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“FI- GS“ BOILERS WITH GASIFICATION

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 mixing valve or thermostatic control

recirculation pump, (according to the fig. ”Installation scheme”, pg. 21-

25.)

The boiler operating temperature must be in the range 80 – 90 °C,

while the minimal return temperature 65°C.

Use quality dry fuel (2 years old wood ), of maximum humidity of

20%.

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-GS BOILER ON SOLID FUEL, that operates on the grounds of wood gasification principle, an innovating and modern product with special qualities and performances. This product provides you maximum satisfaction if you use the boiler according to the recommendations of this book. We guarantee 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.

This manual refers to the assembling, installation and use of the product. Carefully reading the instructions, you shall get important information for the perfectly safe operation of this boiler, thus obtaining optimum performances and long term use. To introduce them on the Romanian market and for the product’s compliance with the essential security requirements stipulated by the European Directives, the boilers have been assessed by ISCIR CERT, consequently the compliance certificate 033B1 – 584/EC was issued.

TERMOFARC

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Important warning …………………………………………….………………………………………………………5 Do not forget …………………………………………………….…………………………………………………….6 Boiler description ……………………………………………….………………………………………………………7 Gasification ………………………………………………………….…………………………………………………….7 Identification………………………………………………………….………………………………………………….8 Component parts ……………………………………………………………………………………………………..8 Technical data……………………………………………………………………………………………………………11 Accessories …………………………………………………………………………………………………………….13

Chapter 1 .......................................................................................................................... Error! Bookmark not defined. ASSEMBLING INSTRUCTION................................................................................... Error! Bookmark not defined.

1.1. Choosing the boiler .......................................................................................... Error! Bookmark not defined. 1.2. Boiler’s location and position .......................................................................... Error! Bookmark not defined. 1.3. Assembling the cover and the control panel ................................................... Error! Bookmark not defined. 1.4. Hydraulic connections ...................................................................................... Error! Bookmark not defined. 1.5. Safety elements ................................................................................................. Error! Bookmark not defined. 1.6. Connection of the safety elements ................................................................... Error! Bookmark not defined. 1.7. Operation of the safety exchanger (cooling coil). .......................................... Error! Bookmark not defined. 1.8. Open systems and closed systems ................................................................... Error! Bookmark not defined. 1.9. Pump for the heating circuit ............................................................................. Error! Bookmark not defined. 1.10. ESBE mixing heat valve ............................................................................... Error! Bookmark not defined. 1.11. 4 way valve ....................................................................................................................................................... 21 1.12. Ventilation.......................................................................................................................................................... 21 1.13. Installation connection schemes ....................................................................................................................... 22 1.14. Electric diagram of the boiler ........................................................................................................................... 27 1.15. Connection to the stack ..................................................................................................................................... 27 1.16. Filling in the system ......................................................................................................................................... 28

Chapter 2 ......................................................................................................................................................................... 29 PUTTING INTO SERVICE ........................................................................................................................................ 28

2.1. The first putting into service .............................................................................................................................. 29 2.1.1. Checks during the first putting into service ........................................................................ Error! Bookmark not defined. 2.1.2. Putting into servie ................................................................................................................. Error! Bookmark not defined. 2.1.3. Commissioning to the beneficiary ....................................................................................... Error! Bookmark not defined.

Chapter 3 .......................................................................................................................... Error! Bookmark not defined. USE AND MAINTENANCE INSTRUCTIONS ...................................................................................................... 31

3.1. Boiler’s operation ............................................................................................................................................... 31 3.2. Ignition .............................................................................................................. Error! Bookmark not defined. 3.3. Control pannel .................................................................................................. Error! Bookmark not defined. 3.4. Combustion aer and unblocking the oneway valve ........................................ Error! Bookmark not defined. 3.5. Fuel feed and re-feed ........................................................................................................................................... 34 3.6. Airing the fuel storage ......................................................................................................................................... 34 3.7. Continuous operation ........................................................................................ Error! Bookmark not defined. 3.8. Summertime operation ...................................................................................... Error! Bookmark not defined. 3.9. Short term interruption of the operation............................................................................................................. 35 3.10. Long term interruption of the operation ......................................................... Error! Bookmark not defined. 3.11. Requirements for the fuel ................................................................................................................................. 35 3.12. Exploitation ..................................................................................................... Error! Bookmark not defined. 3.13. Boiler’s cleaning ............................................................................................. Error! Bookmark not defined. 3.14. Maintenane of the boiler and of the heating system ..................................... Error! Bookmark not defined. 3.15. Boiler’s tightness ............................................................................................ Error! Bookmark not defined. 3.16. Changing the door packing cord .................................................................... Error! Bookmark not defined. 3.17. Changing the nozzle . ...................................................................................... Error! Bookmark not defined.

Chapter 4 ........................................................................................................................... Error! Bookmark not defined. BREAKDOWNS AND SOLUTIONS .......................................................................... Error! Bookmark not defined. Chapter 5 ......................................................................................................................................................................... 41 SPARE PARTS ............................................................................................................... Error! Bookmark not defined. Chapter 6 ......................................................................................................................................................................... 42 QUALITY CONDITIONS AND WARRANTY ...................................................................................................... 42 Chapter 7 ......................................................................................................................................................................... 44 WORK PROTECTION AND FIRE FIGHTING NORMS ................................................................................... 44 PROTOCOL OF HOUSE TESTING ........................................................................................................................ 45 DECLARATION OF CONFORMITY ....................................................................... Error! Bookmark not defined.

TABLE OF CONTENTS

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This manual is an essential part of the product and must be handed to the user. It must be kept the entire operation time of the product 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 in the environment and kept it out of the reach of children.

Before installing FI–GS boiler, please carefully read the “Boiler Installation” chapter.

The assembling shall be exclusively executed by authorized personnel in compliance with the norms in force (STAS – Romanian Standard - 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 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 this product repairs. Never use the boiler if it does not operate appropriately.

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

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 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 manufacturer’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 execute cleaning or maintenance operations while the boiler is in use.

An unpleasant scent or smoke may appear during the first putting into service of the

boiler; this is normal and it shall disappear after a short time of use.

If you do not use the installation for a long time, call for the service authorized team of Termofarc to check it.

The room where the boiler shall be assembled must be permanently 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 the boiler is stopped and cold.

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

The body of the boiler needs to be null-connected for protection 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 errors and the inobservance of the manufacturer’s instructions

The used fuel must be dry wood (2 years) with maximum humidity of 20%.

Soot, tar and acid steam may appear during the combustion process. To diminish their formation, the boiler must operate at optimum parameters (the temperature of the heating agent in the boiler must be of 80 – 90 oC and the temperature of the return heating agent must be of minimum 65 oC). We recommend the use of 4 way valves, thermostat controlled recirculation pumps or heat valves TV (25, 32, 40) according to the assembling way.

