Summary of Contents for ICI Caldaie ASGX EN Series
- Page 1 Superheated water heat generator ASGX EN ASGX EN_3000_17000_en_00 - 10/2019 Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 2 INDEX General information Hydraulic connections Starting hydraulic circuit Introduction Flue exhaust Range Front door opening Compliance ASGX EN 3000 ÷ 7000 Warnings ASGX EN 8000 ÷ 17000 Prohibitions Turbulator assembly Hazards Electrical connections Identification Burner assembly Appliance description Water characteristics Technical data Frequency of analysis Dimensions and connections...
- Page 3 General information INTRODUCTION Dear Customer, Thank you for having chosen an appliance of the series ASGX EN , a high quality and efficiency product, reliable and safe. We recommend entrusting its maintenance to Professionally Qualified Personnel who, when necessary, uses original spare parts. This manual contains important information and suggestions that must be observed for easier installation and best possible use of the appliance.
- Page 4 In case of damage or loss, request a copy from Technical Assistance Service ICI CALDAIE S.p.A. . This body must be intended for the use it was expressly designed for. The manufacturer will be exempted from any liability, contractual and extra-contractual, for any injury/damage caused to people, animals, or property due to the failure to perform maintenance and/or scheduled periodic checks and improper uses.
- Page 5 – Dangers due to water leaks . Disconnect the boiler from the electrical power supply, close the water supply and promptly contact the Technical Assistance Service Authorised ICI CALDAIE S.p.A. or professionally qualified personnel. – Routine and extraordinary maintenance must be entrusted to professionally qualified personnel with the purpose of promptly detecting any damage to the generator's pressurised body and the safety and control accessories.
- Page 6 DANGER – Danger deriving from the fuel. Sensing the presence of fuel in the thermal power plant, it is appropriate to follow the precautions below to avoid the risk of explosions and fires: - do not smoke or cause sparks - do not turn on lights or electrical devices in general (mobile phones) - open doors and windows - close the fuel shut-off valve normally placed outside the thermal power plant...
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Page 7: Appliance Description
APPLIANCE DESCRIPTION The ASGX EN range provides super-heated water boilers with three flue gas passes and completely wet furnace back. Manufactured from steel, quality tested according to the prevailing standards and welded with automatic submerged arc welding processes. Suitable for liquid and gaseous fuels. Complete with regulation and safety accessories for automatic operation. -
Page 8: Technical Data
TECHNICAL DATA ASGX EN DESCRIPTION u.m. 3000 3500 4000 5000 6000 7000 Nominal power 3000 3500 4000 5000 6000 7000 Thermal capacity 3333 3888 4444 5555 6666 7777 100% efficiency (ref. NCV) NG max flow rate G20 352,65 411,47 470,28 587,92 705,43 822,94... -
Page 9: Dimensions And Connections
DIMENSIONS AND CONNECTIONS ASGX EN 3000-7000 1 Electrical panel N1 Boiler flow line 2 Pressure gauge N2 Boiler return line 3 Thermometer N3 Instruments fittings 4 Pressure gauge valve N4 System intake/drain fitting 5 regulation thermostat N5 Safety valve fittings 6 Safety thermostats N6 Bulb-holder pockets 7 Safety pressure switch fitting... - Page 10 ASGX EN 8000-17000 1 Electrical panel N1 Boiler flow line 2 Pressure gauge N2 Boiler return line 3 Thermometer N3 Instruments fittings 4 Pressure gauge valve N4 System intake/drain fitting 5 Upper inspection hatch N5 Safety valve fittings 6 Lower inspection hatches N6 Safety and regulation thermostat fittings N7 Condensate drain N8 Control pocket...
- Page 11 BURNERS The burners that can be installed on the ASGX EN boilers must be CE marked according to European Directives: – Gas Directive 2009/142/EC – Electromagnetic Compatibility Directive 2014/30/EU – Low Voltage Directive 2014/35/EU – Machinery Directive 2006/42/EC (for liquid fuel burners) 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: –...
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Page 12: User Obligations
PAPERWORK These generators, supplied in single-block, are CE marked according to the Directive 2014/68/EU "PED". The documentation supplied with the generator is: – declaration of conformity of the whole – use and maintenance manual (always housed in the electrical panel) –... -
Page 13: Pressure Gauge
COMPONENTS The superheated water boilers ASGX EN feature a series of components that can be divided into: – Safety components (safety valves, safety pressure switch, safety thermostat). – Indicator components (temperature indicator, pressure gauge, flame warning light). – Adjustment components (Thermostat). In the descriptions below, accessories are divided based on the values they control. - Page 14 OPERATING PRESSURE SWITCH Device that controls the generator pressure and keeps it within the preset value. Instructions for calibration The electric switch has three screws (1-2-4 from left to right). Upon reaching the set pressure the contact 1-2 is switched into contact 1-4.
