ICI - Innovative Creations, Inc. AX User's Manual
Contents
1. NANA ZZZZZ 0 0 0 NV S LL clalala afa a mmelmi lt g lt 8 873 573 8 879 5 EAI 3 3 9 0 o lolo lo lo lo lololololololo a kal kal Kal kal Kal Eal sol col Ol WI WMINININ AW A 0 0 0 CAS von ol ol colool tl stl tlt t e 5 c o o o o o o 0 0 0 0 8 8 oi lojo o o afolo ole Oo o o ele elele Pa elela a mmoi lt gy y 0 0 il se O x 2 3 5 5 9 3 8 9 3 8 8 1 QOL Ol M Nol mlO P Cc 9 10 STITSTINININ 02 35 SS 95 TPT PT PNP NY NINIAN mimi 2 D O CON L 20035 gt 30 0x9 olololololo Sgot els t E MO QO O lo OJO DIA O MW eo a 5S ORVVEH o o AJETIN N O O10 O r N ee tres rZene 5 Ot ee cielefle elele eleie NININ 9 PA eec OLILX E Fo a Aa Aal ESTEA EAIA Di See Ge oOo os Os 3 o lolo lo lo lo lololololololo NEBSZESLESOS 8 4 8 319 6 N IL o c ecielelele e N A arf au cr cul cu aul av TAMTNONODSr lol oe Poe ee ed ed ee ed dl oh Te A 00 00 N oO ov2. Periodic safety equipment control procedure on steam boilers every 6 hours Power off the boiler panel and wait 20 seconds Power on and check the intervention of the safety devices Pressure Level 1 Level 2 Power off Troubleshooting Solve the problem Reset using the proper switches Disconnect the water pump by switching the selector to Check the intervention of the level gauge next to the MINIMUM LEVEL indicator by discharging the water or by regulating the drawing of steam Restart the pump and reset the level gauges Check the intervention of the pressure switch by reducing the calibrated pressure Set the pressure switch to the calibrated pressure and reset the pressure safety block GO OK END OF TESI 19 WATER LEVEL LIMITS 8 6 3 Extraordinary maintenance water level limits substitution To replace the water level limits or parts of it follow strictly the instructions below 1 Ensure that the new ceramic plug is intact 2 Check the length of the rod 3 Ensure that the rod is coaxial to the plug axis 4 Inspect the electrical system and in particular ensure that the resistance of the electric circuit linking the ceramic plug to the electrical panel is intact resistance must be over 10 MOhm Ensure that the automatic level control consisting of the two ceramic plugs and their conductivity relays work we
3. STEAM GENERATOR 2 tet 2 k2 CHARACTERISTICS allinea 2 lis TECHNICAL DATA rali aaa ale 3 2 ACCESSORIES oi 4 2 01 PRESSURE lella 4 2 1 1 Pressure tela ANEA 4 2 1 2 Operation pressure ale 5 2 1 3 Safely pressure leto teats 5 2 1 4 a ao 6 22 EF 6 2 2 EE 6 2 2 2 Automatic level regulator and water level liMitS 7 229 FEED WATER aA 7 3 INSTALLATION alleati 8 E E N 8 WATER CONNEGTIONS assll iolanda 8 329 JBEECTRIC CONNEC TIO ING sleale 9 SA SMOKESTACK aLaaa 9 3 BURNER rionn ee 9 3 5 1 Boller Burner Ad Hera peeve as 9 4 IBOILER OPERATION E 10 a teh 10 d NORMAL OPERATION o cisi ni earn
4. Lalslo o v o 9 NJ 0 0 OOlzlziz Eo v 0 2 n 3 T O LN O OO Olt Olt tT Ol O E t o o NIN o o o a a m jw o 8 A TIS rl cI cI CI CININININININ O LL 32 ggg f 5 8 9 5 9 5 8 8 5 3 8 8 8 5 1 5 5 518 8 9 9 5 9 9 9 9 5 OSs ogo 5 o o o o o o 2 2 z z z z lO OF OJ N NIN 0 0 O O oo ololelcelolo 2 2 2 2 2 2 2 L 9 5 99 85 5191 ojo a 9 ano o qloiN o v o o olo lo lo lo lololololololo HI50_ 25 NIVI Ml oy ol Gl ail an ojo o o r r vu o o wo o o OH gt gt D Pe eleleleiNINIm oy EIN TI TILOLOININ O OlO lt lt oO orc ce Q NIO epepepep epee pep ep ei el NININ Salt of o t 8 N ols olojo eR A E dA bk N 6 dei ISS 4 3 8 ZNO SINS JuL 58 N NIN O z W o Fu NMTOOKRK ODOT g 6 5 8 8 5 8 8 3 3 5 5 8 8 1919919199 ARE 5 calmigio oco ale ele M 5 gt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt 1 gt lt gt lt gt lt PIPIPIPIPIFIFIFIFIFIPIIP LILL LLL LLL Li Lidice 80 C feeding water ACCESSORIES 2 ACCESSORIES AX steam boilers are fitted with a seri
5. CO CON O ah ESE ey I T ey N B we suggest that as well as the acoustic alarm in the boiler room a further acoustic alarm be provided in an area where personnel is normally present MAX ci i A A A As TL n A er A A e i n gt N a pa 51 MMI 1 el UU I l MIN 1 Sot Eo a 2 3 FEEDWATER An electric centrifugal pump supplies the water The inlet side of the pump must never be under suction pressure but always under positive pressure due to the difference in height between the pump itself and the feed water tank While a pump can operate under suction head from a cold water tank up to 5 6 m if the water is hot the pump cannot operate and indeed needs the water to be delivered under a certain pressure The height of the feed water tank varies with the temperature as shown in the following table Feed water temperature Positive water head Celsius metres i 8 i 8 i 9 O WARNING e Avoid the use of feed water at temperatures lower than 60 Celsius being rich in Oxygen and therefore such as to cause corrosion e To avoid pump cavitation problems the feed water temperature should not be higher than 90 Celsius INSTALLATION 3 INSTALLA
