ICI Caldaie ASGX EN Series Manual Download Page 3

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General information

General information

INTRODUCTION

Dear Customer,
Thank you for having chosen an appliance of the series

ASGX EN

, a high quality and efficiency product, reliable and safe.

We recommend entrusting its maintenance to

Professionally Qualified Personnel

who, when necessary, uses original spare parts.

This manual contains important information and suggestions that must be observed for easier installation and best possible use
of the appliance.

IMPORTANT

Failure to observe the instructions in this manual will void the warranty conditions.

IMPORTANT

This manual refers to boilers with “standard accessories”.
For boilers

that “do not require continuous monitoring”

by the operator refer to the specific technical manual.

RANGE

MODEL

CODE

12 bar

ASGX EN3000

86803000

ASGX EN3500

86803500

ASGX EN4000

86804000

ASGX EN5000

86805000

ASGX EN6000

86806000

ASGX EN7000

86807000

ASGX EN8000

86808000

ASGX EN9000

86809000

ASGX EN10000

86810000

ASGX EN11000

86811000

ASGX EN12000

86812000

ASGX EN13000

86813000

ASGX EN14000

86814000

ASGX EN15000

86815000

ASGX EN16000

86816000

ASGX EN17000

86817000

COMPLIANCE

Superheated water heat generators Series

ASGX EN

comply with the following European Directives:

–

Directive 2014/68/EU (PED)

–

Low Voltage Directive 2014/35/EU

–

Electromagnetic Compatibility Directive 2014/30/EU

NOTE

The serial number is indicated on the boiler nameplate.

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

Summary of Contents for ASGX EN Series

Page 1: ...ASGX EN_3000_17000_en_00 10 2019 EN Superheated water heat generator ASGX EN Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...ssure gauge 16 Safety valves 17 Temperature 17 Thermoregulation and message display 19 Thermometer 19 regulation thermostat 19 Safety thermostat Installation 20 Product receipt 21 Handling 21 Film removal 22 Installation room 22 Positioning 22 Room ventilation 23 System cleaning 23 Hydraulic connections 24 Starting hydraulic circuit 24 Flue exhaust 25 Front door opening 25 ASGX EN 3000 7000 25 ASG...

Page 3: ...at do not require continuous monitoring by the operator refer to the specific technical manual RANGE MODEL CODE 12 bar ASGX EN3000 86803000 ASGX EN3500 86803500 ASGX EN4000 86804000 ASGX EN5000 86805000 ASGX EN6000 86806000 ASGX EN7000 86807000 ASGX EN8000 86808000 ASGX EN9000 86809000 ASGX EN10000 86810000 ASGX EN11000 86811000 ASGX EN12000 86812000 ASGX EN13000 86813000 ASGX EN14000 86814000 ASG...

Page 4: ...ction of the accessories to the boiler body gasket seal check Pay the due attention during handling and installation It is necessary to check that the operating water conductivity values are within those provided in the supplied technical manual Analyse the water when necessary ascertaining that the values are within the limits expressed in this technical manual and carry out the due chemical trea...

Page 5: ...ventilate the room by opening doors and windows close the fuel shut off device Perform any technical or cleaning intervention before disconnecting the appliance from the electrical power supply and wearing the Personal Protective Equipment P P E according to Italian Legislative Decree 81 08 Modifying safety or adjustment devices without the boiler manufacturer s authorisation and indications Plug ...

Page 6: ...r is properly installed and adjusted and the presence of ventilation openings in the thermal power plant are compliant with the regulations in force IDENTIFICATION Each generator ASGX EN is identified by the following nameplates Boiler body nameplate 1 this plate carries the boiler body main data and is riveted on a special support Assembly nameplate 2 this plate carries the data relating to the b...

Page 7: ...remove the burner it is equipped with visor for flame control The smoke box is fixed with bolts to the back of the generator It is equipped with smoke duct fitting cleaning door and can be dismantled The body is thermally insulated with high density rock wool mat protected with stainless steel panels They are equipped with lower water side inspection opening flanged hatch They use a single control...

Page 8: ...6 18681 100 efficiency ref NCV 91 91 91 91 91 2 91 91 91 8 91 5 91 NGmaxflowrateG20 Stm3 h 930 23 1046 51 1162 91 1279 19 1392 4 1511 75 1628 03 1729 05 1850 38 1976 87 NGmaxflowrateG30 kg h 690 41 776 71 863 11 949 41 1033 42 1122 01 1208 31 1283 29 1373 33 1467 21 NGmaxflowrateG31 kg h 682 93 768 29 853 75 939 11 1022 22 1109 85 1195 21 1269 38 1358 45 1451 31 Maxfluegasflowrate kg h 13860 43 15...

