Unical BAHR'UNO, Instructions On Installation, Use And Maintenance

Page 1: ...BAHR UNO INSTRUCTIONS ON INSTALLATION USE AND MAINTENANCE ...

Page 2: ...at Output Temperatura max di esercizio C Max Working Temperature Potenza Termica al focolare kW Heat Input Temperatura min ammiss TSmin C Max Allowable Temperature Fluido Fluid Acqua Water Pressione di prova idrosta ca bar Hydraulic Test Pressure Produzione vapore kg h Steam Capacity Data di prova idrosta ca Hydraulic Test Date Superficie riscaldata m2 Hea ng Surface Massa di riempimento max kg Ma...

Page 3: ...ly conditions 17 3 4 Handling 17 3 5 Positioning in boiler room 18 3 6 Water features 19 3 7 Hydraulic connections 22 3 8 Pneumatic connection 22 3 9 Gas connection 23 3 10 Condensation drainage 23 3 11 Connection to the flue 24 3 12 Burner assembly 25 3 13 Furnace door adjustment opening closing 26 3 14 Electrical connections 27 3 15 Control panels 28 3 16 Commissioning 31 2 TECHNICAL FEATURES AN...

Page 4: ... the instruc tions described in this manual also any operation must be car ried out by professionally qualified and authorised personnel ATTENTION THE RUNNING OF THE STEAM GENERATOR MUST BE ASSIGNED TO QUALIFIED PER SONNEL AS DEFINED BY ITALIAN LEGISLA TIVE DECREE 1 MARCH 1974 IT IS STRICTLY FORBIDDEN FOR PERSONS NOT SPECIFICALLY ENABLED TO USE RUN MAINTENANCE THE GENERATOR ATTENTION Incorrect ins...

Page 5: ...ever activate lights or elec trical devices the territory as defined in art 6 of Italian Ministerial Decree of 1 December 2004 No 329 The user has the obligation to submit the steam generator to the periodic inspections of law provided for by the Italian Min isterial Decree of 1 December 2004 No 329 as foreseen by Annex B Table Internal visit and operation verification every 2 years Integrity chec...

Page 6: ... the boiler immediately In case of serious damage to the boiler or to the water supply tanks immediately inform the authorised inspection body be fore carrying out repairs Comply with the technical instructions An official authorisation is required to install and operate the steam generators that must be available before start up In the event of explosion the system user is obliged to imme diately...

Page 7: ... of control panel BASIC IMC or IML and relative ac cessories connected to them that can be connected BASIC control board composed of BASIC control panel including wiring pressure gauges probes burner power no 4 level probes min max safety no 2 probe holder flanges no 2 level indicators manifold with pressure gauge 3 way valve pressure switches 2 control 1 safety IMC control board composed of IMC c...

Page 8: ...inity control unit TDS 5 Supply pump s unit 6 Flow regulation pneumatic valve optional 7 Thermometer optional 8 Drain valve 9 Economiser optional 10 Smoke chamber 11 Safety valve 12 Steam intake valve 13 Manhole 14 Probe holder flange 15 Probe holder flange 16 Pressure gauge 17 Pressure switch 18 Insulating coating 19 Front door 20 Three way valve 21 Safety probe 22 Level probe ...

Page 9: ...g material towards the outside and a layer of refractory material towards the inside It is mounted on hinges that allow opening reversibility and complete adjustment 2 3 GENERAL FEATURES It is equipped with self cleaning flame warning light suitably positioned to control the correctness of combustion in opera tion on the same is bolted the burner coupling plate supplied blind can be prepared for t...

Page 10: ...630 1800 1800 1980 1980 2220 2220 2350 2350 2725 2725 C mm 725 725 725 815 815 880 880 945 945 1075 1075 1170 1170 1410 1410 Ø mm 219 219 219 219 219 258 258 358 358 408 408 408 408 508 508 Weight empty kg 1030 1030 1030 1330 1330 1630 1630 2130 2130 2740 2740 3360 3360 4650 4650 Weightin oper kg 1340 1340 1340 1898 1898 2444 2444 3290 3290 4403 4403 5500 5500 7620 7620 T1 DN 50 DN 50 DN 50 DN 65 ...

