IVAR GV User manual

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TECHNICAL MANUAL
INSTALLATION, USE AND MAINTENANCE INSTRUCTIONS
GVGVO
STEAM BOILER

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Dear Customer,
Thank you for choosing a boiler by IVAR.
In your interest and to maintain the highest level of performance and duration
of your appliance, we recommend that you follow the instructions contained in
this booklet and have regular maintenance performed by qualified personnel.
We would like to remind you that failure to follow the instructions contained in
this booklet may invalidate the guarantee.

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CONTENTS
page 4 – GENERAL WARNINGS
page 5 – GENERAL SAFETY RULES
page 6 – “GV” BOILER TECHNICAL SHEET
page 7 – “GVO” BOILER TECHNICAL SHEET
page 8 – HANDLING AND POSITIONING
page 9 – PLANT TYPE
page 10 – STARTING UP OF THE BOILER
page 10 – STOP UP OF THE BOILER
page 10 – ONCE A WEEK
page 11 – FAULTS AND REMEDIES
page 12 – BOILER HOUSE
page 13 – BOILER CONNECTION
page 15 – ELECTRIC PANEL
page 16 – RECOMMENDED SPARE PARTS

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GENERAL WARNINGS
This instruction booklet is an integral and essential part of the product.
Should the appliance be sold or transferred to another owner, or if you move
and leave the appliance behind, always ensure that this booklet accompanies
the appliance so that the new owner and/or installation technician can consult
it.
This appliance must be used for the purpose for which it was specifically
intended.
All contractual or non-contractual responsibility of the manufacturer is
excluded in the event of damages to persons, animals or things caused by
errors in installation, adjustment, maintenance and improper use.
The manufacturer's responsibility is excluded for all damage to persons and/or
things resulting from a clear risk for the user which he could have avoided by
taking suitable safety measures.
After having removed the packaging, check the contents for breakages. If you
are in doubt do not use the appliance, contact your supplier.
Do not leave the packaging materials (wooden cage, nails, staples, plastic
bags, polystyrene foam, etc.) within the reach of children, as they are potential
sources of risk.
The installation must be performed in compliance with the regulations in force,
following the manufacturer's instructions, by professionally qualified personnel.
The term “professionally qualified personnel” means persons with specific
technical skills in the sector of steam systems.
To guarantee the efficiency of the appliance and ensure correct operation, it is
indispensable to have regular maintenance performed by professionally
qualified personnel, following the manufacturer's instructions.
Any repairs to the appliance must be carried out using only original spare
parts.
If you decide not to use the appliance for a long period, ensure you have
professionally qualified personnel to carry out the necessary operations to
preserve the generator.

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GENERAL SAFETY RULES
The use of any component utilising energy power, fuels and water requires
that certain fundamental rules be respected, such as:
Do not allow children or unskilled people to use the appliance;
If you notice smell of gas, do not turn on electric switches, household
appliances, telephone or any other objects that could cause sparks. If this is
the case:
- open doors and windows immediately to clear the air in the room;
- turn off the fuel taps;
- contact professional qualified personnel.
Do not touch the appliance with wet or damp parts of the body and/or with
bare feet.
Do not perform any maintenance and cleaning operations without having
disconnected the electric power and turned off the fuel supply tap(s).
Do not pull, disconnect, unwind electric cables coming from the boiler, even if
they are disconnected from the mains supply.
Do not block or reduce the ventilation openings in the room to prevent the
formation or toxic and explosive mixtures caused by gas leakage; it is also
uneconomic and polluting because it causes bad combustion.
Do not expose the appliance to atmospheric agents.
The generator has not been designed to work outdoors and is not provided
with automatic anti-freezing systems. Keep the boiler turned on in freezing
conditions.
Other important warnings to be respected:
-If the power cable of the appliance is damaged, have it replaced by
professionally qualified personnel;
-do not fix (and do not allow other persons to fix) electric cables on the
system pipes or near sources of heat;
-ensure that the earthing cables of the appliance are not connected to the
water system;
-do not touch the hot parts of the system (in particular the door and the
smoke box) as they normally remain hot even for some time after the
appliance has been turned off.
In the event of a water leak, turn off the system and contact exclusively
professionally qualified personnel.

