BIOMASS HEATING SYSTEMSVAPOREM SERIES

STEAM BOILER

Installati on & Operati on Manual

www.woodco-energy.com V.1.0 06/16

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INDEX

INTRODUCTION 21. CARRYING AND TRANSPORT 3 1.1. SETTING BOILERS ON VEHICLE 4 1.2. TRANSPORTING BOILER ON VEHICLE 4 1.3. SETTING DOWN THE BOILER TO BOILER HOUSE 42. ASSEMBLING AND CONNECTING 4 2.1. INSTEAD OF MONTAGE THE BOILER 43. CHIMNEY CONNECTION 64. ASSEMBLING ACCESSORIES OF STEAM BOILER 65. BOILER OPERATION 116. GETTING STARTED WITH BOILER AND FIRST START UP 127. BOILING 128. CONTROL PANEL AND STARTING THE BOILER 149. OPERATING THE RUNNING BOILER 19 9.1. FLAME 19 9.2. WATER LEVEL 19 9.3. FOAM 19 9.4. FEED WATER OF BOILER 19 9.5. BLOW-DOWN 1910. SHUTTING OFF THE BOILER 1911. DISCHARGING 2012. OPERATING RULES FOR EXTRAORDINARY CONDITIONS 2013. PRECAUTIONS 2014. CLEANING AND MAINTENANCE 20 14.1. DAILY CLEANING AND MAINTENANCE 20 14.2. MONTHLY CLEANING AND MAINTENANCE 21 14.3. ANNUAL CLEANING AND MAINTENANCE 21 14.4. CLEANING AND MAINTENANCE 21 14.5. CLEANING OUT OF THE BOILER 21 14.6. CLEANING OF THE GAS SIDE 21 14.7. CLEANING WATER SIDE 2215. PROTECTION THE BOILERS 22 15.1. PROTECTING GAS SIDE OF THE BOILER 22 15.2. PROTECTING WATER SIDE OF THE BOILER 22 15.2.1. FOR SHORT PERIOD TIME 22 15.2.2. FOR ONE DAY 22 15.2.3. FOR ONE WEEK 22 15.3. MAINTENANCE OF THE EMPTY BOILER 2316. MAN HOLES MAINTENANCE 2317. FEED WATER AND THE BOILER WATER 2318. TAKING SAMPLE OF THE BOILER WATER AND ANALYSIS 2319. SERVICE 24 19.1. SERVICE STATION 2420. MANUFACTURER 24

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INTRODUCTION

Dear Customer,

Thank you for choosing WOODCO quality.

The WOODCO branded steam boilers produced with cylindrical body, are biomass fired. The product you bought has been created as a result of the precise studies by our company’s engineers in accordance with the instructions of TS 497, TS 377, TS 377 EN 12953 and 97/23/AT directives and standards.

Our steam boilers are designed and manufactured consistently to the between 0,5 – 10 bar operational pres-sures. All boilers we produce, are exposed to the test on the test pressures and durations indicated in the hydraulic test unit the standards present within our factory, and those tests as being reported. Also boiler welding areas are exposed to NDT test in accordance with the European standards and instructions.

This user guide has information for installation, operating and maintenance of the boiler.

This manual should not be relied upon exclusively for installation, starting up and operating the appliance. One must check local standards and directives for system piping, technical service and boiler operation. Customers should employ a licensed or certificated boiler operator for safe and efficient use of the boiler.

For a healthy and long life of the unit, you to read all of this manual with care before using our product, please do not operate boiler before reading all pages of manual.

Please keep the user manual in boiler room as a reference source.

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1. CARRYING AND TRANSPORT

1.1. SETTING BOILERS ON VEHICLE 1.1.1. To place the boiler on the vehicle a crane must be used. 1.1.2. The covers of the vehicle body must be opened before boiler is settled on it 1.1.3. You must use a carrying circle during lifting of the boiler with a crane. You attach the hook of crane’s boom to the boiler’s carrying circle. You must be ensure safety of hook’s pin. You shall discharge hydraulics of the boom by raising up boom of crane slowly. You shall lift up the boiler slowly but the bottom of the boiler must be higher than 30 - 40 cm from surface of the vehicle. You must avoid sudden acts that will cause shaking the boiler. You should carry the boiler as by near to the vehicle as possible. After carrying the boiler to within the vehicle, raise up the boiler 30 - 40 cm higher than the vehicle’s body level and lower the boiler on vehicle body. Take off the hook of the crane from the carrying circle of the boiler.

ATTENTION: The boiler must be carried using carrying circle in perpendicular position. When you lift up the boiler by crane, there must be no one under the boiler. The boiler can be transported with all of its accessories.

1.2. TRANSPORTING BOILER ON VEHICLE 1.2.1. When the boiler is being carried by a vehicle it must be tied with barriers which protect from slipping .The boiler should not be carried with fragile materials. After setting the boiler on the vehicle, the boiler must be covered with canvas.

