3. Организационная часть

3.1 Основные правила эксплуатации

Перед включением электрических водонагревателей необходимо проверить надежность соединения корпуса с заземляющим контуром. Водонагреватели периодического действия (однофазные) должны иметь трехполюсную розетку с заземляющим контактом.

Перед включением водонагревателя открывают водопроводный вентиль и проверяют, заполнен ли водонагреватель водой (для этой цели открывают один из водоразборных кранов, установленных на разводящей магистрали горячей воды, идущей от водонагревателя) и надежно ли соединен его корпус с заземляющим контуром. Места соединений проводов и шин должны быть плотно затянуты гайками, кроме того, не должно быть наложения одного провода на другой. Убедившись, что водонагреватель заполнен водой, его включают, оставляя открытым один из водоразборных кранов на разводящей магистрали горячей воды.

В процессе технического обслуживания электрод защиты от «сухого хода» очищают от накипи и контролируют продолжительность разогрева водонагревателя. При несоответствии данных водонагревателя его технической характеристики проверяют исправность ТЭНов и контактных соединений.

Неисправности имеющие место в процессе эксплуатации водонагревателей и способы их устранения приведены в таблице 2:

Таблица 2 - Возможные неисправности водонагревателей и способы их устранения

Неисправности	Вероятные причины	Способы устранения
При включенных рубильнике, тумблере и заполненном водой резервуаре сигнальная лампа не зажигается	Нет контакта лампы в патроне или она перегорела	Ввернуть лампу до предела или заменить лампу
При включенном водонагревателе вода не нагревается до заданной температуры (95°С)	Нарушен контакт проводки. Перегорели один или несколько тэнов	Проверить и исправить проводку или заменить перегоревшие тэны
Вода в нагревателе недостаточно горячая или кипит	Нарушение регулировки термосигнализатора	Отрегулировать термосигнализатор путем установки желтой и красной стрелок на требуемые пределы регулирования температуры
Время разогрева воды в нагревателе превышает норму	Поверхность тэнов покрыта слоем накипи	Очистить тэны от накипи

UNIVERSAL CONTINUOUS ACTION

ELECTRIC POWER BOILER

Technical Guide

КИПЯТИЛЬНИК

ЭЛЕКТРИЧЕСКИЙ

НЕПРЕРЫВНОГО ДЕЙСТВИЯ

УНИВЕРСАЛЬНЫЙ

КНЭ-50/100

Руководство по эксплуатации

ТУ 5151-001-71693142-04

г. Челябинск

2004

This Technical Guide is intended to introduce to the users, service and maintenance personnel the general installation, exploitation and safety rules for the model.

USB-50/100 is a high voltage heating device, specific precautions should be taken within the installation and maintenance of the such devices.

The only personnel having qualification degree appropriate for the working with systems under 1000 Volts, trained and examined in accordance with The Rules of Technical Exploitation of Electric Power Devices, The Safety Rules of Exploitation of Electric Power Devices is to be allowed to the start-up and maintenance operations.

The Rules of Technical Exploitation of Electric Power Devices and The Safety Rules of Exploitation of Electric Power Devices are approved by Gosenergonadzor (Government Organization for Supervision on Electrical Systems).

1. General Description and Operation

Description and Operation of the model.

The model application.

The model is applicable for preparation of boiled water on the public catering establishments. It is normally operated in the places with factitious climate condition.

The conforms to the safety requirements by the standards GOST R MEK 335-1-94, GOST 27510.52-95.

Technical features.

Feature	Rate
Productivity, liters/hour, not less than Mode 1 Mode 2	50 100
Water tank capacity, l.	2,5
Boiled water receiver capacity, l.	3,5
Nominal power, kW Mode 1 Mode 2	6 9
Nominal voltage, V	380
Power source	Three-phases A/C, 50HZ
Pressure in water supply line, MPa	0,05…0,6
Time of heating water to the boiling, min, not more than	3
Weight, kg Option 1 Option 2	7 11

Completeness.