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GV
STEAM BOILER (12 bar)
type GV 125 200 300 400 550 700
Kw 87 139 209 278 383 488
Nominal capacity Kcal/h 75000 120000 180000 240000 330000 420000
Kw 98,9 158 237,5 316 435,3 554,6
Furnace capacity Kcal/h 85230 136400 204600 272750 375000 477300
Furnace pressure mbar 223333
Steam production Kg/h 125 200 300 400 550 700
Electric pump n° 111111
stadi 112222
Water content dm338 38 54 54 68 77
A – mm 1250 1250 1350 1350 1350 1350
B – mm 800 800 900 900 900 900Dimensions
C – mm 1500 1500 1500 1500 1500 1750
Steam oulet connection DN 32 32 40 40 40 40
Stack connection Ø - mm 115 115 160 160 160 160
Empty weight Kg 600 600 800 800 900 960
I.VAR. INDUSTRY reserves the right to make any modifications considered necessary for improving production

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GVO
STEAM BOILER (12 bar)
1 – WATER PUMP
2 – ELECTRIC ENGINE
3 – WATER FLOWMETER
4 – PANEL
5 – STEAM REGUL. PRESSURE SWITCH
6 – STEAM MAX PRESSURE SWITCH
7 – STEAM MANOMETER
8 – STEAM SAFETY THERMOSTAT
9 – STEAM SAFETY PRESSURE SWITCH
10 – BURNER
11 – STEAM DELIVERY
12 – MANOMETER COCK
13 – SAFETY VALVE
14 – WATER PRESSURE SWITCH
15 – WATER MANOMETER
16 – START VALVE DISCHARGE
17 – STEAM TRAP
18 – FLAME SPY
19 – CONDENSATE DISCHARGE VALVE
20 – SMOKE SIDE CLEANING VALVE
21 – COUNTERWASH VALVE
TYPE GVO 200 450 750 1000 1500 2000 2500 3000*
Nominal capacity kW 140 314 523 698 1045 1395 1745 2093
kcal/h 120000 270000 450000 600000 900000 1200000 1500000 1800000
Furnace capacity kcal/h 133350 300000 500000 666700 1000000 1333350 1666700 2000000
Furnace pressure mbar 2 3 5 5 6 8 8,5 8,5
Steam production kg/h 200 450 750 1000 1500 2000 2500 3000
Electric pump n° - nr.
stadi - stages 1 11 21 21 21 22 22 22 2
Water content dm³ 45 89 118 153 201 218 249 299
A mm 1250 1500 2000 2400 2650 3000 3300 3800
Dimensions B mm 1000 1150 1150 1150 1350 1350 1350 1350
C mm 1150 1350 1350 1350 1600 1600 1650 1650
F mm 200 220 220 220 330 330 400 400
Steam oulet connection DN 32 40 40 50 65 80 100 100
Stack connection Ø mm 120 160 200 250 350 350 450 450
Empty weight kg 700 1400 1700 2000 2500 3000 3200 3600
* 10 bar
I.VAR. INDUSTRY reserves the right to make any modifications considered necessary for improving production

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HANDLING AND POSITIONING
For the lifting of the generators GVO, please see the diagram below.
GVO L min.
200 900
450 1100
750 1400
1000 1700
1500 1900
2000 2200
2500 2300
3000 2750

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PLANT TYPE
1 – GVO boiler 10 – max pressure switch 19 – water tank 28 – discharges
2 – water pump 11 – safety pressure switch 20 – steam collector 29 – safety discharge
3 – electric engine 12 – steam thermostat 21 – stop valves 30 – condensate return
4 – water pressure switch 13 – steam valve 22 – steam trap
5 – water manometer 14 – safety valve 23 – steam output 32 – burner
6 – flame spy 15 – start valve discharge H – pump water level 33 – no return valve
7 – water flowmeter 16 – softener 25 – water to tank 34 – air discharge
8 – counterwash valve 17 – salt tank 26 – hard water 35 – tank discharge
9 – regulat.pressure switch 18 – dosing pump 27 - filter 36 – smoke side discharge

