Unical BAHR 12 User manual

BAHR’12
INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

2
DATA PLATE
Modello
Model
Pressione max. ammiss. PS (bar)
Max. Design Pressure
Numero di Fabbrica
Serial Number
Pressione max. di esercizio (bar)
Max. Working Pressure
Anno di Fabbricazione
Manufacturing Year
Temperatura max. ammis. TSmax (°C)
Max. Allowable Temperature
PotenzaNominale (kW)
Heat Output
Temperatura max. di esercizio (°C)
Max. Working Temperature
PotenzaTermica al focolare (kW)
Heat Input
Temperatura min. ammiss.TSmin (°C)
Max Allowable Temperature
Fluido
Fluid
Acqua
Water
Pressione di prova idrostaca (bar)
Hydraulic Test Pressure
Produzione vapore (kg/h)
Steam Capacity
Data di prova idrostaca
Hydraulic Test Date
Superficie riscaldata (m2)
Heang Surface
Massa di riempimento max. (kg)
Max. Filling mass
Volume Totale V (l)
Total Volume
Tara (kg)
Tare

3
1 GENERAL INFORMATION ....................................................................................................................................................................................4
1.1 General warnings .......................................................................................................................................................................................... 4
1.2 Symbols used in the manual ......................................................................................................................................................................... 5
1.3 Safety warnings.............................................................................................................................................................................................. 5
General informationTechnical featuresInstallation instructionsMaintenance instructions
4 INSPECTIONS AND MAINTENANCE..............................................................................................................................................................38
4.1 General rules for running steam generators ................................................................................................................................................ 38
4.2 Maintenance instructions ............................................................................................................................................................................ 39
4.3 General rules for decommissioning............................................................................................................................................................. 39
Operating anomalies.......................................................................................................................................................................................... 40
Residual risks from Risks Analysis pursuant to the European Directive 97/23/EC - PED ................................................................................... 42
3 INSTALLATION INSTRUCTIONS .......................................... 13
3.1 General warnings ...............................................................13
3.2 Installation standards.......................................................13
3.3 Supply conditions ............................................................14
3.4 Handling ..........................................................................14
3.5 Positioning in boiler room.................................................15
3.6 Water features .................................................................16
3.7 Hydraulic connections .....................................................19
3.8 Pneumatic connection .....................................................19
3.9 Gas connection................................................................20
3.9 Condensation drainage....................................................23
 3.11Connectiontotheue ......................................................21
3.12 Burner assembly..............................................................22
3.13 Furnace door: adjustment, opening, closing ....................23
3.14 Electrical connections......................................................24
3.15 Control panels..................................................................25
3.16 Commissioning................................................................28
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................7
2.1 General description of the range 7
2.2 Description of components ........................................................................................................................................................................... 8
2.3 General features ........................................................................................................................................................................................... 9
2.4 Dimensions ................................................................................................................................................................................................. 10
2.5 Operation data ............................................................................................................................................................................................ 12
3.17 Subsequent start-ups and operation................................35
3.18 Instructions for stopping the generator.............................36
3.19 Instructions for the emergency stop of the generator .......36
3.20 Instructions for decommissioning
and storage......................................................................37

4
1GENERAL INFORMATION
This document is the Technical Manual for installation, use and
maintenance of BAHR '12 type high pressure ame blowing
steam generators.
BAHR’12steam generators(with the exceptionof those tted
with Basic electrical panels) are equipped to “Operate without
continuous supervision” by a person authorised to run it up to a
maximum of 24/72 hr.
The BAHR '12 type steam generator is manufactured, tested
and certied as SET in compliance with the Essential Safety
Requirements of Directive 97/23/EC "PED - Pressure Equip-
ment Directive" according to the B+F conformity assessment
modules.
ATTENTION!
The BAHR '12 series steam generators must
be operated within the limits for which they
were designed; any other use must be con-
sidered improper and therefore dangerous.
These design limits are given:
- on the data plate applied on the appliance;
- on the declaration of conformity supplied
with the generator.
ATTENTION!
This manual is an integral and essential
part of the supply and must be delivered to
the user.
In the event that the generator is transferred in use or sold to
other Users (change of destination or move) make sure that the
appliance is transferred together with this installation, use and
maintenance manual so that it can be consulted by the entrust-
ed installer, the maintenance technician and the new owner.
Before starting installation, starting the ignition process or un-
dertaking any maintenance, carefully read the instructions and
procedures contained in this manual; they provide important in-
formation regarding the safety of the system and the safety of
persons.
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 operation must be car-
riedoutbyprofessionallyqualiedandauthorisedpersonnel.
ATTENTION!
THE RUNNING OF THE STEAM GENERATOR
MUST BE ASSIGNED TO QUALIFIED PER-
SONNEL AS DEFINED BY ITALIAN LEGISLA-
TIVE DECREE 1 MARCH 1974
IT IS STRICTLY FORBIDDEN FOR PERSONS
NOT SPECIFICALLY ENABLED TO USE,
RUN, MAINTENANCE THE GENERATOR.
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
ATTENTION!
THE GENERATOR IS NOT DESIGNED TO BE
INSTALLED OUTDOORS, BUT MUST BE LO-
CATED WITHIN THE APPROPRIATE PREM-
ISES (BOILER ROOM).
OUTDOOR OPERATION CAN DAMAGE THE
SET, THUS RESULTING IN SERIOUS DAN-
GER DUE TO:
• collapse / burst of framework aimed at the
pressure containment for embrittlement of the
metal parts of the framework making up the
pressurised body;
• collapse/burst for failed operation/inhibition of
the safety and adjustment accessories;
• damage due to impairment of safety equip-
ment / adjustment due to the action of rainwater;
• minimum temperature not compatible with the
minimum allowable for the set/components, dur-
ing the expected life.
• impairment of the IP protection of electrical
parts not suitable for operating the set outdoors
under the action of atmospheric agents.
ATTENTION!
PURSUANT TO THE LEGISLATION IN
FORCE IT IS NOT PERMITTED TO OPER-
ATE THIS GENERATOR BEFORE YOU HAVE
COMMUNICATED COMMISSIONING TO THE
NATIONAL CONTROL BODIES AS PRE-
SCRIBED IN "DECREE 1 December 2004,
no. 329, Regulation with standards for the
commissioning and use of pressure equip-
ment and assemblies referred to in article
19 of the Legislative Decree 25 February
2000, no. 93" to which the equipment User
must strictly adhere because RESPONSI-
BILITY of the same.
1.1- GENERAL WARNINGS

