INSTRUCTION MANUAL

ROSS
FULLY AUTOMATIC THERMIC FLUID
HEATER

MANUFACTURED, SOLD & SERVICED BY

ROSS BOILERS
33, Burhani Industrial Estate, Kondhwa Bk. Pune 411 048, India.
www.rossindia.com
 CONTENTS

1. Introduction --02--
2. Transportation --02--
3. Specifications --03--
4. Installation --03--
5. Commissioning --06--
6. Maintenance --09--
7. Trouble Shooting --11--
8. Service & Spares --14--
9. Drawings
a) Burner
b) P & I Diagram
c) Electric Diagram
 1. INTRODUCTION

Ross has been manufacturing process heat equipments since a decade. The
technocrats at Ross have more than 30 years experience in this field. With this vast
and valuable experience Ross assures you of a very efficient, reliable and trouble free
unit.

Ross thermic fluid heaters are designed for maximum efficiency. They combine the
benefits of advanced design & well proven construction techniques. Units are
designed with adequate safety margins to ensure reliable operation. Superfluous &
unnecessary items are eliminated. All standard make components ensure trouble free
operation of the boiler.

The fully automatic burner control ensures regulated fuel oil combustion. The burner
is designed to operate on HSD or LDO & has an efficiency of 87± 2%. Fuel oil pump
is directly coupled with the blower motor.

Ross thermic fluid heaters utilize thermic fluid for heat transfer. These thermic fluids
remain in the liquid phase upto a temperature of about 300°C without any pressure
built up. Hence there is no explosion hazard. A dearator and expansion tank is
supplied with the boiler. The dearator effectively removes air and gases from the
system thus preventing cavitation of the thermic fluid pump and the consequent
effects on heat transfer. Thermic fluid expands at the rate of 7 % volume for every
100°C rise in temperature. The expansion chamber accommodates this increased
volume of the thermic fluid in the system due to heating.

This manual is prepared with a view –

a) To help in installation & commissioning of the boiler.
b) To help the user in understanding the construction & operation of the equipment.
c) To guide the user in starting & stopping procedures of the equipment.
d) To guide the user on routine maintenance and trouble shooting the exact fault.

We have competent, trained & experienced service engineers to provide efficient &
prompt after sales service. They are always available to render assistance in solving
& trouble shooting of problems.

2. TRANSPORTATION

Use lifting hooks provided on top of the boiler for lifting & lowering the unit.

During transportation the boiler should be properly placed and secured on the vehicle
with the help of ropes to avoid jerks. The boiler should always be kept & handled in
a vertical position. Under no circumstances the load of the boiler should be borne on
the control panel or other structural members of the unit. Due care should be taken
while handling the boiler to avoid damages to the instruments provided on the unit.
It is advisable to unload the boiler as close to the boiler house as possible, preferably
just outside the main door of the boiler house, on some skid or pipe rollers, so that
the boiler movement into the boiler house becomes easier. The soil at the place of
unloading should be hard enough to bear the weight of the boiler, to prevent it from
sinking.

3. SPECIFICATIONS
BURNER
A detailed drawings of the burner is enclosed. For efficient combustion the burner
should be adjusted properly according to the diagram. The position of the diffuser
plate with respect to burner cone is to be finalized by our commissioning engineer.
The view glass housing & the photocell housing are mounted on the burner plate.
The photocell housing has an attachment for cooling air. This cooling air is required
by the photocell as it cannot withstand high temperatures.

The burner assembly should not be disturbed. Incorrect burner setting results in
improper combustion & excess soot formation thus lowering boiler efficiency.

BLOWER
The blower contains a damper to control the air required for combustion. The damper
is adjusted during firing the unit so that no smoke is seen in the exhaust. If white
smoke is seen then close the damper slightly until the smoke becomes colorless. If
black smoke is seen open the damper until the smoke becomes colorless. The fuel oil
pump is directly coupled to the blower motor. The blower alignment should not be
disturbed during maintenance of the unit.

