, FI-NSP BOILER ON SOLID FUEL – PELLETS made up of the pellets burner, the pellets tank with the feeding system and the boiler type FI-NS already on the market for a long time.

This manual refers to the assembling, installation and use of the product. Thoroughly studying the instructions, you shall get important information for the safe operation of this boiler, thus obtaining optimum performances and long term use. To market them and for the product’s compliance with the essential security requirements stipulated in the European Directives, the boilers have been assessed by ISCIR CERT, consequently the compliance certificate 041B1 – 584/EC being issued.

TERMOFARC

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GENERAL ISSUES Important warning ………………………………………….………………………………………………………6 Be aware! ………………………………………………………….…………………………………………………….7 Boiler description …………………………………………….………………………………………………………8 Identification……………………………………………………….………………………………………………….8 Component parts …………………………………………………………………………………………………..9 Technical data ……………………………………………………………………………………………………………11 Accessories …………………………………………………………………………………………………………….15 CHAPTER 1 ..................................................................................................... Error! Bookmark not defined. ASSEMBLING INSTRUCTIONS ............................................................................... Error! Bookmark not defined.

1.1. Choosing the boiler .......................................................................................... Error! Bookmark not defined. 1.3. Assembling and position of the boiler ........................................................... Error! Bookmark not defined. 1.4. Assembling the pellets burner and the feeding system .................................. Error! Bookmark not defined. 1.5. Hydraulic connections ...................................................................................... Error! Bookmark not defined. 1.6. Safety elements ................................................................................................. Error! Bookmark not defined. 1.7. Connection of the safety elements ................................................................... Error! Bookmark not defined. 1.8. Operation of the safety exchanger (cooling coil). ........................................... Error! Bookmark not defined. 1.9. Open systems and closed systems ................................................................... Error! Bookmark not defined.

1.9.1. Open systems (with open expansion tank) ........................................................................... Error! Bookmark not defined. 1.9.2. Closed systems (with closed expansion tank) ..................................................................................................................... 25

1.10. Pump for the heating circuit............................................................................ Error! Bookmark not defined. 1.11. ESBE mixing heat valve ................................................................................ Error! Bookmark not defined. 1.12. 4 ways valve..................................................................................................... Error! Bookmark not defined. 1.13. Ventilation ......................................................................................................................................................... 26 1.14. Installation connection schemes ....................................................................................................................... 26 1.15. Connection to the stack ..................................................................................................................................... 31 1.16. Filling in the system .......................................................................................................................................... 31 1.17. Circuit diagram of the boiler ............................................................................................................................. 32

Chapter 2 ......................................................................................................... Error! Bookmark not defined. DESCRIPTION OF THE PELLETS BURNER ....................................................................................................... 33

2.1. Applicability ........................................................................................................................................................ 33 2.2. Component parts of the burner ........................................................................................................................... 33 2.3. Circuit diagram of the burner.............................................................................................................................. 34 2.4. Operation of the burner ....................................................................................................................................... 35 2.5. Functions of the programmable automaton ....................................................................................................... 35

2.5.1 Setting the parameters ........................................................................................................................................................... 36 2.6. Adjusting the burner ............................................................................................................................................ 37 2.7. Time parameters ajustment according to the heating plant ............................................................................. 37 2.8. Constructive safety rules ..................................................................................................................................... 38

Chaper 3...................................................................................................................................................... 39 PUTTING INTO SERVICE........................................................................................... Error! Bookmark not defined.

3.1. The first putting into service ............................................................................. Error! Bookmark not defined. 3.1.1. Checks during the first putting into service ......................................................................... Error! Bookmark not defined. 3.1.2. Putting into service ............................................................................................................................................................... 39 3.1.2.1. Putting into service – operating on wood ........................................................................................................................ 39 3.1.2.2. Putting into service – operating on pellets ...................................................................................................................... 40 3.1.3. Commissioning to the beneficiary ....................................................................................................................................... 40

Chapter 4 .................................................................................................................................................... 41 USE AND MAINTENANCE INSTRUCTIONS ......................................................... Error! Bookmark not defined.

4.1. Boiler’s operation ................................................................................................................................................ 41 4.1.1. Operation of the boiler on wood........................................................................................... Error! Bookmark not defined. 4.1.2. Operation of the boiler on pellets ........................................................................................................................................ 41

4.2. Ignition ................................................................................................................................................................. 42 4.2.1. Ignition for the operation on wood ...................................................................................................................................... 42 4.2.2. Ignition for the operation on pellets .................................................................................................................................... 42

4.3. Adjustments ....................................................................................................... Error! Bookmark not defined. 4.3.1. Thermostat controller of the draft (used during the operation on wood) ......................... Error! Bookmark not defined. 4.3.2. Control panel (for the automatic operation on pellets) ...................................................... Error! Bookmark not defined.

4.4. Fuel feeding and re-feeding ................................................................................................................................ 44 4.4.1. Feeding and re-feeding for the operation on wood ............................................................................................................ 44 4.4.2. Feeding and re-feeding for theautomatic operation on pellets ......................................................................................... 45

TABLE OF CONTENTS

CUPRINS

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4.5. Continuous operation ........................................................................................ Error! Bookmark not defined.

4.5.1. Continous operation on wood ............................................................................................... Error! Bookmark not defined. 4.5.2. Continous operation on pellets ............................................................................................. Error! Bookmark not defined.

4.6. Summertime operation ........................................................................................................................................ 45 4.6.1. Summertime operation on wood ........................................................................................... Error! Bookmark not defined. 4.6.2. Summertime operation on pellets ......................................................................................... Error! Bookmark not defined.

4.7. Short term interruption of the operation............................................................................................................. 45 4.8. Long term interruption of the operation. .......................................................... Error! Bookmark not defined. 4.9. Requirements for the fuel .................................................................................. Error! Bookmark not defined.

4.9.1. Requirements for wood.......................................................................................................... Error! Bookmark not defined. 4.9.2. Requirements for pellets ........................................................................................................ Error! Bookmark not defined.

4.10. Use ................................................................................................................... Error! Bookmark not defined. 4.10.1. Use when operating on wood.............................................................................................. Error! Bookmark not defined. 4.10.2. Use when operating on pellets ........................................................................................................................................... 48

4.11. Cleaning the boiler and the burner ................................................................................................................... 48 4.11.1 Way of cleaning the boiler .................................................................................................................................................. 49

4.12. Maintenance of the boiler and of the heating system . .................................................................................... 49 4.13. Boiler’s tightness. .............................................................................................................................................. 50 4.14. Changing the door’s packing cord ................................................................................................................... 50 4.15. Changing the grates .......................................................................................................................................... 50

Chapter 5 ......................................................................................................... Error! Bookmark not defined. BREAKDOWNS AND SOLUTIONS .......................................................................... Error! Bookmark not defined. Chapter 6 ......................................................................................................... Error! Bookmark not defined. SPARE PARTS ............................................................................................................... Error! Bookmark not defined. Chapter 7 ......................................................................................................... Error! Bookmark not defined. NORMS OF LABOR PROTECTION AND FIRE FIGHTING ............................. Error! Bookmark not defined. Chapter 8 .................................................................................................................................................... 53 QUALITY AND WARRANTY CONDITIONS ........................................................ Error! Bookmark not defined. HOUSE TEST REPORT ............................................................................................... Error! Bookmark not defined. DECLARATION OF CONFORMITY ....................................................................... Error! Bookmark not defined.

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This manual is an integral and essential part of the product and must be handed to the user. It must be kept the entire operation time of the products and if the product changes its owner, it must be handed over to the new one.

Carefully read this manual and keep it in a safe place for subsequent use.

After opening the packing, check and inventory the components to make sure all of them are present and complete. Do not dispose the packaging elements in the environment and keep them out of the reach of children.

Before installing the FI – NSP boiler, carefully read the chapter “Installation Instructions”.

The assembling shall be exclusively executed by authorized personnel in compliance with the norms in force (Romanian Standard - STAS 7132-86; STAS 3417-85; Norm I 13-94; Norm I 13/1-96; PT C 9-2003; PT A2-2003; ISCIR collection; GP 051-2000; P 118-99). All guidelines of this manual are to be observed; any deviation may cause damages that the constructor does not undertake the responsibility for.

In cases of faulty operation of the boiler, stop it immediately and contact one of the centers providing repairs for this product. Never use the boiler if it does not operate appropriately.

In case of breakdown, exclusively original component parts shall be used for replacement. To use other components than those recommended by the manufacturer, first of all you need to obtain its written approval and consent.

Never use the boiler with removed or faulty safety devices. In case of breakdown, exclusively original component parts shall be used for replacing.

This boiler is meant to be used as it was designed. Any other use is considered inappropriate.

To guarantee the efficiency and safety of the boiler’s operation, we recommend an annual check made by specialized and authorized personnel, respecting the constructor’s conditions.

Before starting, using or making any maintenance operations, carefully read the instructions of this manual. Most of the accidents are caused by the inobservance of simple security measures and of the use procedures.

Never make cleaning or maintenance operations while the boiler is in use. During the first putting into service of the boiler, an unpleasant scent or smoke may

appear; this is normal and it shall disappear after a short time of use. If you do not use the installation for a longer period of time, call for the service

authorized team of Termofarc to check it. The room where the boiler shall be assembled needs to permanently be clean, dry and

well ventilated. Children and mentally disabled persons are prohibited to use the boiler.

The boiler may only be used by trained adult persons; unsupervised children are not allowed near the boiler.

Do not touch the hot boiler with unprotected hands, use gloves. Warning! The hot parts of the boiler may cause serious burns.

It is forbidden to use the boiler empty or partially filled with water. The use of the boiler empty or the partially filled with water may cause an explosion. From time to time you must check the pressure of the water in the heating installation. The boiler’s refill and fill with heating agent shall be done only when it is stopped and cold.

It is forbidden to deposit flammable objects and materials on or around the boiler.

The body of the boiler needs to be null-connected for protection in order to have earthing and to prevent the electric shocks if the electric components become faulty.

IMPORTANT WARNING

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The manufacturer disclaims all responsibility for the damages caused by assembling or use faults

and the inobservance of the manufactureer’s instructions.

While the boiler is manaully operating by wood feeding, the wood must be dry, with a maximum humidity of 25%, and while operating automatically, the humidity of the pellets must be of maximum 12%.

During the combustion process soot, tar and acid steam may appear. To diminish their quantity, the boiler must operate at optimum parameters (the temperature of the heating agent in the boiler must be of 70 - 90°C, and the temperature of the return heating agent must be of minimum 60°C). We recommend the use of four ways valves, of thermostat control re-circulation pumps or of heat valves TV (25, 32, 40) according to the assembling way.

The boiler shall not be used below the nominal capacity. In the transition period or in the summertime (when we only need household hot water – ACM), the boiler shall be started daily.

The boiler shall be located at the same level as the rooms to be heated or at the subsoil and it may operate by gravitation (natural) or induced (with pump) draught. The location of the boiler in dwelling rooms or on the access halls is forbidden.

You must have enough room to store the fuel, strictly respecting the firefighting regulations.

The floor, the ceiling and the walls must be executed of fire-proof materials according to the applicable standards.

The heat power plant must be endowed with admission inlets or pipes for the fresh air with the section of 400 cm2. The mechanical exhaust of the air is not allowed.

The burn gases pipes must be well sealed and insulated, have the minimal section according to the “technical data” chart and the stack sufficiently high to provide an appropriate draught of the boiler.

When placing the boiler, the following distances shall be respected: 0.6 m in the lateral of the boiler; 0.6 m in the backside; 1.5 m in the front and 0.6 m to the ceiling.

The boiler shall be connected to an open expansion tank, accordingly dimensioned. We may use a closed expansion tank if a permanent source of water is provided and the boiler may be protected against overheating. On the safety turn - return pipes for the connection of the boiler with the expansion tank, no closing or throttle parts shall be fitted.