1.3. SETTING DOWN THE BOILER TO BOILER HOUSE 1.3.1. Boiler shouldn’t be positioned in dwelling or working areas .It must be positioned in a special plant room ,again crane must be used .You must take into consideration topic A If it is impossible to bring crane to the boiler room ,you can land the boiler at an appro priate place than it be carried by instruments rollers on.

2. ASSEMBLING AND CONNECTING

2.1. PLACING THE BOILER IN THE PLANT ROOM 2.1.1. Fitting up steam boiler and chimney connecting must be done by qualified service personnel. Attach safety and control instruments, connections that existed prior to installation. Services such as these are made by specialist service companies. 2.1.2. The height of the boiler room must be 2 meter higher than the boiler’s height. 2.1.3. Distances of between boilers and distances of side walls from boilers has been indicated on figure 1 .There must be distance in front of the boiler at least as much as itself length 2.1.4. There must be at least two doors facing each other, one of them must have ventilation to let air to the boiler room and these doors must be 2 meter height and 0.6 m width. These doors must be divided from other places. 2.1.5. The boiler room must be ventilated. Pressure decrease can be max. 0.5 mbar in the boiler room 2.1.6. There must be an air opening in the wall and this wall must be as much as %10 floor area of the boiler room. 2.1.7. Minimum 15 cm concrete base must be in place to appropriate dimensions to place boiler in position.

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Figure 1 - Boiler Room Plan

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3. CHIMNEY CONNECTION

3.1. Boiler must be connected to the chimney by connecting parts which have the same dimensions as stack connection of the boiler. 3.2. The distance between chimney and the boiler must be less than 2,5m. if possible .If you have to use elbows, you cannot use more than two elbows . 3.3. Be careful about sharp bends because tar can be formed in the chimney by the chimney fumes. Excessively long chimney connection pipes in a horizontal section cause poor draft of chimney as a result of quick cooling . 3.4. Chimney draft is very important for the burning quality .The diameter of chimney must be in appropriate dimensions for your boiler.

4. ASSEMBLING ACCESSORIES OF STEAM BOILER

4.1. All accessories must have the specifications and quantities as indicated in norms and standards 4.2. Any failures caused by accessories provided by the customer is not at our responsibility and guarantee conditions do not apply.

TECHNICAL SIzESWOODCO MODEL 348 499 697 1395 2093 2761 3546

HEAT CAPACITY kW 348 499 697 1395 2093 2761 3546STEAM CAPACITY kg/h 525 700 1100 2100 3100 4100 5100WATER VOLUME It 835 1235 1235 2265 3545 4475 5837STEAM VOLUME It 255 321 321 639 1423 1646 2238

A mm 3671 3976 3976 4281 4586 4891 5196B mm 2662 2967 2967 3272 3577 3882 4187C mm 3361 3666 3666 3971 4276 4581 4886

�D mm 250 350 350 450 550 650 750E mm 1715 2020 2020 2325 2630 2935 3240F mm 2045 2350 2350 2655 2960 3265 3570G mm 1665 1970 1970 2275 2580 2885 3190H mm 3061 3366 3366 3671 3976 4281 4586

COUNTER PRESSURE mbar 2,6 5,1 5,1 6,1 7,1 7,6 8FUEL TYPE Wood Pellets, Wood Chip, Fruit Stones

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Figure 2 - Boiler and Chimney

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Figure 3 - Boiler and Equipment

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Figure 4 - Boiler and Equipment

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1. Boiler2. Manometer3. Pressure Switches4. Thermometer5. Vacuum Breaker6. 7. Indicators Collector8. Water Level Electrode9. Thermocouple10. Fanti ni Cosmi Level Controller11. Valve12. Water Level Indicators13. Valve14. Level Collector15. Valve16. Air Vent Valve17. Steam Exit Valve18. Safety Valves19. Valve20. Check Valves

21. Blow-down Valve22. Bott om Blow-down Valve23. Disco Check Valves24. Valve25. Pump26. Valve27. Strainer28. Thermometer29. Condensate Tank30. Water Level Indicators31. Valve32. Magneti c Float C433. Mini Water Level Electrode34. Valve35. Solenoid Valve36. Overfl ow Mouth37. Fan38. Reducer And Motor39. Gear Protect40. Silo

Pressure Switch:There must be two on the boiler .One of them is for limit pressure switch. It stops burner in case of alarm. Other one is pressure adjustment switch. If you use a two stage system ,you must use three pressure switches. The most important point for a choosing pressure switch is that adjustment pressure must be in the middle of working range.It is preferred that diff erenti al mustn’t be more than % 10 working pressure.

Manometers:There must also be two Checking manometers. It is used for pressure of boiler. Working pressure in manometers must be approximately3/4 equipment design pressure value.