The model comprises of:

• water tank ;

• automation unit ;

• cable assembly (to connect electric circuit of tank with automation unit).

Standard kit.

Standard kit includes :

• model - 1 pc.

• Electric cable plug - optional

- Technical Guide - 1 pc.

Components arrangement and operation of model.

Assembly of main components of model and connection of the device to the electric power line is performed in accordance with layout (Fig. 1, 2).

Connection of to the water supply line is to be made via coupling joint to the supply tube on the bottom of water tank.

The tank is equipped with drain tube for the drainage water via hose connected to the tube.

Water heating in the model is provided by the means of TEHUs (Thermal Electric Heating Units), incorporated in to the water tank. Control and monitoring of the heating device are provided by the means of control buttons and indicators on the front panel of automation unit.

The heating device is operable in two heating modes: 6kW and 9kW.

Packing.

All the components of standard kit supplied are to be packed in to carton box. Literature in plastic bag or film placed in to heater’s tank.

Description and operation of model components.

Description and operation of water tank.

1. The tank consists of upper and lower reservoirs partitioned by wall and common lid.

In the lower reservoir are located: grounding bolt; drainage hose fitted to the drain tube attached to the reservoir; water inlet branch tube; TEHUs (Thermal Electric Heating Units) terminals.

The upper reservoir consists of three components: feed water vessel with feed and drain tubes introduced inside the vessel via the wall; vessel for preparation of boiled water equipped with TEHUs; vessel for boiled water receive and collection.

The preparation vessel has protection lid installed on.

The feed tube is equipped with hydrometric float (feed valve & float) regulating level of water fed from supply line. Besides, to the bracket mounted to the wall partitioning feed vessel and boiled water preparation vessel are attached: level gauge sank in to the feed vessel and “upper level gauge” (ULG) and “lower level gauge” (LLG) sank in to the boiled water collection vessel. The gauges wires run through the drain tube in to the lower compartment of the heating device.

The boiled water preparation and collection vessels communicates via a hole in the partitioning wall.

Collection vessel has a tube branch with outer valve fitted.

2. Water flows from the supply line in to the feed vessel via inlet tube and regulating valve.

From the feed vessel water fills boiled water preparation vessel via the hole between them.

The both vessels are filled up to 10-12 mm. to the edge of drain tube, that is regulated by feed valve & float unit.

Level gauges sink in to the water. Shorting gauges to the water gives an admission signal to automation unit for the switching of the TEHUs on.

Since the TEHUs are switched on, the water heating process has started. When boiling begins, water by the expansion phenomena slops after protection lid on preparation vessel in to the collection vessel and fills it up. While the drain valve is closed, the water level will grow gradually up shorting consequently to the LLG and ULG.

When water level reaches the ULG it gives a signal to automation unit to switch TEHUs off.

By the consumption of hot water via the drain valve and if the water level in collection vessel has dropped lower than LLG, it turns the automation unit to switch TEHUs on again.

This is continuous process regulated by hot water consumption.

If cold water supply capacity involuntary will be lower than hot water consumption, the water level in feed vessel drops lower than gauge, this will switch TEHUs off and LED alarm signal – “Level” will appear on the control panel.

Description and operation of automation unit.

1. The automation unit of the model includes: casing; control board; indication board; two cable assemblies; sensor; front panel with LEDs and control buttons.

2. Principles of operation of automation unit are provided by electric circuit layouts for automation unit (Fig. 4) and for control board (Fig. 5).

3. Layout of connection of automation unit with heating device and with mains power supply is provided on the Figures 1, 2.

Casing of heating device must be well grounded.

Black wire of CABLE ASSEMBLY 1 is to be connected with neutral “N” of mains power supply.

Black wire of CABLE ASSEMBLY 2 is to be connected with TEHUs common point.

Yellow-green wire of CABLE ASSEMBLY 1 is to be connected with ground.

Yellow-green wire of CABLE ASSEMBLY 2 is to be connected with model grounding terminal.

