ICI Caldaie 86240350, Installation, Use And Maintenance Manual

Page 1: ...5000_EN Ed 08 03 2019 EN Low pressure reverse flame steam boiler SIXEN INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...18 Handling 18 Film removal 19 Installation room 19 Positioning 19 Room ventilation 20 System cleaning 20 Hydraulic connections 20 Flue exhaust 21 Front door opening 21 Door opening reversal to the right 23 Front door adjustment 24 Turbulator assembly 25 Burner assembly 25 Electrical connections 26 Loading and supply of the generator system 26 Hydrostatic head diagram 27 Water characteristics 28 F...

Page 3: ...r SIXEN EXP 350 86240354 SIXEN EXP 1000 86241004 SIXEN EXP 2000 86242004 SIXEN EXP 3500 86243504 SIXEN EXP 500 86240504 SIXEN EXP 1350 86241354 SIXEN EXP 2500 86242504 SIXEN EXP 4000 86244004 SIXEN EXP 650 86240654 SIXEN EXP 1700 86241704 SIXEN EXP 3000 86243004 SIXEN EXP 5000 86245004 SIXEN EXP 800 86240804 SIXEN 15 bar SIXEN 350 86250350 SIXEN 1000 86251000 SIXEN 2000 86252000 SIXEN 3500 8625350...

Page 4: ...ring handling and installation Periodically check the condition of the same accessories exclusion of fractures Once installation is completed check the intervention of the safety valve by carrying out a preventive hydraulic test at the PT pressure indicated on the ID plate Make sure the safety level switch is working properly in accordance with the contents of the technical manual supplied with th...

Page 5: ...the room by opening doors and windows close the fuel shut off device Perform any technical or cleaning intervention before disconnecting the appliance from the electrical power supply and wearing the Personal Protective Equipment P P E according to Italian Legislative Decree 81 08 Modifying safety or adjustment devices without the boiler manufacturer s authorisation and indications Plug or dimensi...

Page 6: ...fore ensure the generator is properly installed and adjusted and the presence of ventilation openings in the thermal power plant are compliant with the regulations in force 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 Assembly nameplate 2 this plate carries the ...

Page 7: ...tion pressure switch no 2 pressure switches only for EXP ver sions 3 Block pressure switch 4 Pressure gauge 5 1st safety level probe minimum 6 2nd safety level probe minimum 7 Level adjustment probes start stop 8 Level indicator 9 Level indicator discharge 10 Front door 11 Level test valves 12 Flame control warning light 13 Burner application plate 14 Steam inlet valve 15 Check valves 16 Inspectio...

Page 8: ...70 420 420 470 420 470 480 530 480 530 480 530 Øb mm 225 225 225 225 280 280 320 320 360 360 360 400 400 Øc mm 250 250 300 300 350 350 400 400 450 450 500 550 600 tb ØxP 1 mm 36x1220 36x1220 36x1500 36x1500 36x1220 36x1500 36x2000 36x2000 48x2400 48x2700 48x2700 48x2700 48x2700 tb 1 n 20 26 30 40 40 58 64 72 74 74 92 102 114 Attachments Description u m SIXEN 350 500 650 800 1000 1350 1700 2000 250...

Page 9: ...redropsonexhaustside mbar 10 6 5 9 9 10 11 Ratedpressure bar 12 15 12 15 12 15 12 15 12 15 12 15 Min maxoperatingpressure bar 12 bar version 8 11 5 bar 15 bar version 12 14 Totalcapacity l 3050 3380 4020 5000 6950 7400 Capacityatlevel l 2300 2490 2825 3600 4800 5200 Evaporating surface m2 3 14 3 43 4 12 4 43 5 75 6 46 Steamproduction 1 kg h 2000 2500 3000 3500 4000 5000 Ratedfrequency voltage Volt...

Page 10: ...chamber considering also the possible resistance draught of the smoke duct the length of the combustion head must be adequate to the penetration into the combustion chamber provided by ICI and shown in the table the length and shape of the flame must be suitable to the flame inversion combustion chambers The burner manufacturers have this information as they are required by certification Øb P6 Des...

Page 11: ...ificate declaration of conformity use and maintenance manual feed pump characteristic curve Machinery Directive 2006 42 EC for liquid fuel burners wiring diagram always housed in the electrical panel m USER OBLIGATIONS Check which pressure equipment commissioning and use regulations are in force in the country of use FIRE PREVENTION Refer to the Regulations in force in the Unit Installation Countr...