Automati c Water Feed Equipment Of Boiler:When the adjusted water level reduces in the boiler this equipment provides feeding water in the boiler by using feed pumps and it provides a consistent level of water. It is the most important safety and control instrument on the boiler. It is of two types ,one of them is with a fl oat mechanism, the other one with liquid contact is preferred.In the boiler, even you choose a feed equipment with the fl oat mechanism, your limit level control equipment must also be equipped with liquid contact.

Water Level Electrode Of The Boiler:It is used for controlling the water level.

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Water Level Indicators:There are two pieces of water level indicators in the boiler. There are three types with steel body and magnetic type.

Vacuum Breaker:It is used for preventing vacuum in the boiler.

Safety Valves:It can be with a spring or with a weight. There must be two used on the boiler. One of them can be with spring,the other one can be with weight. Both of safety valves can be attached on the safety connecting mouth of the boiler. Materials can be steel or a special casting. They must be dimensioned in such a way when safety valves open no pressure increases in the boiler must occur. The safety valve must be opened to a safe place and out of the boiler via a pipe with bigger diameter. Certainly there mustn’t be any valve around the safety valve exit and inlet.Safety valve must be chosen to discharge the steam when boiler is at its maximumcapacity without increasing the maximum working pressure by 6%. Safety valve must set to 10% higher than working pressure. All valves should be CE certified.

Equipment Of The Boiler:Main steam discharge pipe dimension should the same as the exit valve dimen-sion of the boiler. There must have a check valve and a closing valve inlet of feed water to the boiler. Surface blow-down is used for regulating the salt concentra-tion of boiler.Blow-down valve is used for throwing away mud,sediment,and dirt from boiler. Blow down process can be done manually.

Control board and alarm system:There must be an electrical control board equipped with feed water system of the boiler ,a safety system and protection party alarm system of boiler,1) Maximum pressure system and alarm 2)Minimum water level and alarm3)Boiler must include furnace over heat safety and alarm

ATTENTION: Preparation of the installation depends on using steam of boiler. Any adjustments or assembling of instruments on the boiler must be done by qualified service company.

ATTENTION: Do not change the adjustments of equipment and do not allow people unauthorized operate the boiler.

5. BOILER OPERATION

5.1. Boiler operators are responsible for interfering in any urgent situation. The most important point is operators must know the principles of all equipment, property of working, pressure, temperature and flow-rates must be known by the operator. They must know all control circuit,

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measurement equipment and their function and workings of electrical protection circuit very well. 5.2. BOILER OPERATOR MUST HAVE A VALID LICENCE OR CERTIFICATE 5.3. Operating boiler without licensed or certificated operator makes the guarantee invalid. 5.4. There must be a boiler operating note book and it must be filled daily. This table must be filled daily. If the controls are not done periodically and this notebook is not filled regularly then the guarantee is not valid.

6. GETTING STARTED WITH BOILER AND FIRST START UP

6.1. All equipment of chimney draft system and burning equipment must be working correctly ,all dumpers must be fixed both opening and closing easily. 6.2. If there is automatic burning system or any other automatic controls, all settings tests, calibrations of these systems must be controlled. Tests, adjustments and function controls of electrical protection and locking system must be done and all equipment of system must be existence and in a working condition 6.3. All blow-downs, discharging valves, level indicators,feed water manual valves and control valves must be checked and must have no leakages. 6.4. If there is an automatic control of water level, all settings, tests, calibrations and inspections of functionality of this control system must be done and it must be proven to work correctly. 6.5. Be sure whether water level indicators are working or not, 6.6. If steam boiler is out of service for a long time, before starting ,all inspections must be done and all anomalies must be eliminated. 6.7. Water must be filled in the boiler in appropriate chemical condition. EN12953-10 The boiler feed water composition must be as indicated in Table 5-1 & 5-2. otherwise guarantee is not valid. 6.8. The water given to the boiler mustn’t be cold .The temperature difference of water to the boilers metal surface must not exceed 10°C. 6.9. Water feed must be stopped after filling the boiler, check whether there is any blockage in the pipes and valves and boiler must be discharged by discharging valve. 6.10. If the boiler is not connected to main steam pipe or by only one valve ,steam discharge valve must be controlled by opening and closing. This valve must not be tightened very much while supplying steam, giving consideration to expansion of same. 6.11. First Flame: when you ignite the boiler, first it must be small according to the equipment’s capacity. The smallest flame must be maintained for at least one hour without making it bigger 6.12. Water level must be kept stable by making blow-downs from time to time.( Water level will rise because of heating of the boiler water). 6.13. After obtaining homogeneous heat inside the boiler, the flame can be enlarged and the pressure of the boiler can be increased, the time for increasing the boiler pressure must be according to boilers capacity. Quick pressure rises must be avoided. 6.14. Safety valve must be controlled 6.15. Water level indicators, manholes and inspection door must be viewed occasionally and if there is leakage,it must be eliminated. When leakages occur at high pressures and temperatures do not attempt to eliminate. Wait for the boiler to cool down than take out those parts from system.

