ICI Caldaie REX, Technical Manual

Page 1: ...TECHNICAL MANUAL REX REX F REX K REX K F REX DUAL REX DUAL F STR PRESSURISED STEEL BOILERS ...

Page 2: ...ator is provided with a manufacture plate that can be found in the envelope with the boiler documents The plate lists Serial number or identification code Rated thermal output in kcal h and in kW Furnace thermal output in kcal h and in kW Types of fuels that can be used Max operating pressure A manufacture certificate is also provided which certifies the hydraulic test positive performance The ins...

Page 3: ...X REX 25 REX K 25 2 0 6 95 0 80 0 10 185 188 187 10 5 13 5 14 0 15 5 220 431 230 50 IP X0D 20 X X X X REX 30 REX K 30 2 0 6 89 0 80 0 10 184 186 186 10 5 13 5 14 0 16 5 300 475 230 50 IP X0D 20 X X X X REX 35 REX K 35 2 9 6 85 0 80 0 10 183 186 185 10 5 13 5 14 0 18 5 356 542 230 50 IP X0D 20 X X X X REX 40 REX K 40 4 1 6 82 0 80 0 10 182 185 184 10 5 13 5 14 0 20 5 360 584 230 50 IP X0D 20 X X X ...

Page 4: ... K 8 F 1063 853 415 912 415 54 5 756 700 994 630 413 240 341 200 250 130 200 50 50 1 1 1 2 1 2 REX 9 REX K 9 REX 9 F REX K 9 F 1030 855 415 912 415 54 5 756 700 1119 755 513 265 341 200 250 130 200 50 50 1 1 1 2 1 2 REX 10 REX K 10 REX 10 F REX K 10 F 1030 855 415 912 415 54 5 756 700 1119 755 513 265 341 200 250 130 200 50 50 1 1 1 2 1 2 REX 12 REX K 12 REX 12 F REX K 12 F 1030 855 415 912 415 54...

Page 5: ...77 26 57 35 56 72 1151 24 REX 160 F REX K 160 F 1600 1 376 000 1675 1 440 500 95 52 177 25 131 55 130 13 2641 03 800 688 000 835 1 718 160 95 80 88 37 65 59 64 87 1316 67 REX 180 F REX K 180 F 1800 1 548 000 1885 1 621 100 95 49 199 47 148 05 146 44 2972 10 900 774 000 940 4 808 780 95 70 99 52 73 86 73 06 1482 81 REX 200 F REX K 200 F 2000 1 720 000 2094 1 800 840 95 51 221 59 164 46 162 68 3301 ...

Page 6: ...ue ncy Insulation class Electric power mbar C C C mbar bar l kg Volt Hz IP W GAS GASOIL HEAVY OIL GAS GASOIL HEAVY OIL T 12 C With electr contr excluded pump and burner N a t g a s L p g G a s o il H e a v y o il W o o d REX400 9 0 6 89 0 80 0 10 184 186 186 10 5 13 5 14 0 60 6 4450 7420 230 50 IP X0D 20 X X X X REX450 10 0 6 70 0 80 0 10 179 182 182 10 5 13 5 14 0 52 6 4900 7920 230 50 IP X0D 20 ...

Page 7: ...0 50 IP X0D 20 X X X X REX DUAL 150 5 2 6 95 0 80 0 10 185 188 187 10 5 13 5 14 0 25 5 1710 2409 230 50 IP X0D 20 X X X X REX DUAL 170 7 2 6 91 0 80 0 10 184 187 187 10 5 13 5 14 0 27 5 1710 2409 230 50 IP X0D 20 X X X X Flue gas temp at boiler output and air at 20 deg CO2 Fuel Characteristics Efficiency 100 N C V Effic 100 stars NG max flow rate G20 NG max flow rate G30 NG max flow rate G31 Max f...

Page 8: ...0 1710 440 1320 830 54 5 1034 5 989 806 750 590 2048 1250 1650 398 200 250 160 250 80 80 1 1 1 1 2 1 2 REX DUAL 60 REX DUAL 60 F 1993 490 1470 1910 490 1470 930 54 5 1034 5 1089 906 850 690 2049 1250 1651 398 200 250 180 250 80 80 1 1 1 1 2 1 2 REX DUAL 70 REX DUAL 70 F 1993 490 1470 1910 490 1470 930 54 5 1034 5 1089 906 850 690 2299 1500 1901 398 200 250 180 250 80 80 1 1 1 1 2 1 2 REX DUAL 80 R...

