OPERATING INSTRUCTIONS FOR STEAM BOILER
Contents
1. Model no Steam capacity Thermal Oil usage hr Dimensions Weight capacity Kg hr 2 area Btu Kg Litre L x Wx H mm Kg MS100 100 15 20 254 000 7 8 75 2200 x 1000 x 1650 600 MS200 250 30 50 635 000 17 21 25 2600 x 1100 x 2000 900 250 300 50 65 754 000 18 22 50 3000 x 1200 x 1800 1200 350 400 60 90 992 000 26 32 50 3100 x 1200 x 2000 1460 500 550 80 120 1 390 000 36 45 00 3700 x 1400 x 2200 1780 750 800 130 180 1 985 000 55 68 75 4100 x 1500 x 2500 2300 950 1000 180 220 2 541 000 68 85 00 4500 x 1700 x 2600 2750 1350 1350 220 270 3 513 000 100 125 00 5000 x 1800 x 2700 3580 2000 2000 300 400 5 121 000 150 187 50 5700 x 2100 x 3000 4200 Electric supply 220 240v up to model S500 16 amp thereafter 380 415v three phase 50 hz 32 amp Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual BOILER DRAWING 1 2 3 4 6 a 19 10 1 12 13 14 15 16 17 18 19 5 19 20 21 R Bi H i il 2 0 2 5 9 6 52 8 2 5 NS A DARE ARRON lt cf Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operat2. Temperature The temperature at which different diseases are killed determines the steaming time Steaming at a high temperature for a short time gives better results than steaming ata lower temperature for a longer time without the problems of overcooking the soil Since each grower is faced with different problems it is not possible to be specific about the temperature required but a general rule of thumb is that sustaining a temperature of 90 95 C max for 30 minutes kills all harmful bacteria without destroying the nutrients Lower temperatures may be sufficient in many cases depending on soil conditions During the steaming operation the temperature of the soil must be checked at regular intervals to ascertain when the required temperature normally 90 C has been achieved at the required depth It is absolutely essential that the temperature and not the steaming time monitor the steaming Conditions vary and only the temperature determines whether the steaming has been completed or not IMPORTANT Great care should be taken when placing the thermometer supplied with the boiler under the sheet Place weighting bags in a v shape near the side edge of the sheet to prevent steam escaping Allow the steam to settle and carefully lift the sheet to insert the thermometer Only the probe on the end of the thermometer picks up the temperature and this will show to what depth steaming has been completed Insert the thermometer
3. Wilk Recycling Systems OPERATING INSTRUCTIONS FOR STEAM BOILER Low pressure Superheated Steam Model no S350 Serial no 501 Year of build 2002 THE OPERATING INSTRUCTIONS FAIL TO SERVE THEIR PURPOSE IF THEY ARE NOT COMPLIED WITH AND DO NOT REACH THE PERSONNEL WHO OPERATE AND MAINTAIN THE BOILER PLEASE ENSURE THE MANUAL IS READ THOROUGHLY BEFORE THE BOILER IS PUT INTO USE Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants England RG26 3PZ Tel 0118 981 6588 Fax 0118 981 9532 Contents General description Technical data Boiler drawing Legend of boiler drawing Steaming techniques Steaming advice sheet steaming Positioning the boiler Electrical connection Connecting the oil supply Water connection Water treatment Dosing plant Setting into operation Water level controls Close of steaming operation Converting from steaming to heating where fitted Maintenance cleaning Possible breakdowns solutions Translation for test certificate Translation for pressure test certificate as these must be produced in German translations have been provided Appendix Control panel layout Circuit diagrams Test certificates Oil burner instructions 13 14 14 14 15 15 16 17 18 19 19 20 20 21 22 24 25 26 Steam Boiler Operating and Maintenance Manual 3 General Description The construction approved portable steam boiler is a horizontal two pass fire
4. Number Type BN Gph Degree Control Number Burner pump Type Make Reg no Type Boiler Mixer Oil Flue gas Air Hourly Operating Steam A B Pre heat Through put CO2 Soot Temp Suction Air flac Water Pressure Temp Over Temp Temp Positio Usage Steam Pressure Litre outlet open C mm mm mm bar C kg hr C C bar The boiler underwent a final test run to check for problem free functioning Signed and dated Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 29 TRANSLATION OF PRESSURE TEST CERTIFICATE Confirmation of Water Pressure Test Group II Steam Boiler We hereby confirm that the steam boiler Model Serial no Production date Max operating pressure 1 Bar In the production factory of Moschle On The construction and water pressure tests were undertaken at 4 bar The following were confirmed The important safety dimensions of the steam boiler The safety test of the important parts of the steam boiler were successful The pressure components and materials were checked against the materials list The water pressure test was successfully undertaken The boiler plate was stamped with this mark Dated and signed Wilkie Recycling Systems Ltd Brick
