installation and operation instructions - ariterm

Read these instructions carefully before installing, commissioning or maintenance

MOVING FLOOR FUEL STORAGE SYSTEMS T62, -3, -4, -5, -6

INSTALLATION AND

OPERATION INSTRUCTIONS

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Content

1. Ariterm Oy ......................................................................................................................................... 3

1.1 Disclaimer .................................................................................................................................................3

1.2 General .....................................................................................................................................................4

1.3 Fuels ..........................................................................................................................................................4

1.4 Operating principle ...................................................................................................................................4

1.5 Heating system, assembly and back-fire protection ................................................................................4

2. Safety instructions ............................................................................................................................. 5

2.1 Fire crawls backwards to the direction of the fuel storage ......................................................................5

2.2 Injuries caused by transmission or moving parts .....................................................................................5

2.3 Exposure to hazardous dust or gases .......................................................................................................5

3. Delivery / technical data .................................................................................................................... 6

3.1 Delivery content .......................................................................................................................................6

3.2 Transport, handling and storage ..............................................................................................................6

3.3 Technical data ...........................................................................................................................................6

4. Installation ......................................................................................................................................... 8

4.1 Receiving and checking the delivery ........................................................................................................8

4.2 Requirements concerning the operating environment ............................................................................9

4.3 Installation of the equipment ...................................................................................................................9

4.3.1 Preparation and planning .................................................................................................................9

4.3.2 Mechanical installation .................................................................................................................. 11

4.3.3 Electrical installation...................................................................................................................... 14

4.3.4 Installation of extinguishing system .............................................................................................. 15

5. Commissioning ................................................................................................................................. 17

5.1 Testing the moving floor........................................................................................................................ 17

5.2 Testing the safety systems .................................................................................................................... 17

5.3 Adjusting ................................................................................................................................................ 17

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6. Hydraulic systems ............................................................................................................................ 18

6.1 General .................................................................................................................................................. 18

6.2 Safety ..................................................................................................................................................... 19

6.3 Inspection of delivery ............................................................................................................................ 19

6.4 Filling the oil tank .................................................................................................................................. 19

6.5 Start-up and Commissioning ................................................................................................................. 20

6.5.1 Gear Pump Start-up ....................................................................................................................... 20

6.5.2 Regulation and Air Removal .......................................................................................................... 20

6.5.3 Assembly ........................................................................................................................................ 20

6.5.4 Commissioning .............................................................................................................................. 21

6.6 Maintenance .......................................................................................................................................... 21

6.6.1 Oil Change ...................................................................................................................................... 22

6.6.2 Maintenance table......................................................................................................................... 23

6.6.3 Hydraulic drawings ........................................................................................................................ 24

7. Service and maintenance ................................................................................................................ 27

7.1 Maintenance .......................................................................................................................................... 27

7.2 Troubleshooting .................................................................................................................................... 27

7.3 In case of emergency ............................................................................................................................. 27

NOTES ...................................................................................................................................................... 28

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1. Ariterm Oy

ARITERM IS A FINNISH MANUFACTURER OF HEATING SYSTEMS

Our main products are central heating boilers used for heat production and service water heating, bio burner

equipment and bio heating system solutions. Our wide range features several modern heating solutions for

private homes, larger living spaces and industrial properties.

Ariterm is actively taking part in the development of the heating industry and works in close contact with

various organizations and officials in the field. We also use a certified ISO 9001 quality system to ensure that

the quality of our products is verified at every stage of production. Further to this we use a certified

environmental system that follows the ISO 14001 standard.

Ariterm Oy’s boilers and cooled burners (operating temperature over 110 °C) are manufactured according to

the H or H1 module of the Pressure Equipment Directive (PED). To prove this all the boilers have a CE 0424

stamp which has been granted by Inspecta Tarkastus Oy.

1.1 Disclaimer

Moving floor with accessories is always part of larger assemblies. This document doesn’t include complete

information of installation, operating and maintenance for assemblies. The designer of the assembly takes

responsibility of having good enough know-how and competence of designing assemblies. Assemblies must be

designed, assembled and operated in accordance with the local laws and regulations in force.

Read these instructions with care before installing, commissioning, maintenance, adjusting, when operating

the moving floor first time or after a long break! Holder of the assembly takes responsibility of that operating

personnel are trained and training fulfill the local laws and regulations in force. Operating personnel must be

able to recognize the potential risk factors related to usage or the characteristics of the product.

