Unical DIATHER Series User manual

INSTRUCTIONS ON INSTALLATION,
USE AND MAINTENANCE
DĨATHER’

2
DATA PLATE
example
Modello
Numero di Fabbrica
Anno di Fabbricazione
Potenza Nominale [kW]
Potenza Termica al focolare [kW]
Model
Serial Number
Manufacturing Year
Heat Output
Heat Input
Press. max ammiss. Serp. PS [bar]
Temperatura max. ammis. TSmax [°C]
Temperatura min. ammis. TSmin [°C]
Pressione di prova Serpentino [bar]
Data di prova idrostatica
Max Design Coil Pressure
Max Allowable Temperature
Min. Allowable Temperature
Hydraulic Test Pressure Coil
Hydraulic Test Date
Superficie riscaldata [m²]
Volume Totale V [I]
Heating Surface
Total Volume
DIATHER’
Categoria di Rischio
Category
Gruppo / Fluido
Group / Fluid
1 / Olio Diatermico
1 / Diathermic Oil
Via Roma, 123 - 46033 Castel dArio - Mantova - Italy’
I
10
345
-----------
25
4000
A16U00XXX
2016
4650
5470
157
2465
15/02/2016

3
1 GENERAL INFORMATION ................................................................................................................................................................................... 4
1.1 General warnings........................................................................................................................................................................................... 4
1.2 Symbols used in the manual......................................................................................................................................................................... 4
1.3 Safety warnings ............................................................................................................................................................................................ 5
General informationTechnical featuresInstallation instructionsMaintenance instructions
4 INSPECTIONS AND MAINTENANCE .............................................................................................................................................................. 24
4.1 General rules for running the generators..................................................................................................................................................... 24
4.2 Maintenance instructions ............................................................................................................................................................................ 25
4.3 General rules for decommissioning ............................................................................................................................................................. 25
Operating anomalies.......................................................................................................................................................................................... 26
3 INSTALLATION INSTRUCTIONS .................................................................................................................................................................... 11
3.1 General warnings ..................................................................................................................................................................................... 11
3.2 Installation standards................................................................................................................................................................................ 11
3.3 Supply conditions ..................................................................................................................................................................................... 12
3.4 Handling .................................................................................................................................................................................................. 12
3.5 Positioning in boiler room ......................................................................................................................................................................... 13
3.6 Hydraulic system features and connections ............................................................................................................................................. 14
3.7 Fuel supply ............................................................................................................................................................................................... 15
3.8 Connection to the flue............................................................................................................................................................................... 15
3.9 Burner assembly....................................................................................................................................................................................... 16
3.10 Furnace door: adjustment, opening, closing............................................................................................................................................. 17
3.11 Electrical connections .............................................................................................................................................................................. 17
3.12 Electric control board................................................................................................................................................................................ 18
3.13 Commissioning......................................................................................................................................................................................... 20
3.14 Start-up and subsequent checks.............................................................................................................................................................. 22
3.15 System stop.............................................................................................................................................................................................. 22
3.16 Instructions for the emergency stop of the generator ............................................................................................................................... 23
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................6
2.1 General description of the range ................................................................................................................................................................... 6
2.2 Description of components ........................................................................................................................................................................... 7
2.3 Control and safety devices............................................................................................................................................................................ 7
2.4 System accessories...................................................................................................................................................................................... 8
2.5 Dimensions ................................................................................................................................................................................................... 9
2.6 Operation data ............................................................................................................................................................................................ 10

