ICI Caldaie REX 140-F Service manual

REX_140_350_F_en_00 - 08/2019
EN
PRESSURISED STEEL BOILERS
REX 140-350 F
INSTALLATION, USE AND MAINTENANCE MANUAL
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

2
INDEX
SYMBOLS USED IN THE MANUAL
aDANGER
To indicate actions that, if not performed correctly, can result in injury of generic origin or may generate malfunction
or damage to the appliance; therefore require particular caution and adequate preparation.
dIT IS FORBIDDEN
To indicate operations that SHOULD NOT be performed.
mIMPORTANT
To indicate particularly useful information and important.
The illustrations and data presented are not binding. The company reserves the right to make without prior notice any changes it
deems appropriate for continuous improvement and constant updating.
General information
3 Introduction
3 Range
3 Compliance
3 Warranty
4 Warnings
4 Prohibitions
5 Hazards
5 Identification
6 Appliance description
6 Structure
7 Dimensions and connections
8 Technical data
9 Control panel
9 Burners
Installation
10 Product receipt
11 Handling
11 Installation room
12 System cleaning
12 Hydraulic connections
12 Starting hydraulic circuit
12 Water circulation
13 Flue gas discharge and combustion air suction
14 Control panel installation
15 Front door opening
15 Door opening inversion (to the right) for models from
140 to 180
16 Front door adjustment
16 Door adjustment (opening on the right)
16 Turbulator assembly
17 Burner assembly
17 Electrical connections
18 Water treatment
18 Limestone build-ups
18 Limestone diagram
18 Corrosion on water side
19 System filling and emptying
Use
20 Preliminary checks
20 Commissioning
20 Checks after commissioning
22 Stop periods
22 Short periods of time
22 Long periods of time
22 Decommissioning of old appliances
Maintenance
23 Boiler
24 Burner
25 Any anomalies and remedies
25 Environmental protection and disposal
26 Exploded views of drawings
Useful information and declarations
27 QR code
28 Declaration of Conformity
Notes
Notes
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General information 3
1 General information
INTRODUCTION
Dear Customer,
Thank you for having chosen an appliance of the series REX , a high quality and efficiency product, reliable and safe.
We recommend entrusting its maintenance to Professionally Qualied Personnel who, when necessary, uses original spare parts.
This manual contains important information and suggestions that must be observed for easier installation and best possible use
of the appliance.
mIMPORTANT
Failure to observe the instructions in this manual will void the warranty conditions.
RANGE
MODEL CODE MODEL CODE
REX 140-F 83813210 REX240-F 83816210
REX160-F 83813220 REX300-F 83817210
REX180-F 83814210 REX350-F 83818210
REX200-F 83815210
COMPLIANCE
REX boilers comply with the following European Directives:
–European Regulation on Gas Equipment GAR 2016/426/EU
–Low Voltage Directive 2014/35/EU
–Electromagnetic Compatibility Directive 2014/30/EU
–Efficiency Directive 92/42/EEC
–Energy efficiency 
NOTE
The serial number is indicated on the boiler technical nameplate.
WARRANTY
The warranty conditions for boilers series REX are included in the CONSTRUCTION - WARRANTY CERTIFICATE supplied with the
product.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information4
WARNINGS
mIMPORTANT
–The appliance must be used for the purposes for which it has been expressly designed and any manufacturer’s liability shall
be excluded in case of damage to persons, animals or property due to insufficient maintenance or improper use.
–This manual is an integral part of the boiler and must be carefully read before installation and commissioning of the
appliance. 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.
–The appliance is delivered in several separated packages. Upon receipt, check that the supply is intact and undamaged and
promptly contact the ICI CALDAIE S.p.A. if it does not correspond to the order.
–The installation of REX boilers must be performed by a Certified Body which, at the end of the operation, must provide
the owner with the declaration of conformity certifying that the installation has been correctly carried out, namely in
compliance with the Standards and the national and local Laws in force, and with the indications included in the instruction
manuals supplied by ICI CALDAIE S.p.A. .
–The maintenance of the appliance is a legislative obligation. The User must have it carried out by an Authorised Company
or by qualified personnel (maintenance technician) in compliance with the requirements of the local Standards in force.