6. lee io 18 8 6 1 004 RE RR NR RIO IR ORTI 18 8 6 2 Periodic control every 6 hours Of USE 18 8 6 3 Extraordinary maintenance water level limits substitution 20 11 20 S 2 TECHNICAL CHARACTERISTICS 1 TECHNICAL CHARACTERISTICS 1 1 GENERAL The AX series steam boilers are type semi fixed horizontal smoke tube type complete with accessories The boilers are suitable for operation with pressurised burners for gas fuel oil or heavy oil Safety reliability high efficiency and high quality saturated steam are the characteristics of our boilers Please consult the instructions with attention This high pressure steam 12 15 kgf cm generator uses a combustion chamber with flue gas inversion For operation at up to 3000 kg h of steam generated there is partial exoneration in Italy in the employment of specialist boiler operators Local requirements as to personnel qualification MUST be taken into account for the country where the unit is installed 1 2 CHARACTERISTICS e Working pressure switches for operation controlling the 1 and 255 burner flame e Locki
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8. 10 MAINTENANCE 11 Si ORDII5IZARG Baia Let 11 52 PERIODICO Lele 11 5 2 1 Periodic control every 6 hours Of USE 11 59 SCHEDULED clone hea 19 5 4 ConservaTION DURING WHEN OUT OF SERVICE ii 19 5 4 1 Conserva Onnea edo rate 19 5 4 2 13 WATER CHARACTERISTICS oinin aaea alata 14 6 1 FEEDWATER LIMIT VALUES entering the boiler 14 62 OPERATING WATER LIMITING VALUES iia Seid caid 14 FREQUENCY OF THE ANALYSES Luella asia 14 TROUBLESHOOTING 15 6 WATER LEVEL GIMITS 16 Sul 16 17 9 ELECTRICAL CONNEC TIONS 17 84 STEAM GENERATOR OPERATION isien naaa a a a aaia aaa 18 95 FIRSTSTAREUP iii elicoidale 18 9 6 MAINTENANCE
9. the conductivity relay being of the delayed type Open the boiler drain and check on the level indicator at what level the pump start probe acts Set the pump switch to 0 leaving the drain open and check the actuation level of the safety probes with respect to the minimum level reference plate Close the drain and set the pump switch to AUT Switch on the burner and bring the boiler up to pressure adjusting the operation pressure WARNING On boilers with a man way during the first start up it is important to tighten progressively the nuts on the man way cover as the pressure increase Otherwise a hazardous situation is created due to steam leaks that quickly deteriorate the gasket creating a dangerous situation for the boiler room personnel 4 2 NORMAL OPERATION With cold start ups verify that The boiler is full of water to the minimum level The increase of the water volume due to heating does not raise the water level too far if necessary drain the boiler at regular intervals to bring the visible level back to the centre of the water level sight glasses On reaching the set pressure the steam take off valve can be opened very gradually in order to heat the steam delivery lines eliminating any condensate that may be present in the pipework The man way gasket does not leak 10 5 1 MAINTENANCE MAINTENANCE ORDINARY Periodically purge the level gauges probe holder if fitted and the boiler to avoid the accumulati
10. Solve the problem Reset using the proper switches Disconnect the water pump by switching the selector to 0 Check the intervention of the level gauge next to the MINIMUM LEVEL indicator by discharging the water or by regulating the drawing of steam Restart the pump and reset the level gauges Check the intervention of the pressure switch by reducing the calibrated pressure Set the pressure switch to the calibrated pressure and reset the pressure safety block GO OK END OF TEST 12 MAINTENANCE 5 3 SCHEDULED All boilers must be periodically stopped for careful inspection and maintenance the time interval between stops is established by experience by the operating conditions by the quality of the feed water and by the type of fuel used Before entering the boiler shell for inspection or for cleaning check carefully that there is no possibility of entry of water or steam via the pipework to which the boiler is connected Every valve must be locked and if necessary isolated by removing a piece of pipework or by inserting a blind flange The parts under pressure must be carefully examined internally to identify any encrustation corrosion and other potential sources of danger linked to the feed water All deposits must be removed mechanically or chemically and the effective thickness of the structures must be verified using suitable instruments to determine that