Content of the introductions based on the limited best knowledge of the product. Besides this document must

be familiar with the other instructions of the assembly e.g. the case-tailored automation instructions. Failure to

follow these or other instructions related to the assembly can cause damage or danger to persons, property or

the environment.

Ariterm Oy is not responsible for any damage if:

• instructions of this document are not followed

• any instructions related to the assembly are not followed

• the product or the assembly being used in violation of uses

• operating personnel of the product or the assembly is incompetent to the task

• other spare parts than supplied or approved by Ariterm being used.

The product has a limited warranty. Modifying product without promise of Ariterm Oy will void the warranty

and release manufacturer, Ariterm Oy, from responsibility of manufacturer.

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1.2 General

Moving floor fuel storage systems provide a wide range of innovative solutions. They are an essential part

of bio-fuel burning systems designed for wood chips. They meet the most up-to-date operational and

safety standards. The moving floors are designed for MultiJet and Biojet burners of different capacities.

All Ariterm moving floors have prefabricated, robust constructions on which it is easy to build a fuel

storage of desired size and form. All models have hydraulic cylinders and a storage screw with its own

actuator.

1.3 Fuels

Domestic energy sources as fuels are an economical and an environmentally friendly alternative. The most

common fuels are e.g. wood chip and pellet. These energy sources have different characteristics which affects

the selection of the equipment and their usage. The T6 moving floors systems are designed for wood chip

usage.

1.4 Operating principle

The fuel storage is filled with wood chip. The fuel is conveyed to the storage screw with hydraulic cylinder

operated moving floor conveyors. Moving floor unit includes two, three, four, five or six conveyor modules

(depending on a model). Every other of modules moves in a different direction ensuring that fuel don’t stuck

top of the unit. Storage screw conveys fuel from the storage to the burner through two separate feeding

screws with a feeding funnel in between.

The fuel storage is controlled by automation which operates the cylinders only when needed. There is a

photoelectric sensor in end of every conveyor module. Sensor indicates when there is enough fuel and stops

movement of the moving floor unit. Storage screw conveys fuel to a funnel where is another photoelectric

sensor which stops the storage screw when the funnel is full. Storage screw has also an inspection hatch for

maintenance and fuel checking. The inspection hatch is equipped with safety switch which stops storage screw

to avoid body part injuries.

NOTE! that the running screw or moving floor can cause fatal injury! Do not ignore safety switch or do

maintenance before power of the devices are turned off!

1.5 Heating system, assembly and back-fire protection

Bio heating system consists of a moving floor, screws: a storage screw, a middle screw and a burner screw, a

bio boiler and a burner with an automatic control system. Together they form a working unit. It also includes a

triple back fire protection, flame control automation and alarms for important system functions. The moving

floors are developed to be used together with Arimatic burner automation. The triple back-fire protection

consists of a feeding funnel between the two feeding screws, of a back-fire thermostat connected to the

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automation, which in a case of back fire runs the burner screw empty of fuel, and of a self-operating AVTA

water extinguishing system. Other details of the fire safety solution include a rising burner screw and a heat-

insulating flange. Optional safety equipment includes a pulse operated extinguishing system which should be

used with an UPS in case of power failure. See Figure 7 to check necessary connections.

2. Safety instructions

2.1 Fire crawls backwards to the direction of the fuel storage

How to prevent back fire:

• Keep a low pressure in the boiler’s fire chamber always (sufficient chimney length or flue gas fan, see

recommendations)

• Keep the automatic extinguishing systems in working order always

• Minimize the risks already at the planning stage. The burner screw pipe must be long enough. Also, the

clearance between the pipe and the burner screw must be measured correctly.

• Fill the fuel storage before the fuel runs out

• If the fire crawls backwards during a burner rest period, reduce the air vent of the flue gas fan. A good

draft in the chimney may feed too much oxygen to the embers.

2.2 Injuries caused by transmission or moving parts

How to prevent:

• Switch off the power from the main switch before approaching moving parts.

• Inform other staff of maintenance actions and put a sing of maintenance on sight.

• Use gloves.

DANGER! During maintenance, the safety switch must always be locked!

2.3 Exposure to hazardous dust or gases

How to prevent:

• Always use respiratory protection (dust mask) if the wood chip is mouldy and you have to handle it by

hand.

• To prevent wood chip from becoming mouldy it must be dried by machine (mould grows at 25 %

humidity).

• When the moving floor space is in use ventilate the space carefully before any entering!

