Ecovapor Manual EN

EN
Steam generating unit with integrated burner
ECOVAPOR
INSTALLATION, USE AND MAINTENANCE MANUAL
ECOVAPOR_350_3000_EN Ed. 01 - 03/2019

INDEX
General information 47 Gas train assembling

4 Introduction 48 Front door opening
4 Range 48 Front door adjustment
4 Compliance 48 Door adjustment (opening on the right)
4 Warranty 49 Turbulator assembly
5 Warnings 49 Electrical connections
6 Prohibitions
First commissioning
6 Hazards
50 Preliminary activities to be carried out before the
7 Hazards "first" commissioning
7 Paperwork 50 Hydrostatic head diagram
8 Fire prevention 51 Water characteristics
8 Identification 52 FREQUENCY OF THE ANALYSES
9 Appliance description 52 Water feeding procedure
9 Structure 53 Level probe positioning
9 Front view 53 FIRST START-UP
10 Side view 55 Combustion system calibration
11 Dimensions and connections 56 Checks after commissioning
11 Front view 56 Stop periods
12 Side view
13 P&ID Maintenance
15 Technical data 57 Periodic verifications
15 Safety component calibrations
59 Lifecycle of main components
15 Components
59 Methods for checking the safety devices
59 Checking of the minimum level safety level switches
Combustion system 59 Check the maximum level switch (if any)
19 Description 59 Check of the safety pressure switch
21 Burner modulation strategy 60 Routine maintenance
21 Compliance 60 Extraordinary maintenance
22 System logics ECOVAPOR in case of no flame 60 Level switch replacement
22 Failure upon ignition 61 Any anomalies and remedies
22 Failure during standard operation 61 Protecting the environment
61 Decommissioning and disposal
Adjustment and control system
62 System for 24 or 72 h operation without continuo-
23 Control panel
us supervision
25 Graphic interface
28 Operating modes Optional components
31 Complete list of menus and parameters 64 Backup supply pump
31 Main parameter menu
64 Second level indicator
33 Information menu
37 Generator parameter menu 64 Second safety valve
40 Service parameter menu 65 Steam outlet electric valves
41 Modbus/slave interface parameters 65 Steam non-return valves
65 Steam flow meter
Installation 65 Electrical energy meter
43 Product receipt 66 Mid thermal energy meter
44 Handling 66 Turbine gas meter
44 Film removal 66 Gas manual shut-off valve
45 Installation room 66 Gas pressure controller
45 Positioning
45 Room ventilation Useful information and declarations
46 System cleaning 67 QR code
46 Hydraulic connections
47 Flue exhaust Appendixes for Technical Personnel
2
SYMBOLS USED IN THE MANUAL
DANGER
a To indicate actions that, if not performed correctly, can result in injury of generic origin or may generate malfunction
or damage to the appliance; therefore require particular caution and adequate preparation.
IT IS FORBIDDEN
d To indicate operations that SHOULD NOT be performed.
IMPORTANT
m To indicate particularly useful information and important.
The illustrations and data presented are not binding. The company reserves the right to make without prior notice any changes it
deems appropriate for continuous improvement and constant updating.
3
1 General information
INTRODUCTION
Dear Customer,
Thank you for having chosen an appliance of the series ECOVAPOR, a high quality and efficiency product, reliable and safe.
We recommend entrusting its maintenance to Professionally Qualified Personnel who, when necessary, uses original spare parts.
This manual contains important information and suggestions that must be observed for easier installation and best possible use
of the appliance.
IMPORTANT
m Failure to observe the instructions in this manual will void the warranty conditions.
RANGE
MODEL CODE
ECOVAPOR 350 _ECS24 BOILER 350 KG/H 12 BAR 86440350
Models for 24 h Operation without ECOVAPOR 1000 _ECS24 BOILER 1000 KG/H 12 BAR 86441000
Continuous Supervision(ECS24) ECOVAPOR 1350 _ECS24 BOILER 1350 KG/H 12 BAR 86441350
Models for 72 h Operation without ECOVAPOR 1000 _ECS72 BOILER 1000 KG/H 12 BAR 86441004
Continuous Supervision (ECS72) ECOVAPOR 1350 _ECS72 BOILER 1350 KG/H 12 BAR 86441354
COMPLIANCE
The steam generators Series ECOVAPOR comply with the following European Directives:
–– Directive 2014/68/EU (PED)
–– Low Voltage Directive 2014/35/EU
–– Electromagnetic Compatibility Directive 2014/30/EU
NOTE
The serial number is indicated on the boiler nameplate.
WARRANTY
The warranty conditions for boilers series ECOVAPOR are included in the CONSTRUCTION - WARRANTY CERTIFICATE supplied with
the product.
WARNINGS
IMPORTANT
m –– The instructions manual is an integral and essential part of the product. If the body is sold or transferred to a new owner
or if you relocate and leave the system, always make sure that the manual accompanies the boiler body, so that it can be
consulted by the new owner and/or by the installer. In case of damage or loss, request a copy from Technical Assistance
Service ICI CALDAIE S.p.A.. This body must be intended for the use it was expressly designed for. The manufacturer will
be exempted from any liability, contractual and extra-contractual, for any injury/damage caused to people, animals, or
property due to the failure to perform maintenance and/or scheduled periodic checks and improper uses.
–– Upon receipt of the steam generator, ensure the integrity and completeness of the supply and, if it does not comply with
the order, promptly contact ICI CALDAIE S.p.A..
–– The ECOVAPOR steam generators must be installed by a Certified Company which, at the end of the work, must issue the
owner with the declaration of conformity for proper installation, ie in compliance with the national and local laws and
regulations in force, and the instructions given in the instruction manuals supplied by ICI CALDAIE S.p.A..
–– The first Commissioning must be carried out byTechnical Assistance Service ICI CALDAIE S.p.A. after the necessary
preliminary checks. Once the commissioning operations are completed, the Technical Assistance Service must fill out the
System Booklet and deliver it to the User.
–– If the appliance is not used for a long period, professionally qualified personnel must intervene to perform the operations
described in the specific paragraph, necessary for storing the steam generator.
–– The periodic check and maintenance of the appliance is a legislative obligation. The User must have it performed by
professionally qualified personnel.
–– Make sure the safety valves properly open at the design pressure.
–– Make sure the safety pressure switch intervenes properly which, by shutting down the burner, eliminates the cause of the
pressure increase.
–– Check the correct connection of the accessories to the boiler body (gasket seal check).
–– Pay the due attention during handling and installation.
–– Periodically check the condition of the same accessories (exclusion of fractures).
–– Once installation is completed, check the intervention of the safety valve by carrying out a preventive hydraulic test (at the
PT pressure indicated on the ID plate).
–– Make sure the safety level switch is working properly, in accordance with the contents of the technical manual supplied
with the boiler.
–– It is necessary to check that the operating water conductivity values are within those provided in the supplied technical
manual.
–– Make sure the water loading pump is working properly as described in the technical manual provided with the boiler
(pump wear, hydrostatic head in suction, water supply temperature, pump connection/disconnection from the level
control probes).
–– Analyse the water when necessary, ascertaining that the values are within the limits expressed in this technical manual
and carry out the due chemical treatments. Check the intervention of the safety probes by lowering the level below the
minimum required.
–– Level switch operation must be manually checked every 24 or 72 hours.
–– Do not step on or damage the protective sheath of the cable with any other mean.
–– It is not necessary to consider the boiler connections as support points for the weight of the pipes.
–– It is good practice to provide expansion joints and appropriate supports for the pipes connecting the boiler to the system
–– Check that the panel power supply complies with the wiring diagram supplied.
–– Make sure the generator is properly earthed.
–– Check the plant’s electrical system.
–– Before opening the manhole, check that the pressure in the boiler body is equal to the atmospheric pressure (0 relative bar).
–– Before opening the door, check that the burner is off and disconnected.
–– Switch off the burner and the pump before closing the shut-off valve.
General information 5
IMPORTANT
m –– Avoid contact with the non-insulated parts of the equipment during its operation. When adjustments or checks are carried
out during operation, it is necessary to protect oneself with suitable clothing (P.P.E. according to Italian Legislative Decree
81/08).
–– Climb up and down the top of the boiler body to perform ordinary and extraordinary maintenance operations using PPE
according to the Regulations in force in the Unit Installation Country.
–– Pay attention to sharp edges on the generator and its accessories.
–– The boiler must be kept sheltered from adverse weather conditions, with regard to the minimum temperature (-10 ° C) and
from the rain.
–– The user is responsible for considering the seismic degree of the user area in the design of the heating plant.
–– After an earthquake, have technical personnel assess any damage by carrying out NDCs (non-destructive checks), if
necessary.
–– The manufacturer shall not be held liable in the event of accidents caused by incorrect decommissioning.
–– The personnel in charge must be able to prove to have sufficient knowledge and experience relating to the safety and
control / regulation accessories supplied with the generator and good familiarity with the instructions contained in the use
and maintenance manual and be capable and physically suitable.
–– During handling, always maintain a distance of at least 5 m from the projection of the appliance to the ground
–– In case of violent impact during handling, visually check the integrity of the appliance, all over; run the hydraulic test again.
–– For any downgrading, comply with what specified in the Regulations in force in the Unit Installation Country.
–– Boiler design takes into account only the loads due to static internal pressure, temperature, equipment weight in operating
conditions (static load), weight in test conditions (static load), boiler support connection.
–– In order to limit boiler operating cycles, it is started at pressures below 0.5 barg.
PROHIBITIONS
IT IS FORBIDDEN
d –– Operate electrical devices or appliances such as switches, household appliances, etc. if you smell fuel or unburnt materials.
In this case:
-- ventilate the room by opening doors and windows
-- close the fuel shut-off device
–– Perform any technical or cleaning intervention before disconnecting the appliance from the electrical power supply and
wearing the Personal Protective Equipment (P.P.E. according to Italian Legislative Decree 81/08).
–– Modify the safety or adjustment devices without the steam generator manufacturer’s permission and instructions.
–– Plug or dimensionally reduce the ventilation openings of the installation room. The ventilation openings are essential for
proper combustion.
–– Perform any welding/repairs. If necessary, contact the manufacturer/verifying party for operation (in Italy according to MD
329/04).
–– Expose the generator to atmospheric agents.
–– Leave flammable substances and containers in the room where the appliance is installed.
–– Use generator fittings as pipe supporting points.
–– Disperse the packaging material in the environment and leave it within the reach of children as it may be a potential source
of danger. It must be disposed of in accordance with the legislation in force.
–– An improper use of the system.
HAZARDS
DANGER
a –– Dangers due to water leaks. Disconnect the boiler from the electrical power supply, close the water supply and promptly
contact the Technical Assistance Service Authorised ICI CALDAIE S.p.A. or professionally qualified personnel.
–– Danger of explosion. Routine and extraordinary maintenance must be entrusted to professionally qualified personnel
with the purpose of promptly detecting any damage to the generator's pressurised body and the safety and control
accessories.
HAZARDS
DANGER
a –– Danger deriving from the fuel. Sensing the presence of fuel in the thermal power plant, it is appropriate to follow the
precautions below to avoid the risk of explosions and fires:
-- do not smoke or cause sparks
-- do not turn on lights or electrical devices in general (mobile phones)
-- open doors and windows
-- close the fuel shut-off valve normally placed outside the thermal power plant
-- disconnect the electrical power supply by using the switch normally placed outside the thermal power plant.
–– Danger of burns. During normal operation, the generator has hot parts that, upon accidental contact without suitable
personal protection, can cause serious burns. Potentially hot parts include:
-- accessories and valves connected to the generator
-- door and smoke chamber
-- upper tread walkway.
–– Danger from fumes. An incorrect adjustment of the closing door or an insufficient draught in the flue can leave fumes
inside the thermal power plant, causing fatal intoxication deriving from carbon monoxide which, by its nature, is colourless
and odourless. Therefore, ensure the generator is properly installed and adjusted and the presence of ventilation openings
in the thermal power plant are compliant with the regulations in force.
PAPERWORK
These generators, supplied in single-block, are CE marked according to the Directive 2014/68/EU "PED".
The documentation supplied with the generator is:

–– declaration of conformity of the whole
–– use and maintenance manual (always housed in the electrical panel)
–– safety valve certificate, declaration of conformity, use and maintenance manual
–– feed pump characteristic curve
–– Machinery Directive 2006/42/EC (for liquid fuel burners)
–– wiring diagram (always housed in the electrical panel).
USER OBLIGATIONS
m Check which pressure equipment commissioning and use regulations are in force in the country of use.
FIRE PREVENTION
Refer to the Regulations in force in the Unit Installation Country.
IDENTIFICATION
Each system ECOVAPOR is identified by the following nameplates:
–– Assembly nameplate (1): it is glued on the external surface of the front plate coating of the front panel; this plate carries the
data relating to the boiler complete with the accessories, which may vary from those of the generator body only.
–– Generator body nameplate (2): it is positioned under ICI CALDAIE logo, which is screwed to the upper coating of the front
plate; this plate carries the main data of the generator body and is riveted on a special support.
–– Energy saver nameplate (3): it is positioned under the coating panel, on the rear side; this plate carries the main data of the
energy saver and is riveted on a special support. To access it, remove the fastening nuts and slide out the panel.
ICI CALDAIE S.p.A.

Via G. Pascoli, 38 / Fraz. Campagnola
37059 ZEVIO (VR) - ITALY
m2
MODELLO N.F. DATA PT SUP. RISCALDATA
1 2 BOILER TYPE S.N. DATE PT HEATING SURFACE
bar bar ĀC ĀC
PS PT TS Max. TS Min.
MW MW kg/h
POTENZA POTENZA PRODUZIONE VAPORE
HEAT INPUT HEAT OUTPUT STEAM CAPACITY
CATEGORIA CLASSE FLUIDO COMBUSTIBILE

CATEGORY (PED) FLUID GROUP (PED) FUEL
1370 l kg
CAPACITA'/CAPACITY MASSA/WEIGHT
ICI Caldaie SpA Via G. Pascoli, 38 37059

Campagnola di Zevio VR
Serial N. 1773F17 YEAR 2017
Fam/Type: C1 - 92GF-4T 4R 650A 3P 4NC
Description: ECXV 2-6
Tube Inside Tube Outside
TS °C -10/240 -10/340
PS barg 22 atm
3 PT barg 32 /
Fluid: WATER Volume: 2,3 L

Fabbricante/ManufactureDAVCOIL Srl
Via dell’aArtigianato 11 - 37029 San Pietro In Cariano (VR)
The appliance is also accompanied by construction certificate attesting the successful result of the hydraulic test.
APPLIANCE DESCRIPTION
Systems ECOVAPOR are automatically-operated appliances for high pressure (12 bar) steam production from 350 to 3000 kg/h.
The horizontal combustion chamber is of the reverse flame type and the tube bundle is complete with helical turbulators.
The patented combustion system, with pre-mixing and flue gas recirculation, only for natural gas (CH4), allowing to obtain high
efficiency levels, low emissions and a thermal power modulation from 1 to 10, is integrated inside the front door and in the rear
smokebox.
The generator body is thermally insulated through a high-density mineral wool mattress protected by stainless steel panels to
minimise losses.
They use a single control panel where the whole electric wiring of the appliance merges, and including the touch-screen
operator's panel, the burner managing control unit, with display, the burner motor inverter, controls of several devices and an air-
conditioning system to ensure a temperature suitable to the devices.
The steam generating system ECOVAPOR has been designed for the installation inside closed heating plant rooms with an
ambient temperature below 50 °C; it rests on a support made of carbon steel section bars ensuring its stability.
They are equipped with water side inspection opening (flanged hatch).
STRUCTURE
FRONT VIEW
1 2 3 4 5 6 7 8 9 10 11
16
19
17
18
12
13
14
15
1 Door locking system 11 Front door

2 Front door 12 Pressure transducer
3 Pressure transducer 13 Pressure transducer
4 Pressure transducer 14 First safety level probe (minimum)
5 First safety level probe (minimum) 15 Maximum level probe
6 Maximum level probe 16 Capacitive probe with pre amplifier
7 Capacitive probe with pre amplifier 17 Pressure gauge
8 Pressure gauge 18 Second safety level probe (minimum)
9 Second safety level probe (minimum) 19 Front door
10 Front door
IMPORTANT
m Drawing, legend and data refer to standard models
For specific models refer to the supplied accessory manual
SIDE VIEW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
32
16
31
30
17
29
18
28 27 21 26 25 24 23 22 21 20 19
1 Pressure gauge 17 Rear smoke chamber

2 Probe holder cylinder 18 Energy saver
3 Capacitive probe with pre amplifier 19 Sludge separator pneumatic drain valve (optional for
4 Maximum level probe versions ECS24)
5 First safety level probe (minimum) 20 Globe valve
6 Second safety level probe (maximum) 21 Water inlet
7 Steam inlet 22 First feed filter
8 Steam inlet valve 23 First electric feed pump
9 Sanitisation check probe 24 Check valves
10 Sample cooler (optional for ECS24 versions) 25 Second electric feed pump (optional)
11 Second safety valve drain (optional) 26 Second feed filter (optional)
12 Second safety valve (optional) 27 Salinity control system
13 First safety valve 28 Lower inspection point
14 First safety valve drain 29 Level indicator discharge
15 Chimney fitting 30 Front door
16 Fan 31 Second level indicator (optional)
32 First level indicator
IMPORTANT
DIMENSIONS AND CONNECTIONS
FRONT VIEW
Q1
L4
L6
H
H1
L2
Dimensions
ECOVAPOR
Description u.m.
350 500 650 800 1000 1350 1700 2000 2500 3000
H mm 1825 1825 1930 1943 2150 2150 2300 2300 2460 2540
H1 mm 1350 1350 1468 1468 1680 1680 1840 1840 2000 2000
L mm 1810 1810 1965 1965 2160 2160 2370 2370 2540 2540
L2 mm 1180 1180 1300 1300 1510 1510 1660 1660 1840 1840
L4 mm 1230 1230 1350 1350 1560 1560 1710 1710 1890 1890
L6 mm 376 376 415 415 495 495 495 495 538 538
Q1 mm 980 980 980 980 980 980 1000 1000 1000 1000
IMPORTANT
SIDE VIEW
N9 N6 N1 N3 N10 N10 P4
N5 N5 Øc
Q2
N8
H6
N11 N2 N2 N4
Q3 P2
P
Dimensions
ECOVAPOR
Description u.m.
350 500 650 800 1000 1350 1700 2000 2500 3000
H6 mm 1489 1489 1640 1640 1870 1870 2103 2103 2287 2287
P mm 2478 2478 2800 2800 2830 3240 3445 3805 4072 4570
P2 mm 1993 1993 2245 2245 2228 2638 2730 3090 3178 3678
P4 mm 442 442 489 489 530 530 664 664 756 756
Øc mm 198 198 248 248 298 298 348 348 448 448
Q2 mm 1900 1900 1900 1900 1900 1900 1900 1900 1900 1900
Q3 mm 400 400 400 400 400 400 400 400 400 400
tb (ØxP) [1] mm 36x1220 36x1220 36x1500 36x1500 36x1220 36x1500 36x2000 36x2000 48x2400 48x2400
tb [1] mm 20 26 30 40 40 58 64 72 74 74
[1]
Tb=Turbulators size and quantity
Hydraulic fittings
ECOVAPOR
Description u.m.
350 500 650 800 1000 1350 1700 2000 2500 3000
N1 DN/in 32 32 40 40 50 50 65 65 80 80
N2 DN/in 1”1/2 1”1/2 1”1/2 1”1/2 1”1/2 1”1/2 1”1/2 50 50 50
N1/N2 PN [2] 16 16 16 16 16 16 16 16 16 16
N3 DN/in 1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
N4 DN/in 32 32 32 32 32 32 32 32 32 32
N5 DN/in 25 25 25 25 25 25 25 25 25 32
N6 DN/in 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"
N8 DN/in 50 50 50 50 50 50 50 50 50 50
N9 DN/in 100 100 100 100 125 125 125 125 125 125
N10 DN/in 40 40 40 40 40 40 40 40 40 50
N11 DN/in 125 125 125 125 125 125 125 125 125 150
[2]
PN=Nominal pressure
IMPORTANT
P&ID
EXHAUST FLUE GAS (OPTIONAL)
STEAM
General information
LAH
Outside Boiler 106
OPTIONAL
Room
LYH STOP
106 I WP01 (WP02)
STOP BU01
STOP BU01
PSV
109
I I
LFC Ratio signal for
106 I WP01 (WP02)
LALL LALL LAH
108 107 105
STOP BU01
PFC Ratio signal for
I-0
I
103 BU01 Ambient TE
S S I-0
I temperature 128 EK100
LIC
PSV LYLL LYLL 106 LYH General control station
110 108 107 105
PAH PIC I START-STOP
104 103 BU01 ECS
PI
102 Ecovapor control system
LE LE LT LE S
108 107 106 105
PSH PT
PP
104 103
to FIC128
PSV
BU01
BU01
STOP
STOP
BU01
112
STOP
TT TI
128a PCA STOP
111
ON/OFF
I LG LG 126
I BU01
from BK????
BG
123 BAL
I
PAL
124 PC
113 To steam boiler PAL
126
OV SV 127
BE PI
125a 125b 129
PSL 124
To Chimney 113 PSL
Economizer Flue gas OZ SV 127 OPTIONAL
OPTIONAL for GSS24 OPTIONAL
TypeB from boiler
Mixer
Burner
CE Automatic
TE BU01
Flue gas 119
114 Salinity Control
FIC TDS01
Steam Boiler
128
PI SB01
116
ON/OFF
TI TT I from PIC103
115 128b
AIR
FT Ratio signal
128 I from PFC103
ONLY for models > ECOVAPOR1350
STOP BU01
Gas line for PILOT FLAME from PSL127 - PC126 -
OPTIONAL BE124 - PSL113
PCV BV BV I and from PSH104 -
128a 128a 128b
LYLL107 - LYLL108 -
1 CAH120
S S
BK
STOP CAH 300
BU01 I 120
M
ON-OFF
From LIC106 I SC I Ratio signal from
117a LFC 106
CIC
Speed Control 120
I-0
CYC
120
Feed water
WP01 OPTIONAL for GSS24