7. BOILING

7.1. Boiler must be boiled with a chemical cleaner and alkali detergent for cleaning the dirt, rust and filth on the water surface of a newly installed boiler or repaired boiler because of contacting high pressure. 7.2. You must take out the water level indicator during boiling and you must put on a temporary glass to prevent water level indicator from dirt after finishing boiling, you must put on water

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level indicator in its place. 7.3. Quanti ty and Kinds of materials used for boiling must be like this; Per tonne of boiler water 2 kg sodium carbonate 2 kg trisodium phosphate 1 kg sodium hydroxide

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7.4. During using this chemical materials, personnel must wear rubber gloves ,rubber shoes, glasses and uniform. 7.5. Water must be added to the boiler until normal level. 7.6. Chemical materials must be added in the boiler water after the chemical material dissolves. Synthetic detergent without no foam must be mixed at sufficient quantity to the these chemical materials. 7.7. The doors must be closed and it must be ignited with the smallest flame and must be boiled after the chemical material and the detergent is added to the boiler. The boiler pressure must be increased to the pressure of the system and during boiling it must be stable at the same level. After that water must be added until normal level attained and by making blow-downs as much as half of the water level indicator. A sample must be taken from the boiler water and must be analysed frequently until water becomes clean. The boiler must be discharged and must be washed by pressurized water. Dirt and,sediment must be cleaned.

8. CONTROL PANEL AND STARTING THE BOILER

8.1. In the first firing; valves within the installation must be controlled, the valves which must be in on and off position must be positioned accordingly.(main steam valve, surface blow-down and level indicator blow-down valves must be off position, condenser and water feed pomp inlet -outlet valves and air vent valve must be open position) 8.2. Control panel and Boiler electric connection must be controlled and to be sure that its done correctly. 8.3. Turn on the main switch located on the side surface of the control panel. 8.4. You have to see below picture-1 screen when panel is ready.

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1. It shows boiler temperature. 2. In the first run water level electrode gives warning “NO WATER” because boiler has no water inside. As the water level is normal green light “WATER OK” will appear. 3. In the first run Automatic Water Feed Equipment which is second safety equipment gives warning “NO WATER” cause of no water inside boiler As the water level is normal green light “BOILER WATER OK” will appear 4. The button shows the alarm list when boiler gives a warning. 5. The button is used to reset the alarm. After being pressed this button will alarm if fault is not solved. 6. Allows you to silence the alarm siren for a 3-minute period. The siren is activated again, if fault not fixed. 7. Indicates that the pump 1 is running. If the pump is deactivated in red “POM.1 NO” text will be displayed. 8. Indicates that the pump 2 is running. If the pump is deactivated in red “POM.2 NO” text will be displayed. *** in the first run only 1 pump runs. 9. This button enables the transition to boiler setting page. 10. This button enables the transition to manual controls page. 11. Button for Automatic ignition start -stop 12. In the first firing level indicators gives warning “CONDENSATE TANK EMPTY” because of no water in condensate tank. As the water level is normal green light “ CONDENSATE TANK FULL” will appear. 13. It show that the system is not working yet. When the system begins operation a display “SYSTEM START” text will appear. 14. Boiler flue temperature of safety setting value will be entered here. Once clicked upon, will open the keypad and press enter after the value set. 15. Indicates how many degrees the temperature of the flue at this point in time 16. It shows current menu page 17. It shows date 18. It shows hour

Picture - 1

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8.5. Press Boiler setting button and switch to below page (Picture - 2)

1. Indicates fuel delay time. First value is setting value, second one is the countdown after started to operate. 2. Indicates fuel feeding time. First value is setting value, second one is the countdown after started to operate 3. Indicates ignition time. First value is setting value, second one is the countdown after started to operate 4. Indicates ash removing delay time. First value is setting value, second one is the count down after started to operate 5. Indicates ash removing operate time. First value is setting value, second one is the countdown after started to operate 6. It shows fuel feeding motor running situation. When motor is run “ON” warning appears on screen 7. It shows fan running situation. when fan is running “ON” warning appears on screen 8. This screen shows the alarm warning of Boiler working under normal conditions, In case of failure display shows “ALARM RESET” warning message will appear. 9. It shows ash removing motor running situation. When it is running “ON” warning appears on screen 10. It shows Automatic ignition running situation. When it is running “ON” warning appears on screen

8.6. Enter values for following in this page then go to home page to press right bottom button. fuel feeding and delay time, automatic ignition, ash removing and delay 8.7. Go to following page (figure 3 ) to click manual control

Picture - 2

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1. Start and stop solenoid valve manually for control 2. Start and stop Pomp1 manually for control 3. Start and stop Pomp2 manually for control 4. Start and stop fan manually for control 5. Start and stop fuel feeding manually for control 6. Start and stop Ash removing manually for control 7. Before the first ignition enter fuel feeding time in this space 8. Its starts first run. 9. This button shows the alarm warning of Boiler working under normal conditions, In case of failure display shows “ALARM RESET” warning will appear.

