Operating instructions
Temperature limiter with actual value display for Quick Steam Generator
I004 Version 3 (08/10)
Contents 1
Scope of the Operating Instructions ........................................................................................................................ 1
2
Use in Accordance with Regulations ....................................................................................................................... 2
3
Safety .......................................................................................................................................................................... 2
4
Operating and Maintenance Staff ............................................................................................................................. 2
5
General Risks and Accident Prevention .................................................................................................................. 2
6
Description of Structure and Function / Description of Process........................................................................... 2
6.1
Construction ................................................................................................................................................................. 2
6.2
Function ....................................................................................................................................................................... 2
7
Technical Data (Dimensions, Weight, Operating Conditions)................................................................................ 3
8
Transport and Storage............................................................................................................................................... 3
8.1
General notes on transport........................................................................................................................................... 3
8.2
Interim storage ............................................................................................................................................................. 3
9
Assembly .................................................................................................................................................................... 4
10
Electrical Installation ................................................................................................................................................. 4
11
Setting and Adjustment ............................................................................................................................................. 4
12
Start-up ....................................................................................................................................................................... 4
13
Operation .................................................................................................................................................................... 4
13.1
Behaviour in the event of operating faults .................................................................................................................... 4
14
Measures in the event of unusual observations and operating faults .................................................................. 5
15
Care and Maintenance ............................................................................................................................................... 7
15.1
Testing the temperature limiter, flue gas ...................................................................................................................... 7
15.2
Testing the function of the temperature limiter, steam.................................................................................................. 7
16
Replacement Parts ..................................................................................................................................................... 7
1
Scope of the Operating Instructions
These Operating Instructions contain basic information. They apply in combination with the following operating instructions: •
A002 Basic Safety Instructions
•
C001 Dampffix DF Quicksteam Generator
For the operation of the system as a whole, the operating instructions for the individual components are binding along with the relevant statutory provisions and official requirements.
Page 1 of 7
Operating instructions
Temperature limiter with actual value display I004
for Quick Steam Generator
Version 3 (08/10)
2
Use in Accordance with Regulations
The temperature limiter may only be used on quick steam generators for monitoring the steam and flue gas temperature.
3
Safety
Please read the Operating Instructions: •
4
A002 Basic Safety Instructions
Operating and Maintenance Staff
Please read the Operating Instructions: •
5
A002 Basic Safety Instructions
General Risks and Accident Prevention
Please read the Operating Instructions: •
6 6.1
A002 Basic Safety Instructions
Description of Structure and Function / Description of Process Construction
The liquid-filled enclosed measuring system consists of a temperature sensor, measuring line and a Bourdon spring. The change in volume created by the heat hitting the temperature sensor and thus the pressure change in the enclosed system is transmitted through the measuring line to the Bourdon spring and displayed via the angle deflection of the indicator shaft on the display dial. The switching disc positioned on the indicator shaft is triggered when the switching point is reached and locks the current switching status.
6.2
Function
The temperature limiter is a combination of temperature limiter and actual value display. In addition to the locking function, it is intrinsically safe, i.e. if there is a break in the capillary tube, the temperature limiter switches the firing off. The temperature limiter shows a fixed switching off point which is marked by a triangle. If the actual temperature exceeds the switching off point that has been set permanently ex-factory, the built-in micro-switch turns off the firing and locks it, i.e. the system is no longer functional. The boiler is unlocked by means of the operating selector switch on the control cabinet of the quick steam generator. This is possible once the temperature has fallen 3% below the switching off point set ex-factory.
