INSTRUCTIONS ON INSTALLATION,
USE AND MAINTENANCE
DĨATHER’
2
DATA PLATE
example
Modello
Numero di Fabbrica
Anno di Fabbricazione
Potenza Nominale [kW]
Potenza Termica al focolare [kW]
Model
Serial Number
Manufacturing Year
Heat Output
Heat Input
Press. max ammiss. Serp. PS [bar]
Temperatura max. ammis. TSmax [°C]
Temperatura min. ammis. TSmin [°C]
Pressione di prova Serpentino [bar]
Data di prova idrostatica
Max Design Coil Pressure
Max Allowable Temperature
Min. Allowable Temperature
Hydraulic Test Pressure Coil
Hydraulic Test Date
Superficie riscaldata [m²]
Volume Totale V [I]
Heating Surface
Total Volume
DIATHER’
Categoria di Rischio
Category
Gruppo / Fluido
Group / Fluid
1 / Olio Diatermico
1 / Diathermic Oil
Via Roma, 123 - 46033 Castel dArio - Mantova - Italy’
I
10
345
-----------
25
4000
A16U00XXX
2016
4650
5470
157
2465
15/02/2016
3
1 GENERAL INFORMATION ................................................................................................................................................................................... 4
1.1 General warnings ........................................................................................................................................................................................... 4
1.2 Symbols used in the manual .........................................................................................................................................................................4
1.3 Safety warnings ............................................................................................................................................................................................ 5
General informationTechnical featuresInstallation instructionsMaintenance instructions
4 INSPECTIONS AND MAINTENANCE .............................................................................................................................................................. 24
4.1 General rules for running the generators ..................................................................................................................................................... 24
4.2 Maintenance instructions ............................................................................................................................................................................ 25
4.3 General rules for decommissioning .............................................................................................................................................................25
Operating anomalies ..........................................................................................................................................................................................26
3 INSTALLATION INSTRUCTIONS .................................................................................................................................................................... 11
3.1 General warnings ..................................................................................................................................................................................... 11
3.2 Installation standards................................................................................................................................................................................ 11
3.3 Supply conditions ..................................................................................................................................................................................... 12
3.4 Handling .................................................................................................................................................................................................. 12
3.5 Positioning in boiler room ......................................................................................................................................................................... 13
3.6 Hydraulic system features and connections ............................................................................................................................................. 14
3.7 Fuel supply ............................................................................................................................................................................................... 15
3.8 Connection to the flue............................................................................................................................................................................... 15
3.9 Burner assembly....................................................................................................................................................................................... 16
3.10 Furnace door: adjustment, opening, closing............................................................................................................................................. 17
3.11 Electrical connections .............................................................................................................................................................................. 17
3.12 Electric control board ................................................................................................................................................................................ 18
3.13 Commissioning ......................................................................................................................................................................................... 20
3.14 Start-up and subsequent checks .............................................................................................................................................................. 22
3.15 System stop .............................................................................................................................................................................................. 22
3.16 Instructions for the emergency stop of the generator ............................................................................................................................... 23
2 TECHNICAL FEATURES AND DIMENSIONS ................................................................................................................................................... 6
2.1 General description of the range ...................................................................................................................................................................6
2.2 Description of components ........................................................................................................................................................................... 7
2.3 Control and safety devices ............................................................................................................................................................................ 7
2.4 System accessories ...................................................................................................................................................................................... 8
2.5 Dimensions ................................................................................................................................................................................................... 9
2.6 Operation data ............................................................................................................................................................................................ 10
4
1
GENERAL INFORMATION
This document constitutes the Technical Manual of instal-
lation, use and maintenance of the DĨATHER type 3 effec-
tive smoke passes diathermic oil generators, and it is an
integral and essential part of the product.
In the event that the generator is transferred
in use or sold to other Users (change of
destination or move) make sure that the ap-
pliance is transferred together with this in-
stallation, use and maintenance manual so
that it can be consulted by the entrusted in-
staller, the maintenance technician and the
new owner.
Installation must be performed in compliance
with the standards in force according to the
instructions of the manufacturer and by pro-
fessionally qualified personnel.
Professionally qualified personnel means per-
sons with specific technical skills in the dia-
thermic oil system sector.
ATTENTION!
The DĨATHER series diathermic oil heat gen-
erators must be operated within the limits
for which they were designed; any other use
must be considered improper and therefore
dangerous.
IT IS STRICTLY FORBIDDEN FOR PERSONS
NOT SPECIFICALLY ENABLED TO USE,
RUN, MAINTENANCE THE GENERATOR.
Before starting installation, starting the igni-
tion process or undertaking any maintenance,
carefully read the instructions and proce-
dures contained in this manual; they provide
important information regarding the safety of
the system and the safety of persons.
ATTENTION!
Incorrect installation, inadequate use and
maintenance of the appliance can cause
damage to persons or property, for which
the MANUFACTURER is not liable.
