ICI Caldaie 83801010 Instructions For Installation, Use And Maintenance Manual Download

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REX_7_130_en_04 - 03/2020

PRESSURISED STEEL BOILERS

REX 7 ÷ 130

INSTALLATION, USE AND MAINTENANCE MANUAL

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

Summary of Contents for 83801010

Page 1: ...EX_7_130_en_04 03 2020 EN PRESSURISED STEEL BOILERS REX 7 130 INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...al control panel 8 Dimensions and connections 9 Technical data 10 Technical data 11 Control panel 11 Burners Boiler welding 12 Product receipt 13 Handling 13 Installation room 14 System cleaning 14 Hydraulic connections 14 Starting hydraulic circuit 15 Flue gas discharge and combustion air suction 16 Front door opening 17 Front door adjustment 17 Turbulator assembly 18 Insulating casing assembly 1...

Page 3: ...809010 REX 75 83810010 REX 85 83810020 REX 95 83811010 REX 100 83812010 REX 120 83812020 REX130 83812030 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 only be supplied for installations in non EU countries for any applic...

Page 4: ...raordinary 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 perfor...

Page 5: ...ards in force IDENTIFICATION Each REX 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 installe...

Page 6: ...2 P235GH fire tubes welded to the front and rear tube plates equipped with 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 we...

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: ...3 703 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 130 130 130 130 130 160 160 160 180 180 225 225 225 280 280...

Page 9: ...ure Nom output air 20 C OIL C 191 195 197 199 186 193 180 188 186 186 Fluegastemperature Nom output air 20 C FUEL OIL C 191 194 197 199 186 193 180 187 186 185 CO2 GAS 10 5 10 5 10 5 10 5 10 5 10 5 10 5 10 5 10 5 10 5 CO2 OIL 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 CO2 FUELOIL 14 14 14 14 14 14 14 14 14 14 Fluidpressuredrop ΔT 12K mbar 8 10 13 16 23 35 63 98 50 67 Ratedpressure bar 5 5 5...

Page 10: ... 0 8 Heatlosseswithburneroff 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Fluegastemperature Nom output air 20 C GAS C 182 185 185 185 184 185 186 185 185 Fluegastemperature Nom output air 20 C OIL C 185 188 188 188 187 188 189 188 188 Fluegastemperature Nom output air 20 C FUEL OIL C 184 187 187 187 187 188 188 188 187 CO2 GAS 10 5 10 5 10 5 10 5 10 5 10 5 10 5 10 5 10 5 CO2 OIL 13 5 13 5 13 5 13 5 13 5 1...

Page 11: ...s with flame inversion combustion chamber Since the 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 ...

Page 12: ...he 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 combustion chamber m IMPORTANT PACKAGING as for the package ICI CALDA...

Page 13: ...talling the appliance 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 m IMPORTANT The front space A must be greater than the boiler length to...

Page 14: ... 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 15: ... 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 the joint...

Page 16: ...stable 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 ...

Page 17: ... 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 nat...

Page 18: ...ce 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 sla...

Page 19: ...hing 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 t...

Page 20: ...p 2 P6 5 Øb 4 3 1 1 2 1 Burner 2 Flange 3 Gasket 4 Door 5 Thermoceramic material 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 ...

Page 21: ...f 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 from the combustion is not ful...

Page 22: ...ssure 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 23: ...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 24: ...ut considering the losses through the boiler casing Efficiency diagram significant losses only Tf Flue gas temperature in chimney C Ta Ambient temperature in C G Gas Go Diesel fuel Ho Nafta Example Flue gas temperature 210 C Ambient temperature 20 C CO2 13 Fuel Diesel fuel Efficiency 91 4 The pressurisation must fall within the values indicated in the table of the technical data Cooke Industries P...

Page 25: ...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 26: ... 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 27: ...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 28: ...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 29: ... 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 30: ... 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 31: ...PEAN COMMUNITY STANDARDS 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 Electromagne...

Page 32: ...Notes 32 6 Notes Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 33: ...Notes 33 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 34: ...Notes 34 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 35: ...Notes 35 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 36: ... 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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