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Summary of Contents for ICI Caldaie REX F 7
- Page 1 PRESSURISED STEEL BOILERS REX 7 ÷ 130 F INSTALLATION, USE AND MAINTENANCE MANUAL REX_7_130_F_en_05 - 01/2021 Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 2 INDEX General information Introduction Preliminary checks Range Commissioning Compliance Checks after commissioning Warranty Stop periods Warnings Decommissioning of old appliances Prohibitions Maintenance Hazards Boiler Identification Burner Appliance description Any anomalies and remedies Structure Environmental protection and disposal Optional control panel Exploded views of drawings Dimensions and connections Technical data...
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Page 3: Warranty
This manual contains important information and suggestions that must be observed for easier installation and best possible use of the appliance. IMPORTANT Failure to observe the instructions in this manual will void the warranty conditions. RANGE MODEL CODE REX F 7* 83801210 83801220 REX F 8* 83802210 REX F 9* 83802220... - Page 4 Moreover, it must be carefully stored for subsequent consultations and must ALWAYS accompany the boiler during its entire life-cycle (from installation to disposal). In case of damage or loss, request a copy from ICI CALDAIE S.p.A. Technical Assistance Service.
- Page 5 In case of loss, request a copy to the Technical Assistance Service of ICI CALDAIE S.p.A. providing the serial number indicated in the CONSTRUCTION CERTIFICATE - WARRANTY or the sale delivery note.
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Page 6: Appliance Description
APPLIANCE DESCRIPTION High-efficiency ICI CALDAIE S.p.A. REX F steel boilers must be used for heating systems with water temperature within 60° and 100°C and/or in a system for domestic hot water production, within the limits of their performance and power. -
Page 7: Optional Control Panel
OPTIONAL CONTROL PANEL The (optional) control panel, made of plastic with protection grade IP40, contains the regulation and safety instruments: The upper casing of the control panel can rotate to access the terminal board and unwind the capillary tubes of thermostats and thermometers. -
Page 8: Dimensions And Connections
DIMENSIONS AND CONNECTIONS N3 N5 Dimensions REX F Description u.m. 10* 12* 15* 20* 25* 30* 35* 100 120 130 mm 1063 1063 1030 1030 1030 1080 1080 1080 1180 1180 1190 1380 1380 1510 1510 1510 1660 1660 1660 mm 853 853 855 855 855 905 905 905 1005 1005 1015 1205 1205 1335 1335 1335 1485 1485 1485 mm 415 415 415 415 415 440 440 440 490 490 500 610 610 675 675 675 750 750 750 mm 912 912 912 912 912 962 962 962 1061 1061 1095 1285 1285 1417 1417 1417 1568 1568 1568... -
Page 9: Technical Data
TECHNICAL DATA REX F DESCRIPTION u.m. Effective rated Flow thermal 74,2 84,7 95,2 105,6 126,5 157,8 263,5 315,5 Efficiency at 100% (ref. P.C.I.) 94,34 94,45 94,54 94,7 94,86 95,06 95,24 94,88 95,09 95,37 Efficiency of 100% (stars) Max gas flow rate - G20 7,85 8,96 10,07... -
Page 10: Control Panel
CONTROL PANEL The control panels which can be installed on REX F boilers are mentioned in the table. They must be ordered separately from the boiler and for to their technical and installation characteristics refer to the manual provided with the panel. To choose the most appropriate control panel for the system refer also to the CATALOGUE , and to use it refer to the manual supplied with the control panel. -
Page 11: Installation
IMPORTANT PACKAGING: as for the package, ICI CALDAIE S.p.A. complies with the specific recycling systems of each country, ensuring an optimal reuse of them. All the materials used for the packaging respect the environment and can be recycled, such as wood, plastic, cardboard. -
Page 12: Installation Room
HANDLING REX F boilers are equipped with fittings for lifting operations and, in any case, they must be carefully moved with equipment suitable for their dimensions and weights. ATTENTION The Personal Protective Equipment required by current legislation must be used. INSTALLATION ROOM The REX F boiler installation room must be for exclusive use, meet the Technical Standards and Legislation in force and equipped with adequately sized ventilation openings. -
Page 13: System Cleaning
The components shall be charged to the installer that, at the end of the works, must issue a declaration of conformity. 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 14 FLUE GAS DISCHARGE AND COMBUSTION AIR SUCTION The smoke duct and the connection to the chimney must be built in compliance with the Standards and the Laws in force, with rigid pipes, resistant to the temperature, condensate, mechanical stresses and sealed. IMPORTANT The smoke duct must have a diameter equal to or larger than the boiler fitting.