CONTROL PANEL
The prewired panel box which is supplied with the unit consists of contactors and
thermal overload relays which are provided for the thermic fluid pump motor and
blower motor. Electronic timer is provided for time lag between blower fan starting
and fuel oil spray. Sequence controller is provided for controlling the sequence of
operation. Ignition transformer is provided to generate spark between the electrodes.
Temperature indicator cum controllers are provided for continuous on-off operation
of the unit & for high temperature alarm.

4. INSTALLATION

4.1 BOILER ROOM

The unit can be installed anywhere in the plant, however a separate room is always
preferable. The room should be properly ventilated, preferably with large windows on
all sides.
The unit should be installed on a raised foundation of about 100 mm. The foundation
should be preferably made from concrete & must be leveled properly. This is to
prevent equipment from oil, corrosive chemicals, spilled water etc. which may corrode
& reduce the life of the boiler.

Back side & right side clearance of approximately 1000 mm should be provided for the
unit. Front clearance should be at least 1500 mm. To allow adequate area for
movement, operation and maintenance. Clearance of minimum 2000 mm should be
provided on the left hand side for maintenance of coil.

The thermic fluid circulation pump should preferably be placed on the right side and
as close as possible to the thermic fluid inlet of the unit. Provide adequate clearance
on all sides of the pump.

The dearator tank can be installed at any suitable place in the plant. The expansion
tank should be installed at least 600 mm. above highest point in thermic fluid pipeline,
but in no case less than 2 metres from floor level.

The boiler house has to be properly illuminated to keep it bright. Safety regulations,
fire insurance, factory act etc. should be given due consideration.

Provide a box for tools and the maintenance spares of the boiler. The tool box should
contain a spanner set, screw drivers etc. & a calibrated beaker for measuring fuel
consumption. The list of essential spares is given at the end of the manual. Also
provide a fire extinguisher in the boiler room for emergencies.

4.2 CHIMNEY
It is necessary to consult smoke nuisance inspectorate and obtain prior approval of
the chimney design & drawings. The minimum height of the chimney should be 1.5
meters above the highest point of the building.

The chimney should be designed properly to discharge the products of combustion

with minimum resistance and back pressure in combustion chamber, which affects
combustion. Do not reduce the diameter of the chimney below its suggested size.

A removable distance piece should be provided immediately after the unit . This piece
can be removed whenever required without disturbing the main chimney or the unit.
All connections should be with flanges & bolts.

The chimney should be either self supported or supported with guy ropes.
Interconnecting duct between the unit & the main chimney should be as short as
possible & with minimum directional changes. Angle of 45 deg. between the
interconnecting duct and the unit is preferred. Sharp bends will create back pressure
and combustion problems.
Due care should be taken to ensure that weight of the chimney is not directly
transferred on the unit. A hood at the chimney top should be provided to prevent
entry of rain water into the chimney. Keep vertical clearance of 0.7D and hood
diameter of 2.5 D (D=Diameter of the chimney). Provide access with cover at the
chimney bottom for soot removal. The chimney & the ducting should be painted with
aluminum heat resistant paint to avoid external corrosion. Lag the interconnecting
duct inside the boiler room.

4.3 FUEL OIL TANK & PIPING.

A typical fuel oil storage tank is shown in the P & I diagram. The fuel oil tank should
be of adequate capacity complete with a tight lid, level indicator, inlet & outlet
nozzles, drain & vent. The tank should be installed at a minimum height of 1 metre.
The tank should be provided with a 80 mesh ‘Y’ Strainer at the outlet.

It is important to use only M.S. black ‘C’ class pipes for fuel oil lines. GI pipes should
never be used for fuel oil lines as the sulphur in the oil corrodes the zinc in the GI
pipe. The fuel oil outlet should be connected to the filter provided on the unit with
correct size of M.S. pipe line.