–Ordinary and extraordinary maintenance must be carried out by qualified personnel in order to promptly detect any
damage to the boiler body under pressure and to the safety and control accessories.
PROHIBITIONS
dIT IS FORBIDDEN
–Operate electrical devices or appliances such as switches, household appliances, etc. if you smell fuel or unburnt materials.
In this case:
- ventilate the room by opening doors and windows
- close the fuel shut-off device
- ask the Technical Assistance Service or qualified personnel to intervene as soon as possible.
–Any technical or cleaning operation carried out before disconnecting the appliance from the power supply mains, by
positioning the system main switch and the control panel main switch to “OFF”.
–Modifying safety or adjustment devices without the boiler manufacturer’s authorisation and indications.
–Plug or dimensionally reduce the ventilation openings of the installation room. The ventilation openings are essential for
proper combustion.
–Exposing the boiler to atmospheric agents. It is not designed to operate outdoor and it does not feature automatic anti-
freeze systems.
–Leave flammable substances and containers in the room where the appliance is installed.
–Disperse the packaging material in the environment and leave it within the reach of children as it may be a potential source
of danger. It must be disposed of in accordance with the legislation in force.
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General information 5
HAZARDS
aDANGER
–In case of water leakages, disconnect the boiler from the power supply mains, close the water supply and contact, as soon
as possible, the Technical Assistance Service Authorised by ICI CALDAIE S.p.A. or qualified personnel.
–Sensing the presence of fuel in the thermal power plant, it is appropriate to follow the precautions below to avoid the risk
of explosions and fires:
- do not smoke or cause sparks
- do not turn on lights or electrical devices in general (mobile phones)
- open doors and windows
- close the fuel shut-off valve normally placed outside the thermal power plant
- disconnect the power supply by means of the switch which is usually located outside of the plant room.
–During the normal operation, the appliance has hot parts, such as the channel and the flue gas box, which in case of
accidental contact without appropriate personal protection can cause severe burns.
–An incorrect adjustment of the closing door or an insufficient chimney draught can cause the presence of smoke inside
the heating plant room, leading to fatal intoxications due to carbon monoxide, which is by nature colourless and odourless.
Therefore, make sure that the boiler is correctly adjusted and installed and that the heating plant room features vents
compliant with the standards in force.
IDENTIFICATION
Each REX boiler can be identified through the construction plate inside the envelope of the documents supplied with the boiler,
which includes technical/efficiency information such as:
–serial number or identification marking
–nominal thermal power in kW
–nominal thermal flow in kW
–types of fuels which can be used
–maximum operating pressure.
–CE marking
mIMPORTANT
The boiler installer MUST apply the construction plate, at the end of installation, in the front upper side of the front
tube plate, so that it can be easily identified and read. In case of loss, request a copy to theTechnical Assistance Service
of ICI CALDAIE S.p.A. providing the serial number indicated in the CONSTRUCTION CERTIFICATE - WARRANTY or the
sale delivery note.
The appliance is also accompanied by construction certicate attesting the successful result of the hydraulic test.
mIMPORTANT
The installation must be performed in compliance with the local standards by qualied personnel , namely by
personnel with specific technical skills in the field of the heating system components. An incorrect installation may
cause damage to persons or property for which the manufacturer will not be liable.
During commissioning check the effectiveness of all adjustment and control devices in the control panel.
The warranty validity is subject to compliance with the instructions in this manual.
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General information6
APPLIANCE DESCRIPTION
High-efficiency ICI CALDAIE S.p.A. REX 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.
The chosen control panel should be equipped with a safety thermostat with manual reset from 110°C.
They have been provided with cylindrical furnace with reverse flame closed at the back by a fully wet convex bottom, supported
by a stub and that can be coupled with forced draft burners.
Some of the main characteristics of the equipment are listed below:
–boiler body made in quality steel, made up by the front tube plate flanged towards the furnace with RSB process and by the
convex, instead of flat, rear plate, for better resistance to the internal pressure, with laser-cut holes
–cylindrical combustion chamber, with reverse flame, closed at the back with fully wet convex bottom, supported by a stub.
