Appendix 6 Maintenance Procedures

K135-07332 Uniconfort MUM v. 1.
UNICONFORT s.r.l.
S. MARTINO DI LUPARI (PD) - ITALY - Tel. 049/5952052 - 9461303 - Fax 049/5952099
http://www.uniconfort.com info@uniconfort.com
USE AND MAINTENANCE MANUAL

FOR SOLID FUEL
STEEL BOILERS
MOD. GLOBAL
CAREFULLY READ THE INSTRUCTIONS IN THIS MANUAL BEFORE INSTALLING,

COMMISSIONING, RUNNING, ADJUSTING OR MAINTAINING THE EQUIPMENT.
FAILURE TO OBSERVE THE FOLLOWING INSTRUCTIONS MAY CAUSE SERIOUS

PERSONAL INJURY, DEATH OR CONSIDERABLE MATERIAL DAMAGES
Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 1

K135-07332 Uniconfort MUM v. 1.3
CONTENTS
REF. HEADING PAGE
PART 1 - SAFETY
1.1 Preliminary safety information
1.2 Glossary
1.3 Boiler operator and maintenance technician skills
PART II - CONFORMITY
2.1 Product described in the manual
2.2 Community and national legislation
2.3 Main technical reference regulations
2.4 Product conformity
PART III TECHNICAL SPECIFICATIONS
3.1 Terms and definitions
3.2 Machine features
3.3 Machine technical specifications
3.4 Restrictions
PART IV - INSTALLATION
4.1 Packaging
4.2 Storage
4.3 Transport and handling
4.4 Assembly and dismantling
4.5 Installation site preparations
4.6 Commissioning
4.7 Inspection, test and trials
PART V BOILER OPERATIONS
5.1 Personal safety devices
5.2 Start up
5.3 Normal and special use (foreseen and reasonably foreseeable)
5.4 Risk conditions and abnormal use
5.5 Emergency instructions
PART VI DIAGNOSTICS AND MAINTENANCE
6.1 Personal safety devices
6.2 Diagnostics: Malfunctions, faults, breakdown
6.3 Routine maintenance
6.4 Extraordinary maintenance, inspections and checks
6.5 Out of order / Lock out
6.6 Dismantling
6.7 Demolition, decontamination, recycling
PART VII - APPENDIXES
7.1 Recommended spare parts
7.2 Spare parts list
7.3 Drawings
7.4 Boiler ID plate (copy/photo)
7.5 PLC Manual

PART I
PRELIMINARY SAFETY INFORMATION
This publications called the Use and Maintenance manual, hereinafter referred to as MUM for brevity,
is addressed to:
The installation site system safety manager
The heating system operator
Maintenance technicians
The manual must be kept by a supervisor in a suitable place so that it is always available for
consultation in the best conditions.
In the event of loss or deterioration, apply for replacement documents directly from Uniconfort srl.
Manual legend
All the instructions in this manual must assist the operator and qualified technician in correctly and
safely operating, using and maintaining the machine.
Manual instructions are accompanied by symbols to facilitate reading, specifying the various types of
information provided.
Pay attention to this symbol where included in the manual.

It indicates a potentially hazardous situation.
There are three hazard levels:
HAZARD
This is the most serious hazard symbol and warns the operator that failure to correctly perform the
described operations will cause serious and/or permanent injury or even death.
Safety messages and plates describe the precautions required to prevent hazards.
Ignoring these precautions may also seriously damage the machine.

WARNING
This signal warns that if the described operations are not correctly performed, they can cause serious
and/or permanent injury or even death.
The Warning signal indicates a lower risk level than Hazard.
If the hazard is not avoided, serious injury or death may result.
Safety messages and plates describe the precautions required to prevent hazards.
Ignoring these precautions may also seriously damage the machine.
CAUTION
This signal warns that if the described operations are not correctly performed, they can cause
machine and/or personal damages.
The Caution signal indicates a lower risk level than Hazard and Warning.
Used in safety messages it means that, in the event hazards are not avoided, small or
moderate injury or damages may result.
The message can also be used for hazards that only cause machine damages.
NOTE
In safety messages, a note is used for the precautions to be taken to avoid operations that
may shorten the machine working life.
THIS INSTRUCTION MANUAL MUST BE READ BEFORE STARTING ANY OPERATION.
GUARANTEED GOOD WORKING ORDER AND FULL MACHINE PERFORMANCE
STANDARDS ARE STRICTLY TIED TO THE CORRECT APPLICATION OF ALL THE
INSTRUCTIONS IN THIS MANUAL.
Manual conservation
The use and maintenance manual is an integral part of the machine

CAUTION
It must be kept for the entire machine working life and delivered to any other
subsequent user or owner
Do not remove, tear or rewrite manual parts for any reason
Keep it integral and in a safe place, away from humidity and heat
It must be easily identifiable and known to all machine operators and technicians
After consultation, the manual must be replaced in its storage place and kept for the
entire machine working life
Liability
The instructions in this manual do not replace but summarise the obligations on the
observance of current legislation on safety and accident regulations.
With reference to that indicated in this instruction manual, the manufacturer is not liable in the event of:
- Use in conflict with current national safety and accident laws
- Incorrect preparation of the section and structures where the machine will operate
- Failure or incorrect observance of manual instructions
- Mains voltage defects
- Unauthorised machine modifications
- Use by untrained personnel
Incorrect boiler use and/or improper maintenance operations can cause serious personal
injury or even death.
Users and maintenance technicians must carefully read the content of this manual before
using the machine and/or before performing maintenance.
WARNING
If someone is involved in a serious accident during machine use or maintenance, it means
that the instructions in this manual were not followed.
The procedures and precautions included in this manual are only applicable to the machine
for its foreseen use. Should the machine be used for purposes other than that foreseen, the
operator is liable of his safety and the safety of those involved.
Qualified personnel - Operator

As per Presidential decree 459/96 and subsequent updates, we specify that:
Operator means the person or persons assigned to operate, adjust, maintain, clean and repair the
system.

First level system operator

Unqualified personnel only capable of conducting simple duties such as operating the
machine using the control panel and operations during production with the guards installed
and enabled.
Second level system operator

Unqualified personnel capable of conducting the abovementioned duties and with experience and
prior training to conduct simple maintenance operations such as changing a disc or adding oil to the
converter, gear motor or lubricant in specific points.
Mechanical and/or electrical maintenance technician

Qualified technician capable of operating the machine in normal conditions, to operate it with the
guards disabled, to work on mechanical parts to perform adjustments or more complicated
maintenance and necessary repairs.
Normally, if qualified, this technician can also perform work on live electrical systems.
Further qualifications
Please remember that legislative provisions and national or local regulations usually set further
qualifications such as test certificates at the end of specific training courses, to operate heating
systems.
For Italy, Ministerial decree 12/08/68, Law 615 dated 13/07/1966 and Presidential decree 1391/70
apply.

PART II - CONFORMITY
2.1 THE PRODUCT
Boiler mod. Global is described by regulations as

- A heating boiler
- A boiler for forced draught burners
- Boilers for solid fuel, manually and automatically fed
2.2 COMMUNITY AND NATIONAL LEGISLATION
For product type and, more in general, as a machine and production instrument, the plant/system falls
under the application of some European Directives and specifically:
MACHINE DIRECTIVE
Directive 98/37/37 issued by the European Parliament and Council on June 22, 1998 concerning the
approximation of member state machinery legislations
and subsequent amendments (currently in effect)
MACHINE DIRECTIVE
Directive 2006/42/CE issued by the European Parliament and Council on May 17,
2006 on machinery that amends directive 95/16/CE (recast)
(nationally implemented within 29/06/2008, in effect as of 29/12/2009)
ATEX Directive 94/9/CE issued by the European Parliament and Council on March 23, 1994, on the
approximation of member state legislation concerning equipment and protection systems intended to be used in
potentially explosive atmospheres.
PED DIRECTIVE
Directive 97/23/CE issued by the European Parliament and Council on May 29, 1997 on the approximation of
member state machine legislation concerning pressurised equipment
LOW VOLTAGE DIRECTIVE

Directive 2006/95/CE issued by the European Parliament and Council on December 12, 2006
on the approximation of member state legislations concerning electrical material intended to
be used within some voltage limits
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE
Directive 89/336/CEE issued by the Council on May 3, 1989 on the approximation of member state legislations
concerning electromagnetic compatibility
and subsequent amendments (in effect until 19/07/07)
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE

Directive 2004/108/CE issued by the European Parliament and Council on December 15, 2004 on the
approximation of member state legislations concerning electromagnetic compatibility that repeals directive
89/336/CEE
(implemented by 20/01/2007, in effect as of 20/07/2007 with transitory period until 20/07/2009)

W ORKMANS SAFETY DIRECTIVES
Directive 89/391/CEE issued by the Council on June 12, 1989 on the implementation of measures aimed to
promote the improvement of workmans safety and health
Directive 89/655/CEE issued by the Council on November 30, 1989 on the minimum safety and health requisites
for the use of work tools by workers during work (second special directive as per article 16, paragraph 1 of
directive 89/391/CEE)
Directive 89/656/CEE issued by the Council on November 30, 1989 on the minimum safety and health requisites
for the use of personal safety equipment by workers during work (third special directive as per article 16,
paragraph 1 of directive 89/391/CEE)
Directive 99/92/CE issued by the European Parliament and Council on December 16, 1999 on the minimum
requirements for improving the safety and health protection for workers potentially at risk from explosive
atmospheres (fifteenth special directive as per article 16, paragraph 1 of directive 89/391/CEE)
(Atex 2 directive)
As for Italian regulations, the legal context mainly consists of the following regulations:
Presidential decree no. 547 dated 27/04/1955

Workmans safety regulations
Legislative decree no. 626 dated September 19, 1994

Implementation of directives 89/391/CEE, 89/654/CEE, 89/655/CEE, 89/656/CEE, 90/269/CEE, 90/270/CEE,
90/394/CEE, 90/679/CEE, 93/88/CEE, 95/63/CE, 97/42, 98/24 and 99/38 on improving the safety and health of
workers during work.
(title amended by Legislative decree 25/2002)
Legislative decree no. 242 March 19, 1996

Amendments and integrations to legislative decree no. 626 dated September 19, 1994 on the implementation of
community directives concerning improving workmans safety and health on the work site.
Presidential decree no. 459 dated 27/04/1996

Regulation for the implementation of directives 89/392/CEE, 91/368/CEE,
93/44/CEE and 93/68/CEE on the approximation of member state legislations concerning machinery.
Legislative decree no. 359 dated August 4, 1999

Implementation of directive 95/63/CEE that amends directive 89/655/CEE
on the minimum safety and health requirements for the use of work tools by workers.
Legislative decree no. 25 dated February 2, 2002

Implementation of directive 98/24/CE on the protection of workers health and safety against risks derived by
chemical agents during work.
Legislative decree no. 233 dated June 12, 2003

Implementation of directive 1999/95/CE on the minimum requirements for improving the safety and health
protection for workers potentially at risk from explosive atmospheres