From time to time, you shall clean the smoke tracks using the upper doors. The cleaning of the smoke tracks shall be carried out when the boiler is turned off and cooled down.

From time to time or whenever necessary, the ash must be removed from the ash pan through the drawer. This operation shall be carried out only when the boiler is turned off and cold. We recommend the cleaning of the burner from ash and wastes each 2 – 5 days, depending on the quality of the used pellets.

After its putting into service, the manufacturer or its representative has the obligation to train the beneficiary related to the correct use and maintenance of the boiler.

The execution of the installation and the putting into service shall be made by personnel authorized by ISCIR (according to the prescriptions PT C9/2003) observing the requirements of the product’s technical book.

BE AWARE!

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While the boiler is manaully operating by wood feeding, the wood must be dry, with a maximum humidity of 25%, and while operating automatically, the humidity of the pellets must be of maximum 12%.

During the combustion process soot, tar and acid steam may appear. To diminish their quantity, the boiler must operate at optimum parameters (the temperature of the heating agent in the boiler must be of 70 - 90°C, and the temperature of the return heating agent must be of minimum 60°C). We recommend the use of four ways valves, of thermostat control re-circulation pumps or of heat valves TV (25, 32, 40) according to the assembling way.

The boiler shall not be used below the nominal capacity. In the transition period or in the summertime (when we only need household hot water – ACM), the boiler shall be started daily.

The boiler shall be located at the same level as the rooms to be heated or at the subsoil and it may operate by gravitation (natural) or induced (with pump) draught. The location of the boiler in dwelling rooms or on the access halls is forbidden.

The operating FI-GS boilers must be supervised.

FI-NSP boilers are manufactured from steel sheet of 5 namely 6 mm in the inside part and 4 mm at

the external part, welded, made in eleven manufacture sizes. From the construction point of view, they are boilers with water chamber, with chamber-type

burning point and two convective circuits of burned gases. Their construction permits the use in two operating alternatives: 1. automatic operation, being endowed with automatic burners on pellets; 2. manual feed operation, using solid fuel (wood, coal, coke, wood scrap, wood wastes) in the

burning process; They are meant for the heating of the buildings and the production of household hot water. They

are endowed with two heat exchangers: coil producing household hot water (the range FI-15NSP – FI-50NSP), and cooling coil – protection against the overheating (all range of powers).

It may be assembled in a gravitational operation installation or in force circulation installation with circulation pump;

BOILER’S DESCRIPTION

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Each boiler has its own identification plate.

IDENTIFICATION

fig.1.

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Water chamber: they are made up of two plan-parallel walls of steel plate of 5 – 6 mm width, namely 4 mm, located at a distance of 60 mm. The walls of the chambers are reinforced with round steel cross-ties of Ø 10 mm welded at both ends.

Boiler doors: allow the wood feed and the cleaning of the pellets burner grate (the middle one), the ash exhaust (the lower one) and the cleaning of the convective routes (the upper one). The door of the ash pan also plays a part in the admission of combustion air by means of a throttle, in the manual feeding operation on solid fuel (wood, coal, coke, wood scrap briquettes, wood wastes). The air throttle is controlled by the draft thermocontroller on the front part of the boiler. It provides the closing of the throttle and thus the reduction of the combustion primary air feed when the temperature of the water in the boiler reaches the set value. The lateral door (the range FI - 80 NSP – FI – 150 NSP) allows the cleaning of the pellets burner grate. The back door represents the assembling place of the burner on the pellets.

Convective system: as membrane walls of pipes Ø 42 x 4.5 mm it provides two circuits for the burnt gases, in which zigzag turbulence nozzles are designed. The grate: is plane, for the combustion of the solid fuel in layer. The ash pan: is a drawer that may be taken out through the door in the lower part of the boiler.

Heat insulation: it is executed of mineral wool. The coil for preparing household hot water (the range FI-15NSP – FI-50NSP): is made up of galvanized pipe of 1/2” and inserted into the water chambers. The cold water enters through the upper part at approx. 10°C and comes out through the lower part at approx. 60°C.

The cooling coil: is made up of galvanized pipe inserted in the water chambers; in the upper part it is connected to the running water network and in the lower part it is connected to the heat valve, with an impurities filer interposing between them. Its function is to cool the boiler in case of overheating. The control panel for automatic operation: in the upper part of the boiler there is the adjustment, safety and automation control panel with the following component parts : - Thermostat for controlling and adjusting the boiler - Safety thermostat (stops the pellets burner at over-temperature whenever the first thermostat is faulty – manual resetting) - Thermo-manometer - Led general switch - Wire fuse 6 - 10A The automatic pellets burner: made up of the burner body, turboventilator, electric igniter, control elements with programmable automaton and photosensor. Pellets feeding system: made up of pellets tank (bunker), conveyor worm, engine and reductor for the conveyor worm drive, feeding tube, flexible tube. Reinforcements: the following reinforcements are located in the upper part of the boiler: - ½” bleeder ( 2.5 bar ) - draft thermoragulator

- airing device - heat valve - environmental thermostat with radiocommand (wireless)

COMPONENT PARTS

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Data related to the constructive sizes of FI-GS boilers:

TECHNICAL DATA

fig.2.

fig. 3.

1. Water chamber 2. Pipes supporting the grate 3. Plane grate 4. Convective system 5. Convective floor 6. Turn connector 7. Stack connector 8. Coil for preparing household hot water (the range FI-15NSP – FI-50NSP) 9. Cooling coil 10. Inspection (cleaning) door 11. Fuel feeding door 12. Ash pan door with combustion air admission valve 13. Ash pan drawer 14. Steel septum 15. Pellets burner

FI-NSP HOT WATER BOILER

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Side view

Front view

fig. 5. fig. 4.

TECHNICAL DATA fig.6. fig.7.1

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fig.7.2

fig.7.3

TECHNICAL DATA

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Boiler

Name UM FI-15NSP FI-22NSP FI-27NSP FI-33NSP FI-40NSP FI-50NSP

Boiler width (B) mm 540 540 595 595 595 635

Boiler height (H) mm 1280 1280 1280 1280 1280 1280

Total height (Ht) mm 1350 1350 1350 1350 1350 1350

Boiler length (L) mm 740 800 850 910 960 1020

Boiler total length (Lt) mm 1240 1300 1350 1410 1460 1540

Diameter of the stack inlet (ØD1) mm 146 146 146 166 166 166

Boiler’s weight kg 267 285 329 355 372 410

Weight of the system (no water) kg 387 405 449 475 492 575

Weight of the burner kg 26.6 26.6 26.6 26.6 26.6 33.1

Maximum operating pressure bar 2 2 2 2 2 2

Testing maximum pressure bar 4 4 4 4 4 4

Rated heat power on wood Kcal/h (kW)

15.000 17,4

22.000 25,6

27.000 31,4

33.000 38,4

40.000 46,5

50.000 58

Rated heat power on pellets Kcal/h (kW)

12.900 15

18.900 22

23.200 26,9

28.400 33

34.400 40

43.000 50

Efficiency – operation on wood % 78-80 78-80 78-80 78-80 78-80 78-80

Efficiency – operation on pellets % 85-90 85-90 85-90 85-90 85-90 85-90

Nominal consumption of wood with Hi= 3500 kcal/kg Kg/h 5,5 8,06 9,9 12,1 14,7 18,3

Nominal consumption of pellets with Hi= 4150 kcal/kg Kg/h 2,59 3,8 4,7 5,7 6,9 8,6

Thermo-manometer inlet (RTM) ţoli ¼” int ¼” int ¼” int ¼” int ¼” int ¼” int

Aerator inlet (A) ţoli ½” int. ½” int. ½” int. ½” int. ½” int. ½” int.

Bleeder inlet (SS) ţoli ½” ext ½” ext. ½” ext. ½” ext. ½” ext. ½” ext.

Turn (one way) inlet (RT) ţoli 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext

Return (two ways) inlet (RR) ţoli 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext

Draft controller inlet (RRT) ţoli ¾” int ¾” int ¾” int ¾” int ¾” int ¾” int

Cool water / household hot water inlet (AR / ACM) ţoli ½” ext ½” ext. ½” ext. ½” ext. ½” ext. ½” ext.

Cooling coil inlet (ARR/RST) ţoli ¾” ext ¾” ext ¾” ext ¾” ext ¾” ext ¾” ext Heat valve probe inlet (S) ţoli ½” int. ½” int. ½” int. ½” int. ½” int. ½” int.

Boiler emptying inlet (RG) ţoli ½” int. ½” int. ½” int. ½” int. ½” int. ½” int.

Necessary stack draft mbar 0,2 – 0,3 0,2 – 0,3 0,2 – 0,3 0,2 – 0,3 0,2 – 0,3 0,2 – 0,3

Water content in the boiler L 94 103 109 137 146 162

Temperature of the burn gases °C 180-250 180-250 180-250 180-250 180-250 180-250

Maximum operating temperature °C 90 90 90 90 90 90

Recommended operating temperature °C 70-90 70-90 70-90 70-90 70-90 70-90

Household hot water flow (∆t=30°C) l/min 9 9 9 12 12 12

Consumed electric power at ignition W 720 720 720 720 720 720

Consumed electric power while operating W 120 120 120 120 120 120

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Boiler

Supply voltage / frequency V/Hz 220 / 50 220 / 50 220 / 50 220 / 50 220 / 50 220 / 50

Boiler

Name UM FI-60NSP FI-80NSP FI-100NSP FI-130NSP FI-150NSP

Boiler width (B) mm 700 725 800 935 935

Boiler height (H) mm 1280 1280 1395 1395 1395

Total height (Ht) mm 1350 1350 1465 1465 1465

Boiler length (L) mm 1130 1380 1490 1530 1680

Boiler total length (Lt) mm 1650 1900 2150 2190 2340

Diameter of the stack inlet (ØD1) mm 196 196 216 246 246

Weight of the boiler kg 471 607 732 896 975

Weight of the system (no water) kg 636 773 911 1075 1154

Weight of the burner kg 33.1 33.1 46.9 46.9 46.9 Maximum operating pressure bar 2 2 2 2 2

Testing maximum pressure bar 4 4 4 4 4

Rated heat power on wood Kcal/h (kW)

60.000 69,6

80.000 93

100.000 116

130.000 150,8

150.000 174

Rated heat power on pellets Kcal/h (kW)

51.600 59,9

67.600 78,5

84.300 98

110.000 127,9

127.000 147,5

Efficiency – operation on wood % 78-80 78-80 78-80 78-80 78-80

Efficiency – operation on pellets % 85-90 85-90 85-90 85-90 85-90

Nominal consumption of wood with Hi= 3500 kcal/kg Kg/h 22 29,3 36,6 47,6 55

Nominal consumption of pellets with Hi= 4150 kcal/kg Kg/h 10,4 17,5 21,9 28,4 32,8

Manometer connector (M) ţoli ¼” int ¼” int ¼” int ¼” int ¼” int

Aerator inlet (A) ţoli ½” int. ½” int. ½” int. ½” int. ½” int.

Bleeder inlet (SS) ţoli ¾” ext 1” ext 1” ext 1” ext 1” ext

One way inlet (RT) ţoli 1½” ext 2” ext 2” ext 2½” ext 2½” ext

Two-way inlet (RR) ţoli 1½” ext 2” ext 2” ext 2½” ext 2½” ext

Draft controller inlet (RRT) ţoli ¾” int ¾” int ¾” int ¾” int ¾” int

Cool water / household hot water inlet (AR / ACM) ţoli - - - - -

Cooling coil inlet (ARR/RST) ţoli ¾” ext ¾” ext ¾” ext ¾” ext ¾” ext

Heat valve probe inlet (S) ţoli ½” int. ½” int. ½” int. ½” int. ½” int.