Page 12: ...he index by a toothed sector lever system The pressure gauge is mounted on a three way valve that allows performing the following operations Communication between generator and pressure gauge normal operating position Communication between pressure gauge and the outside position needed to purge the siphon Communication between generator pressure gauge and sample pressure gauge position needed for ...

Page 13: ... direct the valve so as not to harm people or damage property Interception valves must not be provided The exhaust pipe must be designed in such a way that any low temperatures do not create ice that ob structs the outlet N B Bracket at no more than 1 m away m IMPORTANT The operation of the safety valves is sensitive to pressure losses that occur in the drain conveying pipe during their opening Th...

Page 14: ... maximum one of the pressure transmitter but always lower than the opening pressure of the safety valve The safety pressure switch intervenes in case of steam pressure regulator failure adjustment pressure switch or pressure transmit ter and permanently stops the burner 2 1 5 6 4 4 3 1 Sealed anti tampering cap 2 Polyamide cover 3 Stainless steel bellows 4 Pressure connection G 1 2 A 5 Protection ...

Page 15: ...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 Pressure switch calibration Rotate the knob 1 until setting the index of the scale 2 to the pressure value at which you wish the burner to restart Remove the cover of the pressure switch and set the drum 3 to the value selected...

Page 16: ...l looses part of its transparency partially opaque signs of internal roughness due to erosion or corrosion as it in volves loss of geometry and reading becomes difficult Minimal leaks from the gaskets or shut off groups are also noticed 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 followi...

Page 17: ...ing documentation declaration of conformity use and maintenance manual safety valve certificate with declaration of conformity and use and maintenance manual feed pump characteristic curve electrical diagram m IMPORTANT The instruction manual is an integral part of the appliance and so MUST be carefully read before installing and com missioning the generator carefully stored for future consultatio...

Page 18: ... ATTENTION Do not expose the packed product to direct sunlight FILM REMOVAL The boilers can feature the following types of protective films a ATTENTION Remove the PROTECTIVE FILM if any After handling and after having installed all components BEFORE STARTING THE BOILER The generated heat makes it impossible to remove the film The film exposure to direct sunlight makes it impossible to remove it Co...

Page 19: ...ranged around the boiler the boiler can be installed inside an outdoor prefabricated heating plant room compatibly with the dimensions of the sup plied boiler model and in compliance with the Legislation in force in the place of installation COMPULSORY request upon order placing A P2 vedere Dimesioni e attacchi A P2 90 minimo 600 mm NO A P2 see Size and fittings m IMPORTANT A space is necessary at...

Page 20: ...s have been connected to a drain well in order to avoid that in case of intervention the rooms are flooded Make sure that the water and heating system pipes are not used as earthing point of the electrical system The air must be filtered with a 25 μm mesh m 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...

Page 21: ...2 3 4 6 7 8 5 8 Dx Sx SIXEN 350 1700 SIXEN 350 1700 SIXEN 2000 5000 SIXEN 2000 5000 1 m IMPORTANT The door should be secured before performing the opening inversion and adjustment operations a DANGER IT IS DANGEROUS TO UNSCREW the ring nuts 8 located on hinge side This could cause the detachment of the door with possible severe damages to persons and property Dx 8 Cooke Industries Phone 64 9 579 2...

Page 22: ...old the door Dx Sx 8 1 Proceed as follows to reverse the opening direction of the door loosen drilled ring nut 1 and socket ring nut 8 Dx Sx 1 8 loosen locking nuts 2 present on tie rods and release the conical washers 4 Sx 2 4 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 23: ...ed in the following paragraph FRONT DOOR ADJUSTMENT a DANGER Incorrect door adjustment with consequent damage to people and property voids the warranty conditions 1 2 3 6 4 5 7 Dx Sx VERTICAL ADJUSTMENT To make the adjustment with the door ajar loosen the counter nuts 1 of the hinge units act on the adjustment nuts 2 to lift or lower the door by centring the gasket on the stop plate then block the...

Page 24: ...to the stop plate naturally returns remaining ajar This is to ensure the hinge side fume seal a DANGER THERE MUST BE NO FLUE GAS LEAKS 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 a DANGER The turbulators have very pointed and sharp ends Therefore wear suitabl...

Page 25: ...enerators are equipped with electrical panel IP 55 protection rating complete with all connections to the various generator components already made in the factory The panel model is determined by the version of the ordered generator and the wiring diagram specific and detailed is present inside the panel The installer connections must be made by professionally qualified personnel in compliance wit...

