Technical manual
Contents
1. TECHNICAL MANUAL INSTALLATION USE AND MAINTENANCE INSTRUCTIONS STEAM BOILER 1 Dear Customer Thank you for choosing a boiler by IVAR In your interest and to maintain the highest level of performance and duration of your appliance we recommend that you follow the instructions contained in this booklet and have regular maintenance performed by qualified personnel We would like to remind you that failure to follow the instructions contained in this booklet may invalidate the guarantee CONTENTS page 4 GENERAL WARNINGS page 5 GENERAL SAFETY RULES page 6 GV BOILER TECHNICAL SHEET page 7 GVO BOILER TECHNICAL SHEET page 8 HANDLING AND POSITIONING page 9 PLANT TYPE page 10 STARTING UP OF THE BOILER page 10 STOP UP OF THE BOILER page 10 ONCE A WEEK page 11 FAULTS AND REMEDIES page 12 BOILER HOUSE page 13 BOILER CONNECTION page 15 ELECTRIC PANEL page 16 RECOMMENDED SPARE PARTS GENERAL WARNINGS This instruction booklet is an integral and essential part of the product Should the appliance be sold or transferred to another owner or if you move and leave the appliance behind always ensure that this booklet accompanies the appliance so that the new owner and or installation technician can consult it This appliance must be used for the purpose for which it was specifically intended All contractual or non contractual r2. boiler 2 water pump 3 electric engine 4 water pressure switch 5 water manometer 6 flame spy 7 water flowmeter 8 counterwash valve 9 regulat pressure switch 10 max pressure switch 11 safety pressure switch 12 steam thermostat 13 steam valve 14 safety valve 15 start valve discharge 16 softener 17 salt tank 18 dosing pump 19 water tank 20 steam collector 21 stop valves 22 steam trap 23 steam output H pump water level 25 water to tank 26 hard water 27 filter 28 discharges 29 safety discharge 30 condensate return 32 burner 33 no return valve 34 air discharge 35 tank discharge 36 smoke side discharge A STARTING UP OF THE BOILER A1 Check the hardness of the water max 0 5 F A2 Open drain valve 15 A3 Shut off the delivery valve 13 A4 AB Switch on the main switch on the electrical panel Switch on the pump switch on MANUALE Wait the water flows by the drain valve A6 Switch on the burner switch A7 Switch on the pump switch on AUTOMATI CO Wait steam mixed with water flows by the drain valve A8 Close slowly the drain valve and contemporary open slowly the delivery valve B STOP OF THE BOILER B1 B2 B3 B4 Switch off the burner switch Open the drain valve Close the de
3. ENGINE 9 STEAM SAFETY PRESSURE SWITCH 16 START VALVE DISCHARGE 3 WATER FLOWMETER 10 BURNER 17 STEAM TRAP 4 PANEL 11 STEAM DELIVERY 18 FLAME SPY 5 STEAM REGUL PRESSURE SWITCH 12 MANOMETER COCK 19 CONDENSATE DISCHARGE VALVE 6 STEAM MAX PRESSURE SWITCH 13 SAFETY VALVE 20 SMOKE SIDE CLEANING VALVE 7 STEAM MANOMETER 14 WATER PRESSURE SWITCH 21 COUNTERWASH VALVE Nominal capacity 1200000 1500000 1800000 1 kcal h 133350 300000 500000 666700 1000000 1333350 1666700 2000000 Furnace pressure 2 3 3 152 6 8 1 85 s5_ Steam production ei s Do z000 2500 2000 Electric pump stadi oe Tarona cS mmf 1250 1500 2000 2400 2650 3000 3300 3800 881189 11589 139 1 190 1 1606 100 169 1691 Furnace capacity Dimensions mm 200 220 220 220 330 330 400 400 Steam outer connection __DN _32_ 40 40 50 65 so f wo 10 Stack connection mm 120 160 250 350 350 450 450 Empty weight kg 700 1400 1700 2000 2500 3000 3200 3600 10 bar I VAR INDUSTRY reserves the right to make any modifications considered necessary for improving production HANDLING AND POSITIONING For the lifting of the generators GVO please see the diagram below GVO L min 200 900 450 1100 750 1400 1000 1700 1500 1900 2000 2200 2500 2300 3000 2750 PLANT TYPE 1 GVO
4. LES The use of any component utilising energy power fuels and water requires that certain fundamental rules be respected such as Do not allow children or unskilled people to use the appliance If you notice smell of gas do not turn on electric switches household appliances telephone or any other objects that could cause sparks If this is the case open doors and windows immediately to clear the air in the room turn off the fuel taps contact professional qualified personnel Do not touch the appliance with wet or damp parts of the body and or with bare feet Do not perform any maintenance and cleaning operations without having disconnected the electric power and turned off the fuel supply tap s Do not pull disconnect unwind electric cables coming from the boiler even if they are disconnected from the mains supply Do not block or reduce the ventilation openings in the room to prevent the formation or toxic and explosive mixtures caused by gas leakage it is also uneconomic and polluting because it causes bad combustion Do not expose the appliance to atmospheric agents The generator has not been designed to work outdoors and is not provided with automatic anti freezing systems Keep the boiler turned on in freezing conditions Other important warnings to be respected the power cable of the appliance is damaged have it replaced by professionally qualified personnel do not fix and do not allow o