11. TION 3 1 SITING Our steam boilers are supplied as units and do not need any foundation work A flat even floor only is needed that can be raised by 5 10 cm 3 2 WATER CONNECTIONS The steam boilers once positioned are connected to the system as follows Fig 9 Water From the condensate collection tank 10 if existing otherwise from the treated water tank to the suction side of the feed water pump 9 Steam From the main steam take off valve 3 to the user services distributor or others from the safety valve outlets 6 to outside the boiler room in a safe position Drains From the level indicator drains 16 the boiler drain 17 to the drainage network Fuel Connection to the burner foreseen for fuel oil or natural gas Fig 9 System diagram LEGEND 10 Condensate collection tank 1 Boiler 11 Water level 2 Smokestack 12 Water treatment 3 Steam take off 13 Water supply 4 Burner 14 Breather 5 Pressure switches 15 Condensate tank drain 6 Safety valves 16 Level indicator drain 7 Condensate return 17 Boiler drain 8 Electric pump supply 18 Safety valve drain 9 Feed water pumps 19 Example of user service INSTALLATION 3 3 ELECTRIC CONNECTIONS The boilers are provided with a switchboard protection level IP 55 completely assembled to the various boiler accessories Before connecting the switchboard make sure that the electric system has been correctly installed checking in particular the
12. ce the faulty relay Level probes short circuited Dismantle the control probes for inspection of the ceramic insulation Pump cavitation Suction head difference in height between supply tank and pump insufficient in relation to the water temperature Clean the pump suction filter Reduce the head loss in the pipe between collector tank and the pump by increasing the pipe section nvert two phases three phase pump Burner always ON Erroneous electrical connection to the Consult the wiring diagram panel See Intervention safety level 1 or 2 Control and or safety pressure switches Check the adjustment of the pressure inactive switches Check the pressure switch connections to the control panel Burner always OFF Problems with the burner See the specific burner Manual Burner fuses interrupted Replace the fuses No consent to the burner from the control Replace the control pressure switch pressure switch No consent to the burner from the safety See Intervention safety level 1 or 2 level relay Erroneous connection to the control panel Consult the wiring diagram 15 WATER LEVEL LIMITS 8 WATER LEVEL LIMITS 8 1 GENERAL The water level limits consists in n 2 level rods n 2 probes electrical cables n 2 electronic relays The device prevents the lowering of the level of water in the steam generators and the consequent overheating of the membrature The principle of survey and control of the level is ba
13. charging steam when the maximum design pressure of the boiler is reached The valves used on boilers can be of the type Lever and weight Fig 5 or Spring Fig 6 The boiler operator must pay much attention to the safety valves and carry out careful and diligent maintenance The safety valve is the most important and sensitive accessory on the boiler and represents the best guarantee that the internal pressure of the boiler does not exceed the design pressure As during normal operation of a boiler the safety valve never acts it is good practice to check that the valve is free i e that the valve plug is not stuck to the seat by acting on the side lever spring valves or on the horizontal lever carrying the weight lever and weight valves until the valve starts to discharge steam WARNING On first start up you must verify that safety valve adjustment is made to the boiler design pressure Generally the spring safety valve is supplied already adjusted while the lever and weight type must be adjusted by moving the weight along the lever until the opening pressure value corresponds to the boiler design pressure The safety valve installed on steam boilers must have the discharge piped to outside the boiler room Particular care must be taken in designing the discharge line we show some here The discharge line should e of diameter at least equal to that of the discharge flange on the safety valve e Only wide radius curves
