ICI Caldaie SIXEN Installation, Use And Maintenance Manual

ICI Caldaie SIXEN Installation, Use And Maintenance Manual

Low-pressure reverse flame steam boiler

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EN
Low-pressure reverse flame steam boiler
SIXEN
INSTALLATION, USE AND MAINTENANCE MANUAL
SIXEN_350_5000_EN Ed. 08 - 03/2019
Cooke Industries - Phone: +64 9 579 2185
Email: sales@cookeindustries.co.nz
Web: www.cookeindustries.co.nz

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Summary of Contents for ICI Caldaie SIXEN

  • Page 1 Low-pressure reverse flame steam boiler SIXEN INSTALLATION, USE AND MAINTENANCE MANUAL SIXEN_350_5000_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 INTRODUCTION Dear Customer, Thank you for having chosen an appliance of the series SIXEN , 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.
  • 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 proper- ty 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 ac- cessories.
  • Page 6 IDENTIFICATION Each generator SIXEN 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.
  • Page 7: Appliance Description

    They use a single control panel in which the entire electrical wiring converges. The appliance rests on a carbon steel profile base that ensures its stability. Steam boilers SIXEN are certified both for liquid and gaseous fuels for steam production from 350 to 5000 kg/h at high pressure (12-15 bar).
  • Page 8: Dimensions And Connections

    DIMENSIONS AND CONNECTIONS Mod. 2500÷5000 Dimensions SIXEN Description u.m. 1000 1350 1700 2000 2500 3000 3500 4000 5000 1825 1825 1930 1943 2150 2150 2300 2300 2460 2540 2710 2850 2970 1340 1340 1460 1460 1670 1670 1830 1830 1990...
  • Page 9: Technical Data

    Maximum/minimum temperature (15 bar): CONTROL PANEL The SIXEN 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.
  • Page 10 BURNERS The burners that can be installed on the SIXEN 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 11: Fire Prevention

    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 12 COMPONENTS The SIXEN 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 13 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 14 VALVE MAINTENANCE The valve is a very delicate mechanism, so the system operator must check its efficiency. If necessary, contact a technician author- ised by the manufacturer. It is good practice for the safety valves installed to protect the plant: –...
  • Page 15 Intrinsic safety operation for increasing pressure The figure shows a section of the intrinsic safety bellows for increasing pressure. When pressure increases, the contact lever interrupts the connection between terminals 1 and 2. Should the internal bellows pierce, the pressure will be sent to the external bellows. The external bellows surface is three times higher than the one of the internal bellows.
  • Page 16 With these valves you can periodically test the efficiency of the level control system by performing the following operations. Open the purge valve for a few seconds and close it again. If the water disappears and then quickly returns to the starting point with large swings, it can be assumed that the level works well. Whereas, if the water slowly returns or stops at a different point from the previous, it means that one of the communications is obstructed;...
  • Page 17: Installation

    Installation PRODUCT RECEIPT The SIXEN 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 18: Film Removal

    Pay the utmost care during handling and use the Personal Protective Equipment requested by the prevailing regu- lations. The SIXEN steam generator must be handled using means adequate to the size and weight of the appliance, using the provided lifting eyebolts.
  • Page 19: Installation Room

    INSTALLATION ROOM POSITIONING The SIXEN 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.
  • Page 20: 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 21: 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 SIXEN 350 to SIXEN 1700. SIXEN 350÷1700 SIXEN 350÷1700 SIXEN 2000÷5000...
  • Page 22 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 23: Front Door Adjustment

    – 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 24 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 25: Burner Assembly

    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 26: Loading And Supply Of The Generator/System

    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 27 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 28 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 29: Preliminary Checks

    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 30: Checks After Commissioning

    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 31: Maintenance

    Maintenance Periodic maintenance is an obligation required by the safety Legislation and duration of the appliance, and it must only be entrust- ed to professionally qualified personnel. The frequency of the operations is shown in the specific paragraph. IMPORTANT Before performing any maintenance or cleaning: –...
  • Page 32: Methods For Checking The Safety Devices

    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 33: Routine Maintenance

    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 34: Any Anomalies And Remedies

    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 35 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 36 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 mainte- nance manual. – Keep water at a temperature above 60 °C to facilitate deoxygenation. PRESENCE OF SLUDGE –...
  • Page 37 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 38 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 39 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 40 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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