- Page 15 SAFETY PRESSURE SWITCH It is set at a pressure higher than the maximum one of the regulation pressure switch, but always lower than safety valve opening value. The safety pressure switch is triggered in case of regulation pressure switch fault and permanently stops the burner. The burner will be switched on again only after the water pressure value has decreased and the control panel has been manually reset.
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Page 16: Safety Valves
SAFETY VALVES The safety valves are able to maintain the pressure in the generator to the design pressure (save temporary peaks of 10% max of the max PS of the whole) even if all other pressure control devices (pressure switches and transmitters) are out of use. These valves are regulated by specific national and international standards, therefore they are sized, tested, installed and maintained in compliance with the applicable regulations and the contents of this manual. - Page 17 VALVE MAINTENANCE The valve is a very delicate mechanism, so the system operator must check its efficiency. If necessary, contact a technician authorised by the manufacturer. It is good practice for the safety valves installed to protect the plant: – to be operated (once a week) with system pressurised, by activating the manual lifting lever of the shutter –...
- Page 18 Thermoregulator parametrization example Push the enter key (4), field 2 to display the HSET variable and field 3 to display the variable parametrization (example: working temperature hysteresis 2°C); to modify the variable push the up and down keys (5). Attention: HSET hysteresis affects both above and below the Set Point; this means that, for example, if the desired Set Point temperature is 110°C and hysteresis 2°C, the control at 2nd stage burner will be interrupted at 112°C and activated again at 108°C.
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Page 19: Safety Thermostat
THERMOMETER It is of the inert gas recessed type, 0/120°C range, boiler with 100 mm diameter and 4000 mm long temperature detection capillary tube. REGULATION THERMOSTAT The regulation thermostat stops the burner when the required temperature is reached and restarts it automatically at a pre-set value.It also features a contact to activate the second flame of a two-stage burner. -
Page 20: Installation
Installation PRODUCT RECEIPT The ASGX EN generators are supplied complete with accessories. The combustion chamber contains: – turbulator unit to be inserted in the smoke pipes during installation – thermoceramic material to be inserted in the gap between burner mouthpiece and door insulation The control panel contains the following documentation: –... -
Page 21: Film Removal
HANDLING ATTENTION Pay the utmost care during handling and use the Personal Protective Equipment requested by the prevailing regulations. The ASGX EN generator must be handled using means adequate to the size and weight of the appliance, using the provided lifting eyebolts. -
Page 22: Installation Room
INSTALLATION ROOM POSITIONING The ASGX EN boiler installation room must be for exclusive use, meet the Technical Standards and Legislation in force and equipped with adequately sized ventilation openings. It is recommended to position the boiler, if possible, lifted from the floor to minimise dust extraction by the burner fan. For information only, below is some useful information: –... -
Page 23: System Cleaning
The air must be filtered with a 25 μm mesh. 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. -
Page 24: Flue Exhaust
STARTING HYDRAULIC CIRCUIT 1 Generator 12 System pumps 23 Air supply pressure switch 2 Pressure transducer 13 Flow switch 24 Pressure transducer 3 Thermometer 14 Water mains 25 Level regulation probes 4 Pressure gauge 15 Water softener 26 Expansion vessel safety valve 5 Thermostat 16 Water load solenoid valve 27 Expansion vessel drain... - Page 25 FRONT DOOR OPENING ASGX EN 3000 ÷ 7000 The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx). ASGX EN 3000 ÷ 7000 ASGX EN 8000 ÷ 17000 – Loosen the retaining screws (1) located on the hinges of door arms. –...
- Page 26 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. DANGER The turbulators have very pointed and sharp ends. Therefore, wear suitable protective gloves during insertion (equipment according to current regulation).
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Page 27: Electrical Connections
Technical Standards and the local and national Legislation. 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. -
Page 28: Burner Assembly
BURNER ASSEMBLY Having chosen the burner to be used, refer to the Manual supplied with it for information about: – the installation and fastening to the boiler – the connection to the fuel supply – the electrical connections – the adjustments to be made –... -
Page 29: Water Characteristics
WATER CHARACTERISTICS The values in the following tables are extracted from tables 5.1 and 5.2 in EN 12953-10 (requirements concerning the quality of water supply and the water in the generator). Even for generators that are not covered by the aforementioned provision it is however necessary to adopt at least the indicated limits and however, to refer to the specialised companies that manage selecting the type of treatment to be carried out on the basis of a thorough analysis of the water available. - Page 30 NOTE These values are valid assuming the presence of a thermal deaerator. In the absence of the deaerator, it is appropriate, however, to raise the temperature of the water contained in the tank to at least 80°C to reduce the content of dissolved gas (O and CO It is, in any case, appropriate to use chemical conditioning to de-oxygenate the water supply completely and to minimise the corrosive CO...