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Page 15: Front Door Opening
FRONT DOOR OPENING The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx). DANGER It is DANGEROUS TO UNSCREW the ferrules (8) on the side of the hinges. This may cause the door to detach, with possible serious harm to people and property damage. -
Page 16: Front Door Adjustment
FRONT DOOR ADJUSTMENT DANGER Incorrect door adjustment with consequent damage to people and property voids the warranty conditions. DOOR ADJUSTMENT (OPENING ON THE RIGHT) VERTICAL ADJUSTMENT To make the adjustment: – with the door ajar, loosen the counter-nuts (1) of the hinge units –... - Page 17 INSULATING CASING ASSEMBLY To fit the insulating casing proceed as follows: – wrap the heat insulating mat around the boiler body and fasten it with the supplied strap (1) – prepare the slats (2) inserting the locking plugs (3) in the corners of each one of them, as shown in the figure below –...
- Page 18 POSITIONING THE CONTROL PANEL NOTE The image of the control panel is only indicative as it may vary depending on the chosen model. Proceed as follows to position the control panel: – Fit the relevant support (9) of the control panel present in the kit on the front crosspiece of the boiler –...
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Page 19: Burner Assembly
IMPORTANT Connect the earth cable to an effective earthing system. ICI CALDAIE S.p.A. is not liable for any damage caused by the lack of the earthing system and the failure to comply with the instructions of the wiring diagrams. -
Page 20: Water Treatment
WATER TREATMENT The thermal system water must comply with the Laws in force, therefore it is good practise to use treatment units when the line water is particularly rich in calcium carbonate, which causes scale build-ups and corrosion. The table includes some indicative values: Characteristics Scale Filling water... -
Page 21: System Filling And Emptying
SYSTEM FILLING AND EMPTYING FILLING – Before filling the system, disconnect the power supply by positioning the system main switch to “ OFF ” and check that the drain valve of the boiler is closed – open the filling valve of the boiler and the shut-off valve of the water system and allow the water to enter slowly, in quantities proportional to the venting capacity of the automatic or manual air separators, and until the expansion vessel pre-filling static pressure value can be read on the manometer –... -
Page 22: Preliminary Checks
PRELIMINARY CHECKS Before commissioning the boiler and carrying out the functional tests, check that: – the turbulators are installed – the system has been filled and the hydraulic circuit pressure, in a cold state, is correct – the flue gases are correctly discharged and there are correctly dimensioned vents –... - Page 23 Combustion guide values: FUEL Flue gas temperature % CO Gas (Methane) 190°C 0 – 20 ppm A diagram determines the boiler efficiency according to the flue gas and air temperature and the carbon dioxide percentage (%CO ), but without considering the losses through the boiler casing. Efficiency diagram (significant losses only) (%) __tab__Flue gas temperature in chimney °C 10 10,5 11...
- Page 24 STOP PERIODS SHORT PERIODS OF TIME In case of system switch-off for a short period of time: – position the central panel switches and the control panel switch to “ OFF ” IMPORTANT If the external temperature is below ZERO: –...
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Page 25: Maintenance
Maintenance Periodic maintenance is prescribed by Law and must be performed only by qualified personnel, at least once a year or more frequently, depending on the boiler output and on the fuel used. The boiler maintenance and cleaning operations are essential for its safety and to keep its efficiency high, extending its service life. IMPORTANT Before performing any maintenance or cleaning: –... - Page 26 – remove the inspection door of the smokebox – clean the surfaces of tube bundle and combustion chamber with a brush (4) and/or other suitable tools – suck, through the smokebox cleaning door, any deposit build-up. If necessary, remove the smokebox and 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.
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Page 27: Any Anomalies And Remedies
ENVIRONMENTAL PROTECTION AND DISPOSAL 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. - Page 28 EXPLODED VIEWS OF DRAWINGS Ring nut for flame inspection window Flow and return gaskets Flame inspection window gasket Turbulators Flame inspection window glass Smokebox Pressure test point on flame inspection window Isolcart insulating panels for smokebox cleaning door Complete door Smokebox fibreglass braid Door Slat covering frame kit...
- Page 29 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.
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Page 30: Declaration Of Conformity
Company certified according to ISO 9001, OHSAS 18001 & ISO 14001 icicaldaie.com DECLARATION OF CONFORMITY 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:... - Page 31 Notes Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 32 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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