Spirax Sarco PLC User manual

3.635.5275.253 Ed. 1 IT - 2010
© Copyright 2010
EXPER
TISE SOLUTIONS SUST
AINABILITY
PLC Unit Control
for CSM-K Clean Steam Generators
Installation, Operation and Maintenance Manual
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
The ATEX Directive 94/9/EC is repealed and replaced by the new
ATEX Directive 2014/34/EU with effect from 20 April 2016.

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ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare insicurezza conprodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
Working safely with cast iron
products on steam
Cast iron products are commonly found on steam
and condensate systems.
If installed correctly using good steam
engineering practices, it is perfectly safe.
However, because of its mechanical properties,
it is less forgiving compared to other materials
such as SG iron or carbon steel.
The following are the good engineering practi-
ces required to prevent waterhammer and ensu-
re safe working conditions on a steam system.
Safe Handling
CastIronisa brittlematerial.If theproduct isdropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspectedand pressuretested bythe manufacturer.
Please remove label before commissioning

Vapore
Steam
Flusso
Flow
Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:
Steam Mains - Do's and Dont's:
Flusso
Flow
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Intervalli di 30÷50 m. intervals
Pendenza - Gradient 1:100
Vapore
Steam Gruppo di scarico
Trap set
Condensa - Condasate
Pendenza - Gradient 1:100
Gruppo di scarico
Trap set
Gruppo di scarico
Trap set
Condensa - Condasate
Condensa - Condasate
Vapore
Steam

Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque gures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle ange devono essere serrati in modo
graduale e in sequenza, come indicato in gura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.

Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Distanza breve
Short distance
Punto di ssaggio
Fixing point
Movimento assiale
Axial movement
Distanza
media
Medium
distance
Tiranti limitatori
Limit rods
Piccolo
movimento
laterale
Small
lateral
movement
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Guide
Guides
Guide
Guides
Guide
Guides
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Movimento assiale
Axial movement

33.635.5275.253
Table of Contents
Limits of Responsability Pag. 4
Control Unit Pag. 6
Location and identication of components Pag. 7
Control Features Pag. 8
External Connections Pag. 9
Display and Keyboard Pag. 10
Initial Screen Pag. 11
Manual Mode Pag. 13
Manual set-up of feed water Pag. 14
Manual control of the Pressure Pag. 17
Manual control of the Bottom Blowdown Valve Pag. 21
Automatic mode Pag. 22
Pressure control Pag. 24
Level setup Pag. 25
Set-up of the bottom blowdown period Pag. 26
General considerations in Automatic Operation Pag. 28
Alarms and Blocks Pag. 29
Conguration Pag. 31
Parameters protected by a password Pag. 34
Repairs Pag. 39

43.635.5275.253
Limits of Responsability
This manual covers the procedures for the Installation, Operation and Maintenance of the PLC unit for the
control of indirect Steam Generator Systems. This manual is intended to be as complete and up to date as
possible. SPIRAX SARCO reserves the right to update it at any time and without obligation to notify product
owners of such changes.
Responsabilities
SPIRAX SARCO is not responsible for inaccuracies in specications, procedures and / or the content of
other product literature supplied by the manufacturers of components used on SPIRAX Steam Generators.
For manufacturing and control of Steam Generators SPIRAX SARCO utilizes only high quality components.
In case of a complete supply of a system SPIRAX SARCO will take full system responsibility. Where instead
SPIRAX SARCO has no direct control on other manufacturers and their quality level the responsibility will
be assumed only for the supplied parts.
Note: the symbol points out the “Warnings”
SPIRAX SARCO is not responsible for injury to personnel or product damage due to improper
actions and procedures used for installation, operation and maintenance.
These procedures should only be performed by trained and certied personnel. Prior to attempt these proce-
dures the personnel should completely and carefully read and understand this manual and other applicable
manuals for all supplied products. All personnel should also pay strict attention to all Notes, Cautions and
Warnings described in this manual.
In case SPIRAX SARCO supplies a Steam Generator without any auxiliary control equipment,
this manual is applicable only for the Generator part. The main contractor of the system will then
assume the responsibility for the supplied components, for their relevant manuals and for the com-
plete generation system.

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Information
This manual has been conceived as an operating guide for the control unit of SPIRAX SARCO Steam
Generators. Since every unit is built according to customer specications, the manual instructions might
sometimes appear too general and incomplete. Additional specic notes will be supplied when the proce-
dures substantially differ from those included in the standard manual.
Should this manual not respond to all questions or the procedures are not clearly comprehensive,
the user is invited to contact SPIRAX SARCO for any clarication.
Warnings
In the following pages several points with specic warnings are listed. Warnings are moreover repeated
when the procedures refer to areas of potential hazard.
All warnings and relevant precautions have to be carefully studied and followed to reduce the risk of injury
during operations of Installation, Start-up and Maintenance.
Every product or system using steam, diathermic oil, superheated water under pressure or
electric power can represent a potential hazard to personal injury when procedures are not properly
followed.
The simultaneous presence of water and electric power can generate hazardous conditions.
Areas with potential hazard
1. All connections and electric cables
2. All steam lines, valves, joints and pressure controllers
3. All steam lines, diathermic oil or superheated water, valves, joints and pressure controllers
Connections of main power supplies
All procedures for the connections of main power supplies have to be performed by trained and qualied
electrical personnel. The PLC unit for the control of SPIRAX SARCO Steam Generators are designed to be
installed in covered locations, unless otherwise specied by the customer.
Make sure to disconnect power before starting any operation of installation or maintenance.

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Control Unit
Description
The control and safety unit is a PLC type intelligent equipment designed to start-up, control and operate
indirect steam generation systems, either in local mode or by ultimate means of a remote system.
PLC
S1
L1
PE IG
BC
L2
PRB