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ICI Caldaie REX Technical Manual

Manual is about: PRESSURISED STEEL BOILERS

Summary of REX

  • Page 1

    Technical manual rex/rex f/rex k/rex k f rex dual/rex dual f str pressurised steel boilers.

  • Page 2

    1 index 1 general warnings .............................................................................................................................................. 1 2 technical specifications.........................................................................................................

  • Page 3

    2 2 technical specifications 2.1 rex/rex f/rex k/rex k f 7-130 boiler efficiency 100% (n.C.V.) effic. 100% (stars) ng max flow rate g20 ng max flow rate g30 ng max flow rate g31 max flow rate of flues efficiency at 30% (n.C.V.) ng min flow rate g20 ng min flow rate g30 ng min flow rate g31 min flow ...

  • Page 4

    3 pressure losses flue gas side heat losses through the chimney heat losses through the casing heat losses with burner off flue gas temp. At boiler output and air at 20 deg. C co2 press. Losses water side design pressure total capacity total weight electric supply freque ncy insulation class electri...

  • Page 5

    4 2.2 rex/rex f/rex k/rex k f 140-500 boiler efficiency 100% (n.C.V.) ng max flow rate g20 ng max flow rate g30 ng max flow rate g31 max flow rate of flues efficiency at 30% ng min flow rate g20 ng min flow rate g30 ng min flow rate g31 min flow rate of flues kw kcal/h kw kcal/h % m³/h kg/h kg/h kg/...

  • Page 6

    5 2.3 rex 400-600 boiler characteristics efficiency 100% (n.C.V.) ng max flow rate g20 ng max flow rate g30 ng max flow rate g31 max flow rate of flues efficiency at 30% ng min flow rate g20 ng min flow rate g30 ng min flow rate g31 min flow rate of flues kw kcal/h kw kcal/h % m³/h kg/h kg/h kg/h kw...

  • Page 7

    6 2.4 rex dual/rex dual f (staked) 14-170 boiler 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 flow rate of flues efficiency at 30% ng min flow rate g20 ng min flow rate g30 ng min flow rate g31 min flow rate of flues ...

  • Page 8

    7 h h1 h2 h3 h4 h6 h7 h8 h10 h11 l l1 l2 l4 p p2 p3 p4 p6 Øb Øc n1 n2 n3 n4 n5 n6 n8 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm dn/in dn/in dn/in dn/in dn/in in in rex dual 14 rex dual 14 f 1693 - 415 1245 1610 415 1245 780 54,5 884,5 939 756 700 540 1365 630 996 369 200-250 130 ...

  • Page 9

    8 2.5 rex dual/rex dual f (side by side) 80-260 boiler characteristics efficiency 100% (n.C.V.) ng max flow rate g20 ng max flow rate g30 ng max flow rate g31 max flow rate of flues efficiency at 30% ng min flow rate g20 ng min flow rate g30 ng min flow rate g31 min flow rate of flues kw kcal/h kw k...

  • Page 10

    9 h h1 h2 h4 h6 h10 l l2 l4 p p2 p3 p4 p5 p6 Øb Øc n1 n2 n3 n4 n5 n6 n8 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm dn/in dn/in dn/in dn/in dn/in in in rex dual 80 rex dual 80 f 1690 1015 500 1095 500 50 1901 890 955 1872 1502 600 850 422 230-280 225 250 100 100 1" 1" 1"1/4(1) 1/2" 1/2" rex d...

  • Page 11

    10 2.6 str boiler 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 flow rate of flues efficiency at 30% ng min flow rate g20 ng min flow rate g30 ng min flow rate g31 min flow rate of flues kw kcal/h kw kcal/h % % m³/h kg...

  • Page 12

    11 3 installation before connecting the boiler, perform the following operations: • thoroughly clean all the system pipes in order to remove any foreign matter that could affect correct op- eration of the boiler; • check that the flue has an adequate draught, that there is no narrowing of passages a...

  • Page 13

    12 3.2 hydraulic connection 3.2.1 hot water heating system with closed expansion vessel - furnace output ≤ 300.000 kcal/h - pressure 5 bar (fig. 1) 3.2.2 hot water heating system with closed expansion vessel - furnace output > 300,000 kcal/h - pressure 5 bar (fig. 2) ensure that the hydraulic pressu...

  • Page 14

    13 3.2.3 rex dual/rex dual f (side by side) 80÷260 positioning instruments key 1. Pressure switch fitting 2. 1 st safety valve fitting or thermal drainage 1 st safety 3. 1 st boiler circulator consent thermostat and safety thermostat bulb wells 4. Manometer fitting with control manometer flange 5. 2...

