How To

Refer to images.

• Ensure the E-Stop is not obstructed and remains in clear access.
• Push the E-stop button to ensure it remains in the depressed position.
• Try starting the unit as per training given. The unit should not start.
• If the unit starts in normal operation this counts as a failed test. Report this to your supervisor immediately.

Ensure you have a clean rag to wipe the dipstick.

1. Check the engine oil level before starting or more than 5 minutes after stopping the engine.

2. Remove the oil level gauge, wipe it clean and reinstall.

3. Take the oil level gauge out again and check the oil level.

CAUTION
To avoid personal injury:

• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.
• Do not touch muffler or exhaust pipes while they are hot; severe burns could result. Always stop the engine and allow it to cool before conducting inspections, maintenance, or for a cleaning procedure.
• Contact with engine oil can damage your skin. Use gloves when using engine oil. If you come in contact with engine oil, wash off immediately.

Always wear correct PPE when operating the AIR-VAC

• The auxillary power connections are located next to the isolator key for the AIR-VAC  (image 1).
• Allways verify the unit is switched off and isolated when coupling your tooling. 
• The AIR-VAC needs to be running to use the hydraulic outputs.
• Turn on via the green button on the control panel.
• Power up the remote, press and hold down the power button for two seconds, release and press again (Image 3).
• Put the left side switch into tipping/hydraulic output mode (image 4).
• Decide what flow rate you need 50l/m (A) or 25l/m (B).
• Toggle the flow rate switch to your desired choice (image 5).
• You can now use your hydraulic tool. 

• Isolate the AIR-VAC.
• Lift the Dashboard inspection hatch. 
• Push the battery down from the top and pull it out.
• Turn the remote upside down and push the battery to the right to release.
• Chnage the batteries. 
• Start the unit.
• Ensure the remote isolator is not engaged. Press and hold the power button.

• Ensure the isolator key is turned on.
• Cycle through with the arrow on the left of the display screen on the control panel.
• The display will show volts, revs and hours.
• Hours are displayed on the screen with a small clock after the figure.

• Verify you have isolated the AIR-VAC. 
• Undo the two latches on the filter lid and lift the filter lid (PIC1).
• Connect filter blaster to a compressor using whip checks (PIC2 shows the whipcheck attached to the filter blaster and compressor hose prior to connecting the hose to the filterblaster).
• Push down to make a seal between the Filter and Debris Cone.
• Start with the smallest filter (furthest from the debris door) and give a minimum of 10 second pulsing blasts to each filter. Work your way along (PIC3).
• Shut the lid and fasten the two latches.
• Repeat on the opposite side.
• Tip the debris skip to empty the filter chamber.

• Ensure the AIR-VAC is isolated prior to starting work.
• Open the two quick release clamps to the filtration access doors (image 1).
• Open Filter door (image 2).
• Remove the six nuts and washers which secure the filter securing plate. Keep these in a safe place for re-use (image 2).
• Lift out the filter plate (image 3).
• Carefully remove each filter element (image 5).
• Jet wash filters with warm soapy water.  Do not place the nozzle to close to the filter element. Damage could occur (image 4).
• Inspect for damage, holes & wear. Replace if damaged. Material will by-pass.
• For best results, allow the filters to dry naturally.
• Whilst the filters are drying, use HP water to clean the filtration compartment – tip the AIR-VAC to allow excess debris and water out (image 89).
• Check and clean the chamber between the filters and debris area - it may be easier to access via the top inspection hatch (image 9).
• Relocate the filters back in size order (image 6 shows correct order).
• Replace the filter securing plate and the six washers and nuts (image 2).
• Final check – visually inspect inside each filter ensuring no tools or bolts have been left. Loose debris inside the filters can cause fatal damage to turbines.
• Close the Filter lid door and secure. Repeat this process on the opposite side.

Recognition of radio identification code of the portable control unit (Rc400 G2B)

In the RC400 radio remote controls, the portable control unit works with the linked central unit in radio mode through a unique identification code.  When a portable control unit (or a central unit) is replaced, it’s required to update this code to ensure that the system works again.  The portable control unit connected with the serial cable works always (the identification code is ignored).

Recognition procedure:

1. Remove battery from the portable control unit.  Connect the serial cable between the portable control unit and the central unit.

2. Press the emergency stop button of the portable control unit and turn off the central unit (switch in “OFF” position). The lights of the central unit must be turned off.

3. Turn on the central unit (switch in “REMOTE” position) and unlock the portable control unit emergency stop button.

4. Hold the ON/SIGNAL button for about 10 seconds (the red light of the portable control unit turns on and short and repeated sound signals are emitted to ensure that programming is in progress, the internal display of the central unit shows “Po and Id”).

5. When the programming is finished, the portable control unit turns off and the central unit returns in stand-by mode.

6. Leaving the cable connected, power on again the portable control unit.  If everything has worked good, the display inside the receiver will show “1-“. 

Note: if a graphic display is installed on the portable control unit, after the second power on, it can take even one or two minutes to load the display configuration. Meanwhile, on the display, some messages will inform of the work in progress.  The display inside the receiver will show a rotating segment until the process has finished.

When the display configuration has been completely transferred the display inside the receiver will show “1-“ (or “1P”).

7. Disconnect the cable, insert the battery and test the radio.

8. If something goes wrong repeat the procedure from the beginning.

Applicable to AIR-VAC Serial No. 002 onwards

When the Portable Control Unit (PCU) inclination exceeds the safety limit, the PCU internal buzzer
is activated (Tilt sensor pre-alarm signal); if the PCU inclination exceeds the safety limit for more than 2 seconds, all functions are disabled by the external MC2M controller.

Reset the remote. 

Has the battery lost charge?

Replace the battery with with one that if fully charged.

There are two (2) bearing in the door hinges, which needs to be greased every month. To do so, find the grease nipples under the hinges then connect the grease gun and add grease till you see it squeezing through the hole next to the grease nipple of from the top of the bearing housing.

To avoid the blower / air induction bars mounted within the chamber bending / warping, ash should be removed before it blocks the holes. If the ash covers the blower bars, air stops cooling them down, causing overheating and bending / warping. Ash can be pushed away from the blower bars when loading and when ash deposits become excessive, they should be completely scrapped out.

If the blower bars begin to bend / warp, as a temporary measure they can be rotated and put in upside down. Side bars can be swapped either side of the boiler.

As the blower bars are performing in a very aggressive environment, i.e., the main loading area and subjected to extreme temperatures. These parts will eventually need to be replaced. The guidance above will help to extend the blower bars lifetime. Replacement parts are available at GlenFarrow UK Ltd.

The shunt pump and flow switch are located within the large grey box attached to the rear of the biomass boiler.

The shut pump should have a permanent electrical supply and be continually operating to circulate water around the water filled door. The flow switch monitors the operation of the shunt pump to check for a continuous circulation of water around the front door. Should there be no circulation of water around the front door, the flow switch will stop the main fan in order to prevent the biomass boiler from overheating.

• Scrape / clean the top tubes using the round scraper or wire brush attachments provided.
• After cleaning the tubes, remove all deposits form the chimney box at the back of the boiler.

• Use the handle to open the chimney box hatch
• Clean out all the deposits within the chimney box
• Clean the drain hole located next to the bottom hinge of the chimney box hatch.

The Biomass Boiler and heating equipment are not frost protected. The boiler and the system should be drained if not used during the cold weather. For larger systems, which include several buildings, separate sections should be drained if not in use.

Before draining the Boiler, the cold main should be isolated.

Systems with open vent and the header tank, boiler feed from the header tank should be left on in order to drain the header tank as well. All the pumps have to be switched off before starting to drain the system. This can be done by switching on the main electrical supply on the boiler and switching the main circulator(s) isolators next to them if the circulators are fed from separate connection. On the sealed systems Mikrofill unit has to be switched off before starting to drain the system. This can be done by pressing ‘off’ button on the unit or switching off the switch next to the Mikrofill unit.

The Boiler can be drained through various drain points on the boiler (see Fig.1 on page 5). The door has to be drained separately from the boiler. Similar drain points can be found on every heating unit. The majority of the water within the system can be drained via the boiler, in order to avoid too much water being expelled within the premises heated.

Copper coils (log dryer coil, FCU’s etc.) have to be purged with compressed air stream, after the system is drained.

Note: If there is a plate heat exchanger (HE) installed on the system, the section after the HE needs to be drained separately.

Pressure Correct

The EDF continuously monitors the system pressure, when the system pressure is within the set parameters the unit will show ‘Pressure Correct’ on the LCD display

Filling stopped due to low mains water pressure

The EDF continuously monitors the inlet water pressure, if the pressure falls below an acceptable level then the unit will operate a safety shutdown. When water pressure is reinstated the unit will operate as normal.

High or low pressure alarms

If, for any reason, the system water pressure reaches a high or low condition; as determined be the set parameters, the EFD will show the alarm message, the relevant BMS relay will operate and the boiler/chillers relay will shut down the boiler or chiller (if connected). When the normal operating pressure is resumed the unit will automatically reset.

• Close the drain points
• Attach the filling loop hose
• Open cold mains on the Mikrofill unit and open the taps on the filling loop
• Check the pressure gauge. Valves should be closed when it reaches 0.4 bar.
• Wait till you can’t hear the air coming from the Automatic Air Vents (AAV’s)
• Check the pressure and keep filling the system till it fills above 0.2 bar after the air stopped coming out of AAV’s
• Switch the Mikrofill unit ON
• If it stops filling and comes up with the fault ‘filling stopped due to leak’, switch the unit off and switch it back on.
• When it stops filling, switch the pumps back on.
• To get rid of the air in the pipework quicker, switch the main circulator on and off in 1 minute intervals. Keep switching till you won’t hear continuous gurgling noise in the pipework.
• For first day after system was filled up, please load smaller amounts of fuel, as because there can be some air in the system and too much fuel might get the boiler overheated.