5. all drain cocks on the boiler and water level indicator also the taps on the water feed and softeners while the boiler water is still hot If there is a danger of frost the boiler must be put in a room protected from frost It is particularly important that the solenoid valve and the water softening plant are removed or at least drained and stored at room temperature as frost would cause severe damage All water must be drained before storing CONVERTING FROM STEAMING TO HEATING The optional heating accessories can be supplied at a later date if required The boiler can also be used for heating by fitting the heating accessories Remove the superheater 5 and fit the blind flange to seal the chamber The heating flow is connected at V and the return at B 2 The safety valve SV is removed as the boiler operates at more than 1 bar when heating 3 The pressure regulator battery P must also be removed for the same reason and the opening sealed with a 3 stopper 4 The electrical connections for the thermostats and safety thermostats are put in place when the operating switch is changed from Steaming to Heating 5 Further information can be obtained from the circuit diagram Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 23 MAINTENANCE CLEANING REGULAR MA
6. filter must be bled during the pre aeration phase Turn the thumb screw with the plastic tube and keep open until the oil is free of air Then tighten the thumb screw again 4 The burner solenoid then releases oil to the burner for nozzle 1 the burner flame ignites and the Operating lamp comes If the burner fault light comes repeat as above 5 To safeguard the superheater only switch on nozzle 2 after steam has been produced The nozzle 2 lamp will now come on IMPORTANT As soon as steam is produced the safety valve should be briefly opened to check that it is operating In the unlikely event of all pressure controls failing the safety valve would allow the steam to escape from the boiler to release the pressure Please check safety valve regularly DO NOT ADJUST PRESSURE STATS OR THERMOSTATS at any time Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 21 WATER LEVEL CONTROLS The water level regulator and limiter control the water feed to the boiler maintaining the correct levels indicated by the water level lights orange Should the water supply fail the boiler will shut down and lock off automatically The water level limiter is a safety control which switches the boiler off as soon as the water falls below the lowest permissible water level The water requlat
7. of water provided Are you using a very soft water supply If water is too soft the conductivity can make the controls malfunction A chemical can be added if no other supply is available Water pressure The magnetic valve requires a constant minimum 2 bar maximum 6 bar pressure to open Any temporary drop in pressure will affect the water controls Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 27 WATER LEVEL LIMITER ELV 3 Despite normal water level either one or both of the water level lights go out The ELV 3 unit may be need to be replaced Always ensure the electrodes are free of scale PRESSURE AND TEMPERATURE REGULATORS When steaming the boiler has a maximum operating pressure of 1 bar When heating the boiler has a maximum temperature of 95 C If this is exceeded the steam valve will open to release the steam Check if there is an obvious reason and replace the regulator if faulty Eg pressure may have built up if the steam outlet has been closed Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 28 TRANSLATION OF TEST CERTIFICATE Boiler Heating oil Model no Serial no Mixer Burner Nozzles Manufacturer Nozzle 1 Nozzle 2 Type Make
8. tube boiler The feed water is taken from a suitable clean supply and a minimum 2 bar is required Depending on the local water quality a suitable water treatment is required The boiler produces superheated steam 200 C at low pressure Normal operating pressure approx 0 5 bar max operating pressure 1 bar In the case of failure of water supply excess pressure or temperature the boiler shuts off and locks out automatically This prevents spontaneous restarting The automatic controls ensure the best possible operating safety The boiler is completely insulated and thereby provides optimal use of heat giving high efficiency and low fuel consumption The stainless steel canopy is 6mm thick with 50mm thick insulation including the boiler doors and rear floor The construction of this steam boiler is subject to the regulations for steam boilers which are controlled by the relevant authorities Construction code 02 216 684 696 The following requirements are thereby fulfilled a The working materials of the parts under pressure are quality materials the requisite attributes of which must be documented by the rolling and tube mill with certificates b The welding tasks are performed only by approved welders The boiler has undergone a pressure test at 4 bar and was fully tested before leaving the factory Copies of all relevant certificates can be provided on request Technical Data
9. work in the house while steaming is taking place There is no need for licensed contractors for steaming There is no need to pay someone to steam for you With your own boiler you can set it up and leave it to steam while you get on with other jobs Other than checking the temperature you need only come back 2 3 hours later and set up the next bed Our boilers have been in use in Europe since the early 50 s and many of them are still in use today With regular servicing and maintenance it should give you in excess of 20 years service The manual contains important information on using and maintaining the boiler please ensure that it is read thoroughly before putting it into use If you require any further advice we would be pleased to hear from you NB Although we have used the accepted term of steam sterilisation the word pasteurisation is more accurate The soil is not left sterile as the beneficial bacteria remain and actually benefit from steaming Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 10 STEAMING ADVICE SHEET STEAMING These notes will help you to understand the basic principles of steaming With experience you will soon be able to determine your own method of operation If you have problems with particular weeds or diseases it may be worth obtaining advice as to the s