CV
120
Pump Station Sample
Cooler
WP01 (WP02) I-0
Blowdown
BWD01 S
KV KY
M 118 118
ON-OFF
From LIC106 SC
Ratio signal from
I I
LFC 106
117b
S
Speed Control
Compressed
Air Industrial
Water
Feed water
Analysis
WP02 Compressed KZ Point
OPTIONAL 118
Air
13
Identification letters
( ISA Symbols )
First letter Succeeding letters

Primary Field Optional
location mounted
Measured or Modifier Readout or Output
initialing variable Modifier
passive function function
Discrete
A Analysis Alarm instruments
Burner
User's choice User's choice User's choice Shared display
B Combustion Shared control
User's choice
C - Conductivity - Control
Computer
function
D User's choice Differential
Sensor Programmable
E Voltage (Primary logic control
element)
F Flow rate Ratio Pilot
(Fraction) Light
Glass
G User's choice Viewing device
Instruments
H Hand High supply or
connection to
I Current Indicate process
(Electrical)
J Power Scan Pneumatic
Time Time rate Control signal
K
Time schedule of change station
L Level Light Low Electric
signal
M User's choice Momentary Middle
Intermediate
Interlock I
N User's choice User's choice User's choice User's choice logic
O Orifice
User's choice
Restriction Reset for
latch-type R
P Pressure Point (Test) actuator
Vacuum Connection
Q Quantity Integrate I-
Totalize ON - OFF
0
R Radiation Record
Analog
S Speed Safety Switch output M
Frequency variable
T Temperature Transmit
Limit of
U Multivariable Multifunction Multifunction Multifunction supply
Vibration
V Mechanical Valve, Damper
analysis Louver
W Weight Well
Force
X Unclassified X Axis Unclassified Unclassified Unclassified
Y Event, State or Y Axis Relay, Compute,
Presence Convert
Position Z Axis Driver, Actuator
Z Final control
Dimension
element
TECHNICAL DATA
ECOVAPOR
DESCRIPTION u.m.
350 500 650 800 1000 1350 1700 2000 2500 3000
Useful nominal power [1] kW 238 341 443 545 681 920 1158 1363 1703 2044
Nominal thermal flow kW 254 362 471 580 725 979 1232 1450 1812 2175
Minimum nominal power kW 30 43 55 68 85 115 145 170 213 256
Minimum thermal flow kW 31 44 58 71 89 120 151 177 222 266
Efficiency at 100% (ref. P.C.I.) [1] % 94
Furnace depression (Flue gas pressure drop) mbar n.a. -32 n.a.
Rated pressure bar 12-15
Total capacity l 921 1250 1830 2190 2640 3050 3380 4020
Capacity at level l 673 950 1280 1475 2000 2300 2490 2825
EXCHANGE surface m2 8,30 12,80 14,20 22,30 25,00 31,5 40,5 48
Steam production [1] kg/h 350 500 650 800 1000 1350 1700 2000 2500 3000
Rated frequency ~ voltage Volt /Hz 400/50
Electric protection rating IP IP55
Absorbed power kW 6 7 9 14,5 15,5 19,5
Allowed fuels Natural gas
Lower calorific value MJ/m3 34,2
Max. / min. fuel pressure values mbar 17,25
Fuel nominal flow rate (G max gas flow rate) Stm3/h 26,85 38,35 49,86 61,37 76,71 103,56 130,40 153,42 191,77 230,12
Minimum fuel flow rate Stm3/h 3 4 5 6 8 10
Flue gas temperature at nominal power °C 135 135 135 135 135 135 135 135 135 135
kg (12 bar
Total weight 2180 2180 2550 2550 3240 3690 4400 5250 5920 6320
version)
[1]
80 °C treated water feed temperature.
SAFETY COMPONENT CALIBRATIONS

The components listed below are adjusted at the indicated pressure values
–– safety valve: 12 bar (factory sealed - do not modify)
–– safety pressure switch: 11 bar (factory sealed - do not modify)
–– pressure transducer: 10 bar (adjust during installation, if necessary).
COMPONENTS
The steam generating systems ECOVAPOR feature a series of components that can be divided into:
–– Safety components (safety valves, safety level switches, safety pressure switch).
–– Indicators (level indicator, manometer, flame light).
–– Adjustment components (level adjusters, pressure switches, pressure transducers).
–– Feed components (centrifugal pump).
–– Operation components (shut-off valves, drain valve).
Hereinafter are the descriptions of the operation of each single component.
PRESSURE GAUGE
The manometer indicates the reached steam pressure value. The value of the design pressure is shown in red on the graduated
scale.
The manometer is fitted onto a three-way valve allowing to carry out the following operations:
–– Communication between generator and pressure gauge (normal operating position).
–– Communication between pressure gauge and the outside (position needed to purge the siphon).
–– Communication between generator, pressure gauge and sample pressure gauge (position needed for pressure gauge
comparison).
IMPORTANT
m To define the desired position, refer to the two marks (1) present on valve handle.
1
8
6 10
bar
4 12
2 14
0 16
Three-way valve
SAFETY VALVES
The safety valves are able to maintain the pressure in the generator to the design pressure (save temporary peaks of 10% max of
the max PS of the whole) even if all other pressure control devices (pressure switches and transmitters) are out of use.
These valves are regulated by specific national and international standards, therefore they are sized, tested, installed and maintained
in compliance with the applicable regulations and the contents of this manual.
The use and maintenance manual is supplied with the safety valves.
3
SC
5
1 Cap SC Drain
2 Lifting lever IF Fluid inlet
3 Hat
4 Spring
5 Valid body
IF
IMPORTANT
m Before starting the generator, remove the steel wire used to lock the lever during transportation. Make sure that the
lifting lever is free to move.
The safety valves have been designed and manufactured to operate without lubrication; simply keep them clean and
in good working order.
The use and maintenance manual is supplied with the safety valves.
In case of conveyed drain, blow the conveyor pipe so as to compensate the reaction force generating upon fluid drainage (refer
to the valve use manual supplied with the appliance).
Make one or more draining holes in the conveying pipe to drain any condensate.
Drain must take place in the atmosphere, direct the valve so as not to harm people or damage property.
>3Ā%
NOTE: Clamp at no more than 1 m Typical suggested diagram
IMPORTANT
m The operation of the safety valves is affected by the load losses occurring in the drain conveyor pipe, if any, during
their opening. The load losses inside safety valve drain conveyor pipe must be equal to 0.The nominal diameter of the
drain pipe must be greater than or equal to the size of the outlet fitting of the safety valve. A diameter ≥ 1.5 DN (PSV)
is recommended.
SAFETY PRESSURE SWITCH

The safety pressure switch detects the steam generator pressure and is activated in case of steam pressure controller failure
(regulation pressure switch or pressure transducer) by permanently stopping the burner. The burner will be switched on again
only after the steam pressure value has decreased under the calibration pressure value of the safety pressure switch and the
control panel has been manually reset. For further details, refer to the manual of the supplied component.
IMPORTANT
m The safety pressure switch is calibrated at 11 barg and is sealed.
IT IS FORBIDDEN
d Modify the adjustment of the safety pressure switch.
PRESSURE TRANSDUCER
The 0 - 16 bar (4 - 20 ma) pressure transducer detects the steam pressure inside the generator and converts it into a current value,
then transmits it to the control panel supervising generator operation.
IMPORTANT
m The technical specifications of this device are available in the manual supplied with it.
CAPACITIVE PROBE
The capacitive probe, combined with the pre-amplifier, has been designed for the adjustment or ON-OFF control of the conductive
liquid level. It can also be used with one or more control units/transducers to provide, besides the control, also any level and/or
outlet alarms of a BMS supervision system.
The pre-amplifier is finger screwed on probe upper end, and can be easily removed without affecting the operation of the probe.
Pre-amplifier Probe 1 Ring
2 Plate
1 3 Case
4 Body
5 Tip
2 6 Insulating coating
3
20 mA
4
4 mA
Pre-amplifier
The pre-amplifier is a current loop level transducer to be used in combination with the capacitive probes. It generates a 4 – 20 mA
output signal, which is proportional to the water level present inside tank or generator.
It features two keys and a two-colour (red and green) light signal indicator to be used during commissioning. The device consists
of an austenitic stainless steel tubular body screwed on the top of the capacitive probe, and features a DIN 43650 connection head
and a Pg 11 cable gland. Do not replace the cable gland with another one not of the Pg 11 type.
Probe
The capacitive probe is a metal bar with a special coating ensuring a complete isolation from the liquid where it is immersed. It
measures the capacity of a tank through the capacity variation, which is directly proportional to the level variation. The capacity
value is measured by the pre-amplifier and transmitted to a control unit or to a transducer as a direct current signal. Controls
and settings are on the control unit. The pre-amplifier sensitivity is defined based on the immersed length of the probe, and the
relevant wiring diagrams are included in the related installation and maintenance instructions.
2 Combustion system
DESCRIPTION
The steam generating system ECOVAPOR is equipped with a patented combustion system with premixing and external
recirculation, integrated into the boiler, with vector flame development, characterised by the presence of a suction fan in the rear
part. Therefore, the mixing-combustion process occurs under depression, preventing any possible leakages and further increasing
the safety level. More specifically, the combustion system consists of the following components.
AIR/GAS MIXING SYSTEM

It is fitted inside the generator system, with no moving parts subject to wear, containing:
–– system for pre-heated air suction through the boiler body and door holes to increase the system energy efficiency
–– gas supply line consisting of gas train and flexible supply duct. The gas train features a combined pneumatic gas valve for
adjustment and safety operations with continuous modulation. Complete with filter, minimum pressure switch and tightness
control pressure switch
–– air filter, contributing to the cleaning and additional air pre-heating
–– cone; the sucked air binds to the gas inside the cone, keeping the mixing ratio within the limits of a good combustion.
COMBUSTION HEAD
Patented, with low emissions and wide modulation range, containing:
–– stainless steel cylinder body, resistant to corrosion and high temperatures
–– metal braid cylinder internal coating, made of patented refractory stainless steel metal fibre
–– electrode ignition system specifically designed to reduce the effects of deformation due to high temperature
–– flame detection with ionisation probe.
In sizes from 1700 to 3000, burner is ignited by the flame.

Burner start-up is allowed by an ignition pilot flame, basically consisting of a gas supply tube, an ignition electrode and an
ionisation electrode.
Once the control device enables the start-up, the electrode sets off a spark, the pilot flame gas valves open and allow the ignition
of the pilot flame which, in the second phase, ignites burner main flame.
After a set time, the control device will turn the pilot flame off.
FLUE GAS SUCTION

It is integrated into the rear chamber, composed of a centrifugal fan with AISI 316L backward-curved blade impeller.
Combustion system 19
SAFETY AND CONTROL SYSTEMS
For the correct operation of the combustion system through:
–– safety pressure switch on the air side to stop the combustion in case of fan abnormal operation
–– combustion management system consisting of a flame electronic supervisor, interconnected with the steam production
control system.
7 5
1 Air gas channel ECOVAPOR
2 Inverterjet gasket
3 Air/gas channel flange gasket
4 Inverterjet head
5 Cone assembly Ø68 ( 2 pcs.) ECOVAPOR
1
6 Air filter ECOVAPOR 350/500(e-1009)
7 Double end nipple 1" x 150 two-wire 25 Mm AISI316
2
8 Brahma high voltage transformer
9 Ignition electrode cable with plug
10 Ionisation electrode cable with plug
4 11 Galvanised M8 nut ISO 4033
13 6 12 Galvanised 8x15 plain washer UNI 6592
13 Galvanised 5x50 CH Phillips screw cl4.8
10 14 Galvanised 5x10 plain washer UNI 6592
8 3 11 12
14 15 Galvanised raised M5 nut cl8
9
15
A B ELECTRONIC IGNITION - Models 350 - 1350

1 Ionisation Electrode
2 Ignition Electrode
A B PILOT FLAME IGNITION - Models 1700 - 3000

1 Pilot Flame Unit
2 Flame Indicator
20 Combustion system
BURNER MODULATION STRATEGY
The burner is of the modulating type with PID (Proportional - Integral - Derivative) control.
The burner starts when the measured steam pressure is under the setpoint value shown in the operator panel of the control
panel, less the ignition differential, while it stops when the measured steam pressure reaches the setpoint value plus the turning
off differential.
The modulation occurs within the "modulation range", which is the sum of the "low modulation range" and the "high modulation
range".
The PID system is optimised to keep the pressure close to the “setpoint” value.
Above the "high modulation range" the burner will be immediately set to the minimum.
Under the "low modulation range" the burner will be immediately set to the maximum.
The sampling frequency is increased close to the upper and lower limits of the "modulation range" and converts the calculated
power value into a 4-20 mA analogue signal.
OFF
SETPOINT
ON
BURNER
THERMAL
POWER
HMR High modulation range

LMR Low modulation range
DA Ignition differential
DS Turning off differential
PID Proportional Integrative Derivative Modulation
IMPORTANT
m All the above-mentioned parameters are set from the control panel.
COMPLIANCE
The Combustion System complies with the following European Directives and Standards:
–– Directive 2009/142/EC (GAS)
–– Directive 2014/68/EU (PED)
–– Electromagnetic Compatibility Directive 2014/30/EU
–– EN 676 - EN 746-2 - EN 50156-1 standards
Combustion system 21
SYSTEM LOGICS ECOVAPOR IN CASE OF NO FLAME
Hereinafter is the description of the logics that the System ECOVAPOR executes if the burner flame, due to a failure, does not turn
on or if the flame is not detected upon ignition, or if it turns off during operation.
FAILURE UPON IGNITION

If the burner is not able to turn on the flame, the system closes the pneumatic gas valve and repeats the ignition phase twice
(each attempt is preceded by a leak test of the gas valve). If the System cannot detect the flame after the third attempt, it shuts
off the burner. The flashing error message “Loc.c 2” and “Loc.d 1” appears on the equipment display (1), inside the control panel.
FAILURE DURING STANDARD OPERATION

If the flame turns off during operation, the System closes the pneumatic gas valve and shuts off the burner, with relevant indication
on the control panel display. The flashing error message “Loc.c 7” and “Loc.d 0” appears on the control unit display (1), inside the
control panel.
To restore operation, press key (RESET), positioned on panel front side, several times.
IMPORTANT
m The list of all possible burner failures is included in the specific chapter at the end of this manual.
22 Combustion system
3 Adjustment and control system
CONTROL PANEL
The generator control panel ECOVAPOR, (400V 3N - 50Hz) complies with insulation class IP 55 necessary to be installed inside a
Heating Plant Room with ambient temperature values ranging between +5 °C and +50 °C.
It is certified for the management of safety chains, equipped with an air-conditioning system and the control system can be
expanded; in addition, it has a connectivity through LAN line, WiFi, Modbus, Modem.
Closed panel Open panel
8 15
9 16
5
17
10
4
3 6
2 11
7
12
13
18
14
1
1 Connectors for electrical connections Internal components

2 Emergency button (SCRAM) 8 Generator managing basic board
3 Button for safety circuit opening 9 Burner managing control unit display
4 Muting of the acoustic signal and "Reset" of the alarms not 10 Safety devices
automatically reset 11 Auxiliary equipment supply
5 Operator panel (touch-screen) 12 Fuses
6 Button for safety circuit closing and preset for generator 13 Water level control unit
running 14 Sludge blowdown control unit
7 Main Switch 15 Generator managing expansion board
16 Burner managing control unit
17 Air-conditioning system
18 Burner motor inverter
Adjustment and control system 23

IMPORTANT
m Each appliance leaving the factory bears the Nameplate, shown herebelow, specifying the configuration of the
managed generator ECOVAPOR.
Nameplate
ECS-hABCDEFGH
ECS Name of the control panel C Number of pumps (1 or 2) F Internal sensor supply (0=No;
h Hours without continuous D Sludge drain (0=No; 1=Yes); 1=Yes)
supervision (ECS24 or ECS72) (compulsory for ECS72) G Metering/cascade (0=No; 1=Yes)
A A Burner fan (1=3 kW; 2=5.5 kW) E TDS (0=No; 1=Yes); (compulsory for H Motor-driven steam outlet valve
B Pump size (1=1.5 kW; 2=2.2 kW) ECS72) (0=No; 1=Yes)

GRAPHIC INTERFACE
OPERATOR PANEL
The operator panel allows displaying the operating data of System ECOVAPOR as well as managing the parameters based on the
factory setting of the appliance and on the selected access level.
The parameters that can be displayed and set, are organised in pages and depend on the structure of the appliance, on the
installed components or accessories and on the selected operating access level.
MAIN PAGE
When the control panel is powered, with plant room main switch and panel switch set to “ON”, the main page with USER access
level will be displayed.
2 3
1 Selection key of the ACCESS LEVELS

2 MENU ACCESS keys
3 Displaying area of the appliance OPERATING DATA when it is running or QUICK ACCESS to the selected item to edit it, if this is
allowed.
Access levels
There are three available access levels, represented by the following icons.
1 2 3
1 Level USER (for User)