4
1GENERAL INFORMATION
This document constitutes the Technical Manual of instal-
lation, use and maintenance of the DĨATHER type 3 effec-
tive smoke passes diathermic oil generators, and it is an
integral and essential part of the product.
In the event that the generator is transferred
in use or sold to other Users (change of
destination or move) make sure that the ap-
pliance is transferred together with this in-
stallation, use and maintenance manual so
that it can be consulted by the entrusted in-
staller, the maintenance technician and the
new owner.
Installation must be performed in compliance
with the standards in force according to the
instructions of the manufacturer and by pro-
fessionally qualified personnel.
Professionally qualified personnel means per-
sons with specific technical skills in the dia-
thermic oil system sector.
ATTENTION!
The DĨATHER series diathermic oil heat gen-
erators must be operated within the limits
for which they were designed; any other use
must be considered improper and therefore
dangerous.
IT IS STRICTLY FORBIDDEN FOR PERSONS
NOT SPECIFICALLY ENABLED TO USE,
RUN, MAINTENANCE THE GENERATOR.
Before starting installation, starting the igni-
tion process or undertaking any maintenance,
carefully read the instructions and proce-
dures contained in this manual; they provide
important information regarding the safety of
the system and the safety of persons.
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
To guarantee appliance efficiency and its correct
operation, periodic maintenance must be per-
formed by professionally qualified personnel, fol-
lowing the manufacturer's instructions.
Any appliance repairs must be performed using
original spare parts only.
This appliance is intended for the use for
which it was expressly designed.
The manufacturer will have no contractu-
al or extra-contractual liability for damage
caused to persons, animals or property, due
to incorrect installation, adjustment, mainte-
nance and misuse.
ATTENTION!
THE GENERATOR IS NOT DESIGNED TO BE
INSTALLED OUTDOORS, BUT MUST BE LO-
CATED WITHIN THE APPROPRIATE PREM-
ISES (BOILER ROOM).
1.1 - GENERAL WARNINGS
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

5
General information
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
qualified installers in accordance with the law and author-
ised by the relevant gas company.
- The interventions to the electrical system must only be car-
ried out by specialised and qualified personnel, according to
the law.
- Commissioning must be done by professionally qualified
personnel.
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 2014/68/UE.
Behaviour in case of fuel leaks
Danger
The leaking of fuel can cause explosions
and serious injuries.
- Do not smoke!
- Avoid naked flames and sparks. Never activate lights or
electrical devices.
- Close the shut-off 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
building.
- Shut-off 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 off the system.
- Ventilate the place of installation.
Interventions on the system
- Close the fuel shut-off valve and make sure that it cannot be
opened accidentally.
- Disconnect the system supply voltage (e.g. acting on the
individual 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.
Hot surfaces
Risk of burns caused by contact with hot
surfaces:
- oil pipes,
- 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. Re-
place the faulty parts with original SCHUS-
TER 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
not approved and unauthorised modifica-
tions may compromise safety and affect the
warranty rights. For the replacement, only
use original SCHUSTER spare parts.
Behaviour in case of fire spreading
Danger
In case of fire, do not put it out using water
but only use powder, CO2 systems, etc..
As for the diathermic oil and its safe use, we
recommend to strictly adhere to the manu-
facturer's provisions specified on the rela-
tive technical data sheet.

6
2.1 - GENERAL DESCRIPTION
2TECHNICAL FEATURES
AND DIMENSIONS
The furnace is accessed through a burner support door fixed
to the generator by hinges; the door is internally coated with a
suitable layer of refractory cement and is fitted with flame light
and burner support plate.
The rear flue gas casing is fixed to the generator by bolts, is
internally insulated with insulating concrete and is fitted with
cleaning door.
The generator body is covered with a suitable layer of high den-
sity rock wool and externally covered with a painted sheet met-
al casing; this reduces the heat losses, improving the overall
performance.
The DĨATHER type diathermic oil boilers provide a maximum
temperature of use of 300°C with a thermal gradient of 40°C
between oil inlet and outlet.
NOTE:
The DĨATHER boilers are CE marked accord-
ing to Directive 2014/68/UE (category I). Weld-
ing procedures and devices are approved and
certied according to Standards EN 15614,
EN287 and UNI EN ISO 9606.
The design does not take account of fatigue
stress nor of damage due to earthquake or
other natural events.
The DĨATHER model diathermic oil boilers are of the type with
four principle helical tube bundle, with execution in two concen-
tric rings inserted in a fumes hermetically sealed sheet metal
cylindrical body.
The tubes constituting the tube bundle are made of "seamless"
quality steel.
The first "ring" characterises the furnace along which the flame
extends; the second "ring" originates a three flue gas pass path
which allows an optimal exploitation of the entire exchange sur-
face.
The base consists of electrowelded steel profile frame

