AND COMPONENTS 199
INDUSTRIAL AUTOMATIC PURGING SYSTEMO FOR BX RANGE GENERATORS The automatic bottom blow down unit prevents unnecessary purging duplication or verifiable omission with the manual system. This system allows sludge accumulated at the bottom of the boiler to be regularly and automatically evacuated through a cyclical opening in the blow down valve. Purging interval and duration are set by the user based on boiler water characteristics as indicated in the generator technical manual. The system requires compressed air availability - rapid opening purge piston valve with pneumatic actuator and return spring - compressed air electronic valve - regulating cycle timer on board of electric panel s of automatic purging as single additional accessory BX 60-90 86900034 BX 200-1750 86900033 s of automatic purging with multiple additional accessories BX 60-90 86900037 BX 200-1750 86900044 Technical characteristics: - purge valve diameter in 1 - compressed air connection diameter in ¼ - min/max compressed air pressure bar 4/10 - cycle air consumption l 0, 62 - purge interval adjustment range h 0-12 - purge duration adjustment range s 0-12 AUTOMATIC PURGING SYSTEM FOR SIXEN AND GX RANGE BOILERS The automatic bottom purging unit prevents unnecessary purging duplication or omission verifiable with the manual system. This system allows sludge accumulated at the bottom of the generator to be regularly and automatically evacuated through a cyclical opening in the purge valve. Purging interval and duration are set by the user based on boiler water characteristics as indicated in the generator technical manual. The system requires compressed air availability - steel body, spherical, rapid opening purge valve with pneumatic actuator and return spring - compressed air electronic valve - regulating cycle timer on board of electric panel s of automatic blow down as single additional accessory GX 86900036 SIXEN 86900040 s of automatic blow down with multiple additional accessories GX 86900042 SIXEN 86900039 Technical characteristics: - purge connection diameter DN 32 * - compressed air connection diameter in ¼ - min/max compressed air pressure bar 4/10 - cycle air consumption l 0, 62 - purge interval adjustment range h 0-12 - purge duration adjustment range s 0-12 * DN 40 per GX 200 ICI CALDAIE SpA CATALOGUE
SOFTENING CONTROL GROUP (PNEUMATIC OR ELECTRONIC TDS) INDUSTRIAL TDS control system limits the salt and mineral levels dissolved in boiler water within permitted manufacturer values, thus avoiding any risk of entrainment due to high salinity levels and minimizing the amount of purge required and associated costs. The system conducts measurements continuously, just below evaporation surface, the electrical conductivity of boiler water whose value is related to dissolved salts concentration. The output value is compared with the input value. If this value is found higher, the purging valve opens until the value drops below the set point. Technical characteristics - purge connection diameter DN 20 - compressed air connection diameter in ½ - min/max compressed air pressure bar 3/6 - cycle air consumption l 0, 33 - conductivity measuring range µs/cm 10-9990 Model salinity control unit (TDS pneumatic) 17090037 salinity control unit (TDS electrical) 17090035 - conductivity probe with integrated temperature probe - steel purge valve - pneumatic actuator with compressed air solenoid valve closed when electrical power is missing, or alternatively electric actuator - shut-off valve at flow start - no return valve - electric regulator on board of electric panel ICI CALDAIE SpA CATALOGUE 201
INDUSTRIAL SALINITY CONTROL GROUP (ELECTRONIC LIGHT TDS) For generators BX 600 and SIXEN 2000 assembled electrically and hydraulically to the generator. TDS control system limits the levels of salts and minerals dissolved in boiler water within permitted manufacturer values, thus avoiding any risk of entrainment due to high salinity levels and minimizing the amount of purge required and associated costs. The system is contains a in line kit connected to a specific boiler connection just below the water level. It works by opening the exhaust valve at regular intervals so that a precise amount of water reaches the conductivity probe located in the measurement chamber placed in-line with the drain valve. The probe measures the electrical conductivity of boiler water whose value is related to concentration of dissolved salts. The output value is compared with the input value from the regulator. If low, at the end of exhaust time the valve closes. If high, the system continues to repeat the discharge cycle until the measured value returns within limits. Technical characteristics 17090051 - blow down diameter in ½ - boiler maximum pressure bar 14 - maximum purge flow kg/h 590 - conductivity measuring range µs/cm 10-9990 - conductivity probe with measurement chamber - drain solenoid valve - filter - 2 shut-off valves - no return valve - electric regulator on board of electric panel D Generator Legend (1) Shut-off valve (2) Filter (3) Conductibility probe (4) Measurement chamber (5) Drain solenoid valve (6) No return valve (7) Electronic regulator Drain 202 ICI CALDAIE SpA CATALOGUE
SAMPLE COOLER INDUSTRIAL In order to make sure that the generator is operating within the parameters of conductivity,water samples must be analyzed In order to obtain accurate and safe samples, it is essential that there is adequate cooling in order to condense any rising steam before sample acquisition. The cooler reduces water temperature up to 25 C making it ready for an immediate sampling. 38040100 - AISI 304 barrel with an internal water-cooling coil - spherical, cooling water immersion valve - handweel valve for sample acquirement ICI CALDAIE SpA CATALOGUE 203
INDUSTRIAL BACKUP SUPPLY PUMP FOR STEAM BOILER In order to ensure generator continuous operation while avoiding production stoppages in the event of fuel pump failure, a second backup pump is provided, installed in parallel with the service pump. Detailed Description of the operation In the event of primary pump failure, also indicated by a blinking light on board of the electrical panel, pump switch is carried out by the operator using a switch located on board the electrical panel. once the malfunction cause is removed This selector is located between the level relay (or regulator) and pump power and security branches, branches that are completely split and independent. Backup pump control is executed in the same way as the service pump. Both pumps, hydraulically connected to the same supply pipe, are accompanied by dedicated non-return and shut-off valves, to avoid water flowing against standby pump current. Contact ICI Caldaie depending on model - backup feed pump with characteristics similar to service pump - pump suction filter - 1 non return valve on pump downstream - 2 interception valves on pump downstream - general control panel electrical commands containing: - pump 1-pump 2 switch - pump 2 electrical power branch - pump 2 operation indicator - pump 2 damage alarm indicator 204 ICI CALDAIE SpA CATALOGUE
MODULATING LEVEL ADJUSTMENT SYSTEM BY MEANS OF 2 WAY SOLENOID VALVE INDUSTRIAL With this system, the level in the boiler is continuously adjusted by a PID regulator that controls the opening of a modulating valve downstream of the pump to supply maintained always in function. The water flow is thereby constantly adapted to steam request, thus avoiding cyclicity in steam production that can occur with on/off level controls. Ensuring a continuous supply water flow to the generator, the use of the modulating supply is compulsory in the presence of the economizer in order to ensure its proper functioning. Detailed Description of the operation - capacitive probe with pre-amplifier - two-way, steel, modulating valve with electric, positional actuator - electric level regulator on board of electric panel The water level in the generator is detected in a continuous manner by a capacitive probe, inserted into a calm water barrel. A preamplifier amplifies measured electrical capacity and converts it into a current signal proportional to the measured level. The signal is transmitted to the electrical panel where an electronic regulator processes the signal in proportional-integral-derivative. Using the thresholds suitably set up, the controller provides the output on/off for the start and the stop of the feed pump, which operates continuously within this range, a low early warning and one high-level, and a continuous signal within set field of work (level) This continuous signal is transmitted to the positioning device of an electrical valve adjustment located downstream of the supply pump. The positioning device converts the analog signal into an electrical signal that is transmitted to valve actuator in order to regulate opening or closing. The modulating valve is accompanied by a handwheel for emergency manual opening and closing and a stopper that restricts the closure in order to protect the pump. Description product codes boiler model valve GR.ALIM.MODUL.DN 15 VALV.ELETTR. KV 1 39050016 SIXEN 650-1350 17110107 GR.ALIM.MODUL.DN 15 VALV.ELETTR. KV 1,7 39050017 SIXEN 1700-2000 / GX 1000-1200 17110128 GR.ALIM.MODUL.DN 20 VALV.ELETTR. KV 1,7 39050021 SIXEN 2500 / GX 1500 17110128 GR.ALIM.MODUL.DN 20 VALV.ELETTR. KV 2,7 39050022 SIXEN 3000-3500 / GX 1750-2000 17110144 GR.ALIM.MODUL.DN 25 VALV.ELETTR. KV 2,7 39050026 SIXEN 4000 17110137 GR.ALIM.MODUL.DN 25 VALV.ELETTR. KV 4,8 39050027 SIXEN 5000 / GX 2500-3500 17110125 GR.ALIM.MODUL.DN 32 VALV.ELETTR. KV 4,8 39050033 GX 4000-5000 17110125 ICI CALDAIE SpA CATALOGUE 205
INDUSTRIAL High level security kit Kit designed to prevent an excessive increase of water level inside the boiler. Upon reaching the set level, the system intervenes by stopping the supply pump and indicating the event with an audible alarm. Alarm resetting and pump restart automatically occur once normal level in the boiler is restored. Model High level security kit 90060010 FX or FX DUAL high level security kit 96140110 - conductivity probe mounted directly on the boiler body for high safety level - high-level relay in generator electric control panel 206 ICI CALDAIE SpA CATALOGUE