2 Level SERVICE (for the technical service - requires the numerical code/Password released by ICI SpA)
3 OEM (exclusive for the manufacturer ICI SpA - requires the numerical code/exclusive Password of ICI SpA)
The access level icon will change based on the selected level.
To select the desired access level, proceed as follows:

–– touch the to select the access level
CAMBIO LIVELLO
User
Service
OEM

–– touch icon corresponding to the desired access level
–– press “YES” on the displayed page to confirm the selection or press “NO” to go back to the previous page.
Confermare User
SI NO
IMPORTANT
m “OEM level“ can be EXCLUSIVELY selected by ICI SpA.
When Level SERVICE is selected and confirmed, the following page will be displayed:
Confermare Service
–– type in the code/password, provided by ICI SpA, using the keyboard and press “OK” to confirm.
In case of error, touch key to cancel the last entered number or touch key to go back to previous page.
Menu access keys

There are five available access levels, represented by the following icons.
1 2 3 4 5
1 GENERAL PARAMETERS. It can be used with any Access Level. It allows accessing the specific items/parameters of the selected
Access Level
2 INFORMATION. It provides the information in READ-ONLY mode
3 GENERATOR PARAMETERS. It allows setting the parameters indicated in the different displayed pages
4 SERVICE. It allows displaying all the activities to be carried out by the Technical Service. Each performed activity must be
confirmed with “OK”, then the following activity will be displayed
5 BACK. Back to previous page

Displaying area
18 17 16 15
1
2
14
3
13
5 12
6 7 8 9 10 11
1 CURRENT DATE AND TIME (in display-only mode) to set or edit them, select "user level / general parameters / display-date-time
2 TIME LEFT TO PERIODICAL CHECK (ECS 24 HOURS or ECS72 HOURS); The message flashes when there are less than two hours
left to the periodical check. Touch this area to display the messages relating to the checks to be carried out by the SERVICE
(Technical Service). Press “OK“ to shift to next message and, once finished, the time to next check will be automatically set
(ECS 24 hours or ECS 72 hours)
3 TDS VALVE(Salinity Control Device); The valve opening is indicated by an animation. Touch this area to access the configuration
menu of the TDS system. When the TDS is disabled, below the valve, a red indication appears.
4 ESTIMATED OPERATING POWER; thermal power estimated on the basis of the burner testing data. SOFT START will be shown
steady on if set in the parameters or flashing if active. Touch this area to access the configuration menu of the burner
5 GAS FLOW RATE (if the meter is installed)
6 BLOWDOWN VALVE; the valve opening is indicated by an animation. Touch this area to access the configuration menu of the
valve. When the automatic drain is disabled, below the valve, a red indication appears
7 ESTIMATED COMBUSTION EFFICIENCY
8 FLAME PRESENCE
9 MEASURED CO2
10 TDS VALUE (Salinity Control Device). Touch this area to access the configuration menu of the TDS system. When the TDS is
disabled, below this value, a red indication appears
11 WATER DELIVERY FLOW RATE (if the meter is installed)
12 PUMPS OFF / PUMPS 1 and 2 ON with relevant modulation percentage. Touch this area to access the configuration menu of the
water feed pumps. When a pump is on, the animation indicates the water flow towards the generator
13 FLUE GAS RECOVERY UNIT; the temperature indicated is detected at the energy saver flue gas outlet
14 WATER LEVEL; touch this area to access the configuration menu of the water feed pumps
15 GENERATOR START-UP - GENERATOR STATUS ; the icon is white when the safety circuits are open (boiler not ready). To close
them and preset the generator for start-up, press the electromechanical button “I”. The icon is flashing green when the safety
circuits are closed (boiler ready). To open them and stop the generator, press the electromechanical button “0”. The button
turns steady green if it is pressed while flashing, thus operating the burner (steam production start) and, when pressed again,
the burner stops. The setpoint pressure value is indicated under this key
16 AMBIENT TEMPERATURE (in display-only mode). It indicates the ambient temperature allowing to check that it is within the
design values (+ 5°C minimum + 50 °C maximum)
17 GENERATOR PRESSURE; touch this area to access the pressure configuration menu
18 STEAM FLOW RATE (if the meter is installed)

OPERATING MODES
Hereinafter are some pages relating to the operating modes for the displaying and entering or editing of data and parameters.
Then there are the tables with the complete list of the available parameters.
To edit generator settings, proceed as follows:

–– select USER Level
–– touch key (GENERAL PARAMETERS) to display the page
–– touch the desired item (i.e. ”Language”) to display the page
–– select the desired LANGUAGE (i.e. “ITALIAN”) by touching the corresponding icon .
If an alarm is in progress while operations or displaying activities are in progress, the following icon appears on all the pages .
–– Touch key to go back to the previous page and select another item to check or edit (i.e. “DISPLAY - DATE - TIME”). The
page will be displayed.

–– to scroll the page, keep a finger on the screen and move it up or down
–– to edit one item (i.e. “Year”) touch the Light Blue Area and set the new value using the displayed keyboard
Anno
2018
–– touch key to confirm, store the change and go back to the previous page (in this case “DISPLAY - DATE - TIME”) to select
another item to be edited
–– to edit a non-numerical item (i.e. “Daylight saving time”) simply touch under the preferred setting (i.e. “ON” or “OFF”).
In case of error, touch key to cancel the last entered number or touch key to go back to previous page.
When all the necessary changes have been made, touch key to go back to the starting page and select another item (i.e.:
“MODBUS”). Refer to the ModBus parameter list available in paragraph “3.5 Modbus/slave interface parameters” on page 41.
ACTIVE ALARMS
In case an alarm is present in the main page, the following message with the description of the active alarms will be displayed:
–– touch the message red area to hide or display the alarm description.

ACTIVE FORCING
In case of active forcing in the main page, the following message will be displayed:
–– touch the message yellow area to directly access the “FORCING MENU” (at SERVICE level only)
–– touch the arrow to hide the alarm description.

COMPLETE LIST OF MENUS AND PARAMETERS
MAIN PARAMETER MENU
ACCESS PATH: → LANGUAGE
ACCESS PATH: → DISPLAY - DATE - TIME

No. Parameter Description Reading level Writing level Visibility Conditions
01.02 Year USER USER ALWAYS
01.03 Month USER USER ALWAYS
01.04 Day of the month USER USER ALWAYS
01.05 Hours USER USER ALWAYS
01.06 Minutes USER USER ALWAYS
01.08 Daylight saving time USER USER ALWAYS
Stand-by time USER USER ALWAYS
Touch delay USER USER ALWAYS
ACCESS PATH: → GENERAL CONFIGURATION

15.01 Expansion 2 enabling OEM OEM Always
15.02 Flue gas sensor enabling SERVICE SERVICE Always
15.03 Ambient sensor enabling SERVICE SERVICE Always
15.04 Level transducer enabling OEM OEM Always
15.05 Blowdown valve enabling OEM OEM Always
15.06 TDS enabling OEM OEM Always
15.07 Second pump enabling OEM OEM Always
15.08 Modulating feed valve enabling OEM OEM If the level transducer is enabled
15.09 Maximum level alarm enabling SERVICE SERVICE Always
15.10 IC1E1 inlet configuration SERVICE SERVICE Always
15.11 EGR valve enabling OEM OEM Always
15.12 Steam control valve enabling OEM OEM If expansion 2 is enabled
15.13 Cascade enabling OEM OEM If expansion 2 is enabled
15.14 ECO 1 inlet water temperature probe enabling OEM OEM If expansion 2 is enabled
15.15 ECO 1 outlet water temperature probe enabling OEM OEM If expansion 2 is enabled
15.16 ECO 1 water meter enabling OEM OEM If expansion 2 is enabled
15.17 ECO 2 inlet water temperature probe enabling OEM OEM If expansion 2 is enabled
15.18 ECO 2 outlet water temperature probe enabling OEM OEM If expansion 2 is enabled
15.19 ECO 2 water meter enabling OEM OEM If expansion 2 is enabled
15.20 ECO 1 inlet flue gas temperature probe enabling OEM OEM If expansion 2 is enabled
15.21 ECO 2 outlet flue gas temperature probe enabling OEM OEM If expansion 2 is enabled
15.22 Water delivery meter enabling OEM OEM If expansion 2 is enabled
15.23 Gas meter enabling OEM OEM If expansion 2 is enabled
ACCESS PATH: → ModBus

15.24 Fan Inverter ModBus enabling SERVICE SERVICE Always
15.25 Electric energy meter ModBus enabling SERVICE SERVICE Always
15.26 Pump 1 ModBus enabling SERVICE SERVICE Always
15.27 Pump 2 ModBus enabling SERVICE SERVICE Always
15.28 Steam meter ModBus enabling SERVICE SERVICE Always
15.29 ECO 1 heat meter ModBus enabling SERVICE SERVICE Always
15.30 ECO 2 heat meter ModBus enabling SERVICE SERVICE Always
ModBus Slave Address setting
15.31 USER USER Always
(1 ...250)
ModBus Slave Baud rate setting
(2400 – 4800 – 9600 – 19200 – 38400 – 57600 – 115200)
ModBus Slave Data bit setting
(7 - 8)
ModBus Slave Parity setting
(No – Even – Odd – Mark – Space)
ModBus Slave Stop bit setting
(1 – 2)

ACCESS PATH: → OFFSET AND SCALES
08.01 Pressure value at 4 mA SERVICE SERVICE Always
08.02 Pressure value at 20 mA SERVICE SERVICE Always
08.03 Pressure offset SERVICE SERVICE Always
08.04 TDS value at 4 mA SERVICE SERVICE If the TDS sensor is enabled
08.05 TDS value at 20 mA SERVICE SERVICE If the TDS sensor is enabled
08.06 TDS offset SERVICE SERVICE If the TDS sensor is enabled
08.07 Level Offset SERVICE SERVICE If the level sensor is enabled
If the flue gas temperature probe is
08.08 Flue gas temperature offset SERVICE SERVICE
enabled
If the ambient temperature probe is
08.09 Ambient temperature offset SERVICE SERVICE
enabled
08.12 Steam flow pressure value at 4 mA SERVICE SERVICE If the steam control valve is enabled
08.13 Steam flow pressure value at 20 mA SERVICE SERVICE If the steam control valve is enabled
08.14 Steam delivery pressure offset SERVICE SERVICE If the steam control valve is enabled
08.15 Cascade manifold pressure value at 4 mA SERVICE SERVICE If the cascade control is enabled
08.16 Cascade manifold pressure value at 20 mA SERVICE SERVICE If the cascade control is enabled
08.17 Cascade manifold pressure offset SERVICE SERVICE If the cascade control is enabled
If the pump flow pressure probe is
08.18 Pump flow pressure value at 4 mA SERVICE SERVICE
enabled
08.19 Pump flow pressure value at 20 mA SERVICE SERVICE
enabled
08.20 Pump flow pressure offset SERVICE SERVICE
enabled
08.21 ECX 1 water inlet temperature offset SERVICE SERVICE If the probe is enabled
08.22 ECX 1 water outlet temperature offset SERVICE SERVICE If the probe is enabled
08.23 ECX 1 water meter pulse value (water delivery) SERVICE SERVICE If the meter is enabled
08.24 ECX 2 water inlet temperature offset SERVICE SERVICE If the probe is enabled
08.25 ECX 2 water outlet temperature offset SERVICE SERVICE If the probe is enabled
08.26 ECX 2 water meter pulse value SERVICE SERVICE If the meter is enabled
08.27 ECX 1 flue gas inlet temperature offset SERVICE SERVICE If the probe is enabled
08.28 ECX 2 flue gas outlet temperature offset SERVICE SERVICE If the probe is enabled
08.29 Make-up water meter pulse value SERVICE SERVICE If the meter is enabled
08.30 Gas meter pulse value SERVICE SERVICE If the meter is enabled
Burner maximum power (kW)
Power is estimated based on the output modulation signal,
08.31 SERVICE SERVICE Always
unless the feedback on IC1 input expansion 1 is present. In this
case, the feedback will be considered.
08.32 First stage burner power (kW) SERVICE SERVICE Always
08.34 Estimated CO2 (%) SERVICE SERVICE Always
08.35 % O2 at 4 mA SERVICE SERVICE If the oxygen sensor is enabled
08.36 % O2 at 20 mA SERVICE SERVICE If the oxygen sensor is enabled
08.37 CO2 offset % SERVICE SERVICE If the oxygen sensor is enabled

INFORMATION MENU
ACCESS PATH: → INLET STATUS
11.01 Ambient temperature in °C USER - If the sensor is enabled
11.02 Boiler pressure sensor value in % SERVICE - Always
11.03 Boiler pressure in Bar USER - Always
11.04 Burner fed USER - Always
11.05 Burner flame presence USER - Always
11.07 Level value in % USER - Always
11.08 TDS value in % SERVICE - If the TDS sensor is enabled
11.09 TDS value in µS USER - If the TDS sensor is enabled
Steam production enabling
Contact is system start.
When this contact is open, burner, TDS valve and drain valve will
11.11 not be enabled. USER - Always
Only water feed system is active.
System activates when the contact is closed by the safety
circuits.
Alarm reset button
The contact will be normally open and its 1-second closing
will be always necessary to mute the siren and to delete alarm
displaying.
11.12 Alarm displaying will be always active even if the alarm USER - Always
conditions disappear.
Some alarms require to be reset also to restore operation.
If the contact is already closed when the alarm occurs, to
activate the next closing again, it will have to be opened.
11.13 Flue gas temperature in °C USER - Always
11.14 Steam flow pressure in % SERVICE - If the steam control valve is enabled
11.15 Steam flow pressure in Bar USER - If the steam control valve is enabled
11.16 Cascade pressure value in % SERVICE - If the cascade is enabled
11.17 Cascade pressure value in Bar USER - If the cascade is enabled
11.18 Pump flow pressure in % SERVICE - If the flow pressure sensor is enabled
11.19 Pump flow pressure in Bar USER - If the flow pressure sensor is enabled
11.20 ECX 1 water inlet temperature USER - If the sensor is enabled
11.21 ECX 1 water outlet temperature USER - If the sensor is enabled
11.22 ECX 2 water inlet temperature USER - If the sensor is enabled
11.23 ECX 2 water outlet temperature USER - If the sensor is enabled
11.24 ECX 1 flue gas inlet temperature USER - If the sensor is enabled
11.25 ECX 2 flue gas outlet temperature USER - If the sensor is enabled
11.27 Value O02 in % USER - If the oxygen sensor is enabled
11.28 Value CO2 in % USER - If the oxygen sensor is enabled
ACCESS PATH: → OUTLET STATUS

13.01 Burner modulation percentage USER - Always
13.02 Pump 1 modulation percentage USER - Always
Only with level sensor and pump 2
13.03 Pump 2 modulation percentage USER -
enabled
13.04 Feed valve modulation percentage USER - Only with feed valve enabled
13.05 Burner enabling (T1-2) USER - Always
13.08 Cumulative alarm signal system USER - Always
13.09 Blowdown valve USER - If the valve is enabled
13.10 Pump 1 USER - Always
13.11 Pump 2 USER - If the second pump is enabled
13.12 TDS valve USER - If the valve is enabled
13.13 Acoustic signal USER - Always
13.14 Time without continuous supervision expired USER - Always
13.15 Energy saver pump USER - If the pump is enabled
13.17 Dosing pump enabling USER - If the pump is enabled
13.23 Steam flow valve modulation percentage USER - If the valve is enabled

ACCESS PATH: → ALARMS
12.01 Cumulative alarm signal system USER - Always
Expansion board communication alarm
CANBUS communication alarm among PLC modules.
This alarm generates:
- alarm signalling on the panel
- siren triggering
12.02 USER - Always
- burner enabling opening
- pump stop
- valve closing
This effect remains until key (R - Reset) is pressed
even if the alarm conditions disappear.
12.03 Minimum level 1 alarm USER - Always
12.04 Minimum level 2 alarm USER - Always
12.05 Maximum level alarm USER - Always
12.06 Safety pressure gauge alarm USER - Always
12.07 Burner shut-off USER - Always
12.08 Wrong supply USER - Always
12.09 Burner fan alarm USER - Always
12.10 Pump 1 alarm USER - Always
12.11 Pump 2 alarm USER - If the second pump is enabled
12.12 Deaerator / water treatment alarm USER - Always
12.13 Emergency button activated USER - Always
12.14 Pressure sensor alarm USER - Always
12.15 Ambient temperature probe alarm USER - If the sensor is enabled
12.16 Burner modulation feedback signal alarm USER - If the feedback is enabled
12.17 Level sensor alarm USER - If the level sensor is enabled
12.18 TDS sensor alarm USER - If the TDS sensor is enabled
12.19 TDS limit alarm USER - If the TDS sensor is enabled
12.20 Flue gas temperature sensor alarm USER - If the sensor is enabled
12.21 Flue gas high temperature: alarm USER - If the sensor is enabled
12.22 Flue gas high temperature: burner stop USER - If the sensor is enabled
If the device ModBus management is
12.23 Fan inverter failure alarm USER -
enabled
12.24 Fan inverter high temperature alarm USER -
enabled
12.25 Fan inverter wrong supply alarm USER -
enabled
12.26 Fan inverter excessive current alarm USER -
enabled
12.27 Time without continuous supervision expired USER - Always
12.28 EGR valve alarm USER - If the valve is enabled
12.29 Oxygen sensor alarm USER - If the oxygen sensor is enabled
12.30 Oxygen % limit alarm USER - If the oxygen sensor is enabled
ACCESS PATH: → DATA AND METERS

Number of burner starts
14.01 It represents the progressive number of the flame presence USER - Always
signal rising edges
Burner hours of operation
14.02 USER - Always
It represent the total time of flame presence
14.05 Burner power output estimation USER - Always
14.06 Burner total energy output estimation USER - Always
Only if ambient and flue gas probes are
14.07 Combustion efficiency estimation USER -
present
14.08 Number of openings of the drain valve USER - Only if the valve is enabled
14.09 Opening hours of the drain valve USER - Only if the valve is enabled
14.10 Number of openings of the TDS valve USER - Only if the valve is enabled