General information
5
The generator is excluded from commissioning
vericationasitmeetsart.5,paragraphd)ofthe
Italian Ministerial Decree. 1 December 2004 No.
329; However, the user MUST COMMUNICATE
COMMISSIONING TO THE LOCAL COMPE-
TENT AUTHORITIES AS SET OUT IN ART. 6
OF THE SAME:
The user has the obligation to communicate the commissioning
together with INAIL (formerly ISPESL) and competent ASL in
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
qualiedinstallersinaccordancewiththelawandauthorised
by the relevant gas company.
- The interventions to the electrical system must only be carried
outbyspecialisedandqualiedpersonnel,accordingtothe
law.
-Commissioningmustbedonebyprofessionallyqualiedper-
sonnel.
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 97/23/EC.
Behaviour in case of fuel leaks
Danger
The leaking of fuel can cause explosions
and serious injuries.
- Do not smoke!
 Avoidnakedamesandsparks.Neveractivatelightsorelec-
trical devices.
theterritory,asdenedinart.6ofItalianMinisterialDecreeof1
December 2004 No. 329
- The user has the obligation to submit the steam generator to
the periodic inspections of law provided for by the Italian Min-
isterial Decree of 1 December 2004 No. 329.
as foreseen by Annex B Table:
-Internalvisitandoperationvericationevery2years
- Integrity check every 10 years
-Closetheshut-o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 build-
ing.
-Shut-o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othesystem.
- Ventilate the place of installation.
Interventions on the system
- Closethefuelshut-ovalveandmakesurethatitcannotbe
opened accidentally.
- Disconnect the system supply voltage (e.g. acting on the in-
dividual 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.
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

6
Hot surfaces
Risk of burns caused by contact with hot
surfaces:
- steam pipe,
- hot water pipe,
- manhole inspection cover,
- 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. Replace
the faulty parts with original Unical 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
    -

warranty rights. For the replacement, only
use original Unical spare parts.
Draining boiling water
Attention
Purge and desalination water can reach
temperatures of 100°C and more.
Before being conveyed to the drainage sys-
tem, it must be cooled to a temperature of
< 35°C.
Draining condensate produced by combustion gas-
es
Attention
Upon operating of the boiler system, or under
certain operating conditions, condensation may
form in the smoke passes and in the smoke
chamber.
The system installer must provide a suitable type of installation
that allows the safe discharge of condensate water.
The produced condensate water must be neutralised in compli-
ance with the standards in force.
Safety Guidelines
If there is a risk of imminent damage, decommission the
boiler immediately.
In case of serious damage to the boiler or to the water supply
tanks, immediately inform the authorised inspection body be-
fore carrying out repairs.
Comply with the technical instructions.
An ocial authorisation is required to install and operate the
steam generators that must be available before start-up.
In the event of explosion, the system user is obliged to imme-
diately report to the authorised inspection body, regardless of
whether people have been injured or not. In the event of dam-
age, do not change the created state, before the authorised in-
spection body has carried out a check, unless this constitutes a
preventive measure to avoid further damage and to safeguard
the safety of people.
Access to the boiler room is forbidden to unauthorised person-
nel.
Keep the boiler room clean, well lit and, above all, free from for-
eign objects that obstruct the operation.
During operation, keep the prescribed exits open and free.
The service personnel is responsible for recording all events,
such as:
- faults,
- new settings,
- use of spare parts,
- repairs.
The routine readings of the operating equipment must also be
recorded.
Immediately report any visibly phenomena on welding seams,
not-hermeticdamagedpointsorwithrstsignsofrust,unusual
behaviour of the operating equipment and system components,
anomalous noises inside the boiler.
System faults and defects that cannot be eliminated must be
equally reported to the manufacturer.
All boiler components and adjustment devices must be protect-
ed against rain, water and steam leaks. Any damage or leaks
must be immediately repaired.