10. INTENANCE WILL ENSURE GOOD PERFORMANCE AND PROLONG THE LIFE OF THE BOILER All water supplies contain minerals in various concentrations depending on the water supply These coagulate at 60 C and form boiler slurry If this is not cleaned out of the boiler it will thicken and form hard boiler scale To prevent this the drain cocks on the boiler and water level indicator must be opened briefly approx every 4 hours to enable all deposits to be rinsed out of the boiler until the water runs clear This is best done during operation IMPORTANT EVERY MORNING BEFORE STARTING WORK IT IS VERY IMPORTANT TO CLEAN OUT THE BOILER AS THE DEPOSITS WILL HAVE SETTLED OVERNIGHT Although the boiler produces very little soot any deposit means a loss of efficiency The flame tubes must therefore be brushed out with the brush supplied as required AFTER 4 WEEKS OPERATING TIME the boiler should be completely cleaned To open the boiler door on the model S750 S2000 boilers unscrew the bolt in the centre of the door and turn the slot to the vertical position a Brush out and clean the flame tubes the heating tube and the flue gas chamber Soot reduces the performance of the equipment therefore a clean boiler saves fuel and reduces costs b Clean the outer casing and rub with acid resin free oil eg linseed oil Clean the oil burner prefilter pumps and nozzle filters in addition to the ignition electrodes and diaphragms Service the oi
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12. ax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 11 Laying the sheets The steam injector should be laid on the edge of the bed and be protected with a frame which can be either a tunnel of wire mesh or a wooden frame approx 2m long x 50cm wide This should then be covered with sufficient sacking or similar to protect the steaming sheet from the very hot injector otherwise the sheet could tear The injector is initially left open to draw in a mixture of air and steam This not only helps to raise the sheet quickly but the air also provides a protective layer to prevent the sheet being damaged by the initial injection of hot steam It is therefore important that the back of the injector is unobstructed at this stage to allow the air to be drawn in The air should then be restricted by gradually closing off the injector until pure steam is led under the sheet for effective steaming The steam is normally injected at the end of the sheet A However if the bed is long and narrow it is better to inject the steam from the middle of the sheet to either side On sheets over 6m wide a distributor with 2 injectors must be used C In general it is best to steam short wide bed than long narrow bed maximum bed length should be 50m to S350 30m long The sheet must be longer than the bed size to allow it to rise Lay the sheet on the prepared bed with weighting bags all round to ensure
13. d clean off any chalk deposits Check if boiler needs to be decalcified Too much water water flows from the boiler even when switched off Check and clean magnetic valve as shown above Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 26 Water coming from steam outlet on boiler Check magnetic valve If you pull the plug off the valve and the water stops then the valve is functioning properly If the water still flows then the valve may be faulty and should be checked It is more likely that there is dust blocking the tiny air hole in the diaphram Clean replace and try again If the valve is functioning properly then the ELV unit is faulty Water quality Is the water frothing bouncing etc in the sightglass This would suggest unsuitable water supply Has the water been in use for more than a day or two If the water is left in the boiler for too long it will froth in the sightglass The water must be emptied and refilled after 1 2 days use or possible more often with poor water quality Flush out the boiler after any problems are encountered Is the dosing plant being used filled with powder The dosing plant is designed to protect your boiler by treating the raw water Has something changed with the water quality source The water treatment supplied with the boiler is suited to the sample
14. d to 35cm deep or 1m deep using a vacuum system Crops grown in open fields can also be steamed There are various methods again depending on the steaming depth required and we can supply a totally self contained unit which also incorporates fuel tank water tank generator and spading machine Steaming is not an exact science and we would be pleased to advise on individual applications New accessories are constantly being developed to further improve efficiency and reduce the labour time involved Please call us for further information Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 9 THE BENEFITS OF STEAM CONGRATULATIONG For health and environmental reasons you have made the right decision by purchasing your steam boiler But also steam sterilisation actually gives a better yield and a healthier crop both of which mean increased profit Consumers are now demanding better quality products and residues in crops particularly salads is a serious concern Your crops will be much more acceptable now that you are using steam giving you the edge when competing in a tough market As there are no waiting times your land is fully utilised at all times No need to wait until the whole house is empty steam as and when you want without even having to worry about the weather Staff can even continue to