14.11 Opening hours of the TDS valve USER - Only if the valve is enabled
14.12 Number of starts of pump 1 USER - Always
14.13 Pump 1 hours of operation USER - Always
14.14 Number of starts of pump 2 USER - Only if the second pump is enabled
14.15 Pump 2 hours of operation USER - Only if the second pump is enabled
14.18 Number of electrical power F1 rising edges USER - Service
14.19 Electrical power hours F1 USER - Service
14.20 Number of electrical power F3 rising edges USER - Service
14.21 Electrical power hours F3 USER - Service
14.22 Make-up water total flow rate USER - Only if the meter is enabled (PT9 E2 inlet)
14.23 Make-up water instant flow rate USER - Only if the meter is enabled (PT9 E2 inlet)
Only if the meter is enabled (PT1 E1 or
14.24 Gas total flow rate USER -
PT10E2 inlet)
14.25 Gas instant flow rate USER -
PT10E2 inlet)
Only if the ModBus meter or the PT3E2
14.26 ECX1 water total flow rate (delivery) USER -
inlet is enabled
14.27 ECX1 water instant flow rate (delivery) USER -
inlet is enabled
Only if the ModBus meter or the PT3E2 -
14.28 ECX1 energy USER -
PT1E2 - PT2E2 inlets are enabled
14.29 ECX1 power USER -
14.30 ECX2 water total flow rate USER -
inlet is enabled
14.31 ECX2 water instant flow rate USER -
inlet is enabled
Only if the relevant ModBus meter is
17.01 Total absorbed electrical energy (kWh) USER -
enabled
17.02 Total absorbed current (A) USER -
enabled
17.03 Total absorbed power (W) USER -
enabled
18.02 Pump 1 speed (RPM) USER - Only if the Pump 1 ModBus is enabled
18.03 Pump 1 motor supply frequency (Hz) USER - Only if the Pump 1 ModBus is enabled
18.04 Status of pump 1 run digital enabling (On-Off ) USER - Only if the Pump 1 ModBus is enabled
18.05 Pump 1 absorption (A) USER - Only if the Pump 1 ModBus is enabled
18.06 Pump 1 absorbed power (W) USER - Only if the Pump 1 ModBus is enabled
18.07 Pump 1 total absorbed energy (kWh) USER - Only if the Pump 1 ModBus is enabled
18.08 Pump 1 inverter temperature (°C) USER - Only if the Pump 1 ModBus is enabled
18.10 Pump 1 pre-alarm signal USER - Only if the Pump 1 ModBus is enabled
19.02 Pump 2 speed (RPM) USER - Only if the Pump 2 ModBus is enabled
19.03 Pump 2 motor supply frequency (Hz) USER - Only if the Pump 2 ModBus is enabled
19.04 Status of pump 2 run digital enabling (On-Off ) USER - Only if the Pump 2 ModBus is enabled
19.05 Pump 2 absorption (A) USER - Only if the Pump 2 ModBus is enabled
19.08 Pump 2 inverter temperature (°C) USER - Only if the Pump 2 ModBus is enabled
19.10 Pump 2 pre-alarm signal USER - Only if the Pump 2 ModBus is enabled
20.01 Steam total flow rate (kg) USER -
enabled
20.02 Steam instant flow rate (kg/h) USER -
enabled
20.03 Steam pressure (Bar) USER -
enabled
20.04 Steam temperature (°C) USER -
enabled
20.05 Water equivalent flow rate (l/h) USER -
enabled
20.06 Steam power (kW) USER -
enabled
20.07 Steam energy (kWh) USER -
enabled

ACCESS PATH: → DATA AND METERS → → DIAGRAMS
02.31 Boiler pressure setpoint in Bar USER - Always
11.03 Boiler pressure in Bar USER - Always
11.15 Steam flow pressure in Bar USER - If the steam control valve is enabled
13.23 Steam flow valve modulation percentage USER - If the valve is enabled
11.17 Cascade pressure value in Bar USER - If the cascade is enabled
11.01 Ambient temperature in °C USER - If the sensor is enabled
11.13 Flue gas temperature in °C USER - Always
11.09 TDS value in µS USER - If the TDS sensor is enabled
11.04 Burner fed USER - Always
11.05 Burner flame presence USER - Always
13.01 Burner modulation percentage USER - Always
14.01 Number of burner starts USER - Always
14.02 Burner hours of operation USER - Always
14.05 Burner power output estimation USER - Always
Burner total energy output estimation
14.06 It is the integral of power by time, calculated with the same USER - Always
PID sampling interval.
Combustion efficiency estimation
Efficiency = 100-(0.86+36.6/CO2)*(TF-TA)/100.
14.07 Efficiency is not calculated if the flue gas probe is not present. USER - Always
If the ambient probe is not present, an air temperature of 25 °C
is estimated
14.08 Number of openings of the drain valve USER - Only if the valve is enabled
14.09 Opening hours of the drain valve USER - Only if the valve is enabled
14.10 Number of openings of the TDS valve USER - Only if the valve is enabled
14.11 Opening hours of the TDS valve USER - Only if the valve is enabled
04.05 Level setpoint SERVICE SERVICE If the level probe is enabled
11.07 Level value in % USER - Always
14.12 Number of starts of pump 1 USER - Always
14.13 Pump 1 hours of operation USER - Always
13.02 Pump 1 modulation percentage USER - Always
14.14 Number of starts of pump 2 USER - Only if the second pump is enabled
14.15 Pump 2 hours of operation USER - Only if the second pump is enabled
Only with level sensor and pump 2
13.03 Pump 2 modulation percentage USER -
enabled
13.04 Feed valve modulation percentage USER - Only with feed valve enabled
11.19 Pump flow pressure in Bar USER - If the flow pressure sensor is enabled
14.18 Number of electrical power F1 rising edges SERVICE - Always
14.19 Electrical power hours F1 SERVICE - Always
14.20 Number of electrical power F3 rising edges SERVICE - Always
14.21 Electrical power hours F3 SERVICE - Always
14.22 Make-up water total flow rate USER - Only if the meter is enabled (PT9 E2 inlet)
14.23 Make-up water instant flow rate USER - Only if the meter is enabled (PT9 E2 inlet)
14.24 Gas total flow rate USER -
PT10E2 inlet)
14.25 Gas instant flow rate USER -
PT10E2 inlet)
14.26 ECX1 water total flow rate (delivery) USER -
inlet is enabled
14.27 ECX1 water instant flow rate (delivery) USER -
inlet is enabled
17.01 Total absorbed electrical energy (kWh) USER -
enabled
17.03 Total absorbed power (W) USER -
enabled

20.01 Steam total flow rate (kg) USER -
enabled
20.02 Steam instant flow rate (kg/h) USER -
enabled
20.04 Steam temperature (°C) USER -
enabled
GENERATOR PARAMETER MENU

ACCESS PATH: → PRESSURE SETTINGS
unit of
No. Description Range Default Reading Writing Visibility
measurement
Soft start.
Enabled /
02.01 With the control enabled, burner stays at the minimum power - Enabled USER USER ALWAYS
Disabled
until reaching the “Soft start threshold”.
Soft start threshold.
02.02 With the soft start enabled, burner stays at the value set in 0.0 – 12.0 Bar 1,0 USER USER ALWAYS
parameter 2.22 until reaching this threshold.
02.22 Soft start power USER USER ALWAYS
02.10 Pressure setpoint. 0.1 – 20.0 Bar 0,0 USER USER ALWAYS
Boiler maximum pressure
02.21 0.0 – 20.0 Bar 12 USER OEM ALWAYS
Maximum limit at which the OFF can be set.
Turning off differential.
02.23 When the measured pressure reaches the setpoint (parameter 0.1 – 2.0 Bar 0,5 USER USER ALWAYS
02.10) plus this differential, the burner stops
Ignition differential.
02.24 When the measured pressure reaches the setpoint (parameter 0.1 – 2.0 Bar 0,5 USER USER ALWAYS
02.10) less this differential, the burner starts again
ACCESS PATH: → BURNER SETTINGS

unit of
No. Parameter Description Range Default Reading Writing Visibility
measurement
02.03 Type of burner
Low modulation range.
02.11 Pressure range, above the setpoint, inside which the PID system 0.1 – 10.0 Bar 2,0 SERVICE SERVICE ALWAYS
is active.
High modulation range
02.12 Pressure range, under the setpoint, inside which the PID system 0.1 – 10.0 Bar 1,0 SERVICE SERVICE ALWAYS
is active.
Stabilisation time.
02.13 Time, since burner start (flame presence), during which power is 0 – 300 s 90 SERVICE SERVICE ALWAYS
kept at the minimum value.
Sampling period.
02.14 1 – 60 s 20 SERVICE SERVICE ALWAYS
Time interval taken as a reference by burner PID system.
Sampling time adaptation.
Within the range between setpoint and modulation field
02.15 0 – 1000 % 0 SERVICE SERVICE ALWAYS
limits, the frequency progressively increases until reaching the
percentage indicated by this parameter.
Burner PID proportional factor.Weight of the proportional factor
taken as a reference by the burner PID system. The proportional
length is used to accelerate / decelerate the approaching speed
02.16 to the setpoint. The definition of the correct speed stabilises the 0 – 20 - 10 SERVICE SERVICE ALWAYS
system since it prevents a too quick approach to the setpoint
that could result in overshoots due to inertia. The proportional
length also increases control responsiveness.
02.17 Burner PID integral factor SERVICE SERVICE Always
02.18 Burner PID derivative factor SERVICE SERVICE Always
02.19 Time from minimum power to maximum power

ACCESS PATH: → FLUE GAS PROBE
unit of
No. Parameter Description Range Default Reading Writing Visibility
measurement
Flue gas probe alarm threshold
If other than OFF, an alarm is signalled above the set threshold. With flue
03.01 Off – 0/300 - Off USER SERVICE
Alarm is reset if the value goes below the threshold minus the gas probe
hysteresis set in parameter 03.03.
Burner switching off threshold
If other than OFF, the burner will be switched off above the set
With flue
03.02 threshold and alarm will be signalled. Alarm is reset if the value Off – 0/300 - Off USER SERVICE
gas probe
goes below the threshold minus the hysteresis set in parameter
03.03
Flue gas probe hysteresis With flue
03.03 1/300 K - 10 USER SERVICE
Hysteresis used by parameters 03.02 and 03.03. gas probe
03.04 EGR Flue gas temperature limit
03.05 EGR Flue gas temperature limit hysteresis
03.06 EGR Valve opening time
03.07 O2 maximum limit
03.08 O2 minimum limit
03.09 O2 limit hysteresis
03.10 O2 probe fluxing time
03.11 O2 probe fluxing stand-by
03.12 O2 probe reading delay
ACCESS PATH: → FEED PUMPS

unit of
measurement
Pump switching.
The pump that has to operate can be selected. By selecting this
Pump 1 /
pump, this latter will always work. By selecting "AutoSwitch", With
Pump 2 /
04.01 the operation will be alternate based on the time set in next - Pump 1 USER USER second
Automatic
parameter. Switching will nevertheless be automatic in case a pump
Switching
thermal switch triggers. Parameter available only if two pumps
are present.
Switching time.
This parameter is active if pump automatic switching has been With
04.02 selected in the previous parameter. After a pump has operated 1-999 Hours 24 USER USER second
for the time set, the other pump will be activated. The reversal pump
occurs when there is no feeding request.
Level Off
04.03 When the level is above the setpoint plus this differential, the 0-100 % 40 SERVICE SERVICE ALWAYS
pump stops. Parameter present if the level sensor is enabled.
Level On
04.04 When the level is under the setpoint minus this differential the 0-100 % 10 SERVICE SERVICE ALWAYS
pump starts. Parameter present if level sensor is enabled.
Level Setpoint
04.05 0-100 % 50 SERVICE SERVICE ALWAYS
xValue of the level that the modulation system has to maintain.
Sampling period
04.06 Time interval taken as a reference by modulating feed system 1-60 s 2 SERVICE SERVICE ALWAYS
PID system.
Sampling time adaptation
Within the range between setpoint and modulation field
04.07 0-1000 % 0 SERVICE SERVICE ALWAYS
limits, the frequency progressively increases until reaching the
percentage indicated by this parameter.
Burner PID proportional factor
Weight of the proportional factor taken as a reference by the
PID system. The proportional length is used to accelerate /
decelerate the approaching speed to the setpoint. The definition
04.08 0-20 - 10 SERVICE SERVICE ALWAYS
of the correct speed stabilises the system since it prevents a too
quick approach to the setpoint that could result in overshoots
due to inertia. The proportional length also increases control
responsiveness.

unit of
measurement
Burner PID integral factor.Weight of the integral factor taken as
a reference by the PID system. The integral length is necessary
04.09 to ensure accuracy at full operation. Nevertheless, if this value is 0-20 - 2,5 SERVICE SERVICE ALWAYS
too high, it can cause excessive overshoots before reaching the
setpoint. It can also cause fluctuations around the setpoint.
Burner PID derivative factor.
Value of the derivative factor taken as a reference by the PID
system. The derivative length, duly sized, favours stability (i.e.
a protection against excessive overshoots), but it does not
04.10 contribute to ensure accuracy at full operation. The derivative 0-20 - 5 SERVICE SERVICE ALWAYS
component tends to mitigate the harsh direction changes of
temperature trend, which are due to a possible excessive action
of the integral and proportional components. It also increases
control responsiveness to sudden load variations.
Variation maximum speed
04.11 It represents the maximum speed to increase and decrease 0-20 %/second 10 SERVICE SERVICE ALWAYS
speed modulation.
Level probe filter.
04.12 Number of transducer readings used to calculate the average 0-100 - 10 SERVICE SERVICE ALWAYS
value. Readings take place every 100 milliseconds.
Pump manual operation.By activating this function, the selected
04.13 pump is activated until boiler maximum level. The modulating On/Off - Off USER USER ALWAYS
pump is forced to the maximum.
ACCESS PATH: → TDS

unit of
measurement
TDS alarm threshold. If the TDS
07.03 TDS level above which burner is stopped and the relevant alarm 0 – 6000 µS 6000 USER USER sensor is
is triggered. enabled
TDS alarm hysteresis.
If the TDS
When the TDS value drops under the alarm threshold minus
07.04 0 – 1000 µS 100 USER USER sensor is
this hysteresis, the alarm will be reset and the burner will be
enabled
restarted.
TDS valve opening threshold.
TDS level above which the TDS valve is opened intermittently.
If the TDS
The valve is opened and closed intermittently based on
07.05 2000 – 6000 µS 4000 USER USER sensor is
parameters 07.07 and 07.08. For TDS2: When the intermittent
enabled
opening is active, the TDS value is read during openings,
parameters 06.02 and 06.03 are not active.
TDS valve opening hysteresis. If the TDS
07.06 When the TDS value drops under the opening threshold minus 1 – 1000 µS 100 USER USER sensor is
this hysteresis, the valve stays closed. enabled
TDS drain valve opening time. If the TDS
07.07 TDS valve opening time for drainage (washing) and consequent 1 – 99 s 15 USER USER sensor is
dilution (for TDS lowering). enabled
If the TDS
TDS drain valve pause time.
07.08 1 – 999 s 30 USER USER sensor is
Duration of TDS pause time during drainage (washing).
enabled
TDS enabling.
Off: Valve always closed, no alarm is triggered when threshold is
exceeded and burner is not stopped. The read TDS value flashes
to indicate that the TDS control is disabled. No alarm is triggered If the TDS
07.09 even in case of faulty TDS probe. Four dashes “µS - - - -“ will flash Off/On - Off USER USER sensor is
instead if the read value enabled
On: The valve opens according to the programmed automatisms,
when the threshold is exceeded, the alarm will be signalled and
the burner turned off.

ACCESS PATH: → BLOWDOWN VALVE
unit of
measurement
Opening time of the blowdown valve. If the
Duration of the programmed opening of the blowdown valve. blowdown
06.01 0 - 99 s 10 USER USER
When the value is 0, the valve does not open. The valve symbol valve is
flashes on the display. enabled
If the
Pause time of the blowdown valve.
blowdown
06.02 Time between one opening and the following one of the 1 - 999 min 60 USER USER
valve is
blowdown valve.
enabled
SERVICE PARAMETER MENU

ACCESS PATH: → FORCING
Reading
No. Description Writing Level Visibility Conditions
Level
10.01 Burner enabling OEM OEM Always
10.07 Blowdown valve OEM OEM Only if enabled
10.08 Pump 1 Modulation SERVICE SERVICE Only if the level transducer is enabled
Only if the second pump and the level
10.09 Pump 2 Modulation SERVICE SERVICE
transducer are enabled
10.11 Pump 1 Enabling OEM OEM Always
10.12 Pump 2 Enabling OEM OEM Only if the second pump is enabled
10.13 TDS Valve Enabling OEM OEM Only if enabled
10.14 Acoustic alarm SERVICE SERVICE Always
10.15 Alarm for operation without continuous supervision expired SERVICE SERVICE Always
10.06 Cumulative alarm signal SERVICE SERVICE Always
10.16 Energy saver pump OEM OEM If enabled
Only if expansion 2 and relevant function are
10.17 Feed valve modulation (OC1) SERVICE SERVICE
enabled
10.18 Steam valve modulation (OC2) SERVICE SERVICE
enabled
10.20 Dosing pump (V1A outlet) OEM OEM
enabled
10.26 Enabling duration SERVICE SERVICE Always
10.27 Enable forcing SERVICE SERVICE Always
Notes
–– By accessing the forcing parameter, all the available outlets will be displayed. The desired status of each outlet can be set.
–– Forcing is interrupted by quitting the menu, unless an additional duration is entered whose countdown starts upon quitting
the menu.
–– Outlets can be forced also for an unlimited time (HOLD).
–– Whenever accessing the forcing menu, the default parameters will be available, except for the unlimited time forcing. Forcing
will be disabled upon PLC rebooting and after any level change.

MODBUS/SLAVE INTERFACE PARAMETERS
Once the ModBus communication parameters have been set, the following parameters will be available:
WORD PARAMETERS
Reading: Read Output Registers (03) or Read Input Registers (04).
ModBus PARAMETER REF. Parameter Description Scale Scale
300007 or 400007 02.10 Pressure setpoint Bar 10
300008 or 400008 02.10 Turning off differential Bar 10
300009 or 400009 02.10 Ignition differential Bar 10
Inlets
300011 or 400011 11.01 Ambient temperature °C 10
300012 or 400012 11.03 Boiler pressure Bar 10
300013 or 400013 11.07 Water level % 1
300014 or 400014 11.09 TDSvalue µS 1
300015 or 400015 11.13 Flue gas temperature °C 10
Outputs
300031 or 400031 13.01 Burner modulation % 1
300032 or 400032 13.02 Pump 1 modulation % 1
300033 or 400033 13.03 Pump 1 modulation % 1
Data and meters
300041 or 400041 14.01 Number of burner starts - 1
300042 or 400042 14.02 Burner hours of operation - 1
300043 or 400043 14.05 Burner estimated power kW 1
300044 or 400044 14.06 Burner estimated energy MWh 1
300045 or 400045 14.07 Estimated combustion efficiency % 1
300046 or 400046 14.08 Number of openings of the blowdown valve - 1
300047 or 400047 14.09 Hours of operation of the blowdown valve - 1
300048 or 400048 14.10 Number of openings of the TDS valve - 1
300049 or 400049 14.11 Hours of operation of the TDS valve - 1
300050 or 400050 14.12 Number of starts of pump 1 - 1
300051 or 400051 14.13 Hours of operation of pump 1 - 1
300052 or 400052 14.14 Number of starts of pump 2 - 1
300053 or 400053 14.15 Hours of operation of pump 2 - 1
Hours left to the expiration of time for operation without continuous
300054 or 400054 14.16 hh 1
supervision
Minutes left to the expiration of time for operation without continuous
300055 or 400055 14.17 mm 1
supervision
Parameter Description
300056 or 400056 14.24 Water delivery total flow rate cu.m 1
300057 or 400057 14.25 Water delivery instant flow rate l/h 1
300058 or 400058 14.26 Gas total flow rate cu.m 1
300059 or 400059 14.27 Gas instant flow rate cu.m/h 1
FAN INVERTER
300071 or 400071 16.01 Fan absorbed power W 1
300072 or 400072 16.02 Fan absorbed current A 10
300073 or 400073 16.04 Fan supply frequency Hz 1
300074 or 400074 16.09 Fan absorbed energy kWh 1
ELECTRICAL ENERGY METER
300081 or 400081 17.01 Total absorbed electrical energy kWh 1
300082 or 400082 17.02 Total absorbed current A 10
300083 or 400083 17.03 Total absorbed power W 1
Pump 1
300091 or 400091 18.01 Modulation percentage (with Bus control) % 1
300092 or 400092 18.02 Pump rotating speed RPM 1
Pump 2
300101 or 400101 19.01 Modulation percentage (with Bus control) % 1
300102 or 400102 19.02 Pump rotating speed RPM 1
STEAM METER
300111 or 400111 20.01 Steam total flow rate t. 1
300112 or 400112 20.02 Steam instant flow rate Kg/h 1
300113 or 400113 20.03 Steam pressure at the meter Bar 10
300114 or 400114 20.04 Steam temperature at the meter °C 10