Boiler emptying inlet (RG) ţoli ½” int. ½” int. ½” int. ½” int. ½” int.

Necessary stack draft mbar 0,3 – 0,4 0,3 – 0,4 0,3 – 0,4 0,3 – 0,4 0,3 – 0,4

Water content in the boiler L 191 238 296 325 359

Temperature of the burn gases °C 180-250 180-250 180-250 180-250 180-250

Maximum operating temperature °C 90 90 90 90 90

Recommended operating temperature °C 70-90 70-90 70-90 70-90 70-90

TECHNICAL DATA

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Boiler

Consumed electric power at ignition W 935 985 985 985 985

Consumed electric power while operating W 335 385 385 385 385

Supply voltage / frequency V/Hz 220 / 50 220 / 50 220 / 50 220 / 50 220 / 50 Data related to the constructive sizes of the feeding system:

Name UM Boiler FI-15NSP – FI40-NSP FI-50NSP – FI-150NSP

Lenght (A) mm 1100 1500 Width (B) mm 760 830 Height (C) mm 1460 1730 Volume of the pellets tank L 500 850

TECHNICAL DATA

fig.8.

1. Body of the boiler 2. Supply system 3. Pellets tank provided with a cleaning door (4)

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Data related to the constructive sizes of the pellets burner:

Burner model Min-max power Kw

Electrical supply Fan W

Pellets consumption at rated power with Hi=4150 kcal/kg

Kg/h V Hz

27 10 - 32 220 50 80 2,08 – 6,65 40 25 - 48 220 50 80 5,19 – 9,97 60 35 - 70 220 50 80 7,27 – 14,54 80 45 - 95 220 50 135 9,35 – 19,73

150 90 - 180 220 50 135 18,7 – 37,4

TECHNICAL DATA

COMPONENT PARTS 1. Conveyor worm 2. Pellets feeding pipe 3. Conveyor worm driving engine and reductor 4. Flexible tube 5. Turboventilator 6. Body of the burner 7. Grate of the burner 8. Electric igniter 9. Thermocouple 10. Programmable automaton – control block

fig.9.

fig.10.

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Accessories delivered with FI-NSP boiler

- Fire iron, brush and scraper (basic package)

Control panel (basic package)

- Ash pan drawer (basic package)

Burner on pellets (basic package)

- Steel baffles (basic package)

The pellets feeding system (basic package)

- Household hot water coil (basic package for the range FI-15NSP – FI-50NSP)

- Bleeder (2.5 bars) (basic package)

- Environmental thermostat with radio control (wireless) (basic package)

- Aerator (basic package)

- Assembling, use and maintenance instructions (basic package)

Accessories recommended as mandatory

- Open expansion tank Or

- Closed expansion tank

Burner model

A [mm]

B [mm]

C [mm]

D [mm]

E [mm]

F [mm]

G [mm]

H [mm]

I [mm]

J [mm]

L [mm]

Ht [mm]

27 300 290 345 240 220 228 60 171 185 320 750 530

40 300 290 345 240 220 228 60 171 185 320 750 530

60 295 340 395 240 280 228 60 182 252 320 830 535 80 295 340 395 240 280 228 60 182 252 320 830 535

150 360 400 450 300 360 216 60 230 308 400 1050 575

ACCESSORIES

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- 4 ways valve or

Heat mixing valve TV 60ºC(25, 32, 40)-return TV 72ºC(25, 32, 40)-turn

- Heat valve STS 20 or TS 130- ¾”

- Circulation/ recirculation pump

Chapter 1

ASSEMBLING INSTRUCTIONS

This chapter addresses both to authorized persons proceeding to assembling the boiler, as well as to the beneficiary who is interested in the executed works complying with the safety norms while using all the elements contributing to the installation’s good operation.

The boiler may be assembled by companies or by ISCIR authorized personnel. The assembling shall be executed on the grounds of a project, complying with the norms in force and with the boiler’s technical book. Attention! If the boiler is not be assembled, store it in a dry place.

1.1. Choosing the boiler

The boiler must be chosen so that the rated power corresponds the heat losses and the heat necessary according to STAS 1907, essential requirement for the accurate and economic operation. Choosing a boiler with greater rated power shall result in tar deposits on its inside walls.

1.2. Location and position of the boiler The boiler shall be assembled only in the heat power plants executed compliant with a project drafted by

specialized institutions, observing the safety measures stipulated in STAS 7132-86; STAS 3417-85 ; Norm I 13-94; Norm I 13/1-96; PT C 9-2003; PT A2-2003; ISCIR collection; GP 051-2000; P 118-99.

The boiler shall be assembled in a separate room at the subsoil, basement or ground floor of the civil or industrial buildings, except for those included in the A and B classes of inflammation or explosion danger. As well, it is forbidden to assemble the boilers directly under rooms where personnel cannot self-evacuate (such as the hospitals), under showrooms, stores, kindergartens or under their access ways.

ASSEMBLING

LOCATION

The boilers room must be separate from the adjacent rooms and have sufficient windows. The room where the boiler shall be assembled must be large enough to allow the boiler assembling on a perfectly even surface. (Eventually on a metallic or concrete base) respecting the distances according to fig. 11. The boiler shall not be assembled on flammable material support. The room must have a fresh air access hole, with an opening of 400 cm2 – permanently open to the outside. We recommend a siphon trap assembled and drinking water pipes with enough pressure to fill in the heat plant installation.

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Attention! Locating the boiler in dwelling rooms and on the access halls is forbidden!

1.3. Assembling the boiler’s components

The boiler is delivered completely assembled and equipped. If you encounter problems when

moving it to its operating place, the components may be disassembled as it follows, according to blueprint in fig. 12. When disassembling it, start by removing the cover. Then remove the lateral covers by unscrewing the M6stud bolts located two in the upper part and two in the lower lateral part. If necessary, you my also disassemble the back cover by unscrewing the M6stud bolts, then the three smaller components (between doors) shall be removed if you unscrew the stud bolts M6. When the boiler is located where it is meant to operate, before assembling it, we proceed to its dressing up. The component parts shall be assembled according to the blueprint in fig.12. The assembling starts by fixing the back cover by means of the M6 stud bolts. Then, the three smaller components (between doors) shall be fixed using the M6 stud bolts. Then, the two lateral covers shall be fixed using the stud bolts M6, two in the upper part and two in the lower lateral part. When assembling the top cover, the probes and the inlets of the control device shall the inserted in the corresponding case and in the coupling inlet ¼”.

1.4. Assembling of the pellets burner and of the feed system

ASSEMBLING

fig.12.

fig.11.

ASSEMBLING

fig.13.

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FI-NSP (1) boiler may be used in two operating alternatives: 1. Automatic operation on pellets, by assembling the pellets burner (2) in the door (orifice) (1)

on the back side of the boiler using the packing (3), fig.13. It shall be fixed with M10 screws, making sure that the burner is well assembled. The contact between the burner and the boiler must be tight to prevent gas leaking into the chamber of the power station.

After assembling the burner, the next step is the electricity connection to the control panel of the boiler and the electric connection of the feeding system (moto reductor of the conveyor worm drive) to the burner’s connections.

The burner is endowed with two plugs for the connection of the feeding system: - the lower plug is of normal voltage and it required for the initial charge of the feeding system. After the system charge (the kicking off of the feeding tube), the connector of the motoreductor driving the conveyor worm shall be moved into the upper plug. - The upper plug is controlled through the control block of the burner and during the normal (automatic) operation the feeding system shall be connected here.

After assembling the burner, position the pellets tank and fix the feeding system made up of the conveyor worm, motoreductor and feeding tubes. The feeding system must be positioned in such a way as to create a 45° angle with the horizontal and the vertical plan. Proceed to the connection of the feeding system to the pellets burner by means of the flexible tube, respecting the straight position and the well-tightened connections.

2. Wood operation and/or wood waste with manual feeding. If this operation is a long-term one, it is recommended for the burner on pellets to be dissassembled, and the door (1) (orifice) on the back of the boiler to be obstructed with the metallic sheet (4) fig.13. of the boiler.

1.5. Hydraulic connection

After positioning and adjusting the covers, the next step is the hydraulic connection of the boiler. The turn and the return of the boiler are endowed with exterior and/or interior threads according to the table ”Technical data”. The household hot water coil shall be connected to the water network (at the scale FI-15NSP – FI-50NSP). The cooling coil is connected according to fig. 14. All the hydraulic connections of the boiler installation will be executed according to the ” installation schemes”.

For the filling of the boiler and/or the system, the installer will connect a running water pipe to the return pipe (return of the installation). To this connection, a direction valve (retention valve) and a filling tap will be interlaced.

Attention: A direction valve will be interlaced to the filling connector of the installation! For the proper operation and for the protection of the boiler against the corrosion we recommend:

- to avoid the acid condense and the tar, by increasing the temperature at the return of the boiler, choose one of the following assembling methods:

- mix heat valve V 60ºC, having the role of maintaining water at the return of the boiler at temperature of 60ºC, or on the turn pipe of the installation a mix heat valve TV 72ºC that has the same role (for the capacities of ≤ 70 Kw). - thermostat –controlled recirculation pump between the turn and the return (by-pass). - 3 way mixing valve with or without servo-engine.

- to obtain household hot water we recommend the installation of an accumulator, - to increase the operation autonomy and the taking over of the heat excess, we recommend the assembling of the boiler together with a puffer. The capacity of the puffer will be of minimum 25 liters per 1Kw installed.

Observation: to obtain the desired heat comfort in the house (the ambient temperature), we recommend that the radiators are equipped with thermostat valves.

BOLIER’S CONNECTION

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The boiler is assembled in heating systems equipped with opened or closed expansion tanks if the

requirements of the chapter ”Safety elements” are met.

Attention: Installing the boiler in heating systems equipped with closed expansion tanks is allowed only provided that the heat from the temperature lag is taken over, if the overheating in case of fault of current is avoided and if the failure of the circulation pump or lack of heat necessary are avoided. Otherwisewise, the assembling of the boiler shall be with an OPEN expansion tank!

In designing the central heating system, it is very important to carefully size the pipes and the pressure loses on these heating elements.

Before assembling the boiler, the system must be washed and cleaned of fats, dirt and free mechanical particles. Within the circuit, a separating device must be installed to collect the mechanical impurities that might appear after assembling the installation.

The connections may be done by soldering or by compression adapting pipes in case of copper pipes, couplings or collars in case of steel pipes. The pipes must be provided with a necessary slope for easy airing and emptying towards the points thus designed in the installation. The emptying points must be located in accessible points allowing water draining. The airing points must be placed in the highest areas. Manual airing of the pipes of the old installation is not enough, which is why it is recommended to fix manual airings on each heating element (radiators, registers etc). The cold water pipe feeding the coil for hot household water and cooling coil will be permanently open (The ACM network is closed only using the valves of the consumption points) to allow the taking over of the circuit expansion. If the installation has pipe sections exposed to negative temperatures, the water pipes will be heat-insulated.