7
General information
2.2 - DESCRIPTION OF COMPONENTS
Corpo mantellato
e coibentato
Uscita fumi
Manometro
Manometro
Pressostato differenziale
Porta anteriore
Quadr
o elettrico
Cased body
and insulated
Pressure gauge
Pressure switch differential
Pressure gauge
Front door
Inspection door
smoke chamber
Control panel
2.3 - SAFETY DEVICES AND
CONTROL
The DIATHER generators are equipped with the following safety
and control devices:
DIFFERENTIAL PRESSURE SWITCH
Connected between oil inlet and outlet (scale 0.5 ÷ 4 bar), com-
plete with valves and pressure gauges.
The dierential pressure switch is intended as a safety compo-
nent since it bocks the burner if the pressure dierence drops
below the pre-set value.
Dierential pressure switch calibration
Divide by 13 the oil side load loss value (see oper-
ating data table) and round down the result. From
this subtract 0.4 and you have the pressure in bar
to set on the pressure switch.
The dierential pressure switch installed as standard on the
DIATHER generators is the DANFOSS RT 260A model; to cal-
ibrate, carefully follow its manufacturer's instructions provided
with the generator documentation.
Following the intervention, restore the pressure switch at a pres-
sure of 0.3 bar higher than the calibration (xed dierential).
WORK AND SAFETY THERMOSTATS
N°1 Safety thermostat placed on the ow pipe, which locks out
the generator in case the operating temperature is exceeded.
T alarm = 300°C
N°1 Thermoregulator placed on the ow pipe, for the ignition,
shutdown and burner adjustment.
T 1st stage = 280°C (**)
T 2nd stage = 250°C (**)
(**) Factory setting (adjustable)
N°1 Thermoregulator placed on the return pipe for the measure-
ment of the return temp.
T return = 150°C
PRESSURE GAUGES
Two stainless steel and laminated glass pressure gauges with
scale adjusted to the boiler design pressure, complete with
steel shut-o valve.
Respectively positioned on:
- oil ow
- oil return
The pressure gauge is installed on appropriate tool unit
equipped with siphon tting for the dispersion of heat.
ATTENTION
Any disassembly/replacement of the devic-
es listed must be performed with the boiler
o, depressurised to atmospheric pressure
and suitably cooled; the manufacturer is not
liable for damages to persons and/or prop-
erty or animals due to non-compliance with
this requirement.

8
2.4 - SYSTEM ACCESSORIES
EXPANSION VESSEL
In operation, the volume of oil in circulation varies due to the
temperature changes.
The increase in diathermic oil volume is around 7% for a tem-
perature increase of 100°C.
This involves the need to absorb the oil expansions by inserting
an expansion vessel in the circuit.
It is good practice that, with system cold, the
oil occupies at least 1/4 of the expansion ves-
sel capacity to ensure an appropriate seal
and, with system hot, does not exceed 3/4 of
the tank capacity to prevent any overow.
If it is assumed that the system features are such to make it dif-
cult to maintain a temperature suciently low in the expansion
vessel (60 - max 70°C at temperature), we recommend provid-
ing a heat sink on the connection pipe of the expansion vessel.
The expansion vessels used are mainly of the open type (at-
mospheric): in this case, they will be placed at a height, so that
the minimum level exceeds the max level reached by the system
or the utilities, by at least 1.5 m.
The minimum height, subject to exceptions to be examined
case by case, will be such to ensure a 6 m seal at least on the
intake axis of the circulation pump.
It will be placed preferably in a ventilated area to avoid the tem-
perature increasing excessively and protected against water
inltration.
When wanting greater pressures in the system, or it is not pos-
sible for some reason to place the vessel at an adequate height,
be it only for aesthetic reasons, you can place an expansion ves-
sel in the boiler room, of the pressurised type. This vessel will be
pressurised with nitrogen, using cylinders and decompression
station, and equipment with the necessary safety devices.
The connection pipe to the expansion vessel:
- must be free of shut-os
- must be such to prevent convective motions of the oil
- must not be insulated.
DIATHERMIC OIL COLLECTION TANK
It is a simple container with a higher capacity than the total of
the system.
It must be placed outside the boiler room, preferably outdoors
and in ventilated premises protected from rain, in pit below
ground level not buried, on oor, or raised.
If buried, it will be necessary to also adequately lower the load-
ing height to avoid intake problems.
In case of landll, it is mandatory to use a double-wall vessel as
provided for all ammable liquids.
The system loading pump, with its group of valves, is located
near the oil storage tank.
SYSTEM LOADING UNIT
It consists in a gear pump coupled to an electric motor, com-
plete with two-way steel valves.
It must be placed in a position protected from rain and level with
the collection vessel, in order to facilitate the intake of the pump.
OIL CIRCULATION PUMP(S) UNIT
They are normally single-state centrifugal pumps coupled to the
motor through a elastic joint.
Everything is assembled on the base which ensures alignment
of the components.
The pump seal is of the air-cooled type.
SHUT-OFF VALVES
The shut-o valves for diathermic oil systems must have a sphe-
roidal cast iron body and be tted with bellow seal.
DIATHERMIC OIL FILTER
Upstream of the circulation pump(s) install a lter for diathermic
oil with spheroidal cast iron or steel body and with a large mesh
lter basket.
EXPANSION COMPENSATORS
The expansion compensators must be installed to absorb the
axial expansions of the pipes due to high operating tempera-
tures.
The pipes must be suitably bracketed so that the compensators
can perform their function without the burden of any weight that
might cause misalignment between the jointed pipes, leading to
possible failure of the bellows and leaking of oil.