5. askets Change them if necessary see water pump instructions b Defect on fuel side Contact the burner service manual CHIMNEY BLOCK The burner goes out The chimney block lamp up on the control panel To start burner again press the reconnection push button on the thermostat The chimney block indicates that the boiler is dirty Clean the boiler with a pressure water jet and drain from plug Note The action of the safety equipment flow switch steam block chimney block causes stoppage of the burner flame The limit block lamp lights up on control panel To resume the operation press limit release push button BOILER HOUSE A boiler house is generally made up of the following equipment 1 The steam boiler itself complete with burner 2 Water conditioning plant generally composed of a water softener with change of bases and possibly a mattering unit for conditioning products 3 Purified water and condensate collecting tank having a capacity at least one and half times the hourly steam output of the generator 4 Steam collector header and distributor 5 Connection pipes between the single parts The boiler house dimension must be such as to guarantee an easy access to the various part means that the boiler operation can be checked and kept under control a bad access means negligence leading to probable breakdowns due to carelessness The boiler room has to be ventilated and must the
6. esponsibility of the manufacturer is excluded in the event of damages to persons animals or things caused by errors in installation adjustment maintenance and improper use The manufacturer s responsibility is excluded for all damage to persons and or things resulting from a clear risk for the user which he could have avoided by taking suitable safety measures After having removed the packaging check the contents for breakages If you are in doubt do not use the appliance contact your supplier Do not leave the packaging materials wooden cage nails staples plastic bags polystyrene foam etc within the reach of children as they are potential sources of risk The installation must be performed in compliance with the regulations in force following the manufacturer s instructions by professionally qualified personnel The term professionally qualified personnel means persons with specific technical skills in the sector of steam systems To guarantee the efficiency of the appliance and ensure correct operation it is indispensable to have regular maintenance performed by professionally qualified personnel following the manufacturer s instructions Any repairs to the appliance must be carried out using only original spare parts If you decide not to use the appliance for a long period ensure you have professionally qualified personnel to carry out the necessary operations to preserve the generator GENERAL SAFETY RU
7. ipings for light oil gas oil b pipings for heavy oil fuel oil pipings for gas Gas oil pipings The pipings conveying oil from the tank to the pump and viceversa must be made with welded fittings for iron pipings and biconical fittings for copper ones Fuel oil pipings In this case it is always recommendable to prepare a plant having the day fuel tank located in the boiler room and the transfer pump between this and the storage tank The day fuel tank must be complete with electric and steam preheater where possible and convenient the piping from the day fuel tank to the burner pump must be insulated and in the event of heavy fuel oil wound with a heat tape Special instructions should be requested case by case Gas pipings Connect the maingas network to the burner For town gas it is advisable to provide a pressure stabiliser CHIMNEY The chimney is usually made of a sheet steel piping of suitable diameter which must be taken from the boiler flange to the outside of the room over the top of the roof When its height exceeds 12 meter a draught equaliser should be provided at the base Should several boilers be connected to one chimney it is important to make sure that exhausts do not interfere with each other STEAM The steam pipings must have an appropriate diameter PN 16 valves are always used The pipes must be insulated and the header must be provided with a steam trap EXHAUSTS Connect the exhausts to the tra
8. lack of fuel delivery 3 Chimney block lights out This indicates that the boiler is dirty on the fume side LIST RECOMMENDED SPARE PARTS WATER PUMP SAFETY DEVICE BOILER BURNER Suction valves Delivery valves Valves springs set Valves seat gaskets set Piston gaskets Lid gaskets Head gaskets Manometer in glycerine bath Thermometer with electric contacts Contacts for thermometer Steam pressure switch Water pressure switch Flow switch Octal relay Magnetic starter with over load and under voltage protection Type RT 124 thermostat Pilot lamps set Stop running switch Gaskets for door Inspection window Boiler inox diffuser Electrode set n 2 Nozzles set n 2 Milled disk Burner diffuser Photoresistence Gas oil pump Hydraulic jack Flame relay NOTES 2 GAEL LUUL LUULU 12 A S r l ILVAR INDUSTRY S r l Via S Pierino 4 Z A l 37060 Trevenzuolo VERONA Italy Telefono 045 6680082 Telefax 045 6680051 P IVA 02835480233 e mail info ivarindustry it Web site www ivarindustry it code ist GV GVO ing rev 00 18
