Unical BAHR'UNO User manual

BAHR’UNO
INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

2
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
DATA PLATE

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..............................................................................................................................................................41
4.1 General rules for running steam generators ................................................................................................................................................ 41
4.2 Maintenance instructions ............................................................................................................................................................................ 42
4.3 General rules for decommissioning............................................................................................................................................................. 42
Operating anomalies.......................................................................................................................................................................................... 43
Residual risks from Risks Analysis pursuant to the European Directive 97/23/EC - PED ................................................................................... 45
3 INSTALLATION INSTRUCTIONS .......................................... 16
3.1 General warnings ...............................................................16
3.2 Installation standards.......................................................16
3.3 Supply conditions ............................................................17
3.4 Handling ..........................................................................17
3.5 Positioning in boiler room.................................................18
3.6 Water features .................................................................19
3.7 Hydraulic connections .....................................................22
3.8 Pneumatic connection .....................................................22
3.9 Gas connection................................................................23
3.10 Condensation drainage....................................................23
 3.11Connectiontotheue ......................................................24
3.12 Burner assembly..............................................................25
3.13 Furnace door: adjustment, opening, closing ....................26
3.14 Electrical connections......................................................27
3.15 Control panels..................................................................28
3.16 Commissioning................................................................31
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................................38
3.18 Instructions for stopping the generator.............................39
3.19 Instructions for the emergency stop of the generator .......39
3.20 Instructions for decommissioning and storage.................40

4
1GENERAL INFORMATION
This document is the Technical Manual for installation, use and
maintenance of BAHR'UNO type low pressure ame blowing
steam generators.
BAHR’UNO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’UNO type steam generator is manufactured, tested
andcertiedasSETincompliancewiththeEssentialSafetyRe-
quirements of Directive 97/23/EC "PED - Pressure Equipment
Directive" according to the B+F conformity assessment mod-
ules.
ATTENTION!
The BAHR’UNO series steam generators
must be operated within the limits for which
they were designed; any other use must be
considered improper and therefore danger-
ous.
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

5
General information
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.

7
Technical features
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’UNO
Unical STEAMER is designed for a maximum allowable pres-
sure PS = 1,0 bar.
The range includes no. 15 models with a steam production of
140 kg / h (nominal power = 94 kW)
at 3000 kg / h (nominal power = 2012 kW).
The BAHR’UNO 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’UNO STD, HPO and HP models are already provid-
ed for mounting, 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
- safety valves
C) Assembly control panel
 on request the generator can be equipped with 3 dierent
types of control panel (BASIC, IMC 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)
IMC control board composed of:
- IMC 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
1
19
18
16
20
17
11
12
15
14
22
21
21
22
10
8
6
7
5
4
2
3
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

9
Technical features
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.
2.3 - GENERAL FEATURES
It is equipped with self-cleaning ame-warning light, suitably
positioned to control the correctness of combustion in opera-
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
BAHR’UNO OR
BAHR’UNO
Model
140
160
200
300
400
500
600
800
1000
1250
1500
1750
2000
2500
3000
A
mm
720
720
720
780
780
860
860
950
950
1090
1090
1200
1200
1470
1470
W
mm
1560
1560
1560
1680
1680
1800
1800
1940
1940
2085
2085
2210
2210
2480
2480
B
mm
1100
1100
1100
1550
1550
1750
1750
2120
2120
2527
2527
2750
2750
2830
2830
L
mm
1865
1865
1865
2315
2315
2515
2515
2885
2885
3322
3322
3545
3545
3625
3625
D
mm
580
580
580
635
635
685
685
745
745
860
860
905
905
1080
1080
E
mm
1220
1220
1220
1340
1340
1460
1460
1600
1600
1790
1790
1920
1920
2250
2250
H
mm
1485
1485
1485
1630
1630
1800
1800
1980
1980
2220
2220
2350
2350
2725
2725
C
mm
725
725
725
815
815
880
880
945
945
1075
1075
1170
1170
1410
1410
Ø
mm
219
219
219
219
219
258
258
358
358
408
408
408
408
508
508
Weight
empty
kg
1030
1030
1030
1330
1330
1630
1630
2130
2130
2740
2740
3360
3360
4650
4650
Weightin
oper.
kg
1340
1340
1340
1898
1898
2444
2444
3290
3290
4403
4403
5500
5500
7620
7620
T1
DN 50
DN 50
DN 50
DN 65
DN 65
DN 80
DN 80
DN 100
DN 100
DN 125
DN 125
DN 125
DN 125
DN 150
DN 150
T2
DN 50
DN 50
DN 50
DN 65
DN 65
DN 80
DN 80
DN 100
DN 100
DN 125
DN 125
DN 150
DN 150
DN 100
DN 100
T3
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
T4
1/2”
1/2”
1/2”
1”
1”
1”
1”
1”
1”
1”
1”
1 1/2”
1 1/2”
1 1/2”
1 1/2”
T1 Steam inlet
T2 Safety valve drain
T3 Water supply
T4 Boiler drain
D
E
H
A
W
B
Ø
L
C
T1 T2
T4
T3
(2X)
(2X)
2.4 - DIMENSIONS