Remeha Avanta Plus HPKI_K Maintenance and Cleaning Instructions

MAINTENANCE Ash container
Maintenance
Ash removal
Placement
On the boiler´s side
Procedure
Check up the ash content in the container, empty it when
necessary.
Maitenance period
When necessaryd
Pos.
MAINTENANCE-01
MAINTENANCE Igniter
Maintenance
Igniter
Placement
On the side of heating boiler
procedure
Unscrew the ignition tube and clean it
Maintenance period
Half a year
Pos.
MAINTENANCE-02
CLEANING Multicyclone
Maintenance
Multicyclone
Placement
Maintenance cover on the side of heating boiler
Procedure
Open the cover plate and clean the multicyclone using
industrial vacuum cleaner
Maintenance period
Quarterly
Pos.
MAINTENANCE-03
MAINTENANCE Ash removal from rost
Maintenance
Ash removal from rost
Placement
On the heating boiler´s back side, near the stocker
Procedure
Open the cover plates, or door and remove the ash from
the rost.
Maintenance period
Quarterly
Pos.
MAINTENANCE-04
MAINTENANCE Cleaning of the
combustion chamber
Maintenance
Combustion chamber UTSK- under stocker
Placement
‚Front side of the heating boiler
Procedure
1. Cleaning of retort and combustion chamber
2. Cleaning of the surface over the fire bricks
Maintenance period
Quarterly
Pos.
MAINTENANCE-05a
MAINTENANCE Cleaning of
combustion chamber
Maintenance
Combustion chamber UTSK- step grate
Placement
‚Front side of the heating boiler
Procedure
3. Cleaning of the combustion surface
4. Cleaning of the surface over the fire bricks
Maintenance period
Quarterly
Pos.
MAINTENANCE-05c
MAINTENANCE Cleaning of burning
grate
Maintenance
Burning grate UTSK- understocker
Placement
Front side of the heating boiler
Procedure
1. Remove the ash from the combustion space
2. Cleaning of the burning grate
Maintenance period
Quarterly
Pos.
MAINTENANCE-06a
MAINTENANCE Cleaning of burning
grate
Maintenance
Burning grate UTSK-Step grate
Placement
Front side of the heating boiler
Procedure
3. Remove the ash from beneath of the step grate
4. Clean the gragesurface and the buring space
Maintenance period
Quarterly
Pos.
MAINTENANCE-06c
MAINTENANCE Cleaing of heat
exchanger
Maintenance
Heat exchanger
Placement
Front side of the heating boiler
Procedure
Clean the heat exchanger using the delivered brush.
Maintenance period
Quarterly
Pos.
MAINTENANCE-07
MAINTENANCE Cleaning of suction
blowers
Maintenance
Suction blower
Placement
Back side of the heating boiler
Procedure
Clean the suction blower from ash using an industrial
vacuum cleaner.
Pay attention to the flue gas sensor, also when cleaning
the flue gas pipe.
Maintenance period
Quarterly
Pos.
MAINTENANCE-08
MAINTENANCE Cleaning of flue gas
tube
Maintenance
Flue gas tube and chimney
Placement
Down the suction blower
Procedure
1. Clean and exhaust the flue gas tube
2. Clean the chimney
Maintenance period
Quraterly
Pos.
MAINTENANCE-09
CLEANING Compressor
Maintenance
Compressor
Placement
In the heating room near the switch box
Procedure
Empty the condensed water vessel on the compressor
Maitenance period
Half a year
Pos.
CLEANING-02
CLEANING
Maintenance
Cleaning
Place
Heating room
Procedure
Cleaning of all motors and blowers
Maintenance period
Half a year
Pos.
CLEANING-03
CLEANING Hydraulic aggregate
Maintenance
Hydraulic aggregate
Placement
In the heating room near the heating boiler
Procedure
1.
2.
3.
4.
Check
Check
Check
Check
up
up
up
up
the
the
the
the
oil level
equipment pressure
operational temperature
sealing of cylinder and hoses
Maintenance period
Once a month
Pos.