The flame runs through the central part, while the hot gases return peripherally to the front, partially wet, part to be conveyed
to the tube bundle
–EN10217-2 P235GH fire tubes, welded to the front and rear tube plates, equipped with helical turbulators
–rear smokebox made in steel metal sheet, consisting of a single piece that can be easily opened to inspect the fire tubes,
fastened by means of bolts, complete with chimney fitting and cleaning door
–containment tube bundle equipped with connections necessary for the system and the operating equipment, all welded
with approved processes carried out by qualified welders
–casing made with easily removable painted steel panels, that protect the insulation made with high-density fibreglass wool
mats
–front door made in steel metal sheet thermally insulated with ceramic fibre, fitted on hinges, that can be easily opened by
means of drilled ring nuts and with supplied lever.
mIMPORTANT
REX boilers have finned extruded parts in aluminium (Pat. Fin-e) inserted into the fire tubes. They can be used ONLY
with gaseous fuels.
STRUCTURE
N2 N3 N5 N5
N3
N1
N4
789
4
N6
5
6
N7
10
3
N8
2 12
1 Control panel (accessory)
2 Front door
3 Flame inspection window
4 Rear smokebox
5 Flue gas drain fitting
6 Inspection door
7 Insulating casing
8 Door hinges
9 Burner (accessory)
10 Burner support flange
N1 Boiler flow fitting
N2 Boiler return fitting
N3 Instruments fitting
N4 System intake/drain fitting
N5 Safety valve(s) fitting
N6 Bulb-holder pockets
N7 Condensate drain fitting
N8 Control pocket
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General information 7
DIMENSIONS AND CONNECTIONS
H2
Øb
P6
P2
116H1
H
L2
L
ØcH10
H6
H4
P5P4P3
P
N2 N3 N5 N5 N1
N4
N7
N3 N8
N6
Dimensions
Description u.m. REX F
140 160 180 200 240 300 350
H mm 1746 1746 1746 1876 1876 2146 2146
H1 mm 1630 1630 1630 1760 1760 2030 2030
H2 mm 880 880 880 945 945 1080 1080
H6 mm 880 880 880 945 945 1080 1080
H10 mm 150 150 150 150 150 150 150
L mm 1470 1470 1470 1600 1600 1870 1870
L2 mm 1270 1270 1270 1400 1400 1670 1670
P mm 2886 2886 3096 3220 3480 3480 3935
P2 mm 2300 2300 2510 2510 2770 2770 3225
P3 mm 831 831 771 903 903 903 903
P4 mm 1300 1300 1850 1550 1950 2050 2050
P5 mm 755 755 475 767 627 527 982
P6 mm 350-400 350-400 450-500 450-500 450-500 450-500 450-500
Øb mm 320 320 320 360 360 400 400
Øc mm 400 400 400 500 500 550 550
Attachments
Description u.m. REX F
140 160 180 200 240 300 350
N1 DN/in 150 150 150 200 200 200 200
N2 DN/in 150 150 150 200 200 200 200
N1/N2 PN 16 16 16 16 16 16 16
N3 DN/in 1" 1" 1" 1" 1" 1" 1"
N4 DN/in 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4
N5 DN/in 1"1/2 1"1/2 1"1/2 2" 2" 2" 2"
N6 DN/in 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"
N7 DN/in 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"
N8 DN/in 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"
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General information8
TECHNICAL DATA
DESCRIPTION u.m. REX F
140 160 180 200 240 300 350
Effective rated
[1]
kW 1400 1600 1800 2000 2400 3000 3500
Thermal capacity kW 1517 1733 1950 2167 2600 3250 3792
Efficiency at 100% (ref. P.C.I.)
[1]
% 92,29 92,33 92,31 92,29 92,31 92,31 92,3
Max gas flow rate - G20 Stm3/h 160,53 183,39 206,35 229,31 275,13 343,92 401,27
Max gas flow rate - G30 kg/h 119,14 136,11 153,15 170,19 204,2 255,25 297,82
Max gas flow rate - G31 kg/h 117,85 134,63 151,49 168,35 201,99 252,48 294,59
Max flue gas flow rate kg/h 2391,9 2732,51 3074,62 3416,72 4099,44 5124,41 5978,92
Efficiency at 30% (ref. N.C.V.)