15. ded its banks onto barren soil and then the hot sun shone on the sodden fields the land became fertile and crops could be grown Since then countless scientific investigations have proved that using steam to disinfect the soil naturally is the safest and most extensively used method Modern steaming techniques have been developed which are far simpler than the old methods which many growers still remember No one would doubt the advantages of steaming and our boilers now offer many different methods of steaming Steam also helps to combat soil fatigue and releases the beneficial nutrients in the soil Steam leaves no harmful or poisonous residues in the soil It is absolutely harmless and can be used without any risk to the environment in all fields of horticulture and vegetable cultivation After steaming planting can begin as soon as the soil has cooled without any uneconomical waiting time Partial areas can be steamed without any danger to adjacent areas of cultivation The remaining heat after steaming further encourages the growth of the beneficial bacteria and the crop itself Your steam boiler Your boiler is manufactured to the highest standards and is completely automatic with numerous safety features You only have to prepare the soil lay the sheets switch on the boiler and check the temperature under the sheets at regular intervals The boiler is fitted with a superheater to produce steam at up to 200 C but normally operat
16. epth However the following can be used as a guide steaming time 1 to 1 5 hours per 10cm steaming depth It is generally agreed that most harmful bacteria are killed at 70 C however we recommend that you steam to 90 C to ensure that the high temperatures have been sustained for long enough to reach any cold pockets in the soil You should not exceed 100 C as steaming at too high a temperature could also kill off the beneficial bacteria Prior to steaming it would be advisable to have your soil examined and take advice on any especially difficult pest which you have to cope with The steaming depth is determined by your crop and the depth of roots on both the crop and any weeds diseases which are present in the soil Can steam other materials Steam has many applications outside horticulture eg sterilising wine vats hospital equipment etc Any material that can withstand the high temperatures can be steam sterilised either in a container or a tailor made system designed and built to suit your particular application Compost and soil can be sterilised in trailers fitted with a grid of steaming pipes and covered with a steaming sheet or lid The injector is then connected to the trailer for quick and easy steaming If you have large quantities of compost special bays can be constructed with built in pipework for constant steaming Normally one bay would be filled emptied while the other bay is steaming The compost can be lai
17. essary outside the glasshouse cladding should be added to the pipes especially in the colder months ELECTRICAL CONNECTION Single phase boilers require voltage frequency of 220 volt 50hz 16 amp Three phase boilers require voltage frequency of 380 or 440 volt 50hz 32 amp The plug should be inserted at the control panel CONNECTING THE OIL SUPPLY In preference to a long fuel line recommended max 3m long it is more convenient to use a clean oil container which must obviously be sited on steady ground preferably ona trolley manoeuvrability The oil feed pipe from the burner should be connected if possible at least 10 cm from the bottom of the oil barrel to prevent contamination The oil return pipe from the burner where fitted can be inserted into the top of the barrel These pipes should not be longer than 3 metre The pipes can be extended max 5m if the oil tank is sited on the same level or higher than the boiler IMPORTANT Ensure that the oil pipes have no sharp bends Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 15 WATER CONNECTION The boiler should have been supplied with suitable treatment plants according to the quality of the local water supply Having prepared the relevant water softener the water should be connected using a water hose with a Geka coupling directly t
18. hat the siren sounds if any faults occur Switching on Boiler 1 Switch on main ON OFF switch and the boiler fills automatically The filling time is approx 10 20 minutes depending on the size of the boiler until the water is visible in the sight glass 2 When both low water level lights come on press the re set button which releases the locking relays and the boiler is ready for operation Important while the boiler is heating up the steam outlet valve must be left open with the pipework disconnected otherwise the pressure will build up and shut down the boiler No personnel are allowed within the area of the steam outlet while it is open As soon as steam is produced the pipework can be connected close steam outlet while connecting pipework 3 Switch the siren on position 1 After a few seconds the burner motor is set in motion for pre aeration Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 20 IMPORTANT Should the burner fault light come on the burner must be reset at the start position by pressing the reset button This procedure may be repeated 1 or 2 times until the oil pump has completely drawn in the oil If the burner is not set in motion after these attempts the oil flow line must have air in it and this should be cleared IMPORTANT With single strand oil filters the