CLEANING-05
LUBRICATION Silo discharge
Maintenance
Replacement of gear smear in the silo discharging system
Emptying of silo is necessary
When working in silo, observe the safety rules for works
in silo room
The permission for works is imperatively required.
Placement
Beneath the tapered part of silo room
Grease substance
Smear for gears
Amount of grease substance
See the Operation instruction to discharge systems
Maintenance period
Every 2 years
Pos.
SILO-01
LUBRICATIONCross feed worm screw
Maitenance
Lubrication of the flange bearings of cross feed worm
screw
Placement
Behind the gear motor( on the motor side)
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Maintenance period
Quarterly
Pos.
PUSH R-01
LUBRICATION Cross feed worm screw
Maitenance
Lubrication of the flange bearings of cross feed worm screw
Placement
Vis a vis the driving side
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Maintenance period
Quarterly
Pos.
PUSH-02
MAINTENANCE Hydraulic push rods
Maintenance hydraulic aggregate
5. Check up of the oil level
6. Check up of the device pressure
7. Check up fo the operational temperature
Place
Hydraulic room
Maintenance period
Once a month
Pos.
PUSH-03
MAITENANCE
Hydraulic push rods
Maintenance of hydraulic aggregate
Check up of the cylinder and hoses tightness
Placement
Hydraulic space
Maitenance period
Once a month
Pos.
PUSH-04
LUBRICATION PLAN conveyor
view from above
side view
Maintenance
Lubrication of the worm screw flange bearing on the side
of motor
Placement
Behind the gear motor
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased point
Maintenance period
Quarterly
Pos.
WORM SCREW-01
LUBRICATION
Ash worm conveyor
Multicyclone
Maintenance
Lubrication of bearings on the ash worm conveyor on
multicyclone
Placement
Vis a vis the driving side
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Maintenance period
Quarterly
Pos.
LUBRIC-01
LUBRICATION
Ash conveying rising worm screw
Maintenance
Lubrication of rising worm screw bearing
Maintenance
Lubrication of bearing on the ash worm conveyor on
multicyclone
Placement
Vis a vis the driving side
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Pos.
LUBRIC-02
LUBRICATION Grate ash removal
Maintenance
Lubrication of bearing on worm screw removing ash from
grate
Maintenance
Lubrication of bearing on the ash worm conveyor on
multicyclone
Placement
Vis a vis the driving side
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Pos.
LUBRIC-03
LUBRICATION Suction blowers
Maintenance
Lubrication of the bearing between the suction casing and
the motor for suction blowers.
Place
On the suction blowers placed on the backside of boiler
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Maintenance period
Quarterly
Pos.
LUBRIC-04
CLEANING
Cleaning of heat exchanger
Maitenance
Cleaning of heat exchanger
Placement
Front side od heat exchanger
Procedure
Remvoe the condensed water by pressure vessel of heat
exchanger
Maitenance period
Half a year
Pos.
CLEANING-01
CLEANING Compressor
Maintenance
Compressor
Placement
In the heating room near the switch box
Procedure
Empty the condensed water vessel on the compressor
Maitenance period
Half a year
Pos.
CLEANING-02
CLEANING
Maintenance
Cleaning
Place
Heating room
Procedure
Cleaning of all motors and blowers
Maintenance period
Half a year
Pos.
CLEANING-03
CLEANING Underpressure tube
Maintenance
Cleaning of the underpressure tube
Placement
Underpressure switch
Procedure
Pull the hose from the underpressure switch connector
and clean it by suction – WARNING – do not blow through
it – you could damage the undepressure switch connector,
Or
pull out the hose from the underpressure switch connector
and measuring unit in switch box and flush the hose.
Maintenance period
Half a year
Pos.
CLEANING -04
CLEANING Hydraulic aggregate
Maintenance
Hydraulic aggregate
Placement
In the heating room near the heating boiler
Procedure
8.
9.
10.
11.
Check
Check
Check
Check
up
up
up
up
the
the
the
the
oil level
equipment pressure
operational temperature
sealing of cylinder and hoses
Maintenance period
Once a month
Pos.