[1]
% 91,7 91,8 91,8 91,7 91,8 91,8 91,7
Pressure drops on exhaust side mbar 6 6,5 7 6 7,5 8 9
Heat losses through the chimney % 6,91 6,87 6,89 6,91 6,89 6,89 6,9
Heat losses through the casing % 0,8 0,8 0,8 0,8 0,8 0,8 0,8
Heat losses with burner off % 0,1 0,1 0,1 0,1 0,1 0,1 0,1
Flue gas temperature (Nom. output, air = 20°C) - GAS °C 184 183 184 184 184 184 184
Flue gas temperature (Nom. output, air = 20°C) - OIL °C 187 186 186 187 186 186 187
Flue gas temperature (Nom. output, air = 20°C) - FUEL
OIL
°C 187 186 186 187 186 186 186
CO 2 - GAS % 10,5 10,5 10,5 10,5 10,5 10,5 10,5
CO 2 - OIL % 13,5 13,5 13,5 13,5 13,5 13,5 13,5
CO 2 - FUEL OIL % 14 14 14 14 14 14 14
Fluid pressure drop (ΔT=12K) mbar 38 50 63 25 35 55 75
Rated pressure bar5555555
Total capacity l 1500 1500 1650 2000 2300 3150 3650
Total weight Kg 2600 2600 2750 3650 3900 5200 5700
Rated frequency ~ voltage
Volt ~
Hz 230 ~ 50 231 ~ 50 232 ~ 50 233 ~ 50 234 ~ 50 235 ~ 50 236 ~ 50
Electric protection rating IP IP40 IP40 IP40 IP40 IP40 IP40 IP40
Absorbed power
[3]
W 20 20 20 20 20 20 20
Allowed fuels Methane - LPG - Diesel - Naphtha
[1] Average temperature 70°C.
[2] Efficiency Directive 92/42/EEC.
[3] With electronic control unit (circulator and burner excluded).
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General information 9
CONTROL PANEL
The control panels which can be installed on REX 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.
Description Code
Thermostatic control panel QACC10ELMCE
eterm boiler control panel QETERM01CE
eterm system control board QETERM02
BURNERS
The burners that can be installed on the REX boilers must be CE marked according to European Directives:
–European Regulation on Gas Equipment GAR 2016/426/EU
–Electromagnetic Compatibility Directive 2014/30/EU
–Low Voltage Directive 2014/35/EU
–Machinery Directive 2006/42/EC (for liquid fuel burners)
Since the optimal operation of the boiler depends on the correct selection of the burner and its adjustment, find below some
points to take into account:
–The firing range of the burner must include the boiler operating point (flow-back pressure in combustion chamber
considering the pressure at the base of the chimney as ZERO)
–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 burner manufacturers have this information as they are required by certification.
Øb
P6
Description U/M REX F
140 160 180 200 240 300 350
Øb mm 320 320 320 360 360 400 400
P6 mm 350-400 350-400 450-500 450-500 450-500 450-500 450-500
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Installation10
2 Installation
PRODUCT RECEIPT
The boilers are provided already covered with embossed aluminium with protective heat-shrink film.
–The document envelope (1) contains:
-adhesive nameplate
-instruction manual
-construction certificate and warranty
Inside the combustion chamber there is the turbulator unit to be inserted in the fire tubes during boiler installation.
1
mIMPORTANT
The instruction manual is an integral part of the appliance and it MUST be carefully read before installing and
commissioning the boiler, carefully stored for further consultations and it MUST always accompany the boiler.
mIMPORTANT
The control panel must be ordered separately from the boiler and is supplied in a separate package.
m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.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

Installation 11
HANDLING
REX 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.
aATTENTION
The Personal Protective Equipment required by current legislation must be used.
INSTALLATION ROOM
The REX boiler installation room must be for exclusive use, meet the Technical Standards and Legislation in force and equipped
with adequately sized ventilation openings.
The spaces around the boiler and towards the ceiling must be suitable for:
–installing the appliance
–reaching the safety devices
–maintenance
–repairing any breakage
–opening the door of the installed burner, considering its opening direction (towards the right or the left)
It is recommended to position the boiler, if possible, lifted from the floor to minimise dust extraction by the burner fan.