1.6. Safety elements

Open expansion tank with safety pipes turn-return or close expansion tank Bleeder adjusted at the pressure of 2.5 bars (according to the technical data table); Cooling coil connected to cold water network and to the drain installation trough a heat bleeder “heat valve ” STS 20 or TS 130;

Attention: It is forbidden to assemble closing elements, such as valaves, interposed between the boiler and the connector to the expansion tank! It is forbidden to assemble closing elements of tap type interposed between the boiler

and the bleeder! The bleeder and the heat valve must be EC certified. We recommend the assembling of bleeders even when you decide to assemble the boiler

with an open expansion tank. 1.7 Connection of the safety elements Means of protecting the boiler against overheat (overheat that may lead to the damage of the boiler):

- If there is a permanent source of water, the connection of the cooling coil is executed with the heat valve STS 20 - ¾” (Fig.14.) - Assembling the boiler operating through trough heat siphonage (gravitational circulation) - When using certain hydrophore type equipments, the boiler may be protected by means of

using a back-up source of electricity (battery or generator) for the circulation pump. -

SAFETY ELEMENTS

BOILER’S CONNECTION

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1.8. Operation of the safety exchanger (cooling coil)

When the water temperature in the boiler reaches 95 – 97 ºC, the temperature sensor

immersed in the water chamber opens the heat valve and the cold water starts running through the safety coil, draining to the existing sewerage, thus cooling the body of the boiler. The thermostat valve remains open until the temperature of the heat agent drops below 95ºC.

The cold water feeding pipe of the cooling coil will remain permanently open in order to allow the undertaking of the dilatations on this circuit.

1.9. Open systems and close systems

Depending on the conditions, the project of the heat installation will mandatory include a close or open expansion tank and the way of connecting to the installation according to STAS 7132-86 Attention! The boiler will mandatory be connected to an open or close expansion tank, adequately dimensioned. For the connection of the boiler to the expansion tank no closing or throttle pinching elements shall be fixed on the safety turn-return pipes.

1.9.1. Open systems (with open expansion tank)

The open expansion tank will be adjusted in the highest point of the installation, but not higher than 20 m, from the water entrance pipe into the boiler as close as possible to the vertical axis of the boiler. It shall be heat insulated and protected against freezing. The bottom of the expansion tank must exceed by 1.5 m the highest level of the installation;

The hydraulic equilibration of the installation is necessary for feeding all the radiators in the best conditions. This is executed by: - choosing the routes of the pipes; - dimensioning the pipes;

ASSEMBLING SYSTEM

The maximum entrance pressure of the cold water will be of 6 bars, and the temperature of 10 – 15 ºC.

OPEN SYSTEMS

fig.14.

SAFETY ELEMENTS

ver.2 24

- using circulation pumps. The open expansion tank is absolutely necessary within the gravitational circulation installations.

OPEN SYSTEMS

Fig. 11.

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1.9.2. Closed systems (with closed expansion tank)

If there is a permanent source of water and assembling an expansion tank is impossible/difficult, it is recommended to choose the assembling alternative with expansion tank with membrane (closed). Their use has lots of advantages, out of which the most important is the prevention of the air admission in the system and its oxidation. The closed expansion tank must be dimensioned according to the quantity of water in the installation and the boiler to be able to take over the expansions of the water and of the system. Computation of the closed tank capacity:

Q= v x (P1 + B) / B x 1,3 ; where Q – tank capacity P1 – hydrostatical pressure [kPa] B – pressure difference (50 kPa) v – volume of water in the system after heating up v = G x Δv G – water weight [kg] 1.3 – safety coefficient Δv – increase of the water volume up to a certain temperature (i.e. at Δt = 80ºC Δv =0,0355 [l/kg])

Air pressure in the closed expansion tank must be adjusted according to the hydrostatical pressure of the construction, according to the total water volume in the system. You shall check at least once a year the integrity “of the membrane” of the expansion tank and the air pressure within it.

CLOSED SYSTEMS

fig.15.

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1.10. The pump of the heating circuit

The discharge of the heating pump is calculated according to the empirical formula: Q = Pu/1000·15 [m3/h], where:

Q - represents the discharge of the circulation pump for the heating circuit in m3/h; Pu is the rated power of the boiler in kcal/h; As far as the pumping height is concerned, it is considered 2-2.5 m per storey, either we compute

the pressure drops on the installation and choose the pump with the computed pumping capacity and a height equal or higher than the value obtained.

1.11. Mix heat valve ESBE

The mix heat valve TV 60ºC is assembled on the return of the installation and it maintains the water at the return of the boiler at the temperature of 60ºC. The mix heat valve TV 72ºC is assembled on the turn pipe of the installation and it plays the same role.

1.11. 4 way valve The 4 way mixing valve is used to provide hot water to the return of the boiler, at an optimum temperature so as to avoid the formation of condense (return water at minimum 65°C). The water vapors combined with other elements resulted after the combustion may generate extremely corrosive chemical compounds that shorten the boilers lifetime. The 4 way valve may be manually adjusted yet a driving servo engine may be assembled as well. The 4 way valve is made up of the steel main body and the internal impeller type butterfly throttle. The rotation angle of the impeller is of approximately 90°.

1.13. Airing When the water system is filled with water for the first time and during the subsequent

water completions, water contains certain amount of oil waste dissolved in. Once the system is heating up, the fuels will be collected in the highest points of the system and

must be eliminated. Installing in these points of the system of airing devices (manual or automatic) will enable the elimination of the wastes dissolved, both at the first filling and also during the operation of the boiler. We recommend the assembling of automatic airing devices (with float bowl or a ball.

1.14. Connections scheme of the installation Attention! The schemes are for orientation only. For a correct installation, comply with the norms in force.

1.14.1 Hydraulic connections scheme with open expansion tank for the FI-GS boilers with cooling copil, household hot water coil and heat valve TV 60ºC

INSTALLATION SCHEME

ELEMENTS OF THE INSTALLATION

LEGEND VED – open expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – bleeder RC – flue inlet T – turn inlet R – return inlet GC – boiler discharge ST – heat valve S – heat valve probe ARR – cold water installation RST – heat water connector Cs– direction valve Pc – circulation pump VT – mix heat fan TV 60ºC SC – sewerage system

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1.14.2 Hydraulic connection scheme with open expansion tank for the FI-NSP boilers with cooling coil, hot water coil and thermostat control re-circulation pump

1.14.3 Hydraulic connections scheme with closed expansion tank for the FI-NSP boilers with cooling coil, household hot water coil and heat valve TV 60ºC .

fig.16. VED – open expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – safety valve A – airing device T – turn inlet R – return inlet GC – boiler discharge ST – heat valve S – heat valve probe ARR – cold water installation RST – heat water connector Cs– direction valve Pc – circulation pump Prc – Anti-condensation recirculation pump SC – sewerage system Fy – impurities filter TS – Pumps control thermostat

fig.17.

INSTALLATION SCHEME

ver.2 28

1.14.4 Hydraulic connections scheme with closed expansion tank for the FI-NSP boilers with cooling coil, hot household water and thermostat control re-circulation pump

INSTALLATION SCHEME

LEGEND VEI – close expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – safety valve A -airing device T – turn inlet R – return inlet GC – boiler discharge ST – heat valve S – heat valve probe ARR – cold water installation RST – heat water connector Cs– direction valve Pc – circulation pump VT – mix heat fan TV 60ºC SC – sewerage system Fy – impurities filter

LEGEND VEI – close expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – safety valve A – airing device T – turn inlet R – return inlet GC – boiler discharge ST – heat valve S – heat valve probe ARR – cold water installation RST – heat water connector Cs– direction valve Pc – circulation pump Prc – Anti-condense re-circulation pump SC – sewerage system Fy – impurities filter TS – Pumps control thermostat

fig.18.

fig.19.

ver.2 29

1.14.5 Hydraulic connections scheme with closed expansion system for the FI-GS boilers with accumulator, cooling coil and 4 ways valve.

1.14.6 Hydraulic connections with open expansion tank for the FI-GS boiler with accumulator, accumulator tank, cooling coil, re-circulation pump with thermostat controlled (this type with an accumulation tank is recommended if the boiler operates more than 50% on wood manual feeding)

1.14.7 Hydraulic connection scheme with closed expansion tank for the FI-NSP boilers with accumulator, accumulator tak, cooling coil and 4 ways valve (this type with accumulating tank is recommended if the boiler operates more than 50% on wood manual feeding)

INSTALLATION SCHEME

LEGEND VEI – close expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – safety valve A airing device T – turn inlet R – return inlet GC – boiler discharge Fy – impurities filter ARR – cold water installation RST – heat water connector Cs– direction valve Pi – heating circuit pump A4 – mix sluice with 4 ways BACM – hot water boiler with accumulation SC – sewerage system Pb – circulation pump ST – heat valve S – heat valve probe TM – thermometer

fig.20.

fig.21.

LEGEND VED – open expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – safety valve A – airing device T – turn inlet R – return inlet GC – boiler discharge Prc – against condende re-circulation pump Pva – pump for the accumulating tank Fy – impurities filter ARR – cold water installation RST – heat water connector Cs– direction valve Pci – heating circuit pump TS – pump control thermostat BACM – hot water boiler with accumulation SC – sewerage system Pb – circulation pump ST – heat valve S – heat valve probe VA – accumulating tank TA –environmental thermostat

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fig.22. 17.

VA4 – 4 ways valve ARR – cold water installation RST – heat water connector Cs– direction valve Pci – heating circuit pump BACM – hot water boiler with accumulation SC – sewerage system Pb – circulation pump ST – heat valve S – heat valve probe VA – accumulating tank TA –environmental thermostat

LEGEND VED – open expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve SS – safety valve A – airing device T – turn inlet R – return inlet GC – boiler discharge Pva – pump for the accumulating tank Fy – impurities filter TM - thermometer

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1.15. Connection to the flue

To exhaust the burnt gases, the boiler shall be connected to an (ordinary) flue made of brick or of sheet, heat insulated, with tubes having the interior diameter according to tables of “Technical data” Selection of an appropriate flue enables the correct and suitable operation of the boiler. Heat insulation is recommended to avoid the temperature losses of the burnt gases.

The draft (the horizontal sections) will be as short as possible and will have an ascending slope of at least 15 -25 degrees towards the flue. The horizontal maximum admitted distance to the connection to the flue will not exceed 1.5 m. It is strictly forbidden to pass the draft through other rooms.

Right angle bents will be avoided. No more than one curved bent shall be used to connect the boiler to the flue. The first deviation element or bent will be assembled at a minimum distance of 3 times the diameter of the flue inlet. It is strictly forbidden to assemble any obstructing systems on the connection canal or on the flue. The minimum height of the (heat insulated) flue is of 6 m (measured from the combustion chamber). It must provide an adequate draft of at least 0.2 mbar.

It is also important to have an appropriate insulation on the stack as burnt gases must have a temperature equal or higher than 130 ºC at the flue exit to eliminate the problems caused by condense.

It is forbidden to connect other gas fuel devices to the stacks also using fire points with liquid and solid fuels. At its basis, the flue must be provided with an inspection door and at the end with a protective cover or a net.

Qualified personnel must build the stack according to the norms in force, subject to STAS 6793 and STAS 3417.

Attention! The flues with insufficient draft diminish the performances of the boiler while a higher draft will cause temperature delay phenomena.

It is mandatory to provide the smoke flue proofness and fixation to prevent the accidental detachment;

1.16. Filling in the system

After executing all the hydraulic connections, you may proceed to filling in the system.

•Open all taps of the radiators, of the boiler and of the system. •Slowly open the delivery cock, making sure that the potential automatic airing valve (breather) operate correctly. Close all the manual airing valves (breathers) when the water begins to flow. •Check the pressure of the system by means of the thermomanometer. •Close the delivery cock and air the boiler. •If necessary, resume the water feed to adjust the water pressure in the installation. • Turn on the circulation pump of the heat agent and check its operation (it will be aired). Attention! From time to time, you shall check the pressure in the heating installation, it rfeed being made only when the boiler is stopped and cold.

It is forbidden to use the empty boiler or the boiler partially filled with water. Using the empty boiler or partially filled with water may lead to explosion.

Provisions for the feeding water

The feeding water for the FI-GS boiler is drinking water if it complies with the following conditions:

• clear and colourless • contains no more than 25 mg/l of particulates • hardness less than 50 mg CaO/l.