2.3 MAIN TECHNICAL REFERENCE REGULATIONS
REGULATION ED. HEADING

UNI EN ISO Machinery safety Fundamental concepts, general design
2005
12100-1 principles. Terms, basic methods.
UNI EN ISO Machinery safety Fundamental concepts, general design
2005
12100-2 principles. Specifications and technical principles.
UNI EN ISO Heat environment ergonomics Assessment methods on mans response
2007
13732-1 to contact with surfaces Part 1: Hot surfaces
UNI CEN/TS
2005 Solid bio-fuels Terms, definitions and descriptions
14588
UNI CEN/TS
2006 Secondary solid bio-fuels Terms, definitions and descriptions
15359
Heating boilers Part 1: Boilers with forced draught burners Terms,
UNI EN 303-1 2005
general requisites, tests and markings
Heating boilers Boilers for solid fuel, with manual and automatic feed,
UNI EN 303-5 2004 with nominal heat power up to 300 kW Part 5: Terms, requisites, tests
and markings
Heating boilers Tests to measure aerial noise emitted by heat
UNI EN 15036-1 2007
generators Part 1: Aerial noise emission by heat generators
Noise Determination of sound power levels of noise sources using
UNI EN ISO
1997 sound pressure Engineering method in an essentially free field on a
3744
reflecting plane
Technical product documentation Instructions for use. Content
UNI 10893 2000
articulation and display order
Electrical constructions for explosive atmospheres due to combustible
CEI EN 50281-3 2004 dust Part 3: Classification of hazardous areas where combustible dust is
or may be present.
Home appliance and similar electrical equipment safety - Safety. Part 1:
CEI EN 60335-1 2004
General regulations
CEI EN 60529 1997 Casing protection levels (IP code)

CEI EN 60730-2- Automatically controlled electrical devices for home and similar use
2003
9 Part 2: Special regulations for heat-sensitive control devices
Electrical systems using nominal voltage not over 1000 V AC and 1500 V
CEI 64-8 2007
DC
Thermoplastic insulation wires with nominal voltage not over 450/750 V
CEI 20-20/1 2003
Part 1: General instructions
Fire tests on electrical wires Part 0: Fire non-propagation test -
CEI 20-22/0 2006
Overview
Electrical installations of buildings Part 1: Fundamental principles,
IEC 60364-1 2001
assessment of general characteristics, definitions

2.4 PRODUCT CONFORMITY
Enclosed below are copies of:

- EC Declaration of Conformity
DECLARATION OF CONFORMITY
Noi, firmatari della presente, dichiariamo sotto la nostra esclusiva responsabilit che la
macchina:
We, the undersigned, declare under our own exclusive responsibility that the machine:
Nous, soussigns, sous notre entire responsabilit, dclarons que la machine:
Tipo/Type/Type/ XXXXX
Numero di serie/Serial number/Numro
XXXX
conforme a quanto prescritto dalle Direttive 98/37/CE-2006/95/CE-89/336/CEE e successive modifiche ed integrazioni.

complies with the requirements of the EEC Directives 89/392-97/23/EC and subsequent modifications and integrations.
est conforme aux prescriptions des Directives 89/392/CEE-97/23/EC et leurs modifications et complments successifs.
il Rappresentante legale della ditta The Legal Representative of the Company

Reprsentant lgal de la socit Responsable Legal de la empresa
___________________________________

PART III TECHNICAL SPECIFICATIONS
3.1 TERMS AND DEFINITIONS
With reference to regulation UNI EN 303-5, the glossary of terms and definitions used in this MUM are
listed below.
Maximum admissible working pressure

Maximum pressure at which the boiler can be safely used.
Test pressure
Pressure at which all boilers and their components are subject during construction at the manufacturers factory
or during assembly by the installation technician [EN 303-1].
Sample test pressure
Pressure at which boilers and their components are subject before mass construction is launched in the
manufacturers factory.
Maximum admissible temperature
Maximum admissible water temperature is limited by safety devices.
Working temperature
Temperature range in which the boiler can operate in normal operating conditions, set on the water temperature
thermostat and according to the manufacturers specifications.
Q heat power
Working heat provided by the boiler to water per unit of time in accordance with EN 303-5 regulation requisites.
Note
Heat power data for solid fuel boilers correspond to average values on a corresponding test period set in accordance with EN 303-5
regulation requisites.
Qn rated heat power
Maximum continuous power specified by the manufacturer for a certain fuel in accordance with EN 303-5
Qmin minimum heat power
Minimum continuous power specified by the manufacturer for every type of fuel in accordance with the requisites
in this regulation
Heat power range
Power field between minimum and rated in which the boiler can be regulated in accordance with EN 303-5
T partial load
Ratio between working heat power in the Q power field and Qn rated power, expressed as a
percent
Operations at partial load
Reduced heat power in the power field is obtained using a regulation device
Qb hotbed power
Power distributed by fuel to the boiler hotbed, expressed according to lower heat power
Hu
K boiler yield
Ratio between Q supplied working power and Qb hotbed power
draught
Pressure difference between static air pressure in the boiler installation site and static pressure of combustion
products at boiler exhaust (measurement section at flue) [EN 303-1]

Smoke side resistance

Pressure difference between the combustion chamber and boiler combustion product exhaust (measurement
section at flue).
Smoke side seal
Seal, on the installation room side, of the feeder, combustion chamber, smoke conduits and boiler section
crossed by combustion products.
tA combustion product temperature
Temperature measured at the boiler exhaust solder pipe (measurement section at flue) [EN 303-1].
Water side resistance
Pressure loss in the boiler with volumetric flow corresponding to rated power, measured between boiler water
supply and return [EN 303-1]
Water temperature thermostat
Device that reads and adjusts water temperature in the boiler.
Temperature safety limiter (automatic reset)
Device that automatically cuts off fuel supply and/or combustion air when
the water temperature reaches the maximum set value.
Fuel and/or combustible air supply can only resume after the water temperature lowers under the set lower limit.
Safety limiter (manual reset)
Device that automatically cuts off fuel and/or combustion air supply when the water temperature reaches a
maximum set value.
Fuel and/or combustible air supply can only resume after the temperature lowers under the limit and after
manual reset or with the assistance of a tool.
Test fuel
Retail quality fuel, representative of the fuel type used for heating boiler tests.
Feed device
Device that feeds duel to the feeder or combustion chamber.
Manual feed
Manual fuel feed at shorter or longer intervals which depend on the combustion capacity and/or heat power.
Automatic feed
Fuel is automatically fed according to heat power.
Feed can be continuous or intermittent.
Combustion period
With manual feed, it is the time required to burn the maximum fuel load until the hotbed is reached.
The combustion process must not be subject to interferences during this period. The residual hotbed must be
able to return the boiler to rated heat power with a new fuel load.
TB rated combustion period
Combustion period at rated heat power.
By-pass device
Device which, when open, permits combustion products to directly reach the hearth (with preheating or by
exceeding the low smoke temperature).
Safety heat exchanger or other excessive heat dissipation
device
Device intended to dissipate excess boiler heat, to limit temperature to a set maximum.
Fuel feeder or loading chamber
Part of the boiler from which fuel feeds combustion. The loading chamber or fuel feeder is the gathering space
required to obtain sufficient combustion length.
Combustion chamber
Part of the boiler where heat is prepared and/or fuel burnt. The combustion chamber can
be part of the loading chamber.
Smoke cleaning system

Techniques used to reduce pollutants contained in smoke.

Ash chamber
Part of the system intended to receive combustion residue (ash/waste).
Accumulation boiler
Boiler that stores excess energy (due to the difference between the boiler heat power and the real heat power
absorbed by the heating system).
Quick cut-off heating system
A heating system is considered quick cut-off if, in any operating system, whether or not correct (for example,
without power or without heat requests) heat production
can be quickly cut-off preventing any hazardous operating conditions both water or fuel side.
In this context, hazardous operating conditions means any boiler water temperature rise over 110 C or any
formation of explosive gas-air compounds in the combustion chamber and/or smoke conduits. System evaluation
must not, therefore, focus on combustion as an isolated element but as an integral part of the general boiler
project (storage capacity, air circuit supply device, combustion products and, specifically,
safety control devices).
Partial cut-off heating system
Most heating power can be briefly cut-off using a control and safety device without cause hazardous operating
conditions on the combustion chamber side.
Residual heat power
Heat power that continues to be transmitted to water by combustion products after the boiler is turned off.

3.2 BOILER FEATURES
Boiler description and possible accessories

Boilers Mod. GLOBAL for the production of
Hot water at + 95C / 3 bar / 0,3 MPa
were expressly designed and constructed to use:
Solid fuel of biological origin (wood stumps, wood chips)
Automatic loading system

The boiler is equipped with an automatic material loading system designed according to the physical
characteristics of the fuel material. Feeding systems may vary. The main systems are listed below:
1. System with Fuocomatic screw feeder driven by a variable speed gear motor
2. Pusher system whose load cycles are regulated by PLC settings
3. A Talpa system for very heterogeneous materials.
Ash removal system

The boiler is also equipped with an automatic ash removal system over and under the grill able to
keep the combustion chamber as clean as possible. System activation frequency is set by the PLC
based on the chemical-physical characteristics of the material burnt in the boiler.
Pilot or power burner

Suitably equipped, Uniconfort boilers can be equipped with a pilot or power burner and therefore can
also be fed with liquid or gas fuel.
The pilot burner is typically used to mitigate the machine the first time it is turned on while the power
burner can provide up to 70% of rated power and, in this case, the boiler can work continuously with
gas, methane or diesel fuel.
Pilot burner settings are standard on all Global models while a further stage must be designed in the
combustion chamber for the power burner.
Pusher
The main purpose of the pusher is to move solid fuel of inconsistent and non-aggregated nature from
the outside to the inside of the boiler overcoming any friction forces due to passage in a closed
channel and cut any parts in excess of its working area. The pusher is able to handle very
heterogeneous materials and therefore make the machine adaptable to the supply of highly
voluminous pieces. The pusher mainly consists of a highly thick steel piston, a rectangular
section channel with a guillotine section at the top where the piston slides, a safety fire barrier door
driven by a hydraulic piston, a hydraulic unit controlled by the PLC that drives the piston in alternating
mode and level sensors that control the safety door.
The pusher is usually fed by a chain conveyor that unloads material on the upper hopper. When the
material reaches a certain level, the sensors on the hopper block material load and send the piston a
signal to close the barrier door.
Simultaneously, the piston starts in backwards movement and material falls in the piston sliding
channel. At this point, material is pushed towards the combustion chamber and when the piston is at
limit stroke, the safety door reopens and the cycle restarts. Obviously, if a piece of wood is larger
than the sliding channel, the piece is cut in the guillotine cutting section.
The cycle can be summarised in four phases:
1. loading on the upper hopper chain conveyor

2. safety door closing and rear piston stroke start

3. material fall in the sliding channel and beginning of material push towards the combustion
chamber
4. safety door opening and loading chain conveyor restart.
The cycle repeats until the PLC panel sends the pusher hydraulic unit a signal to stop and, therefore,
until the boiler reaches rated power.
4
3.2.1 MAIN OPERATING PRINCIPLES
Phase A FUEL LOADING
Fuel (biomass) such as sawdust, shavings, chip wood, etc.