Elbows & short bends should be avoided as far as possible. Gate valves should be
used in fuel lines. All pipings should be thoroughly flushed or blown out (clean)before
being connected to the boiler. This will prevent blocking or damaging the boiler
piping system. Unfiltered fuel will cause choking of fuel pump and the burner nozzle.
A hand pump or motorised pump can be used to transfer the fuel oil from the barrel
to the tank.

4.4 THERMIC FLUID EQUIPMENTS & PIPING.

Refer P & I diagram for installing pipelines.
1. Connect the thermic fluid outlet to utility through isolating wheel valve.
2. Connect thermic fluid pump outlet to unit inlet through an isolating wheel valve.
3. Connect utility outlet to dearator tank through an isolating wheel valve.
4. Connect dearator tank outlet to thermic fluid pump inlet through a strainer and
valves.
5. Use only cast steel flanged valves in thermic fluid line.
6. Avoid using elbows and short bends in the thermic fluid lines as far as possible to
reduce frictional loss.
7. Provide air vents in discharge and return lines. Also provide a drain at the lowest
point of the system. Use S.S. needle valves for air vents.
8. Use 1.5 mm thick oil gaskets between flanges.
9. Keep expansion tank vertically above dearator tank if they are separate.
10. Do not use smaller diameter pipes than those specified and do not use screwed
connections in thermic fluid pipeline.
11. The vent pipe above expansion tank should be free of obstructions and open to
atmosphere. It should also prevent entry of water or foreign matter into the tank.
12. Connect thermic fluid pump to cooling water lines. Cooling water connections can
be made of M.S. or GI. The cooling water inlet to the pump should be given
through a valve. The water outlet can be drained or can be connected back to the
main water tank. The quantity of cooling water passing through the pump
chamber should be adjusted so that the rise in temperature of cooling water
should not be more than 30 deg.to 35 deg.C.
13. After completing the installation of the pipelines, it should be pressure tested
pneumatically. Leakage if any should be rectified. The thermic fluid pump should
never be subjected to hydraulic testing. Blind flanges should be put at the pump
inlet and outlet before carrying out the pressure test. Pneumatic test pressure
should be approximately 6 Kg/cm sq.

4.5 ELECTRIC SUPPLY

Three phase, 415 V, 50 Hz, 4 Wire, AC electric supply with earth is required for
operating the boiler.

The supply to the boiler should be given through a main switch fuse unit having
adequate capacity. A cable of adequate size should be used for giving supply from
the main switch to the control panel on the unit. Earth wire of adequate capacity
should be provided to connect the boiler to a suitable earth plate.

5. COMMISSIONING

NOTE : THE BOILER SHOULD BE COMMISSIONED ONLY BY AN ENGINEER

AUTHORISED BY ROSS.

1. Thoroughly flush the fuel pipe line before connecting it to the systems. This will
prevent foreign matter from blocking or damaging the pipe lines or the equipment.
Ensure that fuel oil tank is full of oil.
2. Set burner, diffuser plate, electrodes and nozzle properly.
3. Tighten all the screws in the control panel & motor terminals.
4. Make electrical connections through mains to control panel R,Y,B respectively.
5. Connect thermic fluid pump to control panel using wires provided.
6. Connect the level switch provided to the expansion tank.
7. Check alignment of thermic fluid pump & motor.
8. Fill the thermic fluid pump with SAE 40 oil upto the marked level.
5.1 FILLING UP THERMIC FLUID IN THE SYSTEM
1. Ensure that the thermic fluid has been sent for analysis and confirmed fit for use.
If bad quality thermic fluid is used, it may crack at higher temperature and
carbonise and choke the system piping and the coil of the unit.
2. The thermic fluid must be pumped into the circuit from the lowest point to ensure
that all the air is driven through vent pipes and no air remains trapped in the
circuit. A hand operated semi rotary gear pump can be used for this purpose.
3. Open all vent points to the atmosphere.
4. Open the inlet valve of the user equipment and close the outlet valve so that the
filling of the oil is through inlet valve only. This ensures through filling of oil and
removal of air from it.
5. Start pumping the thermic fluid and watch closely the vent valves. The moment
oil starts coming out of these points close down the vent valves at respective
points and open the outlet valve so that filling of oil starts in that part of the
system.
6. When level is reached in expansion tank, stop filling oil and let the oil settle down
for half an hour.
7. Put the rotary switch in position 1. The thermic fluid pump will start. Ensure that
all necessary valves are open. Ensure that adequate cooling water supply to pump
is given.
8. Note the inlet and outlet thermic fluid pressures. If the gauge reading is not
steady, it indicates that there is trapped air in the system or air is being sucked in
through flanged joints or through glands of the valves.
9. In case of trapped air, this will be removed gradually by cold circulation through
dearator tank. The cold circulation should be continued until all the trapped air is
removed.
10.The flanged joints and the glands of the valves should be further tightened if found
leaking, till a stage of constant pressure reached. Once system is balanced and
level is maintained for half an hour, then it is ready to be warmed up.