14. efficiency of the earthing system Wiring diagram Refer to the diagram supplied with the specific switchboard 3 4 SMOKESTACK The connection from the boiler to the base of the smokestack must slope upwards in the direction of the gas flow with a slope that should be at least 10 The path should be as short and as possible and the bends and connections designed as to the rules used in the design of air ducts For lengths of up to 2 metres the same diameter as the boiler flue gas outlet can be used see the technical specification table For more tortuous paths the diameter must be suitable increased The smokestack must in any case be dimensioned as to applicable regulations It is advisable to pay great attention to the inside diameter insulation gas tightness ease of cleaning and to the fitting required for taking flue gas samples for combustion analysis 3 5 BURNER To better answer to steam demand it is advisable to install a two stage burner or a modulating burner this avoids large pressure variations consequent on sudden stream demands Further and above all with natural gas every burner start up is preceded by a long period of preventilation of the combustion chamber with consequent loss of heat to the smokestack 3 5 1 Boiler Burner coupling Verify that the spaces between the burner sleeve and the boiler door are suitable filled with flame resistant ceramic insulation Fig 10 KEY 1 Burner 2 Manhole 3 Th
15. emoved from the water also avoiding the successive infiltration of air There are substances that absorb Oxygen such as hydrazine and Sodium Sulphite but after their use the water alkalinity must be checked 13 WATER CHARACTERISTICS 6 WATER CHARACTERISTICS For steam generators with heating surface over 15 sqm there are some regulations that require limit values for water characteristics These values are listed in the tables below However limits should be adopted for all generators as stated by qualified companies that recommend the type of treatment to be carried out basing on careful analysis of the available water Many faults and sometimes serious accidents are caused by the use of water with non conforming features 6 1 FEEDWATER LIMIT VALUES entering the boiler Tab 1 a Va Toara malato fs 1 These values are valid to have a thermo degassing device Without degassing device the temperature of the tank water must be increased to at least 80 Celsius see chapter 2 3 Feeding to reduce the content of dissolved gasses O and CO3 Chemical deoxygenators must be used to remove completely the oxygen from the feed water and reduce as much as possible CO corrosive effects 6 2 OPERATING WATER LIMITING VALUES Tab 2 e A ee Total hardness 3 S Conditioner 2 Clear limpid no persistent foam 1 To maintain in the boiler the param
16. ermoinsulating material 4 Flange All details on the draught tube lenght P6 the diameter of the burner hole b and the pressurization are included in the par Technical Specifications 4 4 BOILER OPERATION BOILER OPERATION 1 FIRST START UP WARNING Before start up insert all the turbolators into the smoke tubes ensuring that there is a space of at least 100 mm at the front after they have been pushed fully inside 2 3 4 5 6 8 9 Verify that all fittings are tight Verify that the feed water pipes are clean carrying out a series of washing operations with drainage to waste before final boiler filling Close the drain valves the steam take off valve and the level drains Open the level control valves and the feed water valve upstream of the feed water pump Check that the upper man way is correctly closed Start the boiler as follows Switch on the control panel by turning the main switch Check that the drive shaft of the feed water pump is free to turn By starting the pump manually for an instant check that the shaft turns in the correct direction Set the pump switch to AUT and verify that burner cannot start before the attainment of the minimum level Check that the pump stops when the maximum level is reached by observing the level indicators and checking the positions of the indicator valves Press and keep pressed the safety water level reset button for at least 10 seconds