Stored in specific vertical and/or horizontal silos
Is extracted by screw feeders and/or stripers and moved to the boiler feed hopper and then
Pushed in the combustion chamber by a scroll screw and/or hydraulic pusher onto the fixed or
mobile grill hotbed.
Phase B FUEL IGNITION

Fuel is manually ignited and/or by a liquid or gas fuel pilot burner.
Phase C COMBUSTION MAINTENANCE
Ignited fuel is fed and oxygenated by combustion air fans divided in primary and secondary air under
the grill and third and forth in the combustion chamber.
Phase D AIR/FLUID HEAT EXCHANGE
Heat thus produced heats the internal walls of the heat exchanger producing
Hot water at +95C 3 bar
Heated air at +150C 12 bar
Saturated steam 12 bar
According to the type of exchanger installed in the boiler.
Phase E COMBUSTION SMOKE EMISSION
Combustion smoke is dispersed through specific flues after being filtered by special filters.
3.2.2 CONSTRUCTION FEATURES
The boiler structure is stand-alone, built of highly thick steel plate with high mechanical resistance,
externally lined with high density anti-radiant material, buffer and protection panelling painted with
weather resistant paints.
Ample and fully blind section combustion chamber with several smoke circuits for excellent dust
separation in combustion smoke with variable combustion chamber working temperatures between
700 C and 1000C equipped with doors for periodic cleaning and maintenance, post-combustion
chamber with high speed gas input in turbulence regime due to the special secondary and third
combustion air injection system.
The brick refractory lining with high aluminium content is suitably secured with specific refractory glues
and high density insulating refractory cast.

Economiser heat exchanger with specially shaped horizontal highly thick

steel exhaust pipes to guarantee the maximum heat exchange and yield,
equipped with inspection exhaust boxes for periodic cleaning and
maintenance.
FUOCOMATIC screw feeder mechanical burner built of highly thick steel

complete with brazier with chrome cast iron elements for primary air
diffusion, removable for periodic cleaning and maintenance.
Variable speed fuel motor complete with manual adjustment control

connected to the feed screw.
Primary, secondary and third air fans equipped with manual and
automatic regulation dampers.
Tilted MOBILE GRILL mechanical burner with chrome cast iron

elements for fuel with humidity from 50 to 100% on dry base with
alternating horizontal operations by mechanical pushers for controlled fuel
feed on mobile grill.
Automatic timed ash removal by feed screw connected to the ash
container. Sectioned under grill ventilation chambers for rational primary
air circulation.

Hydraulic pusher made up of: Material feeder with hydraulic pusher

operations. Equipped with loading hopper supplied complete with
highly thick steel guillotine type air sectioning device driven by a
hydraulic device, oversize piece cutting system with 80 x 80 mm
admissible section and length up to 30 mm.
Mercury steam thermostat valve

Type: DANFOSS AVTA-15
Positive action fire extinguisher device complete with temperature probe
that runs without electricity to put out any flame returns.
Ref.: Fig. 5.3
Fuel feed hopper with grain size from 0 25 mm complete with bridge
breaker star and inspection doors. Feed hoppers can be divided in
various types according to the grain size of the fuel used.
Operating thermostat
Hot water 90 C: Operating range: 50 90C.
3.2.3 SWITCHBOARD AND ELECTRICAL SYSTEM
The machine switchboard and electrical system meet:

Low voltage directive 2006/95/CE
Regulation EN 60335-1
Connections with the installation building electrical system must meet regulations CEI 64-8 / IEC
60364.
Three switchboard versions are available:
Generic switchboard made up of electrical protection devices against short circuits, overloads
and indirect contacts, control devices, operating indicator lights, on/off type thermostat control
equipment.
Lambda tronic PLC control switchboard for programmed and automatic combustion control with
programmable logic controller.
In addition to the circuit operations in the basic version, the controller runs PID type controls such
as:
- Fuel feed command and control base according to required energy,
- Automatic control and regulation of combustion air through automated dampers.
- Automatic exhaust control and regulation (by inverter or driven dampers).
- Total fuel control with lambda probe.

- Ignition and maintenance control with possibility of reducing burnt heat power in modulation up
to 30% of rated power.
Lambda full PLC control switchboard for programmed and automatic combustion control with
programmable logic controller.
In addition to the circuit operations in the basic version, the controller runs PID type controls such
as:
- Fuel feed command and control base according to required energy,
- Automatic control and regulation of combustion air through inverter on fans.
- Automatic exhaust control and regulation (by inverter or driven dampers).
- Total fuel control with lambda probe and CO analysis unit.
- Continuous control and regulation of depression in combustion chamber by digital and analog
deprimometer.
- Ignition and maintenance control with possibility of reducing burnt heat power in modulation up
to 30% of rated power.


GLOBAL BOILER COMPONENTS FOR THE PRODUCTION OF 90C HOT WATER
1 Hot or heated water heat exchanger 28 Ash container

2 Flue outlet 29 Ash conveyor gear motor
4 Pressure gauge 30 Third air fan
5 Manhole (heated water only) 31 Fuel feed pusher
6 Safety valve (heated water only) 32 Pusher hydraulic cylinder
7 Boiler and/or load return 33 Pusher hydraulic unit
8 Safety pipe outlet 34 Automatic exchanger cleaning system
9 Rear exchanger inspection door 35 Pusher hopper with damper
10 Working pressure switch (heated water only) 36 Pusher hydraulic cylinder damper
11 Safety pressure switch 40 Upper base (combustor)
(heated water only)
12 Manual reset safety pressure switch 41 Lower base (combustor)
(heated water only)
13 Pressure control outlet 42 Cold water supply
14 Exhaust unit 43 Temperature display thermometer
15 Upper base inspection door 44 Mobile grill cooling inlet
16 Removable burner support (optional) 45 Mobile grill cooling outlet
17 Pilot burner (optional) 46 Primary air fans
18 Secondary air fans 47 Pusher cooling inlet
19 Lower base inspection door 48 Pusher cooling outlet
20 Ash removal gear motor 46 Primary air fans
21 Under grill inspection door 47 Pusher cooling inlet
22 Generic or PLC switchboard 48 Pusher cooling outlet
23 Grill hydraulic unit housing chamber
24 Positive action fire extinguisher unit
25 Front exchanger inspection door
26 Pilot burner application plate
27 Ash removal system

3.3 MACHINE TECHNICAL SPECIFICATIONS
Boiler working room temperature is between 0 and 40 .
Room humidity must be between 0 and 90%.
3.3.1 TECHNICAL SPECIFICATION AND PERFORMANCE HOT WATER 90C 3 BAR
Thermotechnic boiler data*

DRAUGHT (0.8-1.0)
mbar
WATER CAPACITY l
SMOKE TEMPERATURE AT HEAT POWER (200C) C
SMOKE FLOW AT RATED HEAT POWER m3/h
EXHAUST CONDUIT DIAMETER mm
LOAD LOSS WATER SIDE mbar
RATED HEAT POWER AND HEAT POWER RANGE BY FUEL TYPE kW
WOOD TRUNKS
CHIP WOOD
CHIPBOARD
BARK
BOILER CLASS
COMBUSTION PERIOD FOR EACH TYPE OF FUEL AT RATED POWER (QN) hours
THERMOSTAT REGULATION RANGE C - C
MINIMUM RETURN TEMPERATURE AT LEVEL WITH BOILER RETURN FITTING C
FEED CHAMBER CAPACITY IN LITRES AND LOAD DOOR DIMENSIONS mm
ACCUMULATION TANK REQUIRED IF QMIN > 0,3 QN; l
AUXILIARY POWER W
COLD WATER TEMPERATURE AND SAFETY EXCHANGER PRESSURE C / bar
* See technical boiler sheets for values.

3.3.2 TECHNICAL SPECIFICATIONS AND PERFORMANCE HEATED WATER 150C 12 BAR
Not applicable
3.3.3 TECHNICAL SPECIFICATIONS AND PERFORMANCE SATURATED STEAM 12 BAR
Not applicable
3.3.4 TECHNICAL SPECIFICATIONS AND PERFORMANCE FUEL
Fuel data
FUEL WATER CONTENT % HEAT POWER
BARK 30% OF THE SAME 2000kcal/h
CHIPBOARD 30% OF THE SAME 3000kcal/h
PELLET 30% OF THE SAME 4500kcal/h
COMPRESSED WOOD 30% OF THE SAME 4500kcal/h
BRANCHES 30% OF THE SAME 3000kcal/h
WOOD 30% OF THE SAME 3500kcal/h
3.3.5 TECHNICAL SPECIFICATIONS AND PERFORMANCE SWITCHBOARD
Electrical data
NOMINAL VOLTAGE 400V
NOMINAL FREQUENCY 50Hz
TT OR TN THREE-PHASE SYSTEM 3/N
TOTAL INSTALLED ELECTRICAL POWER Depends on system type
ASSUMED SHORT CIRCUIT CURRENT < 4,5 kA
PROTECTION LEVEL IP 44

3.3.6 BOILER TECHNICAL SHEETS*
* The following data may be subject to change.

Boiler mod. GLOBAL hot water Mod. 30 60 90 120 150
90 C 3 bar u.m.
kcal/h 300.000 600.000 900.000 1.200.000 1.500.000
Power yield
kW 348 696 1044 1392 1740
kcal/h 351.000 702.000 1.053.000 1.404.000 1.755.000
Burnt power
kW 407 814 1221 1629 2036
Installed electric power with exhaust kW 9 13 15 18.5 20
Water capacity L. 1050 2100 3000 3818 4565
Smoke flow 200C mc/h 1.913 3.820 5.731 7.641 9.551
Combustion chamber volume m 1,95 3,90 5,85 7,80 9,75
Post-combustion chamber volume m 0,49 0,98 1,46 1,95 2,44
Mobile grill surfaces m 0,68 1,36 2,04 2,71 3,39
Smoke side DP mbar 1.7 4.5 5.5 6.5 7.5
Water side DP mbar 190 240 290 320 320
Exchanger weight kg 4.556 7.586 10.268 12.488 14.529
Upper base weight kg 6.075 10.115 13.320 16.650 19.834
Lower base weight kg 4.050 6.545 8.880 10.406 11.531
1mc feeder weight kg 860 860 970 970 970
Pusher weight kg 1600 1800 1800 2100 2100
Dimensions A mm 1.500 1.700 1.850 1.850 2.050
B mm 2.700 3.500 4.000 4.500 4.500
Lower base height C mm 1.000 1.100 1.200 1.250 1.250
Upper base height D mm 1.500 1.700 1.800 2.000 2.150
Total exchanger length E mm 3.000 3.800 4.300 4.800 4.800
Exchanger height F mm 1500 1700 1850 2.000 2.100
Total height H mm 4.000 4.500 4.850 5.250 5.500
Base transport length L mm 3.900 4.800 5.300 5.800 5.800
Base transport width A1 mm 1.750 1.950 2.100 2.100 2.300
Exchanger transport width A2 mm 1.600 1.800 1.950 1.950 2.150
Flue fitting D1 mm 300 400 400 450 450
Water supply D2 DN 80 100 125 125 150
Water return D3 DN 80 100 125 125 150
n 1 2 2 2 2
Load and/or safety fitting D4
DN 40 40 40 50 50
Boiler exhaust D6 inches 1"1/4 1"1/4 1"1/4 1"1/2 1"1/2
Burner fitting D7 mm 175 235 235 280 280
Exchanger transport height H1 mm 1650 1850 2000 2150 2250
Overall fuocomatic length L1 mm 5.500 6.300 6.800 7.300 7.300
Overall pusher length L2 mm 6.700 7.550 8.050 8.700 8.700
Fuocomatic length clearance L3 mm 2.600 2.600 2.600 2.600 2.600
Pusher length clearance L4 mm 3.800 3.850 3.850 4.000 4.000