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3. Delivery / technical data

3.1 Delivery content

A complete delivery includes:

• moving floor T62, -3, -4, -5 or -6

• hydraulics unit

• storage screw

• storage screw motor

• feeding funnel flange connection

• limit switch for inspection hatch

3.2 Transport, handling and storage

The moving floor can be lifted with lifting slings from its corners. There are lifting points for forklift under the

moving floor. The moving floor may be stored outdoors but must be protected from the rain. However, indoor

storage is recommended. Electric equipment must be stored indoors.

3.3 Technical data

The T6 moving floors has a range sizes of 2 x 6 (T62) m to 6 x 6 m (T66). One additional module has size of 1 x 6

m. Option to choose right size of the fuel storage makes T6 moving floors suitable for a wide range of fuel

consumption demand even in bigger bio heating systems. The side walls can be built sloping or vertical.

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Equipment

Storage model T62 T63 T64 T65 T66

6400 hydraulic unit 1 1 1 0 0 6600 hydraulic unit 0 0 0 1 1

Number of storage screws

1 1 1 1 1

Number of T6 -modules

2 3 4 5 6

Number of hydraulic cylinders

2 3 4 5 6

Number of photoelectric sensors + M12 plugs

2+2 3+3 4+4 5+5 6+6

Capacities of storage systems

Storage model T62 T63 T64 T65 T66

STORAGE HEIGHT 3 m Maximum storage volume [m3] 34 51 68 85 102

Maximum storage mass (wood chip density 300 kg/m3) [kg]

10200 15300 20400 25500 30600

Energy storage (Wood chip energy density 700 kWh/m3) [kWh]

23800 35700 47600 59500 71400

Maximum reload interval (with 100 kW consumption, 700 kWh energy density and 85 % efficiency) [days]*

8 12 16 20 24

STORAGE HEIGHT 4 m

Maximum storage volume [m3] 46 69 92 115 138


13800 20700 27600 34500 41400


32200 48300 64400 80500 96600


11 16,5 22 27,5 33

STORAGE HEIGHT 5 m (Maximum)

Maximum storage volume [m3] 58 87 116 145 174


17400 26100 34800 43500 52200


40600 60900 81200 101500 121800


14 21 28 35 42

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*NOTE that another fuel and efficiency properties greatly affect the number of maximum reload interval days.

Other consumptions can be calculated e.g. with 1000 kW consumption and T63 with storage height 4 m will

last not more than 1,65 days (1000 kW / 100 kW = 10 → 16,5 days / 10 = 1,65 days).

Technical data of electrical equipment

Equipment – Ariterm title

Type

Capacity Power Current motor rpm

Input Voltage

Additional info

Photo electric sensor – 17644+15095

SMP 8500 MG J + M12 E11509

Sensing range 0,5 m

14 mA 24 Vdc Output: PNP, NC/NO, Sealing class: IP67

Limit switch - 10336

FZ 515 + VFPAP13C6N

Min force 8 N

2 24 Vdc Output: NC/NO, Sealing class: IP67

Gearmotor - 17627

ITB433 I = 78.52, 1108 Nm

2,2 kW 8,8 / 5,1 1400 3x230/400 Vac, 50 Hz

Weight without oil: 94,8 kg, oil volume 4,3 l, Sealing class: IP55

Hydraulic unit – 10891

6400 180 bar, 9,6 l/min

3,0 kW 6,5 A 1420 3x400 Vac, 50 Hz

Weight:42 kg, Sealing class: IP55, Includes oil level indicator

Hydraulic unit – 17689

6600 180 bar, 16 l/min

5,5 kW 10,6 1450 3x400 Vac, 50 Hz

Weight:110 kg, Sealing class: IP55, Includes oil level indicator

4. Installation

4.1 Receiving and checking the delivery

When you receive the delivery, check that the contents correspond to the list of accessories and final

inspection report. If anything is unclear, contact the seller immediately. Before commencing assembly, please

read this installation and operating manual carefully. Also, read the installation instructions for automation.

NOTE warranty does not cover damages caused by improper installation!

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4.2 Requirements concerning the operating environment

The moving floor can be installed in a heated or a non-heated area. If a non-heated area is chosen, the

hydraulics unit should be installed in a warm place, e.g. in the boiler room. In a non-heated area there is a

possibility that the moist fuel may freeze. The frozen fuel does not fall onto the storage screw and the fuel flow

to the burner stops. This causes a malfunction.