9
Technical features
2.5 - DIMENSIONS
T1 Flow
T2 Return
T3 Generator exhaust
T4 Flue gas exhaust
T5 Burner connection
Model
Diather
W
mm
L
mm
H
mm
A
mm
B
mm
C
mm
D
mm
E
mm
F
mm
T1-T2
DN
T3
DN
T4
Øe
T5
mm
120 930 1650 1190 600 1225 800 620 504 368 32 20 200 160
230 1060 1890 1310 700 1465 900 680 596 382 40 20 250 220
350 1060 2210 1310 700 1785 900 680 560 400 50 20 250 220
465 1240 2320 1510 800 1150 1060 780 680 440 65 20 300 260
580 1240 2450 1510 800 1270 1060 780 680 440 65 20 300 260
700 1260 2480 1520 800 1270 1060 780 728 416 65 20 300 280
930 1370 3170 1620 900 1500 1160 840 808 436 80 20 350 280
1160 1540 3350 1790 1000 1780 1320 920 940 450 100 25 350 280
1500 1670 3630 1930 1100 1850 1440 1000 1050 475 100 25 400 320
1900 1670 3810 1930 1100 2100 1440 1000 1050 475 125 25 400 320
2300 1840 4170 2110 1200 2400 1580 1080 1210 475 125 25 450 360
2900 2200 4490 2460 1400 2500 1900 1260 1490 515 150 25 500 380
3500 2200 4710 2460 1400 2750 1900 1260 1490 515 150 25 500 380
4650 2390 5990 2680 1500 3650 2060 1360 1641 540 200 25 600 400
5800 2370 6570 3000 1700 3800 2360 1530 1860 600 200 25 700 400
C
A
W
D
1700
500
B
600
FE
H
L
Ø
T4
C
A
W
D
1700
500
B
600
FE
H
L
Ø
T4

10
2.6 - OPERATING DATA
Project Data U.M. DĨATHER
120 230 350 465 580 700 930 1160 1500 1900 2300 2900 3500 4650 5800
Heat Output Pn Potenza Nominale Pn kW 116,3 232,6 348,8 465,1 581,4 697,7 930,2 1162,8 1511,6 1860,5 2325,6 2906,9 3488,4 4651,2 5813,9
Heat Input Qn Portata Termica Qn kW 134,3 267,6 401,0 534,1 668,5 802,1 1069,3 1336,8 1737,6 2138,4 2672,5 3342,0 4009,2 5346,0 6682,7 Group - Fluid / Gruppo - Fluido 1 - Diathermic Oil /
1 - Olio Diatermico
Category / Categoria di rischio IIIIIIIIIIIIII Heating Surface / Supercie riscaldata m² 7,0 11,0 14,8 19,2 21,2 22,4 31,8 44,2 54,6 59,0 72,8 102,2 104,4 156,4 189,6 Coil Volume / Volume Serpentino l 40 84 130 232 245 201 285 518 639 692 853 1592 1629 2464 2970 Max Coil Design Pressure / Pressione Max amiss. Serpentino PS
bar 10
Max Design Temperature / Temperatura Max amiss. TSmax
°C 300
Working Temperature / Temperatura di lavoro TS
°C 280
Coil Test Pressure / Pressione prova serpentino PT
bar 25
Combustion chamber press./ Press. camera di combustione mbar 1,5 2,0 2,5 3,0 3,2 3,1 3,5 3,8 4,0 4,2 4,5 4,5 5,0 6,0 7,0 Flow rate pump / Portata pompa olio m³/h 6,0 10,6 15,9 22 26,5 31,8 42 50 69 81 101 126 159 202 252 Heat rise / Salto termico °C 40 Loos pressure oil side (250°C)/ Perdita di carico lato olio 250°C m.c.l. 26 23 25 18 20 23 17 24 18 28 24 39 32 36 40