DĨATHER - Unical
Contents
1. Lk D B ALL UTILIZZO pk py T Ziva TD UILZER eae A BUR pk vim CADA BOILER pk A i as 3190 FAS BS MAU ERUCIAT IFE 6 STD N ADA ELIRNER STOP BUR CP Wa z STEN BU R whe DaN ae He ya a CA 5 Bk W a WU a Z lt TPE nosy DU y unn Be viea C Sou s a lt p s KHH HK uk Ski NIq7 MP oni T vas CE wT AS a KUL SEREATOO RACGOLIA LIO OIL STCOKING TANK LEGENDA of system scheme page 11 TSAH oil max temperature alarm TI thermometer TC adjustment thermostat PDA differential pressure switch PI pressure gauge LSAL low level alarm LI level indicator Specifications for the oil loading group To load the system with P300 pump 1 open valves V304 and V301 2 close valves V302 V303 and V305 3 start the pump During operations 1 valves V304 e V302 open 2 valves V301 V303 and V305 closed 3 pump P300 stop To unload the system by pump P300 1 open valves V303 and V305 2 close valves V301 V302 and V304 3 start the pump NOTICES The system scheme page 11 is open vessel type and equipped with all components assuring the maximum operating safety and management of the system if properly dimensioned Some components as showed in the scheme are not standard equipment during the commercial agreement their supplier can be agreed The scheme2. Heater model bpurnernozzle min max L mm DIATER 120 150 200 DIATER 230 350 190 250 DIATER 470 1200 220 300 DIATER 1500 2300 220 300 DIATER 2900 5800 250 350 Fit strongly the burner to the door by the means of the fixing plate in order that the flame is parallel and centered in the furnace if not combustion problems could arise with damage to the boiler IMPORTANT after the burner installation fill the space eventually between the nozzle and the door hole with heat 1000 C resistant material FP fiber Jacket In a such way the door is not overheated and its deformation is avoided If the burner is provided of air inlet connect it by the means of a rubber hose to the plug on the flame gauge in a such way the glass will remain clean If the burner has no air intake remove the intake on the flame gauge and close with a R1 8 plug The fuel connections to the burner must be positioned in a such way to allow the complete opening of the door with the burner installed 22 DOOR OPENING AND RIGGING On DIATHER types up to mod 2300 the door can be opened from both sides On DIATHER types from 2900 to 5800 the door can be opened from left side to right side reverse opening on request Only for DIATHER up to mod 2300 To change the opening of the door by the means of lifting devices operate as follows Hook on the door by the means of the two upside holes Remove t
3. TECHNICAL MANUAL INSTRUCTIONS FOR INSTALLATION OPERATIONS MAINTENANCE DIATHER DIATHERMIC HEAT TRANSMITTING OIL HEATERS Dear Customer Many thanks to have chosen an UNICAL heater It s in your own interest to follow the instructions as described in this manual and carry out the scheduled maintenance by qualified personnel in order to hold the highest efficiency level of the device The missed compliance with the instructions of this manual will void the guarantee CONTENTS Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag 4 general instructions 5 safety main rules 6 introduction 7 the diathermic oil 8 heater description i 10 technical data and dimensions mod DIATHER 11 diathermic oil system scheme 13 system components Pag 13 oil circulation electro pumps Pag 14 differential pressure switch Pag 14 tapping manual valves Pag 15 diathermic oil filter Pag 16 operations and safety thermostats thermometers Pag 17 oil surge tank Pag 17 connection pipe to the oil surge tank Pag 18 diathermic oil trap tank 19 heater installation room 20 electric system 21 stack effluence discharge 21 fuel supply 22 burner connection 23 door opening and rigging 24 hydraulic circuit 26 system replenishment 26 first start Pag 26 preliminary operations Pag 27 cold start Pag 27 ho
4. 4708 5869 7438 9008 11362 18221 22725 Combustion chamber press 1 5 2 2 5 3 3 4 3 5 3 8 4 4 2 4 5 45 6 7 Flow rate pump 6 10 6 15 22 30 42 50 69 81 101 126 202 252 Heat rise 35 40 42 38 42 40 42 40 42 42 42 42 42 Loos pressure oil side 250 C c 26 23 25 18 22 17 24 18 28 24 39 36 40 34 76 125 210 219 286 480 633 732 930 1542 2548 3276 890 1000 1000 1210 1210 1310 1500 1630 1630 1800 2150 2460 2660 1045 1150 1150 1335 1295 1375 1590 1685 1685 1800 2150 2600 2800 1200 1330 1330 1570 1570 1680 1910 2040 2040 2210 2560 2910 3160 750 850 850 1070 1070 1150 1370 1480 1480 1620 1950 2270 2450 1260 1650 2100 2320 2570 2970 3170 3570 3920 4270 4500 6050 6450 32 40 50 65 65 80 100 100 125 125 150 200 200 20 20 25 25 25 25 25 25 25 25 32 40 40 200 250 250 300 300 350 350 400 400 450 500 600 700 Empty weight 530 780 1000 1520 1700 2200 2950 3700 4080 5300 7200 12250 14560 UNICAL AG S p A reserves the right to make any modifications considered necessary for improving production 10 rH pes DIL EXPANSION TANK DO ie DIATHERMIC OIL INSTALLATION SCHEME VASI ESAANSRINE CLIP TK200 TRA f STHF LEV aR IT