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A) STARTING UP OF THE BOILER
A1) Check the hardness of the water : max 0.5 °F.
A2) Open drain valve 15.
A3) Shut off the delivery valve 13.
A4) Switch on the main switch on the electrical panel.
A5) Switch on the pump switch on “MANUALE”.
Wait the water flows by the drain valve.
A6) Switch on the burner switch.
A7) Switch on the pump switch on “AUTOMATICO”.
Wait steam mixed with water flows by the drain valve.
A8) Close slowly the drain valve and contemporary open slowly the delivery
valve.
B) STOP OF THE BOILER
B1) Switch off the burner switch.
B2) Open the drain valve.
B3) Close the delivery valve.
B4) Switch the pump switch on “MANUALE”.
Wait the water flows by the drain valve.
B5) Switch off the main switch.
In this way the coil is full of water then in the best condition to avoid oxygen
corrosion.
C) ONCE A WEEK
Before of the operation described in B)
C1) Close the delivery valve. The boiler will stop for max steam pressure.
C2) Switch off the burner switch and pump switch.
C3) Open the counterwash valve 8so that the coil will be cleaned in the
reverse direction.

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FAULTS AND REMEDIES
FLOW SWITCH BLOCK
The burner goes out. The flow switch block lamp lights up on the control panel.
This means lack of water. Check the water level in the service tank.
STEAM BLOCK
The burner goes out and steam temperature thermometer pointer exceeds
200°C. The steam block lamp lights up on the control panel. This means a
capacity defect in the water pump or excessive fuel capacity in the burner
pump.
a - Water pump defect Check the pump capacity: open valve 13, collect the
outlet water in a bucket for 1 minute, then weigh it and determine the pump
capacity in liters/h. The capacity must coincide with the steam output of the
boiler.
E.G. : a 1.000 Kg/h boiler is equal to 16.7 litres/Minute. If the capacity is
insufficient:
1) remove the water pump bell, check the suction and delivery valves and
relevant seat. Change them if necessary.
2) open lid on the pump head and check the piston gaskets. Change them if
necessary (see water pump instructions).
b - Defect on fuel side Contact the burner service manual.
CHIMNEY BLOCK
The burner goes out. The chimney block lamp up on the control panel. To start
burner again, press the reconnection push-button on the thermostat. The
chimney block indicates that the boiler is dirty. Clean the boiler with a pressure
water jet and drain from plug.
Note The action of the safety equipment: flow switch, steam block, chimney
block, causes stoppage of the burner flame. The limit block lamp lights up on
control panel. To resume the operation, press “limit release’’ push button.

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BOILER HOUSE
A boiler house is generally made up of the following equipment:
1 - The steam boiler itself, complete with burner.
2 - Water conditioning plant, generally composed of a water softener with
change of bases and possibly a mattering unit for conditioning products.
3 - Purified water and condensate collecting tank, having a capacity at least
one and half times the hourly steam output of the generator.
4 - Steam collector-header and distributor.
5 - Connection pipes between the single parts.
The “ boiler house “ dimension must be such as to guarantee an easy access to
the various part, means that the boiler operation can be checked and kept
under control; a bad access means negligence leading to probable breakdowns
due to carelessness.
The boiler room has to be ventilated and must therefore be provided with
suitable openings to allow proper aeration.
We remind you that the burner combustion air fan is up to 3.000 m3/h of air
for the larger models and for each generator, and this air must be able to enter
the boiler room without any difficulty.

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BOILER CONNECTION
WATER CONNECTION
The hard water reaches the conditioning plant. This must be surrounded by
dividing wall; the floor should possibly be made in “gres”; independent drain
for backwashing the conditioner. When the softened water leaves the
conditioner it must then be forwarded to the purified water and condensate
collecting tank.
The condensate tank, especially if the water is at high temperature, must have
a minimum head of about 1.50 meters over the generator pump level.
RELATION BETWEEN THE WATER TEMPERATURE AT THE PUMP
AND HEAD, NECESSARY TO AVOID THE CAVITATION.
The connection piping between the tank and boiler must have an adequate
diameter.
Never make a rigid fitting between the boiler piping and pump - Interpose m.
0.30 of high temperature resisting flexible rubber hose.
Do not use elbows but bend pipes to avoid head loss.
A breather pipe should be applied to the condensate collecting tank and let
through to the outside of the room to discharge the fumes.
It is recommendable for the water pipings and tank to be galvanised.