Boiler mod. GLOBAL hot water Mod. 180 240 300 400 500
90 C 3 bar u.m.
kcal/h 1.800.000 2.400.000 3.000.000 4.000.000 5.000.000
Power yield
kW 2088 2784 3480 4640 5800
kcal/h 2.106.000 2.808.000 3.510.000 4.680.000 5.850.000
Burnt power
kW 2443 3257 4072 5429 6786
Installed electric power with exhaust kW 28 36 45 50 60
Water capacity L. 5478,261 6720 8400 10880 13600
Smoke flow 200C mc/h 11.461 15.282 19.102 25.469 31.837
Combustion chamber volume m 11,70 14,56 18,20 24,27 30,33
Post-combustion chamber volume m 2,93 3,64 4,55 6,07 7,58
Mobile grill surfaces m 4,07 5,01 6,26 7,76 8,48
Smoke side DP mbar 10.4 11.1 12.3 14,5 16,3
Water side DP mbar 360 400 450 505 600
Exchanger weight kg 16.144 19.939 21.751 27.695 31.956
Upper base weight kg 23.063 26.235 31.800 37.674 45.799
Lower base weight kg 16.400 18.656 20.606 26.910 35.242
1mc feeder weight kg 1.080 1.080 1.080 1.080 1.080
Pusher weight kg 2.500 2.500 2.600 2.600 2.800
Dimensions A mm 2.050 2.120 2.120 2.300 2.300
B mm 5.000 5.500 6.000 6.500 7.500
Lower base height C mm 1.600 1.600 1.800 2.000 2.270
Upper base height D mm 2.250 2.250 2.500 2.800 2.950
Total exchanger length E mm 5.300 5.800 6.300 6.800 7.800
Exchanger height F mm 2.100 2.280 2.280 2.470 2.470
Total height H mm 5.950 6.130 6.580 7.270 7.690
Base transport length L mm 6.300 6.800 7.300 7.800 8.800
Base transport width A1 mm 2.300 2.370 2.370 2.550 2.550
Exchanger transport width A2 mm 2.150 2.220 2.220 2.400 2.400
Flue fitting D1 mm 500 550 600 700 800
Water supply D2 DN 150 175 175 200 250
Water return D3 DN 150 175 175 200 250
n 2 2 2 2 2
Load and/or safety fitting D4
DN 65 65 80 80 100
Boiler exhaust D6 inches 1"1/2 1"1/2 1"1/2 2" 2"
Burner fitting D7 mm 305 305 305 350 350
Exchanger transport height H1 mm 2250 2430 2430 2620 2620
Overall fuocomatic length L1 mm 7.800 8.300 8.800 9.450 10.450
Overall pusher length L2 mm 9.200 9.700 10.200 11.000 12.000
Fuocomatic length clearance L3 mm 2.600 2.600 2.600 2.750 2.750
Pusher length clearance L4 mm 4.000 4.000 4.000 4.300 4.300

Machine dimensions and weight

3.3.7 TECHNICAL SPECIFICATIONS AND PERFORMANCE NOISE
Noise emitted by the machine

The sound power level emitted by the boiler is measured in accordance with the specific regulation for
boilers UNI EN 15036-1, with the procedure described in regulation UNI EN ISO 3744 and weighted
with curve A.
It is less than 70 dB at operator work station (in front of the machine).
3.4 BOILER USE
Appropriate Uniconfort boiler use is set:

- Following the instructions in the use and maintenance manual.
- Burning fuel that has a wood mass, specifically those stated in the fuel specifications in
the boiler purchase contract.
- Observing the boiler safety regulations in this manual.
- Boiler use by personnel trained by Uniconfort technicians.
Inappropriate Uniconfort boiler use is set by:

- Boiler use by unauthorised personnel or untrained personnel.
- Tampering with boiler safety devices that guarantee boiler and personnel safety.
- Mechanical and electrical modifications to supplied system equipment without the
manufacturers prior authorisation.
- Use of other manufacturers spare parts or accessories without the manufacturers prior
authorisation.
The customer is fully liable for inappropriate boiler use or failure to observe the instructions in
this manual, voiding warranty rights.

PART IV - INSTALLATION
4.1 PACKAGING
Boilers Mod. GLOBAL are supplied without packaging.
4.2 STORAGE
If not immediately installed,

The boiler must be stored in a dry place, away from the elements and at a temperature between 0
and 40 C.
The machine must be placed away from heat sources or flames.
The machine must be kept in a stable position, avoiding stacking other loads on it.
4.3 TRANSPORT AND HANDLING
Given the significant boiler mass and risks associated with handling, it must always be handled by
expert personnel equipped with suitable lifting means after consulting the information indicated in this
manual section.
Similar documents can be directly consulted by personnel such as the lifting sheet, applied and clearly
visible on the boiler structure.
The boiler must be handled with care, avoiding collisions or accidental falls that could jeopardise its
integrity.
The barycentre for slinging is indicated in Fig. 3.1.
The boiler is transported by inserting hooks in the lifting rings or holes on the upper part of the boiler
(see Fig. 3.2) and lifting it with a crane.
During transport, avoid collisions of any nature.

Lifting rings
4.4 GLOBAL WATER ASSEMBLY
Introduction
Biomass boilers manufactured by Uniconfort are boilers made up of several modules assembled with
bolted connections or welded seals, characterised by extreme simplicity. Essentially, assembly
consists in a sequence of stacking or flange operations where solid or liquid seals are applied to
prevent or consistently reduce air loss in the combustion chamber.
Definitions
Lower base: The part of the boiler that houses the mobile or fixed grill.
Upper base: Part of the boiler that houses the main combustion chamber and post-combustion
chamber.
Burner support base: Part of the boiler that insulates heat exchange upwards and contains the power
burner.
Heat exchanger: Part of the boiler where heat exchange processes occur between hot smoke and
carrier liquid.
Ash removal system: A system of hoppers with internal driven feed screws that remove ash from the
combustion chamber and carries it to a storage silo.
Rotary joint: The joint to be applied to one of the ash removal screws that must be connected to a
cooling water flow to cool ash.
Cooled grill: A mobile grill equipped with a pair of manifolds that continuously cool the fixed row vents.
Mobile grill: A movement system equipped with a certain number of fixed vent rows alternated with
mobile vents moved by a hydraulic or mechanical system. Mobile vent movement against fixed ones
creates alternating movement that moves material forward during combustion.
Vent: An insert made of special cast iron or refractory steel, resistant to chemical agents and
temperature changes. A sequence of vents in overlapping rows creates the mobile grill.
Feed mouth: The part of the machine through which material is introduced for combustion. This part of
the machine is usually specially insulated or cooled by a flow of water to keep the interface at low
temperatures.
Pusher: A material movement system made up of a loading hopper that dumps to a closed conduit
where an alternating piston pushes material in a conduit towards the feed mouth.
Safety fire barrier door: A mechanical damper, driven by a hydraulic unit that separates and seals the
pusher from other moving parts and prevents air passage between to the combustion chamber during
pusher loading phases.

Flood thermostat valve (fire extinguisher): A thermostat bulb valve positioned on the pusher hopper,
that floods the hopper if plate temperature exceeds a certain set value. This valve thus creates an
automatic fire extinguisher for flames that could return up the loading mouth towards the pusher
hopper.
Safety valve: Valves connect on suitable flanges on the upper part of the heat exchanger that
discharge pressure and water flow when over the previously set value which corresponds to the
maximum working pressure.
Requirements:
A set of generic tools (clamp, wrenches, hammers, levers, etc.) and a welding machine are required
for boiler assembly to secure some parts.
A carpenters ruler is required to check geometry.
A crane with 12 meter lifting capacity and chains with 40 ton capacity are required for at least two days
to handle pieces. Ladders or scaffolding and a lifting system with at lease 3 ton capacity for at least 6
working meters (fork lift) are required to assemble accessories.
Personnel
At least three people on day shift for about 5 6 business days are required for part handling and
assembly. At least one person must be a good mechanic with welder qualifications. At least one
electrician is required for electrical connections (8 10 days). At least one plumber is required for
hydraulic connections.
Reference drawings
System reference drawings must be directly requested from the Uniconfort engineering office and
must be approved by the engineering manager.
Assembly procedure
The entire ash removal system must be placed in trenches dug according to the layouts supplied by
Uniconfort. This system must include ash collection tanks facing upwards and placed at the level of
the lower base.
Before positioning the lower base, ceramic strips must be applied to the collection hopper edges.
When resting the lower base on the hoppers, make sure the edges with ceramic fibre are compressed
by the shaped under the base.
When coupled, spot weld the hopper edges to the base to keep the ceramic fibre continuously
compressed. After the lower base is positioned where indicated in the layout, Uniconfort will install
additional ceramic strips (supplied) on the upper flange of the base around the entire perimeter. These
strips must be compressed by the weight of the upper base. Next position the upper base. In general,
bases have a male/female coupling system made of refractory cement to centre the parts. When fine-
tuning the position, the upper flange on the lower base must couple with the lower flange on the upper
base. This coupling is obtained using screws and is required to keep a minimum of compression
between the flanges to compensate any planarity errors or deformation which, even if minimum, are
possible during movement processes between the parts.
Fastening screws must be slightly tightened and checked during heating phases.
Again, ceramic strips must be placed around the entire perimeter of the upper base before positioning
the burner support (where applicable) and/or heat exchanger.
Once all the modules are in place, all system accessories can be assembled for which all air stumps
and fans and pre-assembled wires with their relevant protection raceways must be assembled.
When this phase is completed, assemble the coupling mouth flange to the entire pre-assemble
pusher-damper system. Before closing the flange, apply a thick layer of silicon at high temperature
between the two surfaces to seal surfaces against air loss.

At this point, the exhaust mouth on the previously assembled redler may not be at the same height as
the damper loading mouth. This difference can be compensated with elastic flanges or, better, by
creating a compensation hopper that joins the two parts.
At this point position the hydraulic unit that drives the pusher pistons and damper and hydraulically
connect the parts. Electrical connections are made after they are filled with oil. Pay careful attention to
the unit motor rotation direction avoiding conflicting motion.
In the same way the mobile grill hydraulic control unit is positioned and connected to the movement
pistons. Electrical connections are also required in this case.
Another important assembly phase involves the hydraulic connections of cooling parts. These
operations should be performed when all infrastructural hydraulic work is completed. The cooling
system layout is supplied by Uniconfort in the preliminary phase for their dimensioning. Connections to
be made are essentially the following:
1) Connection from a manifold to the cooled screw by a rotating joint.
2) Connection from a manifold to the cooled segment of the pusher.
Connection from a manifold to the cooled grill (if applicable). Pay attention because the grill
is cooled with flow from bottom
3) to top and crossing the supply with exhaust. Therefore, once the flow input and output
positions are selected, the remaining flanges must be closed.
4) Connection to the exhaust deflector tooth (if applicable). For the power burner model, a
pipe must be connected from the manifold to the flame deflector tooth on the burner
module. This connection, which can also be closed if the burner is not used, must be fully
open for use to avoid significant temperature changes in the post-combustion chamber.
Capacities and priorities to be applied to the various flows are provided by Uniconfort in functional
layouts.
Another hydraulic connection must be made with the thermostat flood valve. This connection must
be made with a continuously available water source to guarantee protection against flame returns,
therefore it must be connected to the fire extinguisher mains.
For steam boilers, a self-exciting steam pump is also supplied. This 3-way pump (input, output and
draught) called an injector, must be connected between the boiler supply and return and must always
have a tepid water mass available (with a tank with at least a couple of priority meters over the
injection position) or fire extinguisher water, suitable de-pressurised (to have a priority of a couple of
meters). In the event of power outage and provided there is at least 4 bar residual pressure in the
boiler opening the supply and draught conduits will trigger pumping that will inject water in the boiler to
restore safety levels.
Safety valves must be flanged to the upper part of the exchanger using the nozzles. These safety
valves include condensation non-return and non-blast exhaust channels for outdoor exhaust.