AUTO DIAGNOSIS HIGH LEVEL SECURITY UNIT INDUSTRIAL This system is designed to guarantee with absolute certainty that the level in the boiler does not exceed the allowed value while avoiding the flooding of the same. Consists of a fail safe type probe connected to a level electronic relay with selfdiagnosis function, able to indicate: - presence of water above stated level; - loss of insulation within the probe; - failure situation within the device (self-test); - connection interruption between the probe and the device; in accordance with EN 12953-9 point 5.4.8. In the event of an operation, the system gives an audio-visual alarm and stops provisioning the feed pump. Alarm restoration happens automatically once the level is back below allowed value. The supplied system, fully assembled to the generator is tested, and is in accordance with main European directives: - Low Voltage Directive 73/23/EC and 93/68/ CE - Directive EMC 89/366/CE, 92/31/CE, 93/68/CE e 93/97/CE - Directive PED 97/23/CE. 90060040 - fail safe level probe - level electronic relay with self-diagnosis function Technical characteristics - probe connection diameter in ½ - maximum pressure bar 25 - maximum temperature C 226 - probe security degree IP 65 - water minimum conductibility μs/cm 0, 5 ICI CALDAIE SpA CATALOGUE 207
INDUSTRIAL AUTO DIAGNOSIS LOW LEVEL SECURITY UNITI This system, provided as an alternative to series low level probes, is able to ensure with absolute certainty that boiler level does not drop dangerously below allowed value. Consists of 2 fail safe type probes connected to 2 distinct level electronic relays with self-diagnosis function, able to indicate: - water absence below stated level; - loss of insulation within the probe; - failure situation within the device (self-test); - connection interruption between the probe and the device; in accordance with EN 12953-9 point 5.4.8. In the event of an operation, the system gives an audio-visual alarm and permanently stops the generator. The generator restore operation will be carried out only after manual reset and error elimination by the operator. The supplied system, fully assembled to the generator is tested, and is in accordance with main European directives: - Low Voltage Directive 73/23/EC and 93/68/ CE - Directive EMC 89/366/CE, 92/31/CE, 93/68/CE e 93/97/CE - Directive PED 97/23/CE. 90060050-2 fail safe level probes - 2 independent electronic level relays with auto diagnostic function Technical characteristics - probe connection diameter in ½ - maximum pressure bar 25 - maximum temperature C 226 - probe security degree IP 65 - water minimum conductibilitya μs/cm 0, 5 208 ICI CALDAIE SpA CATALOGUE
GSS GLOBAL SECURITY SYSTEM INDUSTRIAL Description GSS 72/1 global security system 72H (BX 60 600) - (SIXEN 350 2000) GSS 72/2 global security system 72H (SIXEN 2500 5000) - GX (BX 800 1750) 86900067 86900068 Comprehensive security system, designed and built to ensure the overall operation safety of steam generators, in line with the new CE directive concerning the conduction without supervisor for 72 continuous hours. Supplied system, (EC certificate by Notified Body as a whole in accordance with the European Directive 97/23/EC), consists of an equipment series electrically and hydraulically assembled and tested at our establishment, and more specifically: A. Automatic sludge removal unit, able to prevent the accumulation of sludge in the boiler body composed of: - 2 way pneumatic valve made of steel, with the lever for manual operation and stop relay. - PLC for adjusting opening frequency and duration - compressed air electrovalve - connections and electrical controls in general control panel of the boiler - mechanical and electrical assembly B. Auto controlled security level containing: - 2 low level security probes, mechanically and electrically independent mounted directly in the boiler body, with manual reconnection with self-test, complete with relay burner unit - high level safety probe, mounted directly in the boiler body - connections and electrical controls in general control panel of the boiler - mechanical and electrical assembly C. Pressure security unit containing: - Fail Safe, manual reinsertion safety pressure switch, complete with burner unit relay - connections and electrical controls in general control panel of the boiler - mechanical and electrical assembly D. Salinity control unit (TDS) containing: - conductivity probe - salinity regulation and control unit - purging system, electric version 72/1 and pneumatic version 72/2, complete with shut-off valves. - electrical controls in general control panel of the boiler - mechanical and electrical assembly E. Boiler control panel certified for safety chain management, complete with PLC and operator panel able to monitor, status signals and alarm view: - inserted generator - control panel power supply - generator pressure view - hot water level view (optional) - modulate supply management predisposition (optional) - burner production view - water supply pump status view - steam high pressure security block - water low level security block - salinity alarm - operation burner - burner block - cumulative alarm signal system All provided material, with particular regard to electrical panel and electrical system, is made in accordance with European Regulations in force, more specifically: - Directive 97/23/CE - Directive 73/23/CE - European Guide Lines 8/15 and 9/20 - Norm EN 12953 60954-1 - Norm EN 50156-1 60730-1 The whole system will be labeled CE as a whole in accordance with European Directive 97/23/EC and test conducted at your establishment with functional parameter setting. ICI CALDAIE SpA CATALOGUE 209