The boiler shall not be used below the rated capacity. In the transition period or in the summertime (when we only need household hot water (A.C.M.), the boiler shall be daily started/turned on.

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 of fire-proof materials according to the applicable standards.

The heat power plant must be endowed with admission openings for the fresh air with the section of 400 cm2 (the minimal admitted section 200 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. It is forbidden to connect two or several boilers to a single stack.

When placing the boiler, the following distances shall be respected: 0.6 m to the side of the boiler; 0.8 m to the back; 1.5 m to the front and 0.6 m to the ceiling.

The boiler shall be connected to an open or close expansion tank, accordingly sized. 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 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 middle and lower doors. The cleaning of the smoke tracks shall be carried out when the boiler is turned off and left

to cool down.

From time to time or whenever necessary, the ash must be removed from the ash pan using the middle and lower small doors of the boiler. This operation shall be carried out only when the boiler is turned off and cold.

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

NOTE !

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The used fuel must be dry wood (2 years) with maximum humidity of 20%.

Soot, tar and acid steam may appear during the combustion process. To diminish their formation, the boiler must operate at optimum parameters (the temperature of the heating agent in the boiler must be of 80 – 90 oC and the temperature of the return heating agent must be of minimum 65 oC). We recommend the use of 4 way valves, thermostat controlled recirculation pumps or heat valves TV (25, 32, 40) according to the assembling way.

The boiler shall not be used below the rated capacity. In the transition period or in the summertime (when we only need household hot water (A.C.M.), the boiler shall be daily started/turned on.

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

The operating FI-GS boilers must be supervised.

FI-GS boilers are constructed for the combustion of wood, wood scraps (at a rate of 20%) or

briquettes and it operates on the grounds of the gasification principle, being endowed with air fan providing combustion air to the combustion chamber. The air introduced by the fan is directed on two air channels. The primary air (the upper channel) allows wood combustion from bottom to top (totally) while the wood gas passes through the refractory nozzle and the secondary air (the lower channel) helps burning the wood gas.

They are made in ten manufacture sizes, namely with heat power of 18; 25.6; 30.1; 40.6; 52.2; 60.3; 80; 104.4; 130 and 150 Kw.

From the construction point of view, they are steel boilers with the interior width of 5 or 6 mm and the exterior width of 4mm, welded, with water chamber. The boilers have two compartments separated by a refractory concrete plate endowed with combustion nozzles. The upper compartment is meant for the fuel storage and as gasification chamber and the lower one is the main combustion chamber where the wood gas combustion actually takes place.

They are endowed with two heat exchangers: coil producing household hot water (range 18 – 40 KW), and cooling coil – protection against the overheating (all range of powers).

In the front part, there are three doors, the fan endowed with one-way adjustment valve, the driving handle of the combustion valve whose rod is followed by a micro switch (the position of the rod in the open – closed positions), namely the control panel.

The boiler’s doors allow the wood supply (the upper one), the ash exhaust and the cleaning of the firebox and of the convective routes (the lower and the middle one). They are coated with refractory concrete and the closing sealing is made using a packing cord.

The control panel includes a control thermostat adjusting the operating temperature in the boiler (by turning the fan on and off), a safety thermostat with manual resetting device, a thermostat of minimum (turns off the fan after the temperature fall in the boiler), a general switch, a wire fuse and a thermo-manometer. They are meant for the heating of the buildings and the production of household hot water. It can also be assembled into an installation with gravitational operation or with induced draught with circulating pump;

BOILER DESCRIPTION

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Each boiler has its own identification plate.

GASIFICATION

Uscare

Piroliză

Ardere primară

Ardere principală

Ardere totală

The principle of wood gasification (or distillation) is a process offering maximum efficiency of the wood combustion, minimum smoke and noxious substances emission in the atmosphere and a substantial decrease of the energy costs.

The wood (15-20%) humidity is loaded in the fuel storage where, in contact with the embers produced on the refractory surface, generates wood gas through the phenomenon called „wood distillation”, that, combined with the primary (combustion) air, make up a gaseous mixture. This fuel is blown through the refractory nozzle into the combustion chamber where the combustion takes place as “turned-up flame”. The steps of the gasification process and of the wood gas combustion:

1. Wood drying – the wood vapors in the wood are eliminated, that combined with the combustion products also form tar.

2. carbonization (pyrolisis) –wood gas is formed and the dry

wood turns into coal through the process called ”distillation”; 3. Primary combustion – the combustion of the created fuel and

heat tranfer to the previous and subsequent level.

4. Main combustion – the fuel mixture is blown (transferred) through the refractory nozzle where it self-lights at 560 oC combined with the secondary air.

5. Total (final) combustion – the combustion of the wood gas takes place in the main combustion chamber combined with the secondary air at temperatures of 1200 oC. Next is the heat transfer to the main heat agent through the boiler exchanger and then the burned gases are exhausted through the flue.

IDENTIFICATIONA

fig.1.

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Water chambers: are made up of two plan-parallel walls made up of steel plate of 5 – 6 mm width, namely 4 mm, located at a distance of 50 mm. The walls of the chambers are reinforced with round steel cross-ties of Ø 12 mm welded at both ends. Boiler doors: allow the wood supply (the upper one), endowed with a curtain – type plate against smoke propagation in the heating plant room, the cleaning and ash exhaust from the combustion chamber (the middle one) and the cleaning of the connective routes (the lower one).

Fuel storage: is located in the upper part of the parallelepiped-shaped boiler; in the initial phase, wood ignition and embers bed production take place here; afterwards the wood trunks are loaded. Flue-gas collector: the burnt gases after the heat transfer are gathered in the flue-gas collector located in the back of the boiler and exhausted into the stack. It has three cleaning and inspection covers, two on the lower sides (left - right) and one on the boiler’s upper wall.

COMPONENT PARTS

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The by-pass circuit of the burnt gases: in the back wall of the fuel storage there is a pipe connected to the flue-gas collector. A rod handle (where is the roll of a micro switch following the open – closed position of the rod), located on the top of the feed door drives a valve meant to open and close the pipe in the following cases: - in the phase of ignition and loading (the fuel storage door is open), the valve leaves the pipe open allowing the direct exhaust of the smoke from the fuel storage. - when the boiler is on (the fuel storage door is closed, the fan is on, the rod of the valve maximum pulled driving the roll of the micro switch and gasification takes place), the valve closes the pipe forcing the wood gas to pass through the combustion nozzle. The refractory concrete plate and the combustion nozzles: separate the fuel storage from the main combustion chamber, being supported on a pipes structure. The combustion nozzles are located in the middle of the concrete plate and they are meant to support the embers and to allow the passing of the formed wood gas. The heat exchange area and the convective system: The wood gas, passing through the combustion nozzles, creates a flame reaching to the refractory material catalyst; the heat transfer and the transit of the connective system take place here. The convective system has the shape of membrane walls made up of pipes of Ø 42x4.5 mm that provides two circuits for the burnt gases. Air distribution ramp: in the front part of the boiler, between the upper and middle door, there is the forcing channel of the air ramp, endowed with one-way gravitation valve that turns off when the fan stops. The air is divided into primary and secondary air. The primary air is distributed in the upper part of the fuel storage by means of two distribution pipes. Here it mixes with the wood gas and creates the burning fuel, passing through the combustion nozzle. The secondary air is immediately distributed to the combustion nozzle by means of two circular section pipes with holes (face to face, staggered) directly supplying oxygen in the flame formation area.