4.4.1 GLOBAL STEAM ASSEMBLY
Introduction
Biomass boilers manufactured by Uniconfort are boilers made up of several modules assembled
with bolted connections or welded seals, characterised by extreme simplicity. Essentially, assembly
consists in a sequence of stacking or flange operations where solid or liquid seals are applied to
prevent or consistently reduce air loss in the combustion chamber.
Definitions:
Lower base: The part of the boiler that houses the mobile grill.
Upper base: Part of the boiler that houses the main combustion chamber and post-combustion
chamber.
Heat exchanger: Part of the boiler where heat exchange processes occur between hot smoke and
carrier liquid.
Ash removal system: A system of hoppers with internal driven feed screws that remove ash from
the combustion chamber and carries it to a storage silo.
Rotary joint: The joint to be applied to one of the ash removal screws that must be connected to a
cooling water flow to cool ash.
Cooled grill: A mobile grill equipped with a pair of manifolds that continuously cool the fixed row
vents.
Mobile grill: A movement system equipped with a certain number of fixed vent rows alternated with
mobile vents moved by a hydraulic or mechanical system. Mobile vent movement against fixed ones
creates alternating movement that moves material forward during combustion.
Vent: An insert made of special cast iron or refractory steel, resistant to chemical agents and
temperature changes. A sequence of vents in overlapping rows creates the mobile grill.
Feed mouth: The part of the machine through which material is introduced for combustion. This part
of the machine is usually specially insulated or cooled by a flow of water to keep the interface at low
temperatures.
Fuocomatic: A material movement system made up of a loading hopper that dumps to a closed
conduit where a feed screw driven by a variable speed gear motor pushes material in a conduit
towards the feed mouth.
Pusher: A material movement system made up of a loading hopper that dumps to a closed conduit
where an alternating piston pushes material in a conduit towards the feed mouth.
Safety fire barrier door: A mechanical damper, driven by a hydraulic unit that separates and seals
the pusher from other moving parts and prevents air passage between to the combustion chamber
during pusher loading phases.
Fire extinguisher thermostat valve: A thermostat bulb valve positioned on the pusher hopper, that
floods the hopper if plate temperature exceeds a certain set value. This valve thus creates an
automatic fire extinguisher for flames that could return up the loading mouth towards the pusher or
fuocomatic hopper.
Safety valve: Valves connected on suitable flanges on the upper part of the heat exchanger that
discharge pressure and water flow when over the previously set value which corresponds to the
maximum working pressure.

SLAC level probe: It is made up of a level regulator and is connected to an electrode (steel rod)
which must be long enough to reach the
level set to stop the fuocomatic or pusher (automatic feed system).
Pump level probe START-ON: It is made up of a level regulator and is connected to an electrode
(steel rod) which must be long enough to reach the level set to start the feed pump.
Pump level probe START-OFF: It is made up of a level regulator and is connected to an electrode
(steel rod) which must be long enough to reach the level set to stop the feed pump.
Feed pump: (option): An important element for correct boiler operations. It pumps supply water
into the exchanger. Capacities and priorities must strictly observe the values indicated by the
engineering office. Supply water comes from the condensation collection tank.
If the steam produced and used in the system is fully disposable, water supplying the boiler must
come from collection tanks and its temperature must never drop under 60C.
Requirements:
A set of generic tools (clamp, wrenches, hammers, levers, etc.) and a welding machine are required
for boiler assembly to secure some parts.
A carpenters ruler is required to check geometry.
A crane with 12 meter lifting capacity and chains with x ton capacity are required for at least two
days to handle pieces.
Ladders or scaffolding and a lifting system with at lease 3 ton capacity for at least 6 working meters
(fork lift) are required to assemble accessories.
Personnel
assembly. At least one person must be a good mechanic with welder qualifications. At least one
electrician is required for electrical connections (8 10 days). At least one plumber is required for
hydraulic connections.
Reference drawings
D00GLOB-DP-1 Complete boiler
XXXXXXX-XX-X Executive layout of the civil works for the job
XXXXXXX-XX-X Executive layout of the system for the job
D00IDRI-GV-0 Cooling water layout
D00INIE-PT-0 Steam injector circuit layout
Assembly procedure:
The entire ash removal system must be placed in trenches dug according to the layouts supplied by
Uniconfort. This system must include ash collection tanks facing upwards and placed at the level of
the lower base.
Before positioning the lower base, ceramic strips must be applied to the collection hopper edges.
When resting the lower base on the hoppers, make sure the edges with ceramic fibre are
compressed by the shaped under the base.
When coupled, spot weld the hopper edges to the base to keep the ceramic fibre continuously
compressed. After the lower base is positioned where indicated in the layout, Uniconfort will install
additional ceramic strips (supplied) on the upper flange of the base around the entire perimeter (see
base and exchanger coupling diagram in the manual).
These strips must be compressed by the weight of the upper base. Next position the upper base. In
general, bases have a male/female coupling system made of refractory cement to centre the parts.
When fine-tuning the position, the upper flange on the lower base must couple with the lower flange
on the upper base. This coupling is obtained using screws and is required to keep a minimum of
compression between the flanges to compensate any planarity errors or deformation which, even if
minimum, are possible during movement processes between the parts.
Fastening screws must be slightly tightened with torque clamps to a torque around 50 Nm and
checked during the heating phases.

Again, ceramic strips must be placed around the entire perimeter of the upper base before
positioning the heat exchanger.
Once the exchanger is filled with water, check screw tightness during heating phases.
Once all the modules are in place, all system accessories can be assembled for which all air stumps
and fans and pre-assembled wires with their relevant protection raceways must be assembled.
When this phase is completed, assemble the coupling mouth flange to the entire pre-assembled
pusher-damper system. Before closing the flange, apply a thick layer of silicon at high temperature
between the two surfaces to seal surfaces against air loss.
At this point, the previously assembled redler exhaust mouth (fuel loading system from the silos)
may not be at the same height as the damper loading mouth. This difference can be compensated
with elastic flanges or joints (supplied) or, better, by creating a compensation hopper that joins the
two parts.
At this point position the hydraulic unit that drives the pusher pistons and damper and hydraulically
connect the parts. Electrical connections are made after they are filled with oil. Pay careful attention
to the unit motor rotation direction avoiding conflicting motion.
In the same way the mobile grill hydraulic control unit is positioned and connected to the movement
pistons. Electrical connections are also required in this case.
Another important assembly phase involves the hydraulic connections of cooling parts.
These operations should be performed when all infrastructural hydraulic work is completed. The
cooling system layout is supplied by Uniconfort in the preliminary phase for their dimensioning.
Connections to be made are essentially the following:
1) Connection from a manifold to the cooled ash removal screw by a rotating joint.
2) Connection from a manifold to the cooled segment of the pusher.
3) Connection from a manifold to the cooled grill (if applicable).
Pay attention because the grill is cooled with flow from bottom
to the top, crossing supply with exhaust. Therefore, once the flow input and output
positions are selected, the remaining flanges must be closed.
4) Connection of the level indicators with the relevant flanges on the exchanger side
5) Connection of the instrument holder pipe by a flange with the flanged nozzle, near the
probe holder pipe over the exchanger.
Boiler control devices are already pre-assembled, therefore
check the assembly of:
1 the manual reset pressure switch with relevant coil
2 the working safety pressure switch with relevant coil
3 the working pressure switch with relevant coil
4 the pressure gauge with relevant coil and pressure control outlet.
6) Connection and installation of all level probes on the
probe holder barrel.
7) Connection of the supply pump between the boiler feed nozzle
and the tank or condensation collection tank.
Check operating data supplied by the job (engineering office)
with the typical feed curve for the pump in question.
Capacities and priorities to be applied to the various flows are provided by Uniconfort in
functional layouts or tables.
Another hydraulic connection must be made with the thermostat flood valve. This connection
must be made with a continuously available water source to guarantee protection against flame
returns, therefore it must be connected to the fire extinguisher mains. Mains pressure upstream from
the valve must not exceed 0.5 bar, therefore a pressure reducer must be installed.

Check service pressure switch calibrations, comparing the set pressures with the pressures
required by the customer job or issued by the engineering office.
If the automatic exchanger cleaning door is installed, an additional pneumatic connection must be
made. Therefore, a certain quantity of dry compressed air at about 6 7 bar must be available.
The connection is made on the air manifold over the cleaning door. This connection must be able
to fill the 30 litre tank in 20 seconds. Therefore, check compressed air compressor potential based
on this instruction.
Smoke filtering system assembly procedure:
Introduction:
The smoke filtering system is all the piping connected to the boiler that receives exhaust smoke
and filters it with suitable parts until discharged in the flue.
Definitions:
Single wall flue: A flue made of stainless steel plate, simply rolled around itself. Standard pipe
sizes are used and may be cut to custom sizes.
Dual wall flue: A flue made up of two stainless steel sheets rolled on themselves and one with a
suitable layer of insulating material. Standard sizes are used while non standard sizes are created
with telescopic pieces that slide between the parts to cover a certain range of extension.
Connection band: Each flue is made up of a male part (smaller) and female part (larger). Once
the two parts are coupled, they are sealed (with high temperature silicon) and a connection band
applied to tighten the two parts, guaranteeing the seal.
Cyclone: A cylinder shaped mechanical type filter with a side attachment to the hopper and vertical
outlet. The height of the attachment is always lower than the outlet. An ash collection wheeled
container is located at the base of the cyclone which must be sealed for correct operations.
Multi-cyclone: A parallelepiped shaped mechanical type filter with an attachment to the hopper
lower than the hopper outlet.
An ash collection wheeled container is located at the base of the multi-cyclone which must be
sealed for correct operations.
Sleeve filter: A parallelepiped shaped mechanical type filter with an attachment to the hopper lower
than the hopper outlet. It is usually must longer than it is high and wide. In the filter are a certain
number of cyclones (sleeves made of stainless steel mesh) that capture dust during operations.
On the upper part of the filter is a battery of solenoid valves located on a manifold that discharge a
pulsating flow of air on sleeves to clean them. On the lower part of the filter is a collection hopper on
which a screw conveyor operates to remove ash to an
external wheeled container.
On the upper part of the filter are containment fences for safety purposes during sleeve
maintenance. The upper filter cover includes a series of access doors to the filter batteries.
Manual damper: A stainless steel damper for the air conduit that can be used in the event of
emergency or to roughly adjust system air output flow.
Driven damper: A stainless steel damper with a servo motor that controls opening based on a
depression value to be obtained in the combustion chamber.
By-pass damper: A negative control driven damper. This damper is always closed during normal
operations and automatically opens thanks to a return spring when there is a power outage or
exhaust faults or a PLC request.
Smoke exhaust: An electro-fan equipped with an intrinsic cooling system that permits use at typical
combustion smoke temperatures. This exhaust can be driven by an inverter based on typical
combustion logic.
Chimney: A stainless steel or galvanised steel chimney made up of to assembled modules. The
base module includes the connection flange to the chimney base. Flange dimensions are supplied
with the executive system layout. There is always an inspection door and exhaust and condensation
exhaust nozzle at the base of the chimney. There is always a sleeve with a probe inlet for smoke
samples at the chimney inlet.