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FUEL CONNECTION
(see also burner instruction book)
These may be three types:
a - pipings for light oil (gas oil);
b - pipings for heavy oil (fuel oil);
c - pipings for gas.
Gas oil pipings
The pipings conveying oil from the tank to the pump and viceversa, must be
made with welded fittings for iron pipings and biconical fittings for copper
ones.
Fuel oil pipings
In this case it is always recommendable to prepare a plant having the day fuel
tank located in the boiler room and the transfer pump between this and the
storage tank. The day fuel tank must be complete with electric and steam
preheater (where possible and convenient), the piping from the day fuel tank
to the burner pump must be insulated and, in the event of heavy fuel oil,
wound with a heat tape.
Special instructions should be requested case by case.
Gas pipings
Connect the maingas network to the burner. For town gas it is advisable to
provide a pressure stabiliser.
CHIMNEY
The chimney is usually made of a sheet steel piping of suitable diameter which
must be taken from the boiler flange to the outside of the room over the top of
the roof. When its height exceeds 12 meter, a draught equaliser should be
provided at the base.
Should several boilers be connected to one chimney, it is important to make
sure that exhausts do not interfere with each other.
STEAM
The steam pipings must have an appropriate diameter PN 16 valves are always
used. The pipes must be insulated and the header must be provided with a
steam trap.
EXHAUSTS
Connect the exhausts to the traps, taking care to make suitable raisers to
avoid sprays.
ELECTRIC LINES
The electric lines are connected to the RST and N terminals of the boiler panel.
The cable section must be suitable to stand the installed electric power.
Check to ensure that the network voltage coincides with the one on the rating-
plate and the wiring diagram.

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WARNING
It is recommended to purge all the piping which have to be connected to the
boiler to ensure that they do not contain any foreign bodies such as fragments
of gaskets, welding slag or anything else which might damage the generator
equipment before finally connecting it to the boiler!
ELECTRIC PANEL
The control switches with relevant pilot lamps are installed on this panel.
1 - Main switch in position “1” supplies voltage to the panel.
2 - The green pilot lamp signals that the panel is live.
3 - The red lamps signal defects in working of various circuits.
4 - The main switch in position “0” cuts off the current to the panel.
5 - The main switch in position “1” starts up the boiler.
TROUBLES SIGNALLED BY THE PANEL LAMPS AND REMEDIES TO BE
TAKEN
1 - Feed water block lights out
The burner goes out - lights up on the panel - check whether there is water in
the service tank.
Pump defect: check the capacity in liters/minute - if capacity is insufficient
remove the pump bell - check gaskets and change them if necessary.
2 - Steam block lights out
The burner goes out, due to the lack of fuel delivery.
3 - Chimney block lights out
This indicates that the boiler is dirty on the fume side.

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LIST RECOMMENDED SPARE PARTS
WATER PUMP Suction valves
Delivery valves
Valves springs set
Valves seat gaskets set
Piston gaskets
Lid gaskets
Head gaskets
Manometer in glycerine bath
SAFETY
DEVICE Thermometer with electric contacts Contacts for thermometer
Steam pressure switch
Water pressure switch
Flow switch
Octal relay
Magnetic starter with over load and under
voltage protection
Type RT 124 thermostat
Pilot lamps set
Stop-running switch
BOILER Gaskets for door
Inspection window
Boiler inox diffuser
BURNER Electrode set (n.2)
Nozzles set (n.2)
Milled disk
Burner diffuser
Photoresistence
Gas oil pump
Hydraulic jack
Flame relay

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NOTES

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I.VAR INDUSTRY S.r.l .
Via S. Pierino, 4 (Z.A.I.) - 37060 Trevenzuolo – VERONA - Italy
Telefono 045/6680082 - Telefax 045/6680051 - P.IVA 02835480233
e-mail: [email protected] – Web site: www.ivarindustry.it
code: ist-GV-GVO-ing rev.00