CAREFULLY READ AND FOLLOW THE IN-
STRUCTIONS CONTAINED IN THIS MANUAL
BEFORE CARRYING OUT ANY OPERATION
To guarantee appliance efficiency and its correct
operation, periodic maintenance must be per-
formed by professionally qualified personnel, fol-
lowing the manufacturer's instructions.
Any appliance repairs must be performed using
original spare parts only.
This appliance is intended for the use for
which it was expressly designed.
The manufacturer will have no contractu-
al or extra-contractual liability for damage
caused to persons, animals or property, due
to incorrect installation, adjustment, mainte-
nance and misuse.
ATTENTION!
THE GENERATOR IS NOT DESIGNED TO BE
INSTALLED OUTDOORS, BUT MUST BE LO-
CATED WITHIN THE APPROPRIATE PREM-
ISES (BOILER ROOM).
1.1 - GENERAL WARNINGS
1.2 - SYMBOLS USED IN THE MANUAL
Pay special attention when reading this manual to the parts marked by the symbols:
NOTE!
Tips
for the user
ATTENTION!
Possible dangerous
situation for the product
and the environment
DANGER!
Serious danger for
personal safety and life
5
General information
1.3 - SAFETY WARNINGS
Please strictly adhere to the safety warnings to avoid danger
and damage to people and property.
Addressees
The following instructions are intended exclusively for special-
ised personnel.
- Interventions on the gas system must only be carried out by
qualified installers in accordance with the law and author-
ised by the relevant gas company.
- The interventions to the electrical system must only be car-
ried out by specialised and qualified personnel, according to
the law.
- Commissioning must be done by professionally qualified
personnel.
Standards
In case of intervention, follow:
- the accident-prevention regulations,
- the environmental protection standards,
- the operating safety standards,
- the provisions of the Insurance Institute against accidents at
work
- Directive 2014/68/UE.
Behaviour in case of fuel leaks
Danger
The leaking of fuel can cause explosions
and serious injuries.
- Do not smoke!
- Avoid naked flames and sparks. Never activate lights or
electrical devices.
- Close the shut-off valve on the fuel supply line.
- Open doors and windows.
- Evacuate people from the dangerous area.
- Inform the gas and electricity company from outside the
building.
- Shut-off electric power supply from a safe position (from out-
side the building).
Behaviour in case exhaust gas leaks
Danger
The exhaust gas can cause fatal intoxica-
tion.
- Switch off the system.
- Ventilate the place of installation.
Interventions on the system
- Close the fuel shut-off valve and make sure that it cannot be
opened accidentally.
- Disconnect the system supply voltage (e.g. acting on the
individual switch or on the main switch) and make sure that
voltage is disconnected.
- Make sure that it cannot be switched on again.
Attention
Any electrostatic discharges may damage
the electronic components.
Before carrying out the works, discharge
the electrostatic charge to the ground.
Hot surfaces
Risk of burns caused by contact with hot
surfaces:
- oil pipes,
- front door and smoke chamber,
could become hot.
Comply with the safety standards at work!
Repairs
Attention
It is not allowed to carry out repair work
on parts with technical safety function. Re-
place the faulty parts with original SCHUS-
TER spare parts only.
Additional components, spare parts and parts sub-
ject to wear
Attention
Spare parts and pieces subject to wear that
were not tested with the system can jeop-
ardise its operation. The installation of parts
not approved and unauthorised modifica-
tions may compromise safety and affect the
warranty rights. For the replacement, only
use original SCHUSTER spare parts.
Behaviour in case of fire spreading
Danger
In case of fire, do not put it out using water
but only use powder, CO2 systems, etc..
As for the diathermic oil and its safe use, we
recommend to strictly adhere to the manu-
facturer's provisions specified on the rela-
tive technical data sheet.
6
2.1 - GENERAL DESCRIPTION
2
TECHNICAL FEATURES
AND DIMENSIONS
The furnace is accessed through a burner support door fixed
to the generator by hinges; the door is internally coated with a
suitable layer of refractory cement and is fitted with flame light
and burner support plate.
The rear flue gas casing is fixed to the generator by bolts, is
internally insulated with insulating concrete and is fitted with
cleaning door.
The generator body is covered with a suitable layer of high den-
sity rock wool and externally covered with a painted sheet met-
al casing; this reduces the heat losses, improving the overall
performance.
The DĨATHER type diathermic oil boilers provide a maximum
temperature of use of 300°C with a thermal gradient of 40°C
between oil inlet and outlet.
NOTE:
The DĨATHER boilers are CE marked accord-
ing to Directive 2014/68/UE (category I). Weld-
ing procedures and devices are approved and
certied according to Standards EN 15614,
EN287 and UNI EN ISO 9606.
The design does not take account of fatigue
stress nor of damage due to earthquake or
other natural events.
The DĨATHER model diathermic oil boilers are of the type with
four principle helical tube bundle, with execution in two concen-
tric rings inserted in a fumes hermetically sealed sheet metal
cylindrical body.
The tubes constituting the tube bundle are made of "seamless"
quality steel.
The first "ring" characterises the furnace along which the flame
extends; the second "ring" originates a three flue gas pass path
which allows an optimal exploitation of the entire exchange sur-
face.
The base consists of electrowelded steel profile frame
7
General information
2.2 - DESCRIPTION OF COMPONENTS
Corpo mantellato
e coibentato
Uscita fumi
Manometro
Manometro
Pressostato differenziale
Porta anteriore
Quadr
o elettrico
Cased body
and insulated
Pressure gauge
Pressure switch differential
Pressure gauge
Front door
Inspection door
smoke chamber
Control panel
2.3 - SAFETY DEVICES AND
CONTROL
The DIATHER generators are equipped with the following safety
and control devices:
DIFFERENTIAL PRESSURE SWITCH
Connected between oil inlet and outlet (scale 0.5 ÷ 4 bar), com-
plete with valves and pressure gauges.
The dierential pressure switch is intended as a safety compo-
nent since it bocks the burner if the pressure dierence drops
below the pre-set value.
Dierential pressure switch calibration
Divide by 13 the oil side load loss value (see oper-
ating data table) and round down the result. From
this subtract 0.4 and you have the pressure in bar
to set on the pressure switch.
The dierential pressure switch installed as standard on the
DIATHER generators is the DANFOSS RT 260A model; to cal-
ibrate, carefully follow its manufacturer's instructions provided
with the generator documentation.
Following the intervention, restore the pressure switch at a pres-
sure of 0.3 bar higher than the calibration (xed dierential).
WORK AND SAFETY THERMOSTATS
N°1 Safety thermostat placed on the ow pipe, which locks out
the generator in case the operating temperature is exceeded.
T alarm = 300°C
N°1 Thermoregulator placed on the ow pipe, for the ignition,
shutdown and burner adjustment.
T 1
st
stage = 280°C (**)
T 2
nd
stage = 250°C (**)
(**) Factory setting (adjustable)
N°1 Thermoregulator placed on the return pipe for the measure-
ment of the return temp.
T return = 150°C
PRESSURE GAUGES
Two stainless steel and laminated glass pressure gauges with
scale adjusted to the boiler design pressure, complete with
steel shut-o valve.
Respectively positioned on:
- oil ow
- oil return
The pressure gauge is installed on appropriate tool unit
equipped with siphon tting for the dispersion of heat.
ATTENTION
Any disassembly/replacement of the devic-
es listed must be performed with the boiler
o, depressurised to atmospheric pressure
and suitably cooled; the manufacturer is not
liable for damages to persons and/or prop-
erty or animals due to non-compliance with
this requirement.
8
2.4 - SYSTEM ACCESSORIES
EXPANSION VESSEL
In operation, the volume of oil in circulation varies due to the
temperature changes.
The increase in diathermic oil volume is around 7% for a tem-
perature increase of 100°C.
This involves the need to absorb the oil expansions by inserting
an expansion vessel in the circuit.
It is good practice that, with system cold, the
oil occupies at least 1/4 of the expansion ves-
sel capacity to ensure an appropriate seal
and, with system hot, does not exceed 3/4 of
the tank capacity to prevent any overow.
If it is assumed that the system features are such to make it dif-
cult to maintain a temperature suciently low in the expansion
vessel (60 - max 70°C at temperature), we recommend provid-
ing a heat sink on the connection pipe of the expansion vessel.
The expansion vessels used are mainly of the open type (at-
mospheric): in this case, they will be placed at a height, so that
the minimum level exceeds the max level reached by the system
or the utilities, by at least 1.5 m.
The minimum height, subject to exceptions to be examined
case by case, will be such to ensure a 6 m seal at least on the
intake axis of the circulation pump.
It will be placed preferably in a ventilated area to avoid the tem-
perature increasing excessively and protected against water
inltration.
When wanting greater pressures in the system, or it is not pos-
sible for some reason to place the vessel at an adequate height,
be it only for aesthetic reasons, you can place an expansion ves-
sel in the boiler room, of the pressurised type. This vessel will be
pressurised with nitrogen, using cylinders and decompression
station, and equipment with the necessary safety devices.
The connection pipe to the expansion vessel:
- must be free of shut-os
- must be such to prevent convective motions of the oil
- must not be insulated.
DIATHERMIC OIL COLLECTION TANK
It is a simple container with a higher capacity than the total of
the system.
It must be placed outside the boiler room, preferably outdoors
and in ventilated premises protected from rain, in pit below
ground level not buried, on oor, or raised.
If buried, it will be necessary to also adequately lower the load-
ing height to avoid intake problems.
In case of landll, it is mandatory to use a double-wall vessel as
provided for all ammable liquids.
