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Installation

HANDLING

ATTENTION

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.

ATTENTION

–

Do not expose the packed product to direct sunlight.

FILM REMOVAL

The boilers can feature the following types of protective films:

ATTENTION

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.

Содержание ECOVAPOR Series

Страница 1: ...ECOVAPOR_350_3000_EN Ed 01 03 2019 EN Steam generating unit with integrated burner ECOVAPOR INSTALLATION USE AND MAINTENANCE MANUAL...

Страница 2: ...nt opening on the right 49 Turbulator assembly 49 Electrical connections First commissioning 50 Preliminary activities to be carried out before the first commissioning 50 Hydrostatic head diagram 51 W...

Страница 3: ...ore require particular caution and adequate preparation d IT IS FORBIDDEN To indicate operations that SHOULD NOT be performed m IMPORTANT To indicate particularly useful information and important The...

Страница 4: ...KG H 12 BAR 86441700 ECOVAPOR 2000 _ECS24 BOILER 2000 KG H 12 BAR 86442000 ECOVAPOR 2500 _ECS24 BOILER 2500 KG H 12 BAR 86442500 ECOVAPOR 3000 _ECS24 BOILER 3000 KG H 12 BAR 86443000 Models for 72 h...

Страница 5: ...rly 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...

Страница 6: ...ure 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...

Страница 7: ...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 b...

Страница 8: ...of the energy saver and is riveted on a special support To access it remove the fastening nuts and slide out the panel 1 2 Via G Pascoli 38 Fraz Campagnola 37059 ZEVIO VR ITALY FLUID GROUP CLASSE FLU...

Страница 9: ...r 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...

Страница 10: ...d safety valve optional 13 First safety valve 14 First safety valve drain 15 Chimney fitting 16 Fan 17 Rear smoke chamber 18 Energy saver 19 Sludge separator pneumatic drain valve optional for version...

Страница 11: ...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 171...

Страница 12: ...36x2000 48x2400 48x2400 tb 1 mm 20 26 30 40 40 58 64 72 74 74 1 Tb Turbulators size and quantity Hydraulic fittings Description u m ECOVAPOR 350 500 650 800 1000 1350 1700 2000 2500 3000 N1 DN in 32 3...

Страница 13: ...SV OV SV BE 124 124 BAL STOP BU01 I STOP BU01 125a 125b STOP BU01 from PSL127 PC126 BE124 PSL113 and from PSH104 LYLL107 LYLL108 CAH120 I Ratio signal from PFC103 I ON OFF from PIC103 I AIR Mixer EK1...

Страница 14: ...ser s choice User s choice User s choice User s choice User s choice User s choice User s choice User s choice User s choice Control Differential Voltage Sensor Primary element Flow rate Ratio Fractio...

Страница 15: ...sion 2180 2180 2550 2550 3240 3690 4400 5250 5920 6320 1 80 C treated water feed temperature SAFETY COMPONENT CALIBRATIONS The components listed below are adjusted at the indicated pressure values saf...

Страница 16: ...regulatedbyspecificnationalandinternationalstandards thereforetheyaresized tested installedandmaintained in compliance with the applicable regulations and the contents of this manual The use and maint...

Страница 17: ...side 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 PS...

Страница 18: ...nsducer 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 t...

Страница 19: ...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 COMB...

Страница 20: ...channel flange gasket 4 Inverterjet head 5 Cone assembly 68 2 pcs ECOVAPOR 6 Air filter ECOVAPOR 350 500 e 1009 7 Double end nipple 1 x 150 two wire 25 Mm AISI316 8 Brahma high voltage transformer 9...

Страница 21: ...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 lim...

Страница 22: ...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 DURIN...

Страница 23: ...panel Open panel 6 7 4 3 1 2 5 9 10 11 12 8 14 18 13 17 16 15 1 Connectors for electrical connections 2 Emergency button SCRAM 3 Button for safety circuit opening 4 Muting of the acoustic signal and...

Страница 24: ...late ECS hABCDEFGH ECS Name of the control panel h Hours without continuous supervision ECS24 or ECS72 A A Burner fan 1 3 kW 2 5 5 kW B Pump size 1 1 5 kW 2 2 2 kW C Number of pumps 1 or 2 D Sludge dr...

Страница 25: ...e main page with USER access level will be displayed 1 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...

Страница 26: ...o 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 c...

Страница 27: ...ION 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 i...

Страница 28: ...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 co...

Страница 29: ...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 b...

Страница 30: ...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 arr...

Страница 31: ...led 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 e...

Страница 32: ...If the pump flow pressure probe is enabled 08 19 Pump flow pressure value at 20 mA SERVICE SERVICE If the pump flow pressure probe is enabled 08 20 Pump flow pressure offset SERVICE SERVICE If the pum...

Страница 33: ...ade 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...

Страница 34: ...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 12 23 Fan inve...