19. ing and Maintenance Manual LEGEND OF BOILER DRAWING 10 11 12 13 14 15 16 17 18 19 20 21 Burner Water connection Water flow meter Dosing plant Hand inspection flange Magnetic valve Bypass valve manual filling Non return valve Waiter level sight glass Electrodes for water level control and limiter Safety valve Electrical connection Pressure gauge Control panel Safety pressure limiter Pressure regulator Steam dome Serial plate Emptying and deslurrying Superheater Steam outlet Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 6 Steaming Techniques Before chemicals were introduced steam was the natural way to disinfect soil However the old methods of steaming were laborious and growers found it much quicker and easier to use chemicals In recent times we have become much more environmentally aware and realise the dangers of putting more and more poisonous chemicals into the soil and then proceeding to grow crops which may have to be consumed As resistance to various chemicals increases even stronger doses have to be used The human factor also has to be taken into account and the potential danger to staff and animals should not be underestimated What are the benefits of steam Even the ancient Egyptians found that when the Nile floo
20. ing at only 0 5 bar pressure approx The 50mm thick insulation provides 96 efficiency It is extremely cost effective with a life span of at least 20 years if properly maintained Being portable it is sited as close as possible to the area to be steamed thereby injecting the steam straight into the soil without the need for complicated pipe runs A siren sounds to notify a fault or if water oil or power supplies fail and the boiler shuts down automatically The control panel fault lights will show where the fault lies Another factor that must be considered is the layout of your nursery and the glasshouse itself Suitable access to the doors and any internal obstructions must be taken into account when deciding what size beds within the boiler s capacity you wish to steam Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 7 How deep can steam With sheet steaming depths of up to 25cm can be achieved which is normally suitable for most growers however for depths up to 50cm we can supply either a plough system or a vacuum system depending on the application For shallow steaming we supply a range of steaming hoods The hood is placed over the area to be steamed for approx 30 minutes then moved around as required How do prepare the soil The only preparation required is to dig down to at lea
21. into the soil until the temperature reading settles at 90 C or the required temperature Then slowly push the thermometer into the soil until the temperature drops thereby indicating the depth at which the temperature has been achieved Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 13 Each 10cm deep normally takes 1 11 2 hours depending on conditions and soil preparation This is a rough guide only and applies to sheet steaming There are other methods of either speeding up the steaming time or steaming to deeper than 25 cm Moving to the next area While the first area is being steamed it is advisable to prepare the second sheet using alternate beds to speed up the changeover process at the end of the first steam The steam injector can then be moved to the next bed while the first area cools By preparing alternate beds the sheet can be flipped over onto the next adjacent bed after the sheet has cooled while steaming continues After steaming the sheet should not be moved for at least 1 hour but max 2 hours to contain the steam and allow the sheet to cool to prevent damage The sheet must then be removed to allow the soil to cool and prevent condensation The surface should be lightly raked over to allow the air into the soil Planting can then begin IMPORTANT if the soil needs to be finel
22. is laid over the area to be steamed weighted down on all sides but left open at the front end to allow the injector to take in air initially As soon as the sheet has lifted which only takes a few minutes the injector must also be closed off and the sheet weighted down around it Then only minimal supervision is required to check the temperature at regular intervals The next bed to be steamed should now be prepared with the sheet laid and weighted down At the end of the first steam the injector is simply moved to the next bed and steaming commences again While the first sheet cools it is best to leave it on the bed until required as the sheet continues to hold the steam in the soil After steaming gently rake over the surface to allow oxygen to enter the soil All tools must be sterile Ideally disinfectant trays should also be used at glasshouse doors How long do have to steam for Steaming should be done with a thermometer not a clock It is impossible to know whether the soil has been sterilised purely based on the time you have been steaming Steaming is completed when the soil has reached the required temperature normally 90 C at the required depth The time it takes will Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 8 depend on the soil condition the ambient temperature and the steaming d