Page 9: ...2210 2420 2420 2570 2570 H2 mm 1230 1230 1335 1335 1410 1410 H4 mm 2400 2400 2610 2615 2765 2765 H6 mm 1230 1230 1335 1335 1410 1410 H10 mm 125 125 125 125 125 125 L mm 2200 2200 2410 2410 2560 2560 L1 mm 1960 1960 2170 2170 2320 2320 L2 mm 1300 1300 1400 1400 1600 1600 P mm 3879 4379 4379 5373 5389 5889 P2 mm 3430 3930 3930 4930 4930 5430 P3 mm 1012 1012 1012 1006 1264 1264 P4 mm 1500 2000 2000 3...

Page 10: ...840 H10 mm 171 171 105 105 105 105 128 200 200 200 L mm 2700 2700 3140 3140 3140 3140 3265 3650 3650 3650 L1 mm 2490 2490 2940 2940 2940 2940 3065 3450 3450 3450 L2 mm 1700 1700 2000 2000 2000 2000 2000 2250 2250 2250 P mm 7035 7535 7735 7735 8235 8235 8183 8820 8820 9320 P2 mm 4750 5250 5400 5400 5900 5900 5900 6500 6500 7000 P3 mm 1548 1548 1800 1800 1800 1800 1673 1706 1706 1706 P4 mm 3885 4255...

Page 11: ...g also any resistance draught of the smoke duct the length of the combustion head must be adequate to the penetration into the combustion chamber provided by ICI and shown in the table the length and shape of the flame must be suitable to the flame inversion combustion chambers The burner manufacturers have this information as they are required by certification Øb P6 m IMPORTANT The gap between th...

Page 12: ...ificate declaration of conformity use and maintenance manual feed pump characteristic curve Machinery Directive 2006 42 EC for liquid fuel burners wiring diagram always housed in the electrical panel m USER OBLIGATIONS Check which pressure equipment commissioning and use regulations are in force in the country of use FIRE PREVENTION Refer to the Regulations in force in the Unit Installation Countr...

Page 13: ...ale marked in red One of the ends is open and it communicated with the inside of the generator whose pressures is to be measured the other end closed and free to move is connected to the index by a toothed sector lever system The pressure gauge is mounted on a three way valve that allows performing the following operations Communication between generator and pressure gauge normal operating positio...

Page 14: ...til setting the index of the scale 2 to the pressure value at which you wish the burner to restart Remove the cover of the pressure switch and set the drum 3 to the value selected for the differential burner stop based on the Scale of the differential regulation disc Scale of the differential regulation disc Example Pressure switch type RT 5 Scale index 9 bar Drum index 4 corresponding to 2 1 bar ...

Page 15: ...4 close and contacts 1 2 open Contacts go back to their initial position when the pressure drops below the set value minus the differential value fixed at 1 2 bar I II 1 4 2 IS DM 1 4 2 1 4 2 I Alarm triggered by the increase of the pressure above the set value II Alarm triggered by the decrease of the pressure below the set value minus the differential value IS Scale setting DM Mechanical differe...

Page 16: ... information refer to the supplier s manual m IMPORTANT Before starting the generator remove the steel wire that blocks the lever during transport Make sure that the lifting lever is free to move In case of conveyed drain bracket the conveying pipe to compensate the reaction force generated when the fluid is drained Make one or more draining holes in the conveying pipe to drain any condensate Drai...

Page 17: ...ont 1 Instructions 1 2nd stage of burner on enabled to work 2 Burner on enabled to work 2 Display of flow temperature measured or indication of the variable during the thermoregulator parametrization phase HSET SP AL2 HAL2 3 Display of the burner AL2 ON OFF variable or of the sets of variables during the thermoregulator parametrization phase HSET SP AL2 HAL2 4 Enter key its pressure allows accessi...

Page 18: ...0 C and hysteresis 2 C the burner ON OFF control will be interrupted at 122 C and activated again at 120 C At the end of the parametrization wait a few seconds the thermoregulator goes automatically to normal visualization Message display front Alarms 1 Alarm output connected Buzzer on electric panel enabled 2 Alarm indicator 3 Indication of several alarms There is more than one alarm 4 Alarm s in...