A (*)
P2
≥ 90°
> 600 mm
NO!
(*) A ≥ P2 (see "Size and fittings*)
mIMPORTANT
–The front space (A) must be greater than the boiler length to be able to extract the turbulators or replace a fire tube in
case of breakage.
–In the case of several boilers installed in the same room, check the accessibility to the most remote boiler to be able to
perform ordinary and extraordinary maintenance.
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Installation12
aATTENTION
–Consider the spaces necessary to access the adjustment and safety devices and to perform maintenance.
–If the burner is fed with gas of specific weight greater than that of the air, the electrical parts must be positioned at least
500 mm from the ground.
SYSTEM CLEANING
Before connecting the boiler to the system, it is RECOMMENDED to wash the pipes thoroughly in order to remove any residues
which may compromise the correct operation of the boiler.
HYDRAULIC CONNECTIONS
STARTING HYDRAULIC CIRCUIT
The hydraulic circuit must be built by an authorised company or by qualified personnel, in compliance with theTechnical Standards
and the Law in force.
The components shall be charged to the installer that, at the end of the works, must issue a declaration of conformity.
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 the construction of the plant.
mIMPORTANT
–Make sure that the hydraulic pressure measured downstream of the pressure regulator on the supply line does not
exceed the operating pressure indicated on the boiler nameplate.
–Make sure that the drains of the safety valves of the boiler and the heater, if any, are connected to a drain funnel, so that
the valves do not flood the room in case of intervention.
–Make sure that the water and heating system pipes are not used as earthing point of the electrical system.
–Once the heating system has been filled, it is recommended to close the supply tap and keep it closed so that any
system losses can be signalled by an hydraulic pressure drop detected on the system manometer.
–For reasons of technical expertise, the system components must be chosen and installed by the installer, that must
operate in accordance with good practice regulations and Laws in force.
WATER CIRCULATION
The temperature difference between flow and return must not exceed 30°C in order to avoid thermal shocks to the boiler. The
return temperature from the system must be higher than 50°C (with exclusive methane gas or LPG operation) in order to protect
the boiler from corrosion due to acid flue gas condensate.
The warranty does not cover any damage caused by the condensate.
It is useful to mitigate the return temperature by installing a mixing valve and/or a recirculation pump.
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Installation 13
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.
mIMPORTANT
The smoke duct must have a diameter equal to or larger than the boiler fitting.
Indicative diagram
Ø C
H6
Description u.m. REX F
140 160 180 200 240 300 350
H6 mm 880 880 880 945 945 1080 1080
Ø C mm 400 400 400 500 500 550 550
aDANGER
–the chimney must ensure the draught necessary for the boiler operation and provided for by the Technical Standards in
force, considering a “zero” pressure at the connection with the smoke duct
–unsuitable or badly dimensioned chimneys and smoke ducts can cause condensation problems and adversely affect
the combustion parameters
–non-insulated drain pipes can lead to a potential risk and the tightness of the joints must be ensured with materials
resistant to the temperatures of the drain flue gases (we recommend at least 250°C)
–check that the chimney has a suitable draught, does not feature chokes and is clear from debris; check that no drains of
other equipment are connected to the chimney (unless this has been made to serve several utilities).
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Installation14
CONTROL PANEL INSTALLATION
NOTE
The image of the control panel is only indicative as it may vary depending on the installed model.
1
15 6
2
3
9
4
8
7
–Choose the installation side of the control panel (RH or LH), remove the covers (1) and break the pre-cut opening (2)
–take the arm kit complete with support (3) from the inside of the furnace.
–open the control panel (4) and cut the window prearranged on the rear side
–route the bulbs (5) of the thermostat and thermometer through the window, then insert them in the square pipe of the
support and, through the upper openings, route them in the protection pipe until reaching the pockets (6). Then lock with
specific clamps to prevent them from being pulled out
–connect the burner cables (7) to the control panel using a protection sheath and lock them with cable rings (8)
–fasten the control panel to the support (3) with the kit supplied
–fasten with two screws (9) the arm-control panel unit to the boiler upper part
–refit the covers (1).
The bracket supplied, equipped with shaped plate with double drilling, allows installing the panels at two inclinations, choosing
the preferred position (see figures).