23. k sheet The dosing plant can be cleaned by repeated rinsing with water no alcohol or chemicals In the case of heavy soiling it must be dismantled and washed out End of operation After operation the water content in the dosing plant MUST be emptied through the drain valve The water supply hose raw and the connection hose to the water feed pipework are to be uncoupled so that the equipment can take in air Open the drain valve so that the substance can dry quicker If there is a danger of frost the complete dosing plant should be removed and stored Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 19 SETTING INTO OPERATION Selection Switch Steaming Heating When using the boiler for Steaming Switch to 1 Steam to introduce the pressure controls Heating Switch to 2 Heat to introduce the thermostatic controls THE SETTING OF THE PRESSURESTATS AND THERMOSTATS WHERE FITTED MUST NOT BE ALTERED THESE ARE SAFETY CONTROLS TO SHUT DOWN THE BOILER AT THE APPROPRIATE PRESSURES TEMPERATURES Safety Siren Switch This switch only controls the siren When filling the boiler to the normal water level the switch must be in position O filling If not the siren will sound constantly It is important that when the boiler is full the switch is put back to 1 operation to ensure t
24. l burner according to the burner manual d The solenoid valves on the water feed pipe and the level controls must be removed and cleaned of any deposits to ensure correct operation e Open the upper and lower inspection flanges as well as the washout valve and check for lime deposits Wash out the boiler thoroughly with a hose IF SCALE HAS BUILT UP DECALCIFY THE BOILER f The boiler door seals must be checked to ensure that they form a complete seal when the door is shut These seals and the refractory bricks in the door must be checked for damage and replaced as necessary Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 24 POSSIBLE BREAKDOWNS AND SOLUTIONS Most breakdowns can be linked to operator error and the following should be checked FIRST OF ALL CHECK a Is there an electrical supply b Is there sufficient oil Is there sufficient water at the correct pressure 2 Bar ELECTRICS 1 Check supply to control panel plug fuses etc 2 Check fuses in control panel 3 Check ON OFF switch 4 Press re set button on control panel If all the above fail to correct the fault a qualified electrician must check out the system The electronic relays are the main controls for the boiler and can be exchanged if necessary WATER Check water in sight glass Check supply
25. nd corrosion and preventing premature boiler abrasion and loss of efficiency The Phoscentra 411 adds a small amount of phosphate to the raw water supply If the water contains sand soil mud etc it is advisable to install an additional filter Filling The unit is filled with 1 kg of powder and the usage is approx 20gm 1000 It water eg S350 Boiler using 400 It hr water 125 hrs steaming 1kg powder Important the first time the dosing plant is used fill the powder to the level then add water to 5cm above the powder level When mixed stir if necessary the unit can then be fitted to the boiler If this procedure is not followed the powder could be washed out when the boiler fills and flows through the dosing plant Check before every steaming operation and replenish after approx 1 3 of the substance has been used Close the by pass valve open the ventilating bolt loosen the securing ring and fill with Phoscentra up to the max mark If too much powder is being used it can cause the water to foam this can be seen in the sightglass which will totally interfere with the water level controls Check that the dosing nozzle tiny screw is properly screwed into the coupling to give correct dosage Technical Data Max water temperature 40 C Max operating pressure 10 bar Connections 1 2 3 4 1 ATTENTION In bright sunlight a green film can form in the cylinder To avoid this cover the transparent cylinder with blac
26. o the boiler before the filter Ensure the water supply is coming from a clean source The emergency connection should only be used if the magnetic valve fails during steaming Connect the hose from the Dosing Plant by passing the valve The raw water supply hose remains on its normal position The water must then be controlled manually and at the end of the steaming operation the solenoid must immediately be replaced IMPORTANT the water pressure before the solenoid valve must be at least 2 bar WATER TREATMENT Water contains calcium magnesium iron chloride oxygen carbonic acid etc in varying degrees dependant on the water supply from one area to another causing boiler scale and corrosion Boiler scale primarily consists of chalk accumulating primarily on the boiler walls and to some extent can cause complete obstruction of the pipes This causes a considerable reduction in heat transfer thereby drastically reducing the efficiency of the boiler Corrosion unlike scale which builds up in the boiler system actually eats into the boiler steel It is therefore important that the appropriate water treatment plant is used conjunction with the boiler 1 Water hardness up to 15 dh 263 ppm requires only the dosing plant fitted as standard 2 Water hardness above 15 dh 263 ppm also requires either a single or twin column ion exchanger dependent on the degree of hardness If you water source changes you must ensure