17. es of accessories that can be subdivided as follows Safety accessories safety valves water level limits safety pressure switches e Observation accessories level gauge pressure gauge flame inspection e Control accessories level ad pressure switches Feed water accessories centrifugal pump injector or alternating steam pump e Manual operation accessories stop valves purge valve In the following description the accessories are subdivided as to the physical parameter they control pressure and level 2 1 PRESSURE 2 1 1 Pressure gauge Fig 2 The pressure gauge is Bourdon type consisting of a flat elliptical section metal tube bent to an arc One end of the tube is open and communicates with the boiler where the pressure is to be measured the other end closed and free to move is connected by a lever system to a toothed arc and to the gauge indicator hand The gauge shows in red the design pressure The gauge is carried on a three way valve to allow the following operations e Communication between boiler and gauge normal operation position e Communication between gauge and the atmosphere position necessary to purge the siphon e Communication between the boiler the gauge and a test gauge position necessary to verify the gauge omologato ISPESL 1 6 Fig 2 ACCESSORIES 2 1 2 Operation pressure switch Device that controls the boiler pressure and holds the pressure between the set maximum a
18. eters of alkalinity and silica within the prescribed or recommended limits the boiler must be purged if possible continuously The values of the concentrations in the feedwater and in the boiler water are linked to the continuous purge by the following relationship S 100 lt 2 Cc Where S Percentage of purge with respect to the feed water supplied to the boiler Ca Real concentration of a certain salt or ion in the feed water Cc Maximum allowed concentration in the boiler for the same salt 2 Correct management presupposes normally the use of conditioners whose dosages and limits are in relation to the nature and characteristics of the additives themselves 3 Determinedon a filtered sample 4 The two parameters have the same physical meaning but the values can be correlated only if the chemical composition of the water is known 6 3 FREQUENCY OF THE ANALYSES The frequency of analysis is determined evidently as a function of the use of the boiler and of the quality of the water used it is advisable in any case to check the pH the total hardness and the alkalinity of the feed and boiler waters at least every two days Once a month especially under conditions of variable operation it is advisable to subject meaningful samples of the boiler and feed waters to complete analysis It is also advisable to inspect the return condensate for traces of any highly contaminating oily substances reduction of evaporation from the water
19. ll on 8 7 TROUBLESHOOTING Safety intervention level 1 or 2 Interrupted water level monitoring Scaled stainless steel bar Broken connection cable Faulty safety level relay Temporary replace the safety electronic relay with one of the two relays in the panel If this is the problem replace definitively the faulty relay Water does not load See Loading inconv Insufficient water load Blocked pump See Blocked pump inconv Dirty pump sucking filter Clean the filter Level regulation anomaly Temporary replace the safety electronic relay with one of the two relays in the panel If this is the problem replace definitively the faulty relay Level regulation probes short circuit Dismantle the adjustment probes to inspect visually the ceramic insulation Pump cavitatation Insufficient head different height between the collecting vessel and the pump levels in comparison with water temperature Decrease the pipe resistance between the collecting vessel and the pump by increasing the passage section Pump sense of rotation Invert one of the two phases three phase pump Burner always on Incorrect electrical panel connection Consult the electric diagram Faulty level safety relays See Safety intervention level 1 or 2 Regulation pressure and or safety switches Check the pressure switches regulation OFF Check the pressure switches connection to the electrical panel Burner always off Burner problems See burner man