4. The power supply (A/C 380 V, 50Hz) is to be provided from customer’s electrical distribution box.

Initially, on the control panel LEDs “Power”, mode “6 kW” or “9 kW” will light and, in case of “dry” level gauge in the feed vessel – LED “Level” will light. If level gauge is in the water, the LED “Level” will be off.

Testing of automation unit.

1. Open water supply in to device and switch power on – LEDs “Power”, “6 kW” or “9 kW” will light.

2. Switch the boiler on by pressing of “Operation” button – LED “Operation” on control panel will light. During the operation when electric current is admitted to the TEHUs – LED “Heating” on control panel will light.

3. When water supply is stopped and level gauge is dried – LED “Heating” will turn off, LED “Level” will light.

4. Switching the boiler off is provided by “Operation” button. After the pressing of “Operation” button LED indicators “Heating” and “Operation” will turn off.

5. After the switching of boiler off it is necessary to check the change of operation modes. In this state the only LEDs will light – “Power”, “6kW” or “9kW”. The change of operation mode will take effect by the pressing of appropriate mode button – “6kW” or “9kW” and retrying the steps 2 to 4.

2. Usage of the model

2.1. Exploitation requirements.

The electric boiler must be operated when it is properly grounded. The usage of “0” wire for grounding instead of grounding wire is not allowed.

2.2. Preparing model for the operation. Safety rules.

Unpacking, installation and testing of heating device are to be provided by specialists in maintenance of such kinds of equipment.

After the checking of packing condition of the boiler, unpack it, visually surveying condition of the device, check the completeness, remove anti corrosion lubrication.

Place the boiler tank on the stand (Fig. 3), connect the feeding tube to the water supply via hose, ensure proper drainage of water. For the feeding and drainage connection two holes are to be made in the metal sheet installed on the top of stand.

Screw the automation unit to a wall using special mounting holes in the back of casing of the unit.

Perform electrical connections. Ensure proper grounding circuit.

NOTE: To avoid failures of the boiler, ensure that feeding joints have no leakage. The model is to be connected to 3-phases power supply 380 V/50 Hz.

After the installation of model and connection to the electric power and water supplies, start and test the device.

Allow water feeding in to vessel of the boiler and check for valve/float unit operation. The water feeding from the supply must be stopped when water reach the level 10-12 mm. below the edge of overflow tube. If it is necessary, adjust the float device bending the float arm or moving rubber tap up-down, meanwhile, the “Level” gauge has to be sunk, ULG and LLG gauges have to be dry.

Allow the power on. One of the “6 kW” or “9 kW” LEDs will light on the front panel of automation unit. Choice the mode required pushing the proper button.

Switching the boiler off is provided by pushing the “Operation” button.

2.3. Usage of the model.

Before starting of operation the condition of the boiler should be visually surveyed – the tank lid should be put on, the boiled water valve should be closed.

Use the following sequence while operation:

1. Open water supply valve allowing water feed in to the feeding vessel.

2. Allow power on from the electric distribution box. One of the “6 kW” or “9 kW” LEDs will light on the front panel of automation unit.

3. Choice the mode required pushing the proper “Mode” button.

4. Push “Operation” button.

Use the following sequence for the finishing of operation :

1. Switch the power off.

2. Eliminate the electric power to the boiler turning automatic switch on the distribution box off.

3. Drain all hot water from the boiled water collecting vessel.

4. Shot the water supply valve off.

5. Remove the moisture from boiler’s body.

Typical failures of the model.

Failure	Possible cause	Elimination
The boiler does not work after the switching power on.	No power from mains.	Check the mains and electric distribution box.
Appearance of cold water from draining hose.	The valve/float unit is not properly adjusted. The feed valve rubber tap is unhermetised.	Adjust valve/float unit. Replace rubber tap.
Low productivity.	Missing one phase. TEHU’s failure.	Replace the TEHU.
TEHUs are not switched off after the filling of boiled water collecting vessel.	Gauges are scummed.	Clean the gauges.
Boiler periodically switches off.	Drain valve is clogged.	Clean the valve.