FILLING IN THE SYSTEM

FLUE

ver.2 32

Otherwise water shall be treated.

To avoid limeskale deposits on the household hot water coil and on the cooling coil, a water softner must be fixed to the cold water feed.

1.17. Circuit diagram of the boiler

A three wire cable shall be used for the connection of the boiler to the electric network of 220V, 50Hz.

The boiler room will have electricity, bulb for light and two or three plugs for the lectrical feed of the control panel and of the circulation pumps.

Exclusively authorized persons, according to the applicable norms, will connect the boiler. Attention! The body of the boiler must be connected to the protection null to be earthed and to prevent the electrocution danger. The circuit diagram is the following:

CIRCUIT DIAGRAM

fig.23.

Environmental thermostat Switch Control Thermostat Safety thermostat Receiver Fusible fuse Pellets burner

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Chapter 2

DESCRIPTION OF THE PELLETS BURNER

Attention! For the correct use of the pellets burner carefully read this chapter! The manufacturer is not responsible for the damages caused by the incorrect use and operation of the equipment!

2.1. Applicability

The pellets burner is exclusively designed for the combustion of pellets. They may be assembled on FI-NS hot water boilers observing the concordance between the heat power of the boiler and the burner. They may also be assembled on special or modified boilers that were designed for other type of fuel, yet only by qualified personnel.

2.2. Component parts of the burner

PELLETS BURNER

1. Burner body 2. Programmable automaton 3. Turboventilator 4. Sense valve for the adjustment of the combustion air 5. Electrical burner 6. Thermocouple – protection against the reversion of fire 7. Photosensor 8. Burner grate 9. Signalling leds 10. Automatic fuse (playing also the role of resetting the burner) 11. Upper plug – controls the feeding system by the control panel of the burner according to the preset programme (this is the point from where the operation of the feeding system is controlled under normal-automatic operating conditions) 12. Lower plug – for the initial loading of the feeding system

(ATTENTION! It shall be used only to load the feeding system until the pellets reach the flexible tube, then the connector of the engine driving the conveyor worm into the upper plug)

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2.3. Burner’s circuit diagram

PELLETS BURNER

fig.25.

ver.2 35

2.4. Operation of the burner

The burner is fed with electricity (the green light POWER is on). The feeding system (the conveyor) is loaded with pellets until the first pellets reach the burner,

the geared engine being fed from the lower plug. The connector of the geared engine is moved in the upper plug for an automatic operation. The operating temperature on the maximum thermostat is adjusted and the general switch on

the control panel of the boiler is pressed. A signal is transmitted from the thermostat of the boiler to the burner that is seen by the yellow led, determining the burner to start working. The starting process includes the following stages:

- The feed system, the electric igniter and the turboventillator are on. - After the time of feeding the dose of pellets for the first ignition, the feeding system is

turned off. - Meanwhile the electrical igniter and the fan are operating. (The time set for the electrical

igniter is of 15 min.)

- When the photoelectrical sensor of the burner detects the light of the flame, it starts the burning time of the first dose and the electrical igniter stops.

- Afterwards the device begins the normal activity, the process of pellets feeding and the pause for their combustion. The time of pellets feeding and the pause for their combustion are factory set. The combustion and the supplied quantity of air may be controlled by the valve of the burner’s fan (4) (the above mentioned adjustements are modified, if neccesary).

- When the temperature of the water in the boiler reaches the value set by the thermostat (for exemple 85 0C) the thermostat of the boiler stops, determining the stopping cycle of the burner as it follows: - the fan continues to operate for 15-20 minutes (the factory set parameter), - the geared motor of the feeding system does not receive the operation command, - the pellets in the burner shall continue to burn until the grate is clean. - The decrease of the temperature in the boiler is followed by the starting signal of the thermostat and the burner restarts.

- If the pellets do not burn, a new trial for their burning will start automatically. - If the sensor does not detect the flame during the process, the ignition sequence will start

again. - If the two ignition trials did not succeed, for example the fuel runs out (the manufacture

settings are of 2 trials) then the device stops the normal operation and the ALARM mode starts the ALARM lamp that will light up (red light), which represents a signal for the user to remove the cause of the damage. After the cause removal, the burner will start again stopping and starting from the switch. This must be done by the POWER switch of the burner.

Attention! To avoid the the accidental stop of the boiler power, it is necessary to

assemble a 1000W UPS system!!!

Turning the burner off while operating is done in the following manner: initially lower the temperature from the boiler thermostat, turning the button to the “0” position. After 15 minutes (time necessary for the burning of the pellets in the burner), the burner stops by its switch and the boiler by the general switch.

2.5. Functions of the programmable automaton

The programmable automaton controls the functioning of the burner. This is protected by a password, so the programme will be safe and will not be changed in any unpleasant (unexpected) Way. The possible setting of the parameters is below: - time TT1 - geared motor operating time in the normal cycle

PELLETS BURNER

ver.2 36

- time TT4 - time for the first pellets feeding (starting) - time TT5 - burning time after the stopping command (post ventilation)

- time TT6 - pellets burning time (geared motor break in normal cycle)

- time TB - delay time – enterin in a normal (operating) cycle Note: When the photosensor registeres the flame, the ignition trial stops. There are 2 ignition trials. If the 2 ignition trials are done and the it still does not catch fire, the system enters the damage mode (the ALLARM signal lights up). The intervention of the user is necessary (verify the reason for the ignition failure). Restarting (resetting) will be done by driving the automatic fuse.

2.5.1. Setting the parameters

The settings of the parameters T1, T4, T5, T6 and TB can be done according to the following instructions (for the instant parameter T1):

- press the green button having the symbols Menu/OK on the programmable automaton - by the up and down arrow select the PARAMETER - by pressing the up arrow several times you will reach the set time (period), in this case marked

by TT1 (toperation timp of the gear motor in normal cycle) - by the right arrow select the field, that signifies the time of T1

- by the up and down arrows select the set period. Note: If the up and down arrow is still pressed, after a while the numbers will quickly change.

- press the green button having the symbol Menu/OK - a question CONFIRM CHANGES (confirm changes) will appear (confirm the changes). Answer by YES (yes) by pressing the green button having the symbol Menu/OK - press the green button having the symbol Menu/OK on the programmable automaton and repeat and then ether the RUN mode (mode) (normal activity)

PELLETS BURNER

fig.26.

ver.2 37

Note: If we do something wrong, we answer the question CONFIRM CHANGES? (Confirm changes) by NO (no).

Similarly we can change the time parameters TT6 - pellets burning time (geared motor pause in

the normal cycle) - Similarly we can change the desired parameters - The light RUN indicates that the normal operating mode is on Note: Do not try to change other parameters, except those above.

2.6. Adjusting the burner

If it is too high, decrease the pallets feeding time. If the temperature is too low, insert additional

air. If the level of the pellets inside the burner is too low, verify the temperature of the combustion gasesand and decresae the quantity of air and increase the quantity of pellets from the feeding times. The quantity of the pellets feeding must be changed, using the mode described at point 2.5.1.

The criteria for perfect burning is the flame colour. If the colour is dark yellow, mixed with smoke, probably the feeding with pellets is higher than

necessary and should be reduced at the parameters T4 şi T6 (decreased T4 and/or increased T6). By openning the air valve the combustion process is stable, without any waste (normally the valve is not entirely open). If the valve is opened too much it is possible to throw the unburned pellets in the boiler’s burning point.

If the initial feeding is too high it is likely for the burner (grate) to be plugged. The result is that the first dose of pellets is larger than the required one, they are lighted up and the flame is recorded by the photosensor, and the burner enters the operation mode before the pellets ignite (the entire ignition dose). In this case, the initial feed time must be reduced by adjusting the T4 parameter. Note: When you adjust the burner, you need a device for measuring the combustion gases.

2.7. Settings of the time parameters according to the heating plant

Boiler Burner Feeding system

First feeding time TT4 [min, sec]

Delay time after the

ignition TB [sec]

Operation time of the transporterTT1 [sec]

Pause time of the

transporter TT6 [sec]

Post-ventilation time TT5

[min] FI 15 NSP small 1,30 - 3 35 16 11 15

PELLETS BURNER

The adjustment of the capacity of the burner is made by adjusting the pellets flow and the combustion air flow. The fuel flow is adjusted by setting in the programmable automaton the times of pellets feeding (cycle) and pellets burning (cycle). The combustion air flow is adjusted by screwing in /screwing off the bar (1) that presses the oneway valve (2) fig.27. If the device does not work properly: - verify the quality of the pellets (they must be dustfree). - if there are too many pellets inside the burner, adjust the pellets feeding and adjust the combustion air intake - verify the temperature of the combustion gases (140-220ºC)

fig.27.

ver.2 38

FI 22 NSP 27 1,30 - 3 35 16 11 15 FI 27 NSP 1,30 - 3 35 16 11 15 FI 33 NSP

40 1,30 - 3 32 16 8 15 FI 40 NSP 1,30 - 3 30 16 4 15 FI 50 NSP

60

Large

0,35 53 3 23 20 FI 60 NSP 0,35 53 3 23 20 FI 80 NSP 80 0,35 59 5 23 20

FI 100 NSP 150

0,50 49 5 18 20 FI 130 NSP 0,50 54 5 12 20 FI 150 NSP 0,50 63 5 10 20

2.8. Constructive safety rules

The ignition and burning process is monitored by a digital modular microprocesor (fig.26). The ignition and combustion process is monitored by a photosensor and if it does not ignit after two trials (adjusted function), the burner enters the damage mode. If while operating the pellets feeding from the bunker stops, the burner enters the damage mode. The flexible tube for the pellets transport is transparent and it is made of a special resistent to heat. For the protection system against the flame propagation to the fuel bunker, there is a temperature sensor that starts at the temperature of 90-95 0C, located on the feeding tube of the burner. If during the operation the temperature sensor detects a temperature higher than 90-95 0C, the conveyor worm stops and the burner swithches off. The access to the microprocessor of the automation mode is: the programme is protected by a password.

PELLETS BURNER

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Chapter 3

PUTTING INTO SERVICE

Do not forget: The operations of first putting into service are mandatory and will be executed by qualified personnel, certified by ISCIR.

3.1. The first putting into service

3.1.1. Checks during the first putting into service

When putting into service the boiler for the first time, the following will be checked and observed:

- respecting the boiler assembling conditions and the requirements to be fulfilled in the plant room. - existence and correct choice of the bleeders and their correct connection. - existence and correct dimensioning of the open or closed expansion tanks (as applicable) and the correct connection of the connecting pipes between the boiler and the expansion tank; - verifying the existence and the correct connection of the cooling coil with heat valve. - verifying the electrical connection to the earthing plug - the correct connection to the stack ; the stack must clean, tight, not obturated and protected at the terminal end. - verifying the fans blowing combustion air. - verifying the operation of the adjustment and control device. - verifying the correct connection of the installation filling system and of the heating circuit. - verifying whether the system is filled with water and aired. - verifying the pressure of the air in the expansion tank and its adjustment according to the hydrostatic pressure in the installation (for the installations with closed expansion tank) - verifying the operation circulation pump (electrical feed, rotor’s unblocking, airing). - verifying the tightness of the entire system. - when the boiler reached the operating temperature the system’s tightness is checked again.

3.1.2. Putting into service

3.1.2.1. Putting into service for the wood operation When putting into service, these are the steps to be taken in this specific order:

- the draft thermostatic controller is adjusted at the intended value of the water in the boiler; we recommend operation values of 70 - 90 ºC. - the fire is lighted in the boiler, by introducing through the door of the burning point paper and a sufficient quantity of wood (chips) on the plane grate in order to form an embers layer - after forming the embers layer the burning point is filled with wood (maximum half of the height of the focus point) and the doors are closed; - verifying the draft of the sstack and the temperature of the burnt gases

-verifying the tightness of the boiler’s door, of the stack and the tightness of the burned gases route

-verifying the operation of the draft controller - verifying the operation of the cooling coil– heat valve device

If the ignition is correct the flame is yellowish, slightly reddish and without smoke. Attention! During the first lighting of the fire, condense appears; yet it disappears once the boilers is heating up.