5. THERMINOL 66 synthetic 345 32 307 3 SOLUTIA THERMINOL SP synthetic 315 40 450 DIATHERMIC OIL SPOILAGE PHENOMENA Mainly they are cracking and oxidation The cracking occurs when the maximum allowable oil temperature is exceeded overheating some molecular bridge broke building up carbon and volatile substances The first ones adhere inside the pipe reducing gradually the cross area sclerosis while the volatile substances build up vapor bags leading to operations failures and pumps cavitations The oxidation causes insoluble deposits build up and occurs when the oil enter in contact with air at temperatures higher than 60 C this one can occur in the surge tank This item then has a particular design HEATER DESCRIPTION The diathermic oil heather DIATHER is mono or multi pipe type and with pressurized combustion The coil with two concentric rings and bottom shield is composed by closed spiral pipes The pipes are made of high quality steel unwelded type and large thickness The first ring forms a large feed flame boiler accessible through a hinged door on which a naphtha diesel gas or L P G burner can be installed The door is insulated with insulating and refractory material and is equipped with flame sight glass and burner plate The second ring is the fuel route with three smoke loops in a such way all the useful area is used and low NO number burners can be installed The c
6. it is necessary calculate the surge tank height taking in account the load losses of the valve and filter insert a differential pressure switch connected before and after the filter fitted with pressure gauges and taps This safety device stops the burner if the filter is clogged The filter cleaning is more easy and the system has a supplementary safety device We suggest to use pressure switch DANFOSS RT 262A range 0 1 1 5 bar connecting on N C terminal to the electric circuit blocking the burner The pressure switch rigging is established after the first start according to the pressure difference given by the pressure gauges and increased of 0 2 bar ATTENTION to the hydraulic connections of the pressure switch if they are installed in a reverse mode the pressure switch will never give and alarm 15 OPERATION AND SAFETY THERMOSTATS THERMOMETERS The heater needs a safety pressure switch on the oil outlet of the boiler and adjusted at 300 C with manual reset one or more regulation thermostats of the burner on the oil outlet on the boiler a delayed switching off thermostat of the oil pumps on the oil inlet in the boiler athermometer on the oil outlet athermometer on the oil inlet The safety thermostat with manual reset stops the burner as the max allowable temperature is reached The regulation thermostat switch on and off the burner at the required temperature The del
7. accordingly to the safety requirements The manufacturer is not liable for the damages due to caused by the lack of the grounding The correct dimension of the electric system for the max absorbed power should be checked by qualified personnel making sure particularly that the cable cross section are fitting with the max absorbed power of the device The electrical system must be realized by qualified personnel only Do not use adapters multiple plugs and or additional wires to connect the system to the general power supply network but use a bi polar switch only The electric panels installed on our heaters provide for three phases 400V 50 Hz while the auxiliary circuit is low voltage type 24V different voltage on request The components of the panels are manufactured by the best national and foreign trade marks The assembly is made with the most advanced techniques in order to allow the maximum operating safety and an easy control of the several equipments On request it is available an instrument panel containing the safety and regulation thermostats only with mono phase 230V 50Hz The conformity certificate and the electric diagram is supplied 20 COMBUSTION PRODUCTS DISCHARGE The proper coupling of burner boiler chimney allow a relevant reduction of the consumptions and an optimum combustion with low air pollution The FLUE chimney shall be heat mechanical stress and condensate resistant thermally