The air fan: is of centrifugal type, driven by a single phase electric engine and it is assembled on

the forcing channel of the air ramp.

The coil for preparing household hot water (for the range 18 – 40.6 Kw): is made up of galvanized pipe of 1/2”, it is 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 sensors location: on the upper part of the boiler there is a hole called case for the thermostat and thermometer probe in the control panel. An inside thread connection is also located here for the manometer. The control panel: 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 (maximum) - Thermostat of control minimum (stops the fan

when the temperature of the boiler in the boiler falls below the adjusted temperature – lack of

fuel)

- Safety thermostat (stops the fan at over-temperature whenever the first thermostat is

faulty – manual resetting)

- Thermo-manometer - Led general switch

- Wire fuse 6 - 10A Reinforcements: the following reinforcements are located on the back side of the boiler:

– Safety valve ( 2.5 bar )

– Heat valve ¾” Heat insulation: made of mineral wool.

COMPONENT PARTS

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COMPONENT PARTS

1. Water chamber 2. Coil for preparing household hot water (for the range 18 – 40.6 Kw) 3. Combustion nozzle 4. Cooling coil 5. Mineral wool insulation 6. One way connection 7. Refractory concrete plate 8. Fireproof clay – heat screen 9. Convective system 10. Return connection – for the powers of 18 – 105 Kw, the return connection is of 1½” outside thread and it is located on the left lower back of the boiler (back image) - for the powers of 130 - 150 Kw the return connection is of 2½” outside thread located on the left side of the boiler 11. Horizontal pipes (for plate supporting) 12. Lower cleaning door 13. Combustion chamber door 14. Centrifugal fan 15. Fan protection 16. Fuel storage door 17. Heat insulating door handle 18. Handle rod – ignition valve drive 19. By-pass pipe 20. Stack connection

fig.2.

fig. 3.

21. Valve assembly 22. Primary air distribution pipes 23. Flue-gas collector 24. Fuel storage 25. Secondary air ramp 26. Control panel 27. Lateral cleaning cover 28. Upper cleaning cover

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Data related to the constructive sizes of FI-GS boilers

Boiler

Name UM FI-18

GS

FI-25

GS

FI-30

GS

FI-40

GS

FI-50

GS

FI-60

GS

FI-80

GS

FI-105

GS

FI-130

GS

FI-150

GS

Boiler width (D) mm 605 605 605 605 700 700 820 820 930 930

Boiler height (H) mm 1590 1590 1590 1590 1600 1600 1700 1700 1700 1700

Boiler length (L) mm 950 1070 1130 1240 1280 1450 1510 1750 1750 1900

Boiler total length (Lt) mm 1070 1190 1250 1360 1400 1570 1630 1870 1870 2020

Height of the stack inlet

(E) mm

1365 1365

1365 1365 1430 1430 1530 1530 1520 1520

Stack inlet () mm 170 170 170 170 200 200 220 220 240 240

Height of the one-way

inlet mm 1460 1460 1460 1460 1645 1645 1750 1750 1750 1750

Weight kg 436 507 540 595 680 776 955 1125 1270 1370

Side view

Front view

TECHNICAL DATA

fig. 5. fig. 4.

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Boiler

Name UM FI-18

GS FI-25

GS

FI-30

GS FI-40

GS

FI-50

GS

FI-60

GS

FI-80

GS

FI-105

GS

FI-130

GS

FI-150

GS

Thermo-manometer inlet

(RTM)

Inche

s ¼” int ¼” int. ¼” int ¼” int ¼” int ¼” int ¼” int ¼” int ¼” int ¼” int

Safety valve (SS) Inches ½” ext. ½” ext. ½” ext. ½” ext. ¾” ext. ¾” ext. 1” ext. 1” ext. 1” ext. 1” ext.

One-way inlet (RT) Inches 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext 2” ext. 2” ext. 2½” ext 2½” ext

Return inlet (RR) Inches 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext 1½” ext 2” ext. 2” int. 2½” ext 2½” ext

Col water / household hot water inlet (AR / ACM)

Inches 1½” ext ½” ext. ½” ext. ½” ext. - - - - - -

Cooling coil inlet (ARR ) Inches ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext.

Heat valve inlet (RST ) Inches ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext. ¾” ext.

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

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

Rated heat power Kcal/h

(kW) 15.500

(18)

22.000

(25,6)

26.000

(30,1) 35.000 (40,6)

45.000

(52,2)

52.000

(60,3)

69.000

(80)

90.000

(104,4)

112000

(130)

130.000

(150,8)

Efficiency % 87 – 89 87 – 89 87 – 89 87 – 89 87 – 89 87 – 89 87 – 89 87 - 89 87 - 89 87 - 89

Rated fuel consumption (wood of humidity 18% and

Hi= 3500 kcal/kg)

Kg/h 5

7,06 8,35 11,23 14,45 16,7 22,15 28,9 36 42

Necessary stack draught mBar 0,15 – 0,2 0,2 – 0,25

Minimum stack height ml 6 6 6 6 7 7 8 8 8 8

Water content in the boiler l 118 139 149 164 209 243 326 386 405 449

Temperature of the burn gases °C 130 - 140

Maximum operating

temperature °C 95 95 95 95 95 95 95 95 95 95

Recommended operating

temperature °C 80 - 85 80 – 85 80 – 85 80 – 85 80 – 85 80 – 85 80 - 85 80 – 85 80 – 85 80 - 85

Minimum temperature on the

return °C 65 65 65 65 65 65 65 65 65 65

Consumed electric power W 80 80 80 80 135 135 240 240 400 400

Supply voltage / frequency V/Hz 220 / 50

Maximum pressure Bar 2 2 2 2 2 2 2 2 2 2

Testing maximum pressure Bar 4 4 4 4 4 4 4 4 4 4

Household hot water flow (∆t=35°C)

l/min 12 12 12 12 - - - - - -

Volume of the fuel storage l 100 135 150 175 230 280 400 510 570 655

Time of continuous combustion at the nominal

rate

Hour

s 3 4

TECHNICAL DATA

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fig.6 fig.6

TECHNICAL DATA

fig.7.2 fig.7.3

fig.7.1

FI 18 GS – FI 40 GS

FI 50 GS – FI 105 GS FI 130 GS – FI 150 GS

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Accessories delivered with the boiler

