TECHNICAL MANUAL

AX
STEAM GENERATOR
 INDEX

1 TECHNICAL CHARACTERISTICS ...................................................................................................... 2

1.1 GENERAL ......................................................................................................................................... 2
1.2 CHARACTERISTICS ........................................................................................................................ 2
1.3 TECHNICAL DATA ........................................................................................................................... 3

2 ACCESSORIES.................................................................................................................................... 5
2.1 PRESSURE ...................................................................................................................................... 5
2.1.1 Pressure gauge (Fig. 2)........................................................................................................... 5
2.1.2 Operation pressure switch ....................................................................................................... 6
2.1.3 Safety pressure switch ............................................................................................................ 6
2.1.4 Safety valves .......................................................................................................................... 7
2.2 LEVEL............................................................................................................................................... 7
2.2.1 Level indicator gauge .............................................................................................................. 7
2.2.2 Automatic level regulator and water level limits (Fig. 7) .......................................................... 8
2.3 FEED WATER .................................................................................................................................. 8

3 INSTALLATION ................................................................................................................................... 9
3.1 SITING .............................................................................................................................................. 9
3.2 WATER CONNECTIONS .................................................................................................................. 9
3.3 ELECTRIC CONNECTIONS ............................................................................................................10
3.4 SMOKESTACK ................................................................................................................................10
3.5 BURNER ..........................................................................................................................................10
3.5.1 Boiler - Burner coupling .........................................................................................................10

4 BOILER OPERATION .........................................................................................................................11

4.1 FIRST START-UP ............................................................................................................................11
4.2 NORMAL OPERATION ....................................................................................................................11

5 MAINTENANCE ..................................................................................................................................12
5.1 ORDINARY ......................................................................................................................................12
5.2 PERIODIC........................................................................................................................................12
5.2.1 Periodic control (every 6 hours of use) ...................................................................................12
5.3 SCHEDULED ...................................................................................................................................14
5.4 ConservaTION DURING WHEN OUT OF SERVICE ........................................................................14
5.4.1 Dry conservation ....................................................................................................................14
5.4.2 Wet conservation ...................................................................................................................14

6 WATER CHARACTERISTICS .............................................................................................................15

6.1 FEEDWATER - LIMIT VALUES (entering the boiler) ........................................................................15
6.2 OPERATING WATER - LIMITING VALUES .....................................................................................15
6.3 FREQUENCY OF THE ANALYSES .................................................................................................15

7 TROUBLESHOOTING ........................................................................................................................16

8 WATER LEVEL LIMITS ......................................................................................................................17

8.1 GENERAL ........................................................................................................................................17
8.2 TYPICAL APPLICATIONS ...............................................................................................................18
8.3 ELECTRICAL CONNECTIONS ........................................................................................................18
8.4 STEAM GENERATOR OPERATION................................................................................................19
8.5 FIRST START-UP ............................................................................................................................19
8.6 MAINTENANCE ...............................................................................................................................19
8.6.1 Ordinary.................................................................................................................................19
8.6.2 Periodic control (every 6 hours of use) ...................................................................................19
8.6.3 Extraordinary maintenance (water level limits substitution) ....................................................21
8.7 TROUBLESHOOTING .....................................................................................................................21
8.8 DATA LABEL ...................................................................................................................................22

1
 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/cm2) 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

· Working pressure switches for operation (controlling the 1st and 2nd burner flame).

· Locking pressure switches (stops the burner on reaching the maximum steam pressure; the boiler is
manually reset from the control panel).

· Automatic level regulator (2 probes connected to an electronic conductivity relay maintain the water
level between the set levels).

· 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).

2
 TECHNICAL CHARACTERISTICS

1.3 TECHNICAL DATA

Fig. 1
nd
LEGEND 11 2 level gauge 22 Rapid exhaust valve
1 Switchboard 12 Flame inspection hole 23 Exhaust valve
2 Control pressure switches 13 Burner plate 24 Feed pumps
3 Safety pressure switch 14 Steam take-off
4 Pressure gauge 15 Non return valve N1 Steam intake
5 1st safety level probe 16 Inspection door N2 Feed
6 Level control probes 17 Safety valves N3 Safety valves exhaust
7 2nd safety level probe 18 Feed filter N4 Boiler exhaust
8 1st level gauge 19 Back smokebox N5 Safety valves fitting
9 Level gauge drain 20 Smokestack connection
10 Front plate 21 Cleaning door
Pressure losses Design Total Steam Total Electric Insulation Electric
Characteristics Heat output Frequency Fuel
flue gas side Pressure capacity capacity* weight supply class power