General information
7
2.1 - GENERAL DESCRIPTION
OF THE RANGE
2TECHNICAL FEATURES
AND DIMENSIONS
The series of high pressure steam generators, with smoke
pipes, with ame blowing furnace, high performing BAHR'12
Unical STEAMER is designed for a maximum allowable pres-
sure PS = 12 bar.
The range includes no. 15 models with a steam production of
300 kg / h (nominal power = 204 kW)
at 6000 kg / h (nominal power = 4089 kW).
The BAHR '12 range of generators is made up of the following
versions:
OR suitable for operation with gas burners, gas oil or fuel
oil
STD suitable for operation with gas burners, gas oil or fuel oil
HP0 suitable for operation with gas burners, gas oil
HP suitable for operation with gas burners
EC To further improve the already high value performance of
thegenerator,withoutinuencingthesizes,theBAHR’12
STD, HPO and HP models are already provided for mount-
ing, on request, (already in the factory or at a later time),
the EC economiser composed of:
 • annedpipecarbonsteelexchangecoil,whichcanbe
easily inserted into the rear smoke chamber (drawer in-
sertion);
• a modulating or inverter supply valve
• electrical components;
• processing pipes.
TheECkitisspecicforeachmodelandrequires,incombina-
tion, the water level modulation unit.
The single-block version generator supplied is composed of the
following units:
A) Boiler body complete with:
- manhole,
- frontdoor full with ame warninglight and blind plate for
connection to burner,
- smoke chamber complete with inspection door and clean-
ingandueoutlettting,
- rock wool insulation coating and pre-painted aluminium
casing.
B) Finishing assembly consisting of:
-streamlineowvalveasmainsteamoutlet
- 2 spring safety valves
-blindangeonthesecondarysteamoutlet
C) Assembly control panel
 on request the generator can be equipped with 3 dierent
types of control panel (BASIC, BMI or IML) and relative ac-
cessories connected to them (that can be connected).
BASIC control board composed of:
- BASIC control panel including wiring (pressure gauges,
probes, burner power),
- no.4 level probes (min, max, safety)
- no.2probeholderanges,
- no. 2 level indicators,
- manifold with pressure gauge, 3 way valve, pressure
switches (2 control + 1 safety)
BMI control board composed of:
- BMI control panel including wiring (pressure gauges,
probes, burner power),
- no.4 level probes (min, max, safety),
- no.2probeholderanges,
- no. 2 level indicators,
- manifold with pressure gauge, 3 way valve, pressure
switches (2 control + 1 safety)
IML control board composed of:
- IML control panel including wiring (pressure switches, lev-
el gauges, probes, burner power),
- no. 3 level probes (2 safety, 1 set),
- barrel with capacitive probe
- no.2probeholderanges,
- no. 1 level indicator,
- manifold with pressure gauge, 3 way valve, pressure
switches (1 control + 1 safety), pressure transducer.
D) Supply unit
on request the generator can be equipped with 1 or 2 pumps.
1 pump unit composed of:
- shut-ovalve+checkvalve,
- 1 pump complete with wiring,
- support base
2 pumps unit composed of:
- 2shut-ovalves+checkvalve,
- 2 pumps complete with wiring,
- support base
E) Boiler drain unit
on request the generator can be equipped with automatic
discharge.
F) Salinity control unit (TDS)
on request the generator can be equipped with the TDS 1 or
TDS2 salinity control unit.
The salinity control unit is composed of:
- shut-ovalve
- relief valve
- conductivity probe (CP30 x TDS 1 - CP32 x TDS 2)
- solenoid valve
- wiring connections
G)Water level modulation unit
on request the generator can be equipped with water level
modulation unit for systems with:
- 1 or 2 pumps
NOTE:
Normally, the generators are supplied fully
assembled. In particular cases, to avoid dam-
age during transportation or handling, some
units are supplied unassembled.
For the reassembly, refer to the instructions
supplied together with the documentation
supplied with the device.

8
2.2. - DESCRIPTION OF THE COMPONENTS
1 Control board
2 Level indicator
3 Capacity probe unit (optional - only with IML)
4 Salinity control unit (TDS)
5 Supply pump(s) unit
6 Flow regulation pneumatic valve (optional)
7 Thermometer (optional)
8 Drain valve
9 Economiser (optional)
10 Smoke chamber
11 Safety valve
12 Steam intake valve
13 Manhole
14Probeholderange
15Probeholderange
16 Pressure gauge
17 Pressure switch
18 Insulating coating
19 Front door
20 Three-way valve
21 Safety probe
22 Level probe
1
4
7
10
13
16
19
22
2
5
8
11
14
20
3
6
9
12
15
18
21
11
17
21
22