Requirements:
Personnel
assembly according to exhaust system length and complexity. At least one person must be a good
mechanic with welder qualifications. At least one electrician is required for electrical connections (1
2 days).
Reference drawings
XXXXXXXXX-XX-X Executive layout
Assembly procedure:
Main exhaust conduit parts must be positioned first as accurately as possible (filters, smoke
exhaust, chimney). Once these parts are positioned, complete exhaust conduits between the
boiler and the next closest part. To do this, all complex parts must be assembled such as elbow
and T joints. Once two adjacent pieces are assembled, seal them with sealing silicon and apply
the connection band. Once the containment bands are tightened, tie them with a steel wire and
anchor them to the power plant ceiling or any stable support that can sustain the weight. If the
conduit segments are not very long or distant, if piping does not excessively curve due to its
weight, anchoring may be avoided. Apply an anchoring logic with wires every 2 - 3 meters of
straight piping. Assemble the various segments following the diagrams supplied by Uniconfort,
leaving the part covered by the telescope for last. The avoids errors and assembly tolerance is
compensated by extending the telescope section.
To assemble the dampers, recreate a dual male fitting between the input and output segments.
Stainless steel rings are applied for adaptation with the system for this purpose. In any case, all
operations must be performed to guarantee specific piping seal.
Both the smoke fan and multi-cyclone are supplied pre-assembled, therefore, once positioned
with the connected smoke conduits, only fasten using the hole in the floor and apply the
mechanical or chemical dowels to the relevant base flanges.
The sleeve filter may be supplied in two pieces for size reasons. In this case, assemble the two
parts, sealing the coupling with high temperature silicon.
Once all piping is secured, perform electrical servo motor connections.
An opening on the roof must be made for the by pass pipes and plugged to prevent water from
leaking in the passage way.
4.4.2 WARNINGS AND CHECKS BEFORE INSTALLATION
Before installing the boiler, make sure that all system components meet the technical and dimensional
installation specifications.
The boiler must be installed in a specific room with flat and levelled horizontal floor to permit suitable
boiler support.
The customer must have a technician (surveyor or engineer) check floor load capacity
according to boiler mass.
Design specifications must be met in installation when applicable and space around the boiler must be
guaranteed for the installation of boiler accessories and routine system maintenance including boiler
door openings.

4.4.3 ELECTRICAL CONNECTIONS
Before connecting the boiler switchboard to the mains, make sure the boiler power specifications
(plates and manual) meet installation site mains specifications.
Check:
Power voltage
Required boiler power or current compared to mains capacity (wire section and coordination with
protection devices against overloads and indirect contacts).
Installation must meet current regulations according to the manufacturers instructions and
must be performed by qualified personnel assisted by the enclosed wiring diagram or these
instructions.
Incorrect installation may damage people and property for which the manufacturer shall not be held
liable.
The electrical safety of this machine is only reached when correctly connected to a protection
conductor (PE) according to EN 60335-1, CEI 64-8, IEC 60364 regulations.
It is essential that this safety requisite is met and, in the event of doubt, request an accurate system
evaluation by professionally qualified personnel.
Specification Value
Mains TT or TN/Three-phase + N + PE (protection conductor)
NOMINAL VOLTAGE 400V / 50Hz
MAIN SWITCH CUT-OFF POWER To be defined by end user
CONNECTION WIRES SEE WIRING DIAGRAM SPECIFICATIONS
According to installation but in accordance with regulation
MECHANICAL WIRE PROTECTION
CEI 64-8
Factory mains system switchboard connections
4.4.4 HYDRAULIC SYSTEM CONNECTIONS
Qualified personnel must perform checks and installation.
The hydraulic system must be constructed according to the specifications provided by a thermo-
technical designer who adequately dimensioned pipes and pumps according to boiler potential and
water and/or steam flow required for the various utilities with the necessary priorities according to the
distances and load losses, guaranteeing routine system operations.

The hydraulic diagrams provided by Uniconfort are to be considered purely indicative, with exemplary
indications for the various systems that can be constructed.
The customer is liable for correct system dimensioning and constructions and must select the
engineer and thermo-technical installation technician.
In any case, a circulation pump (anti-condensation) must always be installed to guarantee hot water
temperature uniformity throughout the boiler.
It is very important that the temperature change between hot water supply and return in the boiler
does not exceed 25C, therefore minimum return temperature of hot water in the boiler must not be
under 60 C.
Use suitable pumps, valves, flanges, joints and accessories for the hydraulic system with technical
specifications adapted to the system that may be 90C.
Suitable breathers must be installed at the highest points of the hydraulic system to eliminate air in
pipes and drains at the lowest points of the pipes with their relevant faucets.
It is best to install on hot water supply pipes:
A flow meter
A manual reset safety thermostat
A heat and/or safety release valve
a manual reset safety pressure switch
Any other safety device foreseen by current regulations.
4.4.5 SUPPLY WATER TECHNICAL SPECIFICATIONS AND CHECKS
Steam boiler supply means

For supply means dimensions, art. 21 of Regional Decree n. 824 dated May 12, 1927, which states
that every steam generator must be equipped with two feed devices, each independently capable of
supplying at least double the water needed so that their independent operations are always ensured,
must be met.
However, if water supply regulation is automatic, observe the values in the Presidential Decree n.
1208 table dated Sept. 5, 1996.
The two feed devices must be independent meaning they must be driven by different energy sources;
in most cases, an electro-pump and steam pump are installed.
If two electro-pumps are installed, one must be driven by an energy system provided by diesel or gas
powered generators, or a diesel pump must be directly installed.
Boiler supply water specifications
In order to avoid calcium deposits, mud formation, corrosion, encrustations, etc., supply water must be
treated with softeners and/or conditioning additives and de-ionizing processes conducted to obtain the
following limit values:

UNIT OF MAX PRESSURE

PARAMETERS
MEASURE pressure values for generator max 15 bar
pH 79,5
Total hardness mg/CaCO3 10
Oxygen (2) mg/l O2 0,1
Free carbon dioxide (2) mg/l CO2 0,2
Total iron mg/l Fe 0,1
Copper mg/l Cu 0,1
Oily substances mg/l kg 1
Aspect Clear, limpid and without persistent foam
Note 2: Without a degasser, it is best to raise water temperature to at least 80

to reduce dissolved gas (O2) (CO2)
Boiler working water specifications

In order to avoid calcium deposits, mud formation, corrosion, encrustations, etc., working water must
be treated with demineralisation, degassation and oxygen neutralisation processes to obtain the
following limit values:
UNIT OF MAX PRESSURE

PARAMETERS
MEASURE pressure values for generator max 15 bar
pH 911
Total alkaline mg/CaCO3 1000 (6)
Total hardness (3) mg/CaCO3 10 (6)
Conductivity (4) S/cm 8000
Silicon mg/l SiO2 150
STD mg/l 3500 (6)
Conditioner(s) (5)
Aspect Clear, limpid and without persistent foam
Note 3: Calculated on filtered sample

Note 4: The two parameters have the same physical meaning: Values only associable if the
chemical composition of the water is known
Note 5: Correct management assumes the use of conditioner(s) with doses and limits
according to their specifications.
Steam boiler water analysis frequency

For correct steam boiler management and preservation of all steam and condensation lines, a series
of periodic analyses are required to check the chemical parameters that can influence boiler/system
preservation in real time. Control frequency is recommended by regulation UNI-7550.
Visual minimum water level control in the exchanger

During normal boiler operations, make sure the water level indicated on the instruments on the side of
the exchanger called the level indicator or display unit always corresponds to the signal on the
indicator.

Assembly warnings for system connection parts with pressurised boiler parts
For safety purposes and therefore to meet warranty rights, all pressurised external boiler parts:
hydraulic couplings, steam outlets, safety valves, control and correct operating parts, must never be
subject to external stress. Therefore, they must not be subject to stress, loads, weights, etc. derived
from boiler connections to system parts.
Hot water and heated water boiler hydraulic connections
1. System delivery
2. System return
3. Safety valve
4. Drain boiler
4.4.6 EXHAUST CONDUCT INSTALLATION
A mechanical smoke exhaust connected to a multi-cyclone filter must be installed on the boiler system
to capture particle combustion residue and a chimney installed to expel combustion products.
Chimney and smoke filters must be dimensioned according to the quantity of smoke at 200/250C
temperature, the necessary priority and heat potential of the boiler.
The boiler exhaust must be connected to the multi-cyclone filter and chimney with a passage section
equal to the boiler one, preferably circular made of steel suited for high temperatures and/or
appropriately thick stainless steel. All direction changes must be made with wide angle curves to
promote smoke exhaust and include a sleeve to drain any condensation at low points. It is also helpful
to line chimneys with insulation to avoid the formation of condensation at high temperatures in the
boiler room.
With the pressurised combustion of the current boilers, the chimney no longer covers the primary
draught function but only acts as a conduit for smoke exhaust. However, the chimney must operate in
depression conditions and thus requires suitable dimensioning. Upward smoke speed is determined

by the heat change of the chimney and the depression of the smoke exhaust that sucks smoke from
the multi-cyclone filter and conveys it to the chimney.
Smoke exhaust conduit connection
Vertical chimney column dimensioning needs to take into account many factors for specific
calculations case per case.
To simplify calculations, we recommend considering smoke speed in the vertical conduit equal to 8
m/sec.
For example:
boiler 400000 Kcal/h
Smoke flow at 250C 2740 mc/h
Ascent speed 8 m/sec
Results in:
Chimney section 961 cm2
Corresponding to a diameter of 350 mm
(considering a height not under 12 m).
The smoke exhaust conduit must be installed by qualified personnel, at the point indicated in the
previous figure, on the upper part of the boiler.
Upon customer request, it can be installed by the boiler manufacturer.
4.4.7 FIRE EXTINGUISHER SYSTEM INSTALLATION
The fire extinguisher system is connected to the hydraulic mains with a thermostat valve in the point
indicated in the figure below.
System working pressure must be between 0.5 and 1 bar.
Qualified personnel must install the fire extinguishing system.

Fire extinguishing system connections
4.5 SYSTEM PREPARATION AT THE INSTALLATION SITE
The boiler room, in addition to having the physical dimensions to adequately house the system and
permit all maintenance required for good overall system operations, must also be prepared with all the
safety devices indicated by local regulations.
Boiler room system and structural preparations include:
- Wells that permit water to be drained from the boiler

- A general switchboard with installed power that permits the good operations of all
system devices
- Air vents specifically dimensioned to meet machine fan air absorption
- A fire extinguisher system that supplies the system safety valve
4.6 COMMISSIONING
Before starting the boiler, authorised personnel must make sure that all safety devices installed on the
system are in good working order. The main checks to be performed are:
- Make sure the safety valves operate correctly
- Test flood thermostat valve operations
- Test the steam injector (for steam boilers)
- Test hydraulic system circulation pump operations
4.7 INSPECTION, TEST AND TRIALS
All Uniconfort boilers are subject to cold inspections by specialised personnel on the production site.
The purpose of the inspection is to check the good working order of each single component.
Specifically, tests are conducted on components such as: Automatic ash removal, primary, secondary
and third air fans, automatic exchanger cleaning, mobile grill operations and smoke exhaust.
Final system inspection is conducted after full assembly. Inspection is a delicate operation that must
only be conducted by qualified Uniconfort personnel; system commissioning by the customer must be

officially authorised by the manufacturer else any system damages will not be covered by the
Uniconfort warranty.
PART V BOILER OPERATIONS
5.1 PERSONAL PROTECTION DEVICES
When operating the boiler, the operator must wear, when and where required, suitable personal
protection devices according to the present risks, before conducting the operations described in this
manual.
5.1.1 LIMB PROTECTION
For operations with burn risks:

Wear gloves suited to work in contact with surface temperatures of at least 100 C
In other cases:
Wear protective gloves to avoid prolonged skin combustion ash contact and against abrasion,
puncture or cutting risks from contact with wood splinters.
5.1.2 HEARING PROTECTION
The choice of suitable devices must be made by the system safety manager, taking into account the
effective levels measured at the system installation site.
The sound level produced by the boiler measured in accordance with regulation UNI-EN 15036-1 is 79
dB.

