Forester Operating, Cleaning and Fault - Finding Procedures

Boiler Maintenance – Weekly De-ashing and Cleaning To Light the Boiler from Cold – with Auto-ignition (where fitted) Common Faults – Refer to O&M Manual for Location of Components
Use suitable personal protection (to include gloves, goggles and mask) IMPORTANT:
• Check that the boiler isolation switch on front of the control panel is set to ‘on’. Code Display Text Action
1. Even with the motorised de-ashing auger facility it is still necessary to manually clear clinker and • Check that all boiler isolation switches at numerous locations on boiler are set to ‘on’. Inspect installation and review why stop
000 Emergency Stop
ash from the combustion chamber, with the rake provided on a regular basis. The frequency of this will • Ensure biomass boiler is receiving “enable” signal from BMS panel and that boiler pumps and buffer activated. Clear issues and boiler ready
depend on each site’s operational requirements. vessel pumps are set to ‘auto’ on BMS panel. Safety Thermostat (includes activation of Review why boiler has overheated.
001
2. Activate touch screen display. • Open up panel to ensure all electrical circuit breakers are made and ensure the pneumatic air cleaning cooling coil system) Contact Hoval immediately If issue has been cleared, reset trip safety switch
3. Select ‘chimney sweep’ key, this brings up the maintenance page. switch inside the panel is set to ‘auto’. Circulation pumps not in operation Review and clear fault, reset electrical circuit
4. Select both ‘exhaust fan’ & ‘de-ashing’ keys so they turn green, select hand on right-side of screen 1. Before using the electric ignition system open the boiler door and ensure the retort is clear of 002
Contact Hoval immediately breaker in panel
so this turns green, accept the safety check box. Leave to run for 20 minutes. wood chip fuel - empty excess fuel until retort is empty. Check the electrical circuit breakers within
5. Open lower boiler door, using rake supplied; clear sides of combustion floor, reduce fire bed to level 2. Activate the touch screen display. 004 Collective alarms motors the panel to trace faulty motor. Investigate /
with retort and clear other excess ash, by drawing to front of boiler and leave on de-ash grate. If there 3. Select ‘hand symbol’ to activate manual mode screen. repair. Reset circuit breaker(s).
are any large clinker present, remove into a suitable metal container. 4. Select ‘start with ignition’, button will turn green; Select ‘hand’ symbol on right of page, button will
*BE AWARE THIS CLINKER IS VERY HOT AND CAN BURN. turn green and safety check message box will display; select ‘yes’, button turns green, then select ‘exit’. 015 Overpress combust (plc) Contact Hoval immediately
*BE AWARE THIS CLINKER IS A FIRE HAZARD IF HANDLED OR DISPOSED OF INCORRECTLY. 5. Progress bar at top of display will display ‘starting’ and progress bar will turn green. Check fuel level in the fuel store. Top up fuel
6. Close boiler door, and select ‘automatic’ key to re-start combustion and bring boiler back on line. 6. Select ‘file’ symbol, this will bring up boiler schematic which displays starting parameters. 016 Flue gas cold
level if required.
7. Monitor upper right white data box, this displays combustion chamber temperature. When this
Cleaning Boiler Heating Surfaces – Monthly De-ashing and Cleaning achieves 100°C+, fire bed ignition should have been reached. (This can be checked through lower 024 Boiler or grate door opened May still be open if cleaning has been carried out
door observation port).
027 Fuel missing Fuel delivery required
1. Even with the motorised de-ashing auger facility it is still necessary to manually clear clinker and 8. Boiler will progress through start cycle, before entering ‘normal operation’.
ash from the combustion chamber, with the rake provided on a regular basis. The frequency of this will 9. If the boiler fails to light repeat the procedure from item 1 above. 112 Limit switch cover moving floor Close cover
depend on each site’s operational requirements. 10. If the boiler fails to light after three attempts, contact Hoval for assistance.
2. Activate touch screen display. 123 Lack of fuel (hook bin or walking floor system) Plan fuel delivery
3. Select ‘chimney sweep’ key, this brings up maintenance page. To Light the Boiler from Cold – No Auto-ignition
4. Select both ‘exhaust fan’ & ‘de-ashing’ keys so they turn green, select hand on right-side of screen so
this turns green, accept the safety check box. Leave to run for 20 minutes. 1. Activate touch screen display.
Silo Filling – Rotary Arm
5. Open lower boiler door, using rake supplied; clear sides of combustion floor, reduce fire bed to level 2. Select ‘fuel feeding’ key, accept safety message. This will drive fuel into the boiler retort, and will run 1. Open fuel cell access hatch and bring fuel supply vehicle into its delivery position.