20. mpt a purge close the steam valve leaving the water valve open then open the purge valve This valve must release water taking with it any sludge formed in the pipes Then close the water valve and open the steam valve steam should be released from the purge valve Closing the purge valve and leaving the two water and steam valves open the water should return to the initial level If this does not occur the communication pipes between the level and the boiler must be cleaned ACCESSORIES 2 2 2 Automatic level regulator and water level limits Fig 7 The physical principle employed to detect and control the water level is based on the electrical conductivity of the water The control device consists of a part sited in the control panel electronic relays and of probes of differing lengths immersed in the boiler shell Operation of the system provides for e Automatic pump start and stop Two probes inserted in the boiler of which the longer starts and the shorter stops the pump connected to a single control relay in the control panel e Burner stop at low water level two probes of the same length inserted in the boiler and connected to two distinct control relays in the control panel stop the burner permanently if the water level drops below the admissible level A A L A Boiler probes Sei m m gs G Pump stop J Pump start H H 1 safety burner stop and alarm on 2 safety burner stop and alarm on
21. must be used in the discharge line The entire discharge line must be built to avoid the formation of condensation locks There must be therefore adequate slopes to ensure complete drainage Particular care must be taken if the valve seat and plug are to be ground if this operation becomes necessary due to leaks use abrasives based on silicon carbide or oil based carborundum Carry out the first grinding operation using fine grain abrasive finishing with a very fine grain abrasive 2 2 LEVEL 2 2 1 Level indicator gauge Lh VILL Lea A A WS F The level indicator consists of a pair of valves connected to a sight glass box containing a prismatic glass This device is connected to the boiler both above and below the normal water level while the lower part is fitted with a purge valve so that any sludge can be removed to keep the glass clean Using these valves the efficiency of the level control system can be verified periodically by carrying out the following operations e Open for a few seconds and then close the purge valve If the water disappears from the sight glass and then appears again with ample level oscillation then it can be considered that the level operates correctly If on the other hand the water returns slowly or stops at a level differing form the preceding level then on of the communications may be obstructed To make sure which of the two is obstructed and to atte
22. nd minimum values Instructions for adjustment The electric switch has three screws 2 1 3 from right to left On reaching the set pressure the contact 2 1 switches to 2 3 Adjustment of the pressure switch Fig 3 a Turn the knob 1 until the scale indicator 2 reaches the pressure at which the burner shall restart b Remove the cover of the pressure switch and position the drum 3 at the value selected for the pressure differential Stopping the burner as to the diagram Fig 4 Example Type of pressure switch RT 5 Scale indicator 9 bar Drum indicator 4 corresponding to 2 1 bar Burner start 9 bar Burner stop 11 1 bar Ce gt MAX 1 2 34 5 6 7 8 9 10 ee Fig 3 Fig 4 2 1 3 Safety pressure switch This switch is set at a higher pressure than the maximum of the control pressure switch but always lower than the opening pressure of the safety valves The safety pressure switch acts in the case of a fault to the control pressure switch and stops the burner permanently Restarting the burner can only occur after the steam pressure has fallen and after a manual reset on the switchboard This pressure switch is adjusted in a similar manner to that of the control pressure switch with the only precaution that the drum indicator is set to 1 so that the differential is effectively nil ACCESSORIES 2 1 4 Safety valves These valves have the function of dis