Control panel (basic package)

- Fan

(basic package)

- Thermo-manometer (basic package)

- Household hot water coil

(basic package for the range 18 – 40 Kw)

- Safety valve (2.5 bars) (basic package)

- Cooling coil (basic package)

- Control and adjustment thermostat (2 pieces, of minimum and maximum)

(basic package)

- Assembling, use and

maintenance instructions (basic package)

- Safety thermostat (basic package)

- Fire iron, brush and scraper

(basic package)

Accessories recommended as mandatory

- Open expansion tank Or

- closed expansion tank

- 4 way valves Or

Mix heat valve TV 60ºC(25, 32, 40)- for

the return TV 72ºC(25, 32, 40)- for

the turn

- Heat valve STS 20 or TS 130- ¾”

- circulation and / or recirculation pump

ACCESSORIES

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Chapter 1

ASSEMBLING INSTRUCTIONS

This chapter addresses both 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 to be assembled, it must be stored in a dry place.

1.1. Choosing the boiler The boiler must be chosen so that the rated power complies with the heat losses and the heat necessary according to STAS 1907, essential requirement for the accurate and economical 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.

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

ASSEMBLING ASSEMBLING 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. 8. The boiler shall not be assembled on flammable material support. The room must have a fresh air access inlet, 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.

fig. 8.

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1.3. Assembling the cover and the control panel

The boiler shall be assembled where it is meant to operate. The component parts shall be assembled according to the drawing in fig. 9. as it follows:

- The assembling shall start by screwing the stud bolts (position 1.) supporting the flue-gas collector.

- The flue-gas collector is positioned (position 2.) on the stud bolts and fixed using the 6 M12 nuts (position 3).

- The back covers shall be assembled (position 4) and fixed using the M6 screws (position 5), two in the upper part and two in the lower part.

- The micro switch following the rod driving the ignition valve over which the front cover is assembled (position 6) and fixed using the M6 countersunk screws (position 7), then the handle (position 8) of rod driving the combustion valve.

- The lateral covers are assembled (pos.9 and 10) and then fixed using the M6 screws (pos.11 and 12), two up and two down.

- The control panel is assembled (position 13) in the upper cover and fixed using the M6 screws (position 14).

- The probes and the inlets of the control equipment shall be inserted into the appropriate case and in the coupling inlet ¼” (position 15.)

- The cover is assembled (position 16) and the fan cover is fixed (position 17) between the upper and the middle door.

ASSEMBLING

fig.9.

ver.3 18

1.4. 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 (the range 18 – 40 Kw). The cooling coil is connected according to Fig. 10. All the hydraulic connections of the boiler installation will be executed according to the” installation schemes”.

To fill the boiler and/or the system, the plumber will connect a running water pipe to the return pipe (return of the installation). A direction valve (retention valve) and a filling tap will be interposed in this connection. Attention: A direction valve will be interposed in the filling inlet of the installation! For the proper operation and protection of the boiler against the corrosion we recommend:

- Avoid the acid condense and the tar formation by increasing the temperature at the return of the boiler, one of the following assembling methods will be chosen:

- mix heat valve TV 60ºC, meant to maintain water temperature at the return of the boiler at 60ºC – the required temperature for the return being of minimum 65ºC, or assemble a mixing heat valve TV 72ºC on the turn pipe of the installation with the same role (for the capacities of ≤ 70 Kw). - thermostat controlled recirculation pump between the turn and the return (by-pass). - 4 ways mixing valve with or without servo-engine.

- we recommend the installation of a thermal storage water heater to obtain household hot water, - to increase the autonomy of the operation and of the taking over of the surplus heat, we recommend the assembling of the boiler together with a puffer. The capacity of the puffer will be of minimum 40 liters per 1Kw installed.

Observation: to obtain the desired heat comfort in your house (the ambiental temperature), we recommend you to equip the radiators with thermostatic valves.

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, special attention shall be paid to carefully sizing the pipes and to the pressure loses on these heating elements.

Before assembling the boiler, the system must be washed and cleaned of grease, dirt and free mechanical particles. The circuit must include a separating device to collect the mechanical impurities that might appear after installation execution. The connections are executed by soldering or by compression adapting pipes for copper pipes, couplings or flanges for steel pipes. The pipes must be provided with a necessary slope for easy airing and bleeding towards the points specially designed in the installation. The bleeding 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.

BOILER’S CONNECTION

ver.3 19

If the installation has pipe sections exposed to negative temperatures, the water pipes will be heat-insulated.

1.5. Safety elements

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

Attention: It is forbidden to assemble closing elements - such as interposed valves - between the boiler and the connection of the expansion tank!

It is forbidden to assemble closing elements - such as interposed valves - between the boiler and the bleeder!

The bleeder and the heat valve must comply with the European norms, must be EC certified, bearing this mark.

We recommend the assembling of bleeders even if the boiler is assembled with an open expansion tank.

1.6. Safety elements connection

Ways of protecting the boiler against overheating (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 TS 130 - ¾” or STS 20. (Fig.10.) - Assembling the boiler operating through trough heat siphonage (gravitational circulation), - When using equipments such as a hydrophore, the boiler may be protected using a back-up

source of electricity (battery or generator) for the circulation pump.

1.7. 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.

ASSEMBLING SYSTEMS

SAFETY ELEMENTS INSTALAŢIEI

SAFETY ELEMENTS

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

fig.10.

ver.3 20

1.8. 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 sized.

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.

1.8.1. Open systems (with open expansion tank)

The open expansion tank will be assembled in the highest point of the installation, no higher than 20 m from the water pipe enterance 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; - sizing the pipes;

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

Fig. 11.

ver.3 21

1.8.2. Closed systems (with closed expansion tank)

If there is a permanent source of water and the assembling an expansion tank is impossible/difficult, it is recommended to choose the assembling alternative with expansion tank with membrane (closed). Their use has several 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 in 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 – water head - 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])

The air pressure in the closed expansion tank must be adjusted according to the water head

(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” and the air pressure within it.

1.9. The pump of the heating circuit The capacity of the heating pump is calculated according to the empirical formula:

Q = Pu/1000·15 [m3/h], where:

Q represents the capacity 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.

1.10. ESBE Mix heat valve

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°.

1.12. 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 it.

ELEMENTS OF THE INSTALLATION

INSTALLATION SYSTEMS

ver.3 22

Once the system is heating up, the fuels will be collected in the highest points of the system and must be eliminated. Installing airing devices (manual or automatic) in these points of the system will enable the elimination of the wastes dissolved both during the first filling as well as during the

operation. We recommend the assembling of automatic airing devices (with float bowl or ball)

1.13. Installation connection schemes

Attention! The schemes are for orientation only. For a correct installation, comply with the

norms in force.