5.1.3 RESPIRATORY TRACT PROTECTION
The user must wear a mask for all operations on the boiler, specifically during manual loading, to
avoid inhaling wood dust and/or ash.
The choice of a suitable device must be made by the system safety manager, taking into account dust
grain size.
Generally, semi and quarter masks can be used in accordance with regulations EN 149 and EN 143
for dust filters.
Refer to EN 529 guidelines.
Climbing on the boiler and approaching the smoke exhaust chimney is strictly prohibited unless for
maintenance when the boiler is not operating.
5.2 PRELIMINARY CHECKS AND FIRST START UP
5.2.1 MACHINE INSPECTION
The boiler was factory inspected by the manufacturer before delivery.

The boiler inspection certificate is enclosed with boiler documents.
5.2.2 PRELIMINARY CHECKS
Once confirming that installation was correctly performed observing the instructions in this manual,
carefully check the following:
Hydraulic system system filling
Electrical system (voltage)
Smoke exhaust system
Fuel feed system (chip wood, saw dust, chipboard)
Motor rotation directions
Operating and control device regulations and calibrations.
Also check the following:

Open boiler doors and make sure there is no foreign objects and/or impurities in the brazier and
that all is in good working order;
Make sure all doors correctly close and seal and correct, if necessary, using the specific registers.
Check primary, secondary and circulation (anti-condensation) pump operations making sure water
circulates in the system without air.
Check the level of lubricant oil on gear motors, variation speed gear motors and any other part that
required periodic lubrication.
5.2.3 FIRST START UP
A qualified technician must conduct the first boiler start up.
Proceed as follows to start the boiler with PLC operations:

Turn on the main switch

Put the boiler in manual mode; this function allows the operator to check fan rotation direction
according to the indicated arrows. If the direction is incorrect, exchange the two power phases.
Turn on the circulation pump (anti-condensation) to prevent condensation from forming in the
combustion chamber.
Switch to automatic mode and then press the start button.
Make sure that material in the silo has the specifications indicated in the supply contract.
Wait until material arrives in the combustion chamber covering the chrome cast iron elements and
reaching mid-grill.
Put the boiler in pause.
Turn on the pilot burner for 4 5 minutes until fuel is fully ignited.
Put the machine in pause again, turn off the pilot burner and switch back to automatic mode.
Adjust the quantity of fuel required for boiler capacity using the regulator on the speed variation
gear motor on the feed screw.
Adjust the quantity of primary, secondary and third combustion air following the PLC manual
instructions provided with boiler documents.
Adjust water and/or heated water and/or steam temperature following the PLC manual instructions
provided with boiler documents.
The boiler has an automatic ignition control and maintenance program which stops the boiler in the
event of lack of fuel.
Upon first start up a considerable amount of condensation is formed due to the walls being wet
with still cold water and by the steam that the refractory lining frees; this normal event lasts a
couple of hours and then permanently disappears.
Make sure that qualified personnel perform each re-ignition, physically following the entire ignition
operation.
Once the boiler works regularly, check control and safety thermostat equipment, combustion yield
and depression in the combustion chamber which must be less than 8 or 10 mm H2O.
5.2.4 TRIAL STAGE
The boiler does not need a special trial stage but requires careful attention upon first start up.
Slowly bring the boiler to working temperature to avoid sudden temperature increases in the
combustion chamber that could cause material damages to the refractory lining with obvious
cracks
Water heating time: From 0 to 90 C in at least 48 hours.
5.2.5 COMMISSIONING REPORT
Every new heating system must be reported to the specific organisations for inspections.
Operating and control instruments must meet current technical regulations and the hydraulic
inspection certificate.

The boiler is equipped with a metallic sticker indicating general specifications concerning heat power
yield and absorbed expressed in kcal/h and kW.
Every boiler is equipped with documents including:

Declaration of conformity
Inspection certificate (hydraulic inspection)
Installation and use instruction booklet
Wiring diagram
PLC manual (where applicable)
5.3 NORMAL AND SPECIAL USE
As already indicated in the general technical specifications, the boiler discussed in this manual is
intended to produce:
Hot water at 90C / 3 MPa (3 bar)
Boilers are designed and constructed to work with
Wood scraps (dust, sawdust, shavings, chip wood, pellets, etc.) with relative humidity content from
0 100 % H2O dry base, with grain size not over 30 mm.
Boilers can correctly work in alternative with a forced draught burner powered by
diesel
naphtha
Methane gas
lpg
Operations are obviously not simultaneous.
The supply type can be selected on the control panel (par. )

Furthermore, to protect the delicate parts of the burner nozzle, a removable carriage is installed to
remove the burner from the combustion chamber when the boiler operates with wood scraps and
relevant safety interlocks to stop and/or start the burner.
Burner removal carriage

Boiler operations are described below:

Solid fuel (wood scraps) in the vertical and/or horizontal container (silo) crosses a feed hopper and is
pushed to the brazier or mobile grill by a mechanical auger screw burner driven by a variable speed
gear motor or pusher driven by a hydraulic cylinder, that permit fuel quantity to be regulated according
to boiler capacity.
Fuel is ignited
By the pilot burner installed on the specific support (see photo at the top)
And/or by a cloth dampened with gas and/or diesel and inserted in the combustion chamber in
contact with fuel.
The flame is fed by combustion air put into motion by specific fans divided in primary, secondary and
third air and according to the boiler type.
The heat produced by combustion heats the internal boiler walls crossing the heat exchanger and
combustion residue is dispersed through a suitably dimensioned exhaust flue.
Water in the boiler is heated by the heat released through the exchanger walls until reaching working
temperature which is:
+ 90 C for hot water,
Climbing on the boiler and approaching the smoke exhaust chimney is strictly prohibited
unless for maintenance when the boiler is not operating.
The boilers described in this manual must only be operated within the foreseen use
restrictions.
Any other use is considered improper and can therefore cause risks to people and systems.
The manufacturer shall not be liable for any damages caused by improper, incorrect and
unreasonable use.

Damper for manual or automatic combustion air flow regulation
Air flow absorbed by fans can be regulated by either using the automatic dampers or by controlling the
electrical fan motors with an inverter. This second option saves absorbed energy and provides
improved combustion air regulation.
5.4 RISK CONDITIONS AND ABNORMAL USE
Do not start the boiler if there is no water to be heated in the hydraulic system.
Do not attempt to open loading doors if the boiler is running.
Do not attempt to open cleaning doors if the boiler is running.
In general, do not clean, maintain or repair the machine when running.
Do not permit unauthorised personnel to use the machine
In observance of the applicable European directives concerning machinery and work site safety,
Uniconfort has reduced potential risks due to incorrect boiler use, installing the following safety
devices:
Micro switches on doors and lids that stop boiler operations when opened
Working and safety thermostats that stop boiler operations when they reach a preset temperature
Positive action thermostat fire extinguisher valve that also operates in the event of a power outage
to avoid flame return in the fuel feed screw.
An ignition control unit that stops boiler operations in lack of fuel.
Circuit breakers that stop boiler operations should one of the boiler motors overload.
Hazards that could not be eliminated by the safety measures adopted by the manufacturer are
caused by incorrect boiler use or failure to observe the safety regulations indicated in this
manual.
5.5 EMERGENCY INSTRUCTIONS
When the boiler is in emergency conditions a light turns on and the switchboard emits an acoustic
signal. If the system includes a dial system, a phone call is made to a preset number when these two
signals occur.
In this case, the operator must go to the system, check safety device operations and, if necessary, call
authorised personnel to resolve the problem.
What not to do in the event of emergency:
Open inspection doors
Manually intervene on water discharge valves or safety valves in general
Enter the silo chamber or in the mobile surface work area
Open the pusher connection hoppers or fire barrier damper work hopper.
For steam boilers, in the event of main supply pump fault or power outage, promptly start the injector
as described below:

1) Check the water level on the indicator on the side of the exchanger
and check the position compared to the minimum safety level
notch.
Fig.
Control or signal
2) Start the injector to fill the exchanger with water, ref.
observing the 1 Door lock main switch
instructions and indications in the use and instruction 2 Indicator light-on
manual, supplied with the boiler, paying attention to 3 Indicator light-off
open the manual damper between the injector and 4 Start button
line that fees the boiler with the pump. 5 Wood operations light
6 Burner operations light
3) Turn off the injector when the maximum level is 7 Lock light
reached. 8 Wood/burner operations selector
9 Manual/automatic operations selector
4) Check the water level and repeat the previous
operations
(2) and (3) if the level is under the minimum safety level, until
power is restored or the supply pump resumes operating.
5) When pump operations resume or power returns,

close the manual damper before switching to
automatic mode.
In emergency situations,
there may be smoke in the boiler room. In this case, evacuate all smoke and always install a smoke
sensor in the room.
5.5.1 FIRE EXTINGUISHER MEANS
In the event of fire, use powder extinguishers that meet current regulations.
Never use liquid extinguishers.
5.5.2 POSSIBLE EMISSION OF HAZARDOUS SUBSTANCES
In the event of fire, some parts of the boiler may emit toxic gas when burnt.
Use suitable protection means and refer to pertinent national regulations in force.
5.5.3 SWITCHBOARD
The boiler is equipped with a switchboard whose features are grouped in the section dedicated to
general technical specifications.

Machine controls with the ON/OFF switchboard, combustion regulation parameters are manually set by the
technician who starts the boiler and once set, they cannot be changed by unauthorised personnel.
For boilers with switchboard equipped with a PLC with automatic and programmed combustion control,
consult the specific PLC panel user manual supplied with the boiler.
According to the type, the PLC may have various boiler control parameters. For differences please see
the lambda tronic PLC and lambda full PLC descriptions in the switchboard and system" section.
The PLC is programmed so that the system operator can only change "permitted" parameters. There
is also a "reserved" parameter section accessible to Uniconfort technicians in possession of a reserved
password. Access to this section is prohibited to unauthorised personnel and the manufacturer
is not liable for damages caused by failure to observe these instructions.
PART VI DIAGNOSTICS AND MAINTENANCE

6.1 PERSONAL PROTECTION DEVICES
See paragraph 5.1
6.2 Malfunctions, faults, breakdown
Since most malfunctions are caused by incorrect machine use, the following table indicates some possible
malfunctions that may occur and the measures to be taken to resume normal operations.
If the boiler does not operate correctly after performing the operations listed below, please contact your local
technician and/or UNICONFORT.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

The mechanical screw No fuel arrives Fill the silo with fuel
burner does not start Fuel too damp. Remove fuel and
Feed screw malfunction replace with drier fuel.
Pieces of wood jammed in the Eliminate screw fault
screw. Eliminate jammed wood by
Bridge breaker star or spiral rotating the screw one turn in
worn. reverse and remove wood
through the inspection door.
The screw must be rotated
manually or electrically in
manual mode on the PLC.
Replace worn parts.
The boiler does not start No power. Turn on the main switch
Remote motor protection Reset the circuit breaker
triggered Reset the working and/or safety
Thermostats triggered thermostat
Pressure switches triggered Reset pressure switches
Doors open Close doors
Limit stop switch triggered Release the limit stop
Imperfect combustion Boiler jammed by combustion Clean the entire boiler including
with smoke in the products under the brazier
chimney No primary and/or secondary Adjust primary and secondary
combustion air air quantity using the dampers
Excessive fuel Reduce fuel quantity on the
supply chip flow regulator on the
Fuel too damp. variation speed gear motor or
on PLC levels.
Smoke temperature high Heat exchanger dirty Open the heat exchanger door
Combustion chamber in over- after turning off the machine
temperature and clean the pipes with the
supplied brushes.

