ICI Caldaie GREENOx BT COND 180 Technical Manual Download

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93120088 Ed. 27-12/17 27 - St. 10 - 12/17

Appartenente al Gruppo Finluc, iscritto R.I. VR n. 02245640236

Via G. Pascoli, 38 - 37059 Zevio - fraz. Campagnola - VERONA - ITALIA

Tel. 045/8738511 - Fax 045/8731148

The illustration and details reported are indicative only and are not binding. ICI CALDAIE reserves the right to introduce alterations

and/or amendments as it deems fit and proper for the development of the product without the obligation of providing prior notice.

Summary of Contents for GREENOx BT COND 180

Page 1: ... MANUAL EN The above picture is only for reference GREENOx e WITH THREE GAS PASSES The above picture is only for reference GREENOx BT COND LOW RETURN TEMPERATURE WITH CONDENSER LOW NOx PRESSURISED STEEL BOILERS ...

Page 2: ...3 5 3 ELECTRICAL CONNECTION 14 5 4 OPTIONAL CONTROL PANEL 14 5 5 INSTALLATION OF GREENOX E 80 300 BOILER CONTROL PANEL 15 5 6 DOOR 17 5 6 1 DOOR OPENING 17 5 6 2 DOOR OPENING REVERSAL TO THE RIGHT 17 5 6 3 DOOR ADJUSTMENT OPENING ON THE RIGHT 18 5 7 BURNER CONNECTION 19 6 ASSEMBLY 20 6 1 BOILER CASINGS AND CONTROL PANEL 20 7 START UP 24 7 1 PRELIMINARY CHECKS 24 7 2 WATER TREATMENT 24 7 3 FILLING ...

Page 3: ...ciently ventilated Ensure that the boiler fumes are conveyed outside the thermal power plant through a flue compliant with the standards in force Ensure that the acidic condensation that may develop during system start up is evacuated outside the thermal power plant after a neutralisation process in compliance with the standards in force Ensure that there is no danger due to frost inside the therm...

Page 4: ...ature is colour less 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 Repairs Any generator repair must be carried out or authorised by the manufacturer in order to avoid risks to people and property as well as to prevent voiding the Warranty Conditions bei...

Page 5: ...w temperature operations return at 35 C For this reason a double tube and a special smokebox refractory protection are essential to maintain the high temperature of parts in contact with combustion product and without condensate production The boilers are classified as high performance boilers according to the regulations in force due to their extremely high efficiency deriving from optimisation o...

Page 6: ...ct installation may cause damage to persons animals or ob jects for which the manufacturer cannot be held responsible At the first start up all regulation and control devices positioned on the control panel should be checked for efficiency The guarantee shall be valid only upon compliance with the instruction given in this manual Our boilers have been built and tested in observance of EEC requirem...

Page 7: ...t 3 Door opening reversible Characteristics Pressure losses flue gas side Heat losses through the chimney Heat losses through the casing Heat losses with burner off Press losses fluid side Design Pressure Capacity Total weight Electric supply Frequency Insulation class Electric power mbar C C C mbar bar l kg Volt Hz IP W GAS GASOIL HEAVY OIL GAS GASOIL HEAVY OIL ΔT 12K With electr contr excluded p...

Page 8: ... 660 1735 1252 598 740 397 200 250 160 200 50 50 6 1 1 1 1 1 2 1 2 1 2 GREENOx e 25 1520 1345 410 1397 1082 155 755 700 1895 1412 598 900 397 200 250 170 250 65 65 6 1 1 1 1 1 2 1 2 1 2 GREENOx e 30 1520 1345 410 1397 1082 155 755 700 1895 1412 598 900 397 200 250 170 250 65 65 6 1 1 1 1 1 2 1 2 1 2 GREENOx e 35 1675 1500 460 1555 1210 155 800 745 1948 1462 651 900 397 200 250 225 250 80 80 6 1 1 ...