Page 11: ...m 1485 1485 1485 1630 1630 1800 1800 1980 1980 2220 2220 2350 2350 2725 2725 C mm 725 725 725 1167 1167 1266 1266 1379 1379 1417 1417 1482 1482 1677 1677 Ø mm 219 219 219 219 219 219 219 258 258 308 308 358 358 408 408 Weight empty kg 1100 1100 1100 1460 1460 1840 1840 2240 2240 3190 3190 3970 3970 5640 5640 Weight in oper kg 1420 1420 1420 2028 2028 2654 2654 3600 3600 4853 4853 6110 6110 8610 86...

Page 12: ...9 9 119 6 1545 1160 0 61 1 230 16 1 41 7 4 2 240 340 2 2 4 6 1250 838 942 1250 1 119 9 119 6 2250 1663 0 95 0 996 24 34 9 4 5 280 370 2 2 4 6 1500 1006 1130 1500 1 119 9 119 6 2250 1663 0 95 1 195 24 41 9 5 1 280 370 2 2 4 6 1750 1174 1319 1750 1 119 9 119 6 2890 2140 1 29 1 025 32 4 36 2 5 5 280 370 2 2 4 6 2000 1341 1507 2000 1 119 9 119 6 2890 2140 1 29 1 171 32 4 41 4 6 0 280 370 2 2 4 6 2500 ...

Page 13: ... 1 85 4 6 400 268 301 285 400 1 119 9 119 9 730 568 0 262 1 089 6 5 41 2 2 6 3 4 210 340 2 2 4 6 500 335 376 356 500 1 119 9 119 9 1040 814 0 367 0 968 10 33 5 2 8 3 6 240 340 2 2 4 6 600 402 452 428 600 1 119 9 119 9 1040 814 0 367 1 161 10 40 2 3 5 4 3 240 340 2 2 4 6 800 537 603 571 800 1 119 9 119 9 1545 1160 0 610 0 922 16 1 33 4 3 8 4 6 240 340 2 2 4 6 1000 671 754 714 1000 1 119 9 119 6 154...

Page 14: ...6 400 268 282 273 400 1 119 9 119 6 730 568 0 262 1 056 6 5 41 2 4 2 5 0 210 340 2 2 4 6 500 335 353 342 500 1 119 9 119 6 1040 814 0 367 1 126 10 33 5 4 5 5 3 240 340 2 2 4 6 600 402 423 410 600 1 119 9 119 6 1040 814 0 367 0 938 10 40 2 5 1 5 9 240 340 2 2 4 6 800 537 565 548 800 1 119 9 119 6 1545 1160 0 610 1 117 16 1 33 4 5 1 5 9 240 340 2 2 4 6 1000 671 706 685 1000 1 119 9 119 6 1545 1160 0...

Page 15: ...6 400 268 291 282 400 1 119 9 119 6 730 568 0 262 1 125 1 089 6 5 41 2 4 2 5 0 210 340 2 2 4 6 500 335 364 353 500 1 119 9 119 6 1040 814 0 367 0 999 0 968 10 33 5 4 5 5 3 240 340 2 2 4 6 600 402 437 423 600 1 119 9 119 6 1040 814 0 367 1 199 1 161 10 40 2 5 1 5 9 240 340 2 2 4 6 800 537 584 565 800 1 119 9 119 6 1545 1160 0 610 0 952 0 922 16 1 33 4 5 1 5 9 240 340 2 2 4 6 1000 671 729 706 1000 1...

Page 16: ...bserving all local and or national laws published in the official journal as well as applicable technical standards 3 INSTRUCTIONS FOR INSTALLATION 3 1 GENERAL WARNINGS ATTENTION The generator must be destined only to the use for which it has been expressly declared Any other use is to be considered improper and therefore dangerous This generator is used for the production of saturated steam at hi...