CLEANING-05
LUBRICATION Elbow discharge
Maitenance
Lubrication of the flange bearings of elbow discharging
worm screw
Placement
Behind the gear motor
Grease substance
Roller bearings grease K2K-20-DIN 51502
Drop point 160°C/132°F at least
Amount of grease substance
1-2 pump strokes for each greased place
Maintenance period
Quarterly
Pos.
ELBOW-01
LUBRICATION Elbow discharge
Maintenance
Replacement of the gear oil in the elbow discharge system
Emptying of silo is necessary
When working in silo, observe the safety rules for works in
silo room
The permission for works is imperatively required
Placement
Beneath the discharge plate in silo room
Grease subsatnce
‚Gear oil
Amount of grease substance
See the Operation instruction to gears
Maintenance period
Every 5 years
Pos.
ELBOW-02
Notices:
Gear motors – Oil replacement, periods, inbuilt parts, filling quantities, venting screws, filling openings, oil condition
considering.....
Sensor cleaning
Combustion temperature sensor – take of carefully, wipe, install again carefully ....
Examine fire extinguishers according the rule TRVB 118
Notice on maintenance contract
Notice on protective clothing during cleaning works
Notice on manipulation and disposal of used oil, detergents
Control – battery replacement - required?
GREASE-04
Grease for higher temperatures
Hydraulics
Replacement of hydraulic oil
MAINTENANCE AND LUBRICATIONS PLAN
Maintenance
You have bought Gilles heating facility – that means, you have obtained solid equipment, requiring minimum
maintenance. Nevertheless, you should pay attention to the following instructions on maintenance, in order to assure a
long operational life of your equipment.
Attention
An imperative requirement: Before starting cleaning and lubricating the equipment, its operation must be stopped and
the main current supply switched off and assured against an unintentional or unwitting switching on.
Only trained and authorised skilled personal is competent to carry out maintenance works.
Regular and sound maintenances and operation are the best presuppositions of high efficiency and reliability of the
equipment.
Only original spare parts used for replacement assure a due performance of the complete facility and assure a claim for
guarantee.
Namely in case of works in silo, there is highly important to observe duly all the operation instructions and safety rules,
as the works in silo are considered as „dangerous works“, imperatively requiring permission for these works.
Grease lubrication
Places not adequately protected against penetration of water and dirty particles must be greased, because the grease
substance functions as sealing substance. In addition, the greases can better damp stroke impacts on bearings.
The bearings are filled with grease upon the installation, so they are prepared for operation.
The used grease should be suitable for the temperature range from -30 °C to + 90 °C.
Use the pressure oiler for greasing.
The storage temperature may be 50 °C over the room temperature at maximum and must not exceed 90 °C.
Check up it once a week at least.
Quality of grease
Roller bearing grease K2K-20-DIN 51502 – drop point 160°C/132°F at least.
Quantity of grease
The conveying parts are equipped with various driving devices and bearings depending on their dimensions and fuel
quantities delivered, therefore the specified quantities and stroke specifications are only informative.
Lubricated places
The remarked lubricated places must be lubricated ca. once a month (every 200 operation hours). Use pressure oilers for
greasing substances (1 – 2 pump strokes for each lubricated point’).
Lubrication greases
Type of lubrication grease:
K, G, OG, M
• Data for field of use
Consistency class
NLGI
Lower temperature
of field of use
(for synthetic oil additional letters
according to oil type: HC,E,PG,S)
Additional letter
marks:
Additional letter
marks:
C to U
• Data for upper
D,E.F,L,M,S,P,V
• Data for usage possibililies
1
Type of grease
Greases for roller bearings,
sliding bearings and
surfaces according DIN
51825
Greases for closed gears
according DIN 51826
Greases for open gears,
toothings (adhesive
greasing materials without
bitumen)
Greases for sliding
bearings and sealings2)
Greases on the synthetic
basis upon their basic
properties are marked as
greases on the mineral oil
basis.
temperature of field of use
2
Letter marks
3
Symbol
K1)
For greases
on the mineral oil basis
G
OG
M
For greases on the
synthetic oil basis
Insert the marking letter
acc. Table 1,
substance kind 3
1) In ISO/TR 3498:1986 the letters „XM “ are used instead of „K“.
