ICI Caldaie REX 140 Instructions For Installation, Use And Maintenance Manual Download

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REX_140_350_en_02 - 08/2019

PRESSURISED STEEL BOILERS

REX 140-350

INSTALLATION, USE AND MAINTENANCE MANUAL

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

Summary of Contents for REX 140

Page 1: ..._140_350_en_02 08 2019 EN PRESSURISED STEEL BOILERS REX 140 350 INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...t 11 Handling 11 Installation room 12 System cleaning 12 Hydraulic connections 12 Starting hydraulic circuit 12 Water circulation 13 Flue gas discharge and combustion air suction 14 Control panel installation 15 Front door opening 15 Door opening inversion to the right for models from 140 to 180 16 Front door adjustment 16 Door adjustment opening on the right 16 Turbulator assembly 17 Burner assem...

Page 3: ...al will void the warranty conditions RANGE MODEL CODE MODEL CODE REX 140 83813010 REX 240 83816010 REX 160 83813020 REX 300 83817010 REX 180 83814010 REX 350 83818010 REX 200 83815010 COMPLIANCE REX boilers comply with the following European Directives European Regulation on Gas Equipment GAR 2016 426 EU Low Voltage Directive 2014 35 EU Electromagnetic Compatibility Directive 2014 30 EU Energy eff...

Page 4: ...personnel maintenance technician in compliance with the requirements of the local Standards in force Ordinary and extraordinary 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 PROHIBITIONS d IT IS FORBIDDEN Operate electrical devices or appliances such as switches household app...

Page 5: ...tandards in force IDENTIFICATION Each REX boiler can be identified through the construction plate inside the envelope of the documents supplied with the boiler which includes technical efficiency information such as serial number or identification marking nominal thermal power in kW nominal thermal flow in kW types of fuels which can be used maximum operating pressure CE marking m IMPORTANT The bo...

Page 6: ... 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 wel...

Page 7: ...70 3225 P3 mm 831 831 771 903 903 903 903 P4 mm 1300 1300 1850 1550 1950 2050 2050 P5 mm 755 755 475 767 627 527 982 P6 mm 350 400 350 400 450 500 450 500 450 500 450 500 450 500 Øb mm 320 320 320 360 360 400 400 Øc mm 400 400 400 500 500 550 550 Attachments Description u m REX 140 160 180 200 240 300 350 N1 DN in 150 150 150 200 200 200 200 N2 DN in 150 150 150 200 200 200 200 N1 N2 PN 16 16 16 1...

Page 8: ...urneroff 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Fluegastemperature Nom output air 20 C GAS C 184 183 184 184 184 184 184 Fluegastemperature Nom output air 20 C OIL C 187 186 186 187 186 186 187 Fluegastemperature Nom output air 20 C FUEL OIL C 187 186 186 187 186 186 186 CO2 GAS 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 CO2 FUELOIL 14 14 14 14 14 14 14 Fluidpressuredrop ΔT...

Page 9: ...rective 2006 42 EC for liquid fuel burners They must also be able to operate on boilers 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 consider...

Page 10: ...nce and it MUST be carefully read before installing and commissioning the 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 PACKAGING as for the package ICI CALDAIE S p A complies with the specific recycling systems of each country ensur...

Page 11: ...liance 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 A P2 see Size and fittings m IMPORTANT The front space A must be greater than the boil...

Page 12: ...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 13: ...ration 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 joints must be ensured with materials resistant to the tem...

Page 14: ...quare pipe of the support and through the upper openings route them in the protection pipe until reaching the pockets 6 Then lock with specific clamps to prevent them from being pulled out connect the burner cables 7 to the control panel using a protection sheath and lock them with cable rings 8 fasten the control panel to the support 3 with the kit supplied fasten with two screws 9 the arm contro...

Page 15: ...h wrench adjustable 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...

Page 16: ...ides between the stop plate and the band If this is not the case with the door 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 adjus...

Page 17: ... 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 m...

Page 18: ... 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 full...

Page 19: ...sure 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 20: ...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 21: ...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 22: ...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 23: ... 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 24: ...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 25: ... Thermostat if any Check the 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...

Page 26: ...ction window 5 Complete door 6 Door 7 Door fibreglass braid 8 Isolcart insulating panels between burner and door 9 Burner nosepiece mat kit 10 Flow and return gaskets 11 Turbulators 12 Smokebox 13 Isolcart insulating panels for smokebox cleaning door 14 Smokebox fibreglass braid 15 Tube bundle insulation fibreglass wool Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www...

Page 27: ... 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 28: ...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 29: ...Notes 29 6 Notes Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 30: ...Notes 30 7 Notes Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 31: ...Notes 31 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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