Page 17: ... the presence of turbulators and their correct position inside smoke pipes OR STD versions 3 4 HANDLING The BAHR UNO boilers are equipped with lifting eyebolts Pay attention when handling the boiler and use equipment suit able for its weight NOTE Normally the generators are supplied fully assembled In particular cases to avoid dam age during transportation or handling some units are supplied unass...

Page 18: ...parameter C and in any case never less than 1500 mm and it must be checked that with the door opened 90 the distance between the door and the adjacent wall is at least equal to the length of the burner b On the two sides of the generator 0 80 m reduced to 0 60 m if the generator is adjacent to a wall or to another generator and no accessory or control is provided in the passage c On the rear part ...

Page 19: ...pendingontheoperatingmode oraccordingtolocalregulations Record the measured values the top up water flow rate the consumption of chemicals and the necessary maintenance operations in the instruction manual in order to be able to always go back to the operating conditions WARNING Do not put water with a temperature below 60 C in the generator It is recommended to put feed water with an average temp...

Page 20: ... 50 500 10 100 M alkalinity ppm CaCO3 100 1000 100 750 10 250 Iron ppm Fe 0 1 0 1 0 1 Copper ppm CU 0 1 0 1 0 1 Silica ppm SiO2 See Figure 2 Phosphate ppm PO4 10 30 10 30 6 15 Deoxygenating agent ppm Excessive deoxygenating additive according to supplier s specifications Organic substances Not enough to cause traces foams or other problems Table 2 OPERATING WATER FOR STEAM GENERATORS a excluding c...

Page 21: ...er it is advisable to check the pH value the total hardness and alkalinity of the feed water and operating water every two days It is good practice especially in variable operating conditions to monthly subject a significant sample of the feed water and operating water to a full analysis It is also good practice to visually check the condensate returns for any highly polluting oily substances redu...

Page 22: ...izes of the pipes for each boiler model are given in para graph 2 3 DIMENSIONS Carry out the connection of the steam line of use to the valve making sure that the thermal expansions do not cause stresses on the same The drain of the safety valve must be con veyed to outside the boiler room made in such a way so as not to cause damage to people or property in case of steam dis charge The piping dia...

Page 23: ...ndensation drainage in the sewage must be implemented as to prevent releasing gaseous combustion products into the environment or sewage siphoning dimensioned and implemented to allow the correct outflow of liquid waste preventing any leakage installed in such a way as to prevent the liquid contained in it from freezing in the intended operating conditions mixed for example with household waste wa...

Page 24: ...rce it must have a section that is at least equal to the smoke outlet fitting of the generator with rigid conduits heat resistant resistant to condensation to mechanical stress hermetically sealed For the joints seal use materials resistant to at least 300 C ATTENTION The expulsion of exhaust gases must take place without affecting the safety of work ers or third parties Badly dimensioned and shap...

Page 25: ...ical AG Technical Service beforehand ATTENTION The BAHR UNO HPO HPO EC generators can operate with gas diesel oil and mixed gas gas oil burners The BAHR UNO HP HP EC steam generators can only operate with gas burners ATTENTION the flame sight glass can be very hot therefore pay the utmost attention Burner assembly diagram The burner must be installed according to the burner manufacturer s requirem...

Page 26: ...G The following adjustments can be made on the door A Adjustment in the vertical direction by acting on the nut of the upper hinge pin on which the door turns B Adjustment in the transverse direction loosen the hinges fixed on the front plate of the boiler and move them sideways C Adjustment in the axial direction by adjusting the tight ening nuts IMPORTANT BEFORE STARTING THE BURNER CAREFULLY ENS...

Page 27: ...y unsuitable as earthing electrodes ATTENTION THE MANUFACTURER IS NOT LIABLE FOR DAMAGE TO PERSONS AND PROPERTY CAUSED BY AN UNSUITABLE EARTHING SYSTEM Connection to electric power supply The generators are equipped with an electrical panel completely assembled and connected to the various accessories on the generator itself To connect the control panel please refer to the specific manual supplied...