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Installation 15
FRONT DOOR OPENING
The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx).
a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.
DOOR OPENING INVERSION (TO THE RIGHT) FOR MODELS FROM 140 TO 180
4
1
9
23
6
5
8
7
Dx
Sx
NOTE
The ferrules (8) can be "adjusted with wrench" or "perforated for lever adjustment".
DOOR WITH FERRULES PERFORATED ON BOTH SIDES
Proceed as follows to reverse the opening direction of the door:
–screw the left perforated ferrules (1) so that the door seal gasket is pressed in the same way as the right part. Bring the conical
washers (2) of the left tie-rods close to the mechanical tubes (3) of the door and tighten the nuts (4) using a suitable wrench
–on the right opening side, loosen the nuts (5) and free the conical washers (6) from the mechanical tubes (7) of the door.
DOOR WITH WRENCH FERRULES, HINGE SIDE
aDANGER
In models equipped with wrench-adjustable ferrules (8), these must always be mounted on the hinges to prevent the
door from being accidentally opened through the lever (9).
Proceed as follows to reverse the opening direction of the door:
–screw the left perforated ferrules (1) so that the door seal gasket is pressed in the same way as the right part. Bring the conical
washers (2) of the left tie-rods close to the mechanical tubes (3) of the door and tighten the nuts (4) using a suitable wrench
–cross-change the wrench ferrule of a hinge (8) with the opposite perforated ferrule (1), after loosening the locking nuts on the
tie rods and freeing the conical washers
–on the left hinge side, fasten the conical washer (2) onto the door using the nut (4s)
–repeat the last two steps for the other two ferrules also.
aDANGER
When cross-changing ferrules, always make sure that the other two ferrules are fastened, so that they hold the door.
Check the correct adjustment of the tie-rods and hinges ensuring that, during closure, the seal gasket is evenly pressed in the
centre on the whole circumference. If necessary, adjust the door as described in the following paragraph.
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Installation16
FRONT DOOR ADJUSTMENT
aDANGER
Incorrect door adjustment with consequent damage to people and property voids the warranty conditions.
DOOR ADJUSTMENT (OPENING ON THE RIGHT)
123
6
45
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 counter-nuts
(1)
–close the door and centre the tie-rod (4) on the mechanical tube (5), proceeding as in the previous point.
HORIZONTAL ADJUSTMENT
Close the door using the lever and check that there is equal distance on both sides, between the stop plate and the band. If this
is not the case:
–with the door ajar, loosen the locking nuts (6) of the hinge units
–act on the ferrule (7) to adjust the distance depth-wise
–screw the nuts (6) and block the conical washers on the mechanical tubes.
aDANGER
When cross-changing ferrules, always make sure that the other two ferrules are fastened, so that they hold the door.
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.
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.
100 mm
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Installation 17
BURNER ASSEMBLY
Having chosen the burner to be used, refer to the Manual supplied with it for information about:
–the installation and fastening to the boiler
–the connection to the fuel supply
–the electrical connections
–the adjustments to be made
–maintenance
–the necessary checks.
mIMPORTANT
The strip of ceramic insulation supplied with the generator must be wrapped all around the mouthpiece at least once
to protect the burner flange from the irradiation of the flame. It is not necessary for the ceramic insulation to fill the
gap up to the internal surface of the door insulation. If the supplied material is not suitable for the used burner, use
other material having characteristics suitable to withstand 1000°C and dimensions suitable to completely close the
gap.
2
P6
5
Øb
4
3
1
1
2
1 Burner
2 Flange
3 Gasket
4 Door
5 Thermoceramic material
mIMPORTANT
For fuel oil/biogas operation, the door should have concrete insulation and be equipped with suitable tie-rods. Any
changes and/or failure to disclose information during sales will void the warranty conditions.
ELECTRICAL CONNECTIONS
The electric system of a heating plant room used only to heat the buildings must be made by an authorised company that must
comply with regulations, some of which are general while others are specific for the single types of use or combustion.
m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.
dPROHIBITION
Do not use the water and heating system pipes for the earthing connections .