9. livery valve Switch the pump switch on MANUALE xw es Wait the water flows by the drain valve B5 Switch off the main switch In this way the coil is full of water then in the best condition to avoid oxygen corrosion C ONCE A WEE Before of the operation described in B C1 Close the delivery valve The boiler will stop for max steam pressure C2 Switch off the burner switch and pump switch C3 Open the counterwash valve 8 so that the coil will be cleaned in the reverse direction FAULTS AND REMEDIES FLOW SWITCH BLOCK The burner goes out The flow switch block lamp lights up on the control panel This means lack of water Check the water level in the service tank STEAM BLOCK The burner goes out and steam temperature thermometer pointer exceeds 200 C The steam block lamp lights up on the control panel This means a capacity defect in the water pump or excessive fuel capacity in the burner pump a Water pump defect Check the pump capacity open valve 13 collect the outlet water in a bucket for 1 minute then weigh it and determine the pump Capacity in liters h The capacity must coincide with the steam output of the boiler E G a 1 000 Kg h boiler is equal to 16 7 litres Minute If the capacity is insufficient 1 remove the water pump bell check the suction and delivery valves and relevant seat Change them if necessary 2 open lid on the pump head and check the piston g
10. ps taking care to make suitable raisers to avoid sprays ELECTRIC LINES The electric lines are connected to the RST and N terminals of the boiler panel The cable section must be suitable to stand the installed electric power Check to ensure that the network voltage coincides with the one on the rating plate and the wiring diagram WARNING It is recommended to purge all the piping which have to be connected to the boiler to ensure that they do not contain any foreign bodies such as fragments of gaskets welding slag or anything else which might damage the generator equipment before finally connecting it to the boiler ELECTRIC PANEL The control switches with relevant pilot lamps are installed on this panel 1 Main switch in position 1 supplies voltage to the panel 2 The green pilot lamp signals that the panel is live 3 The red lamps signal defects in working of various circuits 4 The main switch in position 0 cuts off the current to the panel 5 The main switch in position 1 starts up the boiler TROUBLES SIGNALLED BY THE PANEL LAMPS AND REMEDIES TO BE TAKEN 1 Feed water block lights out The burner goes out lights up on the panel check whether there is water in the service tank Pump defect check the capacity in liters minute if capacity is insufficient remove the pump bell check gaskets and change them if necessary 2 Steam block lights out The burner goes out due to the
11. refore be provided with suitable openings to allow proper aeration We remind you that the burner combustion air fan is up to 3 000 m3 h of air for the larger models and for each generator and this air must be able to enter the boiler room without any difficulty 12 BOILER CONNECTION WATER CONNECTION The hard water reaches the conditioning plant This must be surrounded by dividing wall the floor should possibly be made in gres independent drain for backwashing the conditioner When the softened water leaves the conditioner it must then be forwarded to the purified water and condensate collecting tank The condensate tank especially if the water is at high temperature must have a minimum head of about 1 50 meters over the generator pump level 50 60 70 80 RELATION BETWEEN THE WATER TEMPERATURE AT THE PUMP AND HEAD NECESSARY TO AVOID THE CAVITATION The connection piping between the tank and boiler must have an adequate diameter Never make a rigid fitting between the boiler piping and pump Interpose m 0 30 of high temperature resisting flexible rubber hose Do not use elbows but bend pipes to avoid head loss A breather pipe should be applied to the condensate collecting tank and let through to the outside of the room to discharge the fumes It is recommendable for the water pipings and tank to be galvanised 13 FUEL CONNECTION see also burner instruction book These may be three types a p
12. ther persons to fix electric cables on the system pipes or near sources of heat ensure that the earthing cables of the appliance are not connected to the water system do not touch the hot parts of the system in particular the door and the smoke box as they normally remain hot even for some time after the appliance has been turned off In the event of a water leak turn off the system and contact exclusively professionally qualified personnel GV STEAM BOILER 12 bar type GV 125 200 300 400 550 700 Kw 87 139 209 278 383 488 Nominal capacity Kcal h 75000 120000 180000 240000 330000 420000 Kw 98 9 158 237 5 316 435 3 554 6 Furnace capacity Kcal h 85230 136400 204600 272750 375000 477300 Furnace pressure mbar 2 2 3 3 3 3 Steam production Kg h 125 200 300 400 550 700 Electric pump n 1 1 1 1 1 1 stadi 1 1 2 2 2 2 Water content dm 38 38 54 54 68 77 A mm 1250 1250 1350 1350 1350 1350 Dimensions B mm 800 800 900 900 900 900 mm 1500 1500 1500 1500 1500 1750 Steam oulet connection DN 32 32 40 40 40 40 Stack connection mm 5 115 160 160 160 160 Empty weight Kg 600 600 800 800 900 960 I VAR INDUSTRY reserves the right to make any modifications considered necessary for improving production GVO STEAM BOILER 12 bar 1 WATER PUMP 8 STEAM SAFETY THERMOSTAT 15 WATER MANOMETER 2 ELECTRIC
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