8. at page 11 is the basic diathermic oil system this is the base for more complex systems 12 SYSTEM COMPONENTS OIL CIRCULATION ELECTRO PUMPS The circulation pump of the diathermic oil is a system main components and must be chosen in accordance with the following criteria Single impeller centrifugal pump diathermic oil type self lubricating and self cooling with mechanical sealing or sealing ring in high temperature proof material max operating temperature 320 C modular cast iron or steel body The rate of flow of the pump is depending by the chosen heather the value is showed in the technical data table The prevalence of the pump must be little higher to the sum of the losses of load of the whole oil circuit the loss of load of any of our heaters is showed in the technical data table The power of the motor coupled to the pump must be higher than the rated one because with the cold oil more density the motor requires an higher power The N P S H value show the minimum necessary to the pump for proper operations This value must not be lower of the surge tank height from the pump less eventual drags If this value is not observed pump cavitations occurs and the right rate of flow inside the boiler is not assured IT IS ABSOLUTELY REQUIRED TO GUARANTEE THE OIL RIGHT RATE OF FLOW this to avoid the diathermic oil cracking and the subsequent damage of the coil In the diathermic oil systems th
9. burner dust FAILURE gas and or unburned products smell PROVISIONS check fuel system tightness if gas check tightness of the smokes circuit door burner plate cleaning door connection between boiler and chimney check that the hose fitting on the flame sight glass is connected to the burner air inlet or plugged FAILURE the boiler does not reach the temperature PROVISIONS check the cleaning of the boiler smoke and oil sides check burner performances and adjustment check thermostats adjustment and for proper operations be sure that the boiler has enough power for the system FAILURE the boiler safety thermostat operates PROVISIONS check thermostats for adjustment and operations FAILURE the boiler differential pressure switch operates PROVISIONS check pressure switch adjustment purge the air from the system check the pump for right performances check oil filter clogging check oil level inside purge tank 32 FAILURE surge tank low level alarm operates PROVISIONS check oil leaks in the system check discharge valves are closed FAILURE surge tank high temperature alarm operates PROVISIONS check la thermostat adjustment check the surge line for position on the system dimensions and lay out cool the surge line FAILURE Oil filter pressure switch operates PROVISIONS check pressure switch adjustment Clean the filter FAIL
10. leaks If there is not the danger of freezing and the meteorological conditions allow it the surge tank can be positioned outdoor CONNECTING PIPE TO THE SURGE TANK The surge pipe must be dimensioned as showed in the table without tapings with a lay out not leading to fluid convective motions not insulated but if the surge tank temperature should be very high it must be cooled Heater rated power Rated diameter of the surge Up to kW pipe mm 600 20 1000 25 1900 32 3000 40 4700 50 7000 65 17 DIATHERMIC OIL TANK This service tank is for the system loading and unloading Generally it is cylindrical horizontal atmospheric type with cradles and hatchway with sleeves for hydraulic connections The tank has a capacity 1 5 times the oil quantity in the system It is usually positioned below the system to allow the oil drain Do not install the tank underground even with double wall or tarred the best solution is to install it inside a watertight concrete vat with a metallic closing or hatchway But the tank can connect indirectly the surge tank with the external atmosphere connecting with a close pipe the surge tank to the tank see scheme fig 11 this pipe has the functions of vent discharge and overflow The minimum dimensions of the connecting pipe and vent are as follows Heater rated power Overflow amp vent pipe rated Up to kW diameter
11. lines shall be laid and sustained in order to avoid the dangerous charges For the main circuit line dimensioning the oil flow speed will be 1 5 2 m s about the connections of our heaters are dimensioned in this way The circuit must be heat compensated The steel lines expand 1 2 mm m every 100 C then from ambient temperature of 20 C to operating temperature of 270 C ten meters of lines expand of 30 mm The dilatations if not compensated shall cause tremendous charges on the system components The way to compensate the dilatations depends from the type of the plant if the plant has a compact layout without long straight lines and with a lot of curves it could be considered as self compensated but if it has a big extension with a lot of long straight lines it is necessary to insert the longitudinal dilatation compensators providing for the required guides and fixed points In the circuit vents and drains must be inserted to speed system charge and empting operations Vents and discharges must be passed to the tank 24 A vertical receiver must be installed where the vent are positioned this provision will ease the start Do not install the vent directly on the line Install a tap for oil sampling The sample must be made with cold oil max 40 C and system stopped or in operation after the cooling but using a commercial sample device Do not sample from vents and drains A seal test must be per
12. the vents several times to eliminate air and steam bubbles After stabilized circulation increase the temperature 50 C hour up to normal operations temperature Hold the operating temperature for some hours and check the system for leaks and other obvious damage and failure Take note of pressures temperatures instruments readings Check the _ inlet outlet pressure difference of the oil and compare it with technical data in order to verify the correct rigging of the pressure switch page 14 27 The burner operator shall adjust the burner at max power allowed by the boiler see metallic plate optimizing the combustion parameters ALL THE PARAMETRS RECORDED AT FIRST START ARE VERY IMPORTANT TO EVALUATE THE FUTURE SYSTEM OPERATIONS Check tightness of the seals of the door burner plate cleaning doors boiler chimney fitting and torque hot to eliminate smoke leaks Turn off the burner operating the pump up the oil temperature decreases below 150 C automatic operations for our electric panels Wait the oil cooling lt 50 C and check the filter cleaning ATTENTION After the burner rigging check that the flame does not contact the coil bottom the concrete could be damaged Check that the flame are centered in the furnace without contact the coil walls a cracking could occur and a subsequent coil failure If oil leaks exist turn off the burner wait oil cooling lt 50 C discharge the system and repai
13. URE mechanical noises vibrations circulation pump cavitations PROVISIONS check joint alignment and bearings conditions check circuit ventilation check the surge tank height FAILURE circulation pump motor overheating high stress PROVISIONS check the motor electric load and the pump absorbed power check the joint alignment FAILURE Oil lift off from surge tank PROVISIONS check cold start initial level check the surge tank capacity I 33 34
14. ater For these types of system other provisions must be taken as Higher lines heat insulation due to higher operating temperature No threaded joints use flanged or welded ones only Do not use non ferrous material especially copper and its alloys Avoid that oil leaks could pollute the environment THE DIATHERMIC OIL The commercial diathermic oils are divided in two classes mineral oils a synthetic oils The first ones are cheaper and have working temperature of about 300 C the synthetic oils are more expensive and have higher working temperature 350 C and more The parameters a diathermic oil choice are the following max working temperature pour point lowest temperature at which an oil will continue to flow when it is cooled under standardized conditions vapour pressure less 600 mbar at 300 C to avoid system pressurization Hereafter a list of suggested diathermic oils trademark and type Oil type Max working Pourpoint Vapour Temperature 2G pressure at C 300 C Mbar EURAL TERMIC 32 mineral 315 9 106 6 ESSO ESSOTHERM 500 mineral 315 9 106 6 IP FORNOLA OILS 30 mineral 300 12 6 7 TOTAL SERIOLA 2100 mineral 305 9 80 FINA CALORAN IT 32 mineral 320 12 65 LEVENIT THERMOIL 1500 mineral 315 9 80 AGIP ALARIA 3 mineral 305 9 Elf Atochem JARYTHERM synthetic 350 24 250 DBT a 320 C SOLUTIA
15. ater oil floats and propagates fire but use powder and CO extinguishers INTRODUCTION The diathermic oil systems use a diathermic fluid as carrier for heat transfer and for its particular characteristics is better than water and steam The main characteristic of a diathermic oil mineral or synthetic is the high boiling temperature more than 350 C at standard atmospheric pressure then it is possible to reach high temperatures without to use high pressure values The main advantages of a diathermic oil system are High operating temperature at atmospheric pressure No scaling and corrosion as water Exemption from the patent tenancy ISPEL accordingly to Italian laws also for the indirect production by means of exchangers of steam or superheated water art D M 21 05 1974 Exemption from regulations for hot or superheated liquids under pressure D M 01 12 1975 Collections R and H ed 1982 Italian laws The main failure of this systems is the possible spoilage of the oil cracking and oxidation that can be avoided taking the following actions Oil periodic check chemical analysis Oil change in accordance with the chemical analysis results Use of the oil at a maximum temperature lower than maximum allowable for that oil type Right positioning and connection of the oil surge tank Maintenance of the pump and safety devices controlling the right oil circulation and temperature in the he