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

Installation18
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 Circuit water
pH* - 7-8
Hardness (CaCo2) °Fr < 15 -
Iron (Fe)** mg/kg - < 0.5
Copper (Cu)** mg/kg - < 0.1
Oxygen (O2) mg/l < 0.05*** -
Appearance Clear Possibly clear
* 8 is the maximum acceptable pH value in case of radiators in aluminium or light alloys.
** Higher values indicate on-going corrosion phenomena.
*** In case of agents which form oxygen film and/or surplus, do not observe this value with intermittent operation or operation
without deaerator, but use the additive.
LIMESTONE BUILD-UPS
Limestone build-ups reduce the heat exchange between the combustion gases and water, leading to an abnormal increase of
temperature of the parts exposed to the flame and thus to a significant reduction of the service life of the boiler.
Limestone gathers in the points where the wall temperature is higher and the best defence against it, at the construction level,
is to eliminate the superheating areas.
Scale build-ups form an insulating layer which decreases the heat exchange of the boiler, penalising its efficiency. This means that
a significant part of the heat obtained from the combustion is not fully transferred to the system water, but is lost through the
chimney.
LIMESTONE DIAGRAM
Lost heat
0 5 10 15 20 30
10
20
30
%
limestone mm
CORROSION ON WATER SIDE
The corrosion of the metal surfaces of the boiler on the water side is due to the iron transit into the solution through its ions (Fe+).
In this process, the presence of dissolved gases, in particular oxygen and carbon dioxide, is very important. Corrosion phenomena
often occur with softened and/or demineralised water, which by nature is more aggressive against iron (acid water with Ph < 7);
in these cases, even when scale build-ups are prevented, corrosions can occur and it is necessary to treat the water with corrosive
process inhibitors.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

Installation 19
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
–close the previously opened boiler filling valve and the water system filling valve
–heat the water for the first time until reaching the system maximum permitted temperature. During this operation, the air
contained in the water is vented through the system’s automatic or manual air separators
–once the air has been expelled, bring the pressure back to the preset value and close the manual and/or automatic supply tap.
–After the initial filling, it is necessary to prevent oxygen and untreated water from entering the system.
–The entry of oxygen causes corrosion, while untreated water causes the formation of limestone.
–Both conditions must be avoided.
NOTE
The system venting will be completed, if necessary, upon the first commissioning of the boiler.
EMPTYING
–Before starting to empty the system, disconnect the power supply by positioning the system main switch to “ OFF ”
–check that the hydraulic system shut-off valve is closed
–connect a rubber hose to the drain valve of the boiler and convey it towards a drain pocket
–close the shut-off devices of the thermal system parts which must not be emptied
–slowly open the boiler drain valve. To facilitate the draining, open the air separators on the system
–once the operation is complete, close the previously opened air separators and the drain valve.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

Use20
3 Use
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
–electrical connections and earth connection are correctly carried out
–the rotors of the circulation pumps are not blocked
–the fuel supply line has been correctly built and that the fuel is available
–hydraulic and fuel circuit taps are open.
COMMISSIONING
To start the boiler after performing the preliminary checks it is necessary to:
–set the regulation thermostat on the control panel to the desired temperature
–check that the release button of the safety thermostat inside the control panel is reset
–correctly adjust the control panel devices according to the installed model
–set the main switch of the control panel to " ON "
–the rotors of the circulation pumps are not blocked
–the fuel supply line has been correctly built and that the fuel is available
–hydraulic and fuel circuit taps are open
–check for voltage presence at the control panel and burner.
The boiler will perform the ignition phase and will operate until the set temperatures will be reached.
mIMPORTANT
In case of LOCK-OUT STOP of the burner, refer to its technical manual.
CHECKS AFTER COMMISSIONING
Once the start-up has been performed, check that the appliance stops and then restarts:
–by modifying the boiler thermostat calibration
–by operating on the control panel main switch
–by operating on the ambient thermostat or chronothermostat
–check the tightness of the door gasket and repeat the adjustment in case of leakages
–check the correct operation of pumps
–check the boiler stop by positioning the system main switch to “ OFF ”
–check the safety thermostat triggering.
If all the conditions are met, start the boiler, bring it to its full operation and collect the combustion data.
NOTE
The flame inspection window is equipped with a hose connector which can be used both as a pressure test connection and for
cooling the flame inspection window.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz