ICI Caldaie 83801210 Instructions For Installation, Use And Maintenance Manual Download Page 1

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REX_7_130_F_en_05 - 01/2021

PRESSURISED STEEL BOILERS

REX 7 ÷ 130 F

INSTALLATION, USE AND MAINTENANCE MANUAL

Cooke Industries - Phone: +64 9 579 2185 Email: [email protected] Web: www.cookeindustries.co.nz

Summary of Contents for 83801210

Page 1: ..._7_130_F_en_05 01 2021 EN PRESSURISED STEEL BOILERS REX 7 130 F INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...e 7 Optional control panel 8 Dimensions and connections 9 Technical data 10 Control panel 10 Burners Installation 11 Product receipt 12 Handling 12 Installation room 13 System cleaning 13 Hydraulic connections 13 Starting hydraulic circuit 14 Flue gas discharge and combustion air suction 15 Front door opening 16 Front door adjustment 16 Turbulator assembly 17 Insulating casing assembly 18 Bulb fas...

Page 3: ... REX F 75 83810210 REX F 85 83810220 REX F 95 83811210 REX F 100 83812210 REX F 120 83812220 REX F 130 83812230 Product not compliant with the requirements set out in the European regulations No 811 813 2013 and therefore not suitable for the installation on the EU territory for plant rooms or produce domestic hot water The product can be supplied only for the installation in non European Union co...

Page 4: ...traordinary maintenance must be carried out by qualified personnel in order to promptly detect any damage to the boiler body under pressure and to the safety and control accessories The boiler is used to heat water at a temperature lower than the boiling temperature at atmospheric pressure and must be connected to a heating and or domestic hot water production system within the limits of its perfo...

Page 5: ...rds in force IDENTIFICATION Each REX F boiler can be identified through the construction plate 1 inside the envelope of the documents supplied with the boiler which includes technical efficiency information such as serial number or identification marking heat input in kW nominal thermal flow in kW types of fuels which can be used maximum operating pressure CE marking m IMPORTANT The boiler install...

Page 6: ...th helical turbulators rear smokebox made in steel metal sheet consisting of a single piece that can be easily opened to inspect the fire tubes fastened by means of bolts complete with chimney fitting and cleaning door containment tube bundle equipped with connections necessary for the system and the operating equipment all welded with approved processes carried out by qualified welders casing mad...

Page 7: ... reset as required by the regulations The circulation pump enabling thermostat located inside the panel can be adjusted from 0 C to 90 C with a tool and is factory set to 50 C its activation differential is 6 C Thanks to this thermostat the circulation pump remains stopped when the temperature is lower than 50 C to avoid the hazardous flue gas condensation 1 2 3 6 4 5 7 KEY 1 NETWORK LIGHT 2 BURNE...

Page 8: ...703 703 P4 mm 240 240 265 265 265 475 475 725 700 980 850 850 1150 1100 1100 1200 1200 1200 1200 P5 mm 341 341 341 341 341 376 376 376 391 361 422 433 422 443 443 593 574 574 574 P6 mm 200 250 200 250 200 250 200 250 200 250 200 250 200 250 200 250 200 250 200 250 230 280 270 320 270 320 270 320 270 320 270 320 270 320 270 320 270 320 Øb mm 130 130 130 130 130 160 160 160 180 180 225 225 225 280 2...

Page 9: ... 441 524 649 786 891 997 1069 1259 1364 Efficiencyat100 ref P C I 1 95 24 95 42 95 53 95 42 95 4 95 29 95 42 95 31 95 31 Efficiencyof100 stars 2 Maxgasflowrate G20 Stm3 h 46 67 55 45 68 68 83 17 94 29 105 5 113 12 133 23 144 34 Maxgasflowrate G30 kg h 34 64 41 15 50 97 61 73 69 98 78 3 83 96 98 88 107 13 Maxgasflowrate G31 kg h 34 26 40 71 50 42 61 06 69 22 77 45 83 05 97 81 105 97 Maxfluegasflowr...

