ICI Caldaie CODEX, Technical Manual

Page 1: ...TECHNICAL MANUAL EN CODEX THREE PASS CONDENSING BOILER WITH LOW NOx ...

Page 2: ...EL 12 7 7 ELECTRICAL CONNECTIONS 16 7 8 OPTIONAL CONTROL PANEL 16 7 9 STARTING 16 7 10 DOOR 17 7 10 1 DOOR OPENING 17 7 10 2 DOOR OPENING REVERSAL to the right 17 7 10 3 DOOR ADJUSTMENT opening on the right 18 7 11 BURNER CONNECTION 19 8 START UP 20 8 1 PRELIMINARY CHECKS 20 8 2 WATER TREATMENT 20 8 3 FILLING THE SYSTEM 20 9 OPERATION 21 9 1 Operation checks 21 9 2 Temporary boiler stop 21 9 3 Pro...

Page 3: ...ently ventilated Ensure that the boiler fumes are conveyed outside the thermal power plant through a flue compliant with the standards in force Ensure that the acidic condensation that may develop during system start up is evacuated outside the thermal power plant after a neutralisation process in compliance with the standards in force Ensure that there is no danger due to frost inside the thermal...

Page 4: ...ature is colourless and odour less Therefore 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 Repairs Any generator repair must be carried out or authorised by the manufacturer in order to avoid risks to people and property as well as to prevent voiding the Warranty Conditions bei...

Page 5: ...mposed of single pass wet back furnace large diameter pipes connected directly to the furnace and the front tube plate two pass corrugated horizontal flue passages whose special surface increases the heat exchange area the flue gas turbulence and the formation of condense the easy drainage of same three pass boiler shell complete with boiler flow constant temperature return variable temperature re...

Page 6: ...cturer cannot be held respon sible At the first start up all regulation and control devices positioned on the control panel should be checked for effi ciency The guarantee shall be valid only upon compliance with the instruction given in this manual Our boilers have been built and tested in observance of EEC requirements IMPORTANT This boiler has been designed to heat water to a temperature less t...

Page 7: ...top of the boiler must be used for lifting The above picture is only for reference When using a forklift the weight of the boiler must be balanced before proceeding This can be achieved by positioning the forks equidistantly from the centre of gravity marked on the sides ...

Page 8: ...0 N C V Efficiency 100 N C V Temp flow return 50 30 C Medium Temp 70 C Heat output Heat input Characteristics Pressurelosses fluegasside Heatlossesthrough thechimney Heatlossesthrough thecasing Heatlosses with burneroff Fluegastemp atboileroutput andairat20deg C CO2 Condense production Press losses fluidside Design Pressure Total capacity Weight Electric supply Frequency Insulation class Electric ...

Page 9: ... temperature return T Inspection plugs Dimensions H H2 H5 H6 H8 H9 H10 H12 L L1 L2 L4 P P2 P6 Øb Øc N1 N2 N1 N2 N4 N7 N9 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm DN in DN in PN DN in DN in DN in CODEX 801 2020 1522 1880 450 202 202 62 91 1493 1310 1298 1060 2443 1732 250 300 280 350 125 100 6 3 4 1 125 CODEX 1000 2020 1522 1880 450 202 202 62 91 1493 1310 1298 1060 2443 1732 250 300 280 ...

Page 10: ...d be sufficiently ventilated and guarantee access for ordinary and extraordinary maintenance operations 7 2 BASE The boiler should be installed on a stand 100 200 mm high in order to create an air trap in the condensate drain which is designed to retain fumes and evacuate water IMPORTANT Make sure the boiler supporting base is perfectly horizontal The door must be at a uniform slope to pro vide a ...

Page 11: ...t probe n 2 16 Fuel shut off valve probe 17 Termometer 18 Regulation thermostat n 1 19 Regulation thermostat n 2 20 Manual reset safety thermostat 21 Shock absorbing pipe 22 Safety valve the 2 nd has a heating capacity above 580 kW 23 Fuel shut off valve 24 Manual shut off valve 25 Manual shut off valve for gas 26 Expansion vessel 27 Level probe glow plug optional 28 System flow 29 Probe sleeves i...

Page 12: ...der to prevent the valves from flooding the room if they open Ensure that the pipes of the water and heating system are not used as an earth connection for the electrical system as this can seriously and very rapidly damage the pipes boiler heater and radiators Once the heating system has been filled you are advised to close the supply cock and keep it closed so that any leaks from the system will...

Page 13: ...ation process The glass wool insulation consisting of 3 layers must be wrapped on the parts shown in the figure and fixed to the connection sides by the appropriate clamps supplied The above picture is only for reference Once the glass wool is attached the wooden support can be removed and the boiler can be placed in its fi nal position 1 1 ...