General information
9
Theameblowinggeneratoriscomposedbycylindricalhearth
withwetendinwhichtheamedevelopsandwherethereversal
of the combustion products occurs.
The fumes, therefore, enter the tube bundle at the front tube
plate and are conveyed towards the rear smoke chamber from
whichtheyescapethroughthechimneytting.
The appliance is dimensioned to ensure low thermal loads in
the combustion chamber and a low surface loading.
Construction features
Boiler body
The boiler body is made up of a cylindrical shell, hearth, hearth
bottomandatsteelpipingplates,sizedaccordingtotheVSG
calculationcode(GeneratorsStabilityVerication)(andCTIrec-
ommendations) and in compliance with the technical standards
in force.
The materials used are accompanied by manufacturing certif-
icates attesting the chemical and mechanical features and in-
spections during the production cycle and therefore their suit-
ability to use.
The welded joints are performed at electric arc according to ap-
provedproceduresbyproperlyqualiedpersonnelandsubject-
ed, according to an internal level of "Manufacture and Control",
to Non Destructive Testing.
The smoke pipes that make up the tube bundle, are welded to
thepipingplatesbymeansofqualiedautomaticprocedures.
Whenproductionisnished,anypressurisedbodyistestedby
carrying out the hydraulic test in compliance with laws / stand-
ards in force.
Front door
The front door is made of welded steel sheet, coated internally
with a layer of insulating material (towards the outside) and a
layer of refractory material (towards the inside). It is mounted on
hinges that allow opening reversibility and complete adjustment.
It is equipped with self-cleaning ame-warning light, suitably
positioned to control the correctness of combustion in opera-
2.3 - GENERAL FEATURES
tion; on the same is bolted the burner coupling plate, supplied
blind, can be prepared for the type of burner indicated by the
customer.
Rear smoke chamber
The smoke chamber, made of welded steel sheet and insulated
withrockwool,isxedtothereartubeplatebyboltstoallowits
removal. It is equipped with suitable cleaning door and smoke
connectionwithhorizontalaxisofsuitablediametertothepower
of the generator.
Base and walking surface covering
Thebaseisconstitutedbyaframemadeofsteelproleselec-
tro-welded to the tube plates and closed by means of welded
steel plate.
The service walkway located at the top of the generator is also
composed of a steel prole frame, covered with chequered
sheet metal (walking surface covering) and, when required,
completed with a parapet with handrail.
Insulation of the planking and gables
The thermal insulation of the planking is obtained with rock wool
mattress, linked with thermosetting resins, suitably supported
and coated on the outside by the pre-painted aluminium case.
The device gables (steam rooms) are also insulated with rock
wool, externally encased. Particular attention has been paid to
the drastic reduction of thermal bridges, through the interposi-
tion of felts and insulating gaskets in order to prevent body con-
tact with the coating, so as to reduce the surface temperatures
andlimitdispersionstothebenetofbothsafetyandyield.

10
2.4 - DIMENSIONS
BAHR’12 OR
BAHR’ 12
Model
300
400
500
600
800
1000
1250
1500
1750
2000
2500
3000
4000
5000
6000
Ø
mm
219
219
258
258
358
358
408
408
408
408
508
508
608
658
658
Weight
empty
kg
1620
1620
2010
2010
2830
2830
3710
3710
4610
4610
6560
6560
8980
10540
11750
Weight in
oper.
kg
2145
2145
2770
2770
3910
3910
5265
5265
6615
6615
9450
9450
13135
16340
18510
T1
DN32
DN32
DN40
DN40
DN50
DN50
DN65
DN65
DN65
DN65
DN80
DN80
DN100
DN125
DN150
T2
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN50
DN50
T3
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN32
DN32
DN32
DN32
DN40
T4
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN40
DN40
DN40
DN40
DN40
DN40
DN40
T1 Steam inlet
T2 Safety valve drain
T3 Water supply
T4 Boiler drain
B
T1
Ø
L
C
D
E
H
A
W
T2
T4T3
T4T3
T2
A
mm
780
780
860
860
950
950
1090
1090
1200
1200
1470
1470
1700
1800
1850
W
mm
1474
1474
1861
1861
1996
1996
2126
2126
2246
2246
2296
2296
2756
2856
3026
B
mm
1550
1550
1750
1750
2120
2120
2526
2526
2750
2750
2830
2830
3300
3800
4003
L
mm
2320
2320
2530
2530
2900
2900
3259
3259
3559
3559
3640
3640
4107
4590
4810
D
mm
635
635
695
695
745
745
860
860
905
905
1080
1080
1170
1195
1210
E
mm
1333
1333
1453
1453
1593
1593
1783
1783
1918
1918
2243
2243
2473
2548
2618
H
mm
1820
1820
1940
1940
2077
2077
2294
2294
2422
2422
2774
2774
3031
3173
3315
C
mm
815
815
880
880
935
935
1015
1015
1170
1170
1405
1405
1500
1525
1600

Technical features
11
BAHR’12 STD - EC - HP - HPEC - HPO - HPOEC
BAHR’ 12
Model
300
400
500
600
800
1000
1250
1500
1750
2000
2500
3000
4000
5000
6000
Ø
mm
219
219
219
219
258
258
308
308
358
358
408
408
458
488
488
Weight
empty
kg
1650
1650
2040
2040
2860
2860
3750
3750
4650
4650
6600
6600
9030
10590
11800
Weight in
oper.
kg
2175
2175
2800
2800
3940
3940
5305
5305
6655
6655
9490
9490
13185
16390
18560
T1
DN32
DN32
DN40
DN40
DN50
DN50
DN65
DN65
DN65
DN65
DN80
DN80
DN100
DN125
DN150
T2
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN40
DN50
DN50
T3
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN32
DN32
DN32
DN32
DN40
T4
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN25
DN40
DN40
DN40
DN40
DN40
DN40
DN40
T1 Steam inlet
T2 Safety valve drain
T3 Water supply
T4 Boiler drain
B
Ø
T1
T4
L
C
D
E
H
A
W
T2
T3
T4T3
T2
A
mm
780
780
860
860
950
950
1090
1090
200
1200
1470
1470
1700
1800
1850
W
mm
1474
1474
1861
1861
1996
1996
2126
2126
2246
2246
2296
2296
2756
2856
3026
B
mm
1550
1550
1750
1750
2120
2120
2526
2526
2750
2750
2830
2830
3300
3800
4003
L
mm
2340
2340
2565
2565
2950
2950
3414
3414
3543
3543
3860
3860
4360
4943
5236
D
mm
635
635
685
685
745
745
860
860
905
905
1080
1080
1170
1195
1210
E
mm
1333
1333
1453
1453
1593
1593
1783
1783
1918
1918
2243
2243
2473
2548
2618
H
mm
1820
1820
1940
1940
2077
2077
2294
2294
2422
2422
2774
2774
3031
3173
3315
C
mm
1167
1167
1266
1266
1349
1379
1555
1555
1685
1685
2004
2004
2187
2261
2326