Page 28: ...AUTO Burner operating mode 23 MODEM ROUTER POWER ON Activation modem router for remote connection optional 24 TDS MODE MAN 0 AUTO Salinity control unit operating mode optional P2 MODE MAN 0 AUTO P2 MODE OVERLOAD P2 MODE RUN HP SAFE Push to Reset P1 MODE MAN 0 AUTO P1 MODE OVERLOAD P1 MODE RUN CP MODE POWER ON B MODE MAN 0 AUTO B MODE LOCK MODEM ROUTER POWER ON H LWL SAFE DIAGNOSTIC B MODE RUN B MO...

Page 29: ...al 3 LWL SAFE 2 Push to Reset Low level probe 2 alarm warning light 4 LWL SAFE 1 Push to Reset Low level probe 1 alarm warning light 13 HP SAFE Push to Reset Safety pressure switch alarm warning light 26 TEST ALARM Push to Reset Alarm warning light Warning lights 7 H LWL SAFE DIAGNOSIC Level probe s anomaly detec tion alarm 9 B MODE POWER ON Presence of power to the burner 11 CP POWER ON Presence ...

Page 30: ...D Pump 2 circuit breaker protection intervention optional 18 P1 MODE RUN Pump 1 running 19 P1 MODE OVERLOAD Pump 1 circuit breaker protection intervention 21 B MODE RUN Burner running 22 B MODE LOCK Burner block Selectors switches 8 MAIN SWITCH 14 P2 MODE MAN 0 AUTO Pump 2 operating mode op tional 17 P1 MODE MAN 0 AUTO Pump 1 operating mode 20 B MODE ON OFF Burner operating mode P1 MODE MAN 0 AUT ...

Page 31: ... for the boiler and is provided with all safety and control devices required by the standards in force the gas used models with gas burner corresponds to that of calibration is the gas supply cock open models with gas burner has gas leakage been checked models with gas burner Are the combustion air intake line and the flue gas evacuation line compliant with the applicable standards in force Are th...

Page 32: ...water reaches the pump bleed the air from the intake located on the upper part of the pump body Start the feed pump s by means AUTactivation from the panel and fill the generator during the filling phase the warning light P1 2 MODE RUNon the panel lights up This operation verifies the correct functioning SET probe intervention IML panel pump OFF probe intervention BASIC IMC panel When you reach th...

Page 33: ... P1 2 MODE MAN 0 AUT in position AUT the pump stops the warning light P1 2 MODE RUN is off Open the discharge line of the generator water version with manual discharge act on the lever valve and hand wheel version with automatic discharge via MANactivation frm the panel on switch BLD MODE MAN 0 AUT During the emptying phase check switching off on the panel of the red LED on the level regulator HWL...

Page 34: ...with automatic discharge by MANactivation from panel Restore the SET level by placing the selector switch P1 2 MODE MAN 0 AUT in position AUTfrom the panel to start the pump When starting the filling phase the warning light P1 2 MODE RUNon the panel lights up During the filling phase check switching off of the red LEDs on the panel on the level regulators LWL SAFE 1 and 2 and the swithing on of th...

Page 35: ...AINED FOR THE PURPOSE Close the steam main intake valve Make sure that the pressure gauge is in direct connection with the generator checking the position of the three way cock Referring to the instructions for the pressure switches safety and work con tained in the document envelope provided with the generator manually ad just the pressure switches at a pressure slightly higher than the calibrati...

Page 36: ... intake valve to lower the pressure inside the generator Calibrate maximum pressure the safety pressure switch For the adjustments refer to the manufacturer s instruc tions supplied The intervention pressure pressure differential must be lower than the calibration value of the safety valves Rearm the safety pressure switch restart the burner and check its stop auto matically by checking the pressu...

Page 37: ...de gaskets By means of the combined action of the two cocks and the drain clean the conduits of communication and the crystal of the level indicator Repeatedly drain the boiler bottom by rapidly opening the drain valves to eliminate possible processing residues Monitor the operation of the level adjustment and pressure reg ulation devices Recommendations for using the generator on the first day of...