5.2 WARMING UP THE SYSTEM

1. Take out the burner rod and check spray through the nozzle. Refit the burner
rod.
2. Put the rotary switch in position 2 and fire the burner. Adjust the air damper
to eliminate smoke.
3. During commissioning thermic fluid heater, the temperature of oil should be
gradually increased. Increase inlet T.I.C. temperature in steps of 10° C.
making sure that there is no cavitation in the system. If cavitation starts, stop
the pump and immediately vent out the gases by opening the vent valves.
Steam & hot gases may come out of these valves and when oil starts oozing
out, the vent valves should be shut. Again start thermic fluid pump by putting
rotary switch in position 1. When the system balances itself, the unit can be
refired. Water can also be removed from drain of buffer tank as water being
heavy settles at the bottom. In this way required T.I.C. temperature can be
 achieved. Set T.I.C. at inlet to required temperature. Set outlet T.I.C.
approximately 30° C higher than T.I.C. at inlet. Set the differential pressure
switch to approximately 1.5 Kg/cm sq.
4. During the entire warming up procedure, a close watch on the pump pressure
and expansion tank level should be kept. If any fluctuations are observed,
continuous circulation of thermic fluid should be done till the fluctuations stop.
5. Check flanged joints for leakages at high temperature and tighten if necessary.
It might also be necessary to add gland packing to valves, to stop such
leakages.
6. Whenever new thermic fluid is put into the system, or heat exchanger is
cleaned or repaired the warming up procedure should be strictly followed.
7. The warming up procedure is required only in the initial run of the unit and not
everyday.
8. At the time of stopping put rotary switch in position 1 so that the thermic fluid
pump operates for some time. At the time of stopping ensure that thermic
fluid temperature should not be more than 100° C.

5.3 RUNNING ATTENTION

Check following points while the unit is running
1. Whether any excessive sound is coming from the motors or elsewhere.
2. Whether proper thermic fluid flow, fuel flow & cooling water flow are
maintained.
3. Check whether all joints are leak tight.
4. Check that the flame is golden yellow in colour.
5. Check whether exhaust from the chimney is colourless.
6. Check that flue gases are not leaking through the top plate or the view glass
or from joints in chimney ducting.
7. Rise in temperature of pump cooling water is not more than 35 deg.C.
8. Pump and circuit pressure guages are steady and not flickering. Flickering of
pointer indicates traces of entrapped gases & air in the column of thermic
fluid.
9. Temperature differences between outlet and return temperature is almost
constant throughout the working of the equipment.
10. Level of thermic fluid in expansion tank is maintained.
11. Leakage through gland packing of thermic fluid pump is not more than 10 to
20 drops per minute.