16. ayed switching off thermostat keep on the oil pumps up to the temperature drops below 150 C this occurs at the system switching off and preserves the diathermic oil by the overheating This instruments digital are installed in our electric panels supplied with the heaters 16 OIL SURGE TANK This tank absorbs the volume dilatation of the oil during the heating process The tank must have an oil air contact surface very reduced as possible and than it will be cylindrical and vertical Considering that the diathermic oil volume increase is about 20 from ambient temperature to 300 C the surge tank shall have a capacity 40 higher than the total oil quantity in the system With oil not heated the tank is filled and with oil heated the maximum is 3 4 of its volume The surge tank needs also visual level gauge minimum level alarm floater with burner stop and manual reset at a little bit less of the capacity max temperature alarm thermostat with burner stop and manual reset at 60 C in order to avoid the oil oxidation thermometer discharge valve The oil surge tank is not insulated and installed upside the circulation pumps considering also load losses filter and valves of the circuit that are added in the connection between the surge tank and circulation pump inlet The surge tank must be positioned on the system highest point a drip pan must be installed downside the tank for eventual
17. ck that The filling group valves are in ON position see pag 12 Discharge and end valves closed Circuit valves open Manually check free rotation of the shaft Proper pump joint alignment see pump instructions Furnace free of debris Door cover for integrity Nozzle buffering carried on see pag 22 Proper door torque see pag 23 The right rotation direction of electric motors pumps and burner Sufficient available fuel and fuel valves open 26 COLD START With system filled start the circulation pump for two or three hours without start the burner During this period open once a time the vents and if installed alternate the operation of the circulation pumps in order to eliminate air bubbles and impurities If the level in the surge tank is lowering empty points of the circuit replenish starting in the meantime the charge pump fill oil in the surge tank only Check flanges for leaks tight the bolts if necessary Check leaks from welding discharge the system to repair When the circulation is stabilized the complete system filling is assured Turn off and clean the oil filter Now a plant is ready to start HOT START Reinstall the filter Start the system Start the circulation pump Start the burner at idle The heating must be uniform not more than 50 K hour At 100 C hold the temperature between 110 and 120 C up to stabilized circulation the water evaporates Open and close
18. ere two installation chances 1 only one circulation pump providing for a spare pump immediately available 2 two circulation pumps in parallel In the first case a pump failure stops the system with the aggravating factor that if the failure occurs at operating temperature the oil stopped in the boiler could overheat In the second case the system stoppage is very short the required time to turn a selector to close and open two valves The oil is not damaged and the maintenance can be carried out at the right time 13 In any case it is strongly recommended the installation of expansion compensating device on the pump inlet and outlet doors in order to avoid any mechanical strengthen the pump The pump must be installed on the ground or on a strong metallic frame DIFFERENTIAL PRESSURE SWITCH It is a very important component for the control of the right oil rate of flow in the heater All our heater are equipped with a differential pressure switch DANFOSS RT 260A range 0 5 4 bar connected with oil inlet outlet fitted with valves and pressure gauges The safety is obtained connecting the pressure switch to the electric circuit that stops the burner The connection must be made on the terminal N A of the pressure switch in order that the burner stop occurs when the pressure difference is lower than the prescribed value To set the rigging pressure operate as follows on the technical data table of our
19. formed after the system installation completion The seal test is performed with compressed air exclude the surge tank and the tank pressurize the circuit and with soap wet all welding Do not use water for the test The circuit insulation must be made after the HOT START For the insulation use high density minimum 100 kg m mineral wool 60 mm min thickness After the insulation all flanged joints and elongation compensators must be visible ATTENTION Do not insulate the surge pipe Do not install joints and compensators upside electric components motors panel boards etc otherwise the oil dripping or leakage could cause a fire 25 LOADING OF THE SYSTEM ATTENTION before to fill the oil in the circuit be sure that no water is inside otherwise dry it with hot air Th Unload the oil drums in the tank and by the filling pump the loading is carried from downside see page 11 It is possible to use an hand pump directly on e loading must be carried on in order to eliminate the air in the circuit installed on the drum Close the vent as the oil drains from them When the surge tank is filled the oil is visible in the level indicator stop the filling pump and close the discharge valves Ch pu eck that the pump is full of oil otherwise add oil through the cap on the mp body manually moving the shaft during the operation FIRST START ELIMINARY OPERATIONS PR Ch e
20. harge follow the instructions on page 26 30 SUGGESTED SPARES For two years of operations the following spares are suggested n 3 seals series door and cleaning door n 1 mechanical seal circulation pump if a reserve pump is available n 1 circulation pump if not installed on the system n 1 safety regulation thermostat n 1 differential pressure switch for the boiler n 1 floater low level surge tank n 1 glass level for surge tank TROUBLE SHOOTING FAILURE THE BURNERS DOES NOT START Provisions check electric connections check fuel flow check cleaning conditions and ventilation of fuel system check the ignition sparks and the burner device check system and boiler alarms check la the rigging thermostat adjustment FAILURE The burner starts regularly but stops immediately after Provisions check the flame the air adjustment and the correct operation of the burner device FAILURE rigging difficulties of the burner and or lack of efficiency PROVISIONS check cleaning of the burner boiler boiler chimney hose and chimney check tightness of the smokes circuit door burner plate cleaning door boiler chimney joint check the fuel flow and the real power given by the burner 31 FAILURE the boiler is dirt of soot PROVISIONS check burner adjustment smoke analysis check fuel quality check chimney clogging and the cleaning of the track air
21. he four nuts Slide the door Loose the two counter nuts on the buckle and drive on the buckles on the other side Reinstall the door inserting the counter nut seat in the door bushings Drive the four nuts Nuts torque rigging Drive the rigging counter nuts without to get out them from the bushings Drive the blocking nuts with cross system as soon as sufficient to guarantee an uniform and air tight closing Drive the rigging counter nut up to their complete blocking Normally every maintenance operation requires a door rigging check 23 HYDRAULIC CIRCUIT The choice and the installation of the circuit components are pertaining to the installer and shall be duly carried out in accordance with the laws in force The designer shall take care and liability of the dimensioning of the circuit in all its parts Use ferrous material only carbon steel lines without welding and of good quality Do not use copper and its alloys because it leads to diathermic oil oxidation The lines must be clean without stain or paint or it shall be necessary a pickling before the oil filling The joints must be welded or flanged use clamp flange use threaded joints for very little diameters only max 12 and for secondary lines vents instruments connections etc In our heater and supply components the flange are of PN16 class The boiler fittings shall not be stressed with the lines weight therefore the
22. heaters take the loss of load value oil side i e 25 m o c divide the value per 13 and round off by defect i e 25 13 1 9 subtract 0 4 from the result and it is obtained the pressure to set on the pressure switch i e 1 9 0 4 1 5 bar To rig the pressure switch open the front cover and rotate the ring up to the rigging value If the differential pressure switch operates the reset occurs at a pressure 0 3 bar higher than the rigging pressure fixed differential MANUAL TAPPING VALVES The valves used in diathermic oil systems must have specific characteristics to have a bellows seal maintenance free and not stuffing box nodular cast iron and fit for diathermic oil to withstand 300 C at least 14 DIATHERMIC OIL FILTER On the system it is necessary to provide only one filter upstream of the circulation pump s The filter must have the following characteristics must be of nodular cast iron or steel and fit for diathermic oil must withstand 300 C at least must have a filter element with large mesh 1 5 2 mm for low drag to oil flow Due to particular installation shared with the oil surged tank connection immediately before the circulation pump it is necessary for the filter cleaning to empty the surge tank in the following way we are suggesting see scheme at pag 12 to connect the fitting to the surge tank upstream the valve and the filter of the circuit In this case