• The humidity in the area should be 20 - 80 % (no moisture condensation)

• Sufficiently strong foundations (check the maximum load)

Necessary connections:

• Electrical connections

• Water supply connection for the automatic extinguishing system.

4.3 Installation of the equipment

4.3.1 Preparation and planning

The moving floor must be installed on a solid surface. The fuel storage, built on the moving floor, must meet all

the valid regulations of solid fuel storage (see local building regulations and recommendations). Contact your

local fire authorities for the most accurate information regarding the regulations. The fuel storage should be

airtight and lockable to prevent access from unauthorized persons.

The burner and the boiler installed to the moving floor must be suitable for solid fuel and they must have

corresponding effective values. The moving floor and the Ariterm bio burners and boilers and fuel screws

(storage, middle and burner screws) have been designed to fit together. When using other products make sure

of their compatibility.

The fuel weight puts a big strain on the moving floor bottom. It is important that:

• the surface (floor) below the moving floor bottom is stable and level

• all support points rest on the floor

• the wall constructions sustain the fuel weight.

The moving floor, the feeding screws and the boiler must be placed in their proper locations before final

fastening to ensure correct fitting. Dimensions and equipment must be ensured before ordering. See example

of a moving floor layout in figure 1 and dimensions in figure 2.

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Figure 1 Components of a moving floor installation

1 Moving floor assembly

(includes a storage screw)

2 Middle screw

3 Burner screw

4 Burner

5 Boiler

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Figure 2 Layout dimensions

4.3.2 Mechanical installation

Installation of the mechanic components must be done by a qualified mechanic. All components can be

assembled with screws and bolts. Make sure that local safety and other regulations are filled. NOTE! that the

components are heavy and some edges might be sharp. Use cloves and lifting accessories when assembling the

heavy components. See the components in figure 3 and exploded view of one model shown in figure 4. The

numbers of the figures referred to list below.

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Figure 3 Main components

Figure 4 Exploded view of a T63 model

HU

U

Mounting

With

M16X30 screws

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List of the numbered main components

No. Item / Name Drawing / Ariterm title

Mass [kg / pcs]

T62 pcs

T63 pcs

T64 pcs

T65 pcs

T66 pcs

1 T6 body T6-1000 693 2 3 4 5 6

2 Rake rod assembled T6-1400 227 2 3 4 5 6

3 Cylinder body T6-1500 165 2 3 4 5 6

4 Mounting frame of screw chute T6-1340 15 0 1 0 1 0

4* Mounting frame of screw chute T62-1340 30 1 1 2 2 3

5 Cover plate of body (welded) T6-1216 14 24 36 48 60 72

6 Hydraulic unit 10891 (T62…4) / 17689 (T65…6)

42 / 110 1 1 1 1 1

7 hydraulic cylinders - 39 1 1 1 1 1

8 Back wall of rake tunnel T6-1361 13 0 1 0 1 0

8* Back wall of rake tunnel T62-1361 26 1 1 2 2 3

9 Cover of rake tunnel T6-1330 11 2 3 4 5 6

10 Screw chute (2 nodules) T62-1300 82 1 - 2 1 -

10* Screw chute (3 nodules) T63-1300 123 - - 1 1 2

11 Partition wall (2 modules) T62-1600 162 1 - 2 1 -

11* Partition wall (3 modules) T63-1600 243 - - 1 1 2

12 Gear motor of storage screw 17627 95 1 1 1 1 1

13 Storage screw (Defined by order) ~200…800 1 1 1 1 1

14 Sensor protective cover T6-1370 0,7 2 3 4 5 6

15 Bearing 1014 0,2 1 1 1 1 1

*Shown in figure 3 and 4

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Gear installation (storage screw)

Figure 5 Mounting positions

See more specific installation guides from instructions of gearmotor’s manufacturer.

4.3.3 Electrical installation

NOTE! The power supply must be equipped with a lockable safety switch. It is installed at the height of approx.

1,5 m beside the entrance way door. Electrical installation may only be carried out by qualified electricians and

in conformity with the applicable safety standards.

Sensor installation (numbers refer to figure 7)

• Flame control thermostat (1) sensor is installed in the boiler chimney duct or fire chamber.

• Back fire thermostat (2) sensor is installed in the sensor pocket on the surface of the feeding pipe. The

set point value is e.g. 75°C

• Sensors for the extinguishing systems are installed in sensor pockets on the surface of the feeding

screw

• The optical level sensor is installed on the inside rim of the feeding funnel hatch collar. It monitors the

fuel level. With Multijet burner, a transmitter-receiver couple is used.