  • Page 15

    14 − 3.3 electrical connection electrical systems of thermal plants designed only for heating purposes must comply with numerous le- gal regulations which apply to in general as well as specifically to each application or fuel type. 3.4 rex/rex f/rex k/rex k f/str control panel (fig. 3) the control ...

  • Page 16

    15 3.5 rex dual/rex dual f operating principles the boiler consists of 2 units of same capacity and one only control panel for both units. Each unit can work independently and the boiler can be operated partially. This means that all panel controls (burner switches, thermostats and thermometers) hav...

  • Page 17

    16 3.6 inverting the door aperture if the door is to be opened to the opposite side, act as follows: 1. Switch the outside nut (or bush) of one hinge with the diametrically opposite closure bush; then at the hinge side, fasten the cone to the door with the inside nut. 2. Repeat the operation for the...

  • Page 18

    17 4 assembly 4.1 rex k/rex k f assembly (fig. 6-7) ensure that installation premises floor is even and perfectly horizontal. For perfect welding, use acid or rutile cored electrodes (check codes aws e6020 or aws e6013 or e44la3 or e44lc3). A) put the boiler rear plate (1) on the floor with the hing...

  • Page 19

    18 mod 7 8 9 10 12 15 20 25 30 35 40 50 62 75 85 95 100 120 130 140 160 180 a 100 100 100 100 100 100 100 100 100 100 85 85 85 85 85 85 85 85 85 85 85 85 b 100 100 100 100 100 100 100 100 100 100 95 125 125 125 125 125 125 125 125 215 215 215 c - - - - - - - - - - - 550 550 605 605 605 680 680 680 -...

  • Page 20

    19 4.2 rex/rex f/rex k/rex k f 7-40 boiler casings (fig. 8) a) wrap the glass wool around the boiler body leaving the bulb well (p) on the right side exposed. B) insert the wires connecting the burner to the control panel in the lower slits of panel (1s) and (1d), allow- ing for the opening directio...

  • Page 21

    20 4.3 rex/rex f/rex k/rex k f 50-130 boiler casings (fig. 9) a) wrap the glass wool around the boiler body leaving the bulb well on the right side exposed. B) insert the wires connecting the burner to the control panel in the lower slits of panel (1s) and (1d), allow- ing for the opening direction ...

  • Page 22

    21 4.4 rex dual/rex dual f 14-70 boiler casings (fig. 10) a) wrap the glass wool around the boiler body leaving the bulb well (p) on the right side exposed. B) open control panel and, through the casing holes (p1 or p2) insert bulbs in their wells (see figure). Fit the control panel. C) fit panels (...

  • Page 23

    22 4.5 str boiler casings (fig. 11) a) wrap the glass wool around the boiler body leaving the bulb well on the right side exposed. B) insert the wires connecting the burner to the control panel in the lower slits of panel (1s) and (1d), allow- ing for the opening direction of the manhole. C) fit the...

  • Page 24

    23 5 start up warning: before start up insert wholly turbolators into the smoke tubes ensuring that they have been pushed inside for at least 100 mm. 5.1 preliminary checks before starting the boiler, check that: - the rating plate specifications and power supply network (electricity, water, gas or ...

  • Page 25

    24 6 operation 6.1 operating checks the heating system must be correctly operated to ensure perfect combustion as far as possible with reduced emissions of carbon monoxide, unburnt hydrocarbons and soot into the atmosphere, and to avoid hazards and damage to people and goods. Guide to combustion val...

  • Page 26

    25 pressurisation values should be included in the range given in the table of technical specifications. Warning the differential temperature between boiler flow and return must not exceed 15°c in order to prevent thermal shock to the boiler structures. The temperature of the return water must be ab...

  • Page 27

    Ici caldaie spa via g. Pascoli, 38 37059 campagnola di zevio vr telefono 045 8738511 fax 045 8731148 info@icicaldaie.Com www.Icicaldaie.Com partita iva 00227490232 rag. Soc. N. 6677 c.C.I.A.A. Vr n. 69600 appartenente al gruppo finluc iscritto r.I. Vr 02245640236 declaration of conformity with the e...

  • Page 28

    93120079 ed. 9-02/09 9 - st. 100 - 02/09 appartenente al gruppo finluc, iscritto r.I. Vr n. 02245640236 via g. Pascoli, 38 - 37059 zevio - fraz. Campagnola - verona - italia tel. 045/8738511 - fax 045/8731148 info@icicaldaie.Com - www.Icicaldaie.Com the illustration and details reported are indicati...