1.13.1 Hydraulic connections scheme with open expansion tank for the FI-GS boilers with

cooling coil, household hot water coil and heat valve TV 60ºC

1.13.2 Hydraulic connections scheme with open expansion tank for FI-GS boilers with cooling

coil, household hot water and thermostat controlled recirculation pump.

INSTALLATION SCHEMES

fig.12.

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 Fy – impurities filter

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 valve inlet Cs– direction valve Pc – circulation pump Prc- recirculation pump TS- pump control thermostat SC – sewerage system Fy – Impurities filter

fig.13.

ver.3 23

1.13.3 Hydraulic connections scheme with closed expansion tank for the FI-GS boilers with

cooling coil, household hot water coil and heat valve TV 60ºC .

1.13.4 Hydraulic connections scheme with closed expansion system for the FI-GS boilers with

cooling coil, household hot water and thermostat controlled recirculation pump.

INSTALLATION SCHEME

LEGEND VEI – closed 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 valve inlet Cs– direction valve Pc – circulation pump VT – mix heat valve TV 60ºC SC – sewerage system Fy – Impurities filter

LEGEND VEI – closed 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 valve inlet Cs– direction valve Pc – circulation pump Prc- recirculation pump TS- pump control thermostat SC – sewerage system Fy – Impurities filter

fig.14.

fig.15.

ver.3 24

1.13.5 Hydraulic connections scheme with closed expansion system for the FI-GS boilers with

accumulator, cooling coil and 4 way valve.

INSTALLATION SCHEME

LEGEND VEI – closed 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 Fy – impurities filter

ARR – cold water installation RST – heat valve connection Cs– direction valve Pi – heating circuit pump VA4 – 4 ways mix valvwe BACM – hot water boiler with accumulator SC – sewerage system Pb – boiler circulation pump ST – heat valve S – heat valve probe

fig.16.

ver.3 25

1.13.6 Hydraulic connections with open expansion tank for the FI-GS boiler with

accumulation, accumulator tank, cooling coil and thermostat controlled recirculation

pump.

INSTALLATION SCHEMES

fig.17.

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 Prc – recirculation pump against the condense Pva – pump for accumulator tank Fy – impurities filter

ARR – cold water installation RST – heat valve connector Cs– direction valve Pci – heating circuit pump BACM – accumulation hot water boiler SC – scurgere canalizare Pb – pompa circulaţie boiler ST – supapă termică S – heat valve probe VA – accumulating tank TA – thermostat

TS- pump control thermostat

ver.3 26

1.13.7 Hydraulicl connections scheme with closed expansion tank for the FI-GS boiler with

acumulation boiler, accumulation tank, cooling coil and 4 way valve.

fig.18. 17.

INSTALLATION SCHEMES

LEGEND VED – open expansion tank RI – radiator ACM – household hot water ARM – household cold water Rt – straight way valve

SS – bleeder RC – flue connection

T – turn connection R – return connection GC – boiler discharge Pva – accumulator tank pump Fy – impurities filter VA4 – 4 way valve

ARR – cold water installation RST – heat valve connection Cs– direction valve Pci – heating circuit pump BACM – hot water boiler with accumulator SC – sewer system Pb –boiler with circulation pump ST – heat valve S – heat valve probe VA – accumulator tank TA –thermostat TM – thermometer

ver.3 27

1.14. Boiler’s circuit diagram

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 danger of electroshocks.

The circuit diagram of the control panel is:

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, with a minimum section of 200 x 200 mm, heat insulated, with tubes having the interior diameter according to table 1. (Technical data). Selection of an appropriate flue enables the correct and suitable operation of the boiler. Heat insulation is recommended to avoid 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.

FLUE

CIRCUIT DIAGRAM

fig.19. 17.

Microswitch Fusible fuse

General switch

Maximum control

thermostat

Control thermostat

Safety thermostat

ver.3 28

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 the Romanian Standards 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 fuel proofness and fixation to prevent accidental detachment;

If there are two or more boilers within the same plant, each boiler shall be connected to a separate flue (each boiler with its own flue)!

1.16. Filling the system

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

•Open all valves 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 on the thermomanometer. •Close the delivery cock and air the boiler. •If necessary, resume the water feed to adjust water pressure in the installation.

• Turn on the circulation pump of the heat agent and check its operation (it will be aired).

Attention! On the feed pipe between the filling tap and the boiler it is recommended to interpose a direction valve to prevent the accidental emptying of the installation!

The water pressure of the heating installation will be checked from time to time; its re-feed shall be executed only when the boiler is turned off and cold.

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

1.16.1. Provisions for the feed water

The feed 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. Otherwise water shall be treated.

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

FILLING THE SYSTEM

THE STACK

ver.3 29

Chapter 2

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.

2.1. The first putting into service

2.1.1. Checks at 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;

- checking the existence and the correct connection of the protection against the boiler condense (4 way valve, thermostat controlled recirculation pump or the TV heat cock).

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, propeller unblocking, airing).

- verifying the tightness of the entire system. - when the boiler reached the operating temperature the system’s tightness is checked again.

2.1.2. Putting into service

When putting into service, the following operations will be carried out in the prescribed order:

- the electric control panel is fed with electric power

- the maximum control thermostat is adjusted to the desired value of the heat agent in the boiler;

we recommend operating values between 80-90 ºC. - the minimum control thermostat is adjusted to “ 0 ” position so that the fan starts and after the

fire lights up and the boiler heats up, we recommend its adjustment at 30ºC, - the fire is lighted in the boiler through the upper door by inserting paper and sufficient wood

(wood chips) on the refractory concrete plate to form an embers bed; to light up, switch the

combustion valve on “open” (push it) and the middle door will be left open for the natural combustion,

- after forming the embers bed, fill in the fuel storage with wood, close the upper door, permit the fed wood to light up and create the wood gas and then close the middle door and pull the

combustion valve to the maximum so that to drive the microswitch on the valve rod (otherwise

the fan will not start) and the motion of the fixing bolt rod is blocked;

PUTTING INTO SERVICE

ver.3 30

- by pressing the general switch, the fan will start up reversing the flame and it produces the “reverse” combustion

- verifying the draft of the stack and the temperature of the burnt gases - verifying the tightness of the boiler doors, flue-gas collector and the tightness on the route of

the burnt gases

verifying the correct operation of the thermostat -verifying the operation of the safety thermostat

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

During a correct combustion, the flame is yellowish-reddish with tips turning to blue.

Attention! During the first lighting of the fire, condense appears; yet it disappears once the boilers is heating up.