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• The limit switch (micro switch) of the inspection hatches are installed on the outside rim of the same

collar. It operates when the hatch is opened.

• Photoelectric sensors are installed at moving floor

modules and sensitivity is adjusted properly.

Sensor indicates when the storage screw have fuel

enough.

The optical level sensor is attached to the frame with an

included angle piece according to the picture. This way the

sensor measuring point on the fuel level can be adjusted

freely and the sensor distance control dial is well within

reach. The transmitter-receiver couple is installed in the

holes of the free fall funnel.

The measuring point is adjusted with a screwdriver. By

turning the adjustment

screw anticlockwise the small scale indicator above moves

clockwise. The measurement distance is usually correct

when set to one o’clock.

How to install the sensors for automatics and burner control: See the electrical drawings and the automation

manual.

4.3.4 Installation of extinguishing system

(numbers refer to figure 7)

A. Self-powered thermostatic extinguishing valve

• The Danfoss AVTA 15 (50 - 90 °C) thermostat valve (3) is attached to the feeding funnel and the burner

screw pipe. The valve sensor is pushed into the sensor pocket in the burner screw pipe. The valve is

then connected to the water line. It is backed up by an expansion tank (4) in case of network pressure

loss.

• A manual override for the AVTA valve is installed in the water line.

• A back-pressure valve is installed in the supply pipe of the expansion tank to prevent the water from

flowing back to the network.

• A pressure gauge with alarm (PIA) is installed close to the expansion tank.

• The AVTA valve is set to about 80°C

• Read the valve sensor manual before installation!

B. Pulse operated extinguishing system, functioning by pressurized water

• A nozzle and a magnetic valve (5) are installed at the front end of the burner screw. They are controlled

by a pulse operated extinguishing system (6), which is set at about 70°C where it operates before the

back-fire thermostat and the AVTA valve. In case of power failure, the functioning of the magnetic

valve can be ensured with a UPS device (7). The Arimatic control centres include a pulse operated

extinguishing system control (no valve).

Figure 6 Sensors at inspection hatches and funnels

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• An expansion tank (4) is installed in case of network pressure loss.

Both the AVTA valve and the pulse operated back fire protection system must have separate expansion tanks.

C. Back fire thermostat

• drives the burner screw for one extra pulse, stops the system and generates an alarm.

• is set to about 75 °C.

• is connected to the control centre.

D. Extinguishing and supervision arrangement for fuel storage

• A manual closing valve is installed in the water line. A mist spraying nozzle is installed in the fuel

storage to achieve the best extinguishing effectivity.

• A fuel storage temperature sensor (9) is installed (optional).

Figure 7 Back-fire protection

1. Flame control thermostat

2. Back fire thermostat

3. AVTA valve, self-operated DN 25

4. Expansion tank 35-50 l (pre-pressure 100 kPa)

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5. Electromagnetic valve, 230 V (optional)

6. Pulse controlled burn back protection (optional)

7. UPS device

8. Limit switch (transition)

9. Alarming temperature sensor of the (optional)

PIA Alarm pressure gauge

Shutter valve

Backpressure valve

KV Cold water

5. Commissioning

5.1 Testing the moving floor

Start the screw motor(s) manually and check:

• the rotation directions

• that the screw reverse function works

Read chapter about using hydraulics and its functions before commissioning the moving floor!

5.2 Testing the safety systems

• AVTA valve: The thermostat is set to a lower temperature. The sensor is heated with warm water until

the valve opens. NOTE! The valve releases large amounts of water!

The sensor closes the valve slowly. Make sure you have an assistant to shut down the water flow when

the function has been tested.

• Pulse operated back fire protection: Reduce the temperature set value and heat the sensor until the

magnetic valve opens. (Optional safety system)

• Back-fire thermostat. Reduce the temperature set value and heat the sensor until the automatics

releases an alarm and starts driving the burner screw.

5.3 Adjusting

Before adjusting read the Automation manual and instructions of components.

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Follow adjustments must be done in automation (default settings shown in automation manual):

• Hydraulic unit

o start delay and running time

• Storage screw

o Funnels emptying time

o Storage alarm delay time

o Inactive time sensor for burner screw

o Funnels forced filling time

o Storage screw start delay time

When using other producer’s automation centre settings can variate.

The photoelectric sensor must be adjusted. Sensor has two adjustments: sensitivity and light/ dark setting.

Sensitivity should be adjusted so that the amount of fuel is suitable for the storage screw.

6. Hydraulic systems

6.1 General

Hydraulic aggregate is generally understood to mean a unit functioning as a part of a machine and producing

pressurized oil. The main component of the unit is a pressurized oil-producing hydraulic pump. To operate the

pump, an electric motor with rotational approximately speed of 1500 r/min is usually used. The system also

contains the necessary directional control valves and control valves for the controlling of the motional direction

of the aggregates, as well as velocity and power. The system pressures are monitored either by stationary or

separate pressure gauges.

Connectors

Use only special connectors or flanges made for hydraulic use. In case sufficient tightness in screw connections

cannot be achieved otherwise, use insulation glue made for this purpose. Do not use hemp, duct tape etc.

Hoses

The hoses must be of high quality and suitable for the operating environments. Do not bend the hoses in steep

angles. Follow the instructions given by hose manufacturer or importer. (THE NORMAL OPERATING LIFE OF THE

HOSES IS APPROX. 3 YEARS).

Valves

The valves must be set on an even surface to avoid twisting. They must be placed in a clean environment or be

protected from dirt. There must be air space around magnetic valves for evaporating thermal power. The

flexibly connected cylinders must be connected to the pipe system with high pressure hoses and the cylinders

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must have enough space to move. The cylinders should not be burdened with side thrust, bending moment or

torque, and the piston rod should not be used as a guide surface.

6.2 Safety

Because the hydraulic aggregate is a pressurized system, care must always be taken during its operation. When

opening the connections, make sure that the system is depressurized. If there are pressure accumulators in the

system, note that they stay pressurized even after the aggregate has been switched off. If you must work in the

operating area of movable aggregates, they must always be locked in place mechanically during maintenance.

6.3 Inspection of delivery

Cleanliness

Our components, power units and actuators have been cleaned carefully at the factory. However, it is

necessary to check that no dirt have accumulated on the components during transport and that the protective

caps have stayed in place.

Alignments and fastenings

The mechanical alignments of the pumps, motors, cylinders, switches and bearings must be inspected, because

an uneven base or damage during transport may have changed the alignments.

Hydraulic accumulators

The inflation pressure of the pressure accumulators must be checked. If necessary, fill with nitrogen until the

value in the connecting pattern is reached. A hydraulic system with an accumulator is pressurized even when

the electric power is off. For this reason, the accumulator pressure must be discharged before opening the

circuit.

Electric devices

Check that the voltage and the frequency are suitable for electrohydraulic components and electric motors.

Remember that only an authorized electric assembly professional can connect the electric devices.

6.4 Filling the oil tank

The oil tank has been cleaned and inspected at our factory, but it should still be inspected once more. Taking

the operating conditions into account, choose the most suitable hydraulic oil for filling the tank. See the oil

recommendation page or ask for more information from your oil company. If the start-up is done in a low

temperature, the oil should also include agents that lower the point of congelation. The viscosity of the oil in

operating temperature should be 3,0° E....5,5° E. (During start-up, viscosity max. 100° E.) It is forbidden to use

non-burning oils without our approval because non-burning oils have bad lubricating properties and thus

require special measures. The tank is filled through the refill hole at the top of the tank. If the oil surface goes

M_T6_23022017_ENG

lower than the minimum value during operation, more oil must be added. The final oil amount check is done

after the system has been vented. At this time, the piston rods of the cylinders should be drawn in.

6.5 Start-up and Commissioning

6.5.1 Gear Pump Start-up

When starting up the gear pump, consider the following:

• check the direction of rotation

• the gear pump is started up unloaded to let air escape the system and so that the pump gets the

necessary lubrication

• in a free circulation system, check that the oil starts to flow from the return pipe into the tank. In a

non-free circulation system with a pressure accumulator, from the loosened outward relief valve into

the tank or out through the connector on the pressurised side.

• if the pump is not getting oil immediately, abort the start-up and restart in short intervals until the oil

starts circulating. If the pump does not start pumping after a few restarts, it has to be filled from the

pipe on the pressurised side and restarted again before the oil has drained back into the tank.

• use the pump carefully at first and avoid loading it with the largest possible load. Keep an eye on how

quickly the pump heats up. In case of abnormal heating or noise, or if the pump will not start pumping

after several tries, contact the supplier.

