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Summary of Contents for ICI Caldaie BNX Series
- Page 1 Low-pressure reverse flame steam boiler INSTALLATION, USE AND MAINTENANCE MANUAL BNX_100_3000_EN Ed. 08 - 03/2019 Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 2 INDEX General information Burner assembly Electrical connections Introduction Loading and supply of the generator/system Range Hydrostatic head diagram Compliance Water characteristics Warnings Frequency of analysis Prohibitions Hazards Identification Preliminary checks Appliance description Commissioning Structure Checks after commissioning Dimensions and connections Mandatory periodic verifications Technical data Stop periods...
- Page 3 General information INTRODUCTION Dear Customer, Thank you for having chosen an appliance of the series BNX , 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. – Danger of explosion. 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...
- Page 7 APPLIANCE DESCRIPTION The BNX steam generators are automatically operated single-block appliances. The horizontal combustion chamber is with flame inversion and the tube bundle is complete with helical turbulators. The single front door is thermally insulated with refractory materials and is mounted on adjustable hinges, easily opened without having to remove the burner;...
- Page 8 DIMENSIONS AND CONNECTIONS Dimensions Description u.m. 1000 1400 1700 2000 2650 3000 1280 1465 1795 1790 1790 2045 2045 2325 2325 2760 2510 2510 1245 1290 1290 1465 1465 1640 1640 1855 1995 1995 1280 1460 1760 1665 1665 1560 1560 1760 1760...
- Page 9 TECHNICAL DATA DESCRIPTION u.m. Effective rated 69,8 Thermal capacity 77,4 Efficiency at 100% (ref. P.C.I.) 90,00 91,00 91,00 91,00 91,00 91,00 Pressure drops on exhaust side mbar Rated pressure 0,98 0,98 0,98 0,98 0,98 0,98 Total capacity 1400 Capacity at level 1100 Exchange surface 2,30...
- Page 10 CONTROL PANEL The BNX steam generator is equipped with a control panel for managing and controlling the appliance. The type of panel is established according to the steam generator configuration. For more details refer to the layout and wiring diagram provided with the installed panel. The following figure shows, by way of example, two of the usable panels.
- Page 11 BURNERS The burners that can be installed on the BNX 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) They must also be able to operate on boilers with flame inversion combustion chamber.
- Page 12 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 COMPONENTS The BNX steam generators are equipped with a set of components that can be divided into: – Safety components (safety valves, safety level switches, safety pressure switch). – Indicator components (level indicator, pressure gauge, flame warning light). – Adjustment components (level regulators, pressure switches, pressure transmitters). –...
- Page 14 The main components of the safety valve are: Lifting lever Spring Valve body Drain Fluid inlet IMPORTANT Before starting the generator, remove the steel wire that blocks the lever during transport. Make sure that the lifting lever is free to move. In case of conveyed drain, bracket the conveying pipe to compensate the reaction force generated when the fluid is drained.
- Page 15 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 16 Manual reset in case of block In the event that the burner is blocked by the safety pressure switch, simply reset it manually. To do this, use the control panel, pressing the blue "RESET" button (circled in red in the image to the side) located to the right of the "START"...
- Page 17 AUTOMATIC LEVEL REGULATOR AND SAFETY LEVEL SWITCH The detection and control principle of the level is based on the electrical conductivity of the water. The following conditions must be met to ensure the proper operation of the level switch: – Water conductivity: >250 μS/cm –...
- Page 18 Installation PRODUCT RECEIPT The BNX 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 19 HANDLING ATTENTION Pay the utmost care during handling and use the Personal Protective Equipment requested by the prevailing regulations. The BNX steam generator must be handled using means adequate to the size and weight of the appliance, using the provided lifting eyebolts.
- Page 20 INSTALLATION ROOM POSITIONING The BNX 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 21 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 22 FRONT DOOR OPENING The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx). DOOR OPENING REVERSAL (TO THE RIGHT) IMPORTANT Door opening inversion is possible ONLY for models from BNX 100 to 2650. BNX 100÷2650 BNX 100÷2650 BNX 3000...
- Page 23 DANGER When cross-changing ferrules, always make sure that the other two ferrules are fastened, so that they hold the door. Proceed as follows to reverse the opening direction of the door: – loosen drilled ring nut (1) and socket ring nut (8) –...
- Page 24 – following a cross pattern, swap the socket ring nut of a hinge (8) with the opposite drilled one (1), – fix the conical washer (2) to the door with nut (4) – repeat the whole sequence for the other ring nuts Check the correct adjustment of the tie-rods and hinges ensuring that, during closure, the seal gasket is evenly pressed in the centre on the whole circumference.
- Page 25 HORIZONTAL ADJUSTMENT Close the door using the lever and check that there is equal distance on both sides, 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 –...
- Page 26 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 27 LOADING AND SUPPLY OF THE GENERATOR/SYSTEM The steam generator is fed with a multistage centrifugal pump. The water must reach the pump intake with a certain head in order to avoid cavitation. The minimum temperature of the sucked water must be greater than 60°C; this favours the elimination of oxygen which, in any case, must be completely eliminated with suitable chemicals.
- Page 28 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 29 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...
- Page 30 PRELIMINARY CHECKS IMPORTANT – Before starting the steam generator, it is advisable to perform " Alkaline boiling " with subsequent passivation, to remove any processing residues. Considering the high risk deriving from incorrect chemical treatments, the operations must be carried out by professionally qualified personnel . –...
- Page 31 CHECKS AFTER COMMISSIONING With cold start, check that: – the generator is filled with water up to the minimum level – the volume increase due to heating (thermal expansion of the water) does not excessively increase the level making draining necessary at regular intervals to bring the level back to half scale of the glass indicator –...
- Page 32 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 33 T(1) Physical verification of the intervention of the devices (as described in the following paragraph "Checking of the minimum level safety level switches"). T(2) Physical verification of the intervention of the devices (as described in the following paragraph "Checking of the minimum level safety level switches").
- Page 34 We recommend replacing the probes once a year. To be evaluated, during cleaning/maintenance, the other mechanical, electromechanical and electronic parts. – The faulty components must be replaced with ICI CALDAIE S.p.A. original components. Maintenance Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz...
- Page 35 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 36 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 37 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 –...
- Page 38 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 39 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 40 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 41 Notes Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 42 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 43 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 44 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...
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