During the operation, all the doors and the combustion valve must be closed to avoid mass ignition of the woods in the fuel storage which may lead to uncontrolled combustion and overheating.

2.1.3. 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.

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.

PUTTING INTO SERVICE

ver.3 31

Chapter 3

USE AND MAINTENANCE INSTRUCTIONS

3.1. Operation of the boiler

FI –GS boiler with gasification operates on solid fuel-dried wood (1-2 years) with maximum

humidity 20%, wood waste in a percentage of 20% and wood scrap briquettes.

The normal operation of the boiler is controlled by the control panel. The temperature of the heat agent is controlled and adjusted trough the maximum control

thermostat. The work temperature of the boiler can be adjusted up to 90 °C, but the recommended value is of 80-90 °C, and the minimum return temperature is 65°C, the necessary value for limiting the low temperature corrosion of the boiler’s walls.

To obtain the return temperature, proceed according to one of the schemes described in the first chapter „Installation schemes”.

When reaching the set temperature the automation of the boiler sets the turn off of the fan. When the temperature drops below the set temperature, the maximum control thermostat restarts the fan. The safety thermostat intervenes when the temperature exceeds 95 °C, indicating the overheating and it completely turns off the boiler; the user must restart it. Restarting the boiler after the intervention of the safety thermostat can be done as it follows: - the intervention of the user and removing the cause that led to overheating - cooling the boiler below 90°C; - manual resetting of the safety thermostat.

For the resetting process, unscrew the protection cover and push the button of unblocking the thermostat on control panel.

The correctly assembled heat valve intervenes at the temperature of 97°C allowing the water to enter the cooling coil submersed in the boiler, thus cooling the boiler; when the temperature drops below this value the heat valve automatically closes.

For normal operation, permanently allow fresh air entering the room where the boiler is located.

Attention! From time to time check the water pressure in the heating installation! During the operation, all the doors and the combustion valve must be closed to avoid mass ignition of the woods in the fuel storage which may lead to uncontrolled combustion and overheating.

It is forbidden to open the doors while the boiler is operating!

3.2. Ignition

Open the upper door (the feed door), lift the smoke screen and support it on the specially

designed location so that the fuel feed is easy, insert sufficient amount of fuel (wood chips) and pieces

of paper above the combustion nozzle. Before lighting the fire, open the combustion valve by pushing the lever (18) in position 1. Fig.20.

The fuel lights up and you must open the middle door for natural combustion. Close the feed door and wait a few minutes for the burning (turned up flame) of the inserted wood

and the forming of the embers bed.

After the formation of the embers bed, fill in the wood fuel storage, close the feed door, leave the fed wood to light up and form the wood gas, then close the middle door and pull the combustion valve

(18) in position 2 (fig. 20.) and block it by means of the screw (30).

DIRECTIONS FOR USE

IGNITION

ver.3 32

The minimum control thermostat is adjusted to the position “0” for the air fan to start up and after the fire is light up and the boiler is heated up, we recommend it to be adjusted to 30ºC.

The maximum panel thermostat is adjusted to the desired value of the water in the boiler; we

recommend operation values between 80-90 ºC. By pressing the general switch the air fan that reverses the combustion shall start and causes “the

turned-up flame”. From this point on, the operation of the boiler is guided by the thermostats on the control panel.

Attention! It is highly forbidden to use inflammable liquids to light up the fire.

When feeding the boiler, do not throw woods into the boiler, please carefully place them.

3.3. Control panel Description of the operation of the control elements

1. Thermomanometer 2. minimum control thermostat (fan )

4. led general switch 5. safety thermostat

ADJUSTMENTS

In position 1: the lever rod is pushed – the combustion valve is opened and the micro switch (31) stops the fan;

In position 2: the lever rod is pulled – the combustion valve is closed, the micro switch is driven

(31) and the fan starts;

fig.20.

fig.22. 17.

fig.20.1

IGNITION

ver.3 33

3. maximum control thermostat (fan ) 6. safety fuse of 6A

Functions of the control elements:

1. thermomanometer – indicates the temperature and hydraulic pressure in the boiler; 2. minim control thermostat– used to disconnect the air fan after wood combustion of the wood

(during the combustion, the minimum control thermostat is adjusted to “ 0 ”position for the air

fan to start up and after the fire is light up and the boiler is heated up, we recommend it to be adjusted to 30ºC)

3. 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 80-90 °C.

4. safety thermostat – turns off the air fan at the over-temperature 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. general switch with led– used for the total disconnection of the electric power. 6. safety fuse 6A – for the protection of the control panel. 31. Roll micro switch – follows the driving rod of the combustion valve and it is meant to stop the fan if the combustion valve is not closed (the driving rod of the combustion valve is not pulled and blocked using the screw 30). Stops the fan in case of accidental opening of the combustion valve.

3.4. Combustion air and disconnection of the oneway valve

A centrifugal air fan assembled on the front side of the boiler provides the combustion air for the FI-GS boilers. The air admission is divided into two circuits through the distribution ramp of the air.

The air distribution ramp is located in the front side of the boiler, between the upper door and the middle door, with oneway gravitational valve that closes when the air fan stops. The air is divided into primary and secondary air.

ADJUSTMENTS

fig.21. 17.

The primary air is distributed in the upper part of the fuel storage by means of two distribution pipes. Here it mixes with the wood gas and creates the burning fuel mix, passing through the combustion nozzle. The secondary air is immediately distributed through the combustion nozzle by two circular section pipes with holes (face to face, staggered) directly supplying oxygen in the flame formation area. Reglajul aerului se face din şurubul aflat pe conducta de refulare principală a rampei de aer. Rotating the screw clockwise – rotation direction 1. fig.21.- the combustion aer flow is reduced. Rotating the screw counter clockwise – rotation direction 2. fig.21.- se the combustion aer flow is increased. The main discharge pipe of the air ramp can be dismantled by unscrewing the 4 M6 nuts; this way you cna check and unblock the one way valve.

ver.3 34

3.5. Feed and re-feed with fuel

Manually feed with fuel, use dried wood (1-2 years) with maximum humidity of 20% and wood

waste in proportion of 20% or wood scrap briquettes. For better use, we recommend to use logs piled one above the other as compactly as possible

having the length described at point 3.11.

The drier the wood is, the more the crumbling level is reduced. The maximum level of fuel filling will be normally limited by the door of the fuel storage.

At the ignition, after forming the embers bed, you can start filling in the fuel storage.