The system loading pump, with its group of valves, is located
near the oil storage tank.
SYSTEM LOADING UNIT
It consists in a gear pump coupled to an electric motor, com-
plete with two-way steel valves.
It must be placed in a position protected from rain and level with
the collection vessel, in order to facilitate the intake of the pump.
OIL CIRCULATION PUMP(S) UNIT
They are normally single-state centrifugal pumps coupled to the
motor through a elastic joint.
Everything is assembled on the base which ensures alignment
of the components.
The pump seal is of the air-cooled type.
SHUT-OFF VALVES
The shut-o valves for diathermic oil systems must have a sphe-
roidal cast iron body and be tted with bellow seal.
DIATHERMIC OIL FILTER
Upstream of the circulation pump(s) install a lter for diathermic
oil with spheroidal cast iron or steel body and with a large mesh
lter basket.
EXPANSION COMPENSATORS
The expansion compensators must be installed to absorb the
axial expansions of the pipes due to high operating tempera-
tures.
The pipes must be suitably bracketed so that the compensators
can perform their function without the burden of any weight that
might cause misalignment between the jointed pipes, leading to
possible failure of the bellows and leaking of oil.
9
Technical features
2.5 - DIMENSIONS
T1 Flow
T2 Return
T3 Generator exhaust
T4 Flue gas exhaust
T5 Burner connection
Model
Diather
W
mm
L
mm
H
mm
A
mm
B
mm
C
mm
D
mm
E
mm
F
mm
T1-T2
DN
T3
DN
T4
Øe
T5
mm
120
930 1650 1190 600 1225 800 620 504 368 32 20 200 160
230
1060 1890 1310 700 1465 900 680 596 382 40 20 250 220
350
1060 2210 1310 700 1785 900 680 560 400 50 20 250 220
465
1240 2320 1510 800 1150 1060 780 680 440 65 20 300 260
580
1240 2450 1510 800 1270 1060 780 680 440 65 20 300 260
700
1260 2480 1520 800 1270 1060 780 728 416 65 20 300 280
930
1370 3170 1620 900 1500 1160 840 808 436 80 20 350 280
1160
1540 3350 1790 1000 1780 1320 920 940 450 100 25 350 280
1500
1670 3630 1930 1100 1850 1440 1000 1050 475 100 25 400 320
1900
1670 3810 1930 1100 2100 1440 1000 1050 475 125 25 400 320
2300
1840 4170 2110 1200 2400 1580 1080 1210 475 125 25 450 360
2900
2200 4490 2460 1400 2500 1900 1260 1490 515 150 25 500 380
3500
2200 4710 2460 1400 2750 1900 1260 1490 515 150 25 500 380
4650
2390 5990 2680 1500 3650 2060 1360 1641 540 200 25 600 400
5800
2370 6570 3000 1700 3800 2360 1530 1860 600 200 25 700 400
C
A
W
D
1700
500
B
600
F
E
H
L
Ø
T4
C
A
W
D
1700
500
B
600
F
E
H
L
Ø
T4
10
2.6 - OPERATING DATA
Project Data U.M. DĨATHER
120 230 350 465 580 700 930 1160 1500 1900 2300 2900 3500 4650 5800
Heat Output Pn
Potenza Nominale Pn
kW 116,3 232,6 348,8 465,1 581,4 697,7 930,2 1162,8 1511,6 1860,5 2325,6 2906,9 3488,4 4651,2 5813,9
Heat Input Qn
Portata Termica Qn
kW 134,3 267,6 401,0 534,1 668,5 802,1 1069,3 1336,8 1737,6 2138,4 2672,5 3342,0 4009,2 5346,0 6682,7
Group - Fluid / Gruppo - Fluido
1 - Diathermic Oil /
1 - Olio Diatermico
Category /
Categoria di rischio
I I I I I I I I I I I I I I
Heating Surface /
Supercie riscaldata
m² 7,0 11,0 14,8 19,2 21,2 22,4 31,8 44,2 54,6 59,0 72,8 102,2 104,4 156,4 189,6
Coil Volume /
Volume Serpentino
l 40 84 130 232 245 201 285 518 639 692 853 1592 1629 2464 2970
Max Coil Design Pressure /
Pressione Max amiss.
Serpentino PS
bar 10
Max Design Temperature /
Temperatura Max amiss.