2) Minor requirements than on greases of type.
1
Additional letter marks
2
Greasing substances
For greasing oils with detergent addition agents
D
e.g. hydraulic oil HLPD
For greasing oil used as mixture with water
e.g. cooling lubricants that may be mixed with water –
E
e.g. cooling lubricant SE
Greasing material added by solid greasing substances
(e.g. graphite, molybdenum disulphide), e.g. greasing
F
oil CLPPF
For greasing substances containing addition agents
increasing the corrosion resistance of material, and/or
L
extending its service life e.g. greasing oil DIN 51217 –
CL 100
For cooling water mixed lubricants containing mineral
M
oils, e.g. cooling greasing substance SEM
For cooling water mixed lubricants on the synthetic
S
basis, e.g. cooling greasing substance SES
For greasing substances that contain agents
eliminating frictions or abrasions or increasing the
P
endurance resistance of materials, e.g. greasing oil
CLP 100
For greasing substances reduced by diluents
1)
V
Greasing oil DIN 51315 – BB-V
Marking letter V shall be added by an abbreviation indicating dangerous materials (in
accordance with ordinance on dangerous materials)
1
Consistency mark (NLGIclasses acc. DIN 51813
2
Fulling penetration specified
according units DIN ISO 21371)
000
00
0
1
2
3
4
5
6
445 to 475
400 to 430
355 to 385
310 to 340
265 to 295
220 to 250
175 to 205
130 to 160
85 to 115 2)
1) 1 unit = 0,1 mm / 2) resting penetration
1
Additional letter marks
2
3
Action against water
acc. DIN 51807 Part
1: Evaluation steps
DIN 51807 2)
0-40 or 1-40
Upper temperature
used 1)
C
D
E
F
G
H
K
M
N
P
R
S
T
U
+ 60 °C
2-40 or 3-40
0-40 or 1-40
+ 80 °C
2-40 or 3-40
0-90 or 1-90
+ 100 °C
2-90 or 3-90
0-90 or 1-90
+ 120 °C
2-90 or 3-90
+ 140 °C
+ 160 °C
+ 180 °C
according agreement
+ 200 °C
+ 220 °C
over + 220 °C
1) The „upper temperature used“ for permanent greasing is identical with
the highest testing temperature used for tests according to DIN 51806
Part 2 (at present the Draft) and/or according to DIN 51821, Part 2. if the
test procedures are performed:
2) 0 means no change
1 means minor change
2 means mean change
3 means great change
1
Additional number marks
- 10
- 20
- 30
- 40
- 50
- 60
2
Lower temperature used
- 10
- 20
- 30
- 40
- 50
- 60
Additional marks for synthetic oils
E
EF
HC
PH
PG
SI
X
Organic esters
Perfluorine - fluids
Synthetic hydrocarbons
Esters of phosphoric acid
Polyglycol oils
Silicone oils
Others
Care
Use a soft, wet cloth for removing impurities from boiler, facings and operational parts. For damping the cloth, use only
soft cleaning agents in order to prevent surface scrapping.
Do not use diluents, alcohol or cleaning spirit in any case.
Operation and maitenance logbook
Date
Time
Operation
hours
<60%
>60%
Output
Course
Combustion
%
T°C
T°C
Flue
gas
T°C
Cleaning
By
oneself
Chimney
sweeper
Remarks
Silo
filling
(m3)
In – out
operation
defect/mainten.
Validation
Maintenace Gilles - Heating facility
Facility:
Date:
Customer:
Only qualified skilled personal may carry out the maintenance works, while observing all the
operation instructions and any currently valid rules. The use of this check list, way, scope and
periods of maintenance works shall be specified and adapted to the local prevailing conditions.
Pos. Description
LUBRICATION – greasing
1
Multicyclone ash removing worm screw
2
Ash rising worm screw (in case of an automatic ash removal)
3
Worm screw remove ash from grate (in case of an automatic
ash removal)
4
Between suction casing and motor
5
Bearing of star feeder
MAINTENANCE - heating boiler
1
Ash container emptying
2
Unscrew and clean the igniter and igniter tube
3
Cleaning of multicyclone
4
Removal ash from grate
5a
5b
5c
5d
quarterly
half a
year
once a
year
Funct.