Page 9: ...eat input 3 Door opening reversible Characteristics Pressure losses fluegasside Heatlosses through thechimney Heatlosses through thecasing Heatlosses with burneroff Press losses fluidside Design Pressure Capacity Total weight Electric supply Frequency Insulation class Electric power mbar C C C mbar bar l kg Volt Hz IP W GAS GASOIL HEAVYOIL GAS GASOIL HEAVY OIL ΔT 12K Withelectr contr excluded pump...

Page 10: ...4 1 1 2 1 2 1 2 1 2 GREENOx e 120 1764 1650 671 1764 890 150 1490 1290 2589 1972 800 1300 489 360 410 320 400 125 125 16 1 1 1 4 1 1 2 1 2 1 2 1 2 GREENOx e 140 1764 1650 671 1764 890 150 1490 1290 2899 2282 850 1550 499 360 410 320 400 150 150 16 1 1 1 4 1 1 2 1 2 1 2 1 2 GREENOx e 170 2065 1950 800 2065 1040 150 1800 1600 2966 2324 875 1500 591 360 410 360 400 150 150 16 1 1 1 4 1 1 2 1 2 1 2 1 ...

Page 11: ...bar C kg h mbar bar l l l kg Volt Hz IP W Forcondensing Temp flow return 50 30 C Forcondensing Temp flow return 50 30 C Forcondensing Temp flow return 50 30 C GAS Forcondensing Temp flow return 50 30 C GAS Forcondensing Temp flow return 50 30 C Temp flow return 50 30 C ΔT 12K Withelectr contr excluded pumpandburner N a t g a s L p g G a s o il H e a v y o il GREENOxBTCOND180 5 0 1 50 0 50 0 10 50 ...

Page 12: ... passages and that it is free from debris also check that other appliances do not discharge into the flue unless designed to serve several utilities See the regulations in force 5 1 THERMAL PLANT 5 1 1 ROOM BOILER Current regulations must always be observed Premises in which boilers will be installed should be sufficiently ventilated and permit access for ordinary and extraordinary maintenance ope...

Page 13: ...d after the reduction valve on the supply pipe does not exceed the operating pressure specified on the rating plate of the component boiler heater etc As the water contained in the heating system increases in pressure during operation ensure that its maximum value does not exceed the maximum hydraulic pressure specified on the component rating plate Ensure that the safety valve outlets of the boil...

Page 14: ...access to the terminal board and uncoil the ther mostat and thermometer capillaries A copy of the wiring diagram is contained inside the control panel cover The regulation thermostats have an operating range from 60 to 100 and can be set by the user by means of the front knob Safety thermostats has a fixed setting of 110 C and can be manually reset in accordance by law Circulator consent thermosta...

Page 15: ...ow on the rear side d Pass the bulbs 5 of thermostats and thermometer through the window and screw them in the square pipe of the bracket and slide them in the protective tube through top openings until they reach the wells 6 Lock them using the special locking springs e Connect the cables of burner 7 to the control panel using a protective sheath and lock them with the cable glands 8 f Secure the...

Page 16: ...16 The bracket provided which is equipped with a 2 hole shaped plate enables the user to mount the panels with two inclinations and hence to choose the position he she prefers see figures 1 2 6 3 4 5 9 ...

Page 17: ...washers 10d from the mechanical tubes 9d of the door Door with wrench ferrules hinge side IMPORTANT NOTE In models equipped with wrench adjustable ferrules 8d these must always be mounted on the hinges to prevent the door from being accidentally opened through the lever 12 In this case proceed as follows 3 Proceed as indicated in point 1 4 Cross change the wrench ferrule of a hinge 8d with the opp...

Page 18: ...nce depth wise 3 Screw the nuts 7s and block the conical washers on the mechanical tubes Check the proper adjustment in depth ensuring that the door manually pushed up to the stop plate naturally returns remaining ajar This is to ensure the hinge side fume seal For any problems related to the reversal and adjustment of the door we recommend contacting our local Authorised Technical Assistance Cent...

Page 19: ...of sufficient size to ensure the air flow dictated by the regulations referred to above and that they are in any case sufficient to obtain perfect combustion i Check that the gas pipes are not used as earth connections for electrical appliances If the boiler is not going to be used for some time close the fuel supply cock or cocks IMPORTANT check that the gap between the burner draught tube and th...