PUTTING INTO SERVICE

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During the operation, all the doors and the ash pan must be closed to avoid mass ignition and overheating. In the case of the wood operation it is recommended to dismantle the pellets burner and to obturate the door (1) (oriffice) on the back side of the boiler using a metallic sheet (4) fig.13. the boiler is endowed with.

3.1.2.2. Putting into service for the pellets operation When putting into service, these are the steps to be taken in this specific order:

- the fuel tank is filled with pellets - the electric control panel of the boiler is powered with electricity

- The burner is fed with electricity (green light POWER is on). - the feeding system is charged (transporter) with pellets until the first pellets reach the burner, the geared engine being fed from the lower plug. - The connector of the geared engine is moved in the upper plug for the automatic operation. - the operation temperature is adjusted from the maximum thermostat (we recommend operating values between 70-90 ºC) and the general switch on the control panel of the boiler is pressed. A signal is transmitted from the thermostat of the boiler to the burner that starts operating (the orange light RUN is on) and the burner starts the ignition process.

The ignition comprises the following steps: - The feeding system and the turboventillator are on. - After the feed time of the pellets dose for the first ignition, the feeding system is off. - During this period the electrical igniter and fan are operating. - When the photosensor of the burner detects the light of the flame, starts the burning time of the first dose and the electrical fan stops. - Afterwards the device starts the normal activity, the pellets feeding process and the pause for their burning. The pellets feeding time and the pause for their burning - are factory set. The air quantity supplied the fan can be adjusted by the oneway valve. Pellets feeding and burning times are strongly connected to the provided quantity of air. - After reaching the set temperature of the water in the boiler (for example 85 0C) the thermostat of the boiler stops the start signal of the burner and the burner stops. The fan continues to operate so that the pellets at the extremity of the burner continue the burning process. When the temperature in the boiler lowers, the stopping signal of the thermostat is next, then the burner starts again. - the draft of the stack and the temperature of the combustion gases are verified -the tightness of the boiler’s doors, of the smoke collector and the tightness on the burned gases trajectory are verified - The proper operation of the thermostat is verified - the functioning of the safety thermostat is verified - the functioning of the cooling coil – heat valve are verified.

In the case of a correct combustion the flame is yellowish-reddish with blue tips.

3.1.3. Commissioning to the beneficiary

It is highly important that the beneficiary is explained in detail the following: 1.The operation way of the boiler and the potential possible problems that might appear. As well, the meanings of each element of the boiler shall be explained. 2.The beneficiary is warned that a drop of the water pressure in the system is caused by a leakage that must be immediately fixed before using the boiler again. 3.The beneficiary must yearly verify the boiler and its operation by means of a qualified person. 4. The beneficiary is warned about the cautions against freezing.

PUTTING INTO SERVICE

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A putting into service protocol and the instructions to the beneficiary report are signed by the parties and the beneficiary signs for having acknowledged the boiler operation way.

These documents will be signed in original by the beneficiary and by the commissioner. In the putting into service protocol, the potential errors omitted by the installers during the

assembling are listed and if the one putting the installation into service considers that these errors are dangerous, he is entitled to refuse the putting into service until their remedy.

The commissioner is not obliged to correct the assembling errors but undertakes that the installations comply from functional and constructive points of view to the chosen boiler

Chapter 4

USE AND MAINTENANCE INSTRUCTIONS 4.1. Operation of the boiler

4.1.1. Operation of the boiler on wood

The FI-NSP boilers operate on any kind of solid fuel (wood, wood waste, wood powder briquettes, coal) by manual feeding. It is important for the wood to be dry, with a maxim humidity degree of 25%,

In normal operating regime, the operation of the boiler is controlled by the thermostat draft controller that adjusts the combustion air according to the needs of the entire system by the opening and the closing of the valve. The produced heat is controled by it. The work temperature of the boiler can be adjusted up to 90 °C, but the recommended value is of 70-90 °C, and the minimum return temperature is 60 °C, the necessary value for limiting the low temperature corrosion of the boiler’s walls.

In order to achieve the return temperature, proceed according to one of the schemes described in the first chapter „Installation schemes”.

When reaching the desired temperature, adjusted on the draft adjuster, the air admission valve closes and because of the lack of oxygen the combustion diminishes. Once the temperature lowers below the adjusted value, the combustion air inlet valve on the boiler opens and allows the resumption of the combustion process.

Attention! In the case of the wood-fueled boiler, the photosenosor of the pellets burner must be removed (taken out of its place)! And in the case of wood operation for a longer time it is important for the pellets burner to be dissassembled and the door (orifice) on the back of the boiler to be obstructed with the metallic sheet that the boiler is endowed with.

4.1.2. Pellets operation of the boiler

In normal operating regime the operation of the boiler is controlled by the control panel of the boiler.

The temperature of the heating agent can be adjusted by the maximum thermostat. The operating temperature of the boiler can be adjusted up to 90 °C, but the recommended value is of 70-90°C, and the return temperature is of minimum 60°C, the necessary value for limiting the low temperature corrosion of the boiler’s walls.

When reaching the set temperature, the automation of the boiler sets the turn off of the pellets burner. When the temperature drops below the set value, the maximum thermostat restarts the burner.

The safety thermostat intervenes when the temperature is higher than 95 °C indicating overheating and turning the boiler off; Only the user may restart it.

Restarting the boiler after the intervention of the safety thermostat is achieved in the following manner: - the intervention of the user and the removal of the overheating cause - cooling the boiler below 90°C;

- manual restarting the safety thermostat

DIRECTIONS FOR USE

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For restarting it the protection cover must be screwed off and the unblocking of the thermostat on the control and command panel.

When restarting it if the pellets do not ignite and do not burn, a new trial for their ignition will start automatically. If the photosensor does not detect a flame during the operation, the ignition algorithm will restart. If there are two failed attempts, for exemple running out of fuel, the device stops the normal algorithm and the ALARM mode intervenes- the red lamp will light up, which represents a signal for the user to remove the cause. After removing the cause, the burner will restart, switching it on and off from the automated fuse. This is to be done by the POWER switch (it will stop the feeding of the logistic mode of the burner and will remedy the cause of the alarm.)

Attention! To avoid the the accidental stop of the boiler power, it is necessary to assemble

a 1000W UPS system!!!

Turning off the burner In order to turn off the burner during the operation the following steps musty be taken: - initially lower the temperature from the maximum thermostat on the control panel of the boiler. - after 15 minutes (time necessary for the combustion of the pellets in the burner), the burner is stopped by its own switch and the boiler by the general switch. Attention! If the above mentioned stage is not performed, the pellets burn without the operation of the burner fan (overheating and negative effects on the photosensor are possible)

Generalities

The heat valve, if installed, intervenes at the temperature of 97°C allowing the access of the water into the cooling coil immersed in the boiler, thus cooling the boiler; when the temperature drops below this value the heat valve closes automatically.

For a normal operation the access of fresh air must always be provided inside the room where the boiler is placed. Attention! From time to time the pressure of the water in the installation must be verified. During the operation all doors and the ash pan must be closed in order to avoid the uncontrolled ignitions and overheating.

4.2. Ignition

4.2.1. Ignition for the operation on wood Open the upper door (feed door) and above the combustion nozzle insert sufficient fuel (wood-chips) and pieces of paper. After lighting up the fuel, wait for several minutes for the combustion of the inserted wood and the creation of an embers layer.

After forming the embers layer the wood fire point will be filled with wood (maximum half of the fire point height), and the doors are closed;

The draft thermostat adjuster is set for the intended value of the water in the boiler; the recommended operating values are 70 - 90 ºC.

From this moment on, the draft adjuster according to the temperature of the heat agent controls the operation of the boiler. The combustion air inhausted through the valve on the door of the fire point is distributed under the plane grate and is controlled through its holes in the area where the flame appears. Attention! It is forbidden to use inflammable liquids for lighting up the fire. When feeding, do not throw the wood on the fire but carefully arrange it.

IGNITION

DIRECTIONS FOR USE

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4.2.2. The ignition for the automated pellets operation The general switch on the control panel is pressed. The ignition comprises the following phases:

- The feeding system and the turbo ventillator are tuned on. - After the time of feeding the pellets dose for the first ignition, the feeding system is off. - During this period the electric igniter and the fan are operating (the time set for the electric igniter is of 15 min). - When the photosensor of the burner detects the light of the flame, the combustion of the first dose starts and the electric igniter stops. - If the pellets do not ignite during the set period for the igniter and the photosensor does not detect any falme while operating, the ignition will re-start (2 ignition attemps are factory-set).

4.3. Adjustments

4.3.1. Thermostatic controller of the draft (used during the wood operation)

The operation of the boiler is controlled by the draft thermostat adjuster FR124. The length of the chain is adjusted between the adjuster and the air admission valve of the boiler. When the boiler reaches 60ºC wait several minutes in order to stabilize the adjuster and adjust the chain so that the air admission valve is closed and the chain is stretched. Then You met set the thermostat at the desired temperature. If the thermostat did not reach the minimum temperature of (aprox.30ºC ) and the adjuster is set at 60ºC, the chain must be stretched and the admission valve must be open.

To indicate the temperatures and the pressures in the boiler and in the installation, a manometer and a thermometer are located on the upper cover of the boiler. The thermometer indicates temperatures between 0 and 120 ºC.

4.3.2. Control panel (for the automatic pellets operation)

Description of the functions of the control elements

ADJUSTMENTS

fig.28 17.

The draft adjuster FR124 automatically controls the inlet of combustion air into the boiler, thus controlling the intensity of the fire to keep the water at the intended temperature, leading to fuel saving and increased autonomy.

Assembling instructions The connector of de ¾” is screwed into the orifice of the boiler. Carefully tighten and fix so that the arrow is above and in the middle. Insert the fixing ring into the place on the body of the thermostat, fix the hexagonal handle and tighten the fixing screw. Install the chain into the hexagonal handle. If you disassemble the adjuster, reassemble it in the same position. Rotate the thermostat at 60ºC, block the hexagonal handle that slightly incline towards the floor so that the chain is in the same axis as the hole of the chain from in the air admission into the boiler.

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Note: the automation of the boiler includes an environmental wireless chronothermostat, by the serial connection to the control thermostat. Functions of the control elements of the boiler: 1. thermomanometer – indicates the temperature and hydraulic pressure in the boiler;

2. maximum control thermostat– connects / disconnects the air fan at the adjusted temperature according to the temperature of the water in the boiler. The temperature can be adjusted up to 90 °C, but the recommended value is of 70 - 90 °C. 3. led general switch - used for the total disconnection of the power. 4. safety thermostat – stops the pellets burner at over-temperatures or when the first thermostat is faulty – manual resetting. To reset, unscrew the protection cover and push the unblocking button of the thermostat on the control panel.

5. wire fuse 6A – for the protection of the control panel.

4.4. Fuel feeding and re-feeding

4.4.1. Feeding and re-feeding for wood operation

Fuel feeding is manually executed, using any type of solid fuel (wood, wood waste, wood powder briquette, coals). We recommend a maximum humidity of 35% for the wood.

The drier is the wood, the lesser is the wood chipping degree . Feeding the boiler with wood takes into account the outside temperature, the inside temperature,

trying not to load the combustion chamber to the maximum capacity if not applicable so as not to overheat the boiler.