8.8. Start and stop motors and solenoid valve manually for control 8.9. Enter fuel feeding time for first burning 8.10. Start first running. 8.11. For first run when started float measuring water level in the condensate and it will turn on valve start to fill water into tank. Then with the rise of water level mini level indicators will start pump and began to feed water into boiler, water feed will continue till level electrode to give full signal, then pump will stop and fuel feeding will start. 8.12. Go to home screen from right bottom button 8.13. After finishing water feeding check magnetic water level indicator also. 8.14. Start Ignition from home page menu to press “IGNITION START” 8.15. At the first burning run the boiler low pressure (1/3 of working pressure) and low fire 8.16. When boiler starts steam generation at the same time turn on the air vent. 8.17. If Boiler gives any failure you can see fault from “ALARM FAULT DISPLAY” screen (Picture – 4 )

Picture - 3

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1. When water is at lowest level, water level electrode gives this fault and it stops fan and fuel feeding motor, pumps continue to run. 2. When water is low level, Automatic Water Feed Equipment (2nd water level safety) gives this fault and pumps continue to run in this alarm 3. Thanks to the mini level electrodes inside the condenser this text indicates condensate water level is low. 4. One of probe stat set by working pressure and connected to PLC, The other probe stat alarm. it stops the system automatically and gives fault to PLC 5. Indicates Pump 1 thermal failure. 6. Phase failure 7. When water is at highest level, water level electrode gives this fault. and it stops fan and fuel feeding motor, 8. Indicates fan thermal failure. 9. Indicates ash removing thermal failure. 10. Indicates fuel feeding motor thermal failure. 11. Indicates Pomp 2 thermal failure. 12. This failure indicates flue temperature higher that set value. It stops fan and fuel feeding motor. 13. Indicates thermocouple fault which is measuring temperature. It stops fan and fuel feeding motor.

8.18. After the boiler produces steam, you must do a blow-down by opening blow-down valve at the back of the boiler. 8.19. Surface blow-down must be done by using surface blow-down 8.20. Some water must be discharged by valves under the level indicators. 8.21. Steam must be discharged by raising slightly the handle of safety valves. 8.22. This process must be done at least twice a day and must be recorded The blow-down quantity may vary according to boiler capacity. 8.23. If there is another boiler that gives steam to the steam system, while the Boiler is joining in the circuit by reaching pressure of system,the steam in the boiler must be prevented from contacting the steam in the circuit and all condensate pipes of the boiler. 8.24. If there is no other boiler that gives steam to the steam system, the system must be heated by external system pressure and must be raised with the boiler pressure

Picture - 4

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8.25. If there is an steam exit valve on the boiler this valve must be opened slowly with highest attention. 8.26. IF THE WATER LEVEL IS LOW, THE BOILER MUST NOT BE OPERATED. 8.27. IF THE BOILER OR ANY EQUIPMENT IS FROZEN NEVER FIRE OR RESTART THE BOILER BEFORE HAVING THE AUTHORIZED ASSOCIATION MAKE THE NECESSARY CHECK. NEVER MELT THE BOILER BY FIRING IT. THE BOILER COULD EXPLODE. 8.28. IF THERE IS NOT SUFFICIENT WATER IN THE BOILER NEVER FEED THE HOT BOILER WITH WATER. IF YOU DO SO BOILER COULD EXPLODE

9. OPERATING THE RUNNING BOILER

9.1. FLAME 9.1.1. When the boiler is being carried by vehicle it must be tied with barriers which protect it from slipping .The boiler should not be carried with fragile materials. After setting the boiler on the vehicle, boiler must be covered with canvas. 9.2. WATER LEVEL 9.2.1. Water level must be maintained at required level during the operation of the boiler. Water level can be controlled automatically. 9.2.2. However, water level must be controlled by the boiler operator because automatic equipment can be broken. 9.2.3. Water level equipment must be cleaned at least once per month in order to work efficiently. Also level electrodes must be kept clean. 9.3. FOAM 9.3.1. Water level must be reduced to normal level by discharging steam when the foam formation happens until foam finishes. You must feed the boiler with water and you must make blow-downs as necessary. 9.3.2. If you can’t prevent foam, you must stop the boiler and you must search for the reasons. 9.4. FEED WATER OF BOILER 9.4.1. Feed water of the boiler must be reviewed for chemicals. Water of the boiler must be analysed continuously to prevent unexpected chemical condition. 9.4.2. The temperature of feed water and outlet pressure of pump must be supplied at required level. 9.4.3. The pipes of feed water of the boiler and feed pumps must be controlled all the time . 9.5. BLOW DOWN 9.5.1. Bottom blow-down must be done at least once in an 8 hour operation (may vary according to conditions) by opening the valve for 4 secs. Blow-down must be done when the steam consumption is low. Blown down system must be checked periodically for leakages. Blow-downs must be recorded 9.5.2. Surface blow-down (TDS control) can be done by opening the valve continuously or can be done by calculation. Level indicators and controllers must be blow-down at least once a day.