23. insulated sealed with the same cross area vertically positioned and dimensioned in accordance with the law requirements The CONNECTION BEETWEEN BOILER AND CHIMNEY shall be realized accordingly to the law and rules requirements with rigid sealed conducts resistant to the temperature condensate and mechanical stress The joints must withstand 500 C at least Chimneys and joints between boiler and chimneys if not proper dimensioned and shaped could amplify the combustion noise causing to deteriorate the combustion parameters generate condensate problems WARNING THE DISCHARGE LINES NOT INSULATED ARE AN HAZARD FUEL SUPPLY The fuel supply pipe line shall be realized in accordance with the law requirements and by qualified personnel only Before the installation all the internal fuel lines must be deeply cleaned Check the internal and external tightness of the fuel system especially if gas is used Check if the fuel system is equipped with safety devices as required by the law requirements Do not use the fuel lines as electric ground Check that the boiler is fitted for the available fuel type 21 BURNER CONNECTION For the burner installation electric connections and required riggings go to the burner user s manual Check the correct choice of the burner for the heater controlling the technical data of both devices The burner nozzle must have the following dimensions FP fiber jacket
24. mm 600 25 1000 32 1900 40 3000 50 4700 65 7000 80 Close to the tank there is the system charge pump with its valves group In accordance with scheme of fig 11 the pump can be used to load re fill and discharge the system 18 INSTALLATION ROOM The heater shall be installed in a room built in accordance with the safety requirements in force and with proper ventilation doors The room is for thermal central only No admittance to the room of unauthorized personnel The space must be enough to allow maneuver and maintenance of all system components pumps valves filters heat exchangers etc The floor must be horizontal and in a such way to hold the base structures A sufficient space must be to open the door with the burner installed A minimum of 0 8 m of space must be provided on the other sides The room must have on the access doors a shoulder in order to form a drip pan for oil leaks Culverts must be provided to install discharge lines and vents from the system to the tank ATTENTION if the burner is supplied by gas with a specific weight higher than air the electrical components must be installed at 0 5 m minimum from the ground 19 ELECTRICAL SYSTEM The electrical system must be realized in accordance with the safety requirements in force and must be dimensioned for the power used by the system The electrical safety of the device is guaranteed only when it is duly grounded
25. oil is inserted in smoke sealed metal sheet cylinder that forms the heater body The heater body bottom is bolted insulated and equipped with cleaning door and smoke exhaust fitting The external insulation is obtained with a double layer of high density rock wool covered by aluminum or stainless steel The maximum operating temperature for DIATHER heater is 300 C while the heat drop inlet outlet oil temperature difference is within 35 and 42 C On request heater with higher temperature and different heat drops can be supplied Smoke circuit of DIATHER heater TECHNICAL DATA AND DIMENSIONS Lt 1 heater 6 delivery manometer m delivery diathermic fluid 2 door 7 backflow manometer r backflow diathermic fluid 3 burner plate 8 blowdown valve s inlet and outlet diathermic fluid 4 smokes outlet 9 name plate 5 differential pressure switch DIATHER 120 230 350 470 700 930 1200 1500 1900 2300 2900 4650 5800 Nominal capacity kW 120 230 350 470 700 930 1200 1500 1900 2300 2900 4650 5800 Btu hx1000 410 785 1194 1604 2388 3173 4095 5118 6483 7848 9895 15866 19790 Boiler capacity kW 138 264 400 540 800 1070 1380 1720 2180 2640 3330 5340 6660 Btu hx1000 471 901 1372 1843 2730 3650
26. r as necessary Before to start the system insulate the circuit Now a plant is ready to start START AND SUBSEQUENT CHECKS For cold start operate at reduced flame up to oil temp of 130 C Start always the circulation pump first and then the burner mandatory condition on our electric panel Check the manual valves of the circuit are fully open Alternate periodically the operation of the circulation pumps if 2 pump available If no check valves are present close the valve on the turned off pump delivery 28 SYSTEM STOP Every time the system is stopped the circulation pump must be operated up to he oil temperature decreases at 150 C automatic operations on our electric panels MAINTENANCE The scheduled maintenance is essential for the safety the efficiency and duration of the generator Before any maintenance operation Wait the system cooling Turn off electric power Close fuel tapings Cleaning smoke side e Every 3 months if naphtha is used e Every 6 months if diesel is used e Every 12 months if gas is used Before the cleaning analyze the combustion and compare with the analysis after the cleaning To clean the smoke side operate as follows e Open the door and the cleaning door e Clean the coil and the cleaning door from the soot using a high pressure water jet machine e Check the fuel system tightness e Check smoke circuit tightness and replace worn seals if necessary Check