3. Service & Maintenance

Service and maintenance are to be provided by personnel certified for III-V level degree and having certification for safety arrangements.

Proposed service and repair cycle :

5M – S – 5M – S – 5M – S – 5M – S – 5M – O

where :

M – maintenance provided once a month ;

S – service and current repair provided once in half of year ;

O – overhaul provided after 30 months of operation.

If stiffness of water is over 4,5 mg/l it may require one more overhaul within stint of heating device.

Service and maintenance include following steps:

• interview the users about common failures of the boiler ;

• visually survey the boiler for conformity to safety arrangements ;

• check the correctness of shield grounding ;

• check the correctness and integrity of electric cable assemblies and wires, workability of LED indications and firmness of joints and contacts ;

• check the correctness of seals and bushings ;

• check the correctness of TEHUs switching off after the filling of boiled water collecting vessel and after the stop of water feeding in to boiling vessel ;

• check the correctness of TEHUs switching on when water level will reach LLG gauge in the boiled water collecting vessel ;

• instruct the users of safety rules ;

NOTE: The service and maintenance of the boiler are provided by personnel of the owner of the device.

• check for scum of the gauges and gaping, clean the gauges and contacts if necessary.

Service and maintenance content:

Part to be checked and serviced	Technical requirements for checking
LED indication workability is to be checked visually	In accordance with clause 1.2 of the guide.
Condition of TEHUs contacts and terminals. Check the tighteness of contacts and tighten if necessary.	The contacts are to be firm and reliable in the condition of variable temperature.
Condition of seals and bushings.	No leakage is allowed.

Current repair is a kind of service containing a minimum volume of repair works to ensure normal operation of the boiler until next scheduled service.

Current repair is provided at the boiler’s installation place.

Current repair contents general maintenance works plus following steps:

• scale the boiling and collecting vessels, TEHUs and gauges from the scum;

• if it is necessary, replace damaged parts, seals and bushings;

• test the boiler in operational mode.

Current repair works are to be provided by service companies or by own certified personnel of the users.

Overhaul is a kind of repair works intended to complete restore of boilers workability and stint with the replacement or restoration of any part of the device.

Overhaul is to be provided by service company.

4. Storage & Transportation of model

Ensure that the boiler is stored in packed condition, on the stand, in the stack of maximum two rows, without allowance of moisture and direct sun rays.

Storaging temperature –50^oC to +50^oC, humidity – max. 80% at +20^oC.

Any kind of transport is allowed securing proper delivery.

5. Resources, storaging and operational life, guarantees for model

Overhaul period – 6000 hours within operational period – 5 years and storaging period – 1 year.

Guarantee – 18 months after the put the device in to exploitation.

6. Unsatisfactory equipment claim

All unsatisfactory claims till expiration of guarantee period and notices are to be forwarded to:

KASKAD-TM LLC,

47, Kuznetsova str.,

Chelyabinsk, 454087,

RUSSIA

Tel. [phone]

7292934

2319514

www.boiler.su

E-mail: [e-mail]

7. Utilization

Before utilization the boiler must be disassembled and separated by the parts and materials.

NOTE: The boiler design is continuously improved – some unsignificant alterations may be not covered by this technical guide.

Настоящее руководство по эксплуатации (РЭ) предназначено для ознакомления обслуживающего персонала и лиц, производящих установку и техническое обслуживание электрокипятильников, с устройством, принципом действия и другими сведениями необходимыми для их установки, правильной эксплуатации и технического обслуживания.

К работам по монтажу, пуску и обслуживанию допускается персонал, изучивший настоящее РЭ и эксплуатационную документацию на электрокипятильник, прошедший проверку знаний Правил технической эксплуатации электроустановок потребителей, Правил техники безопасности при эксплуатации электроустановок потребителей, утвержденных Госэнергонадзором и имеющий квалификационную группу по технике безопасности до 1000В.