Heavy oil
kW kcal/h mbar bar l kg/h kg Volt ~ Hz IP W

Nat. gas

Gasoil
AX 200 233 200.000 3,5 12 730 340 1500 3/N 400 50,0 IP55 4000 X Lpg
X X X
AX 300 349 300.000 3,5 12 940 510 1800 3/N 400 50,0 IP55 4000 X X X X
AX 400 465 400.000 5,0 12 1090 680 2100 3/N 400 50,0 IP55 4000 X X X X
AX 500 581 500.000 4,5 12 1380 850 2600 3/N 400 50,0 IP55 4000 X X X X
AX 600 698 600.000 6,0 12 1585 1020 3000 3/N 400 50,0 IP55 4000 X X X X
AX 800 930 800.000 5,5 12 2030 1360 3600 3/N 400 50,0 IP55 4000 X X X X
AX 2000 1163 1.000.000 7,0 12 2330 1700 4300 3/N 400 50,0 IP55 4000 X X X X
AX 1200 1395 1.200.000 8,0 12 2860 2040 4700 3/N 400 50,0 IP55 10000 X X X X
AX 1500 1744 1.500.000 6,5 12 3630 2560 6000 3/N 400 50,0 IP55 10000 X X X X
AX 1750 2035 1.750.000 7,5 12 4020 3000 6500 3/N 400 50,0 IP55 10000 X X X X
AX 2000 2326 2.000.000 8,0 12 4570 3410 7500 3/N 400 50,0 IP55 15000 X X X X
AX 2500 2907 2.500.000 9,0 12 6220 4270 10000 3/N 400 50,0 IP55 15000 X X X X

Dimensions H H1 H2 H4 H6 L L2 L4 P P2 P6 Øb Øc N1 N2 N3 N4 N5
mm mm mm mm mm mm mm mm mm mm mm mm mm DN/in DN/in DN/in DN/in DN/in
AX 200 1600 1240 575 1440 720 1480 1080 1130 2060 1508 280-330 180 250 32 1”1/4 40 32 25
AX 300 1780 1400 640 1600 815 1640 1240 1290 2092 1511 310-360 225 250 32 1”1/4 40 32 25
AX 400 1800 1400 640 1620 815 1640 1240 1290 2342 1761 310-360 225 250 40 1”1/4 40 32 25
AX 500 1980 1560 700 1780 900 1800 1400 1450 2381 1760 350-400 280 300 40 1”1/4 40 32 25
AX 600 2010 1560 700 1780 900 1800 1400 1450 2631 2010 350-400 280 300 50 1”1/4 40 32 25
AX 800 2160 1710 735 1930 950 1950 1550 1600 2661 2010 370-420 280 350 50 1”1/4 40 32 25
AX 1000 2220 1710 735 1940 1950 1550 1600 2961
950 2310 370-420 280 350 65 1”1/4 40 32 25
AX 1200 2370 1850 810 2080 1000 2100 1680 1730 3163 2512 370-420 320 400 65 1”1/4 40 32 25
AX 1500 2550 1990 850 2240 1080 2260 1840 1890 3413 2710 420-470 360 450 80 1”1/4 40 32 25
AX 1750 2550 1990 850 2240 1080 2260 1840 1890 3713 3010 420-470 360 450 80 1”1/4 50 32 32
AX 2000 2710 2150 880 2390 1240 2450 1950 2000 3785 3013 480-530 360 500 80 1”1/4 50 32 32
AX 2500 2900 2300 950 2550 1240 2600 2100 2150 4283 3504 480-530 400 550 100 40 50 40 32
* 80°C feeding water

3
TECHNICAL CHARACTERISTICS

4
 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).

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:
· Communication between boiler and gauge (normal operation
position).
· Communication between gauge and the atmosphere (position
necessary to purge the siphon).
· Communication between the boiler, the gauge and a test
gauge (position necessary to verify the gauge).

Fig. 2

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 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.
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

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.

6
 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.
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 Fig. 5
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.
• Only wide radius curves 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
Fig. 6
2.2.1 Level indicator gauge

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:
• 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 attempt 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.

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 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:
· 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.
· 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.

Boiler probes:

6 Pump stop
7 Pump start
8 1st safety burner stop and alarm on.
9 2nd safety burner stop and alarm
on.

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.

Fig. 7
2.3 FEED WATER

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)
60 1
70 2
80 3
90 4,5

WARNING
· Avoid the use of feed water at temperatures lower than 60 Celsius, being rich in Oxygen and
therefore such as to cause corrosion.
· To avoid pump cavitation problems, the feed water temperature should not be higher than 90
Celsius.

8
 INSTALLATION

3 INSTALLATION
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

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 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.

3.4 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).