27. ol circuits for the a burner and b boiler If the Burner Fault light comes on first press the burner reset button If the burner locks out again check if the oil filter the ignition electrodes or the diaphragm is dirty Also refer to burner manual If the Boiler Fault light comes on press the reset button If this does not solve the problem the following are possible WATER FEED SYSTEM 1 No water flows into boiler both water level lights go out Water level controls check that terminals 19 and N in the control panel X1 have 220 volt supply If the supply is in order then check the solenoid If there is no supply replace the ELV 3 control unit Solenoid Check if there is a magnetic field on the coil by switching on the main switch and listening for a slight click The solenoid can also be checked with a screwdriver on the iron core of the coil If this is in order clean the rubber membrane Take the solenoid apart and wash with water being careful to rebuild in exactly the same order paying special attention to the small springs There is a small air hole on the rubber membrane which may have become blocked If not replace the solenoid The boiler can be controlled manually with the bypass valve Open this valve sufficiently to allow water to be constantly in the sight glass The solenoid must be replaced as soon as possible to allow automatic operation Electrodes in the water level unit remove an
28. or is fitted with 3 electrodes If the water level falls to the lower level the pump or magnetic valve is switched on to feed water to the boiler e When the water level reaches the upper limit the magnetic valve closes or the pump is switched off e lf the water falls to the minimum level the boiler switches off automatically The sight glass will always show the level rising and dropping however if the water moves violently boiling effect or foams then the water quality must immediately be investigated The boiler will eventually shut down and probably will have to be emptied and refilled with fresh water This unit should be regularly inspected and cleaned of any deposits which may have built up on the probes and could prevent the unit functioning Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 22 CLOSE OF STEAMING OPERATION At the end of the steaming operation the main switch is put to OFF and the power cable and the water feed pipe are disconnected The dosing plant must be completely emptied every day To protect the boiler during steaming the water should be completely emptied and re filled at least every 2 3 days depending on the water quality If the boiler is not being used for longer than 2 days depending on the water quality all water should be emptied by opening
29. st the required steaming depth Ideally the soil should be well loosened with a coarse texture and average moisture content This is best done with a spading machine to ensure that the soil is not too fine Even fist sized lumps are not a problem as the superheated steam will easily penetrate it If however the soil is finely rotovated the steam cannot travel through the soil and will condense on the surface A loose porous structure also guarantees that sufficient oxygen immediately penetrates into the soil after steaming so that the micro organisms can become fully active Adding organic compost straw etc before steaming improves the soil structure The growth promoting bacteria develop very quickly to such an extent that there is a considerable increase in the activity of the micro organisms Organic fertilisers are normally added before steaming to further improve the soil Inorganic fertilisers should as a general rule not be added to the soil until approx 6 weeks after the steaming has taken place as the soil is so fertile How does sheet steaming work Having connected the water oil and power supplies the boiler is allowed to fill and then produce steam This would normally take up to 10 30 minutes depending on the size of the boiler The steam is led from the boiler by a stainless steel flexible hose through quick coupling pipes to the steam injector which is laid at the end of the prepared bed A special steaming sheet
30. teaming depth temperature time required After steaming great care should be taken to avoid contaminating the soil as it will be extremely fertile Good soil preparation is essential for successful steaming To prepare the bed to be steamed check of course that the bed size is compatible with the boiler see Tech Data The area should not be too long and narrow as the steam would have too far to travel and lose excessive heat Sheet steaming can be used to steam to a depth of 25cm although 30cm may be achieved if conditions are excellent The soil should be loosened to the steaming depth required This is best done first with an underground hoe and then with a spading machine steam will be able to penetrate fist sized lumps The soil should first be loosened along the length of the beds and then across them A rotovator should not be used as the soil must not be too fine Steam is unable to travel through fine soil and will condense on the surface thereby compounding the problem Sandy soil however should be damp not wet before loosening to give a better texture A good test is with a handful of soil if the soil runs through the fingers it is too dry if it can be kneaded it is too wet Ideally it should be slightly sticky Loose soil easy to penetrate Fine or wet soil difficult to penetrate Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 F