Bit Parameters
Read: Read Output Status (01) or Read Input Status (02).
ModBus PARAMETER REF. Parameter Description 0 1
Inlets
000001 or 100001 11.04 Burner supply presence NO YES
000002 or 100002 11.05 Flame presence NO YES
Outputs
000011 or 100011 13.05 Burner enabling from PLC NO YES
000014 or 100014 13.09 Blowdown valve opening control NO YES
000015 or 100015 13.10 Pump 1 ignition digital control NO YES
000016 or 100016 13.11 Pump 2 ignition digital control NO YES
000017 or 100017 13.12 Opening control of the TDS valve NO YES
000018 or 100018 13.13 Acoustic signal active NO YES
BUS SIGNALS
000021 or 100021 16.10 Fan ON NO YES
000022 or 100022 18.09 Pump 1 enabling NO YES
000023 or 100023 19.09 Pump 2 enabling NO YES
Alarms
000031 or 100031 12.01 General alarm OK ALARM
000032 or 100032 12.02 Bus communication alarm OK ALARM
000033 or 100033 12.03 Minimum level 1 OK ALARM
000034 or 100034 12.04 Minimum level 2 OK ALARM
000035 or 100035 12.05 Maximum level OK ALARM
000037 or 100037 12.07 Burner shut-off OK ALARM
000038 or 100038 12.08 Wrong power supply OK ALARM
000039 or 100039 12.09 Safety circuit fault OK ALARM
000040 or 100040 12.10 Pump 1 failure OK ALARM
000041 or 100041 12.11 Pump 2 failure OK ALARM
000042 or 100042 12.12 Deaerator alarm OK ALARM
000043 or 100043 12.13 Emergency button pressed OK ALARM
000044 or 100044 12.14 Level sensor failure OK ALARM
000045 or 100045 12.15 Ambient temperature probe failure OK ALARM
000046 or 100046 12.16 Burner modulation feedback failure OK ALARM
000047 or 100047 12.17 Level sensor failure OK ALARM
000048 or 100048 12.18 TDS sensor failure OK ALARM
000049 or 100049 12.19 TDS high value OK ALARM
000050 or 100050 12.20 Flue gas temperature probe failure OK ALARM
000051 or 100051 12.21 High flue gas temperature 1 OK ALARM
000052 or 100052 12.22 High flue gas temperature 2 + burner stop OK ALARM
000053 or 100053 12.23 Fan inverter fault OK ALARM
000054 or 100054 12.24 Fan inverter high temperature OK ALARM
000055 or 100055 12.25 Wrong fan supply OK ALARM
000056 or 100056 12.26 Fan excessive absorption OK ALARM

4 Installation
The installation must be performed in compliance with the local standards by Qualified Personnel, namely by personnel with
specific technical skills in the field of the steam production system components. An incorrect installation may cause damage to
persons or property for which the manufacturer will not be liable.
PRODUCT RECEIPT
IMPORTANT
m Upon receipt of the steam generating system, make sure that the supply is intact and undamaged and promptly
contact ICI CALDAIE S.p.A. if it does not correspond to the order
The ECOVAPOR systems consist of:

–– steam generating system complete with all its parts, any requested component included (assembled and tested).
–– turbulators present inside the combustion chamber, to be inserted inside the flue gas tubes upon installation
–– control panel made based on the generator to be managed
–– gas train, to be assembled on the system upon installation
–– pipe, vibration-damping joint and shutter.
The following documents are located inside the control panel:

–– declaration of conformity
–– use and maintenance manual
–– safety valve(s) certificate, with declaration of conformity and use and maintenance manual
–– feed pump(s) characteristic curve
–– electrical diagram
–– Instructions for:
-- safety pressure switch,,
-- pressure transducer,
-- pre-amplifier,
-- probe(s),
-- gas valve.
Gas Train
IMPORTANT
m All the supplied documentation is an integral part of the appliance and it MUST be carefully read before installing and
commissioning the generator, carefully stored for further consultations and it MUST always accompany the appliance.
Installation 43
HANDLING
ATTENTION
a Pay the utmost care during handling and use the Personal Protective Equipment requested by the prevailing
regulations.
The ECOVAPOR steam generator must be handled using means adequate to the size and weight of the appliance, using the
provided lifting eyebolts.
a a
ATTENTION
a –– Do not expose the packed product to direct sunlight.
FILM REMOVAL
The boilers can feature the following types of protective films:
ATTENTION
a Remove the PROTECTIVE FILM, if any:
–– After handling and after having installed all components.
–– BEFORE STARTING THE BOILER . The generated heat makes it impossible to remove the film.
–– The film exposure to direct sunlight makes it impossible to remove it.
44 Installation
INSTALLATION ROOM
POSITIONING
The room where ECOVAPOR boilers are to be installed must be exclusively used for them, compliant with the Technical Standards
and the Law in force and equipped with adequately dimensioned vents for generator power.
It is recommended to position the boiler, if possible, lifted from the floor to minimise dust extraction by the burner fan.
For information only, below is some useful information:
–– the room must have a main entrance for the passage of the boiler and two doors with panic push-bars for the passage of the
personnel. It must also feature a suitable fire protection system
–– the support base of the generator must be flat and able to withstand the weight of the appliance full of water, complete with
accessories and pipes for the possible execution of the on-site hydraulic test
–– it must be equipped with ventilation openings created as established by the relevant Technical Standards
–– the room must be exclusively used by the personnel in charge of the activities on the generating system. The access
prohibition to unauthorised people must be duly signalled
–– consider the possible the need to replace components that fail over time
–– special buffer zones, duly sized in order to allow the operators to carry out the operating, check and maintenance operations
of all the installed components in full safety and in compliance with the Legislation in force in the place of installation, must
be arranged around the boiler
–– the boiler can be installed inside an outdoor prefabricated heating plant room, compatibly with the dimensions of the
supplied boiler model, and in compliance with the Legislation in force in the place of installation. COMPULSORY request upon
order placing.
P2
max 90°
A (*)
(*) A ≥ P2 (see "Size and fittings*)
IMPORTANT
m –– A space is necessary at the front of the generator, at least equal to the length of the tube bundle to allow the extraction
of the turbulators to clean the pipes and possibly replace the smoke pipes.
–– All generator, safety valves discharges, etc., must be suitably conveyed to inspectionable collection points.
ATTENTION
a –– Consider the spaces necessary to access the adjustment and safety devices and to perform maintenance.
ROOM VENTILATION
The installation room must be equipped with a ventilation system according to the current legislation.
For the dimensions of the openings, always refer to the current legislation.
The ventilation openings are used to allow the inflow of combustion air and to eliminate any fuel gas pockets from the room.
As an indication, in case gases lighter than air (natural gas) are used, the air vents must be positioned in the highest point of the
room.
Installation 45
SYSTEM CLEANING
All system pipes, in particular those already installed, must be thoroughly cleaned and/or washed, to eliminate any machining
residues and possible sludge. The gaskets positioned between joints shall not reduce pipe sections.
HYDRAULIC CONNECTIONS
Once positioned, the ECOVAPOR steam generating systems must be connected to the system in the following points:
–– Water; from the condensate tank (if present, otherwise purified water tank) to the feed pump suction.
–– Steam; from steam main outlet valve to the users (distribution header or others), from the safety valve outlet outside the room
in safety position.
–– Drains; from the level indicator drain, from the boiler drain to the drain line.
–– Fuels; burner connection for natural gas, LPG, diesel fuel and naphtha.
–– Compressed air; air pressure must range between 4 and 10 bar. The air must be filtered with a 25 μm mesh.
IMPORTANT
m –– It is recommended to insulate system pipes to avoid heat losses and a higher fuel consumption. All generator, safety
valve, etc. drains must be duly conveyed to collection points that can be inspected.
–– Make sure that the water and heating system pipes are not used as earthing point of the electrical system.
–– It is good practice to allow for expansion joints and suitable supports for the generator connecting pipes.
IMPORTANT
m ICI CALDAIE S.p.A. is not liable for any harm to people, animals or property damage caused by errors in the choice of
components or in the construction of the plant.
2 3 4
RC
1
5
RI
7
6
SC2
IA
SC1
1 Visual level indicator 6 Feed water purifier SC1 Drains

2 Steam inlet 7 Feed pump SC2 Sludge drain (BDV) - (optional for
3 Safety valve ECS24)
4 Steam generator RC Condensate return IA Water inlet
5 Condensate tank RI Water mains
46 Installation
FLUE EXHAUST
Chimney main specifications, such as height, section type of outlet to the atmosphere, check points, flue gas mass, must be
defined by a company specialised in this filed that will operate in compliance with the prevailing Standards and Legislation. The
connection between chimney and generator (flue gas channel) must be made based on the specific system needs.
IMPORTANT
m The diameter of the connection between chimney and generator (smoke duct) must not be less than that shown in
the "DIMENSIONS AND CONNECTIONS" table (ØC value).
GAS TRAIN ASSEMBLING

Make sure that the “shutter” opening corresponds to the value specified in the table. Should this not be the case, turn screw (1)
until measuring the requested opening.
ECOVAPOR
ECOVAPOR MODEL u.m.
350 500 650 800 1000 1350 1700 2000 2500 3000
Shutter size (Inch) 1" 1" 1" 1/2 1" 1/2 1" 1/2 1" 1/2 1" 1/2 1" 1/2
(A -
Shutter opening 8 10,5 21,7
mm)
(number
From totally closed shutter 4 4" 1/2 9" 1/2
of turns)
(number
From totally open shutter 5" 1/2 9 4
of turns)
(number
Total 9" 1/2 13" 1/2 13" 1/2
of turns)
To assemble the gas train and connect it to the ECOVAPOR steam generating system, use the components supplied and proceed
as follows:
–– connect nipple male side (3) to the air/gas channel (2),
–– connect pipe (5), vibration damper (6) and nipple female part (3) to the shutter (4), thus assembling the gas pipe unit. Duly
tighten all joints.lay the gas pipe unit on the hose clamp supports (7) and connect nipple (3).connect gas valve (8) to shutter
(4) by duly tightening the four screws
–– duly tighten the hose clamp supports (7) and the nipple (3).
8 2
4 7 5 6 3
IMPORTANT
m Apply a suitable product to every joint to ensure proper tightness.
A pressure controller suitable to the gas grid pressure and to generator ECOVAPOR performance specifications must
be installed upstream the gas train.
Before generator commissioning, the GAS LINE LEAK TEST must be carried out, as required by the current Legislation.
Installation 47
FRONT DOOR OPENING
The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx).
DANGER
a It is DANGEROUS TO UNSCREW the ferrules (8) on the side of the hinges. This may cause the door to detach, with
possible serious harm to people and property damage.
Check the correct adjustment of the tie-rods and hinges ensuring that, during closure, the seal gasket is evenly pressed in the
centre on the whole circumference. If necessary, adjust the door as described in the following paragraph.
FRONT DOOR ADJUSTMENT

DANGER
a Incorrect door adjustment with consequent damage to people and property voids the warranty conditions.
DOOR ADJUSTMENT (OPENING ON THE RIGHT)
Sx Dx
5 4
3 2 1
7 6
VERTICAL ADJUSTMENT
To make the adjustment:
–– with the door ajar, loosen the counter-nuts (1) of the hinge units
–– act on the adjustment nuts (2) to lift or lower the door by centring the gasket on the stop plate, then block the counter-nuts
(1)
–– close the door and centre the tie-rod (4) on the mechanical tube (5), proceeding as in the previous point.
HORIZONTAL ADJUSTMENT
Close the door using the lever and check that there is equal distance on both sides, between the stop plate and the band. If this
is not the case:
–– with the door ajar, loosen the locking nuts (6) of the hinge units
–– act on the ferrule (7) to adjust the distance depth-wise
–– screw the nuts (6) and block the conical washers on the mechanical tubes.
DANGER
a When cross-changing ferrules, always make sure that the other two ferrules are fastened, so that they hold the door.
Check the proper adjustment in depth ensuring that the door, manually pushed up to the stop plate, naturally returns remaining
ajar. This is to ensure the hinge side fume seal.
48 Installation
TURBULATOR ASSEMBLY
To assemble the turbulators supplied with the boiler, open the door and insert the turbulators completely into the smoke pipes,
until they penetrate by at least 100 m.
mm
100
The dimensions, diameter and length (ØxP) and the quantities (no.) of the turbulators (Tb) for the various models, are specified in
the ”Hydraulic fittings” table in paragraph “Dimensions and fittings”
ELECTRICAL CONNECTIONS
The ECOVAPOR feature a control panel (IP 55 insulation class) to be completed by fitting the two factory equipped connectors to
the various generator components. Panel model depends on the version of the ordered generator and the specific and detailed
wiring diagram is present inside the panel. The connections outside the generator must be carried out by Qualified Personnel in
compliance with the Technical Standards and with the local National Legislation in force in the country of use.
IMPORTANT
m –– Connect the generator to an efficient earthing system. ICI CALDAIE S.p.A. is not liable for any damage caused by the
lack of earthing and failure to comply with the wiring diagram.
–– Check that the panel power supply complies with the wiring diagram supplied.
–– Make sure the generator is properly earthed.
–– Check the plant’s electrical system.
PROHIBITION
d –– Do not use the water and heating system pipes for the earthing connections.
–– Do not step on or damage the protective sheath of the cable with any other mean.
Installation 49
5 First commissioning
PRELIMINARY ACTIVITIES TO BE CARRIED OUT BEFORE THE "FIRST" COMMISSIONING

IMPORTANT
m Before feeding the steam generating system, it is recommended to perform a "Boiling out" with consequent
passivation, in order to remove any machining residues. Taking into account the high risk resulting from wrong
chemical treatments, the operation must be carried out by Qualified Personnel.
The ECOVAPOR/system is fed by means of a multi-stage centrifugal pump. Water must reach pump suction with quite a high head
in order to avoid possible cavitation phenomena.
The minimum temperature of sucked water must be higher than 60 °C in order to favour oxygen elimination that, in any case,
must be completely eliminated with suitable chemical agents. In addition, if water temperature is >60°C the risk of thermal shock
inside the generator will be reduced.
The height of installation of the feed reservoir depends on the water temperature inside deaerator/feed reservoir, on the structure
of the connecting pipe between deaerator/reservoir and pump and on the characteristics of the pump (refer to the pump manual).
ATTENTION
a The oxygen dissolved in water causes corrosion inside boiler. Refer to the maximum allowed values specified in the
specific section of this manual.
Follow the table below to avoid pump cavitation problems.
DEGASSER TYPE Water supply temperature (°C) Head (H) on suction (metres)
60 1
70 2
Atmospheric degasser
80 3
90 4,5
0.5 bar pressurised thermo-physical
105 6
degasser
Pressurised thermophysical deaerator (3
120 [1] 7
bar)
[1]
Maximum pump suction temperature is 120 °C.
ATTENTION
m –– Avoid using feed water at a temperature below 60°C because rich of dissolved oxygen, thus such to cause corrosion.
–– Before starting the feed pump(s), operate the bleed valve and eliminate all the air present inside the pipe.
HYDROSTATIC HEAD DIAGRAM

Below is an example of hydrostatic head diagram.
H
A
A = value variable based on the type of system.
WATER CHARACTERISTICS
The values in the following tables are taken from tables 5.1 and 5.2 of EN 12953-10 (requirements for water delivery and water
inside generator).
Even for the generators not included in the mentioned standard, it is nevertheless necessary to adopt at least the indicated limits
and consult specialised companies to select the type of treatment to be carried out based on a comprehensive analysis of the
available water.
Water delivery - Limit values (at inlet)

CHARACTERISTICS u.m. Steam generator water with pressure up to 20 bar
Appearance Clear, limpid, without foam or suspended solids
Direct conductivity at 25°C μS/cm See table values "Operating water - threshold values"
pH at 25 °C [a] --- > 9,2 [b]
Total hardness (Ca+Mg) mmol/l < 0,01 [c]
Iron (Fe) mg/l < 0,3
Copper (Cu) mg/l < 0,05
Silica (SiO2) mg/l See the "Maximum acceptable silica content in the generator water up to 20 bar pressures" table
Oxygen (O2 ) mg/l < 0,05 [d]
Oily substances mg/l <1
Concentration of organic substances - See note [e]
[a]
With copper alloys in the system the pH value must be kept within 8.7 and 9.2.
[b]
With a softened water pH value > 7.0, the value of the generator water pH should be provided based on the chart “Operating
water - limit values”.
[c]
At operating pressure <1 bar, a maximum total hardness of 0.05 mmol/l must be acceptable.
[d]
Instead of respecting this value with intermittent operation or operation without deaerator, in case of agents forming the film
and/or excess of oxygen, the additive must be used.
[e]
The organic substances are generally a mixture of several different compounds. The composition of these mixtures and the
behaviour of their single components at the operating conditions of the steam generating system are difficult to predict. The
organic substances can be decomposed to form carbonic acid or other acid decomposition products that increase the acid
conductivity and cause corrosion and deposits. They can also lead to the formation of foam and/or to the production of steam
with suspended water that has to be minimised as much as possible.
Maximum acceptable silica content in the generator water up to 20 bar pressures

Alkalinity Silica
0,5 mmol/l 80 mg/l
5 mmol/l 105 mg/l
10 mmol/l 135 mg/l
15 mmol/l 160 mg/l
Note
These values apply supposing the presence of a thermal deaerator. If no deaerator is present, the temperature of the water
contained inside the reservoir must be increased to at least 80 °C in order to reduce the content of dissolved gases (O2 and CO2).
In any case, it is recommended to use chemical conditioners to completely deoxygenate the water delivery and to minimise the
corrosive effects of CO2.
5.2 Operating water - threshold values

Steam generator water with pressure up to 20 bar
CHARACTERISTICS u.m.
Water delivery direct conductivity > 30 μS/cm Water delivery direct conductivity ≤30 μS/cm
Appearance Clear, limpid, without foam or suspended solids
Direct conductivity at 25°C μS/cm < 6000 [a] < 1500
pH at 25°C --- 10,5 - 12 10 - 11 [b] [c]
Composite alkalinity mmol/l 1 - 15 [a] 0,1 - 1 [c]
Silica (SiO2) mg/l See previous table "Maximum acceptable boiler water silica content up to pressures of 20 bar"
Phosphates (PO4 ) [e] mg/l 10 - 30 6 - 15
Organic substances - See note [d]
First commissioning 51
[a]
With a superheater consider as maximum value 50% of the value indicated as maximum.
[b]
Basic pH adjustment by injecting NaPO4, further injection of NaOH only if the pH value is < 10.
[c]
If the acid conductivity of the generator feed water is < 0.2 μS/cm, and its concentration of Na + K is <0.01 mg/l, the injection
of phosphate is not required. It can be applied under AVT conditions (treatment with volatile chemicals, feed water pH ≥ 9.2 and
generator water pH ≥ 8), in this case the conductivity of the generator water is < 5 μS/cm.
[d]
If treatment with coordinated phosphate is used, considering all other values, higher concentrations of PO4 are acceptable.
[e]
The organic substances are generally a mixture of several different compounds. The composition of these mixtures and the
behaviour of their single components at the generator operating conditions are difficult to predict. The organic substances can be
decomposed to form carbonic acid or other acid decomposition products that increase the acid conductivity and cause corrosion
and deposits. They can also lead to the formation of foam and/or to the production of steam with suspended water that has to be
minimised as much as possible.
FREQUENCY OF THE ANALYSES