23. ng pressure switches stops the burner on reaching the maximum steam pressure the boiler is manually reset from the control panel e Automatic level regulator 2 probes connected to an electronic conductivity relay maintain the water level between the set levels e Water level limits 2 probes connected to two independent electronic conductivity relays stop the burner if the water level falls below the safe minimum reset is manual on the control panel TECHNICAL CHARACTERISTICS 1 3 TECHNICAL DATA NI eg e cil 0844 SPIRIT IAIKIAIXDS fang x x xx xx xD x Ix o o o o o o 0 8 8 3 2 BE OTOIO O O O O OINI NIN NINININI AT AT AT AT ATA A O 9 9 09 69 9 9 69 09 9 09 lo o o o o o o lo o o olo D 3 9 9 9 9 9 9 9 l l l l Q 2 p is I O O 212 Ah 5 x 5 ke N 2 53 5Y vio vio ENI y sos oY O O IN gt E GER 5 4 nio L Iafa o o o o w w See a Z 0 00 Tt oje H sg Ggsss 9 de gt o lolo lolololololo lololo oxo Sonon E Ela alala alolola sl ty 5 cl VINI ir I 2 OJO AIC Not SNO HW OH OH OH olv In 0
24. on of sludge Check the efficiency of the control and regulation instruments examining carefully the electrical parts connections included and the mechanical parts pressure switches it is advisable to replace every year the ceramic probe holders Carry out burner maintenance as to the specific instructions Check the tightness of flange bolts and the state of the gaskets Check the conditions of the boiler door internal covering Clean the flue gas tube bundle and the turbolators Carry out correct maintenance to the pump bearings mechanical seal Check for wear to the discharge valves these tend to wear more quickly due to the abrasive effect of the sludge during blow down 5 2 PERIODIC 5 2 1 Periodic control every 6 hours of use From time to time every 6 hours of use the thermal plant must be inspected by qualified personnel to check the efficiency of all safety accessories Safety pressure switch Water level limits The system can be reset if no anomalies have been encountered power off the panel for approx 20 seconds power on the main switch and press the reset buttons For further details follow the flow chart below 11 MAINTENANCE Periodic safety equipment control procedure on steam boilers every 6 hours Power off the boiler panel and wait 20 seconds Power on and check the intervention of the safety devices Pressure Level 1 Level 2 Power off Troubleshooting
25. sed on water conductivity In order to guarantee the correct operation of the device following conditions must be fulfilled e Water conductivity gt 250 uS cm e Water temperature lt 210 C e Pressure lt 20bar See Operating water Tab 2 EXAMPLE PROBES TANK FOR SAFETY AND REGULATION N 1 G1 2 25 as ii A siti V g Co SHELL FHH a PUMP LEE z Poopo EY i e60 PUMP STARTING 5 TERRE 2nd SAFETY 6 02 PROBE 2 pee D MINIMUM LEVEL WATER LEVEL LIMITS 8 2 TYPICAL APPLICATIONS Boiler probes 6 Pump stop 7 Pump starting 8 1st burner cut out safety device and alarm ON 9 2nd burner cut out safety device and alarm ON NOTE it is recommended that an alarm bell is installed in the boiler room as well as a sound or visual alarm in highly visited rooms 8 3 ELECTRICAL CONNECTIONS Refer to the diagram supplied with the specific switchboard 17 WATER LEVEL LIMITS 8 4 STEAM GENERATOR OPERATION Water level limits 8 5 FIRST START UP Start the boiler as follows 1 Power up the boiler control panel Make sure that the motor driven pump drive shaft is free to rotate and that rotation direction is correct Set the pump selector s
26. surface in the boiler caused by a layer of oil 14 TROUBLESHOOTING 7 TROUBLESHOOTING FAULT PROBABLE CAUSE SUGGESTED REMEDY Safety valve s opening Maximum pressure exceeded as set on Adjust the safety pressure switches the valve Must be equal to the boiler and or limit switches design pressure Loss of the adjustment of the safety valve Check and then adjust the valve using a reference gauge Small leaks from the safety Dirt on the valve seat Clean the seat by opening the valve valve s manually a few times Marks on the valve seat Dismantle the valve and regrind the valve seat with very fine abrasive Pump stopped Pump overload relay has acted Check the motor current Check the relay setting Pump shaft seized Maintenance to the pump Pressure safety switch operates Pressure limit switch set too high Adjust the pressure limit switch Pressure limit switch faulty Replace the pressure limit switch Pressure switch pipe coil blocked Clean or replace the pipe coil Safety level 1 or 2 operates Water level detection interrupted Steel probe encrusted Connection cable interrupted Safety level relay faulty Temporary replacement of the safety electronic relay with one of the two relays in the panel If the problem disappears replace the faulty relay Feed water insufficient Level control faulty Temporary replacement of the electronic control relay with one of those present in the panel If the problem disappears repla