Страница 35: ...absorbed current A USER Only if the relevant ModBus meter is enabled 17 03 Total absorbed power W USER Only if the relevant ModBus meter is enabled 18 02 Pump 1 speed RPM USER Only if the Pump 1 ModB...

Страница 36: ...E 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...

Страница 37: ...l the burner stops 0 1 2 0 Bar 0 5 USER USER ALWAYS 02 24 Ignition differential When the measured pressure reaches the setpoint parameter 02 10 less this differential the burner starts again 0 1 2 0 B...

Страница 38: ...ter available only if two pumps are present Pump 1 Pump 2 Automatic Switching Pump 1 USER USER With second pump 04 02 Switching time This parameter is active if pump automatic switching has been selec...

Страница 39: ...easurement Default Reading Writing Visibility 07 03 TDS alarm threshold TDS level above which burner is stopped and the relevant alarm is triggered 0 6000 S 6000 USER USER If the TDS sensor is enabled...

Страница 40: ...cond 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 Alway...

Страница 41: ...0050 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...

Страница 42: ...LARM 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 ALA...

Страница 43: ...d 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...

Страница 44: ...appliance using the provided lifting eyebolts a a a a ATTENTION Do not expose the packed product to direct sunlight FILM REMOVAL The boilers can feature the following types of protective films a ATTEN...

Страница 45: ...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 insta...

Страница 46: ...naphtha Compressed air air pressure must range between 4 and 10 bar The air must be filtered with a 25 m mesh m IMPORTANT It is recommended to insulate system pipes to avoid heat losses and a higher f...

Страница 47: ...2 1 1 2 Shutteropening A mm 8 10 5 21 7 Fromtotallyclosedshutter number of turns 4 4 1 2 9 1 2 Fromtotallyopenshutter number of turns 5 1 2 9 4 Total number of turns 9 1 2 13 1 2 13 1 2 To assemble t...

Страница 48: ...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...

Страница 49: ...n 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...

Страница 50: ...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 c...

Страница 51: ...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 th...

Страница 52: ...od 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 ins...

Страница 53: ...ice 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 h...

Страница 54: ...ppliance 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...

Страница 55: ...0 60 30 70 PilotFlamePressure START mbar 15 35 CombustionHead p 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...

Страница 56: ...rator 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 cor...

Страница 57: ...fire 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 insi...

Страница 58: ...tors 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 protecti...

Страница 59: ...te on the sludge drain valve m IMPORTANT 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 che...

Страница 60: ...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...

Страница 61: ...permanently replace the faulty relay Level adjustment probes short circuit Disassemble the adjustment probes to visually check the ceramic insulation Pump cavitation Head height difference between the...

Страница 62: ...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 ECO...

Страница 63: ...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 gener...

Страница 64: ...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 towa...

Страница 65: ...olled 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 bet...

Страница 66: ...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 accele...

Страница 67: ...nt 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 b...

Страница 68: ...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...

Страница 69: ...signal 0 OFF Permitted input signal 1 ON or 0 OFF Input output signal 1 ON Cannot be modified Factory setting Can be modified on site 30s DECOMMISSIONING 10 s 10 s 3 s 3 s 30 s Air pressure switch ena...

Страница 70: ...tted input signal 1 ON or 0 OFF Input output signal 1 ON Cannot be modified Factory setting Can be modified on site 30s DECOMMISSIONING POST VENTILATION 10 s 10 s 3 s 3 s 30 s Air pressure switch enab...

Страница 71: ...leak check X5 01 minimum pressure switch Check if the burner side valve leaks Check the wiring to exclude short circuits 2 The leak check cannot be performed The leak check is active but the minimum p...

Страница 72: ...sed with activated frequency 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 80 Limitat...

Страница 73: ...3 6 or 18 with SQM33 7 of position change between 2 basic points in modulation operating mode Bit 2 Significance 4 7 Air drive too steep curve compared to gas train speed Check the position difference...

Страница 74: ...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 Bit 4 Significance 16 Discr...

Страница 75: ...again replace the appliance 115 System meter internal error 116 0 Designed liftetime exceeded 250 000 cycles The warning threshold has been reached The appliance must be replaced 117 0 Lifetime excee...

Страница 76: ...urrent software version the restore is not possible 245 11 Access error to parameter Restore_ Complete Unlock repeat the restore 246 10 Restore time out during saving on EEPROM Unlock repeat the resto...

Страница 77: ...agement internal error Unlock if it occurs again replace the appliance 200 OFF System without errors No error 201 OFF Upr Start lock Start lock in an unparametrised In case of turning off during the f...

Страница 78: ...Appendixes for Technical Personnel 78...

Страница 79: ...Appendixes for Technical Personnel 79...

Страница 80: ...ICI CALDAIE SpA 37059 Fraz Campagnola di Zevio Verona Italy Via G Pascoli 38 Phone 39 0458738511 Fax 39 0458731148 info icicaldaie com www icicaldaie com...

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