Page 9: ... 13 5 14 0 30 5 2400 3686 230 50 IP X0D 20 X X X X REX DUAL 260 6 5 6 94 0 80 0 10 185 188 187 10 5 13 5 14 0 32 5 2400 3686 230 50 IP X0D 20 X X X X Flue gas temp at boiler output and air at 20deg CO2 Fuel Characteristics Efficiency 100 N C V NGmaxflow rateG20 NG maxflow rateG30 NG max flow rateG31 Maxflow rate of flues Efficiencyat 30 NG min flow rate G20 NG min flow rate G30 NG min flow rate G3...

Page 10: ...150 1 1 1 4 1 1 2 1 2 1 2 REX DUAL 170 REX DUAL 170 F 2155 1335 675 1417 675 60 2600 1240 1305 2247 1753 704 1100 443 270 320 280 350 150 150 1 1 1 4 1 1 2 1 2 1 2 REX DUAL 190 REX DUAL 190 F 2155 1335 675 1417 675 60 2600 1240 1305 2497 2003 704 1200 593 270 320 280 350 200 200 1 1 1 4 1 1 2 1 2 1 2 REX DUAL 200 REX DUAL 200 F 2030 1485 750 1568 750 60 2900 1390 1455 2477 2003 703 1200 574 270 32...

Page 11: ...que ncy Insulation class Electric power mbar C C C mbar bar l kg Volt Hz IP W GAS GASOIL HEAVY OIL GAS GASOIL HEAVY OIL T 12 C With electr contr excluded pump and burner N a t g a s L p g G a s o il H e a v y o il W o o d STR20 2 0 7 14 0 80 0 10 189 192 192 10 5 13 5 14 0 16 5 320 780 230 50 IP X0D 20 X X X X STR25 2 5 6 52 0 80 0 10 175 178 178 10 5 13 5 14 0 18 5 320 780 230 50 IP X0D 20 X X X ...

Page 12: ...lled because it uses a burner provided with fan which introduces into the combustion chamber the exact amount of air necessary in relation to the fuel and maintains an overpressure in the furnace equivalent to all the internal resistances of the flue gas path as far as the boiler exhaust At this point the fan pressure should have dropped to zero to prevent the flue connection pipe and the lower ar...

Page 13: ...m has been filled you are advised to close the supply cock and keep it closed so that any leaks from the system will be identified by a drop in hydraulic pressure indicated on the system pressure gauge The generator must be provided with a Safety valve b Expansion vessel connected with a hose 18 mm diameter c Regulation thermostats d Safety thermostat e Cut off pressure switch f Well for control t...

Page 14: ... with control manometer flange 5 2nd safety valve fitting or thermal drainage 1st safety 6 2nd boiler circulator consent thermostat and safety thermostat bulb wells 7 Flanges to weld after the definitive and correct positioning of the boilers 8 1st and 2nd boiler fuel valve bulbs wells 9 Boiler thermometer bulb well 10 1st and 2nd boiler bi thermostats bulbs well digital regulator thermal resistan...

Page 15: ...an be rotated to gain access to the terminal board and uncoil the ther mostat and thermometer capillaries A copy of the wiring diagram is contained inside the control panel cover The regulation thermostats TR1 TR2 have an operating range from 60 to 90 and can be set by the user by means of the front knob Safety thermostats TS has a fixed setting of 100 0 6 C and can be manually reset in accordance...

Page 16: ... The regulation bi thermostats TR1 and TR2 have an operating range from 43 to 85 and can be set by the user by means of the front knob The temperature differential of each bi thermostat is fixed and approx 7 C Safety thermostats TS1 and TS2 have a fixed setting of 100 0 6 C and can be manually reset in ac cordance with Ministerial Decree 1 12 75 R Circulator consent thermostats TM1 and TM2 have a ...

Page 17: ...ified on the burner rating plate e Check that the fuel supply system is sized for the maximum flow rate necessary for the boiler and that it is provided with all control and safety devices provided for by the regulations referred to above f Check that the boiler room vents are sized in order to guarantee the air flow established by the regula tions referred to above and that they are in any case s...