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Page 31: Preliminary Checks
PRELIMINARY CHECKS IMPORTANT – Before start-up, open the door and insert the turbulators completely inside the front ends of the smoke pipes, taking care to push them inside by at least 100 mm. – Check that all fittings are fully tightened. –... - Page 32 COMMISSIONING Start up the boiler as follows: 1) Power the boiler control panel on the general switch. 2) Make sure that the pressurization system has efficiently set the system to the minimum pressure. 3) The boiler must be operated at reduced power (max 50%) until reaching the water operating temperature in order to avoid thermal shocks and thermal expansions between the various parts of the body.During the start-up phase, it is recommended to limit the flow rate of the water passing through the boiler in order to reduce the 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...
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Page 33: Checks After Commissioning
CHECKS AFTER COMMISSIONING The system must be operated properly in order, on the one hand, to ensure an optimal combustion with reduced emissions into the atmosphere of carbon oxide, unburnt hydrocarbons and soot and, on the other, to prevent material damage and injuries to persons. - Page 34 The pressurisation must fall within the values indicated in the table of the technical data. IMPORTANT The temperature difference between flow and return must not exceed 30°C in order to avoid thermal shocks to the boiler. The return temperature from the system must be higher than 50°C with operation with methane gas or LPG and 40°C with operation with fuel oil or naphtha to protect the boiler against corrosion due to the acid condensate of flue gases.
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Page 35: Routine Maintenance
Maintenance Periodic maintenance is an obligation required by the safety Legislation and duration of the appliance, and it must only be entrusted to professionally qualified personnel. The frequency of the operations is shown in the specific paragraph. IMPORTANT Before performing any maintenance or cleaning: –... - Page 36 PERIODIC VERIFICATIONS The frequency of verifications is shown in the table. It MUST be strictly observed . Observation and tests 1 day 1 week 1 month 3 months 6 months 12 months Safety valves T(1) Shut-off valves T(4) Protection devices, High Pressure T(2) T(5) T(12)
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Page 37: Extraordinary Maintenance
METHODS FOR CHECKING THE SAFETY DEVICES CHECK OF THE SAFETY PRESSURE SWITCH The safety pressure switch calibration must be at least 0.5 bar below the calibration of the safety valves. To check the correct intervention of the safety pressure switch, it is necessary to increase the calibration of the adjustment pressure switch(es) and ensure the switch-off of the burner and activation of the block on the boiler electrical panel by visually following the indication given by the pressure gauge. -
Page 38: Protecting The Environment
PROTECTING THE ENVIRONMENT Protection and respect for the environment is a fundamental principle for ICI CALDAIE S.p.A. . The quality of products, lower costs and protection of the environment are of equal importance for the company. ICI CALDAIE S.p.A. , also through ISO 14001 certification, strictly adheres to European laws and standards for the protection and preservation of the environment. - Page 39 Residual Risk Management EXCESSIVE STEAM PRESSURE – Make sure the safety valves properly open at the design pressure. – It is necessary to check the correct activation of the shut-off pressure switch that eliminates the cause of pressure increase by stopping the burner.
- Page 40 CORROSION – Carry out water analysis at the necessary time intervals (refer to user's manual). – Perform water treatments in order to bring the characteristic values back within the limits specified in the use and maintenance manual. – Keep water at a temperature above 60 °C to facilitate deoxygenation. PRESENCE OF SLUDGE –...
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Page 41: Minimum Temperature
HOT SURFACES – Avoid contact with generator uninsulated parts during operation. Should adjustment or check activities be carried out during operation, the operators must wear suitable protective equipment (gloves, shoes and thermal coverall). – Protection with suitable clothing (PPE in compliance with the prevailing laws). –... - Page 42 TAMPERING – The accessories must not be tampered with (safety valve, pressure switches, electric panel or level probes). The generator must be operated by qualified personnel. In case of accident due to tampering, the manufacturer accepts no liability. DECOMMISSIONING – Periodical check by the operator, as stated in the Technical Manual, and appliance decommissioning, if necessary. –...
- Page 43 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.
- Page 44 Notes Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 45 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 46 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 47 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 48 ICI CALDAIE SpA 37059 Fraz. 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...