The analyses have to be carried out at the frequency specified in the table present inside the periodical checks paragraph. It is
nevertheless recommended to check the pH, total hardness and alkalinity values of the water delivery and of the operating water.
It is good practice, mainly under variable operating conditions, to make a monthly complete analysis of a significant sample of
water delivery and operating water. In addition, it is good practice to visually inspect the possible presence of highly polluting
oily substances inside condensate return lines (reduction of the evaporation on the water surface inside generator due to a layer
of oil).
WATER FEEDING PROCEDURE

For generator ECOVAPOR water feeding, proceed as follows:
–– open the water delivery shut-off valves.
–– completely bleed the water delivery pipe to the feed pump by operating on the bleed valve
–– power the system by setting the plant room panel main switch and the Control Panel main switch to “ON”.
–– set feed pump operation to “MAN” by following path → FEED PUMP → PUMP MANUAL OPERATION → ON
–– press key and then icon to start the feed pump
–– check that pump rotor turns in the direction indicated on motor rear side and feed until the water level reaches at least point
(A), visible on the level indicator
–– press icon to stop the pump
–– press and hold key “4 mA” of the pre-amplifier (for ~3 sec.) until the GREEN LED (1) flashes, then release it
–– start pump again by pressing icon and continue filling until the level indicator reaches approx. point (B), visible on level
indicator
–– press icon to stop the pump
–– press and hold key “20 mA” of the pre-amplifier (for ~3 sec.) until the GREEN LED (1) flashes, then release it
–– open the sludge drain or SC2 and forcedly drain the generator until the water level is approximately 65 mm above the
minimum level indicated on the level indicator plate
–– close the sludge drain.
–– set feed pump operation to “AUT” by following path → FEED PUMP → PUMP MANUAL OPERATION → OFF
B
~ 1 cm
1
20 mA
4 mA
~ 1 cm
IMPORTANT
m If, after key 4 mA or 20 mA is pressed, the pre-amplifier LED is RED, it means that the operation has NOT been carried
out correctly. Repeat the operation until the LED flashes green.
LEVEL PROBE POSITIONING

The generator ECOVAPOR is supplied with a pre-calibration (positioning) of the probe pack according to the diagram shown.
Pump must be started (ON) when the water level is 60 mm above the minimum level, which can be seen on the level indicator,
while pump will turn off (OFF) when the level is 90 mm above the minimum level.
The optimal operating level is thus approx. 75 mm above the minimum level (centred between pump ON and OFF).
1 2 3 4
1 Capacitive probe with pre amplifier

2 Maximum level probe
3 First safety level probe (minimum)
5 4 Second safety level probe (maximum)
5 level indicator
MAXIMUM LEVEL
PUMP OFF
SETPOINT
PUMP ON
90
75
60
MINIMUM LEVEL (*)

(*) LWL line indicated by the level indicator plate
The commissioning of generator ECOVAPOR MUST be carried out by an Authorised Technical Service Centre after the following
preliminary checks:
–– check for the presence and interconnection of all the components described in the manual
–– check that the electric, hydraulic and pneumatic connections have been correctly carried out and in compliance with this
manual’s provisions
–– check that all fittings are fully tightened
–– check that water filling has been carried out
–– close drain valves, steam outlet and level indicator drain
–– open the level shut-off and feed valves (upstream and downstream the water pump)
–– check that turbulators have been correctly inserted inside the flue gas pipes and properly close the door
–– check that fuel supply to burner gas train can ensure a constant pressure inside the flame modulation range and that, in any
case, ranges between 20 and 50 mbar. A vibration-damping joint must be positioned between the fuel supply network and
the gas train.
FIRST START-UP
The following devices of generator ECOVAPOR are pre-set and pre-calibrated:
–– inverter (the device is present inside the control panel and is supplied already set)
–– burner managing board (pre-calibrated, the minimum (P1), start (P0) and maximum (P9) speeds can be edited)
–– control panel, set upon testing as for:
-- number of pumps
-- presence of sludge blowdown
-- language
-- date and time
-- burner management setup
–– steam safety pressure switch
–– air pressure switch (1 mbar)
–– gas valve pressure switch for leak check (10 mbar)
–– gas valve pressure switch for grid gas minimum pressure (10 mbar)
–– steam safety valve(s) already calibrated and sealed at the maximum boiler pressure (12 barg)
–– capacitive level probe
–– minimum safety level probes
–– gas valve minimum flow rate (mechanical calibration)
–– gas valve maximum flow rate (mechanical calibration)
–– recirculation flue gas by-pass gate (mechanical calibration).
IMPORTANT
m –– For further information, refer to the manual of the devices supplied with the generator.
–– Upon first start-up, check the efficiency of all the adjustment and control devices present on the control panel.
–– Warranty validity is subject to the compliance of the provisions set forth in this manual.
Start-up procedure
To start the steam generator:
–– power the control panel by setting the central and main switch to “ON”
–– press key
–– touch the flashing icon to start the generator, with the water at minimum temperature (approx. at ambient temperature).
Wait for the appliance to have completed the start-up phases until reaching the maximum power.
When the generator has reached the maximum power, let it stabilise, without waiting for the pressure to rise and carry out the
following measurements/checks:
–– check that the grid gas and the gas valve pressure values t match with those specified for the installed generator. Should this
not be the case, operate on the pressure controller
–– make sure that fan frequency (Hz) and combustion data (CO2 - NOx) match with those specified in the table
–– Through the flame inspection windows (4) check that the colour of the flame and of the metal mesh is light blue. Should this
not be the case, turn the Shutter adjustment screw (+/-) (1), or operate on the flue gas recirculation gate (2).
Operate the appliance at its minimum power and carry out the following measurements/checks:
–– make sure that fan frequency (Hz) and combustion data (CO2 - NOx) match with those specified in the table.
–– through the flame inspection windows (4) check that the colour of the flame and of the metal mesh is light blue. Should this
not be the case, operate on the "OFFSET" screw pre-calibrated with centreline index (+/-) (3).
IMPORTANT
m –– It is of the utmost importance to avoid that burner mesh is red since it indicates a "combustion air defect" and can
irreparably damage the material.
3
2 4
COMBUSTION SYSTEM CALIBRATION
The following equipment is necessary for the calibration of the combustion system:
–– combustion flue gas analyser (%O2 , ppm CO, ppm NOx)
–– digital manometer.
The table shows the reference values with the steam generating system set at 10 bar.
The steam generating system is delivered already calibrated (gas valve setting, inverter setting, managing board setting) but,
during start-up, some adjustments may be required on the gas valve.
ECOVAPOR
DESCRIPTION u.m.
350 500 650 800 1000 1350 1700 2000 2500 3000
MIN Hz 11,5 ÷ 15 12 ÷ 15 14 ÷ 16 12 ÷ 15
Fan Frequency START Hz 14 ÷ 20 20 ÷ 23 23 ÷ 26 14 ÷ 19
MAX Hz 50 ÷ 56 65 ÷ 70 70 ÷ 75 60 ÷ 66
MIN % 7,8 ÷ 8,3 7,8 ÷ 8,3 8,5 ÷ 9,0 8,5 ÷ 9,0
CO2 START % 9,0 ÷ 9,5 9,0 ÷ 9,5 9,0 ÷ 9,5 9,0 ÷ 9,5
MAX % 9,3 ÷ 9,8 9,3 ÷ 9,8 9,5 ÷ 10 9,5 ÷ 10
MIN < 40 < 40 < 40 < 50 < 50
NOx
MAX < 40 < 60 < 60 < 70 < 70
Gas Train Pressure MAX mbar 20 ÷ 25 20 ÷ 25 30 ÷ 60 30 ÷ 70
Pilot Flame Pressure START mbar 15 ÷ 35
Combustion Head Δp* MAX mbar 9 8,4 17,5 23,7
* The pressure difference between points A and B indicated in the fig. and detected by the generator set at 10 bar indicates that
the MAX flow thermal has been reached
1 Pressure test connection A

2 Pressure test connection B
3 Protective plate
3 4 2 4 Fastening screw
The pressure test connection (1) is positioned under the burner protective plate, hence a fastening screw has to be removed to
turn the plate as shown in the figure.
IMPORTANT
m –– With the steam generator running at the Max Power and at a steam pressure of 10 bar, the NOx value must be < 70
mg/kwh.
–– On the generators equipped with manhole, during the first start-up, it is essential to progressively tighten the two nuts
of the hatch while pressure increases. Otherwise, the installation area may become dangerous for the operators in
charge, due to steam seeping through and deteriorating gasket rapidly.
–– Check the intervention of all safety and adjustment accessories described in the relevant chapter.
CHECKS AFTER COMMISSIONING
With cold start, check that:
–– the water level is 60 mm above the minimum level (LWL) indicated on the level indicator; the water volume increase due to
heating (water thermal expansion) should not be excessive in order to avoid having to drain water at regular intervals to bring
the level back to half scale on the glass indicator
–– once the set pressure has been reached, the steam outlet valve must be opened gradually in order to heat the delivery pipe
by eliminating any condensate present inside ducts
–– the manhole gasket seals.
STOP PERIODS
The most serious corrosions for the generator often occur during the stop periods.
The operations to be carried out to ensure a correct storage of the generator mainly depend on the duration of the stop time.
When the generator has to remain unused for long periods a dry storage is recommended. When the stop times are for short
periods or when the generator has a backup function and must be able to become operational in a short time, a wet storage is
recommended.
In both cases, the operations described below tend to eliminate any possible cause of corrosion.
The wet storage, whenever possible, reduces the interval necessary to reach the operating conditions.
Dry storage
Empty and thoroughly dry the generator, then inject a dessicant (such as quicklime, silica gel, etc.) inside the cylindrical body.
Wet storage
Drain water and perform a complete cleaning of the generator. Fill the body up to the normal operating level and, after a short
evaporation time, blowdown to the atmosphere to eliminate all dissolved gases. Then completely fill the generator, with a correct
metering of DEHA (diethyl hydroxyl amine) to develop a residual concentration of more than 100 ppm preventing the attacks of
the oxygen dissolved in water. Add also trisodium phosphate to ensure a total alkalinity above 400 ppm.
Then close all connections.
Make sure that there are no leaks from connections or junctions and take some water samples at regular intervals in order to check
that the alkalinity value has not been altered.
6 Maintenance
Periodic maintenance is prescribed by Law and must be performed only by a Qualified Personnel.
The frequency of the operations is shown in the specific paragraph.
IMPORTANT
m Before performing any maintenance or cleaning:
–– disconnect the electrical power supply by placing the main switch of the system, of the control panel and of the burner,
if any, at "OFF"
–– close the fuel supply
–– use all Personal Protective Equipment required by current Standards and Legislation
–– wait for the generator and the system to cool down.
–– Periodically purge (level indicators, probe support, if any, generator) to avoid the build-up of sludge
–– check the efficiency of the control and adjustment instruments by carefully examining the electrical parts, the connections
and the mechanical parts (pressure switches); it is recommended to replace the probe ceramic spark plugs annually
–– carry out burner maintenance (according to the relative instructions)
–– check the torque of the flange bolts and the state of the gaskets
–– check the state of the internal coating of the doors
–– clean the tube bundle and turbulators
–– carry out proper pump maintenance (bearings, mechanical seal)
–– check the wear of the drain valves, replace them if necessary
–– in case of backfire inside the combustion chamber, before a new ignition, check for any damage of the system, mainly close to
the combustion head.
PERIODIC VERIFICATIONS
WATER MONITORING
The system operator present inside the installation room must frequently check the glass indicator in order to avoid that the water
level inside the generator remains above the minimum value indicated by the glass level. Any lowering under the minimum value
shall trigger the two safety level switches.
PRESSURE MONITORING
The operator of the system in the installation room must frequently verify that the pressure of the generator steam remains below
the maximum value indicated on the generator assembly plate; a possible abnormal increase of the pressure must cause, at first,
the intervention of the safety pressure switch, then the opening of the safety valves.
Check intervals are specified in the table. They MUST be thoroughly respected.
Version 24 h operation without continuous supervision

Observation and tests 1 day 1 month 3 months 6 months 12 months
Safety valves O T(7)
Level indicators T(1)
“TDS-BWD” drain devices (If present) T(2)
Shut-off valves O T(8)
Water load control devices O
Low level protection devices
High level protection devices O T(4) T(13)
Temperature and pressure indicators O
High pressure protection devices O T(4) T(13)
Protection devices, water delivery quality (if present) O T (5) T (9)
Safety systems O T (10)
Pressurised parts, piping, flanges, joints O
Maintenance 57
Temperature, pressure control devices O T(11)
Load system, pumps/valves O T(6)
Analysis of the water quality T(3)
Burner control (combustion) O T(12)
Water quality automatic protection device (if any) T(14)
Burner check (filter, gas valve, air pressure switch, fan,
cone, electrodes, combustion head and control unit, O T(12)
phase sequence check)
Version 72 h operation without continuous supervision

Safety valves O T(7)
Level indicators T(1)
“TDS-BWD” drain devices (If present) T(2)
Shut-off valves O T(8)
Water load control devices O
Low level protection devices
High level protection devices O T(4) T(13)
Temperature and pressure indicators O
High pressure protection devices O T(4) T(13)
Protection devices, water delivery quality (if present) O T (5) T (9)
Safety systems O T (10)
Pressurised parts, piping, flanges, joints O
Temperature, pressure control devices O T(11)
Load system, pumps/valves O T(6)
Analysis of the water quality T (3)
Burner control (combustion) O T(12)
Water quality automatic protection device (if any) T(14)
Burner check (filter, gas valve, air pressure switch, fan,
cone, electrodes, combustion head and control unit, O T(12)
phase sequence check)
0 Observe generator correct operation in all its parts.

There shall be no leaks from the safety valves.
There shall be no leaks from the shut-off valves, pipes, flanges, joints, and pressurised parts in general.
Visually check, through the glass indicators, water correct level. Check pump(s), modulating valve (if present).
Check the correct displaying and adjustment of temperature/pressure values.
Check for the presence of alarms originated by the protection devices.
Check burner correct operation.
T(1) Purge the level indicators
T(2) Manually check, through the switches present on panel front side, that valves (if any) are open.
T(3) Perform generator water analysis (refer to the specific paragraph).
T(4) “Physically” check the triggering of devices (refer to the specific paragraph).
T(5) Analyse water quality by taking a sample from the feed system; check whether it complies with EN12953-10 specifications
(refer to paragraph "water quality" of the generator manual)
T(6) Thoroughly check the feed system, matching of the level on the glass indicators with the parameters entered in the check
device, controller (if any).
T(7) Check safety valves by applying a master manometer to the generator, as a reference of the exact activation pressure.
Checks must be carried out by qualified personnel.
T(8) Check correct sealing; grease, lubricate where necessary.
T(9) Check and new calibration of the analysis system. Checks must be carried out by qualified personnel.
T(10) Check the correct operation of all safety, electric and electronic devices. Checks must be carried out by qualified personnel.
T(11) Check, using master thermometers/manometers, the correct indications provided by the instruments. Checks must be
carried out by qualified personnel.
T(12) Burner check, combustion check, safety device check. Checks must be carried out by qualified personnel.
T(13) Bench testing of safety devices. Checks must be carried out by qualified personnel.
T(14) Check and new calibration of the analysis system.
58 Maintenance
GAS LEAK MONITORING AND AIR FILTER CLEANING (STANDARD)
In addition, it is strongly recommended to carry out periodical tests to check any gas leak and air filter cleanliness.
Monitoring Modes Max. frequency
Gas leak detection 12 months
Air filter cleaning Check of the load loss extent at the filter 12 months
LIFECYCLE OF MAIN COMPONENTS

The lifetime of system components is shown in the table below.
These devices must be replaced once their useful lifetime expires:

COMPONENTS LIFETIME (years)
Level switch 8
Pressure switch 10
Safety modules 20
Combustion control unit 10
Gas valve 10
Gas pressure switch 20
Air pressure switch 20
ATTENTION
a The electronic level relays present inside the control panel must be replaced after 8 years of operation since their
useful lifetime has expired.
METHODS FOR CHECKING THE SAFETY DEVICES

CHECKING OF THE MINIMUM LEVEL SAFETY LEVEL SWITCHES
Position yourself in front of the control panel, leave the steam outlet valve open with standard withdrawal, turn off the pump by
setting switch to "0", wait for the natural lowering of the generator water level. To accelerate this operation, operate on the sludge
drain valve.
IMPORTANT
m The two safety devices must trigger when the water level reaches the “minimum” mark indicated on the side of the
glass indicators. Should this not be the case, check the whole level switch, which consists of:
–– electronic level regulator; check it is intact and, if not, proceed with replacement
–– connection cable between control panel and probe; possible interruption and/or short circuit
–– level probe; check for possible breakage of the ceramic part and consequent loss of electrical insulation
–– level dipstick; possible scale build-ups preventing the probe-water current passage or possible dipstick detachment.
If check outcome is positive, set pump control to “AUT”.
CHECK THE MAXIMUM LEVEL SWITCH (IF ANY)

Set the pump switch on the control panel to MAN and wait for the water level to increase inside the generator.
Check that the pump stops when the maximum point visible in the glass indicator has been reached.
CHECK OF THE SAFETY PRESSURE SWITCH

The safety pressure switch must be calibrated at a pressure lower than that of the safety valve.
To check the correct activation of the safety pressure switch, increase the calibration of the regulation pressure switch(es) and
check burner turning off and shut-off alarm activation from the control panel (visually follow the indication provided by the
manometer).
Maintenance 59
ROUTINE MAINTENANCE
–– Depending on the degree of pollution of the premises, clean the ventilation and/or the air conditioner (if present) filters and
grilles frequently.
–– Every 2-3 months check if there are dust deposits inside the control panel, suck and/or blow to remove any deposit.
–– Every six months check the clamping of the connections to the inner components, paying particular attention to the power
circuits.
–– Every six months check the clamping of the connections to the field control/safety devices, including any junction boxes.
–– Annually check that the electrical panel, the generator and the control unit equipotential is properly connected to earth.
–– Every six months check the condition of the safety devices (probes and pressure switches).
–– Every six months checkthat the pump and burner control circuits still meet the original conditions (refer to paragraph
“Commissioning”)
IMPORTANT
m In order to preserve the proper operation of the generator over time, we recommend requesting a half-yearly/yearly
inspection by the Technical Assistance Service, for a general check of all parts.
EXTRAORDINARY MAINTENANCE
The generator must be stopped periodically for a thorough inspection and maintenance: the time interval between downtime is
established through experience, by operating conditions, by the quality of the feed water, and by the type of fuel used.
Before accessing the generator body for inspection and cleaning, thoroughly check that no water or steam can reach the
generator through the connecting ducts. Each valve will have to be locked and, if necessary, isolated by removing a section of the
connection pipe to the system or by placing a blind flange in-between.
The pressurised parts must be carefully examined internally to look for any build-up, corrosion and other potential sources of
danger pertaining to the feed water.
It is necessary to remove the deposits through mechanical or chemical action and use suitable tools to ensure that the actual
thickness of the internal parts is not affected by corrosion. Any pockmark or other type of corrosion must be scraped and cleaned
with an iron brush until the metal is exposed. Leaks between all fume pipes and tube sheets must be examined carefully: any
welding must comply with legal requirements, not forgetting that the steam generator is a pressure appliance with an explosion
hazard, subject to control by the relative Body.
During the inspection, check all safety accessories (safety valve, safety level switches and safety pressure switches).
LEVEL SWITCH REPLACEMENT