5.4 SEQUENCE OF OPERATION

1. Rotary switch in position 1. Thermic fluid circulating pump ‘ON’ through
contactor C1 and overload relay R1.
2. Rotary switch in position 2. Thermic fluid pump continues to run. Blower
fuel oil pump motor ‘ON’ through contactor C2 and relay R2 providing air for
combustion.
 3. After a time delay ignition occurs between electrodes through transformer
TR. During this time delay period, gases from the combustion chamber are
driven out. This process is called prepurging.
4. Solenoid valve operates providing fuel spray.
5. Flame is established, photocell views the flame and cuts the ignition
transformer and sparking between the electrodes stops.
6. After reaching the preset temperature of thermic fluid, the inlet TIC cuts off
the burner.
7. When the temperature drops below the set value the burner starts and the
same operation cycle is repeated again.
8. If the outlet temperature of the thermic fluid reaches a high value than that
set on the outlet TIC the burner stops and alarm is given.
9. If the differential pressure between the outlet and the inlet drops below the
set value on the DPS then the burner stops and alarm is given.
10. If the level in the expansion tank drops below the required level, then the
burner trips.

6. MAINTENANCE

The performance of the thermic fluid heater depends greatly on the maintenance
carried out. The boiler, its surrounding, the fuel, water & thermic fluid lines, filters
and strainers etc. should be kept clean. The maintenance procedures given below
may be followed as a broad guideline. A few more points can be added to suit
different site conditions. For easy detection of faults and to know deviation from
standard setting, readings obtained at the time of commissioning should be recorded
and should be referred to after every major servicing.

6.1 BURNER ASSEMBLY

The burner plate can be removed by removing 4 bolts provided on top. Clean the
diffuser plate with kerosene/thinner. Emery paper may be used to remove hard
deposits if any.
The burner rod can be removed. Clean the nozzle & the nozzle filter. The soot
deposits on the electrodes have to be cleaned.

CARE SHOULD BE TAKEN SO AS NOT TO DISTURB THE BURNER SETTING.

THIS WILL RESULT IN IMPROPER COMBUSTION AND BACK FIRING.

6.2 OIL FILTER

The oil filter has a MS body with S.S.mesh inside. The S.S. mesh can be removed by
loosening the nut on top. Clean the mesh with kerosene or compressed air. Clean
the filter body with kerosene. The filter can be drained by removing the bolt provided
at the bottom.

6.3 PERIODIC CHECKS

The following periodic checks are to be carried out. They can be recorded properly on
log sheets. These checks are based on eight hours of operation daily, six days a
week.

DAILY CHECKS
1. Ensure that three phases are on.
2. Check fuel oil level in fuel oil tank.
3. Ensure that fuel filter, strainer & burner nozzle are clean.
4. Open fuel inlet valve.
5. Ensure cooling water supply to thermic fluid circulating pump.
6. Check level of thermic fluid in the expansion tank. Never start the unit if sufficient
quantity of thermic fluid is not there in the expansion tank.
7. Open vent valves provided in the thermic fluid lines to remove any air entrapped.
Close them after all the air has been vented out.
8. Clean the photocell and viewing glasses.
9. Check gland packing of thermic fluid pump. Tighten if necessary.

MONTHLY CHECKS
1. All loose connections should be tightened properly.
2. Tighten all nuts and bolts in the unit.
3. Clean filter in fuel line & burner nozzle.
4. Check pressure gauges and temperature gauges. Replace if necessary.
5. Ensure that electrode tips are clean and in proper position with respect to burner
rod diffuser plate as indicated in drawing.
6. Check thermic fluid line leakage if any & take corrective action if necessary.

YEARLY CHECKS
1. Drain and clean fuel oil service tank.
2. The combustion chamber should be cleaned once in a year, however quality of
fuel and burner efficiency will determine the frequency of cleaning.

6.4 TRAINING
A brief training is imparted to the customers by the service engineer while
commissioning the unit. Training courses of short duration (1 to 2 days) are
conducted at our works in Kondhwa Bk., Pune. Customers are requested to make use
of this facility to benefit themselves.
 7. TROUBLE SHOOTING

