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ICI Caldaie ASX1000, Instructions For Installation, Use And Maintenance Manual, Page: 1 / 48

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ICI Caldaie ASX1000 Instructions For Installation, Use And Maintenance Manual Download Page 1

ASX_200_3000_en_00 - 10/2019

EN

Superheated water heat generator

ASX

INSTALLATION, USE AND MAINTENANCE MANUAL

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

Summary of Contents for ASX1000

Page 1: ..._200_3000_en_00 10 2019 EN Superheated water heat generator ASX INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...ons 11 ASX 200 800 5 12bar 12 ASX 1000 3000 5 12bar 13 Burners 14 Paperwork 14 Fire prevention 15 Components 15 Pressure 15 Pressure gauge 16 Safety valves 17 SAFETY MIN MAX PRESSURE SWITCHES 17 Safety thermostat 18 Control panel 18 CONTROL PANEL 18 DESCRIPTION OF SAFETY LOGIC RELATED COM PONENTS 19 Thermoregulation and message display Installation 21 Product receipt 22 Handling 22 Film removal 23...

Page 3: ... that do not require continuous monitoring by the operator refer to the specific technical manual RANGE MODEL CODE 5 bar 12 bar ASX200 86290200 86390200 ASX300 86290300 86390300 ASX400 86290400 86390400 ASX500 86290500 86390500 ASX600 86290600 86390600 ASX800 86290800 86390800 ASX1000 86291000 86391000 ASX1200 86291200 86391200 ASX1500 86291500 86391500 ASX1750 86291750 86391750 ASX2000 86292000 8...

Page 4: ...ion 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 treatm...

Page 5: ...uch as switches household appliances etc if you smell fuel or unburnt materials In this case 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 safet...

Page 6: ...onoxide which by its nature is colourless and odourless Therefore ensure the generator 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 ASX is identified by the following nameplates Boiler body nameplate 1 this plate carries the boiler body main data and is riveted on a s...

Page 7: ...ers pressurised from the outside The range of safety accessories must be completed according to the type of system where the boiler is to be installed Below are the European Standards adopted for the manufacture of the electrical and safety equipment List of equipment for super heated water boilers EN 12953 6 Requirements for safety and limitation devices of super heated water boilers EN 12953 9 R...

Page 8: ...2500 3000 Nominalpower kW 1163 1395 1744 2035 2326 2907 3488 Thermalcapacity kW 1292 1550 1937 2260 2584 3229 3876 Efficiencyat100 N C V 90 02 90 00 90 04 90 04 90 02 90 03 89 99 Hydraulicpressuredrop mbar 54 38 59 80 105 52 60 Ratedpressure bar 5 5 5 5 5 5 5 Totalcapacity l 1765 2265 2875 3155 3605 4570 5450 Totalweight kg 3000 3400 4000 5500 7500 8500 9000 Electricsupply Volt 1 N 230 1 N 230 1 N...

Page 9: ...nalpower kW 1163 1395 1744 2035 2326 2907 3488 Thermalcapacity kW 1292 1550 1959 2260 2584 3229 3876 Efficiencyat100 N C V 90 02 90 00 89 03 90 04 90 02 90 03 89 99 Hydraulicpressuredrop mbar 54 78 59 80 105 52 75 Ratedpressure bar 12 12 12 12 12 12 12 Totalcapacity l 1705 2265 2835 3135 3560 4360 5170 Totalweight kg 4150 4510 5460 6000 8800 9600 10650 Electricsupply Volt 1 N 230 1 N 230 1 N 230 1...

Page 10: ...els refer to the supplied accessory manual ASX 200 800 5 12BAR Dimensions u m ASX 200 300 400 500 600 800 H mm 1730 1815 1900 1980 2005 2090 H1 mm 1240 1270 1270 1450 1450 1580 H2 mm 555 615 615 700 700 740 H4 mm 1360 1390 1390 1570 1570 1750 H6 mm 720 850 850 945 945 1000 L mm 1280 1350 1350 1520 1520 1650 L2 mm 1080 1150 1150 1320 1320 1450 L4 mm 1160 1230 1230 1400 1400 1530 P mm 2000 2080 2280...

Page 11: ...180 L2 mm 1450 1540 1720 1720 1800 1900 1980 L4 mm 1530 1620 1800 1800 1880 1980 2060 P mm 2960 3165 3370 3717 3719 4175 4477 5 P2 mm 2310 2502 2714 3012 3016 3514 3750 P6 mm 370 420 370 420 420 470 420 470 480 530 480 530 480 530 Øb mm 280 320 360 360 360 360 400 Øc mm 350 400 450 450 500 550 600 N1 N2 PN 16 16 16 16 16 16 16 N1 DN in 125 150 150 150 150 200 200 N2 DN in 125 150 150 150 150 200 2...