To replace the safety level switch or part of it, strictly observe the following instructions:
–– check that the ceramic part of the new level probe is intact
–– check the rod length
–– check the coaxiality of the rod with the level probe axis
–– check the integrity of the electrical system, in particular check that the insulation resistance of the electrical cable that
connects the probe to the panel is above 2 MΩ
–– check the integrity of the probe with particular regard to the isolation between the central electrode and the external part,
that must be ≥ at 10 MΩ
–– check the operation of the level switch, consisting of the assembly of the two ceramic probes and relative conductivity relays.
IMPORTANT
m –– The electronic level relays inside the electrical panel HAVE AN AVERAGE CALCULATED DURATION (MTTFd, "Mean Time To
Failure") of 8 YEARS. It is an average time before a dangerous failure occurs. Therefore, they must be replaced after this
operating period. We recommend replacing the probes once a year. To be evaluated, during cleaning/maintenance, the
other mechanical, electromechanical and electronic parts.
–– The faulty components must be replaced with ICI CALDAIE S.p.A. original components.
60 Maintenance
ANY ANOMALIES AND REMEDIES
ANOMALY CAUSE REMEDY
Exceeding of the max pressure regulated on the valve that
Adjustment of block pressure switches and/or limit too high
must be equal to the appliance design pressure
Safety valve(s) opening
Check and subsequent calibration of the valve using a
Safety valve calibration loss
sample pressure gauge
Cleaning of seat by sometimes acting on the manual
Dirt around the shutter seat
Small leak from the safety valve(s) opening lever
(leakage) Valve disassembly and polishing of the internal seat with
Scratched shutter seat
very fine abrasive paste
Check motor absorption
Disconnected pump thermal relay
Pump block Check thermal calibration
Blocked pump shaft Electric pump maintenance
Calibrated limit pressure switch too high Limit pressure switch calibration
Block pressure switch Faulty limit pressure switch Limit pressure switch replacement
intervention Clogged pressure switch coil Coil cleaning or replacement
Block pressure switch failure Pressure switch replacement
Encrusted stainless steel rod
Interrupted water level detection
Interrupted connection cable
Temporary replacement of electronic safety relay with one
of the two relays in the panel
Level 1 or 2 safety intervention Faulty safety level relay
If the problem is solved, permanently replace the faulty
relay.
Lack of water filling See "Loading" Problems
Wrong wiring of control panel probe power cable Wiring diagram check
Pump block See "Pump block" Problems
Dirty pump intake filter Filter cleaning
Temporary replacement of electronic adjustment relay with
one of the two relays in the panel.
Level adjustment anomaly
If the problem is solved, permanently replace the faulty
relay.
Disassemble the adjustment probes to visually check the
Level adjustment probes short-circuit
Insufficient water loading ceramic insulation
Head (=height difference between the collection vessel
level and the pump) insufficient in relation to the water
temperature
Pump cavitation
Pump intake filter cleaning
Reduce resistance of the duct between collection vessel and
pump by increasing the passage section
Pump rotation direction Invert one of the phases (three-phase pump)
Incorrect connection to the electrical panel See the wiring diagram
Faulty level safety relays See "Level 1 or 2 safety intervention"
Burner always on
Pressure switches calibration check
Block and/or adjustment pressure switches not active
Check of pressure switch connections to the electrical panel
See specific Burner manual
Burner fuses interrupted Fuses replacement
Burner always off No consent to burner from adjustment pressure switch Adjustment pressure switch replacement
No consent to burner from level safety relays See "Level 1 or 2 safety intervention"
Incorrect connection to the electrical panel See the wiring diagram
PROTECTING THE ENVIRONMENT

The protection and the respect of the environment are a fundamental principle for ICI CALDAIE S.p.A .
Product quality, energy saving and protection of the environment are equally important objectives for the company. ICI CALDAIE
S.p.A, also through the ISO 14001 certification, strictly adheres to the European laws and standards on environmental protection.
In order to reduce its impact on the environment, the company uses the best technology and materials in its production processes
and always considers their economic impact.
System for 24 or 72 h operation without continuous supervision.
DECOMMISSIONING AND DISPOSAL

Decommissioned appliances contain materials that can be recycled since they do not contain asbestos or non-reusable hazardous
materials.
Maintenance 61
SYSTEM FOR 24 OR 72 H OPERATION WITHOUT CONTINUOUS SUPERVISION
ECOVAPOR is a system certified as assembly under PED Directive 2014/68/EU allowing its operation without continuous supervision
of an authorised operator in compliance with the provisions in force in the country of installation up to 24 hours for ECOVAPOR
24 or up to 72 hours for ECOVAPOR 72.
The generator supplied (CE certified by the Notified Body as a whole assembly in compliance with the European Directive 2014/68/
EU) consists of an equipment set, assembled and electrically and hydraulically factory tested at ICI CALDAIE S.p.A
Control panel, insulation class IP 55 400V/3 +N/ 50Hz, certified for safety chain management, complete with board and operator
panel able to monitor, display and transmit the status signals and alarms. Suitable for operation inside Heating Plant Room under
critical environmental conditions (T min. +5°C, T max. +50°C).
Equipped with:
–– 7" touch screen HMI operator’s panel
–– expandable control and monitoring HW board
–– control system connectivity via LAN, WiFi, Modbus, Modem
–– main disconnecting switch
–– low level 1st alarm relay with manual reset
–– low level 2nd alarm relay with manual reset
–– air-conditioning system
–– special safety circuits.
The main functions are:

–– water level continuous adjustment through capacitive probe and delivery with inverter-controlled pumps
–– inverter controlled motor rpm adjustment of combustion system fan
–– burner modulation adjustment, for the management of any power between the minimum and maximum limits, for an
optimal adaptation to the feed instant request
–– adjustment of automatic sludge blowdown frequency and duration (only for ECOVAPOR 72)
–– adjustment of salinity control unit thresholds TDS (only for ECOVAPOR 72)
–– self-adaptation based on system actual needs
Accessory unit on steam side, including:

–– steam outlet globe valve
–– spring safety valve
–– level indicator with direct reflection
–– interception valve and drain indicator unit.
Pressure control instrumentation containing:

–– large dial 3 way test valve manometer
–– fail safe manual reset safety pressure switch
–– analogue pressure transducer.
Feed water unit mounted on system support, containing:

–– 1 vertical multi-stage centrifugal pump suitable for 120° C water with integrated inverter
–– 1 shut-off globe valve
–– pump suction filter
–– 1 non-return valve.
Conductivity probe automatic level controller, containing:

–– capacitive probe for level control and management.
Auto-controlled safety level unit, containing:

–– 2 low-level safety probes, mechanically and electrically independent, mounted directly on the system, with manual reset and
self-test, complete with burner shut off relay
–– connections and electrical controls in generator control panel
–– mechanical and electric assembling.
This system, supplied as an alternative to the standard low level probes, is designed to ensure that the water level in the generator
does not fall below the allowed value. It consists of two independent "fail safe" probes connected to two separated electronic
level relays with self-checking feature, capable of indicating:
–– the lack of water below the set level
62 Maintenance
–– the lack of water below the set level
–– the lack of insulation inside the probe
–– faults inside the device (self-check)
–– interruption of the connection between the probe and the device in compliance with EN 12953-9 point 5.4.8.
When it trips, the control panel triggers a visual and an acoustic alarm and stops the generator (permanently). The generator
operation is resumed only after the elimination of the fault and the manual reset by the operator. The control panel is supplied
fully assembled on the generator and already tested.
It complies with the following European Directives:

–– EMC Directive 2014/30/EU
–– PED Directive 2014/68/EU
Salinity control unit (TDS - only for ECOVAPOR 72) consisting of:
–– conductivity probe
–– salinity regulation and control unit
–– electric or pneumatic blowdown system complete with shut-off valves
–– electrical controls in generator control panel
The TDS control system limits the salt and mineral levels dissolved in system water within permitted manufacturer values, thus
avoiding any risk of entrainment due to high salinity levels and minimising the amount of blowdown required and associated
costs. The system continually measures the electrical conductivity value of the system water, just below the evaporation surface.
Its value is related to the concentration of dissolved salts. The detected value is compared with the set one. If it is higher, the
blowdown valve opens until the value returns below the set-point.
Automatic sludge drain unit (only for ECOVAPOR 72), to prevent sludge build-up inside generator, it consists of:
–– 2-way pneumatic valve made of steel, with lever for manual operation
–– adjustment of opening frequency and duration
–– compressed air solenoid valve
–– connections and electrical controls in generator control panel
The automatic sludge drain unit prevents unnecessary blowdown duplication or verifiable omission with the manual system.
This system allows sludge accumulated at the bottom of the boiler to be regularly and automatically removed through a cyclical
opening in the blowdown valve. The blowdown frequency and duration are set by the user according to the characteristics of the
generator water, as indicated in this technical manual. The system requires compressed air availability.
High level safety probe, mounted directly in the generator body.

Kit designed to prevent an excessive increase of water level inside the generator. Once the set level is reached, the control panel
stops the feed pump and triggers an acoustic alarm. Alarm resetting and pump restart automatically occur once normal level in
the generator is restored.
Cooler for samples, directly fitted inside the generator, consisting of:
–– AISI 304 barrel with an internal water-cooling coil
–– cooling water injection ball valve
–– handwheel valve for sample picking.
Make sure that the boiler is operating within the desired conductivity parameters by taking and testing water samples. To safely
obtain samples, it is essential that a proper cooling is carried out in order to condensate any rising steam before the withdrawal
point. The cooler reduces the water temperature to 25° C so that it is ready for an immediate sampling.
Integrated energy saver consisting of:

–– 2 check thermometers
–– 1 pressure gauge with three-way test valve
–– safety valve.
Temperature monitoring:
–– ambient temperature
–– flue gas temperature.
Maintenance 63
7 Optional components
BACKUP SUPPLY PUMP
To ensure a continuous operation of the generator by avoiding any production downtime

in case of a supply pump failure, a second backup supply pump is supplied and installed in
parallel with the service one. In case of failure of the operating pump, duly signalled by the
flashing light on the control panel, the exchange is carried out by the operator - after having
eliminated the cause of the malfunction - through the switch present on the control panel.
This switch is located between the level relay (or controller) and the power and protection
branches of the pumps, which are completely split and independent.
The backup supply pump is thus controlled in the same way as the service pump. Both
pumps, hydraulically connected to the same feed pipe, are equipped with a non-return valve
and a shut-off valve dedicated to each pump to avoid the water flow towards the pump in
stand-by conditions.
The kit comes with:

–– no.1 backup supply pump with characteristics similar to service pump
–– no.1 pump suction filter
–– no.1 non-return valve on pump downstream
–– no.1 shut-off valve on pump downstream
SECOND LEVEL INDICATOR

It is supplied as an optional and/or when the prevailing Regulation in the country of
destination of ECOVAPOR requires the second level indicator.
The kit is assembled and tested in our factory and comes with:
–– level indicator with direct reflection
–– interception valve and drain indicator unit.
SECOND SAFETY VALVE

It is supplied as an optional and/or when the prevailing Regulation in the country of
destination of ECOVAPOR requires the spring double safety valve.
STEAM OUTLET ELECTRIC VALVES
The butterfly valve is a safety valve with a disc-shaped shutter turning around a standard axis
of the pipe thus stopping the flow. It can be used as control valve or simply as shut-off valve.
It has proven its worth in recent years as an alternative, with allocation range up to 16 bar, to
ball valves or gate valves.
The main advantages offered by the butterfly valve are:
–– compact dimensions with consequent less space required
–– possibility to be assembled in any position
–– reduced weight with easy transport and maintenance
–– negligible load losses
–– long duration over time
Butterfly valve is adjusted through the electric actuator remotely controlled by the boiler
control panel.
STEAM NON-RETURN VALVES

The check valve, or non-return valve, is a valve allowing a single flow direction.
The disc check valves are used for the "sandwich" assembling between flanges; they are
suitable for use with a wide range of fluids for applications on process lines, cold, hot and
superheated water systems, thermal oils, compressed air, etc.
STEAM FLOW METER

Flowmeter for saturated steam, in sandwich design, i.e. in-between two flanges, equipped
with built-in electronics providing an output with density compensation.
The electronic head is equipped with an LCD. Instant flow rate signal is transmitted through
a 4÷20 mA output.
ELECTRICAL ENERGY METER

–– Electrical energy electronic meter.
–– Connection and insertion with TA.
–– Number of poles: 3 poles + neutral.
–– Measure of power, active and reactive energy.
–– Communication port protocol: ModBus, RS485.
–– Insulation class: IP20, IP40.
Optional components 65
MID THERMAL ENERGY METER
The heat meter kits are used for heating and cooling flow metering.
The range includes kits up to DN200 in order to meter the supply energy to risers
or heat exchangers.
The kits consist of a calculating unit where two PT500 temperature probes (flow
and return) and the pulse output head of a suitable sized volumetric meter must
be connected.
The calculating unit features a Meter Bus output and can communicate with
devices provided with this input such as, for example, CB 1013 interface of MBUS
CB78 centraliser.
The data communicated by the calculating unit to the interface board (CB1013)
can be read also by a e-kronos unit that can be connected up to 90 metres away
with 3x0.35 shielded cable.
The calculating unit can meter also the pulses coming from 3 possible volumetric
meters.
TURBINE GAS METER

The turbine flow meters and quantometers are meters showing the passed volume
in cubic meters at the operating conditions.
The running gas is accelerated and conveyed on impeller blades.
The movement of the impeller is transferred to a eight-digit meter through
reduction gears and a magnetic coupling.
The turbine flow meters are approved for the fiscal measurements of natural gas.
All turbine flow meters are compliant with the international directives and standards
on pressure equipment (PED).
The turbine gas meters are fiscal flow meters detecting gas operating volume.
Meters comply with Directive MID 2004/22/EC.
GAS MANUAL SHUT-OFF VALVE

Female/female ball valve with total passage for the fuel gas and yellow aluminium
lever, galvanised.
GAS PRESSURE CONTROLLER

Gas pressure controller with direct action compensated shutter.
Controllers comply with standard EN 88-2 - EN 334

In compliance with directives:
–– PED 2014/68/EU
–– Gas 2009/142/EC
–– ATEX 2014/34/EU
8 Useful information and declarations
QR CODE
How to register your appliance
The appliance must be registered once the product has been installed, either before or after start-up.
Follow these steps:
–– Obtain a smartphone (iPhone, Samsung Galaxy, Htc,
Blackberry etc.) or a tablet
–– after downloading and installing a "QR Reader"
application (any free application is usually more than
enough), open it and point the camera on the QR
code located on the plate of your appliance (circled in
the image)
–– you will be sent back to a web page on which to
register the data of your appliance and system by
completing the indicated spaces.
Once registered, authenticate your e-mail address by clicking on the link that will be sent by e-mail to the provided inbox.
An additional e-mail will then be received with the credentials to access all services specifically developed by ICI CALDAIE S.p.A.
for those who will register their boiler through the QR Code.
Registration entitles you, even in future months and years, to take advantage of promotions and specific services for registered
appliances (e.g.: discounts on spare parts, spare parts kits on sale, free routine maintenance for certain types of products, etc.).
For info: [email protected] o +39 0458738573
Useful information and declarations 67

9 Appendixes for Technical Personnel
The tables below have to be used by the Technical Personnel to easily identify the components that could have generated any
fault / alarm.
TABLES 1 and 2 indicate the operating phase and the input and output statuses during this phase.
TABLES 3 list the error codes, the diagnosis codes, the causes and the operating phase during which the fault occurred, thus
simplifying the identification of the cause that could have generated it
When a malfunction of one generator component occurs or in case of abnormal situation, the control panel generates a visual
and acoustic alarm. Press button to mute the siren, but the visual indications remain present both on the operator display and
on the burner control unit (1)display present inside the control panel.
In order to display the number of the operating phase during which the fault occurred or the fault error code on the control unit
display, the control panel door has to be opened; this operation can be performed only by Authorised Technical Personnel.
Examples:
Table 1 and 2 - Operating phase 22:
–– General safety circuit ON
–– Operation request ON
–– Fan motor ON
The other inputs and outputs of phase 22 are negligible

or not significant.
Table 3
Loc.c: 12 relates to the LEAK CHECK phase.
Loc.d: 83 indicates that gas valve V2 leaks.
Note
The indications “Loc.c” e “Loc.d” are alternatively shown
on the display.

speed
opens)
reached
Stand-by
(V2 opens)
Spark = ON
V2 (V2 closes)
V2 (V1 closes)
Fan motor = ON
enabling stand-by
Pre-ventilation end
Air pressure switch

Ignition = OFF (0.6s)
Post-ventilation time
Pre-ventilation speed
Ignition speed reached
Pilot Flame Valves = ON
Pilot Flame Stabilisation
Empty the tested section

Post-combustion interval
Motor => Post-ventilation
Fill the tested section (V1
Pressure test across V1 and

Appendixes for Technical Personnel

Phase number on control unit display 10 12 22 24 80 81 82 83 30 36 38 40 42 44 70 72 74
General safety circuit

Table 1; Version without pilot flame
Operation request
Function / Flame signal

inputs
Air pressure switch
Min Gas pressure switch
Cont. Gas pressure switch Sealing
Fan motor
Ignition transformer
Function /
Fuel valve 1
outputs
Fuel valve 2
Timer-result-ratio 5s 2s 30 s 3s 10 s 3s 10 s 2s 2,4 s 0,6 s 2 s 8s 30s
30s
COMMISSIONING DECOMMISSIONING
Input / output signal 0 (OFF)
Permitted input signal 1 (ON) or 0 (OFF)
Input / output signal 1 (ON)
5s Cannot be modified
6s Factory setting
7s Can be modified on site
69
70
speed
opens)
reached
Stand-by
(V2 opens)
Spark = ON
turning off"
V2 (V2 closes)
V2 (V1 closes)
Fan motor = ON
enabling stand-by
Flame stabilisation
Pre-ventilation end
Air pressure switch

Ignition = OFF (0.6s)
Post-ventilation time
Pre-ventilation speed
Ignition speed reached
"V1 and V2 valves = ON
Pilot Flame Valves = ON

Pilot Flame Stabilisation
Empty the tested section

Post-combustion interval
Motor => Post-ventilation
Fill the tested section (V1

Gas valve closing and pilot

Phase number on control unit display 10 12 22 24 80 81 82 83 30 36 38 40 42 44 50 52 70 72 74
Table 2; Version with pilot flame
General safety circuit
Operation request
Function / Flame signal

inputs
Air pressure switch
Min Gas pressure switch
Cont. Gas pressure switch Sealing
Fan motor
Ignition transformer
Function /
Fuel valve 1
outputs
Fuel valve 2
Pilot Flame Valves
Timer-result-ratio 5s 2s 30 s 3s 10 s 3s 10 s 2s 2,4 s 0,6 s 2 s 1,8 s 2s 8s 30s
30s 3s
PRE-VENTILATION TSA1 TSA2 POST-VENTILATION
COMMISSIONING DECOMMISSIONING
Input / output signal 0 (OFF)
Permitted input signal 1 (ON) or 0 (OFF)
Input / output signal 1 (ON)
5s Cannot be modified
6s Factory setting
7s Can be modified on site
Appendixes for Technical Personnel