Carried
out
quarterly
half a
year
once a
year
Funct.
Carried
out
quarterly
half a
year
once a
year
Funct.
Carried
out
quarterly
half a
year
once a
year
Funct.
Carried
out
Bei
Bedarf
Cleaning of the complete combustion chamber UTSK-under
feeding
Cleaning of the complete combustion chamber UTSK-front
feeding
Cleaning of the complete combustion chamber UTSKstepping grate
Cleaning of the complete combustion chamber UTSKcompact
6a
Cleaning of the combustion grate UTSK-underfeeding
6b
Cleaning of the combustion surface UTSK-front feeding
6c
Cleaning of the combustion surface UTSK-stepping grate
6d
Cleaning of the combustion grate UTSK-compact
7
Cleaning of the heat exchanger flue gas duct
8
Cleaning of the suction blower
9
Cleaning of the flue gas tube
CLEANING
1
Emptying of condensed water when heat exchanger is
cleaned
2
Emptying of condensed water vessel on compressor
3
Cleaning of all the motors and blowers
4
Cleaning of the underpressure pipes
5
Maintenance of hydraulic aggregate
WORM SCREW – maintenance of worm
screw conveyors
20
Maintenance period/ Performance
Lubrication of worm screw bearing (on the motor side)
21
Lubrication of the worm screw bearing
ELBOW DISCHARGE - maintenance
1
Lubrication of elbow discharge system bearings
2
Replacement of gear oil in angle gear
SILO – maintenance of silo discharge
system
1
quarterly
half a
year
once a
year
Funct.
Carried
out
quarterly
half a
year
once a
year
Funct.
Carried
out
quarterly
half a
year
once a
year
Funct.
Carried
out
Horizontal discharging – replacement of gear smears
PUSH RODS SYSTEM – maintenance
1
Lubrication of the cross feeder worm screw bearing on the
side of motor
2
Lubrication of the worm screw bearing
3
Hydraulic aggregate
4
Cylinders and hoses
Maintenance Gilles-heating facility
Annexes
Date:
Customer:
Lubricants – greasing
1
Multicyclone ash removing worm screw
2
Ash rising worm screw (in case of an automatic ash removal)
3
Worm screw remove ash from grate (in case of an automatic ash removal)
4
Between suction casing and motor
5
Bearing of star feeder
MAINTENANCE - heating boiler
1
Ash container emptying
2
Unscrew and clean the igniter and igniter tube
3
Cleaning of multicyclone
4
Removal ash from grate
5a
Cleaning of the complete combustion chamber UTSK-under feeding
5b
Cleaning of the complete combustion chamber UTSK-front feeding
5c
Cleaning of the complete combustion chamber UTSK-stepping grate
5d
Cleaning of the complete combustion chamber UTSK-compact
6a
Cleaning of the combustion grate UTSK-underfeeding
6b
Cleaning of the combustion surface UTSK-front feeding
6c
Cleaning of the combustion surface UTSK-stepping grate
6d
Cleaning of the combustion grate UTSK-compact
7
Cleaning of the heat exchanger flue gas duct
8
Cleaning of the suction blower
9
Cleaning of the flue gas tube
CLEANING
1
Emptying of condensed water when heat exchanger is cleaned
2
Emptying of condensed water vessel on compressor
3
Cleaning of all the motors and blowers
4
Cleaning of the underpressure pipes
5
Maintenance of hydraulic aggregate
WORM SCREW – maintenance of worm screw
conveyors
20
Lubrication of worm screw bearing (on the motor side)
21
Lubrication of the worm screw bearing
ELBOW DISCHARGE - maintenance
1
Lubrication of elbow discharge system bearings
2
Replacement of gear oil in angle gear
SILO – maintenance of silo discharge system
1
Horizontal discharging – replacement of gear smears
PUSH RODS SYSTEM – maintenance
1
Lubrication of the cross feeder worm screw bearing on the side of motor
2
Lubrication of the worm screw bearing
3
Hydraulic aggregate
4
Cylinders and hoses