10. SHUTTING OFF THE BOILER

10.1. While discharging, the steam is reduced, feed water must be reduced and flame must be lowered. 10.2. After the flame is extinguished, closing valve must be closed tightly. 10.3. If the water level is normal, feed water pump must be stopped and feed water inlet valve must be closed . 10.4. If the water level is too high than the normal level, Water must be discharged by blow-down. Afterwards the boiler must be cooled. 10.5. You should avoid fast cooling to prevent temperature differentiation in the boiler

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11. DISCHARGING

11.1. The pressure reducing is observed while the boiler is cooling. 11.2. The boiler can be discharged after water temperature becomes under 90° temperature and pressure finishes. 11.3. However,it is very dangerous to discharge the boiler when the boiler isn’t cool enough. 11.4. Blow-down valves must be closed tightly after the boiler discharges fully. And warning signs must be attached on the boiler. Indicating to open the blow-down valves.

12. OPERATING RULES FOR EXTRAORDINARY CONDITIONS

12.1. Whatever the reason is,If the water level reduces under the water level indicators,the boiler must be stopped(If it’s working with solid fuel,fuels must be discharged)and steam dis charging must be closed. 12.2. After words,the reasons caused to reduce water level,must be investigated. 12.3. You must ignite again after burner is ventilated.

13. PRECAUTIONS

13.1. Do not fire the boiler when it has insufficient water. 13.2. Do not put your hands or your head in during the boiler is burning and don’t go in it during the boiler is burning. 13.3. Do not close chimney damper fully. 13.4. Bad chimney draft is harmful for human health and also bad chimney draft reduce the boiler efficiency. 13.5. Chimneys must be clean and well-kept for good burning. Before firing the boiler you should control the draft of chimney. 13.6. Be careful of chimney and connections against chimney’s leakage. 13.7. Cleaning door on the chimney connection must be closed during burning. 13.8. The doors fume box and chimney cleaning door should not be opened. 13.9. You must monitor the boiler during burning frequently. 13.10. Do not cook any food in the boiler. 13.11. Explosion door behind the boiler should able to be accessed easily. Do not put anything in front of the door .Don’t play with explosion door. 13.12. Do not use fuel with high sulphur content and don’t use materials in the boiler that threatens people’s health. 13.13. If you use the boiler with solid fuel, don’t fire the boiler with gasoline, ethyl alcohol, spirit petrol, kerosene. And Don’t put these materials around the boiler. 13.14. Don’t put explosive materials in the boiler 13.15. Don’t burn coke coal in the boiler. 13.16. Please contact the qualified service company when you encounter extraordinary conditions.

14. CLEANING AND MAINTENANCE

14.1. DAILY CLEANING AND MAINTENANCE 14.1.1. You should discharge air (vacuum) of the water level indicator. 14.1.2. You should control and clean water level controller of the boiler. 14.1.3. You should make blow-down a few times in a day. 14.1.4. You should control the UV flame indicator. 14.1.5. You should control the quantity of water in de-aerator and feed water storage tank. 14.1.6. All leaking flanges and connections in the water steam and fuel lines and on the boiler should be tightened and leakages must be fixed. 14.1.7. You should control safety valve whether is opening easily or not. 14.1.8. In the boilers with solid fuels, you should discharge the ashes everyday.

