Summary of Contents for ICI Caldaie ECOVAPOR Series
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Steam generating unit with integrated burner ECOVAPOR INSTALLATION, USE AND MAINTENANCE MANUAL ECOVAPOR_350_3000_EN Ed. 01 - 03/2019...
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INDEX General information Gas train assembling Front door opening Introduction Front door adjustment Range Door adjustment (opening on the right) Compliance Turbulator assembly Warranty Electrical connections Warnings Prohibitions First commissioning Hazards Preliminary activities to be carried out before the Hazards "first"...
SYMBOLS USED IN THE MANUAL DANGER 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 To indicate operations that SHOULD NOT be performed.
General information INTRODUCTION Dear Customer, ECOVAPOR Thank you for having chosen an appliance of the series , a high quality and efficiency product, reliable and safe. Professionally Qualified Personnel We recommend entrusting its maintenance to 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.
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In case of damage or loss, request a copy from Technical Assistance ICI CALDAIE S.p.A. Service .
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HAZARDS DANGER – Dangers due to water leaks . Disconnect the boiler from the electrical power supply, close the water supply and promptly ICI CALDAIE S.p.A. contact the Technical Assistance Service Authorised or professionally qualified personnel. – Danger of explosion.
HAZARDS DANGER – 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...
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.
APPLIANCE DESCRIPTION ECOVAPOR Systems 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.
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SIDE VIEW 9 10 21 26 22 21 Pressure gauge Rear smoke chamber Probe holder cylinder Energy saver Capacitive probe with pre amplifier Sludge separator pneumatic drain valve (optional for Maximum level probe versions ECS24) First safety level probe (minimum) Globe valve Second safety level probe (maximum) Water inlet...
IMPORTANT To define the desired position, refer to the two marks (1) present on valve handle. 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.
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.
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 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.
Combustion system DESCRIPTION ECOVAPOR The steam generating system 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.
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.
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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.
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SYSTEM LOGICS ECOVAPOR IN CASE OF NO FLAME ECOVAPOR Hereinafter is the description of the logics that the System 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).
Adjustment and control system CONTROL PANEL ECOVAPOR IP 55 The generator control panel , (400V 3N - 50Hz) complies with insulation class 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;...
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IMPORTANT Nameplate Each appliance leaving the factory bears the , shown herebelow, specifying the configuration of the ECOVAPOR managed generator Nameplate ECS-hABCDEFGH Name of the control panel Number of pumps (1 or 2) Internal sensor supply (0=No; Hours without continuous Sludge drain (0=No;...
GRAPHIC INTERFACE OPERATOR PANEL ECOVAPOR The operator panel allows displaying the operating data of System 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.
– touch icon corresponding to the desired access level – press “YES” “NO” on the displayed page to confirm the selection or press to go back to the previous page. Confermare User IMPORTANT “OEM level ICI SpA “ can be EXCLUSIVELY selected by SERVICE When Level is selected and confirmed, the following page will be displayed:...
Displaying area 7 8 9 10 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.
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: –...
– 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 –...
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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” SERVICE level only) – touch the arrow to hide the alarm description. Adjustment and control system...
COMPLETE LIST OF MENUS AND PARAMETERS MAIN PARAMETER MENU → ACCESS PATH LANGUAGE → ACCESS PATH DISPLAY - DATE - TIME 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...
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→ ACCESS PATH OFFSET AND SCALES Parameter Description Reading level Writing level Visibility Conditions 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 value at 4 mA SERVICE SERVICE If the...
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INFORMATION MENU → ACCESS PATH INLET STATUS Parameter Description Reading level Writing level Visibility Conditions 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...
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→ ACCESS PATH ALARMS Parameter Description Reading level Writing level Visibility Conditions 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...
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Parameter Description Reading level Writing level Visibility Conditions 14.11 Opening hours of the 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...
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→ → → ACCESS PATH DATA AND METERS DIAGRAMS Parameter Description Reading level Writing level Visibility Conditions 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...
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Parameter Description Reading level Writing level Visibility Conditions 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 19.06 Pump 2 absorbed power (W) USER Only if the Pump 2 ModBus is enabled...
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→ ACCESS PATH FLUE GAS PROBE unit of 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 USER SERVICE Alarm is reset if the value goes below the threshold minus the gas probe...
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unit of Description Range Default Reading Writing Visibility 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 SERVICE SERVICE...
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→ ACCESS PATH BLOWDOWN VALVE unit of Description Range Default Reading Writing Visibility measurement Opening time of the blowdown valve. If the Duration of the programmed opening of the blowdown valve. blowdown 06.01 0 - 99 USER USER When the value is 0, the valve does not open. The valve symbol valve is flashes on the display.
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 300008 or 400008 02.10...
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Bit Parameters Read: Read Output Status (01) or Read Input Status (02). ModBus PARAMETER REF. Parameter Description Inlets 000001 or 100001 11.04 Burner supply presence 000002 or 100002 11.05 Flame presence Outputs 000011 or 100011 13.05 Burner enabling from PLC 000014 or 100014 13.09 Blowdown valve opening control...