Page 20: ...NEL 1 Wrap the fibreglass around the boiler body and use the supplied strap to secure it see fig DIAGRAM OF PLASTIC STRAP LOCKING TO SECURE THE FIBREGLASS TO THE BOILER SHELL 2 Prepare the staves by inserting the four stoppers as shown in the figure ...

Page 21: ...he uprights and the beams to the plates by means of appropriate screws and nuts NOTE the beam shown in the figure if supplied in the package must be placed between the two tube pan els in order to support the staves ...

Page 22: ...re PLEASE NOTE do not cover the upper corner on the manhole side this is required for the subse quent installation of the control panel and its bulbs 5 After inserting the lags and fastening the relevant central masks 1 install the closing profiles 2 using the self tapping screws on the side opposite the manholes 1 2 ...

Page 23: ...illary tubes through the relevant openings until the bulb holding manholes 5 on the shell have been reached 8 Fasten the control panel onto the support using the screws provided SIDE INSTALLATION 6 The control panel can be mounted either on the right or left after mounting the panel support stave 6 7 Place the control panel in the vicinity of the stave 6 and pass the capillaries through the releva...

Page 24: ...con struction level is to eliminate areas that overheat Scale creates an insulating layer which reduces the thermal transfer of the generator affecting system ef ficiency This means that the heat produced by burning the fuel is not fully exploited and is lost to the flue Scale diagram Key fuel not used mm mm scale Corrosion on the water side Corrosion of the metal surfaces of the boiler on the wat...

Page 25: ... CO Gas 10 190 C 0 20 ppm Gas oil 13 195 C 10 80 ppm Heavy oil 13 5 200 C 50 150 ppm A diagram is provided in which the system efficiency is obtained according to the flue gas temperature the ambient temperature and the percentage of carbon dioxide CO2 Dispersions through the boiler casings are not considered Example Flue gas temperature 210 C Ambient temperature 20 C CO2 13 Fuel used GAS OIL Effi...

Page 26: ...temperature gradient between flow and return with burner running at rated output of the boiler must range from 10 C to 25 C This protects the generator both from excessive flow which can cause vibrations and noise and from hot water stagnation which causes limestone build up and cre ates internal thermal shocks It is recommended that the burner switch is always switched on in order to maintain wat...

Page 27: ...er mechanical or electrical The preparation and status of the generator may be different depending on the operations to be performed With the boiler running to check the integrity of the generator when hot fume trace seal water side gasket seal flue draught operation of adjustment and safety accessories With switch off and complete cooling of the generator when having to open the front door with i...

Page 28: ...he integrity of the flame warning light Periodically clean the furnace 1 and the tube bundle 2 using a brush Check the integrity and cleanliness of the turbulators 3 if any in general gaseous fuels should not pro duce any carbon deposit while with the use of liquid fuels it is necessary to clean frequently to avoid substantial fouling To clean more thoroughly the smoke chamber is to be removed in ...

Page 29: ...picture 3 You will be redirected on a web page where you can register the boiler and the plant data filling the blank spaces Once completed the registration it will be necessary to authenticate your email address following the link sent on your mail box You will receive a further email with username and password in order to have access to all the services that ICI has developed for those who regis...

Page 30: ...ONFORMITY WITH THE EUROPEAN COMMUNITY REGULATIONS I undersigned Emanuela Lucchini Managing Director of ICI CALDAIE S p A headquarted in via G Pascoli 38 37059 Campagnola di Zevio VR Italy DECLARE THAT STEEL BOILERS GREENOx e GREENOx BT COND comply with the CE certificate and in accordance with the boards regulations Gas Directive 2009 142 CE Rif EN 303 Efficiency Directive 92 42 CEE EMC Directive ...

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Page 32: ...RONA ITALIA Tel 045 8738511 Fax 045 8731148 info icicaldaie com www icicaldaie com The illustration and details reported are indicative only and are not binding ICI CALDAIE reserves the right to introduce alterations and or amendments as it deems fit and proper for the development of the product without the obligation of providing prior notice ...

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