Page 19: ...vate the second flame of a two stage burner SAFETY THERMOSTAT The safety thermostat stops the burner when the required temperature value is reached and sends an alarm signal The restart is performed only after the alarm cause has been removed and the system has been reset by using the reset button on the control panel NOTE Calibration and sealing at the manufacturer s premises For further informat...

Page 20: ...ntains the following documentation declaration of conformity use and maintenance manual safety valve certificate with declaration of conformity and use and maintenance manual electrical diagram m IMPORTANT The instruction manual is an integral part of the appliance and so MUST be carefully read before installing and commissioning the generator carefully stored for future consultation and MUST alwa...

Page 21: ...ION E QUADRO AUT 0 MAN POMPA POMPA P1 P2 RESET ALLARMI 1 MINIMO LIVELLO 2 MINIMO LIVELLO PROTEZ IONE POMPA ALTA PRESSIO NE 0 1 BRUCIAT ORE TACITAZ IONE ALLARME a ATTENTION Do not expose the packed product to direct sunlight FILM REMOVAL The boilers can feature the following types of protective films a ATTENTION Remove the PROTECTIVE FILM if any After handling and after having installed all compone...

Page 22: ... installation must be arranged around the boiler the boiler can be installed inside an outdoor prefabricated heating plant room compatibly with the dimensions of the supplied boiler model and in compliance with the Legislation in force in the place of installation COMPULSORY request upon order placing NO P2 90 A A P2 see Size and fittings m IMPORTANT A space is necessary at the front of the genera...

Page 23: ... 10 bar m IMPORTANT We recommend insulating the system pipes to avoid heat dispersion and greater fuel consumption Make sure that the drains of the generator safety valves have been connected to a drain well in order to avoid that in case of intervention the rooms are flooded Make sure that the water and heating system pipes are not used as earthing point of the electrical system The air must be f...

Page 24: ...el safety valve 27 Expansion vessel drain 28 Air supply 29 Air supply solenoid valve 30 Use 31 Recirculation pump FLUE EXHAUST The main chimney features such as height section type of outlet in the atmosphere control points smoke mass must be established by a company specialised in the sector that will operate according to the applicable Standards and Legislation The connection between chimney and...

Page 25: ...s 2 Open the doors using the handles 3 m IMPORTANT Retaining screws 1 reduce vibrations When closing the doors tighten again the retaining screws 1 1 2 3 ASGX EN 8000 17000 NOTE Check the correct adjustment of tie rods and hinges making sure that during the closing phase the seal is evenly pressed along the whole middle section of the circumference a DANGER THERE MUST BE NO FLUE GAS LEAKS Cooke In...

Page 26: ...mpletely into the smoke pipes until they penetrate by at least 100 m a DANGER The turbulators have very pointed and sharp ends Therefore wear suitable protective gloves during insertion equipment according to current regulation 100mm Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 27: ...ith the applicable Technical Standards and the local and national Legislation TEN SIO NE QUA DRO AUT 0 MAN POM PA POM PA P1 P2 RES ET ALL ARM I 1 MIN IMO LIVE LLO 2 MIN IMO LIVE LLO PRO TEZ ION E POM PA ALT A PRE SSI ONE 0 1 BRU CIA TOR E TAC ITAZ ION E ALL ARM E m IMPORTANT Connect the generator to an efficient earthing system ICI CALDAIE S p A is not liable for any damage caused by the lack of e...

Page 28: ... least once to protect the burner flange from the irradiation of the flame It is not necessary for the ceramic insulation to fill the gap up to the internal surface of the door insulation If the supplied material is not suitable for the used burner use other material having characteristics suitable to withstand 1000 C and dimensions suitable to completely close the gap Installation sequence of the...

Page 29: ...ncentrationoforganicsubstances See note e a With copper alloys in the system the pH value must be kept within 8 7 and 9 2 b With a softened water pH value 7 0 the pH of the generator water should be provided according to table 5 2 c At operating pressure 1 bar a maximum total hardness of 0 05 mmol l must be acceptable d Instead of respecting this value with intermittent operation or operation with...

Page 30: ...with volatile chemicals feed water pH 9 2 and generator water pH 8 in this case the conductivity of the generator water is 5 μS cm d If there are non iron materials in the system i e aluminum these may require a lower pH value and a direct conductivity however the priority is to protect the boiler e If treatment with coordinated phosphate is used considering all other values higher concentrations ...