At the ignition, after forming the embers bed, you can start filling in the fuel storage. The following steps must be taken when feeding / refeeding:

1. Open the door of the fuel storage. 2. Load (complete) with fuel. 3. Close the feeding door. 4. The operating temperature will be adjusted.

1. thermomanometer 2. minimum thermostat (pellets burner) 3. led general switch

4. safety thermostat 5. safety fuse 6A

FEEDING

fig.29.3 17.

ADJUSTEMENTS

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Attention! While operating, all the doors and the ash pan must be closed to avoid the uncontrolled combustion leading to overheating.

4.4.2. Feeding and re-feeding for the automatic pellets operation

The feeding of the pellets burner is automatic by the feeding system made up of: tank (bunker) of pellets, conveyer worm, engine and reduction gear drive, feeding tube, flexible tube.

For the automatic pellets operation, the fuel tank must be fed (with pellets) from time to time according to the consumption and to the outside temperature. It is recommended to re-feed from time to time so that the pellets in the tank do not run out. If this happens, when you restart the burner you must take the steps valid for the pellets reefed until the first pellets reach the burner, the geared engine being fed from the lower plug.

4.5. Continuous operation

4.5.1. Continuous wood operations

In winter time, we recommend the continuous operation of the boiler and it is not necessary to re-light the fire daily. It is possible to maintain the operation, consequently longer continuous combustion, in these circumstances the maintenance of the temperature at the return of the boiler must be taken into consideration.

4.5.2. Continuous pellets operation

Each boiler FI-NSP with automatic pellets operation is provided with a control panel. The equipments on this panel are meant to control the operation or pause of the pellets burner depending on the temperature.

4.6. Summertime operation

4.6.1. Summertime wood operation

In spring and autumn, feed the system with the wood quantity necessary at that particular time.

During the transition period or in the summertime, when only household hot water is necessary, the boiler will be daily turned on. In this case observe the following indications:

- use very dry wood and split sleanerly; - feed with little wood and repeat if necessary.

4.6.2. Summertime pellets operation

During this period of the year the boiler with automatic pellets operation will start and will stop whenever necessary according to the set temperature. It is important for the equipment to be periodically monitored.

4.7. Short term interruption of the operation

Stopping the boiler’s activity is to finish the fuel combustion in the burning point or in the burner. In this case, we do not recommend you to hurry the boiler’s operation stopping before the fuel combustion. If the fuel runs out, the boiler will automatically stop, its temperature reaching below the temperature adjusted on the minimum thermostat.

OPERATION CASES

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Turning the burner off If during the operation we want to turn the boiler off, we will have to observe the following steps: - initially lower the temperature on the maximum thermostat on the control panel of the boiler. - after 15 minutes (necessary time for the combustion of the pellets in the burner), the burner turns off turns off by its switch, and the boiler by the general switch.

4.8. Long term interruption of the operation For the long term interruption of the operation (i.e. at the end of the cold season) the boiler must be well cleaned of ashes as they lead to corrosion. If the boiler is stopped in wintertime, there is the danger of freezing, which is why the system will be emptied or the heat agent will be mixed with antifreeze solution. Attention! In the case of a long-term interruption of the operation, empty the tank and the pellets feeding system – the pellets are damaged when damped (they bulk up) and they block the conveyer worm!

4.9. Requirements for the fuel

4.9.1. Requirements for wood

The fuel indicated for the FI-GS boilers operating on solid fuel are the pieces of dried wood with the diameter of 200 –250 mm and humidity of 35 %. You can use wood powder briquettes, wood waste or coal.

The length of the wood depends on the depth of the fire point and the size of the boiler, as in the following table:

Boiler model Maximum length of the

wood (mm) FI-15NSP 400 FI-22NSP 450 FI-27NSP 500 FI-33NSP 550 FI-40NSP 600 FI-50NSP 650 FI-60NSP 750 FI-80NSP 1000 FI-100NSP 1100 FI-130NSP 1150 FI-150NSP 1300

The operation of the boiler depends on the type, sizes and humidity of the wood and the

manner of feeding. Do not use wood with high humidity levels as you will not get adequate combustion, the

power decreases, the wood consumption is doubled and a thick layer of tar will deposit on the surfaces of heat change of the boiler, reducing the power of the boiler.

Do not deposit in the plant chamber larger quantity of fuel that is necessary only for one feed or for daily consumption.

The caloric value of the most frequently used types of wood:

FUEL

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Wood type Calorific power / kg kcal MJ kWh

Punk 3900 16,25 4,5 Deal 3800 15,80 4,4 Birch 3750 15,50 4,3 Oak 3600 15,10 4,2 Beech 3450 14,40 4,0

4.9.2. Requirements for the pellets

The pellets are solid types of fuel, with low content of humidity, obtained of wood powder, chip of wood or wood cortex. The resins and the binders naturally existing in wood scrap are meant to keep the pellets compact and this is why these do not contain additives.

Specification of the pellets granularity: diameters of 6 – 10 mm and a length uf up to 50 mm. Calorific power of 4.8 - 5 kWh/kg Maximum humidity of the pellets 12%. Ash content of up to-n 1%. Bulk weight ~ 650 kg/mc

4.10. Use

Attention! From time to time it is recommended to verify water pressure in the heating installation, its re-feed being done only with the stopped and cooled boiler.

Only adult individuals aware of the use instructions and the operation way of the device may use the boiler; it is forbidden to leave unsupervised children near the boiler.

The boiler operation must be supervised from time to time. The notion of “operation must be supervised from time to time” implies the periodic control of the water in the installation and the fuel feeding.

When putting it into service, the responsible staff must train the beneficiary on the adequate use and maintenance of the boiler.

When the boiler operates at a return temperature lower than 60 ºC, condense may appear on the body of the boiler that causes the corrosion of the metallic elements, the tarring of the interior walls and the reduction of the boiler life period.

The long time operation of the boiler at reduced heat loads is not recommended. It is forbidden to overheat the boiler while using it. It is forbidden to use inflammable liquids to light the fire. When cleaning the boiler also inspect the condition of the component parts and the tightness. If certain irregularities are found, they will be fixed by the service units. It is forbidden to deposit inflammable objects or materials on the boiler and closer to the boiler

than allowed. If the ash is removed from the boiler, it is forbidden to store it less than 1.5 m from inflammable

materials. The ash will be stored in covered non-inflammable containers. The operating autonomy is between 6 and 12 hours according to the essence and humidity of the

used wood and the heat load.

4.10.1. Use when operating on wood

While in use, it is necessary to complete the fuel in the boiler. A fuel load burns during variable periods of time, according to the nature and the humidity of the fuel used, the heat load of the installation, the outside temperature and the draft of the stack.

USE

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The operating autonomy is between 3 and 6 hours according to the essence and humidity of the used wood and the heat load.

4.10.2. Use when operating on pellets

It is important for the user to be aware of the manner and principle of operation of the device. The pellets burner is built in such a manner that its use is simple. Its operation depends directly

on the quality and size of the used pellets. In the case of stopping because of a damage (red led turned on), determine the problem that

appeared (fuel lack, dirty photosesor, stifled feeding tube, burning grate stifled with cinder), remedy the problem and restart (reset) the burner by its automatic fuse.

It is necessary that the re-feeding of the tank with fuel to be done regularly. When you notice than in the tank there is a small quantity of pellets re-feed immediately to prevent the boiler to start from “0” (you will have to follow the steps of recharging the feeding system (conveyer) with pellets till the first pellets reach the burner, the geared engine being fueled from the lower plug).

4.11. Cleaning the boiler and the burner Attention! Before any cleaning or maintainance operation, stop the boiler, disconnect the power and let it cool down.

When cleaning the boiler use protective gloves and glasses!

The process of cleaning the boiler needs to be regular or whenever necessary. The cleaning interval depends on the quality of the used wood, the burning intensity, the flue draft and other conditions. It is recommended to clean every 2-5 days. The cumulated combustion products (ash) together with condense and tar aggravate the heat exchange and diminish the efficiency.

As well, a great quantity of ashes will reduce the combustion space and may choke the gas and air routes.

Fuel storage will be cleaned before each ignition from the combustion waste (wood-fueled operation).

The combustion process produces tar that deposits on the walls of the boiler. The tar quantity depends on the essence and humidity of the wood and the temperature of the turn and return of the boiler. This tar must be cleaned at least once a month, by means of the cleaning instruments delivered once with the boiler.

Ashes cleaning manner Open the feed door and sweep the ashes trough the combustion nozzles orifice – cleaning them

also- in the lower chamber from where it will subsequently cleaned out, by taking out the ash-pan drawer.

Trough the upper door the convective ways will be cleaned (of smoke).

MAINTENANCE

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4.11.1 Way of cleaning the burner

If necessary disassemble the burner of the boiler, for a better cleaning. Clean the ash, the cinder and the pellets waste under the grate of the burner. Make sure that there is no waste in the fan and in the area of the air valve. Clean the flame photosensor. For this action, remove the photosensor of its place, clean– wipe the snoot and place it in the adequate position, making sure that you position it properly. When reassembling on the boiler you will take into account: the correct positioning and fixing, correct connection of the electrical connections, connecting and fixing the flexible tube for the pellets feeding.

Pellets tank Because of the fact that the pellets contain residual pellets powder, the pellets feeder must be

cleaned from time to time. The larger the waste quantity is, the more reduced is the feeding with pellets, taht will implicitly will influence the blocking of the conveyer worm. The frequency of the cleaning of the feeding system will depend on the quality of the pellets. The pellets powder can be cleaned trough the specially created door built at the basis of the tank, this being possible also in the case when in the tank there are pellets, by closing the feeding sybarite (at the basis of the pellets tank).

4.12. Maintenance of the boiler and of the heating system

MAINTENANCE

fig.30.

fig.31.

If the boiler is properly dimensioned, the quality of the pellets is better and the cleanning interval is more rare. The burner must be cleanned from time to time and whenever necessary. This will enable the burner to operate as effeciently as possible. Clean the garte of the burner of ash and cinder trough the cleanning doors. Clean the location under the grate of all the pellets remains, by removing the garte according to fig.31.

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The water quantity, namely the pressure in the heating system must be checked at least every 14 days. If necessary the water in the system will be completed.

If the boiler does not operate while there is danger of freezing, the system and the boiler will be emptied of water or there antifreeze solutions will be used. In normal conditions, the boiler will be emptied only if necessary and for short periods of time.

At the end of each heating season, the boiler will be thoroughly cleaned and the potential faults will be fixed.

Once a month clean the return way of the combustion gases (convective ways) trough the upper door.

From time to time, you shall proceed to cleaning the smoke channels by which the boiler is connected to the flue and with this occasion you shall also control the proofness of the burnt gases circuits both to the boiler and also to the flue, as well as its cleaning doors.

During summertime, irrespective of the type of boiler, it is mandatory that the boiler-installation system is completely filled with water to avoid the corrosion phenomena. Attention! From time to time you must clean the convective ways (of smoke) and the connection to the stack!

4.13. Boiler tightness

The boiler proofness is very important, especially the doors and the connector to the stack. If leakages are found at one of these, the smoke may penetrate the plant chamber, but before that, it may cause an uncontrolled combustion in the fuel storage that may lead to overheating the boiler. From this point of view, the packing cord must be oiled every two weeks with oil or plumbaginous vaseline.

After of a certain period of usage the packing cord of the doors must be tested. For a new proofness it must be changed.

4.14. Changing the packing cord of the door

The packing cord is removed by means of a screw driver and its channel is cleaned. In the channel of the packing cord there is introduced temperature resisting silicone paste. The new packing cord is set in the channel created in the door, where will be glued into the silicone previously introduced. The door is grabbed by the handle and the frame of the door is closed so allowing the packing cord to be set.

4.15. Changing the grates

The combustion surface is created of two or more identical grates placed in the body of the boiler on the inferior pipes. In case of damage there will be changed only the damaged part.