Temperature limiter (steam)
Temperature limiter (flue gas)
Page 2 of 7
Operating instructions
Temperature limiter with actual value display I004
for Quick Steam Generator
Version 3 (08/10)
7
Technical Data (Dimensions, Weight, Operating Conditions)
Operating pressure:
31 bar at 237°C
Mechanical connection:
Thread G 1/2" DIN ISO 2999
Measuring principle:
Bourdon spring system
Materials:
Measuring lines:
copper-wound
Capillary tubes: Display ranges:
1.4571
0 - 400 °C 0 - 500 °C
Switching points set ex-factory:
280°C (steam) 370°C (flue gas)
Electrical connection:
Terminal connection
Load data
Umax. = 250 V
Contacts:
Microswitch (one-pole changeover switch)
Protection type:
IP 53, terminals IP00 (EN60 529 / IEC 529)
Display precision:
± 2% of measurement range at reference temperature 23°C on housing and measuring line
Permitted ambient temperature:
maximum 70°C
8 8.1
Imax. = 1.4 A Pmax. = 250 VA
Transport and Storage General notes on transport
Measurement and control devices are sufficiently protected and packed for transport at the factory. Please note the following instructions: •
Under no circumstances should the devices be exposed to temperatures below -40 °C or above +80 °C.
•
Avoid vibrations as far as possible.
•
Always protect equipment from the effects of wetness and damp.
•
If damage to the packaging is observed when the delivery is received, the driver must be informed about this damage. When the driver hands over the delivery, he must confirm in writing on the receipt slip that the packaging is damaged.
•
If damage is found after unpacking, please contact Loos immediately.
8.2
Interim storage
•
All equipment should be stored in the original packing.
•
Store in dry (humidity < 60%), dust-free conditions
•
Temperature fluctuation in the store room < 10 K/h
•
Under no circumstances should the devices be exposed to temperatures below -40 °C or above +80 °C.
Page 3 of 7
Operating instructions
Temperature limiter with actual value display I004
for Quick Steam Generator
Version 3 (08/10)
Important: If stored for extended periods of time (> 1 year), system dropout may occur. This is shown by the fact that the displayed temperature is well below the temperature corresponding to the steam pressure. In this case, the device must be replaced with a new one. (Information about the relationship btween the saturated steam pressure and temperature is given in TI001 Saturated Steam Enthalpy and Water Enthalpy)
9
Assembly Danger! There is a risk of serious scalding. The temperature limiter may only be installed if the boiler is switched off, guaranteed without pressure and sufficiently cooled down.
When installing the temperature sensor, check the leaktightness. During commissioning, if necessary, the connection screw fitting should be tightened or resealed. Particular attention should be paid to ensuring that the measureing line (capillary tube) is not bent. The minimum bending radius is 150 mm.
10 Electrical Installation Important: The electrical connection is an integral part of the component testing. If the connection requirements are not met, the component test is invalid. The electrical connection of the temperature limiter may only be carried out by a Loos Service engineer or qualified electrician.
11 Setting and Adjustment Important: The temperature limiter is set at the factory. As a rule, the setting does not need to be changed. If this is necessary, however, adjustments may only be made by Loos Service engineers or by specialist staff who have been expressly authorised by Loos to carry out this work.
12 Start-up The initial commissioning or re-commissioning after replacement of the temperature limiter may only be carried out by Loos Service or by specialist personnel who have been expressly authorised by Loos to carry out this work.
13 Operation For normal operation, no further measures are necessary apart from the tests described in the Chapter "Care and maintenance".
13.1 Behaviour in the event of operating faults Danger! A lack of water or excessive flue gas temperature can be dangerous. This can seriously damage the boiler, or even destroy it completely. In extreme cases, this may cause extremely serious damage to the plant and acute danger to personnel in the vicinity of the boiler from the hot medium (steam, hot water). If there is insufficient water or the flue gas temperature is too high, the temperature limiter must be triggered and cause a fault switchoff and locking of the firing. If the temperature limiter fails, the boiler heating must be switched off immediately. If necessary, switch off using the emergency switch. The boiler may then only be started up again if the causes for the failure of the temperature limiter have been repaired by experts and a qualified person allows the boiler firing to be switched back on again after a corresponding inspection. Loos
Page 4 of 7
Operating instructions
Temperature limiter with actual value display I004
for Quick Steam Generator
Version 3 (08/10)
recommends that this inspection is carried out by suitably trained Loos service engineers or by personnel who have been expressly authorised by Loos to carry out this work. If the boiler has been damaged by a lack of water or excessive flue gas temperature (e.g. deformation or overheating of heating coils), the boiler must be brought to a standstill immediately. The boiler may then only be started up again if the damage caused has been repaired by experts and a qualified person allows the boiler firing to be switched back on again after a corresponding inspection. Loos recommends that this inspection is carried out by suitably trained Loos service engineers, unless a monitoring organisation has been consulted. Following operating phases with disturbed water conditions (ingress of hardness, foreign matter etc.), the boiler and all safety-relevant equipment must be inspected separately in coordination with a technical expert.