Page 12: ...ber considering 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 ...

Page 13: ...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 14: ...e 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 position ...

Page 15: ... 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 16: ...ressure transducer but always lower than safety valve opening value The minimum pressure must be calibrated at a pressure higher than the water saturated steam pressure at the operating temperature in order to ensure that the boiler body only contains water in a liquid state The safety pressure switches are triggered in case of pressure transducer fault and stops the burner permanently The burner ...

Page 17: ...t from those required 4 The panel supplies utilities having nameplate data different from those described in the multi wire wiring diagram 5 Modifications are applied to extend the panel increase the number of utilities etc DESCRIPTION OF SAFETY LOGIC RELATED COMPONENTS The study and design of the safety measures for the electrical equipment have been carried out in compliance with the provisions ...

Page 18: ...essure allows accessing variable parametrization and if you push it again it scrolls the sequence of variables HSET SP AL2 HAL2 5 Up and down keys for the variables during the thermoregulator parametrization Variable functions HSET Set Point hysteresis working temperature hysteresis burner 2nd stage control SP Set Point working temperature burner 2nd stage control AL2 Limit temperature set burner ...

Page 19: ...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 20: ...ing documentation declaration of conformity use and maintenance manual safety valve certificate with declaration of conformity and use and maintenance manual feed pump characteristic curve 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...

Page 21: ...NTION 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 components BEFORE STARTING THE BOILER The generated heat makes it impossible to remove the film The film exposure to direct sunlight makes it impossible to remove it Cooke I...

Page 22: ...nstallation 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 generato...

Page 23: ...re flooded Make sure that the water and heating system pipes are not used as earthing point of the electrical system The air must be filtered with a 25 μm mesh m IMPORTANT ICI CALDAIE S p A is not liable for any harm to people animals or property damage caused by errors in the choice of components or in the construction of the plant FLUE EXHAUST The main chimney features such as height section typ...

Page 24: ... The installer connections must be made by professionally qualified personnel in compliance with the applicable Technical Standards and the local and national Legislation 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 earthing and failure to comply with the wiring diagram d PROHIBITION Do not use the water and ...

Page 25: ...9 2 3 4 6 7 8 5 8 Dx Sx ASX 200 1200 ASX 200 1200 ASX 1500 3000 ASX 1500 3000 1 m IMPORTANT The door should be secured before performing the opening inversion and adjustment operations a DANGER IT IS DANGEROUS TO UNSCREW the ring nuts 8 located on hinge side This could cause the detachment of the door with possible severe damages to persons and property Dx 8 Cooke Industries Phone 64 9 579 2185 Em...

Page 26: ...old the door Dx Sx 8 1 Proceed as follows to reverse the opening direction of the door loosen drilled ring nut 1 and socket ring nut 8 Dx Sx 1 8 loosen locking nuts 2 present on tie rods and release the conical washers 4 Sx 2 4 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 27: ...RONT DOOR ADJUSTMENT a DANGER Incorrect door adjustment with consequent damage to people and property voids the warranty conditions 1 9 2 3 4 6 7 8 5 8 Dx Sx ASX 200 1200 ASX 200 1200 ASX 1500 3000 ASX 1500 3000 1 VERTICAL ADJUSTMENT To make the adjustment with the door ajar loosen the counter nuts 1 of the hinge units act on the adjustment nuts 2 to lift or lower the door by centring the gasket o...

Page 28: ...ually pushed up to the stop plate naturally returns remaining ajar This is to ensure the hinge side fume seal a DANGER THERE MUST BE NO FLUE GAS LEAKS TURBULATOR ASSEMBLY To assemble the turbulators supplied with the boiler open the door and insert the turbulators completely into the smoke pipes until they penetrate by at least 100 m a DANGER The turbulators have very pointed and sharp ends Theref...

Page 29: ...e of the ceramic thermal insulation 2 P6 5 Øb 4 3 1 1 Burner 2 Flange 3 Gasket 4 Door 5 Thermoceramic material 1 2 3 4 ELECTRICAL CONNECTIONS The generators are equipped with electrical panel IP 55 protection rating complete with all connections to the various generator components already made in the factory The panel model is determined by the version of the ordered generator and the wiring diagr...

Page 30: ...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 31: ...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 32: ...librated by the user based on the needs Make sure that the water delivery pipes are clean by repeatedly 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 Cl...

Page 33: ... 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 34: ...13 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 Effici...

Page 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ... 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 43: ... 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 44: ... 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 45: ...Notes 45 7 Notes 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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