27. they are equal to or greater than the design values All pustules or other types of corrosion must be scraped and cleaned with a steel wire brush to white metal Leaks between fire tubes and tube plates must be carefully examined any welding must be done in all cases observing legal obligations without forgetting that a steam boiler is a pressure vessel with danger of explosion and subject to control by competent authorities During inspection also verify all the accessories with priority to safety valves level probes and pressure switches 5 4 CONSERVATION DURING WHEN OUT OF SERVICE Often during periods of disuse the worst cases of corrosion appear The operations to be carried out to guarantee correct conservation of the boiler depend essentially on the duration of the stop The boiler can be subjected to dry conservation if the period of disuse is long or to a wet conservation for short stops or if the boiler has a back up function and must be ready to come on line in a short time In both cases the necessary operations tend to eliminate the causes of possible corrosion 5 4 1 Dry conservation The boiler must be drained and dried carefully then placing in the boiler shell a hygroscopic substance for example lime or silica gel etc 5 4 2 Wet conservation The boiler must be filled completely given that corrosion is a phenomenon that appears due to the simultaneous presence of water and Oxygen Therefore all traces of Oxygen must be r
28. ual Interrupted burner fuses Replace fuses Lack of burner consent from the regulation Replace regulation pressure switch pressure switch Lack of burner consent from the level safety See Safety intervention level 1 or 2 relays Incorrect electrical panel connection Consult the electric diagram 20 WATER LEVEL LIMITS 8 8 DATA LABEL ICI CALDAIE S p A IC Via G Pascoli 38 S S 434 km 9 37059 ZEVIO Fraz Campagnola pregi VERONA ITALIA Tel 045 8738511 fax 045 8731148 LIVELLOSTATO DI SICUREZZA WATER LEVEL LIMITS Boiler serial number Modello Model O N fabb Serial number Conducibilit dell acqua Water conductivity 210 C Fluido Fluid Acqua Water Data Date ee Boiler final test date Volt Freq Pot Power Omologazione Approval IL LIVELLOSTATO DI SICUREZZA DEVE ESSERE VERIFICATO OGNI 6 ORE DI FUNZIONAMENTO WATER LEVEL LIMIT SHALL BE TESTED PERIODICALLY FOR A MAX OF 6 HOURS ved MANUALE TECNICO see TECHNICAL MANUAL 21 Appartenente al Gruppo Finluc iscritto VR 02245640236 Via G Pascoli 38 37059 Zevio fraz Campagnola VERONA ITALIA Tel 045 8738511 Fax 045 8731148 info icicaldaie com www icicaldaie com The data reported are indicative only and are not binding Our company reserves the right to introduce alterations at any time as it deems fit and proper for the development of the product
29. witch on AUT and verify that burner cannot start before the attainment of the minimum level 4 Make sure that the pump stops when the maximum level is reached observing level indicators and checking the position of their cocks Maintain safety level reset pressed for 10 sec because it is employed an electronic delayed relay Open the boiler discharge and check on the level indicator the intervention point of probe pump start Set the pump selector switch on 0 leaving the discharge open and check the intervention level of safety probes referring to the minimum level information plate 8 Close the discharge place pump selector switch to AUT 8 6 MAINTENANCE 8 6 1 Ordinary e Bleed periodically level indicators probe holder barrel if any boiler to avoid mud deposits e Check the efficiency of the regulation and control instruments by inspecting carefully the electrical also connections it is also recommended that the probe holder ceramic plugs are replaced every year 8 6 2 Periodic control every 6 hours of use From time to time every 6 hours of use the thermal plant must be inspected by qualified personnel to check the efficiency of all safety accessories e Water level limits e Safety valve The system can be reset if no anomalies have been encountered power off the panel for approx 20 seconds power on the main switch and press the reset buttons For further details follow the flow chart below 18 WATER LEVEL LIMITS
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