TSmax
°C 300
Working Temperature /
Temperatura di lavoro
TS
°C 280
Coil Test Pressure /
Pressione prova serpentino
PT
bar 25
Combustion chamber press./
Press. camera di combustione
mbar 1,5 2,0 2,5 3,0 3,2 3,1 3,5 3,8 4,0 4,2 4,5 4,5 5,0 6,0 7,0
Flow rate pump /
Portata pompa olio
m³/h 6,0 10,6 15,9 22 26,5 31,8 42 50 69 81 101 126 159 202 252
Heat rise / Salto termico
°C 40
Loos pressure oil side (250°C)/
Perdita di carico lato olio 250°C
m.c.l. 26 23 25 18 20 23 17 24 18 28 24 39 32 36 40
11
Installation instructions
Before connecting the generator, have profes-
sionally qualified personnel:
a) Thoroughly wash all the piping of the sys-
tem to remove any residues or impurities,
which could jeopardise proper operation
of the generator.
b) Check that the generator is set up to operate
with the available type of fuel.
c) Check that the chimney/flue has an appropri-
ate draught, without any bottlenecks, and that
no exhausts from other appliances are insert-
ed, unless the flue has been implemented to
accommodate several utilities according to
specific standards and prescriptions in force.
Only after this check can the fitting between
the generator and chimney/flue be mounted.
ATTENTION!
The appliance must be installed by a qualified
technician with the technical-professional
requirements according to the law in force
which, under his own responsibility, guaran-
tees compliance with standards according to
good practice rules.
3.2 - INSTALLATION STANDARDS
It must be installed by a professionally qualied technician,
who shall assume the responsibility of respecting all local
and/or national laws published in the ocial journal, as well
as applicable technical standards.
3
INSTRUCTIONS FOR
INSTALLATION
3.1 - GENERAL WARNINGS
ATTENTION!
The generator is intended solely for the use
for which it was expressly designed. Any
other use is to be considered improper and
therefore dangerous.
This generator is suitable for heating dia-
thermic oil.
The installation requirements of systems in
a building always depend on the regulations
in force in the country of installation.
Systems with diathermic oil generator must
be installed in order to facilitate use, mainte-
nance, repair and monitoring of all respective
components and to ensure, for personnel,
compliance with the safety regulations at
work.
Install the diathermic oil generator and rela-
tive devices so that they are protected in case
of shocks, oscillations and other hazards and
to ensure acoustic insulation and meet the
technical safety requirements.
12
3.3 - SUPPLY CONDITIONS
The DĨATHER generators are supplied in monobloc version.
Upon receipt, after removing the packaging, check
the contents are intact.
Carry out a general inspection to verify the absence
of damages due to transport and check the status
of the door refractory and of the smoke box.
NOTE:
The generators are normally supplied fully
assembled. In particular cases, some units
are supplied unassembled to avoid damage
during transport or handling.
For their assembly refer to the instructions
supplied with the documentation provided
with the generator itself.
3.4 - HANDLING
The DĨATHER generators are equipped with lifting eyebolts.
Pay attention to handling and use equipment suitable to their
weights; the ropes between the eyebolts and the hook must be
suciently long to not be inclined more than 45° from the ver-
tical
The generator body with all its parts, both electrical and me-
chanical, must be adequately protected against atmospheric
agents both during transport and possible storage at the cus-
tomer, before the nal installation.
13
Installation instructions
3.5 - POSITIONING IN THE
BOILER ROOM
The generator must be installed in a room that respects the
safety regulations in force in the country of destination, with
adequately sized air vents.
In the absence of specific provisions of the country of destina-
tion, you must observe the following guidelines:
1) The room must be set-up exclusively for use as boiler room:
access to unauthorised personnel must be denied (with
clearly visible signs).
2) Provide wide spaces for the operation and maintenance of
all system components (pumps, valves, filters, etc.).
3) The support surface must be horizontal so as to evenly sup-
port the generator base; raised edges must be realised on
the access openings of the room, in order to contain oil leak-
ages. Finally, tunnels must be provided for the conveyance
of drains and vents.
4) The rooms must be sized to provide the following minimum
distances, net of any clearance:
a) On the front of the generator, verify that with the door
open at 90°, the distance between the door and the adja-
cent 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 next to a wall or to another
generator and no accessory or control is provided in the
passage.
c) On the back of the generator: 0.80 m.
d) From the upper part of the generator: 1.80 m between
the highest walkway and the lowest obstacle of the room
roof and 1 metre between the highest point of the gener-
ator and the lowest obstacle between the generator and
the roof itself.
e) The pipes and the existing transmissions above the gen-
erator must be arranged so as not to obstruct the work,
nor hinder the operator's movements in accessing the
upper part of the generator to view or repair the accesso-
ries.
ATTENTION:
If the burner is fed with fuel gas of a specific
weight greater than that of the air, all electrical
parts must be placed higher than 0.5 metres
from the ground.
IT IS FORBIDDEN TO INSTALL THE GENER-
ATOR OUTDOORS BECAUSE IT IS NOT DE-
SIGNED FOR SUCH PURPOSE.
800
800
800
14
3.6 - HYDRAULIC SYSTEM FEATURES AND
CONNECTIONS
The installer is responsible for selecting and installing the sys-
tem components, that must be done in a workmanlike manner
and in accordance with current legislation.
The designer is responsible for sizing the system, in all its
parts.
