TECHNICAL MANUAL AX STEAM GENERATOR
INDEX 1 TECHNICAL CHARACTERISTICS ........................................................................................................... 2 1.1 GENERAL............................................................................................................................................... 2 1.2 CHARACTERISTICS.............................................................................................................................. 2 1.3 TECHNICAL DATA............................................
TECHNICAL CHARACTERISTICS 1 1.1 TECHNICAL CHARACTERISTICS 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.
TECHNICAL CHARACTERISTICS 1.3 TECHNICAL DATA Fig.
ACCESSORIES 2 ACCESSORIES AX steam boilers are fitted with a series of accessories that can be subdivided as follows: • Safety accessories (safety valves, water level limits, safety pressure switches). • Observation accessories (level gauge, pressure gauge, flame inspection). • Control accessories (level ad pressure switches). • Feed water accessories (centrifugal pump, injector or alternating steam pump). • Manual operation accessories (stop valves, purge valve).
ACCESSORIES 2.1.2 Operation pressure switch Device that controls the boiler pressure and holds the pressure between the set maximum and 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.
ACCESSORIES 2.1.4 Safety valves These valves have the function of discharging 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.
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.
INSTALLATION 3 3.1 INSTALLATION 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).
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 efficiency of the earthing system. Wiring diagram Refer to the diagram supplied with the specific switchboard. 3.
BOILER OPERATION 4 4.1 BOILER OPERATION 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. • 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.
MAINTENANCE 5 5.1 • • • • • • • • 5.
MAINTENANCE 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.
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.
TROUBLESHOOTING 7 TROUBLESHOOTING FAULT Safety valve/s opening PROBABLE CAUSE Maximum pressure exceeded, as set on the valve. Must be equal to the boiler design pressure. Loss of the adjustment of the safety valve SUGGESTED REMEDY Adjust the safety pressure switches and / or limit switches.
WATER LEVEL LIMITS 8 8.1 WATER LEVEL LIMITS 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 based on water conductivity.
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.
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 2 Make sure that the motor-driven pump drive shaft is free to rotate and that rotation direction is correct.
WATER LEVEL LIMITS 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) 5.
WATER LEVEL LIMITS 8.8 DATA LABEL ICI CALDAIE S.p.A. Via G. Pascoli, 38 - S.S. 434 km 9 37059 ZEVIO/Fraz. Campagnola VERONA - ITALIA Tel. 045/8738511 -fax 045/8731148 LIVELLOSTATO DI SICUREZZA WATER LEVEL LIMITS Modello / Model GP1 Boiler serial number N.fabb. / Serial number Conducibilità dell’acqua Water conductivity > 250 µS/cm PS max TS max Fluido / Fluid Data/Date Volt / Freq. / Pot.
Appartenente al Gruppo Finluc, iscritto R.I. VR n. 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. 96020005 Ed. 13-05/09 13 - St.