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14.2. MONTHLY CLEANING AND MAINTENANCE 14.2.1. You should control safety valve 14.2.2. Water level indicator switch and minimum water level switch must be controlled at least in a month by reducing water level to minimum level slowly. 14.2.3. The boiler and all systems of the boiler, pipe connections, flanges, pot-holder, leakages of valves and other failures must be controlled very carefully. If there is a problem, you must note it. 14.2.4. You should tighten all flanges and connection and prevent leakages, if it is necessary, you can charge with new. 14.2.5. Power switch and switch system must be controlled by an electric technician. 14.2.6. Open the door of front fume box and clean fume pipes by brush 3-4 times in a month 14.2.7. Clean front and back boxes and chimney connecting line from soot. 14.3. ANNUAL CLEANING AND MAINTENANCE 14.3.1. Discharge the boiler completely. Open all the man holes. Clean inside of the boiler. You can wash it with pressurized water. Clean the lime in the boiler. Afterwards you may wash the boiler. 14.3.2. You should review monthly maintenance. All bearings should be lubricated. Feed water pump and fuel motors and should be revised. Man hales should be closed and you should put new gasket. The boiler should be filled with water. 14.3.3. You should clean the chimney at least once in a year. 14.4. CLEANING AND MAINTENANCE 14.4.1. The perfect reference for the boiler worker is a clear and well-kept boiler room. 14.4.2. To supply high efficiency and to supply continuity depends on the boiler operator. 14.4.3. Expenses of cleaning and maintenance are not expensive relative to the cost of the machines. 14.4.4. If you clean as advised the boiler will have very long-life, fuel economy and payback will be in a shorter time. 14.4.5. All equipment that does not belong to the boiler room must be removed from the boiler room by person in charge. 14.4.6. It is very important to maintain the boiler room without non relevant items. 14.4.7. There should be clean water connections and dirt water connections in the boiler room. 14.4.8. There shouldn’t be any difficulty for cleaning the boiler room with water. 14.4.9. The boiler room must be one of the most best kept places in the company. 14.5. CLEANING OUT OF THE BOILER 14.5.1. As with all other technological equipment, a 3pass wet back scotch type boiler has to give very clean and good effect to people. 14.5.2. If the control equipment, bushings, flanges have no leakages there won’t be any water and steam leaks anywhere at the boiler. So there won’t be any salt and dirt in the boiler. 14.5.3. It is very important to squeeze all man holes and all flanges after two months. If you don’t squeeze all man holes and all flanges otherwise it will be impossible to avoid leakages. 14.6. CLEANING OF THE GAS SIDE 14.6.1. Opening fumes box’s doors and connections of burner is supplied to determine and solve dirt that has accumulated in the boiler. 14.6.2. If soot layer is less than 0,5mm,you don’t need to clean it. 14.6.3. Soot or dirt layer must be cleaned with special boiler pipe brush. 14.6.4. Thick soot layer cause to drop efficiency of the boiler. 14.6.5. Hard layers can be seen on the wet heat surface by components of soot and sulphur in the boiler that is worked very often in cold condition. 14.6.6. These layers are dangerous for the boiler’s materials. 14.6.7. It must be cleaned in a very short time. It is not enough to clean with normal fume pipes’ brush 14.6.8. A special cleaning machine with electric motor and special moving heads are used for cleaning.

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14.6.9. Before closing front doors again, MOLYKOTE must be applied on bolt and nuts. 14.7. CLEANING WATER SIDE 14.7.1. Man holes must be used to determine sediments on the water side. 14.7.2. The lime layer which is nearly 1mm on the water side of the boiler, not only drops the efficiency but also causes excess heat ng of materials. 14.7.3. Practically, If you feed right feed water to the boiler, lime formation on the heating surface will not occur. 14.7.4. In this case, the boiler must be cleaned with pressured water, If there is still lime in the boiler .You must clean with chemical cleaner. 14.7.5. water must always be controlled whether it includes oil or not. You have to be careful about oil existing on the heating surface of the boiler.

15. PROTECTION THE BOILERS 15.1. PROTECTING GAS SIDE OF THE BOILER 15.1.1. If the boiler won’t be used for a long time,you should make the following processes 15.1.2. To protect it from rust and corrosion; 15.1.3. Furnace; fumes pipes and fume gas side of mirror plates must be cleaned at the boiler temperature approx 40°. 15.1.4. All surfaces of gas side of the boiler are cleaned with oil to prevent it to get in ouch with air. 15.1.5. The air must be dried by putting air drier chemicals in the boiler. 15.2. PROTECTING WATER SIDE OF THE BOILER 15.2.1. FOR SHORT PERIOD OF TIME 15.2.1.1. When the boiler is out of service, the boiler has more rust and corrosion than when the boiler is in service. 15.2.1.2. If there is water with a little alkali and the water in the boiler will rust and corrosion will occur in the boiler. 15.2.1.3. If you don’t take enough precautions for the boiler, even if you discharge all water from the boiler, corrosion will be seen. 15.2.1.4. The boiler with no water can prevent from corrosion. 15.2.2. FOR ONE DAY 15.2.2.1. You must close all the steam and the water valves on the boiler. 15.2.2.2. Before stopping the boiler, 15.2.2.3. You must mix high quantity sodium carbonate and sodium sulphide to the boiler water for oxygen compound. 15.2.3. FOR ONE WEEK 15.2.3.1. The quantity of phosphate of the boiler water is raised by mixing 600 gr trisodium phosphate per m³. 15.2.3.2. Safety precautions are taken by also mixing 700 gr hydrazine and 150 or 250 gr sodium sulphide to the boiler water to prevent rust and corrosions in the boiler. 15.2.3.3. Safety valve is adjusted as 0,2 kg/cm² to discharge out the rest of the oxygen. And water is filled to the boiler until water pass over the safety valve. 15.2.3.4. After the boiler is cool, water is filled and chemical materials are added and all valves are closed very tightly. 15.2.3.5. The temperature of the boiler room must not be dropped under +4°to prevent freezing. 15.2.3.6. The water of the boiler have to be discharged portly with blow-down in order to operate the boiler again. 15.2.3.7. After the boiler must be filled again with normal feed water until water level.