1. Thermic Fluid Pump does not start with switch in Position 1.

SR. OBSERVE PROBLEM ACTION

NO

1 Mains Supply Supply Faulty/Loose. Correct Supply

No neutral Check phases & neutral
2 Fuse Fuse Blown/Loose Change Fuse Wire
Contacts Faulty Fit Correctly
3 Rotary Switch Contacts Faulty Change if necessary
4 Overload Relay Relay tripped Reset relay
Wiring Loose Correct Wiring
5 Contactor No neutral supply Give neutral supply.
Coil phase loose Tighten connections
6 Pump Motor terminal Connections loose Tighten connections
Connections
7 Thermic Fluid Pump Pump Jammed/blocked due Repair/clean Pump
to foreign matter

2. Thermic Fluid starts but does not pump fluid.

SR. OBSERVE PROBLEM ACTION

NO.
1. Position of valves. Valves closed. Open the valves.
2. Direction of rotation Direction reversed Reverse phase connection
3. Blower Motor does not start with Switch in Position 2.
Thermic Fluid Pump starts.

SR. OBSERVE PROBLEM ACTION

NO

1. Rotary Switch Contacts Defective Change/Rewire contacts

2. Blower Motor terminal Contacts loose Tighten Contacts
contacts.
3. Temperature Indicator Indicator tripped Reset Indicator.
Indicator faulty Replace if necessary.
4. Temperature indicator Probe connections faulty Replace probe
Probe
5. Differential Pressure Low flow in system Check & correct pressure.
Switch Switch faulty Replace Switch
6. Timer Connections Loose Tighten Connections.
7. Level Switch Low level in expansion Fill expansion tank to
tank. required level.

4. Boiler firing. Smoke present

SR. OBSERVE PROBLEM ACTION

NO

1 Black smoke Burner setting disturbed. Set burner properly.

Damper closed. Open the damper until
smoke becomes colourless.
Fuel consumption higher than Set consumption to rated
usual. value.

2 White smoke Damper open than usual. Close damper until smoke
becomes colourless.
5. Switch in Position 2. Thermic fluid pump starts, blower starts, boiler
does not fire & gives alarm or fires & gives alarm.

SR. OBSERVE PROBLEM ACTION

NO.
1. Blower Direction of Rotation opposite Reverse phase of
Blower.
2. Fuel Pump Suction Low. Check suction.
Fuel pressure low. Set to preset pressure
No delivery of fuel Change/repair fuel
pump.
3. Fuel Fuel tank empty. Fill fuel tank,
Fuel not proper. Change fuel in fuel
tank.
4. Fuel pipeline Pipeline choked Flush/clean pipeline
5. Solenoid Valve Contacts loose. Tighten contacts.
Dirt in valve seat. Clean valve.
6. Nozzle Nozzle chocked. Air in Clean/replace if
Nozzle. necessary.
7. Photocell Carbon deposits on photocell Clean glass.
Glass.
Contacts faulty Check/tighten
Photocell contacts.
Photocell faulty. Change photocell
8. Transformer Loose primary connections. Check and tighten
Contacts.
No secondary voltage. Check secondary
Contacts.
Transformer faulty. Replace transformer.
9. Electrode caps Caps loose. Tighten caps.
Caps wire loose. Tighten wire.
10. Electrodes Setting not proper Set properly
Electrodes faulty Replace electrodes.
11. Burner Burner setting disturbed. Set burner properly.
12. Damper Damper setting disturbed. Set Damper properly.
 8. SERVICE & SPARES

If our engineer is required to come to the installation site for servicing or

commissioning we shall be pleased to depute him on chargeable basis including travel
time. Please allow sufficient time to schedule our engineer’s visit. Refer to our service
department for latest service terms.

Please allow sufficient time to schedule our engineers visit.

LIST OF RECOMMENDED SPARES

It is suggested to keep certain spares in stock to reduce the down time due to
unpredictable break down. In this event of break down it is better to replace the
defective component.

PARTS QUANTITY
1. Burner controller one
2. Solenoid valve one
3. Photocell one
4. Nozzle one
5. TIC & probe one
6. Fuel oil pump one
7. Electrode caps one
8. Asbestos tape & rope 2 to 5 mts.
9. Differential Pressure switch one
10. Gland packing for pump one
11. Love joy coupling with spider one