Chapter5

BREAKDOWN AND THEIR ELIMINATION The following table there are presented the main faults that might appear in the operation of the

boiler and of the burner and also the measures to remedy these ones:

Breakdown Cause Remedy Buned gases explosion - ash or cinder in the burner

- ash in the ways of the burned gases or in the stack. - inadequate draft of the stack.

- clean the burner - clean the boiler and the stack - insulate the stack - contact a sweeper

BREAKDOWNS REPAIRING

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Ignition failure - grătarul arzătorului nu este poziţionat corect. - ash or cinder in the burner - low quality or wet pellets. - burnt electrical igniter - too large quantity of pellets at the ignition - inadequate draft of the stack - dirty photosensor, damaged or incorrectly placed. - Weak or inadequate connections of the electrical igniter or of the photosensor on the control panel - interrupted pellets feeding

- poziţionaţi corect grătarul - clean the burner. - change the pellets - verify the boiler’s connection to the electrical system - contact the service unit for changing the electric burner - clean the grate of the burner of pellets then decrease the initial feeding time. - clean the stack and the combustion way of the gases. - appeal to a seweeper for verifying the stack - clean the sensor, modify the position of the sensor. - contact the service unit for changing the sensor. - contact the service unit for re-establishing the connections. verify and clean the pellets feeding system.

Photosensor error - dirty or damaged photosensor

- clean the sensor, modify the position of the sensor. - appeal to a service unit for changing the sensor

The control led of the switch does not emit light

- lack of feed voltage - the plug is not correctly connected to the electrical system - defect switch - defect feeder cable

- to be verified - to be verified - to be replaced - to be replaced

Snoot stifled burner and boiler.

- Inadequate draft - inadequate pellets quantity

- appeal to a sweeper in order to verify and clean the stack. - adjust the quantity of pellets.

The boiler does not reach the adjusted temperature (low rated power)

- insufficient water in the system; - too large debit pump; - under-dimensioned boiler; - inadequate quality fuel - insufficient draft; - obstructed combustion air admission - not cleaned boiler -faulty ignition - inadequate pellets quantity

- to be re-filled; - the rotative speed of the pump is adjusted; - projection problem; - the fuel is changed; - new or cleaned flue; - to be cleaned - to be cleaned - see chapter “ Ignition” - adjust the quantity of pellets.

BREAKDOWNS REPAIRING

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High temperature of the water in the boiler, but low temperature of the water in the radiators

- high hydraulic resistence in the heating system - mixing thermostat valve incorrectly assembled

-increase pump rotative speed - changing the connection position

High temperature of the water in the boiler determining the water in the boiler to boil

- over-dimensioned boiler, with over-dimenssioned heating devices and over-dimenssioned water pump - difficult temperature control

- projection problem; - adjusted pump rotative speed; - Too large section of the stack; - Adjustment of the combustion air valve and of the draft adjuster;

Condense appears in the fuel storage and a black liquid comes out of the feed door

- the power of the boiler higher than necessary - the temperature in the boiler is too low

- introduce a smaller quantity of fuel in the fuel storage - increase the operating temperature so that the return water temperature is minimum 60ºC

Lack of tightness at the doors of the boiler

- the cord packing is not tight - damaged cord packing - insufficient draft

- the packing cords of the doors of the boiler are cleaned. - to be replaced - problems related to the stack.

Smoke emission at the boiler flue-gas channel

- insufficient draft - dirty or rusty smoke channel;

- problems related to the stack. - the smoke channel is cleaned

The burner does not operate -the adjustment temperature is reached detached from the safety thermostat;

- adequate operation of the boiler - manually resetting;

The air fan does not work or works noisily

- stuffy, dirty turbine; - faulty condensor, engine; - imperfect contact between the feeding cable and the engine.

- to be cleaned - to be replaced - to be verified

The pellets feeding system does not work

- blocked geared engine - blocked conveyer worm

- it is blocked by cleaning the feeding tube and the dust resulted from the pellets is eliminated

Chapter 6

SPARE PARTS The boiler is designed for long-term usage, without any rapid wearing parts Replacing the parts

becomes necessary to remedy the damages appearing after long-term operating or because of the inobservance of the instructions of use. All the repairing or replacement operations will be achieved only by the maintenance service authorized by the manufacturer.

- List of spare parts - General switch - Thermomanometer - Maximum command thermostat - Safety thermostat - Draft thermostat adjuster - Door packing cord

SPARE PARTS

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- fan - condenser fan - programmable automaton - safety switch ON/OFF - photosensor - electric igniter - gearmotor - thermocouple - conveyer worm coil

Chapter 7

WORK PROTECTION AND FIRE FIGHTING NORMS When assembling, putting into service, exploiting and maintaining the boiler there will be taken

into consideration the following norms: labour protection republican norms; R.E.T. norms (technical use of the plants regulation); P.S.I. prescribtions; ISCIR technical prescriptions C9-2003; P 118; Norm I13-94.

Obtaining these norms and prescriptions, up to date edition, represents the duty of the beneficiary

who exploits and maintains the installation.

Chapter 8

QUALITY AND WARRANTY CONDITIONS

When selling the equipment, it is handed together with: 1. the original invoice 2. the technical documentation of the product 3. conformity declaration of the manufacturer 4. warranty certificate signed by the seller and by the buyer 5. The technical documentation and the warranty certificate will be kept at the location where

the bought equipment is assembled. The buyer will undertake the obligation of choosing the equipment (type, model, size, etc)

The warranty enters into force after the equipment putting into service the by the service company authorized by S.C. Termofarc S.R.L.

If the user put into service the equipment by himself (using a person – company that was not authorised by SC Termofarc SRL), the warranty period will begin the purchase day (invoice date).

I. Buyer’s obligations

1. -to acknowledge and observe the instructions in the present book; - to keep the technical documentation of the product, the original invoice and the warranty certificate;

- to provide once a year the technical revision of the boiler, carried out by the authorized staff;

WARRANTY CONDITIONS

WORK PROTECTION AND FIRE FIGHTING NORMS

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2. To provide the conditions of the equipment putting into service according to its type and features, in the following manner:

- assembling, connection of the installation and tightness and pressure test executed by authorized staff

- loading the installation and airing it - connecting to the electrical mains

- providing the technical conditions of burned gases exhaust 3. To obtain all the necessary documents and approvals for authorizing the equipment

operation according to the legal provisions in force; for certain equipments, the buyer will pay all the taxes charged by the authorities in the field (i.e. ISCIR) in order to authorize its operation.

4. Both for putting into service and for making the interventions, revisions or verifications, the buyer will permit the acces of the service company personnel to the location where the equipment is assembled, including to all the documentation that certifies that all the legal approvals for the certification of the operation have been obtained.

II. Service company obligations

1. The putting into service will be achieved by the service company authorized by S.C. Termofarc S.R.L. and this has the following duties:

- to verify the correctness of the equipment assembling (according to the assembling instructions in the technical book of the product and to the applicable legal provisions).

- To verify the efficiency of the safety devices

- to check the necessary documents demanded by the law and by the producer in order to authorize the operating of the equipments (if applicable).

- to make the necessary adjustments for the operation within the best parameters - to turn on the equipment and to heat test it

- to verify the operation of the equipment within the parameters according to the technical book of the equipment. - to train the user to adequately use and maintain the equipment.

- to draw up the report of putting into service or the report of verifications, trial and tests for the authorization of the putting into service.

2. The verifications made by the service operator concern only the good operation of the equipment that is to be put into service. Any irregularity found at the installation to which it is connected will be registered in “Report of verifications, trial and tests for the authorization of the putting into service”.

3. When the service operator finds, after the check, certain irregularities that might affect the proper and safe operation of the equipment, the buyer will refuse the putting into service until the buyer corrects such irregularities. The found irregularities will be mentioned in the tests report for the authorization of the putting into service.

4. S.C. Termofarc S.R.L. will exonerate of any responsibility concerning the eventual damages caused by the putting into service and exploiting of the the equipment by unskilled or unauthorized personnel or beyond the legal provisions and of the technical prescriptions in force stipulated by the manufacturer in the technical book of the product and by the law.

III. Warranty exclusions:

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The warranty covers only those faults that appear in the normal use of the product it does not apply for:

Damage during the transport

Inobservance of the instructions of “putting into service and use instructions”. Incorrect installation, executed by the unauthorized personnel, incompliant with the

instructions specified in the technical book of the boiler or with the legal regulations in force.

Careless handling and use (heat, mechanical or electrical shock, high degree of impurities

and deposits, excessive humidity in the operating room, location in other positions that those described in the technical book of the product).

Using other fuels than those described and recommended in the technical book of the product.

Interventions and changes unauthorised by S.C. Termofarc S.R.L.; over-exploiting of the equipment (water freezing in the installations, lack of water in the installations, exhaust flue insufficiency of the burnt gases etc) and specified in the technical book of the boiler.

Incorrect treatment of the feed water.

Corrosions caused by condense

The warranty will cease when the user refuses to pay any financial obligations he has to the service company or to SC Termofarc SRL.

IV. Cases of applying the service tariff During the warranty period: - in case of damage caused by facts independent of the manufacturer (situations presented in chapter III.)

when the information given by the user turns out to be erroneous, the transport and the intervention of the service operator will not be included in the warranty.

- when the service operator finds that the damage occurred because an faulty intervention of the user. During the post warranty period: - at any intervention irrespective of the cause.

At putting into service: - when the putting into function is obstructed by the inobservance of the conditions mentioned in the technical book of the product and of the conditions specified in this warranty document.

- when the user obstructs the putting into service of the equipment (i.e. he is not present at the assembling location the set date and time, he can not provide water, fuel, electricity feed, etc. or because of certain damages that he did not communicate in due time to the service company).

The constructing unit warrants the adequate operation of the boiler in normal conditions of exploition, according to the indications included in “The use instructions”.

The warranty period is of 24 months for the body of the boiler and 12 minths for the electrical components since its putting into service. The warranty is granted if:

the boiler is assembled with a 4 ways mixing valve;

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the boiler is installed with mix heat fan (TV 60ºC or TV 72ºC ) or with a re-circulation pump with correctly assembled thermostat control; the design of the heating unit is made by specialists and endorsed by a specialised unit;

the execution of the heating installation is carried out by a specialized – authorized

company The use of the boiler shall be according to the instructions of “putting into service and use instructions”.

Any deviation from the included instructions entails the loss of the warranty by the faults caused out of the beneficiary’s fault.

HOUSE TESTING REPORT

NO. ____________/_____________________ ON THE GROUNDS OF THE EXECUTED TRIALS AND TESTS, WE

HEREBY CERTIFY THE FOLLOWING The boiler type FI______NSP, manufacture number

______________________ manufacture year 20___ was executed compliant with the EXECUTION PROJECT

The technical conditions were observed according to THE TERMS AND CONDITIONS.

The boiler was checked from the construction point of view and it corresponds the aforementioned conditions and the report no.__________________________________

The boiler was tested using hydraulic pressure of 4 bar, for 10 minutes and it resisted without distortions or leakeage being observed.

The boiler is appropriate for operation with the parameters indicated in this technical book (documentation).

MANUFACTURER, Q.C. responsible person

_________________ _________________

Manufacturer, S.C. TERMOFARC S.R.L. Stamp place

HOUSE TESTING REPORT

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DECLARATION OF CONFIRMITY

(attach here)

DECLARATION OF CONFORMITY

Drafted by: Technical Manager Eng. KÖPE JÁNOS-CSABA

Foreman BUBLA LEVENTE

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SC TERMOFARC SRL; 118 Braşovului boulevard, SĂCELE, BRAŞOV County;

Tel: 0268/274945, Fax: 0268/276193 www.termofarc.ro