When feeding/or re-feeling the following steps are to be taken: 1. Turn off the air fan by pressing the switch on the control panel. 2. Open the combustion valve pushing the lever (18) in position 1. fig.20. and the door of the combustion chamber,

3. Wait approximately 30 seconds for the airing to take place. 4. Open the door of the fuel storage. 5. Load (complete) with fuel. 6. Close the door of the combustion chamber and the combustion valve by pulling the lever (18) in position 2 Fig. 20 that reverses the combustion in the boiler 7. The air fan is turned on driving the switch on the control panel. 8. If required, adjust the operating temperature. The fuel re-feed will be done when the wood quantity in the wood storage decreased to 15 % of the total quantity, thus a minimum quantity of smoke is released. Note: The combustion valve may block because of tar deposits. Unblock it by suddenly

pressing of the rod lever (18) of the combustion valve. Attention! Carefully control each and every time if the level of the fuel does not obstruct

the correct closing of the combustion valve.

While operating, all the doors and the combustion valve must be closed to avoid the mass ignition of the wood in the fuel storage that may lead to uncontrolled combustion and overheating. It is strictly forbidden to start up the air fan if the feed door is open.

3.6. Airing the fuel storage

Airing the boiler is mandatory and must be done before each opening of the fuel storage door, as

the volatile substances released during the process of wood combustion are inflammable and may self-ignite in sudden contact with the air, causing an explosion.

To air the fuel storage, the following steps must be taken: -open the combustion valve in order to air. -turn off the air fan from the switch on the control panel and wait about 30 sec. -carefully open the door of the fuel storage in safety conditions.

Attention! Air the boiler before opening the fuel storage door!

FEED

ver.3 35

3.7. Continuous operation The continuous operation of the boiler during wintertime is highly indicated and it is not

necessary to daily light the fire. It is possible to keep it operating, consequently continuous combustion longer than 12 hours (overnight) without other loadings using the boiler at low rate. In such circumstances, you should consider maintaining the temperature at the return of the boiler.

3.8. Summertime operation In spring and autumn, feed the system with the wood 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.

3.9. Short term interruption of the operation Stopping the boiler is done to finish the fuel combustion in the fuel storage. 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.

3.10. 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.

3.11. Requirements for the fuel

The fuel indicated for the FI-GS boilers operating on the grounds of the gasification principle are the pieces of (logs) dried wood (1-2 years) with the diameter of 200 mm and humidity of 15 – 20 %. The length of the woods depends on the capacity of the boiler as in the chart below:

Boiler model Maximum length of the

log (mm) FI 18 GS 330 FI 25GS 450 FI 30GS 500 FI 40GS 600 FI 50GS 650 FI 60GS 800 FI 80GS 900

FI 105GS 1100 FI 130 GS 1100

FI 150 GS 1250 The operation of the boiler depends on the type, sizes and humidity of the wood and the

manner of feeding. If the used fuel is not dried, the following inconveniences may appear:

- you won’t obtain quality combustion and the power of the boiler decreases - Wood consumption doubles, - Tar deposits on the heat exchange surfaces 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.

FUEL

OPERATION

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The calorific power of the most frequently used types of wood:

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

3.12. Use

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.

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

When the boiler operates at a return temperature lower than 65 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. Attention! From time to time it is recommended to check water pressure in the heating installation; its re-feed shall be done only when the boiler is stopped and cool.

USE

FUEL

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3.13. Cleaning the boiler

Attention! Before any cleaning or maintenance operation it is mandatory to disconnect the

boiler from the power source and allow it to cool down.

The process of cleaning the boiler needs to be regular, 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 it every 3-5 days. The accumulated combustion products (ash) together with condense and tar worsen the heat exchange and diminish the efficiency.

As well, large amount of ashes will reduce the combustion space and may choke the gas and air routes.

The fuel storage will be cleaned before each ignition from the combustion waste. The gasification process produces tar that deposits on the walls of the boiler. The amount of tar

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 using the cleaning instruments delivered with the boiler.

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

as well – to the lower chamber where they will subsequently cleaned out. Open the door of the burning point (the middle door) and take out the ashes using the fire iron

without damaging the refractory material. Clean the convective (smoke) ways through the lower door.

3.14. Maintenance of the boiler and of the heating system 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 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.

MAINTENANCE

fig.22.

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Twice a year clean the air distribution ramp, the air fan and the flue-gas collector of the boiler,

the latter having its own cleaning covers. (Fig.22). With the same occasion, the combustion valve will be also cleaned. The stack can be removed if the six M12 nuts are unscrewed from the back side of the boiler and, in this case, the packing cord will be changed. The packing cord will be greased with oil or plumbaginous vaseline to extend its life.

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.

In summertime, irrespective of the type of boiler, it is mandatory that the boiler-installation system is completely filled with water to avoid corrosion.

Attention! From time to time you must clean the combustion valve! 3.15. Boiler proofness

The boiler proofness is very important, especially the doors, the combustion valve and the flue-

gas collector. If leakages are found at one of these, smoke may penetrate the plant chamber, but before that, it may cause an uncontrolled combustion in the fuel storage that may lead to the system overheating. From this point of view, the packing cord must be greased every two weeks with oil or plumbaginous vaseline.

After a certain period of using, the packing

cord settles. To create new proofness, you must change the distance between the door and the body of the boiler. Changing the position of the door is achieved by adjusting the hinge as below: - the right lateral cover is removed, - the check nut is loosened 1, - the door is pulled towards the boiler in closed position - the nut 2 is screwed up and the check nut 1 is screwed up as well (Fig. 23) Repeat for each door.

fig.23

MAINTENANCE

The bolts (closing gear) on which the door handle is screwed up are also adjustable. They will be adjusted for proofness according to the door, as below: - the left lateral cover will be detached, - the check nut 1 will be loosened , - the trap screw 2 will be screwed up and then the check nut 1 will be screwed up as well (Fig. 24)

fig.24.

ver.3 39

3.16. Changing the cord packing of the door The door packing is removed by means of a screwdriver and its channel is cleaned. Temperature-

resistant silicone paste is introduced in the cord channel. The new cord is settled in the channel of the door where it will stick to the previously fixed silicone. The door is grabbed by the handle and the frame of the door is closed for the cord to settle. If necessary, the hinges and the closing device of the door will be adjusted.

3.17. Changing the combustion nozzle The combustion nozzle is made up of one or more combustion nozzles (bricks) identically

positioned in the body of the boiler on the nozzle holder (if the combustion nozzle is damaged, replace only the damaged part). The changing way of these nozzles:

- The old fire clay is pulled out or broken down - Its location is cleaned out of tar and fire clay waste - The new nozzle is placed in its position so that the holes of the secondary air ramp

communicate with the holes of the nozzle. - Seal with clay-fire powder.

