ICI Caldaie 86014065 Installation, Use And Maintenance Manual Download

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FX_N_FX_DUAL_N_en_08 - 04/2020

Instantaneous fire tube steam boiler

FX N / FX DUAL N

INSTALLATION, USE AND MAINTENANCE MANUAL

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

Summary of Contents for 86014065

Page 1: ...L_N_en_08 04 2020 EN Instantaneous fire tube steam boiler FX N FX DUAL N INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...ves the right to make without prior notice any changes it deems appropriate for continuous improvement and constant updating General information 3 Introduction 3 Range 3 Compliance 4 Warnings 5 Prohibitions 5 Hazards 6 Identification 7 Appliance description 7 Structure 8 Dimensions and connections 9 Technical data 10 Control panel 11 Paperwork 11 Fire prevention 12 Components 17 Supply Installatio...

Page 3: ...m IMPORTANT Failure to observe the instructions in this manual will void the warranty conditions RANGE MODEL CODE FX 50 N 86014065 FX 100 N 86014115 FX 150 N 86014165 FX 100 DUAL N FX50 N FX50 N 86014113 FX 200 DUAL N FX100 N FX100 N 86014215 FX 300 DUAL N FX150 N FX150 N 86014315 COMPLIANCE The steam generators Series FX N comply with the following European Directives Directive 2014 68 EU PED Low...

Page 4: ...n during handling and installation Periodically check the condition of the same accessories exclusion of fractures Once installation is completed check the intervention of the safety valve by carrying out a preventive hydraulic test at the PT pressure indicated on the ID plate Make sure the safety level switch is working properly in accordance with the contents of the technical manual supplied wit...

Page 5: ...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 or dimensi...

Page 6: ...ore 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 FX N 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 da...

Page 7: ...stem and a steam pressure control logic Hydraulic and electronic connections of all devices are already made and this helps boiler generator and start up The most critical generator parts and its accessories can be inspected for cleaning and maintenance purposes STRUCTURE 1 2 3 4 5 7 6 8 9 10 12 11 13 14 15 16 17 18 1 Minimum pressure switch 2 Maximum pressure switch 3 Pressure transducer 4 Pressu...

Page 8: ...General information 8 DIMENSIONS AND CONNECTIONS Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 9: ...2 1 2 N5 DN in 1 2 1 2 1 2 N16 in 3 8 3 8 3 8 1 Tb Turbulators size and quantity TECHNICAL DATA DESCRIPTION u m FX N 50 N 100 N 150 N 100 DUAL N 200 DUAL N 300 DUAL N Effectiverated 1 kW 31 7 70 5 104 6 FX50 N FX50 N FX100 N FX100 N FX150 N FX150 N Thermalcapacity kW 34 8 77 4 115 Efficiencyat100 ref P C I 1 91 09 91 04 90 96 Pressuredropsonexhaustside mbar 0 4 1 5 3 2 Ratedpressure bar 5 5 5 Tota...

Page 10: ...l alarms There is more than one alarm 4 Alarm s indicator Alarm indicator box see the type below if there are several alarms the display will display them alternately every 4 seconds 5 Alarm silencing key Press to mute the buzzer when a new alarm appears it will switch back on automatically 6 Key to reset the alarms in the memory If signal 2 is not on and the display is flashing alarm s in the mem...

Page 11: ...anual 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 Range FX N under art 2 of Ministerial Decree no 329 of 1 12 04 is exempted from the commissioning application FIRE PREVENTION Refer to t...

Page 12: ...cted to the index by a toothed sector lever system The design pressure is indicated in red on the manometer 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 Communication between pressure gauge and the outside position needed to purge the siphon Communication between gener...

Page 13: ...rigger pressure and differential pressure can be set using the top screws fig on the right and can be displayed on the two graduated scales KEY 1 Adjuster screw 2 Differential adjuster screw 3 Main arm 4 Main spring 5 Differential spring 6 Bellows 7 Connector 8 Contact system 9 Contact terminals 10 Ground terminal 11 Cable grommet 12 Inverter 13 Locking plate Cooke Industries Phone 64 9 579 2185 E...

Page 14: ...t connection and on the value set The safety pressure switch is set at a pressure higher than the operating pressure switch setting but always lower than safety valve opening value KEY 1 Main shaft 2 Main spring 3 Differential shaft 4 Differential spring 5 Activation lever 6 Bellows 7 Pressure connection 8 Differential knob 9 DIN plug 10 Micro switch 11 Micro switch bracket 12 Adjustment knob Cook...