Page 26: ... pipe and on the features of the pump itself refer to the pump manual a ATTENTION The oxygen dissolved in the water corrodes the boiler Refer to the maximum allowed values indicated in the relevant section of the technical manual Follow the table below to avoid pump cavitation problems DEGASSER TYPE Water supply temperature C Head on the intake metres Atmospheric degasser 60 1 70 2 80 3 90 4 5 0 5...

Page 27: ... a With copper alloys in the system the pH value must be kept within 8 7 and 9 2 b With a softened water pH value 7 0 the pH of the generator water should be provided according to table 5 2 c At operating pressure 1 bar a maximum total hardness of 0 05 mmol l must be acceptable d Instead of respecting this value with intermittent operation or operation without deaerator in case of agents forming t...

Page 28: ... can be applied under AVT conditions treatment with volatile chemicals feed water pH 9 2 and generator water pH 8 in this case the conductivity of the generator water is 5 μS cm d If treatment with coordinated phosphate is used considering all other values higher concentrations of PO4 are acceptable e Organic substances are generally a mixture of various different compounds The composition of such...

Page 29: ... be correct indicated in the rear side of the motor place the pump selector at AUT and check that there is no consent to start the burner before the water has reached the minimum level check that the pump stops when the water reaches the maximum level visible in the glass indicator press for at least 10 seconds the reset button of the water safety level to activate the delayed type conductivity re...

Page 30: ...the stop periods The operations to be carried out to store the generator correctly essentially depend on the duration of the downtime When the generator needs to be stopped for long periods dry storage can be done When the stops are for short periods or when the gen erator is used as a spare and must start running in a short amount of time a wet storage can be made In both cases the operations des...

Page 31: ...the drain valves replace them if necessary PERIODIC VERIFICATIONS The frequency of verifications is shown in the table It MUST be strictly observed Observation and tests 6 hours 1 day 1 week 1 month 3 months 6 months 12 months Safety valves O T 9 Level indicators T 4 TDS BWD Unloading devices if present T 5 Shut off valves O T 10 Water load control devices O Low level protection devices if present...

Page 32: ... check of the safety devices Verifications must be performed by qualified personnel a ATTENTION The electronic level relays inside the electrical panel must be replaced after 8 years of operation as they have reached the end of their life span METHODS FOR CHECKING THE SAFETY DEVICES CHECKING OF THE MINIMUM LEVEL SAFETY LEVEL SWITCHES Stand in front of the electrical panel leave the steam outlet va...

Page 33: ...rces of danger pertaining to the feed water It is necessary to remove the deposits through mechanical or chemical action and use suitable tools to ensure that the actual thickness of the internal parts is not affected by corrosion Any pockmark or other type of corrosion must be scraped and cleaned with an iron brush until the metal is exposed Leaks between all fume pipes and tube sheets must be ex...

Page 34: ...t probes short circuit Disassemble the adjustment probes to visually check the ceramic insulation Pump cavitation Head height difference between the collection vessel level and the pump insufficient in relation to the water temperature Pump intake filter cleaning Reduce resistance of the duct between collection vessel and pump by increasing the passage section Pump rotation direction Invert one of...

Page 35: ...drostatic head in suction water supply temperature pump connection disconnection from the level control probes OVERHEATING DUE TO THERMAL INERTIA Position of water minimum level 100 mm above the highest point of the heated surface Calculation ensuring that the evaporation caused by refractory material thermal inertia does not uncover the highest point of the heated surface OVERHEATING DUE TO SCALE...

Page 36: ... of contained fluid refer to the user s manual POWER SUPPLY A mains voltage control device has been inserted inside the electric system voltage asymmetry phase presence phase sequence Make sure that the panel power supply complies with the indications given in the attached wiring diagram ELECTRIC PANEL ACCIDENTAL OPENING Door lock connected to main switch Voltage adhesive label Inner parts can be ...

Page 37: ...Make sure that hydraulic connections are duly joined together Check the correct connection of electric parts Perform a correct chimney fastening Check generator correct operation FAILING TO CARRY OUT MAINTENANCE Carry out a periodical preventive maintenance and any component repair or replacement operations according to the indica tions set forth in the Technical Manual and anyway for the cases no...

Page 38: ... with the indications set forth in the manual FIRE The plant room must be arranged in compliance with the fire protection regulations in force in the country of installation Check that body and accessories are intact and not damaged after the fire UNIT POOR MANAGEMENT The operator must meet the requirements provided by the prevailing standards in the country of installation The user is anyway obli...

Page 39: ...ta of your appliance and system by 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 entit...

Page 40: ... 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 ...