Boiler Equipment Servicing Periodicity; Most Common Boiler Operation Faults And What To Do - Kalvis -100MG Installation And Service Manual

6.5.

Boiler equipment servicing periodicity

No Equipment (part name)
1 Heat exchanger
2 Heat exchanger door gear
3 Protective valves
4 Closing fittings
5 Ash pushing mechanism
6 Ash container
7 Cleaning gear drives
8 Multicyclone
9 Burner
10 Fuel supply auger
11 Smoke exhauster
Draught measurement
12
equipment
It is recommended, that stokers filled boiler house working log regularly, writing down the main boiler
operation mode data at a set periodicity: supply and return water temperatures, pressure, scheduled boiler
service tasks.
Hopper and auger conveyor operation is carried out according to the operation conditions specified in
their installation and service manuals (enclosed with the equipment).
6.6.

Most common boiler operation faults and what to do

No Potential problems
Condensate leaks
1. from the boiler,
resins form
Boiler fails to
2.
develop power
Smoke temperature
3.
is too high
Constant water
4. pressure reduction
in the boiler
Failures of boiler
8. drives and electrical
control
Sparks, smoke
come out of the
6.
boiler (through
doors and lids)
Burner will not turn
7.
on
Fuel supply hose
8
burned down
Jointed crankshaft
9.
axles.
* See fig. Burner control unit PLUM ecoMAX850P2-O (or KEY RK-2006LPGP2) for Pellet Boilers Installation, Maintenance, Service and
Operation Manual.
IT IS FORBIDDEN:
- To fill the system with cold water when the boiler is hot.
- To extinguish the boiler by pouring water into the hearth or burner.
KALVIS-100MG ... -500MG LT 2019.03.18
Service operation
Heat exchanger flushing
Change of door sealing rope
Lubrication
Manual opening
Closing and opening
Inspection, cleaning if
needed
Inspection, cleaning if
needed
Inspection
Inside cleaning
Inspection
Inspection, inside cleaning
Cleaning
Inspection, inside cleaning
Cause
Too low temperature of water returning to
the boiler
Improper fuel
Incorrectly adjusted burner
Heat exchanger is sooty
Sediment accumulation inside the heat
exchanger
Too high chimney draught
Leaking welded joints
Equipment was damaged during
transportation
Incorrectly connected equipment
Corrosion or other chemical damage
Control system failure
Ash removal augers are stuck
Drive (heat exchanger control, ash removal)
failure
Sealing ropes are worn
Door not closed
Smoke exhauster is out of operation
Emergency thermostat is active
Too highly set burner temperature
Bad fuel is used
Dirty burner
Too low draught
After opening the heat exchanger door, the
turbulators are not properly placed in the
sockets (see Fig. 8).
- 17 -
Periodicity
Once in 2 years
Once a year
Once a 3 months
Once a day
Once a week
Once a month
Once a 2 – 5 days
Once a 3 months
Once a 3 months
Once a month
Once a 3 months
Once a year
Once a 2-4 weeks
Check operation of recirculation pump
Adjust mixing valve
Change fuel supplier
Call manufacturer's representative
Clear sooth away from hearth surfaces
Adjust heat exchanger cleaning device.
Install/adjust smoke exhauster
Call manufacturer's representative
During connection, follow the installation and service
manual
Use proper system water preparation method
Use proper fuel
Find and remove worn parts
Call manufacturer's representative
If ash removal auger is stuck, eliminate its cause
Check state of the drives. Call manufacturer's
representative
Restore sealing by correcting rope (or other material) in the
grooves or if this does not help use new rope
Remove foreign things from the door gap, then close boiler
service doors and fasten them with handles
Check smoke exhauster
Controller failure.
See fig. in controller manual *
Replace hose
Adjust smoke exhauster
Open the heat exchanger door, properly insert the turbulent
(check the turbulent supports if necessary).
Table 2
Remarks
Or as required
Or as required
Depending on fuel type and quality
Depending on fuel type and quality
and boiler power
In line with the instructions of given
unit operation manual
Depending on fuel type and quality
Table 3
What to do