Page 18: ...r plate tube 6 keeping the boiler in upright position or but welding will be more difficult horizontally the choice will depend on the size of premises and the equipment available to turn the boiler upside down Caution smoke tuber 7 must protrude 3 mm from the front plate 1 and approx 10 mm from the rear plate 6 NB the condensate groove for the F version with extruded aluminium must be positioned ...

Page 19: ...on vessel N6 Bulb wells Fig 6 Fig 7 DIMENSIONS AND WEIGHTS OF THE BULKIEST PARTS Furnace Manhole MOD Ø mm length mm weight kg width mm height mm weight kg 7 400 645 24 700 630 33 8 400 645 24 700 630 33 9 400 770 29 700 630 33 10 400 770 29 700 630 33 12 400 770 29 700 630 33 15 450 1018 53 750 680 40 20 450 1018 53 750 680 40 25 450 1240 67 750 680 65 30 500 1240 73 850 778 90 35 500 1490 88 850 ...

Page 20: ...pper panel 2S on the boiler and fit on this panel the control panel uncoil the thermometer and thermostat capillaries and insert the bulbs in the wells e Fit panel 1D as indicated under point c fit panel 2D ensuring that the capillaries are inserted in the slot provided in the panel itself Securing the control panel f Secure the upper panels by screws and close the passage holes with special caps ...

Page 21: ... ensuring that the capillaries are inserted in the slot provided in the panel 3D securing the control panel to panel 3D Super isolation on request f Fit the panels 5S and 5D connecting them to the side panels by means of the brackets fit the front panels 4B and 4A connecting them to panels 5S and 5D Close the manhole casing by fitting the upper panel 6 secured by screws close holes with special ca...

Page 22: ...nd P3 inserting the upper fold into the square tube and the lower fold to the boiler side frame join side panels by inserting the tongues in their slots e Fit panel P5 f Fit the control panel with electrical connections Fig 10 Key P Bulb wells TR1 1st boiler regulation thermostat TR2 2nd boiler regulation thermostat TS1 1st boiler safety thermostat TS2 2nd boiler safety thermostat TM1 1st boiler c...

Page 23: ...on the panel 3S uncoil the thermometer and thermostat capillaries and insert the bulbs in the wells e Fit the panels 1D 2D and 3D ensuring that the capillaries are inserted in the slot provided in the panel 3D securing the control panel to panel 3D f Fit the panels 4S and 4D connecting them to the side panels by means of the brackets fit the front panel 5 connecting it to panels 4S and 4D Close th...

Page 24: ... level is to eliminate areas that overheat Scale creates an insulating layer which reduces the thermal transfer of the generator affecting system ef ficiency This means that the heat produced by burning the fuel is not fully exploited and is lost to the flue Scale diagram Key fuel not used mm mm scale Corrosion on the water side Corrosion of the metal surfaces of the boiler on the water side is du...

Page 25: ...erature CO Gas 10 190 C 0 20 ppm Gas oil 13 195 C 10 80 ppm Heavy oil 13 5 200 C 50 150 ppm A diagram is provided in which the system efficiency is obtained according to the flue gas temperature the ambient temperature and the percentage of carbon dioxide CO2 Dispersions through the boiler casings are not considered Example Fuel used GAS OIL Ambient temperature 20 C CO2 13 Efficiency 91 4 Key Tf F...

Page 26: ...x while the burner is working Always wait few minutes after the burner has been switched off until the insulating parts are cooler 6 2 CLEANING AND SERVICING Close fuel supply and disconnect the electrical mains before starting any cleaning and servicing operations As economic running depends on cleaning of the exchange surfaces and regulation of the burner the follow ing operations should be perf...

Page 27: ...gned Emanuela Lucchini Managing Director of ICI CALDAIE S p A hea dquarted in via G Pascoli 38 37059 Campagnola di Zevio VR Italy DECLARE THAT STEEL BOILERS REX REX F REX K REX K F REX DUAL REX DUAL F STR comply with the CE certificate and with the following regulations or harmonised regulations EN 60335 1 EN 303 1 pr EN 303 3 In accordance with the boards regulations Gas Directive 90 396 CEE Low ...

Page 28: ...ONA ITALIA Tel 045 8738511 Fax 045 8731148 info icicaldaie com www icicaldaie com The illustration and details reported are indicative only and are not binding ICI CALDAIE reserves the right to introduce alterations and or amendments as it deems fit and proper for the development of the product without the obligation of providing prior notice ...