Page 14: ...2 Secure the front struts to the plate using the appropriate screws and nuts The above picture is only for reference 3 Fix the two items 1 and 2 which form the stave steering strut to the front back plate Fit the internal item 1 right and left paying attention to the hole that is closer to the edge and also on the lower side 1 2 ...

Page 15: ...e proceeding as described above 5 Then in the same way fix the two front and back beams NB only models 1400 1600 kW require previous installation of the spacer staves by applying the reverse technique the larger part to the front side and the straight part to the back ...

Page 16: ... in the boiler kit can be installed either to the right hand side or the left hand side of the wall The panel must be fixed to the corresponding stave 1 which has pre prepared holes for the screws and slots for the capillary inlets The above picture is only for reference 8 Fix the control panel 2 to the supporting stave and pass the capillaries 3 through the stave slot until they reach the bulb ba...

Page 17: ...finished installing all the staves proceed with the assembly of the closing frame us ing the 4 self threading screws 10 View of the boiler with the case and control panel in position The above picture is only for reference ...

Page 18: ...o 100 and can be set by the user by means of the front dial Safety limit thermostats TS has a fixed setting of 110 C and can be manually reset For correct installation refer to the boiler casing assembly instructions WIRING DIAGRAM Refer to the diagram supplied with the specific switchboard 7 9 STARTING Open the gas tap check if there is any gas leakage Switch on the burner and heating pump on the...

Page 19: ...hanical tubes 9d of the door Door with wrench ferrules hinge side IMPORTANT NOTE In models equipped with wrench adjustable ferrules 8d these must always be mounted on the hinges to prevent the door from being accidentally opened through the lever 12 In this case proceed as follows 3 Proceed as indicated in point 1 4 Cross change the wrench ferrule of a hinge 8d with the opposite perforated ferrule...

Page 20: ...rew the nuts 7s and block the conical washers on the mechanical tubes Check the proper adjustment in depth ensuring that the door manually pushed up to the stop plate naturally returns remaining ajar This is to ensure the hinge side fume seal For any problems related to the reversal and adjustment of the door we recommend contacting our local Authorised Technical Assistance Centre IMPORTANT Incorr...

Page 21: ...at the air spaces between the burner draught tube and the manhole are suitably filled with thermoinsulating material The thermoinsulating strip provided with the boiler must be wrapped around the mouthpiece for at least an entire circumference of the flame radiation to protect the flange of the burner Not that the ceramic insulation is necessary to fill the gap until the insulation inside surface ...

Page 22: ... life of the boiler Scale is found mostly at the points where the wall temperature is highest and the best remedy at construction level is to eliminate areas that overheat Scale creates an insulating layer which reduces the thermal transfer of the boiler affecting system efficiency This means that the heat produced by burning the fuel is not fully transferred and is lost to the flue Scale diagram ...

Page 23: ... temperature remains near the value set by the thermostat In the case of flue gas leaks from the front of the boiler door and burner plate the closure tie rods of the single parts must be adjusted if this is not sufficient replace the gaskets WARNING Do not open the door and do not remove the fume chamber while the burner is in operation In all cases wait a few minutes after stopping the burner fo...

Page 24: ... inspection in side the furnace and fume chamber With cooling complete empting and safe shut off of the generator towards the system of use in the case of water side internal visit Particular precautions must be taken to avoid the risk of electric shock since the system on the generator has accessories powered at 230V and or at 400V Before intervening on the generator ensure that the connection to...

Page 25: ...ection and respect for the environment is a fundamental principle for ICI CALDAIE S p A The quality of prod ucts 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 pres ervation of the environment In order to reduce its impact on the envir...

Page 26: ... ture 3 You will be redirected on a web page where you can reg ister the boiler and the plant data filling the blank spac es Once completed the registration it will be necessary to authenticate your email address following the link sent on your mail box You will receive a further email with username and password in order to have access to all the services that ICI has developed for those who regis...

Page 27: ... EUROPEAN COMMUNITY REGULATIONS I undersigned Emanuela Lucchini Managing Director of ICI CALDAIE S p A headquarted in via G Pascoli 38 37059 Campagnola di Zevio VR Italy DECLARE THAT STEEL BOILERS CODEX comply with the CE certificate and in accordance with the boards regulations Gas Directive 2009 142 CE Rif EN 303 Low Voltage Directive 2014 35 UE EMC Directive 2014 30 UE S Maria di Zevio li 04 08...

Page 28: ...scoli 38 37059 Zevio fraz Campagnola VERONA ITALIA Tel 045 8738511 Fax 045 8731148 info icicaldaie com www icicaldaie com The data listed is indicative only and is not binding Our company reserves the right to introduce alterations at any time as it deems fit and proper for the development of the product ...