Page 10: ...he optimal operation of the boiler depends on the correct selection of the burner and its adjustment find below some points to take into account The firing range of the burner must include the boiler operating point flow back pressure in combustion chamber considering the pressure at the base of the chimney as ZERO the length of the combustion head must be adequate to the penetration into the comb...

Page 11: ...and it MUST be carefully read before installing and commissioning the boiler carefully stored for further consultations and it MUST always accompany the boiler m IMPORTANT The control panel must be ordered separately from the boiler and is supplied in a separate package m IMPORTANT The mat of boilers from 7 to 40 is positioned outside the appliance for all other models it is inserted inside the co...

Page 12: ...ppliance reaching the safety devices maintenance repairing any breakage opening the door of the installed burner considering its opening direction towards the right or the left It is recommended to position the boiler if possible lifted from the floor to minimise dust extraction by the burner fan A P2 90 600 mm NO A P2 see Size and fittings m IMPORTANT The front space A must be greater than the bo...

Page 13: ...pressure indicated on the boiler nameplate Make sure that the drains of the safety valves of the boiler and the heater if any are connected to a drain funnel so that the valves do not flood the room in case of intervention Make sure that the water and heating system pipes are not used as earthing point of the electrical system Once the heating system has been filled it is recommended to close the ...

Page 14: ...e chimney must ensure the draught necessary for the boiler operation and provided for by the Technical Standards in force considering a zero pressure at the connection with the smoke duct unsuitable or badly dimensioned chimneys and smoke ducts can cause condensation problems and adversely affect the combustion parameters non insulated drain pipes can lead to a potential risk and the tightness of ...

Page 15: ...table ferrules 8 these must always be mounted on the hinges to prevent the door from being accidentally opened through the lever 9 Proceed as follows to reverse the opening direction of the door screw the left perforated ferrules 1 so that the door seal gasket is pressed in the same way as the right part Bring the conical washers 2 of the left tie rods close to the mechanical tubes 3 of the door a...

Page 16: ...ajar loosen the locking nuts 6 of the hinge units act on the ferrule 7 to adjust the distance depth wise screw the nuts 6 and block the conical washers on the mechanical tubes a DANGER When cross changing ferrules always make sure that the other two ferrules are fastened so that they hold the door Check the proper adjustment in depth ensuring that the door manually pushed up to the stop plate natu...

Page 17: ...e 6 if included in the package must be positioned between the two square pipes to support the slats 5 4 4 5 6 insert the slats 2 previously prepared with locking plugs between the uprights and the crosspieces as in the figure Leave the upper corner uncovered on the pockets side for the following installation of the control panel with the relevant bulbs after completing the installation of the slat...

Page 18: ...ing the bulb holder pockets 11 on the tube bundle Fasten the control panel to the support with the supplied screws Complete the installation of the slats and closing profile 8 with the self tapping screws supplied as standard 9 11 10 8 BULB FASTENING To achieve good thermal contact it is necessary to use the retainer 1 to push the copper bulb 2 inside the pocket 3 screwed in the sleeve 4 Insert th...

Page 19: ...2 1 Burner 2 Flange 3 Gasket 4 Door 5 Insulating mat m IMPORTANT For fuel oil biogas operation the door should have concrete insulation and be equipped with suitable tie rods Any changes and or failure to disclose information during sales will void the warranty conditions ELECTRICAL CONNECTIONS The electric system of a heating plant room used only to heat the buildings must be made by an authorise...

Page 20: ...s to a significant reduction of the service life of the boiler Limestone gathers in the points where the wall temperature is higher and the best defence against it at the construction level is to eliminate the superheating areas Scale build ups form an insulating layer which decreases the heat exchange of the boiler penalising its efficiency This means that a significant part of the heat obtained ...