14 Measures in the event of unusual observations and operating faults If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on repair:
Observation/fault:
Temperature limiter, steam (lack of water)
Cause
Repair
Shutoff devices in suctoin and pressure pipe not opened
Open all shutoff valves in the suction and pressure pipes
Heating coil not completely filled with water
Rinse heating coil for at least 7 minutes
Temperature limiter switches off too early
With adjustable devices, check settings
By whom?
Replace device
Amount of fuel set too high
Check amount of fuel and reduce if necessary
Too many standard shutdowns
Increase pressure difference between burner ON and burner OFF Increase steam consumption
Reduce performance to low load
Install steam store
Too much steam removed from boiler
Throttle steam shutoff valve
Install overload protection (e.g. overflow valve)
Feed pump feeds too little or no feed water
See operating instructions E002 "Plunger Pump" or E003 "Prssure Booster Pump"
Page 5 of 7
Operating instructions
Temperature limiter with actual value display I004
for Quick Steam Generator
Version 3 (08/10)
Cause
Repair
Feed pump does not switch on
Check switching points of level regulator and dry running protection
By whom?
Disconnect frequency converter for feed pump, if there is one, and reconnect to power supply after 30 s Filter between feed water container and boiler intake is blocked
Clean filter valve
Heating coil leaks
Repair or replace heating coil
Observation/Fault:
Temperature limiter, flue gas
Cause
Repair
Heating coil blocked (calcified) on water side
Clean heating coil
Heating coil blocked with soot on flue gas side
Clean heating coil
Observation/fault:
Incorrect temperature display
Cause
Repair
System dropout through storage
Replace device
Observation/fault:
By whom?
Temperature limiter can no longer be unlocked
Cause
Repair
Capillary tubes faulty
Replace device
Observation/fault:
By whom?
By whom?
Temperature sensor leaking
Cause
Repair
Faulty seal
Replace seal
By whom?
Page 6 of 7
Operating instructions
Temperature limiter with actual value display I004
for Quick Steam Generator
Version 3 (08/10)
15 Care and Maintenance 15.1 Testing the temperature limiter, flue gas Every month, a reference measurement of the flue gas temperature must be carried out to check that the actual flue gas temperature matches the temperature display on the temperature limiter. If the deviation is more than 20 K, the temperature limiter must be replaced by Loos Service engineers or by personnel who have been expressly authorised by Loos to carry out this work.
15.2 Testing the function of the temperature limiter, steam Note: To test the function, sufficient steam must be produced; if possible, the boiler must be operated at high load. During operation, the "Test temperature limiter" button must be activated at the control cabinet of the quick steam generator. This slows down the feed pump. If the firing performance is high, the set switching off point will be reached in a short time. The firing must then shut off and lock. If the temperature limiter does not switch off when the set switching off point is reached, the function of the temperature limiter must be checked by Loos Service engineers or by personnel who have been expressly authorised by Loos to carry out this work. After the temperature limiter has been triggered, the boiler must be restarted according to Operting Instructions C001, section "Regular/daily start-up".
16 Replacement Parts For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services in Register L (Forms). Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst / Ersatzteilversorgung (customer service / spare parts supply). •
Temperature limiter (steam):
Material number
014099.1
•
Temperature limiter (flue gas):
Material number
014100.1
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