6.5.2 Regulation and Air Removal

System pressure is regulated turning the adjusting screw of the outward relief valve. The pressure rises when

the screw is turned clockwise and lowers when it is turned counterclockwise. Do not exceed the maximum

pressure value. Venting is done with as little pressure as possible, by opening the cylinder connector or venting

screw slightly. Cylinders must be driven to their extreme positions. During the first operating hours, the system

must be used carefully, avoiding maximum load and keeping an eye on possible abnormal noises, heating and

oil leaks. These must be repaired immediately. In case nothing remarkable comes up, the system can be loaded

to the maximum after the trial run.

6.5.3 Assembly

The place of the aggregate must be chosen so that it is dry, has an even temperature and sufficient air circula-

tion around the aggregate. The distance from the wall must also be sufficient for the electric motor ventilation

and maintainability of the components.

If the aggregate is assembled outdoors or in another non-heated area, the oil must be preheated during cold

periods, e.g. with a heating resistor or heating circulation. In addition, the aggregate has to be shielded from

water and impurities with a separate cover. However, the cover should not be too well insulated, otherwise the

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cooling air circulation is hindered. If the environment is very warm around the year, the aggregate must be

equipped with a separate oil cooler.

During the assembly, note that the aggregate is assembled horizontally and fastened tightly to its base. Clean-

liness and care are absolutely necessary in assembling the hose and pipe systems. When a low noise level is

required, it is recommended to use hoses that insulate any possible frame vibrations in the aggregate outlets.

6.5.4 Commissioning

When commissioning the aggregate, inspect the outward cleanness of the aggregate and also look through the

maintenance hatch to inspect the inner cleanness of the oil tank. Make sure that the pipes and connectors are

tight and see that all plugged connections are plugged. Connections and voltages of the electric devices should

be checked from the electric connection manual.

The oil must be chosen according to the operating environment. The choice is affected by operating tempera-

ture, environmental protection and other possible external conditions. The oil to be used must be intended for

hydraulic use, because only these oils include the additives that are necessary for hydraulic operation. When

choosing the oil, contact a professional supplier.

Cleanliness is absolutely necessary when filling the tank with oil. The filling is done either through the refill

opening or through a refill connector designed for the purpose. The oil tank is filled up to the highest indicator

value in the measuring glass.

Before starting up the aggregate, check the rotational direction of the electric motor. Start the motor and stop

it immediately. This way you can check the rotational direction by the fan blades. If the rotational direction is

wrong, check the electric connection of the motor.

Before starting up the aggregate, it would be good to let the adjustment of the outward relief valve go down

and set it to its given value again after start-up. This eliminates possible damages caused by over pressurizing

during commissioning. If possible, also check the functionality of the unloading valves.

When starting up the aggregate, let it run for a few minutes before commissioning the valves. This ensures an

even oil flow in the whole aggregate. If the oil does not start to circulate or the pump starts to make a

thumping noise, the motor must be stopped and restarted after a while. When the aggregate has been in

operation for a sufficient time and the oil flow and noise from the pump are even, the oil can be lead into the

actuator. For safety reasons, use minimum pressures to move the aggregate.

6.6 Maintenance

Cleanliness is important for the functioning of the hydraulics. Impurities in the oil wear down the components

and can obstruct them and cause operational failures. Cleanliness is absolutely necessary when filling up and

changing the oil. Most of the hydraulic

M_T6_23022017_ENG

operation failures are caused by unclean hydraulic oil. The best way is to fill the tank through a separate

filtering pump, because oil taken directly from the barrel is never fully clean. The amount and quality of the oil

should be checked periodically.

Periodic maintenance performed after the first 50 hours:

• change the oil filters

• clean the air filters and change if necessary

• check the oil surface level and add more oil if necessary

• check and repair leaks

• visually inspect the condition of the oil, in laboratory if necessary.

After this, maintenance procedures can be performed every 6 months, weekly in larger or continuously

operating systems if necessary.

Objects requiring continuous monitoring:

• oil surface level

• filter indicators

• surface and temperature alarms

• leak monitoring

• pressure monitoring.

6.6.1 Oil Change

Oil cleanness is inspected visually from time to time. If the oil gets turbid, it has been mixed with condensed

moisture from the tank. The water can be removed from the oil with a device designed for the purpose. In

small systems, it is often better to change the oil. If the oil gets significantly darker, it is apparently oxidizing

fast. In this case, the oil must be changed so that the oxidized oil will not corrode the inner parts of the devices.