with retort and clear other excess ash, by drawing to front of boiler and leave on de-ash grate. If there for 30 seconds. 2. Do not allow the delivery to proceed.
is any large clinker present, remove into a suitable metal container. 3. Repeat this process until the fuel is approx 50mm above the top of the retort. 3. At key switch, rotate key to ‘start’ then allow to return to ‘stop’.
*BE AWARE THIS CLINKER IS VERY HOT AND CAN BURN. 4. Select ‘hand symbol’ to activate manual mode screen. Select ‘exhaust fan’, button turns from grey to 4. Rotary arm will now operate for 20 minutes.
*BE AWARE THIS CLINKER IS A FIRE HAZARD IF HANDLED OR DISPOSED OF INCORRECTLY. green, select hand on right of screen accept safety message. 5. Allow delivery.
5. Open lower boiler door, and reach into the boiler. Make a well in the wood chip fuel push in a quantity 6. Once delivery complete, close access hatch.
6. Open upper boiler door to full extent. of kindling (card-board, rolled up paper or two fire-lighters). IMPORTANT:The Rotary arm must be operating during a fuel delivery.
6. Light the kindling, allow to establish, then scoop wood chip on to the fire and again allow to establish. Silo Filling – Walking Floor Fuel System
*DURING OPENING CHECK CABLING / FLEXIBLE PIPE WORK IS NOT FOULING ON DOOR*. 7. Close lower boiler door, ensure safety locks have been made.
8. Select ‘automatic’ key to start boiler. Boiler will progress through its start cycle, before entering 1. Open fuel cell access hatch and bring fuel supply vehicle into its delivery position.
7. If fitted, remove ‘vanes’ from heating tubes and store in a safe area. ‘normal operation’. 2. Do not allow the delivery to proceed.
8. Using brush supplied, rod out heating tubes. 3. Press green ‘Fuel Dispenser’ button located on front of panel (or remotely if otherwise specified).
9. Once rodding is complete, remove loose ash from all boiler surfaces, trays and access holes. In the Event of a Fault Condition / Power Interruption 4. fuel dispenser will now operate for 20 minutes.
Use either industrial vacuum or dust pan and brush. 5. Allow the delivery to proceed.
6. Once the delivery is complete, close fuel cell access hatch and the fuel dispenser will shut down automatically.
10. Close boiler door, and select ‘automatic’ key to re-start combustion and bring boiler back on line. The following items will cause a error message to be recorded in the event protocol log.
Hook Bin Selections
1. Boiler in error – access from home page by selecting ‘warning’ triangle key.
1. Activate touch screen display.
Turning the Boiler Off 2. Refer to event log which lists an:-
2. Select ‘spec’ key.
3. Make one of the following selections:
1. With the boiler running, at control panel, activate touch screen. • Error code – i.e. ‘000’ Emergency Stop
• Fuel bin asynchronous mode – will search for a full fuel bin.
2. To switch boiler off select ‘Automatic’ key. (A safety check message box will appear – select ‘yes’) • Warning code – i.e. ‘112’ Limit Switch Cover Moving Floor
• Fuel bin 1 > fuel bin 2 – uses bin 1 first then switches to bin 2.
3. The boiler will now shutdown. The shutdown progress will be displayed in the progress bar across • Status code – i.e. ‘259’ Boiler in Operation
• Fuel bin 2> fuel bin 1 – uses bin 2 first then switches to bin 1.
the top of the touch screen display.
• Bin 1 or bin 2 – allows single bin operation.
4. The fire-bed will now burn out. 3. Please refer to pages 93 to page 131 of the Personal Touch manual to understand issues(s)
and possible solutions. Hook Bin Removal and Delivery
4. Do not run the boiler again until clearance has been received from Hoval.
1. Activate touch screen display.
2. Select ‘spec’ key.
3. Select either bin 1 or bin 2 (which ever is to be removed).
4. Un-plug electrical cables, close socket lids and stow cables securely.

July 2012
5. Fuel bin to be removed and taken away.
* Note: Please refer to boiler operating manual for further information on common faults. In addition
6. When re-filled bin is re-delivered, reconnect cables and ensure bin pushes all the way back on to frame stops.
the thermostatic valves on the boiler cooling coil and water dump may have been activated depending
7. Re-set automatic bin operation if in use, as per ‘Hook Bin Selections” above.
on the type of fault or if a power interruption has occurred.

!
Years of Great British Boilers
1887-2012 Important: This equipment should only be placed into operation
and maintained by suitably trained & authorised personnel

www.hoval.co.uk
For more information, please email [email protected]
Always ensure the incoming electrical supply to the boiler control panel is isolated before entering the panel.

Hoval Limited Northgate Newark Nottinghamshire NG24 1JN UK