12
2.5 - OPERATING DATA
Data
project
Useful power *
Thermal output
Steam production
Max pressure
allowable PS
Max. Temperature
allowable TS
Max. Temperature
working TE
Volume V
Water content
at level
Volume CC
Thermal Load
volumetric
Total area
Thermal Load
surface
Dp smoke side
Burner connection
Minimum length
burner head
Absorption
max power
(excluding burner)
Pressure of
compressed air
supply
U of M
kW kW
kg / h
bar
°C °C
L L
m3
MW/m3
m2
kW/m2
mbar
Ø mm
mm
W
bar
BAHR '12 Model
300
204 234 300
12
191,7 191,7
730 540
0,26
0,905
6,5
31,4
2,2
210 340
1,85
4 - 6
400
273 314 400
12
191,7 191,7
730 540
0,26
1,212
6,5
42,0
2,6
210 340
2,2
4 - 6
500
341 392 500
12
191,7 191,7
1030
820
0,36
1,076
10,0 34,1
2,8
240 340
2,2
4 - 6
600
409 470 600
12
191,7 191,7
1030
820
0,36
1,290
10,0 40,9
3,5
240 340
2,2
4 - 6
800
560 644 800
12
191,7 191,7
1500 1080
0,67
1,022
16,1 33,9
3,8
240 340
2,2
4 - 6
1000
700 805
1000
12
191,7 191,7
1500 1080
0,67
1,279
16,1 42,4
4,2
240 340
2,2
4 - 6
1250
852 979
1250
12
191,7 191,7
2195 1555
0,95
1,036
24,0 35,5
4,5
280 370
2,2
4 - 6
1500
1022 1175 1500
12
191,7 191,7
2195 1555
0,95
1,242
24,0 42,6
5,1
280 370
2,2
4 - 6
1750
1193 1371 1750
12
191,7 191,7
2810 2005
1,29
1,066
32,4 36,8
5,5
280 370
2,2
4 - 6
2000
1363 1567 2000
12
191,7 191,7
2810 2005
1,29
1,218
32,4 42,1
6,0
280 370
2,2
4 - 6
2500
1704 1926 2500
12
191,7 191,7
3950 2890
1,86
1,051
49,9 34,1
6,8
360 370
3,0
4 - 6
3000
2045 2310 3000
12
191,7 191,7
3950 2890
1,86
1,261
49,9 41,0
7,0
360 370
3,0
4 - 6
4000
2726 3133 4000
12
191,7 191,7
5780 4155
2,76
1,129
69,0 39,5
8,0
400 370
3,7
4 - 6
5000
3408 3917 5000
12
191,7 191,7
7730 5800
3,48
1,125
85,7 39,8
8,8
400 370
4,0
4 - 6
6000
4089 4700 6000
12
191,7 191,7
8600 6760
3,99
1,178
97
42,2
8,8
420 370
5,5
4 - 6

Installation instructions
13
Before connecting the boiler, have professionally
qualiedpersonnel:
a) Thoroughly wash all the system piping to
remove any residues or impurities which
could jeopardise the proper operation of
the generator.
b) Check that the boiler is set up to operate with
the available type of fuel.
c)Checkthatthechimney/uehasanappropri-
ate draught, without any bottlenecks, and that
no exhausts from other appliances are insert-
ed,unlesstheuehasbeenimplementedto
accommodate several utilities according to
specicstandardsandprescriptionsinforce.
Onlyafterthischeckcanthettingbetween
theboilerandchimney/uebemounted.
ATTENTION!
The appliance must be installed by a quali-
-
al requirements according to the law, who,
under his own responsibility, guarantees
compliance with standards according to
good practice rules.
3.2 - INSTALLATION STANDARDS
Itmustbeinstalledbyaprofessionallyqualiedtechnician,who
shall take the responsibility of observing all local and/or

applicable technical standards.
3INSTRUCTIONS FOR
INSTALLATION
3.1 - GENERAL WARNINGS
ATTENTION!
The generator must be destined only to the
use for which it has been expressly declared.
Any other use is to be considered improper
and therefore dangerous.
This generator is used for the production of
saturated steam at high pressure.
The requirements for system installation in a
building always depend on the regulations in
force in the country of installation.
The systems with steam generator must be
installed in such a way as to facilitate use,
maintenance, repair, and the monitoring of
all the respective components and to ensure
that personnel comply with the safety stand-
ards in the workplace.
Install the steam generator and the relative
devices so that they are protected in case of
shaking, oscillations and other dangers and
in a way to guarantee the acoustic insulation
and meet the technical requirements.
Mount the valves of the steam generator
and of the relative system complete with
their safety devices and discharge so that
the vent and drive take place safely and that
the discharge process is clearly perceptible.