Page 21: ...sure back to the preset value and close the manual and or automatic supply tap After the initial filling it is necessary to prevent oxygen and untreated water from entering the system The entry of oxygen causes corrosion while untreated water causes the formation of limestone Both conditions must be avoided NOTE The system venting will be completed if necessary upon the first commissioning of the ...

Page 22: ...e has been correctly built and that the fuel is available hydraulic and fuel circuit taps are open check for voltage presence at the control panel and burner The boiler will perform the ignition phase and will operate until the set temperatures will be reached m IMPORTANT In case of LOCK OUT STOP of the burner refer to its technical manual CHECKS AFTER COMMISSIONING Once the start up has been perf...

Page 23: ...10 5 11 12 13 14 15 16 C O 2 Ta Tf G 350 300 250 200 210 150 94 93 92 91 90 89 88 87 86 50 40 30 20 Tf__tab__Flue gas temperature in chimney C Ta__tab__Ambient temperature in C G__tab__Gas Example Flue gas temperature __tab__160 C Ambient temperature __tab__20 C CO2 __tab____tab____tab__10 Fuel __tab____tab__Gas Efficiency __tab____tab__93 2 The pressurisation must fall within the values indicated...

Page 24: ...n the central panel switches and the control panel switch to OFF close the fuel and water interception valves of the hydraulic system m IMPORTANT If the external temperature is below ZERO empty the heating system if there is the risk of frost use anti freeze liquid propylene glycol until a maximum percentage of 3 DECOMMISSIONING OF OLD APPLIANCES Decommissioned appliances contain materials which c...

Page 25: ... if any to OFF close the fuel supply use all Personal Protective Equipment required by current Standards and Legislation wait for the boiler and the system to cool down BOILER External cleaning To perform the external cleaning of the boiler cover use cloths moistened with water mixed with denatured alcohol or specific non abrasive detergents Dry the surfaces thoroughly after cleaning Internal clea...

Page 26: ...nd replace the gasket before refitting it Once the cleaning operation is completed reassemble all the components replacing those worn out and operating by following the previous procedure in the reverse order BURNER For burner maintenance and cleaning follow the instructions on the burner manual or any other indication provided by the burner manufacturer Cooke Industries Phone 64 9 579 2185 Email ...

Page 27: ...e efficiency Unburned material odour Flue gases dispersion into the environment Check the boiler body cleanliness Check the flue gas pipe cleanliness Check the tightness of boiler flue gas pipe and chimney Check the door tightness Gas smell Gas supply circuit Check sealing possible obstructions combustion quality Frequent safety valve triggering Excessive pressure in the system circuit Check load ...

Page 28: ... Door internal insulation 8 Door fibreglass braid 9 Isolcart insulating panels between burner and door 10 Burner nosepiece mat kit 11 Flow and return gaskets 12 Turbulators 13 Smokebox 14 Isolcart insulating panels for smokebox cleaning door 15 Smokebox fibreglass braid 16 Slat covering frame kit 17 Slat locking plugs 18 Slats 19 Tube bundle insulation fibreglass wool Cooke Industries Phone 64 9 5...

Page 29: ... completing the indicated spaces Once registered authenticate your e mail address by clicking on the link that will be sent by e mail to the provided inbox An additional e mail will then be received with the credentials to access all services specifically developed by ICI CALDAIE S p A for those who will register their boiler through the QR Code Registration entitles you even in future months and ...

Page 30: ...FORMITY The undersigned Emanuela Lucchini CEO of ICI CALDAIE S p A with registered office in Via G Pascoli 38 37059 Campagnola di Zevio VR Italy Declares that the boilers REX REX F REX K REX K F REX DUAL REX DUAL F conform to the type described in the EC certification and comply with the following Council Directives European Regulation on Gas Equipment GAR 2016 426 EU Electromagnetic Compatibility...

Page 31: ...Notes 31 6 Notes Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 32: ... Campagnola di Zevio Verona Italy Via G Pascoli 38 Phone 39 0458738511 Fax 39 0458731148 info icicaldaie com www icicaldaie com Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

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