In small power units, oil change is done every 1000 operating hours, every 6 months or yearly at the operator’s

discretion, unless the condition of the oil dictates a change.

In large systems, we recommend having the oil analyzed in a laboratory to find the suitable oil change interval.

This can be followed continuously, unless the operating circumstances change significantly. It is difficult to

define an exact oil change interval beforehand because it depends on several factors, e.g. oil quality, hydraulic

operation quality, oil temperature during use and impurities in the oil (water, dirt and metallic impurities, the

use of an immersion heater, filtering efficiency etc.).

When changing the oil, clean the tank thoroughly from the inside and inspect the condition of the paint. The

use temperature ranges of some oil types have been listed in a table in the following page.

• The highest allowed operating temperature is 70 °C

• During start-up, the viscosity can be approx. 100 °E, depending on the pump type

• The optimal operating temperature for the hydraulic system is 35...55 °C.

M_T6_23022017_ENG Page 23

6.6.2 Maintenance table

COMPONENT SCHEDULED MAINTENANCE

Those not listed below: follow component supplier maintenance and operating

manual.

con

tin

uo

us

/ d

aily

Aft

er f

irst

op

era

tin

g h

ou

rs

We

ekl

y

Mo

nth

ly

Eve

ry 6

mo

nth

s

Ye

arly

PRESSURE ACCUMULATORS Check inflation pressure

10-50

X X

TANK Oil surface level check Temperature check Possible leak check Take oil sample Oil change Connector tightness check

X

X

X

50

50

X

X

X

X

X

X

FILTERS Dirt indicator check Filter element change Air filter cleaning

X

X X

X X

INTERMEDIATE SWITCHES Drive motor and pump intermediate switch check

10-50

X

X

VALVES Check pressure relief valve, bleed valve and other adjustment valve settings

10-50

X

X

X

ALARMS Check surface and temperature alarm settings and pressure switch adjustment range

10-50

X

X

X

HYDRAULIC CYLINDERS Check the piston rod and scraper condition visually Clean and lubricate ball joints

10-50

10-50

X

X

X

X

X

X

M_T6_23022017_ENG

6.6.3 Hydraulic drawings

M_T6_23022017_ENG Page 25

One T6 -module

T62

T63

T64

M_T6_23022017_ENG

T65

T66

5,5 kW

400V

14 cm3

60 dm3

M_T6_23022017_ENG Page 27

7. Service and maintenance

7.1 Maintenance

To ensure maximum performance and long life of your equipment follow these maintenance instructions:

• Bearing lubrication before commissioning and then once a year

• Flame control thermostat operation check, once a year

• Testing of the extinguishing systems, once a year

• Hydraulics maintenance, see chapter about hydraulics.

7.2 Troubleshooting

Problem

Solution

The motor guard has tripped even though the boiler sensor indicates a need for more heat. The overcurrent protection has tripped.

Remove the obstacle preventing movement of the silo/feeding screw by turning the screw backwards and check that the screw turns freely. Reset the alarm.

The flame control thermostat has tripped

Check fuel feed. Restart the unit. If necessary, reduce the flame control thermostat settings value.

The feeding screw does not feed fuel when working. The fuel is vaulted in the silo.

Push fuel onto the screw. Use only suitable fuel.

The back-fire thermostat has tripped

Find out the causes of the back fire. Eliminate the fire risk. Start up the unit if it is safe to do so.

The fire extinguishing system has been activated.

Find out the causes of the back fire. Eliminate the fire risk. Start up the unit if it is safe to do so.

7.3 In case of emergency

Ariterm Oy’s moving floors and equipment have been designed to be easy to operate and reliable, when

operated and maintained properly

What to do in a back fire situation The fire in the burner started to crawl backwards to the direction of the fuel

storage. The back fire thermostat has tripped and driven the burner screw forward for 1 min.

1. Drive the screw for multiple cycles to move the overheated fuel to the fire chamber.

2. If the fire has reached the fuel storage, call the fire department immediately!

M_T6_23022017_ENG

NOTES

M_T6_23022017_ENG Page 29

PED 2014 EU

ARITERM OY | PL 59 (Uuraistentie 1) 43101, Saarijärvi, Finland | Phone: +358 14 426 300 | www.ariterm.fi

© Ariterm Oy - All rights to modifications and corrections reserved.

http://www.ariterm.fi/

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