14
3.3 - TERMS OF SUPPLY
The BAHR' 12 generators are supplied in single-block.
Upon receipt, after having removed the packaging
make sure the content is intact.
Carry out a general inspection to verify the absence
of damage due to transport, checking the conditions
of the refractory of the tailgate, the presence of
turbulators and their correct position inside smoke
pipes (OR - STD versions).
3.4 -HANDLING
The BAHR'12 boilers are equipped with lifting eyebolts.
Pay attention when handling the boiler and use equipment suit-
able for its weight.
NOTE:
Normally, the generators are supplied fully
assembled. In particular cases, to avoid dam-
age during transportation or handling, some
units are supplied unassembled.
For the reassembly, refer to the instructions
supplied together with the documentation
supplied with the generator.

Installation instructions
15
3.5 -POSITIONING IN THE
BOILER ROOM
The steam generator must be installed in a place that complies
with the safety requirements in force in the country of destina-
tion, with adequately dimensioned ventilation openings.
Intheabsenceofspecicprovisionsofthecountryofdestina-
tion, the following indications must be complied with:
1) The premises must be enabled to the exclusive use of the
boiler room: access must be forbidden (with visible signs) to
unauthorised personnel.
2) Wide spaces must be set up for operation and maintenance
ofallsystemcomponents(pumps,valves,lters,watertreat-
ment system, heat exchangers, etc.).
3)Thesupportbasemustberaised5-10cm,inconcrete,at
and able to support the weight of the generator and the rela-
tive water content.
For the dimensions of the basement, see paragraph 2.3 - DI-
MENSIONS (A x C parameter)
4) The premises must have dimensions such as to ensure the
followingminimumdistancesarenetofanysize:
a) In order to make it easier to clean the smoke circuit, there
must be a free space on the front of the generator, not less
than the length of the boiler body (see 2.3 - DIMENSIONS,
parameter C) and, in any case, never less than 1500 mm
and it must be checked that with the door opened 90°,
the distance between the door and the adjacent 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 adjacent to a wall or to another
generator and no accessory or control is provided in the
passage.
(*) If the steam boiler is equipped with an econimiser, a cle-
arance equal to the width of the boiler must be left, in
order to allow for it to be removed easily.
c) On the rear part of the generator: 0.80m.
d) From the upper part of the generator: 1.80 m between the
highest walking surface and the lowest obstacle of the
premises cover and 1 metre between the highest point of
the generator and the lowest obstacle between the gener-
ator and the cover itself. It is recommended to leave a free
space at least equal to the length of the generator coil; this
allows for a possible replacement.
e) The piping and transmissions available above the genera-
tor, must be arranged so as not to hinder the work, nor ob-
struct the operator movement in accessing the upper part
of the generator itself to visit or repair the accessories.
ATTENTION:

weight above that of air, the electrical parts
must be placed at a height from the ground
above 0.5 m.
IT IS FORBIDDEN TO INSTALL THE BOIL
ER OUTDOORS BECAUSE IT IS NOT DE
SIGNED FOR THIS PURPOSE AND IT IS NOT

SYSTEMS.
(*) vers. EC-HPEC-HPOEC
800 vers. OR-STD-HP-HPO

16
3.6 - WATER FEATURES
The generator must be fed with water of
quality complying with the requirements set
out in this paragraph.
It must also be ensured that the feed water
and the system water cannot be polluted
by harmful substances (e.g. oil, grease, sea
water).
Standard of reference UNI EN 12953-10 or
UNI 7550.
Most of the waters are not suitable at source for use as feed
water of a steam generator. The type of feed water treatment
depends on the features of the water at source. Its features vary,
so regular checks of the chemical composition are required.
The water supply pipe, downstream of the chemical treatment,
mustbettedwithameterinordertodetecttheowrateofthe
top-up water added to the return condensate water; this also
allows direct control of the amount of steam intake.
It is appropriate to recover as much condensate water in the
supply tank as possible.
The condensate water must eventually be treated so as to meet the
requirements indicated for the generator feed water (as per table 1).
On the basis of these requirements, including those needed for
feed water (as per table 2), it is necessary that, depending on the
featuresatsourceandonthetop-upowrate,awatertreatment
system be installed and allow binders to be added for oxygen
(possibly stabilisers for residue hardness, for alkalinisation or
phosphates)inthefeedwatertankorinitsowpipe.
These requirements should be checked by means of suitable
equipment and, if possible, easy to use every 24 or 72 hours,
depending on the operating mode, or according to local regulations.
Record the measured values, the top-up water ow rate, the
consumption of chemicals and the necessary maintenance
operations in the instruction manual, in order to be able to
always go back to the operating conditions.
WARNING
Do not put water with a temperature below 60°C in the generator.
It is recommended to put feed water with an average temperature of 80°C in the generator.
ATTENTION!
Damages caused by external agents (limescale, oxygen, acid attacks, etc.) are not covered
by the warranty.
Below are the quality requirements for the feed water and for the operating water according
to the European Standard EN 12953-10 (tables 1-2) and indications on the frequency of the
analyses (tables 3-4)
Table 1
FEED WATER FOR STEAM GENERATORS
Parameters Unit Feed water
Operating pressure bar 0.5 - 20 > 20
Appearance Clear, free from solid suspensions without persistent foam
pH a,b 8.7 - 9.2 c 8.7 - 9.2 c
Total hardness ppm CaCO3 (°F) < 1 (<1) < 1 (<1)
Iron ppm Fe < 0.1 < 0.05
Copper ppm CU < 0.05 < 0.03
Oxygen ppm O2< 0.05 d < 0.02 d
Oils - greases ppm < 1 < 1
Organic substances Not enough to cause traces, foams or other problems
a. for boilers fed with water with conductivity less than 30 pSicm use
of Na or K hydroxides is allowed only if the recommended pH range
cannot be obtained with the exclusive use of sodium phosphate;
b. for systems where there is no copper or its alloys, the feed water pH
must be higher than 9.2 ;
c. with water softened to pH > 7, it is necessary to respect the pH range
indicated for boiler waters; when operating without a degasser an ex-
cess of deoxygenating agent must be guaranteed;
d. the excess value to be guaranteed must be indicated by the supplier
of the additives used for chemical conditioning.