When realising the hydraulic system, use only ferrous materi-
als, preferably seamless carbon steel pipes of excellent quality.
Do not use copper and its alloys as their contact with the dia-
thermic oil favours its oxidation.
The pipes must be clean inside, free of rust
or paint, otherwise you must pickle the cir-
cuit before filling with oil.
The joints must be welded or flanged (use
flanges or collar): DO NOT make threaded
joints.
Threaded joints are only permitted for very
small diameters (max ½”) of secondary pipes
(vent pipes, connecting to tools, etc.)
The flanges in the heaters and components are in class PN16.
The generator, once positioned in the boiler room, must be con-
nected to the following points:
- Diathermic oil flow (T1)
- Diathermic oil return (T2)
- Load/Unload (T3)
The pipe dimensions are indicated in paragraph 2.5 - DIMEN-
SIONS.
The generator connections must not be stressed by the weight
of the system pipes: these must be supported and arranged so
as not to create dangerous strains.
In dimensioning the main circuit pipe, the circulation speed of
the oil must be about 1.5 - 2 m/s (the connections of our heat-
ers are sized in this regard).
The circuit must be compensated by thermal expansions.
The steel pipes extend by 1.2 mm/m every 100 K of thermal
gradient: this means that from the room temperature (20°C) to
a work temperature of 270°C, ten metres of pipes stretch by 30
mm. If not compensated, the expansions cause tremendous
efforts on the system components.
The way to compensate the expansions depends on the sys-
tem itself:
- if it is compact, without long straight sections and full of
bends, it could be considered auto-compensated;
- if it is extended and with long straight sections, insert axial
expansion compensators, providing the necessary guides
and fixed points.
The circuit must be fitted with vents and drains of pipes to
speed up system loading and emptying.
Vents and drains must be conveyed to the storage tank.
Provide the system with an inlet for the withdrawal
of diathermic oil to be analysed.
The diathermic oil must be withdrawn cold (max
40°C) with system off or in operation after cooling
the oil with the use of a sampling device (on the
market).
Do not take the oil from the vents or drains.
After realising the system, perform an hydraulic sealing test of
the welds.
The sealing test is carried out with compressed air: after ex-
cluding the expansion vessel and the storage tank, pressurise
the circuit and with soapy water wet all welds to highlight any
leaks.
Do not introduce water in the circuit to perform the sealing test.
The circuit must be insulated AFTER THE HOT START of the
system
For the insulation use high density (min 100 kg/m3) mineral
wool with minimum thickness of 60 mm.
After the insulation, all flanged joints and expansion compensa-
tors must remain visible.
ATTENTION:
- do not insulate the expansion pipe;
- do not provide flanged joints and com-
pensators on the electrical components
(motors, electric panels, etc.): in case of
dripping or oil leak they may cause a fire.
T1
T2
T3
15
Installation instructions
3.7 - FUEL SUPPLY
Danger!
The gas connection must be carried out only
by a qualified installer who must respect and
apply that foreseen by relevant laws in force
in the local prescriptions of the supply com-
pany. Incorrect installation can cause damage
to persons, animals and objects for which the
manufacturer cannot be held responsible.
Check that the fuel supply system is
equipped with the safety and control devic-
es prescribed by current regulations.
If you smell gas:
a) Do not turn electric switches on or off, use
a telephone or any other object which can
create sparks;
b) Close the gas valves;
c) Immediately open doors and windows to
create an air current to air out the room;
d) Request the intervention of professionally
qualified personnel.
Do not use the fuel system pipes as earth-
ing of electrical or telephone systems.
Check that the generator is set up to operate
with the available type of fuel.
Before installation, we recommend a thor-
ough inner cleaning of all fuel adduction
piping to remove any residue which could
jeopardise proper operation of the generator.
Check the internal and external seal of the
fuel supply system.
If using gas, the connections must be per-
fectly sealed.
3.8 - CONNECTION TO THE
FLUE
With combustion pressurised, the chimney loses its primary
function of draught activator and only preserves the function of
smoke conveyor duct.
It remains, normally, the need for them to work in conditions of
depression, and this requires an adequate sizing.
The need for depression on the chimney is justified by safety
reasons, to avoid smoke filtrations in room where, for any rea-
son, there is no tightness.
The lifting force of hot gas must overcome the chimney resist-
ance and of the connection duct to the generator, while the load
losses of flue gas through the generator itself are overcome by
the burner thrust.
The correct burner/generator/chimney cou-
pling drastically reduces consumption and
optimises combustion with low polluting
emissions.
The CHIMNEY must be resistant to heat and condensation,
thermally insulated, hermetically sealed, without bottlenecks or
obstructions, as vertical as possible and sized according to the
provisions of current legislation.