Table 3
(Loc. "c")
(Loc. "d") Diagn. Code Cause Possible remedy
Err.Code
No communication between LMV37.4
no Comm # Check the wiring to exclude interruptions / contact loosening.
and AZL2
No flame at the end of the safety
2 #
interval
1
interval 1
2
interval 2
4
interval 1 (software version £ V02.00)
3 # Air pressure error
0 Air pressure OFF
1 Air pressure ON
Correct the setting of parameters 235 and 335.
2 Air pressure evaluation (Disabling of the air pressure control during operation allowed
only with pneumatic operation!)
4 Air pressure ON - Start lock
Air pressure, combustion pressure -
20
Start lock
68 Air pressure, POC - Start lock
Air pressure, combustion pressure,
84
POC - Start lock
7 # Flame loss
0 Flame loss
3 Flame loss (software version £ V02.00)
The diagnosis corresponds to the time between fuel valve
Flame loss with TÜV test (flame loss
3...255 disabling and flame loss acknowledgement (0.2 second
test)
resolution ® Value 5 = 1 second).
12 # Leak check
Through the leak check X5-01 (minimum pressure switch)
-Check if the burner side valve leaks
The fuel valve 1 leaks (fuel valve 2
0 -Check if the pressure switch for leak check is closed when there
with leak check through X5-01)
is gas pressure
-Check the wiring to exclude short circuits
Through the leak check X5-01 (minimum pressure switch)
The fuel valve 2 leaks (fuel valve 1
1 -Check if the burner side valve leaks
with leak check through X5-01)
The leak check is active, but the minimum pressure switch is
2 The leak check cannot be performed selected as input function for X9-04 (check parameters 238 and
241).
The leak check is active, but it is not assigned to any input (check
3 The leak check cannot be performed
parameters 236 and 237).
The leak check is active, but 2 inputs are assigned (set parameter
237 on max. pressure switch or POC).
The leak check is active, but 2 inputs are assigned (check
parameters 236 and 237).
Check if the gas side valve leaks. Check the wiring to exclude
81 V1 leaks
interruptions.
Check if the burner side valve leaks.
83 V2 leaks Check if the pressure switch for leak check is closed when there
is gas pressure. Check the wiring to exclude short circuits.
20 # Min gas pressure switch
0 No minimum gas pressure Check the wiring to exclude interruptions.
1 No gas - Start lock Check the wiring to exclude interruptions.
22 OFF S # Safety circuit
0 Safety circuit
Minimum pressure switch (Pmin) /
23 #
fuel oil immediate start
0 No minimum gas pressure Check the wiring to exclude interruptions (X5-01).
1 No gas - Start lock Check the wiring to exclude interruptions (X5-01).
Check wiring to exclude interruptions (X9-04). Check oil pre
2 Fuel oil immediate start
heating function.
240 # Internal error Unlock, if it occurs again replace the appliance.
Appendixes for Technical Personnel 71

(Loc. "c") (Loc. "d") Diagn.
Cause Possible remedy
Err.Code Code
60 0 External error: no valid feeding source Unlock, if it occurs again replace the appliance.
Ratio internal error: position
70 #
calculation in modulation
23 Feeding not valid No valid feeding.
26 Curve points not defined Set all curve points for all actuators.
71 # Specific position not defined
0 Rest position Parametrise the rest position for all the used actuators.
1 Pre-ventilation position Parametrise the pre-ventilation position for all the used actuators.
2 Post-ventilation position Parametrise the post-ventilation position for all the used actuators.
3 Ignition position Parametrise the ignition position for all the used actuators.
72 # Ratio internal error Unlock, if it occurs again replace the appliance.
Ratio internal error: position
73 #
calculation in stages
23 Feeding not valid No valid feeding.
26 Curve points not defined Set all curve points for all actuators.
Ratio internal error: data matching
75 #
check
1 Current feeding not matching
2 Target feeding not matching
4 Target positions not matching
It can be caused by different rpm values standardised with activated frequency
16 Different positions reached converter (i.e. after a dataset restore).
Repeat the standardisation and check ratio setting.
76 # Ratio internal error Unlock, if it occurs again replace the appliance.
The appliance could not adjust the rpm difference due to an adjustment limit.
The appliance is not standardised for this motor. Repeat the standardisation.
Warning! Check ratio setting .
The gas train times of the frequency converter are not set with a duration lower
than the gas trains of the appliance (parameter: 522, 523) or wrong setting of the
Limitation of frequency converter operating gas train during modulation (parameter 544).
80 #
adjustment range Frequency converter characteristic is not linear. The input (voltage) configuration
on the frequency converter must be equal to that of the appliance (parameter
645).
The frequency converter does not follow appliance changes fast enough. Check
frequency converter setting (inlet filter, sliding compensation, disabling of several
rpms).
1 Limitation of lower adjustment range The rpm value of the frequency converter was too high.
Bit 0 A line interruption on the actuator connections has been acknowledged. Check
Line interruption
Significance 1 wiring (voltage X54 across pin 5 or 6 and pin 2 >0.5 V).
Check the position difference between basic point and setting of the operating
gas train in modulation (parameter 544).
Operating gas train in 32 s modulation. The slope of the curve must be max. 31°
Bit 3 Too steep curve compared to gas (15° with SQM33.6 or 9° with SQM33.7) of position change between 2 basic points
Significance ≥ 8 train speed in modulation operating mode.
Operating gas train in 64 s modulation. The slope of the curve must be max. 62°
(30° with SQM33.6 or 18° with SQM33.7) of position change between 2 basic
points in modulation operating mode.

(Loc. "c")
Err.Code
2 Limitation of upper adjustment range The rpm value of the frequency converter was too low.
84 # Actuator curve steepness
Check the rpm difference between basic point and setting of the
operating gas train in modulation (parameter 544).
Operating gas train in 32 second modulation. Slope of the curve
maximum 10% with gas train LMV37.4 of 20 seconds (20% with
10 seconds or 40% with 5 seconds).
Operating gas train in 48 second modulation. Slope of the curve
Bit 0 Frequency converter: curve too steep 15 seconds or 30% with 10 seconds).
Significance 1 compared to gas train speed Operating gas train in 64 second modulation. Slope of the curve
20 seconds or 40% with 10 seconds). Between the ignition point
(P0) and the low flame (P1), the variation of the rpm value in
modulation can be 40%, independent of the LMV gas train.
The gas train of the frequency converter must be set approx.
20% faster than the gas trains of the appliance (parameter: 522,
523).
Check the position difference between basic point and setting of
the operating gas train in modulation (parameter 544).
Operating gas train in 32 s modulation. The slope of the curve
must be max. 31° (15° with SQM33.6 or 9° with SQM33.7)
Bit 1 Fuel operation: too steep curve of position change between 2 basic points in modulation
Significance 2-3 compared to gas train speed operating mode.
of position change between 2 basic points in modulation
operating mode.
Bit 2 Air drive: too steep curve compared of position change between 2 basic points in modulation
Significance 4-7 to gas train speed operating mode.
operating mode.
85 # Reference error of an actuator
Fuel drive referencing not successfully completed. The reference
point could not be reached.
0 Reference error of a fuel drive -Check the setting of the type of drive (parameter 613.0 or 614)
-Check if the actuator have been mixed up.
-Check whether the actuator is stuck or overloaded.
Air drive referencing not successfully completed. The reference
point could not be reached.
1 Reference error of the air drive -Check the setting of the type of drive (parameter 613.1).
-Check if the actuator have been mixed up.
-Check whether the actuator is stuck or overloaded.
The parametrisation of an actuator (i.e. status of the reference
Bit 7
Reference error for parameter editing position) has been edited. This error is generated to provoke a
Significance ≥ 128
new referencing.
#
86 # Fuel drive error
The requested position could not be reached within the defined
0 Position error
tolerance. Check whether the actuator is stuck or overloaded.

(Loc. "c")
Err.Code
A line interruption on the actuator connections has been
Bit 0
Line interruption acknowledged. Check wiring (voltage X54 across pin 5 or 6 and
Significance 1
pin 2 >0.5 V).
Bit 3 Too steep curve compared to gas of position change between 2 basic points in modulation
Significance ≥ 8 train speed operating mode.
operating mode.
The actuator has been overloaded or mechanically bent.
Bit 4 Discrepancy compared to the last Check the setting of the type of drive (parameter 613.0 or 614).
Significance ≤ 16 referencing Check if the actuator gets stuck in a point of the operating range.
Check whether the torque for the application is enough.
87 # Air drive error
The requested position could not be reached within the defined
0 Position error
tolerance. Check whether the actuator is stuck or overloaded.
A line interruption on the actuator connections has been
Bit 0
Line interruption acknowledged. Check wiring (voltage X53 across pin 5 or 6 and
Significance 1
pin 2 >0.5 V).
Bit 3 Too steep curve compared to gas of position change between 2 basic points in modulation
Significance ≥ 8 train speed operating mode.
operating mode.
The actuator has been overloaded or mechanically bent.
Bit 4 Discrepancy compared to the last Check the setting of the type of drive (parameter 613.1).
Significance ≥ 16 referencing Check if the actuator gets stuck in a point of the operating range.
Check whether the torque for the application is enough.
90 # Appliance internal error
91 # Appliance internal error
93 # Flame signal detection error
Short circuit on QRB
3 Detector short circuit Check wiring.
Possible fault of the flame detector.
95 # Relay monitoring error
3 = ignition transformer
4 = fuel valve 1
Operation contact external supply Check wiring.
5 = fuel valve 2
6 = fuel valve 3
Measure contacts:
Powered appliance: the fan output must not be powered.
Disconnect the electrical power: disconnect the fan. No ohmic
4 = fuel valve 1
Welded relay connection shall be present between fan output and N.
5 = fuel valve 2
If one of the two tests is not successfully completed, replace the
6 = fuel valve 3
appliance: contacts are welded and their safety can no longer be
ensured.
Measure contacts:
Powered appliance: the fan output must not be powered
Disconnect the electrical power: disconnect the fan. No ohmic
Welded safety relay or supply outside
0 connection shall be present between fan output and N.
the safety relay
If one of the two tests is not successfully completed, replace the
appliance: contacts are welded and their safety can no longer be
ensured.
2 = safety valve
4 = fuel valve 1 The relay is not activated Unlock, if it occurs again replace the appliance.
5 = fuel valve 2
6 = fuel valve 3

(Loc. "c")
Err.Code
99 # Relay operation internal error Unlock, if it occurs again replace the appliance.
Unlock, if it occurs again replace the appliance.
Software version V03.10: with error C:99 D:3 during a
3 Relay operation internal error standardisation of the frequency converter, temporarily disable
the Alarm function in case of start lock (parameter 210 = 0, using
an enabling contact) or interrupt the ON controller signal.
100 # Relay operation internal error Unlock, if it occurs again replace the appliance.
105 # Contact inquiry internal error
0 = min. pressure switch
1 = max / POC pressure switch
2 = pressure switch sealing check
3 = air pressure
4 = feed controller OFF
5 = feed controller ON / OFF
It can be caused by a capacity load or by direct current supply
6 = feed controller CLOSED
"Stuck At" error on the mains voltage inputs. The inlet where the problem
7 = safety circuit / burner flange
occurred is indicated in the diagnosis code.
8 = safety valve
9 = fuel valve 1 ignition transformer
10 = 1 ignition transformer
11 = fuel valve 2
12 = fuel valve 3
13 = unlock
106 # Contact inquiry internal error Unlock, if it occurs again replace the appliance.
110 # Voltage switch test internal error Unlock, if it occurs again replace the appliance.
# Mains voltage too low.
Diagnosis code calculation factor; electrical power value (AC 230
111 # Mains undervoltage
V: 1.683; AC 120 V: 0.843).
112 0 Mains voltage restore Error code to provoke a reset to resume mains voltage (no error).
Mains voltage monitoring internal
113 # Unlock, if it occurs again replace the appliance.
error
115 # System meter internal error
Designed liftetime exceeded (250,000 The warning threshold has been reached. The appliance must
116 0
cycles) be replaced.
Lifetime exceeded
117 0 The turning off threshold has been reached.
Operation no longer reliable
Fuel meter input interruption Too many interference pulses at fuel meter inlet. Improve the
120 0
limitation EMF measures.
Unlock, repeat / check the last parametrisation, restore the
121 # EEPROM access internal error
dataset, if it occurs again replace the appliance.
dataset, if it occurs again replace the appliance
Unlock, repeat / check the last parametrisation, if it occurs again
125 # EEPROM reading access internal error
replace the appliance.
Unlock, repeat / check the last parametrisation, if it occurs again
126 # EEPROM writing access internal error
replace the appliance.
EEPROM access internal error –
128 0 Unlock, if it occurs again replace the appliance.
Initialisation synchronisation
EEPROM access internal error – Task Unlock, repeat / check the last parametrisation, if it occurs again
129 #
synchronisation replace the appliance.
EEPROM access internal error – Time- Unlock, repeat / check the last parametrisation, if it occurs again
130 #
out replace the appliance.

(Loc. "c")
Err.Code
EEPROM access internal error – Page Unlock, repeat / check the last parametrisation, if it occurs again
131 #
on Abort replace the appliance.
EEPROM register initialisation internal
132 # Unlock, if it occurs again replace the appliance.
error
133 #
134 #
135 #
136 # Restore
A backup restore has been started (no error). In a new appliance,
1 Restore started
after the restore an unlock is requested!
For other diagnosis codes on error
# For the measures, refer to error code 137.
code 136, refer to error code 137
137 # Internal error – Backup / Restore
Restore – OK, but the backup size is
Restore successfully completed, but the backup dataset is
157 (-99) lower than the dataset of the current
smaller than that in the current system.
system
Backup – error in backup saving in
239 (-17) Unlock, repeat the backup.
AZL2
240 (-16) Restore – no backup available in AZL2 No backup in AZL2.
Restore – cancellation for unsuitable The backup does not have a suitable ASN and must not be run
241 (-15)
ASN on the appliance.
Backup – the generated backup is not
242 (-14) The backup is wrong and cannot be restored.
consistent
Backup – data comparison between
wrong µCs
The backup data are not compatible with the current software
244 (-12) The backup data are incompatible
version, the restore is not possible.
Access error to parameter Restore_
245 (-11) Unlock, repeat the restore.
Complete
Restore – time-out during saving on
EEPROM
247 (-9) The received data are not consistent The backup dataset is not valid, restore not possible.
The restore cannot be run at this
moment
Restore – cancellation for unsuitable The backup does not have a suitable burner identification and
249 (-7)
burner identification must not be run on the appliance.
Backup – the CRC of a page does not
250 (-6) The backup dataset is not valid, restore not possible.
match
Backup – the burner identification is
251 (-5) Define a burner identification and repeat the backup.
not defined
After the restore, there are still pages
on ABORT
The restore cannot be run at this
moment
254 (-2) Cancellation for error transmission Unlock, repeat the backup.
Cancellation for time-out during
255 (-1) Unlock, check the connections and repeat the backup.
restore
Building automation interface time-
146 # See user's documents of Modbus A7541.
out
1 Modbus time-out
150 # TÜV test
1 (-1) Invalid phase TÜV test can be started only in phase 60 (operation).
The default load of the TÜV test cannot be smaller than the
2 (-2) TÜV test default load too small
lower load threshold.
The default load of the TÜV test cannot be bigger than the lower
3 (-3) TÜV test default load too big
load threshold.
4 (-4) Manual cancellation No error: manual cancellation of the TÜV test by the user.
No flame loss after the disabling of fuel valves:
-Check the extraneous light
5 (-5) TÜV test time-out
-Check valve tightness

(Loc. "c")
Err.Code
No flame loss after the disabling of fuel valves:
-Check the extraneous light
5 (-5) TÜV test time-out
-Check valve tightness
165 # Internal error
166 0 Watchdog internal error-reset
167 # Manual lock The appliance has been manually shut-off (no error).
1 Manual shut-off through contact
2 Manual shut-off through AZL2
3 Manual shut-off through PC software
During the setting of a curve with AZL2, menu use time-out
Manual shut-off through AZL2 time-
8 (setting with parameter 127) or communication interrupted
out / communication interruption
between LMV37.4 and AZL2.
Manual shut-off through the During the setting of a curve with ACS410, the communication
9 interruption of the PC software between LMV37.4 and ACS410 has been interrupted for more
communication than 30 seconds.
Manual shut-off after the unlock The PC software has attempted to unlock a system without
33
attempt of the PC software errors.
168 # Error management internal error Unlock, if it occurs again replace the appliance.
200 OFF # System without errors No error.
Start lock in an unparametrised. In case of turning off during
201 OFF
# Start lock the first curve setting, the original cause of the error must be
Upr
detected through the error log, item 702.
Bit 0
No selected operating mode
Significance 1
Bit 1
No defined fuel gas train
Significance 2-3
Bit 2
No defined curve
Significance 4-7
Bit 3
Standard rpm not defined
Significance 8-15
Bit 4
The backup / restore could not be run
Significance 16-31
Internal error for operating mode
202 # Re-define the operating mode (parameter 201).
setting
Re-define the operating mode (parameter 201). Unlock, if it
203 # Internal error
occurs again replace the appliance.
204 Phase number Programme stop Active programme stop (no error).
#
Device combination not allowed
206 0
(appliance AZL2)
Appliance version compatibility –
207 #
AZL2
0 The version of the appliance is too old
1 AZL2 version too old
The selected operating mode is not
210 0 Select an operating mode enabled for the appliance.
enabled for the appliance

ICI CALDAIE SpA
37059 Fraz. Campagnola di Zevio ( Verona) Italy
Via G. Pascoli 38 Phone: +39 0458738511 Fax:+39 0458731148
[email protected] www.icicaldaie.com

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EN

Steam generating unit with integrated burner

INSTALLATION, USE AND MAINTENANCE MANUAL

ECOVAPOR_350_3000_EN Ed. 01 - 03/2019

General information 47 Gas train assembling

The documentation supplied with the generator is:

ICI CALDAIE S.p.A.

CATEGORIA CLASSE FLUIDO COMBUSTIBILE

ICI Caldaie SpA Via G. Pascoli, 38 37059

Fluid: WATER Volume: 2,3 L

1 Door locking system 11 Front door

1 Pressure gauge 17 Rear smoke chamber

WP01 OPTIONAL for GSS24

First letter Succeeding letters

SAFETY COMPONENT CALIBRATIONS

Hereinafter are the descriptions of the operation of each single component.

NOTE: Clamp at no more than 1 m Typical suggested diagram

SAFETY PRESSURE SWITCH

AIR/GAS MIXING SYSTEM

In sizes from 1700 to 3000, burner is ignited by the flame.

FLUE GAS SUCTION

A B ELECTRONIC IGNITION - Models 350 - 1350

A B PILOT FLAME IGNITION - Models 1700 - 3000

HMR High modulation range

FAILURE UPON IGNITION

FAILURE DURING STANDARD OPERATION

1 Connectors for electrical connections Internal components

Adjustment and control system 23

24 Adjustment and control system

1 Selection key of the ACCESS LEVELS

1 Level USER (for User)

To select the desired access level, proceed as follows:

Adjustment and control system 25

Menu access keys

26 Adjustment and control system

Adjustment and control system 27

To edit generator settings, proceed as follows:

–– touch the desired item (i.e. ”Language”) to display the page

28 Adjustment and control system

Adjustment and control system 29

30 Adjustment and control system

ACCESS PATH: → DISPLAY - DATE - TIME

ACCESS PATH: → GENERAL CONFIGURATION

ACCESS PATH: → ModBus

Adjustment and control system 31

32 Adjustment and control system

ACCESS PATH: → OUTLET STATUS

Adjustment and control system 33

ACCESS PATH: → DATA AND METERS

34 Adjustment and control system

Adjustment and control system 35

36 Adjustment and control system

GENERATOR PARAMETER MENU

ACCESS PATH: → BURNER SETTINGS

Adjustment and control system 37

ACCESS PATH: → FEED PUMPS

38 Adjustment and control system

ACCESS PATH: → TDS

Adjustment and control system 39

SERVICE PARAMETER MENU

() A ≥ P2 (see "Size and fittings)