Installation instructions
17
Figure 1 (extract from the EN 12953-10 standard)
Maximum acceptable direct boiler water conductivity based on the pressure, direct feed water conductivity > 30 mS/cm
1Direct conductivity mS/cm
2Operating pressure in bar
Parameters Unit Conductivity of the feed water
> 30 mS/cm
Conductivity of the
feed water
< 30 mS/cm
Operating pressure bar 0.5 - 20 > 20 > 0.5
Appearance Clear, free from solid suspensions without persistent foam
Conductivity mS/cm < 6000 b See Figure 1 < 1500
pH 10.5 - 12.0 10.5 - 11.8 10.0 - 11.0 c
P alkalinity ppm CaCO3 50 - 750 50 - 500 10 - 100
M alkalinity ppm CaCO3100 - 1000 100 - 750 10 - 250
Iron ppm Fe < 0.1 < 0.1 < 0.1
Copper ppm CU < 0.1 < 0.1 < 0.1
Silica ppm SiO2See Figure 2
Phosphate ppm PO410 - 30 10 - 30 6 - 15
Deoxygenating agent ppm Excessivedeoxygenatingadditiveaccordingtosupplier’sspecications
Organic substances Not enough to cause traces, foams or other problems
Table 2
OPERATING WATER FOR STEAM GENERATORS
a. excluding contribution of chemical conditioning treatments
b. with a superheater the limit is 3000 pS/cm
c. use alkalinisers only if the pH is less than 10; in any case, use of Na
or K hydroxides is allowed only if the recommended pH range cannot
be obtained with the exclusive use of sodium phosphate.
1000
2000
4000
8000
10000
1
0102030402

18
Pressione di esercizio (bar)
Parametri
Valore pH
Durezza totale
Conduttività totale
< 15
Limite
Alcalinità totale
STD
mg PO4/kg
Silice
S/cm
Unità di
misura
Fosfati
Conduttività acida
Frequenza
mg SiO2/kg
mg/kg
S/cm
mg CaCO3/kg
9 - 12
mg CaCO /kg
31000
5
7000
3500
150
30
T-S
T
G
T
S
S
S
Pressione di esercizio (bar)
Parametri
Valore pH
Ossigeno
Anidride carbonica libera
< 15
Limite
Durezza totale
Ferro
mg/litro
Rame
mg O2/kg
STD g/kg
Conduttività totale
g SiO /kg
2
Silice
Unità di
misura
Sostanze oleose
Sostanze organiche
Conduttività acida
Frequenza
S/cm
S/cm
g Cu/kg
g Fe/kg
g CO /kg
2
g O /kg
2
7,5 - 9,5
mg CaCO /kg
35
100
200
100
100
1
T-S
T
S
S
S
S
T
Limit values and frequencies of checks recommended
according to Standard UNI - CTI 7550
FEED WATER
OPERATING WATER
FREQUENCY OF THE ANALYSES
The frequency of the analyses depends on the use of the
generator and the quality of the water used; however, it is
advisable to check the pH value, the total hardness and alkalinity
of the feed water and operating water every two days. It is good
practice, especially in variable operating conditions, to monthly
subject a signicant sample of the feed water and operating
water to a full analysis.
It is also good practice to visually check the condensate returns
for any highly polluting oily substances (reduction of evaporation
on the surface of the boiler water due to a layer of oil).
WATER PARAMETERS CHECK
(DAILY)
Responsibility
Record
System Manager / Operator
Heating System Instruction Manual
WATER PARAMETERS CHECK
(MONTHLY)
Responsibility
Execution
Record
System Manager / Operator
Specialised company
Heating System Instruction Manual
COMPLETE QUALITY ANALYSIS OF THE BOILER AND
FEED WATERS (Specialised company)
Operating pressure (bar)
Operating pressure (bar)
Parameters
Parameters
pH value
pH value
Total alkalinity
Total hardness
Total conductivity
Silica
Phosphates
Acid conductivity
LimitLimit
FrequencyFrequency
Total hardness
Oxygen
Free carbon dioxide
Iron
Copper
Oily substances
Organic substances
Total conductivity
Acid conductivity
Silica
Unit of
measurement
Unit of
measurement
(*) For boilers designed to run in a regime of “Operation without
continuous supervision” for up to 24/72 hours, the frequency of the
tests is equal to the period of exemption.
S = Weekly, in laboratory S/2 (twice-weekly)
T = Each shift
G = Daily
(*)
(*)