Page 15: ...ed to a reflex box that contains a prismatic glass This equipment is connected to the boiler above and below normal water level while at its lower end it features a blowdown tap used to discharge the sludge and keep the glass clean The efficiency of the level control system can be periodically inspected using these taps as follows Open the blowdown valve for a few seconds and then close it If no w...

Page 16: ...CH The safety level switch includes several parts 2 level rods 2 probes cylinder inside or outside the generator electric cables 2 electronic relays with conductivity trip point electrical operation logic suitable for preventing water level in boilers from getting too low as this could result in overheating of the parts in contact with combustion products The principle for measuring and controllin...

Page 17: ...t type with automatic regeneration control The cylinder containing resin and brine tank are contained in a single appliance that also includes the mixing valve for residual hardness adjustment For more information on the softener refer to the relevant manual supplied with the unit Feed water tank The condensate collection tank is in stainless steel AISI 304L and includes 3 level probes regulation ...

Page 18: ...o the users distribution header or others from the safety valve outlet 6 outside the room in safety position Drains From the level indicator drain and cylinder 16 and from the boiler drain 17 to the drain line Fuel Connection to burner preset for Light oil or methane gas LPG Compressed air The air pressure must be between 4 and 10 bar Important the air must be filtered with a 25 μm mesh 1 Generato...

Page 19: ... sudden outlets that would lead to boiler erratic operation Furthermore especially when running on methane gas there is a long combustion chamber pre flushing with air every time the burner restarts and this cools down the small quantity of water in the boiler thus causing a rapid pressure drop This is why we recommend to reduce burner stops as much as possible using one of the above specified typ...

Page 20: ...he electric pump drive shaft can turn smoothly and that direction of rotation is correct 4 Set pump switch to AUT position and make sure that burner start up is not enabled before minimum level is reached 5 Check that pump stops when maximum level is reached looking at the level indicators and checking the position of their taps 6 Press and hold the reset button of the water safety level for at le...

Page 21: ...askets clean the tube bundle and turbulators SCHEDULED Periodical inspection every 6 hours electromechanical panel Periodically every 6 hours of operation the operator must go to the heating plant room to check the efficiency of the safety accessories Block pressure switch Safety level switches If no system fault is detected you can reset the electric panel cut power to the electric panel for appr...

Page 22: ...Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 23: ... PERIODS The most significant corrosion often occurs during idle periods The operations to be carried out to ensure a correct storage of the generator mainly depend on the duration of the stop time Dry storage can be arranged when the generator has to stay idle for a long period of time and wet storage for short idle periods or when the generator is a spare one and should be able to be operating i...

Page 24: ... 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 without deaerator in case of agents forming the film and or excess of oxygen the additive must be used e Organic substances are generally a mixture o...

Page 25: ...ire 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 of PO4 are acceptable f Organic substances are generally a mixture of various different compounds The composition of such mixtures and the behaviour of their individual components under the generator operat...

Page 26: ... Loading Problems Incorrect electrical panel probe power supply electrical cable wiring Wiring diagram check Insufficient water loading Pump block See Pump block Problems Dirty pump intake filter Filter cleaning Level adjustment anomaly Temporary replacement of electronic adjustment relay with one of the two relays in the panel If the problem is solved permanently replace the faulty relay Level ad...

Page 27: ... the suitable treatments EN 12953 10 TURBULENCES IN THE WATER LEVEL Check that the characteristics of the delivery and operating water of the boiler correspond to those indicated in the Technical Manual EN 12953 10 WATER CONDUCTIVITY Water delivery has to be checked and kept within the limit values declared in the instruction manual and prescribed by EN 12953 10 according to a suitable treatment w...

Page 28: ...ody is equal to the atmospheric one 0 relative bar ACCIDENTAL OPENING OF HATCH HANDHOLE OR HEADHOLE IF ANY Before opening the hatch it is necessary to check that the pressure in the boiler body is equal to the atmospheric one 0 relative bar DOOR ACCIDENTAL OPENING Before opening the door check that the burner is off and disconnected The wall temperature must be such not to injure the operator HOT ...

Page 29: ... Wet storage and Dry storage The boiler body must be protected against adverse climatic conditions minimum temperature 10 C and rain effects PRESSURISED BODY REPAIR To carry out repair operations contact the manufacturer and or the Body responsible for the check of operating steam generator technical and bureaucratic details and use suitable means and materials DOWNGRADE AND CHANGE OF USE Boiler d...

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: ...Notes 31 7 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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