PRODUCT RECEIPT IMPORTANT Upon receipt of the steam generating system, make sure that the supply is intact and undamaged and promptly ICI CALDAIE S.p.A. contact if it does not correspond to the order ECOVAPOR systems consist of: –...
HANDLING ATTENTION Pay the utmost care during handling and use the Personal Protective Equipment requested by the prevailing regulations. ECOVAPOR steam generator must be handled using means adequate to the size and weight of the appliance, using the provided lifting eyebolts. ATTENTION –...
INSTALLATION ROOM POSITIONING ECOVAPOR The room where 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: –...
– It is good practice to allow for expansion joints and suitable supports for the generator connecting pipes. IMPORTANT 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.
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.
FRONT DOOR OPENING The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx). DANGER 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.
Technical Standards and with the local National Legislation in force in the country of use. IMPORTANT – 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.
First commissioning PRELIMINARY ACTIVITIES TO BE CARRIED OUT BEFORE THE "FIRST" COMMISSIONING IMPORTANT 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 Qualified Personnel chemical treatments, the operation must be carried out by ECOVAPOR/system...
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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.
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With a superheater consider as maximum value 50% of the value indicated as maximum. Basic pH adjustment by injecting NaPO , further injection of NaOH only if the pH value is < 10. 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.
IMPORTANT 4 mA 20 mA If, after key is pressed, the pre-amplifier LED is , it means that the operation has been carried out correctly. Repeat the operation until the LED flashes green. LEVEL PROBE POSITIONING ECOVAPOR The generator 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.
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- 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) –...
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COMBUSTION SYSTEM CALIBRATION The following equipment is necessary for the calibration of the combustion system: – combustion flue gas analyser (%O , 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.
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 –...
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 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 "...
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Observation and tests 1 day 1 month 3 months 6 months 12 months Temperature, pressure control devices T(11) Load system, pumps/valves T(6) Analysis of the water quality T(3) Burner control (combustion) 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, T(12)
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...
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. Maintenance...
Incorrect connection to the electrical panel See the wiring diagram PROTECTING THE ENVIRONMENT ICI CALDAIE S.p.A The protection and the respect of the environment are a fundamental principle for ICI CALDAIE Product quality, energy saving and protection of the environment are equally important objectives for the company.
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European Directive 2014/68/ The generator supplied (CE certified by the Notified Body as a whole assembly in compliance with the ICI CALDAIE S.p.A consists of an equipment set, assembled and electrically and hydraulically factory tested at 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.
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– 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).
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.
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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.
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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.
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Once registered, authenticate your e-mail address by clicking on the link that will be sent by e-mail to the provided inbox. ICI CALDAIE S.p.A. An additional e-mail will then be received with the credentials to access all services specifically developed by for those who will register their boiler through the QR Code.
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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...
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Table 1; Version without pilot flame Post-ventilation time Motor => Post-ventilation speed Post-combustion interval Pilot Flame Stabilisation Ignition = OFF (0.6s) Pilot Flame Valves = ON Spark = ON Ignition speed reached Pre-ventilation end Pressure test across V1 and V2 (V1 closes) Fill the tested section (V1 opens) Pressure test across V1 and...
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Table 2; Version with pilot flame Post-ventilation time Motor => Post-ventilation speed Post-combustion interval Flame stabilisation "V1 and V2 valves = ON Gas valve closing and pilot turning off" Pilot Flame Stabilisation Ignition = OFF (0.6s) Pilot Flame Valves = ON Spark = ON Ignition speed reached Pre-ventilation end...
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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 interval No flame at the end of the safety interval 1 No flame at the end of the safety interval 2...
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(Loc. "c") (Loc. "d") Diagn. Cause Possible remedy Err.Code Code Internal error Unlock, if it occurs again replace the appliance. Internal error Unlock, if it occurs again replace the appliance. Internal error Unlock, if it occurs again replace the appliance. Internal error Unlock, if it occurs again replace the appliance.
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(Loc. "c") (Loc. "d") Diagn. Code Cause Possible remedy Err.Code Limitation of upper adjustment range The rpm value of the frequency converter was too low. 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.
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(Loc. "c") (Loc. "d") Diagn. Code Cause Possible remedy 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). Check the position difference between basic point and setting of the operating gas train in modulation (parameter 544).
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(Loc. "c") (Loc. "d") Diagn. Code Cause Possible remedy Err.Code 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 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.
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(Loc. "c") (Loc. "d") Diagn. Code Cause Possible remedy Err.Code EEPROM access internal error – Page Unlock, repeat / check the last parametrisation, if it occurs again on Abort replace the appliance. EEPROM register initialisation internal Unlock, if it occurs again replace the appliance. error EEPROM access internal error –...
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(Loc. "c") (Loc. "d") Diagn. Code Cause Possible remedy Err.Code No flame loss after the disabling of fuel valves: -Check the extraneous light 5 (-5) TÜV test time-out -Check the wiring to exclude short circuits -Check valve tightness Internal error Watchdog internal error-reset Manual lock The appliance has been manually shut-off (no error).
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