The connection between GENERATOR and CHIMNEY must
be made:
- in compliance with current standards and legislation,
- with section at least equal to the flue gas outlet fitting of the
generator itself,
- with rigid ducts resistant to temperature, condensation, and
mechanical stress,
- hermetically sealed.
Also remember the need to provide devices for adequate
cleaning and the withdrawal of flue gas samples for combus-
tion analysis.
For sealing the joints, use materials resistant to at least
500°C.
ATTENTION:
Exhaust gases must be extracted without
compromising the safety of personnel or
third parties.
Badly sized and shaped connection fittings
and chimneys between generator and chim-
ney can amplify the combustion noise, neg-
atively affect the combustion parameters,
generate condensation problems.
16
3.9 - ASSEMBLING THE BURNER
ATTENTION!
The seat of the burner blast tube must be
as precise as possible to avoid flashbacks
or heat returns that would make the burner
connection plate red hot.
a. If hole enlargement is imprecise or increased for easi
-
er assembly, take care, after assembling the burner, to
COMPLETELY and CAREFULLY FILL, with the ceramic
fibre supplied, the free space between blast tube and re
-
fractory of the front door. This prevents overheating of
the door which would otherwise irreversibly deform.
For the burner installation, the electrical connections and the
adjustments required, consult the instruction manual of the
burner itself.
Check that the correct burner has been chosen for the genera-
tor, checking the technical specifications of both.
Firmly fasten the burner to the door using
the fixing plate so that the flame is parallel
and centred in the furnace; otherwise, com-
bustion anomalies may occur with the risk
of seriously damaging the generator.
If the burner is provided with air intake, connect it with a rubber
hose to the intake on the flame indicator: in this way the glass
will remain clean.
If the cooling tube is not connected to the
warning light, it could cause the blackening
and breaking of the sight glass.
If the burner is without air intake, remove the intake on the
flame indicator and close the hole with a R 1/8 cap.
The fuel connections to the burner must be positioned so that
the generator door can be opened completely with the burner
mounted.
The flexible fuel connecting tubes must be
long enough to allow opening the door with
burner at 90°.
b. In the presence of adapter flange for door/burner cou-
pling, make sure that the flue gas seal gaskets are
mounted on both coupling surfaces.
c. Black lead the burner fixing screws to facilitate subse
-
quent removal.
Fill the free space with the
ceramic fibre supplied
DIATHER L mm
120 150 / 200
230 - 350 190 / 250
465 - 1160 220 / 300
1500 - 2300 220 / 300
2900 - 5800 250 / 350
L
17
Installation instructions
IMPORTANT
- If having to open the furnace door, let it cool
before opening it to avoid thermal shock to
the refractory lining.
- The rear factory material of the door can
show cracks after a short time of operation;
this however does not reduce its insulation
capacity nor jeopardise its lifespan.
The door is hinged and fixed according to the indicated diagram:
In these cases the two hinges on the left side are normally used
as rotating hinges (from right to left), while the two on the right
side are used as closing hinges.
The exact opposite occurs when the door must open from left
to right.
To invert rotation, just move the
door support lock nuts.
The following adjustments can be made on the door:
A
B
C
Upon commissioning, to avoid damaging
the refractory insulation, operate the burner
at minimum capacity or, if this is not possi-
ble, cause frequent stops to gradually heat
the same and obtain "cooking".
3.10 - FURNACE DOOR: ADJUSTMENT,
OPENING AND CLOSING
A) Adjustment in the vertical direction: by acting on the nut
of the hinge upper pin on which the door turns.
B) Adjustment in the transverse direction: loosen the hinges
fixed on the front plate of the generator and move them side-
ways.
C) Adjustment in the axial direction: by adjusting the tightening
nuts.
3.11 - ELECTRICAL CONNECTIONS
General warnings
Have the electrical system checked by per-
sonnel professionally qualified according to
law, attesting the adequacy:
- of the electrical system to the power loads
absorbed by the generator,
- of the earthing system,
- of the cables
- of a multi-pole switch installed outside the
boiler room, pursuant to current legislation,
easy to access so as to make any maintenance
operations quick and safe.
Adapters, multiple sockets and/or extension
cords cannot be used to power the appliance.
The electrical safety of the appliance is guaran-
teed only when it has been properly connected
to an efficient earthing system carried out as
intended by safety standards in force: pipes of the
gas, water and heating systems are absolutely
unsuitable as earthing electrodes.
ATTENTION!
THE MANUFACTURER IS NOT LIABLE FOR
INJURIES TO PERSONS AND DAMAGE
TO GOODS CAUSED BY AN INADEQUATE
EARTHING SYSTEM.
Connection to the electric power supply
The electric panels installed on the heaters pro-
vide a 400V – 50 Hz three-phase power supply,
while the auxiliary circuit is low voltage (24 V):
different voltage are prepared only on request.
Danger!
Only a qualified technician may perform the
electrical installation.
Before performing connections or any type
of operation on electrical parts, always dis-
connect electrical power and make sure that
it cannot be reconnected accidentally.