Installation instructions
19
To allow the correct functioning of the salinity control unit (TDS)
and of the automatic drain unit (Blow Down), it is necessary to
feedthemwithlteredanddriedcompressedata4-6barpres-
sure.
In the absence of these requirements, the units may not operate
correctly.
The compressor and the tank must be positioned at a safe dis-
tance from the thermal unit, away from sources of heat.
3.7 - HYDRAULIC CONNECTIONS
ATTENTION!
Before connecting the boiler to the system,
thoroughly wash the pipes with a strong jet of
steam, in order to eliminate metallic residue
from processing and welding, oil and grease
which could be present and which, reaching
the boiler, could alter its functioning.
The steam generators, once positioned in the boiler room, must
be connected to the following points:
- Steam outlet ( T1 )
- Safety valve drain ( T2 )
- Water supply ( T3 )
- Boiler drain ( T4 )
Thesizesofthepipesforeachboilermodelaregiveninpara-
graph 2.3 - DIMENSIONS.
3.8 - PNEUMATIC CONNECTION
only for versions equipped with TDS,
     
modulation valve)
Ensure that the hydraulic piping is not used
as earth sockets of the electric system or
telephone lines. They are absolutely not
suitable for this use as serious damage to
the water pipes may be caused.
To ensure a good tightness of the water con-
nectins:
- Thoroughly clean contact surfaces.
- Lubricate threaded clamping elements (do


positioned and that the faces in contact are parallel
Ensure that the gasket is centered correctly.
Do not use adhesive tapes/double sided tapes/glues to in-

seal.
To attain the right torque (5-10 Nm), with a correct com-
pression of the seal, it is very important to tighten the
nuts in a cross-diagram using appropriate torque wren-
ches.
The torque must be carried out in 5 steps:
- 1. Tighten the nuts by hand
- 2. Tighten up to 30% of the recommended end torque

- 3. Tighten up to 60%
- 4. Tighten to the recommended torque
- 5. Tighten to the end torque for adjacent nuts to verify
the correct torque.
If necessary repeat these steps more than once until you

Repeat these steps after 50 hours of plant operation.
Carry out the connection of the steam line
of use to the valve, making sure that the
thermal expansions do not cause stresses
on the same.
The drain of the safety valves must be con-
veyed to outside the boiler room made in
such a way so as not to cause damage to
people or property in case of steam dis-
charge.
The piping diameter must not be smaller than the diameter of
the safety valve drain.
To avoid stagnation of condensation, the drain pipe must be po-
sitioned with adequate slope so as to allow its complete drain-
age.
The pipes arriving to the appliance must be
supported and arranged so as not to cre-

connections themselves.

20
3.9 - GAS CONNECTION
Danger!
The gas connection must be carried out only

apply that foreseen by relevant laws in force
and the local prescriptions of the supply
company. Incorrect installation can cause
damage to persons, animals and objects
for which the manufacturer cannot be held
responsible.
Check the internal and external seal of the
fuel supply system.
If using gas, the connections must be per-
fectly sealed.
Check that the fuel supply system is
equipped with safety and control devices
prescribed by the Standards in force.
If you smell gas:

a telephone or any other object which can
create sparks;
b) Shut the gas cocks;
c) Immediately open doors and windows to

d) Request the intervention of professionally

Do not use the fuel's system pipes as earth-
ing for electric or telephone systems.
Gas connection
PAVIMENTO
DELLA C.T.
150
150
TAPPO DI RIEMPIMENTO
INIZIALE DEL SIFONE
CAMERA FUMO La generatrice superiore del tubo di scarico
non dovrà trovarsi ad un livello superiore
al fondo della camera fumo.
CONDENSATION UPON COMMISSIONING
During the transient start-up (time necessary to bring the gener-
ator in temperature), due to the low temperature of the smoke, a
moderate amount of condensation may be created.
In these conditions, it could be useful to have the condensation
drained into the sewage.
For this purpose, the smoke chamber is equipped with an attach-
ment which the exhaust pipes will be connected to according to
the following notes
When the operating temperature has been reached, it is important
to check that no more condensation has been formed.
Ifnot,afterhavingveriedtheactualfuelowrates,theoperating
temperature should be increased.
The condensation drainage in the sewage must be:
- implemented as to prevent releasing gaseous combustion
products into the environment or sewage (siphoning);
- dimensionedandimplementedtoallowthecorrectoutowof
liquid waste preventing any leakage;
- installed in such a way as to prevent the liquid contained in it
fromfreezingintheintendedoperatingconditions;
- mixed for example with household waste water (washer, dish-
washer drainage, etc.) for the most part with basic pH in order
toformabuersolutiontobethenintroducedinthesewer
system.
It is important to avoid the accumulation of condensate in the
combustion product drainage system (for this reason the evac-
uation duct must have a slope towards the drain, of at least 30
mm / m), with the exception of any liquid head, in the drain trap
of the system for the evacuation of combustion products (which
must be lled after assembly and which minimum height with
theboilerinoperation,mustbeofatleast25mm-seegure).
Do not discharge condensation through gutter drainpipes due to
the risk of it turning into ice and the deterioration of the materials
usually used in making the drainpipes (consult local hygiene
regulations).
Thedrainttingmustbevisible.
Due to the acidity level of the condensation (pH from 3 to 5)
only suitable plastic materials must be used for the drain piping
(special optional kits with neutraliser salts for acid condensation
are available).
* Minimum safety siphon set by the standard
** Minimum head with boiler running at maximum power.
If you do not want to or cannot create a basement, the boiler
can be mounted at ground level and a sump at least 100
mm deep can be made to house the siphon.
3.10 - DRAINING CONDENSATION
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 boiler.
SIPHON INITIAL FILLING CAP
BOILERROOM
FLOOR
SMOKE CHAMBER
BASEMENT
The upper generator of the drain pipe
must not be higher than the bottom of
the smoke chamber
TO DRAIN
CONDENSATION