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15.3. MAINTENANCE OF THE EMPTY BOILER 15.3.1. If you don’t use the boiler very long time you should keep it free of water. 15.3.2. All water in the boiler is discharged when the boiler is at the low pressure and hot by blow-down valve. 15.3.3. After you discharge the boiler, you open safety valve in order to discharge steam. 15.3.4. All man holes are opened and controlled whether inside of the boiler is dry or not. 15.3.5. If it is wet, you should dry inside the boiler. 15.3.6. The pots have diminished lime and chlorine are put in the boiler. You have to change these pots every three months. 15.3.7. To eliminate the rest of oxygen in the boiler,a burning pot with oil-lamp and fire wood is set in the boiler. 15.3.8. After words,all manholes and valves have to be closed. 15.3.9. All holes, flanges, all valves must be very tight to have no leakage. And all of them have to be controlled.

16. MAN HOLES MAINTENANCE

16.1. The doors of the man holes are placed with no cavity. 16.2. Before you place the gaskets, the gasket’s sockets must be cleaned and the gaskets must be pull in the sockets. 16.3. The space between gaskets and their sockets must be equally placed 16.4. Gaskets of the doors are tightened equally and gradually. 16.5. Be careful about gaskets quality and please use gaskets with graphic rubber 16.6. Dimensions of gaskets should be chosen according to the dimensions of holes.

17. FEED WATER AND THE BOILER WATER

17.1. It is essential to eliminate risks at the water steam lines and at the boiler while working with feed water and boiler water. 17.2. These risks are as follow; 17.3. The heating surface of the boiler could be calcified because of hardness of water 17.4. It cause difficulties in heat transfer, drop efficiency, heat dissipation, even at the end of this process; the boiler can be come scrap. 17.5. Oil and organic materials cause to stone heat by making thin layers on the heat surface of the boiler. 17.6. The most dangerous thing is mixing oil in the boiler feed water. 17.7. Free oxygen and free carbon dioxide in the feed water and the boiler water are weaken the materials of the boiler and make corrosion. 17.8. Mostly quantity of the boiler water activate evaporation is dry and calm in normally. 17.9. It causes to pollute pipe system, requirements, turbine and it causes to squeeze the equipments and make narrow cross-sections. 17.10. If there are high quantity of organic components in the water, the water foams and evaporation is getting information.

18. TAKING SAMPLE OF THE BOILER WATER AND ANALYSIS

18.1. There is no standard water feed system, 18.2. Pure water is used for generating steam, its properties change from company to company. 18.3. The date of taking sample and quantity of sample must be corned. 18.4. It is enough to take sample only one time from places where water components change very fast. 18.5. The sample must be taken just after blow-down and the sample must be analysed under the pressure by cooling

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18.6. The sample pot must be clean. The sample pot must be shaken with the same sample before putti ng sample in. 18.7. You must close the opening of the sample pot. 18.8. You have to draw up a daily report about analysis and have to keep it. 18.9. At least 2 litres of water must be carried in the clean pot or glass bott le. 18.10. The following analysis are useful for the boiler water 1. Colour and appearance 10. Sulphate 2. Smell 11. Palkalinate 3. Nitrite 12. Malkalinate 4. Ammonia 13. Free chlorine 5. Hardness 14. Magnesium 6. pH 15. Chlorine 7. Sediment 16. Ferro 8. Conducti vity 17. Silica 9. Organic materials 18. Calcium 18.11. Pure water must be clear and purifi ed from mechanical dirts. 18.12. The total quanti ty of manganese shouldn’t pass over 0,05 mg/kg in the water. 18.13. And the total quanti ty of ferro shouldn’t pass over 0,2 mg/kg in the water. We need them to determine the supplying capacity of the water soft ener. 18.14. You can use fi lter and manganese saving equipment and ferro saving equipments. 18.15. IT IS CUSTOMERS RESPONSIBILITY TO PROVIDE SUITABLE WATER 18.16. CONDITIONS. OTHERWISE OUR GUARANTEE IS NO LONGER VALID 18.17. CHECK EN 12953-10 FOR DETAİLED İNFORMATİON OF BOİLER WATER.

YOU CAN BE SURE THAT THE YOUR BOILER WILL HAVE LONG LIFE IF YOU USE THE BOILER WITHIN RULES IN THE USER GUIDE

19. SERVICE

19.1. SERVICE STATION WOODCO ENERGY Address: Unit D Cahir Business Park, Cahir, Co. Tipperary, Ireland. Tel: +353 52 744533 info@woodco-energy.com

20. MANUFACTURER

WOODCO ENERGY Address: Unit D Cahir Business Park, Cahir, Co. Tipperary, Ireland. Tel: +353 52 7445330

M A N U F A C T U R E R S O F R E N E W A B L E H E A T I N G P R O D U C T S

WoodCo Energy I re landUnit D Cahir Bus iness Park, Cahir, Co. T ipperary, I re land.

t : +353 52 7445330

w: www.woodco-energy.com e: info@woodco-energy.com

Head Off ice: WoodCo Energy SA, Rte de Courgenay 38, 2900 Porrentruy, Switzer land.

t : +41 324668008