The number of ceramic parts making up the combustion nozzle;

Model of the boiler Number of parts FI 18 GS 1

FI 25GS 2 FI 30GS 2

FI 40GS 3

FI 50GS 3 FI 60GS 4

FI 80GS 4

FI 105GS 5 FI 130 GS 5

FI 150 GS 6

Chapter 4

BREAKDOWN AND SOLUTION

The table below shows the main breakdowns that may appear in the operation of the boiler, as well as

the way to correct them

Breakdown Cause Remedy – solution

The control led of the switch no longer lights up

- lack of power source - the plug is not correctly connected to the electrical system - faulty switch - faulty power cable - the micro switch is not driven;

- to be verified - to be verified - to be replaced - to be replaced -pull the rod of the combustion valve.

The boiler does not reach

the adjusted temperature

- insufficient water within the

system;

- to be re-filled;

- the rotative speed of the

BREAKDOWNS SOLUTION

MAINTENANCE

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(low rated power)

- too high pump flow;

- undersized boiler; - inadequate quality of the fuel;

- the combustion valve is open;

- insufficient draft;

pump is adjusted;

- design problem; - the fuel is changed;

- to be closed;

- new or cleaned flue;

The boiler does not reach

the adjusted temperature (low rated power)

- too long ignition (operating

with the open valve); - blocked air fan;

- obstructed combustion air inlet (blocked oneway valve)

- covered combustion nozzle

- not cleaned boiler. - incorrect ignition

- to be closed;

- to be cleaned or - replaced; - to be cleaned. - to be cleaned. - to be cleaned. - see chapter “ Ignition”

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

- high hydraulic resistence in the heating system - mix heat valve is incorrectly assembled between the turn the return of the boiler

- increase pump rotative speed

- change the connection position

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

- t h e c o m b u s t i o n v a l v e remained open and the all the wood i n t he fu e l s t ora ge m a s s i v e l y l i g h t u p - too high flue draft

- wait till the fire minimizes by stopping the air fan, afterwards

close the valve and restart the

air fan; - lower the operating temperature of the control thermostat at the recommended parameters

Condense is formed in the fuel chamber and a black liquid comes out of the feed door

- the power of the boiler is higher than required - the temperature of the water in the boiler is too low - The fan does not supply enough air, dirty air ramp or jammed one way valve

insert less fuel in the fuel storage - increase the operating temperature (80-90ºC) so that the return water temperature is minimum 65ºC - clean, unblock Lack of tightness at the

doors of the boiler - leaking cord packing

- faulty cord packing; - insufficient draft.

- The doors of the boiler are adjusted and the cord is

covered with plumbaginous oil. - to be replaced

- problems related to the flue.

Smoke emission at the cleaning cover (at the boiler stack)

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

- tighten the cover - to be replaced - problems concerning the flue.

BREAKDOWNS SOLUTION LOR

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The air fan does not work

or makes noisily

- the adjustment temperature is

reached - detached from the safety

thermostat; - stuffy, dirty turbine;

- faulty condenser, engine;

- imperfect contact between the feeding cable and the engine.

- correct operation of the boiler

- manually resetting;

-to be cleaned;

- to be replaced;

- to be verified.

Chapter 5

SPARE PARTS

The boiler is designed for long-term use, without any quickly wearing parts. Replacing the parts becomes necessary to remedy the damages appearing after long-term operation or because of the inobservance of the use instructions. All the repairing or replacement operations will be executed only by the maintenance service authorized by the manufacturer. List of spare parts: - refractory ceramics parts – combustion nozzle

- air fan - general switch - thermomanometer - maximum control thermostat - minimum control thermostat - safety thermostat - micro switch from the combustion valve - door proofness cord packing - air fan condenser

SPARE PARTS

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Chapter 6

QUALITY AND WARRANTY CONDITIONS

When selling the equipment, it is handed with:

the original invoice

the technical documentation of the product

conformity declaration of the manufacturer

warranty certificate signed by the seller and by the buyer

The technical documentation and the warranty certificate shall be kept where the bought equipment is.

The buyer is liable for the choice of the equipment (type, model, size etc)

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

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

I. I. Buyer’s obligations

1. – to acknowledge and strictly observe the instructions in the present book;

- to keep the technical documentation of the product, the original invoice and the warranty certificate;

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

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

4. Both for putting into service and for the interventions, inspections or checks, the buyer will permit the acces of the service company personnel where the equipment is assembled, including to all the documentation certifying that all the legal permits for the operation authorization have been obtained.

II. Service company obligations

1. The putting into service will be made by the service company authorized by S.C. Termofarc S.R.L. and it 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

WARRANTY CONDITIONS

ver.3 43

- to check the necessary documents demanded by the law and by the manufacturer to authorize the operation of the equipments (if applicable).

- to make the necessary adjustments for the operation within the best parameters

- to turn on the equipment and to execute the heat test

- 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 protocol of putting into service or the tests report for the authorization of the putting into service.

3. The verifications made by the service operator concern only the appropriate and safe 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 “Tests report for the authorization of the putting into service”.

4. 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.

5. S.C. Termofarc S.R.L. shall be held harmless of any responsibility concerning the potential damages caused by the putting into service and use 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. Exclusion from the warranty:

The warranty covers only those faults that appear in the normal use of the product and 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 than 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-using 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.

WARRANTY CONDITIONS

ver.3 44

The warranty will cease when the user refuses to pay any financial obligations 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 described 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.

- if 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 he did not notify in due time to the service company).

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

The warranty period is of 24 months for the body of the boiler and 12 months for the ceramic components starting with their putting into service. The warranty is granted if:

The boiler is assembled with 4 way valve;

the boiler is installed with mix heat fan (TV 60ºC or TV 72ºC ) or with 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 exploitation instructions”.

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

Chapter 7

WORK PROTECTION AND FIRE FIGHTING NORMS

When assembling, putting into service, exploiting and maintaining the boiler, the following shall be taken into account: The republican work protection norms, R.E.T. norms (regulation of technical exploitation of heating central stations); Fire fighting prescriptions; ISCIR C9-2003 technical prescriptions; P 118; Norm I13-94

Obtaining these norms and prescriptions, their current versions, is incumbent upon the

beneficiary who uses and maintains the equipment;

WARRANTY CONDITIONS

ver.3 45

HOUSE TEST REPORT

NO. ____________/_____________________

ON THE GROUNDS OF THE EXECUTED TRIALS AND TESTS, WE

HEREBY CERTIFY THE FOLLOWING The boiler type FI______GS, 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 to 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 leakages being observed.

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

MANUFACTURER, Q.C. responsible

_________________ _________________

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

HOUSE TEST REPORT

ver.3 46

CONFORMITY DECLARATION

(it shall be attached here)

CONFORMITY DECLARATION

ver.3 47

ver.3 48

Technical book drafted by: Technical Manager Eng. KÖPE JÁNOS-CSABA

ver.3 49

SC TERMOFARC SRL; B-dul. Braşovului, nr.118, SĂCELE, Jud. BRAŞOV;

Tel: 0268/274945, Fax: 0268/276193

www.termofarc.ro