Page 38: ...NTROL SAFETY PRESSURE SWITCH SWITCH ES SAFETY LEVEL SWITCH SWITCH ES INTERVENTION IN REAL CONDI TIONS INTERVENTION IN REAL CON DITIONS BY LOWERING THE WATER LEVEL IN THE BOILER ATTENTION Before leaving the generator under the control of automatisms visually check the operation of the pressure and level regulators level regulator unit adjust ment pressure switches THE SAFETY VALVE IS THE LAST BAS T...

Page 39: ...solated with respect to the branch out of the control unit the generator will slowly cool without risk and will be ready to restart quick ly returning to normal operation NOTE If the shutdown period is such to bring the generator below 100 C it will go Vacuum this does not entail any particular problems except for the auto fill of water for poor seal of the shut off valves on the supply line i e d...

Page 40: ...ollowing operations Completely discharge the water that was used for the conservation carefully wash and subsequently fill with clean water and properly treated 3 20 INSTRUCTIONS FOR SHUTDOWN AND STORAGE Dry conservation Warning This method must be used in the event of pro longed inactivity periods and as protection against frost In this case a short term restart is not possible Complete emptying ...

Page 41: ...the control and safety de vices of the generator Immediately remove any unburned gas leaks by replacing the worn seal gaskets Periodically check at least once a year the parameters of combustion It is forbidden because dangerous even partially obstruct the air vents for the cor rect ventilation of the boiler room It is absolutely forbidden to touch the hot parts of the generator which are heated a...

Page 42: ...horoughly clean the rear smoke chamber and the smoke fitting The frequency of these extraordinary main tenance depends on the type of fuel and the combustion quality on average every 3 4 months for combustion with dense naphtha and at least once a year with use of diesel and gas WATER SIDE disassembly of level probes opening of manhole internal inspection to ascertain the presence of deposits or s...

Page 43: ...heck the intervention threshold of the pressure switches Check the calibration value of the valve Cleaning of the seat by quick and repeated drives of the manual opening lever of the valve Disassembly of the valve and polishing of the seat by means of a very fine abrasive Check calibration of the safety pressure switch Replacing the pressure switch Rod encrusted cable interrupted Check motor absor...

Page 44: ...ided in the burn er manual Check the state of the gaskets closure of the doors burner plate set up and connection to the chimney fitting Check the burner and power supply line according to the instructions given in the specific burner manual Check presence of limescale and carry out a chem ical wash Check cleanliness of the water side and smoke side boiler Check the correct coupling of boiler burn...

Page 45: ...dicated in the project they can cause fragile breakages in welds Rainwater may damage or corrode the generator structure from the outside RISK DANGER Burst of the generator SOLUTION PREVENTION Protect the generator from adverse weather conditions Keep to that indicated in the use and maintenance manual Check that the temperature to which the boiler may be subjected in the expected life cycle is in...

Page 46: ...r must be maintained at a temperature to the minimum design temperature protected from rain stored in its internal parts water side as defined in the use and maintenance manual EVENT CAUSE 26 REPLACING ACCESSORIES Severity Event C The replaced accessories are not suitable for the operation to be performed EFFECT CONSEQUENCE Damage produced to the generator due to the lack of control of the safety ...

Page 47: ...uring lifting and transport due to the detachment of the eyebolts or release or breakage of lifting equipment EFFECT CONSEQUENCE Violent impact with the ground Break of the pressurised body RISK DANGER Immediate danger of crushing people or objects below Danger due to any breakage in the pressurised body SOLUTION PREVENTION Always keep at a distance of at least 5 m from the projection on the groun...

Page 48: ...o that indicated in the use and maintenance manual EVENT CAUSE 34 POOR OPERATION Severity Event D Operation of the generator by personnel not suitably trained EFFECT CONSEQUENCE Compromise the stability and functionality of the generator RISK DANGER Damage to the appliance structure with danger of explosion SOLUTION PREVENTION Subject the pressurised body to periodic checks Internal Visit Integrit...

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Page 50: ...to transcription or printing errors Furthermore it reserves the right to modify its products as deemed necessary or useful without affecting their essential features 46033 casteldario mantova Italy tel 39 0376 57001 telefax 39 0376 660556 info unical ag com export unical ag com www unical eu AG S p A ...