Page 31: ...edly flushing and draining them in the sewer before the final filling Check the quality of the system water according to the indications in paragraph CHARACTERISTICS OF WATER of this manual Check the sealing and correct operation of all fitted components and accessories pipes valves regulators etc Close the drain valves Open the flow and return shut off valves Make sure that the water supply syste...

Page 32: ... condensation phenomenon and the consequent acid corrosion of the parts in contact with flue gases The critical dew point temperature is approximately 57 C with methane gas and approximately 47 C with liquid fuels a ATTENTION On the boilers equipped with manhole during the first start up it is essential to progressively tighten the two nuts 1 of the hatch while pressure increases Otherwise the ins...

Page 33: ...3 5 200 C 50 150 ppm A diagram determines the boiler efficiency according to the flue gas and air temperature and the carbon dioxide percentage CO2 but without considering the losses through the boiler casing Example Flue gas temperature 210 C Ambient temperature 20 C CO2 13 Fuel Diesel fuel Efficiency 91 4 Example Flue gas temperature 210 C Ambient temperature 20 C CO2 13 Fuel Diesel fuel Efficie...

Page 34: ...ations to be carried out to store the generator correctly essentially depend on the duration of the downtime When the generator needs to be stopped for long periods dry storage can be done When the stops are for short periods or when the generator is used as a spare and must start running in a short amount of time a wet storage can be made In both cases the operations described below tend to elimi...

Page 35: ...hat the electrical panel the generator and the control unit equipotential is properly connected to earth Every 6 months check the status of safety devices probes and pressure switches Carry out the maintenance of the burner based on the relevant manufacturer s instructions Check bolt tightening at the flanges and all seals gaskets for wear Check the status of the internal coating of doors and fibr...

Page 36: ...burner T 1 Verification of safety valves by applying a sample pressure gauge to the generator as reference of the exact intervention pressure Verifications must be performed by qualified personnel T 3 Manually check through the switches present on panel front side that valves if any are open T 4 Check correct seal grease lubricate where necessary T 5 Physically check the triggering of safety devic...

Page 37: ...iler through the connecting ducts Each valve will have to be locked and if necessary isolated by removing a section of the connection pipe to the system or by placing a blind flange in between The pressurised parts must be carefully examined internally to look for any build up corrosion and other potential sources of danger pertaining to the feed water It is necessary to remove the deposits throug...

Page 38: ...eck of pressure switch connections to the electrical panel Burner always off Burner problems See specific Burner manual Burner fuses interrupted Fuses replacement No consent to burner from adjustment pressure switch Adjustment pressure switch replacement Incorrect connection to the electrical panel See the wiring diagram PROTECTING THE ENVIRONMENT Protection and respect for the environment is a fu...

Page 39: ...drostatic head in suction water supply temperature pump connection disconnection from the level control probes OVERHEATING DUE TO THERMAL INERTIA Position of water minimum level 100 mm above the highest point of the heated surface Calculation ensuring that the evaporation caused by refractory material thermal inertia does not uncover the highest point of the heated surface OVERHEATING DUE TO SCALE...

Page 40: ...of contained fluid refer to the user s manual POWER SUPPLY A mains voltage control device has been inserted inside the electric system voltage asymmetry phase presence phase sequence Make sure that the panel power supply complies with the indications given in the attached wiring diagram ELECTRIC PANEL ACCIDENTAL OPENING Door lock connected to main switch Voltage adhesive label Inner parts can be a...

Page 41: ... Make sure that hydraulic connections are duly joined together Check the correct connection of electric parts Perform a correct chimney fastening Check generator correct operation FAILING TO CARRY OUT MAINTENANCE Carry out a periodical preventive maintenance and any component repair or replacement operations according to the indications set forth in the Technical Manual and anyway for the cases no...

Page 42: ... with the indications set forth in the manual FIRE The plant room must be arranged in compliance with the fire protection regulations in force in the country of installation Check that body and accessories are intact and not damaged after the fire UNIT POOR MANAGEMENT The operator must meet the requirements provided by the prevailing standards in the country of installation The user is anyway obli...

Page 43: ... 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 44: ...Notes 44 7 Notes Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 45: ...Notes 45 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 46: ...Notes 46 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 47: ...Notes 47 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 48: ... 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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