31. that it is completely sealed and the steam does not escape To ensure that the bags do not roll off when the sheet rises tread heavily on the bags or dig a small trench for added security It is not advisable to use soil to weight the sheets as there is a risk of contaminated soil being carried over to the clean soil Chains are not recommended as they will become very hot and must be insulated to protect the sheet Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 12 The boiler should be sited as close to the bed as possible to reduce heat loss The stainless steel flexible hose is attached to the steam outlet and then connected to the rigid pipes If long pipe runs are required cladding should be added especially in cold weather While the boiler is heating up the steam outlet valve should be left open with the pipework disconnected ONLY when steam is produced can the steam outlet be closed and the pipework connected The second nozzle can then be switched on Should the sheet begin to flap badly the boiler can be set back to one nozzle until the sheet has fully inflated then turned back to two nozzles IMPORTANT the sheet will now start to lift When it is fully inflated and quite tight the back of the injector should be sealed off with soil or similar to prevent more air being drawn in with the steam
32. that suitable treatment is applied Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 16 Dosing Plant Ventilation screw Coupling ue u gt part O ring O ring Receptacle Level of Phoscentra 411 Fixing wing for type 3 4 and 1 Fixing ring for type 1 2 Ga Phoscentra 411 dosing powder Un NO 1823 corrosive contains sodium hydroxide solid Special risks R35 causes severe burns Safety advice 24 25 avoid contact with skin and eyes 526 case of contact with eyes rinse immediately with plenty of water and seek medical advice 36 37 39 wear suitable protective clothing gloves and eye face protection 45 in case of accident or if you fell unwell seek medical advice immediately show label where possible Please ensure that all staff are aware of the potential dangers Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 17 Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 18 Dosing Plant The following water treatment system has proved the most successful in avoiding boiler scale a
33. to boiler Check pressure of supply min 2 bar Check filter near to water feed connection When filling the boiler check the steam valve is open Check magnetic valve is operating and clean if necessary Check if there is a layer of scale or dirt on the electrodes O T If the boiler produces wet steam check first of all that the by pass is closed If so the boiler water has probably become chalky and must be emptied out Clean out any scale or contaminants through the hand hole Flush the boiler out with a hosepipe and refill If the problem still exists there is probably still some scale in the boiler and the procedure must be repeated OIL 1 Check oil supply from tank 2 Check for air in system 3 Check filters are clean also check filter inside pump 4 Check burner if nozzle switches have been switched off on side of burner model SE 350 to SE 750 only 5 Nozzle filters should be checked and cleaned or replaced as necessary 6 Check if burner fault light red is on and press re set button on side of burner Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 25 After a burner fault allow a few minutes before attempting to press the re set button If after several attempts it still locks out a qualified engineer must be consulted LOCKOUT SYSTEMS There are two lockout contr
34. y rotovated afterwards before planting it is essential that all tools also shoes etc are disinfected to prevent contamination being introduced into the soil Do not rotovate as deep as the steaming depth to prevent any untreated soil being brought up from below Wet Steam The boiler produces superheated steam at low pressure and will shutdown if it reaches the maximum setting of 1 Bar Wet steam would only make the soil muddy and would not be successful If wet steam is being produced there are various possibilities 1 The steam boiler is not in a horizontal position 2 The feed pipes are too narrow or too long and the steam is cooling down 3 The ventilation windows in the glasshouse are not closed during steaming excess heat loss through the steaming sheets Insulating blankets can be laid on the sheets to prevent heat loss Wilkie Recycling Systems Ltd Brick Kiln Silchester Road Tadley Hants RG26 3PZ England Tel 0118 981 6588 Fax 0118 981 9532 Steam Boiler Operating and Maintenance Manual 14 POSITIONING THE BOILER To ensure that the boiler operates perfectly it is necessary to check that it is sited both horizontally see spirit level on boiler and vertically level spirit level on boiler The ground should be solid to ensure that the boiler wheels do not sink The boiler should be sited as close to the steaming area as possible with as little pipework as possible to reduce heat loss If excessive pipework is nec
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