The wiring diagram and declaration of conformity are supplied
inserted in the electric panel.
18
3.12 - ELECTRICAL PANEL
Pulsante luminoso
Spia luminosa
Selettore/Interruttore
Luminous button
Luminous light
Selector/switch
ALLARME TERMICO
POMPE
ALARM THERMAL
PUMPS
INTERRUTTORE GENERALE
MAIN SWITCH
TEMPERATURA MANDATA OLIO
OIL DELIVERY TEMPERATURE
TEMPERATURA RITORNO OLIO
OIL RETURN TEMPERATURE
RESET ALLARME
SICUREZZE IMPIANTO
ALARM SAFETY
PLAN RESET
RESET ALLARME
LIVELLO MIN. OLIO
ALARM MIN.
LEVEL OIL RESET
RESET ALLARME
CIRCOLAZIONE OLIO
ALARM OIL
CIRCULATION
RESET ALLARME
TEMPERATURA OLIO
ALARM TEMPERATURE
OIL RESET
TACITAZIONE SIRENA
SILENCING BUZZER
EMERGENZA
EMERGENCY
SIRENA
BUZZER
BLOCCO
BRUCIATORE
BURNER BLOCK
FIAMMA
BRUCIATORE
BURNER FLAME
ALIMENTAZIONE
BRUCIATORE
OFF - ON
BURNER SUPPLY
POMPA OLIO
CARICAMENTO
OIL LOADING
PUMP
POMPA CIRCOLAZ.
CIRCULAT. PUMP
START - OFF - STOP
TENSIONE
COMANDI
POWER ON
24 VAC
1
2
3
4
5
6
8
7
9
10
11
15
14
19
18
17
20
ON POMPA
CIRCOLAZIONE 1
13
19
Installation instructions
Key:
1 MAIN SWITCH
2 OIL RETURN TEMPERATURE
3 ALARM CIRCULATION OIL RESET
4 ALARM TEMPERATURE OIL RESET
5 SILENCING BUZZER
6 OIL LOADING PUMP
7 BURNER FLAME
8 BURNER SUPPLY (OFF - ON)
9 BURNER BLOCK
10 BUZZER
11 EMERGENCY
13 CIRCULATION PUMP 1 ON
14 CIRCULATION PUMP 1 (START-OFF-STOP)
START = The pump starts running and gives consent to the
burner
OFF = The pump stops running when the oil’s temperature
falls below of the minimum set temperature
STOP = The pump stops running immediately
15 POWER ON
17 ALARM THERMAL PUMPS
18 ALARM SAFETY PLAN RESET
19 ALARM MIN LEVEL EXPANSIONS OIL TANK RESET
20 OIL DELIVERY TEMPERATURE
20
3.13 - COMMISSIONING
Preliminary checks before start-up
The installation, operation and maintenance
must be carried out in compliance with the
regulations in force, following the instruc-
tions described in this manual; also, any op-
eration must be carried out by professionally
quali ed and authorised personnel.
ATTENTION!
ANY INTERVENTION ON THE APPLIANCE
MUST BE DONE BY QUALIFIED PERSON.
IT IS STRICTLY FORBIDDEN FOR PERSONS
NOT SPECIFICALLY ENABLED TO USE, RUN,
MAINTENANCE THE APPLIANCE.
AFTER CONNECTING THE HYDRAULIC AND ELECTRICAL SYSTEM AND THE FUEL LINE TO THE GENERATOR,
AND BEFORE STARTING UP THE GENERATOR, CHECK THE FOLLOWING:
have the hydraulic and electrical systems and fuel been connected in compliance with the domestic and local laws
in force and as indicated in this manual?
are the electrical components of the generator wired correctly?
are the connections tightened?
are the network frequency and voltage compatible with the generator control panel (400V 3F+N+E)?
Are the combustion air intake line and the ue gas evacuation line compliant with the applicable standards in
force?
Are the ventilation conditions and minimum distances to perform any maintenance guaranteed?
Are the refractory coverings intact?
is the furnace free of foreign bodies?
has the door been tightened correctly?
is the burner assembled according to the instructions in the manufacturer's manual and has the burner blast tube
in ll been performed correctly?
have the electrical connections of the safety devices on the burner been done correctly?
the fuel feed system is dimensioned according to the ow rate required for the generator and is provided with all
safety and control systems prescribed by current standards?
does the fuel to be used correspond to the burner calibration fuel?
is the fuel supply valve open?
has the system been checked for fuel leaks?
are the lling unit valves in operating position?
are the vent and drain valves closed?
are the circuit shut-o valves open?
is the motor shaft of the pump(s) free to rotate regularly when turning it by hand?
is the pump joint alignment correct?
do the electric motors (pumps and burner) have the correct direction of rotation?
has the operator been trained and provided with the documentation?
Please tick the operations performed
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