27. t start 28 starts and following checks 29 system stoppage 29 maintenance 30 diathermic oil check 31 suggested spares 31 troubleshooting GENERAL NOTICES The instructions manual is essential and integral part of the product Make sure that the manual is always enclosed with the device in order that if the device is sold or transferred the new owner and or the assembler can use it This device must be used for the intended use Improper use maintenance rigging and installation mistakes will void the guarantee and exclude any contractual and extra contractual manufacturer liability for any damage to third parties The manufacturer responsibility is excluded for every damage to third parties due to an hazard obvious for the user and not avoided by the adoption normal safety requirements After the packaging removal ascertain the heater conditions If a doubt could arise do not use the device and call the supplier Keep away from reach of children the packaging components wooden gauge pins clamps plastic bags polystyrene The installation must be carried out in compliance with the running rules in accordance with the manufacturer instructions and by qualified personnel personnel skilled for diathermic oil systems To assure the right operations of the system it is mandatory that the scheduled maintenance as prescribed by the Manufacturer is carried out by qualified personnel Use genuine spare par
28. the sealing of the fuel supply particularly if the gaseous fuels are used Check carefully that the circuit is smoke proof and if necessary replace the warn packing The maintenance of the hydraulic circuit is carried out at the same time of the maintenance of the smoke side Check periodically the alignment and the wear of the circulation pump joint Check the hydraulic circuit tightness and repair as necessary Check the efficiency of the safety and control instruments 29 Check the oil filter clogging use the pressure gauges and clean it if necessary After you have terminated the maintenance and cleaning operations repeat the start preliminary checks see page 26 check the burner adjustment and analyze the smokes DIATHERMIC OIL CHEC Periodically check the diathermic oil to monitor its characteristics The life of the oil is about 20000 hours of operation but it depends from the temperature and the proper system operations if the temperature is at the max limit foreseen for the oil the life of the oil will be sensibly reduced For the oil analysis its sample and check frequency refer to manufacturer instructions Sample the oil from the proper outlet on the system If the oil is completely deteriorated change it Do not mix new oil with the old one After the system discharge clean the lines if the oil was highly deteriorated otherwise the new oil will clean the system To fill the new oil c
29. ts only MAIN SAFETY REQUIREMENTS The use of the devices working with electric energy and fuels implies a strict observance of some fundamental rules The use of the device is forbidden to children and no skilled personnel In case of gas smell do not use electric switches electric devices phones and any other device that could produce sparks but open immediately doors and windows close the fuel valves call qualified personnel Do not touch the system with wet or humid body parts and or bare feet Close electric power and fuel supply before starting the maintenance or cleaning operations Do not pull disconnect or twist the electric cables coming from the heater also if it is disconnected from the electric power supply Do not cover or reduce the area of the ventilation windows it could lead to explosive and toxic mixture build up On the other side it can decrease the combustion quality and increase air pollution Avoid the exposure of the system to the atmospheric agents If the electric supply cable is damaged call qualified personnel for the replacement Do not install electric cables or remove immediately if found installed on the metallic lines of the system or close to heat sources Do not touch device hot parts door because they can stay hot after a short stop also If oil leaks are present shut off the system and call qualified personnel ATTENTION in case of fire do not use w
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