Turn off the machine and

remove ash from the brazier.
No depression in the Check driven smoke exhaust Replace damper servo motor
combustion chamber damper Replace digital deprimometer
Check depression reader
operations
6.3 ROUTINE MAINTENANCE
Cleaning
Boiler waste material is made up of combustion ash deposited in the ash collection chamber at the lower
part of the boiler.
Ash removal is automatic when the boiler includes an automatic ash removal system which conveys ash to
the specific container through a feed screw.
When the automatic ash removal system and automatic exchanger cleaning system are not installed,
open the exchanger, combustion chamber and exhaust chamber doors and remove ash with the
shovels provided with the boiler and/or industrial vacuum.
Dispose of ash according to current regulations.
Clean the combustion chamber, pipe heat exchanger, multi-cyclone, smoke exhaust and under the brazier
whenever the accumulated quantity of combustion residue impedes correct operations.
Check the quantity of accumulated residue every 30 days of boiler operations. The exchanger cleaning cycle
depends on the burnt material ash residue.
General cleaning restores good draught and operations with consequent maximum boiler yield.
Perform general cleaning with the boiler off, making sure all parts are in good working order.
Never empty system water.
To turn off the boiler, see the specific paragraph.
6.4 PERIODIC AND ROUTINE MAINTENANCE

Routine system controls and maintenance are the customers most important duties that guarantee good
operations and long system working life and the possibility of receiving the best boiler performance at all
times.
WARNING INJURY HAZARD: Whenever performing maintenance, the boiler must be off and the
operator must wear protective gloves and safety goggles.
CONTROL
PART TO BE CHECKED OPERATIONS TO BE PERFORMED
FREQUENCY
Gear motors and speed Top off with suitable oil.
50 days
variation gear motors
Check and lubricate with suitable lubricants:
Rotating parts subject to normal
30 days
wear
Cast iron brazier grill 30 days Check and replace any worn cast iron parts
Combustion air fans 30 days Clean with compressed air
Electrical parts and general
30 days Clean with compressed air
switchboard parts
Level probes and infrared Clean the probe reading surface
30 days
probes
Unit oil filter 60 days Remove, clean and replace if necessary
6.5 Extraordinary maintenance, inspections and checks
Routine boiler maintenance increases working life and operating safety.

Maintenance must be performed by a qualified technician.
All boiler maintenance operations must be performed with the machine off and switchboard main switch off.
Authorised and/or qualified personnel must replace any parts.
For boiler parts, please contact your dealer and/or the manufacturer.
Feed screw, gear and chain replacement

Pusher blade replacement
Unit valve gasket kit, pusher mobile surface grill replacement
Lambda probe and CO chimney, combustion chamber probe and water probe replacement
Infrared or proximity fuel level probe replacement
Air vent replacement
Mobile surface pusher grill piston gasket kit replacement
Oil unit pump overhaul
Grill and under grill maintenance

The following series of operating instructions concerns preventive maintenance under and on the grill. Time
indications must only be considered as indicative and calibrated according to real machine use and the type
of fuel used.
Under grill
Under grill is the space located under the grill which may be occupied by an automatic ash removal device.
Due to the nature of the grill (made up of elements with adequate ventilation areas) and nature of the fuel
used (ash formation) the area under the grill can fill with ash.
For this reason, some machines include an automatic ash removal device that can reduce accumulation but
not fully eliminate it.
An inspection door is installed on all machines to let the operator view the area under the grill at a set
frequency.
Theoretically in line with machines without automatic removal devices, inspections must be made weekly
while only monthly with the device installed.
Cleaning can be performed with a specific shovel or industrial vacuum.
Failure to clean can cause an excessive wall of ash to accumulate which could prevent grill movement or, in
catastrophic cases, break transmission parts.
Cited time limits should be calibrated according to real machine use and ash generation for the fuel used.
Therefore, we recommend frequent inspections after machine start to identify the best frequency.
Grill
The grill is the part that creates fuel movement in the combustion chamber. This part, that consists of a
mobile slide that moves in a fixed castle, has a certain number of vents that are suitably shaped chrome
steel casts that guarantee fuel ventilation.
However, these vents slide between fixed and mobile parts in the combustion chamber which has an
aggressive and high temperature atmosphere.
Sliding can cause normal wear for which we recommend you annually check grill wear and replace at least
10 % of parts.
It should be said that most wear occurs in the first month of use when the grill achieves heat and mechanical
balance, after which, wear is linear.
Therefore, the first time the machine is stopped, check lateral grill vents since they are the ones subject to
highest wear.
Foreign objects or the formation of clinkers and glass in the grill due to fuel nature and composition or
internal over-temperatures may, in some cases, damage vents.
Regularly check overall vent integrity.
Any grill deformations (the grill arches at the centre) are due to vent material overheating or the presence of
liquid ash between vents.
In this case, replace at least one element per row with thinner elements to increase total expansion capacity.
In addition to the annual inspection, we recommend a series of visual grill inspections whenever possible to
avoid unpleasant problems (a broken element could significantly increase the ash content under the grill and
significantly increase flame temperature due to abnormal combustion).

6.6 TURNING OFF / OUT OF ORDER / LOCK-OUT
WARNING: Only a thermotechnic service company can disconnect the hydraulic system
To turn off the boiler, turn the main switch on the control panel to off.
Before turning off the boiler for disuse, temporary out of order, keep the circulation pump running for at
least two hours to partially discharge heat accumulated by the refractory material and fuel on the brazier.
o Switch to the manual program and run the machine for about 20 minutes to empty material in
the transport system.
o Switch to pause and leave the machine in pause until the water temperature drops under 70
C and then turn off the main switch.
o After a couple of hours, open the loading and cleaning doors to circulate air to cool the
machine.
o For prolonged disuse, leave the boiler clean and doors semi-open to prevent condensation.
Lock-out, placing the boiler out of order in safety conditions, is obtained by pad-locking the main switch.
If switchboard service or maintenance requires the removal of direct contact protection devices, lower the
protection level under IP2XXA or IP2XXB, the mains must be cut off upstream from the main switch.
The system can only be restarted after the operator confirms that all safety conditions are met, according to
the enclosed start up procedure.
To restart the boiler, see the start up procedure described in chapter 5.
6.7 DISMANTLING
If the operator decides to no longer use the boiler or replace it, it must be dismantled.
This operation should be performed according to the following procedure and in accordance with current
regulations on work site safety.
Call an organisation for disposal and recycling according to ecology regulations.
6.8 DEMOLITION, DECONTAMINATION, RECYCLING, DISPOSAL
In the event of boiler decommissioning, parts susceptible to causing any hazard must be made
innocuous.
All parts that present health hazards must be pre-treated or handled with special care by certified
waste disposal organisations.
These operations and final disposal must always be performed observing pertinent
regulations in force.

PART VII - APPENDIXES
7.1 RECOMMENDED SPARE PARTS
Lambda probe (where applicable)

Chrome steel vents for the mobile grill
Temperature probes (combustion chamber, exhaust and water)
CO probe (where applicable)
Ash removal screw
Level probe
Hydraulic cylinder for the mobile grill
Hydraulic cylinder for ash removal
Driven dampers for air fans (where applicable)
Driven damper for exhaust regulation (where applicable)
7.2 PART LIST
Lambda probe (where applicable)

Chrome steel vents for the mobile grill
Temperature probes (combustion chamber, exhaust and water)
CO probe (where applicable)
Level probe
Hydraulic cylinder for the mobile grill
Hydraulic cylinder for ash removal
Piston gasket kit
Grill hydraulic pump gasket kit
Mobile surface hydraulic unit exchange valve gasket kit
Ash removal screws
Ash conveyor screw
Mobile surface hydraulic unit
Mobile grill hydraulic unit
Boiler fuocomatic screw
Load screw gear motor
Removal screw gear motor
Transport screw gear motor (where applicable)
Hydraulic unit oil filter
Combustion chamber deprimometer
Pusher blades (for pusher supply)
Pusher unit valves
Primary air fan
Secondary air fan
Third air fan
Hydraulic unit connection pipes
Safety thermostat valve

Depression control driven damper (where applicable)

Air fan driven dampers (if inverter is not installed)
7.3 DRAWINGS AND DIAGRAMS
Boiler front and side view model Global model
7.4 BOILER ID PLATE
Data plate is fixed on the boiler
7.5 INSTALLED PART MANUALS
This section includes all manual for various accessory system parts supplied upon request and
specifically:
Mechanical and electrical part manuals

Inverter manual
PLC manual

Appendix 6 Maintenance Procedures

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Appendix 6 Maintenance Procedures

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K135-07332 Uniconfort MUM v. 1.

USE AND MAINTENANCE MANUAL

CAREFULLY READ THE INSTRUCTIONS IN THIS MANUAL BEFORE INSTALLING,

FAILURE TO OBSERVE THE FOLLOWING INSTRUCTIONS MAY CAUSE SERIOUS

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 1

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PRELIMINARY SAFETY INFORMATION

Pay attention to this symbol where included in the manual.

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 3

THIS INSTRUCTION MANUAL MUST BE READ BEFORE STARTING ANY OPERATION.

GUARANTEED GOOD WORKING ORDER AND FULL MACHINE PERFORMANCE

STANDARDS ARE STRICTLY TIED TO THE CORRECT APPLICATION OF ALL THE

INSTRUCTIONS IN THIS MANUAL.

The use and maintenance manual is an integral part of the machine

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 4

Qualified personnel - Operator

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First level system operator

Second level system operator

Mechanical and/or electrical maintenance technician

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2.1 THE PRODUCT

Boiler mod. Global is described by regulations as

2.2 COMMUNITY AND NATIONAL LEGISLATION

LOW VOLTAGE DIRECTIVE

ELECTROMAGNETIC COMPATIBILITY DIRECTIVE

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 7

W ORKMANS SAFETY DIRECTIVES

Presidential decree no. 547 dated 27/04/1955

Legislative decree no. 626 dated September 19, 1994

Legislative decree no. 242 March 19, 1996

Presidential decree no. 459 dated 27/04/1996

Legislative decree no. 359 dated August 4, 1999

Legislative decree no. 25 dated February 2, 2002

Legislative decree no. 233 dated June 12, 2003

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 8

2.3 MAIN TECHNICAL REFERENCE REGULATIONS

REGULATION ED. HEADING

CEI EN 60529 1997 Casing protection levels (IP code)

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2.4 PRODUCT CONFORMITY

Enclosed below are copies of:

Numero di serie/Serial number/Numro

conforme a quanto prescritto dalle Direttive 98/37/CE-2006/95/CE-89/336/CEE e successive modifiche ed integrazioni.

il Rappresentante legale della ditta The Legal Representative of the Company

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 10

PART III TECHNICAL SPECIFICATIONS

3.1 TERMS AND DEFINITIONS

Maximum admissible working pressure

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Smoke side resistance

Smoke cleaning system

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3.2 BOILER FEATURES

Boiler description and possible accessories

Automatic loading system

Ash removal system

Pilot or power burner

1. loading on the upper hopper chain conveyor

Uniconfort srl Caldaie mod. Global MUM v1.3 Pagina 14

3.2.1 MAIN OPERATING PRINCIPLES

Phase A FUEL LOADING