P6

Fig. 10

KEY:
1. Burner
Øb

2. Manhole
1 3. Thermoinsulating material
3 4. Flange

4 2

All details on the draught tube lenght (P6), the diameter of the burner hole (Øb) and the pressurization are
included in the par. Technical Specifications.

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 BOILER OPERATION

4 BOILER OPERATION
4.1 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.

• 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:

1) Switch on the control panel by turning the main switch.

2) 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.

3) Set the pump switch to AUT and verify that burner cannot start before the attainment of the minimum
level;

4) Check that the pump stops when the maximum level is reached by observing the level indicators and
checking the positions of the indicator valves.

5) Press and keep pressed the safety water level reset button for at least 10 seconds, the conductivity
relay being of the delayed type.

6) Open the boiler drain and check on the level indicator at what level the pump-start probe acts.

7) 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.

8) Close the drain and set the pump switch to AUT

9) 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.

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 MAINTENANCE

5 MAINTENANCE

5.1 ORDINARY
· Periodically purge the level gauges, probe holder if fitted and the boiler, to avoid the accumulation 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:

12
MAINTENANCE

13
 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 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 removed 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.

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 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
Characteristics Unit of measurement Pressure [ 15 bar Pressure [ 25 bar
pH 7 I 9,5 7 I 9,5
Total hardness mg/l CaCo3 10 5
Oxygen (1) mg/l O2 0,1 0,05
Free Carbon Dioxide (1) mg/I CO2 0,2 0.2
Iron mg/l Fe 0,1 0,1
Copper mg/l Cu 0,1 0.1
Oily substances mg/I 1 1
Aspect Clear, limpid, no persistent foam.
(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 (O2 and CO2). Chemical deoxygenators must be used to remove completely the oxygen from the feed
water and reduce as much as possible CO2 corrosive effects.

6.2 OPERATING WATER - LIMITING VALUES

Tab.2
Characteristics Unit of measurement Pressure [ 15 bar Pressure [ 25 bar
pH 9 I 11 9 I 11
Total alkalinity mg/l CaCo3 1000 750
Total hardness mg/l CaCo3 10 5
Maximum conductivity (4) mS/cm 8000 7000
Silica mg/l SiO2 150 100
STD (4) mg/l 3500 3000
Conditioner (2)
Aspect Clear, limpid, no persistent foam
(1) To maintain in the boiler the parameters 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:

Ca
S % = 100
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) Determined on 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 surface in the boiler caused by a layer of oil).

15
 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 Check and then adjust the valve using
valve 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.
No water feed See faults "feed water"
Feed water insufficient Pump seized See faults "Pump stopped"
Pump suction filter blocked Clean the filter
Level control faulty Temporary replacement of the
electronic control relay with one of
those present in the panel.
If the problem disappears, replace 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
Pump rotation direction Invert two phases (three-phase pump)
Burner always ON Erroneous electrical connection to the Consult the wiring diagram
panel
Safety level relays faulty 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 Replace the control pressure switch
control pressure switch
No consent to the burner from the safety See “Intervention safety level 1 or 2”
level relay
Erroneous connection to the control Consult the wiring diagram
panel

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 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 based on water conductivity. In order to guarantee
the correct operation of the device, following conditions must be fulfilled:

· Water conductivity > 250 mS/cm

· Water temperature < 210°C
· Pressure < 20 bar

(See. " Operating water " - Tab. 2 ).

EXAMPLE: PROBES TANK FOR SAFETY AND REGULATION

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 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.

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 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.
3 Set the pump selector switch 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;
5 Maintain safety level reset pressed for 10 sec because it is employed an electronic delayed relay
6 Open the boiler discharge and check on the level indicator the intervention point of probe pump start
7 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
· Bleed periodically (level indicators, probe-holder barrel if any, boiler) to avoid mud deposits.
· 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:

· Water level limits

· 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:

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WATER LEVEL LIMITS

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 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. Ensure that the automatic level control consisting of the two ceramic plugs and their conductivity-
relays, work well

8.7 TROUBLESHOOTING

FAULT POSSIBLE CAUSE RECOMMENDED REMEDY

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
Clean the pump sucking filter
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 manual
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

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 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 Boiler serial number
Modello / Model GP1
N.fabb. / Serial number
Conducibilità dell’acqua
> 250 mS/cm
Water conductivity
PS max 20 bar
TS max 210°C
Fluido / Fluid Acqua / Water
Data/Date Boiler final test date
Volt / Freq. / Pot. - Power 24 VAC / 50-60 Hz / 3 VA

Omologazione/Approval
1370
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)

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 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
[email protected] - 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. 12-02/09 12 - St. 10 – 02/09