ICI Caldaie ASGX EN Series User manual

ASGX EN_3000_17000_en_00 - 10/2019
EN
Superheated water heat generator
ASGX EN
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
4 Warnings
5 Prohibitions
5 Hazards
6 Identification
7 Appliance description
8 Technical data
9 Dimensions and connections
9 ASGX EN 3000-7000
10 ASGX EN 8000-17000
11 Burners
12 Paperwork
12 Fire prevention
13 Components
13 Pressure
13 Pressure gauge
16 Safety valves
17 Temperature
17 Thermoregulation and message display
19 Thermometer
19 regulation thermostat
19 Safety thermostat
Installation
20 Product receipt
21 Handling
21 Film removal
22 Installation room
22 Positioning
22 Room ventilation
23 System cleaning
23 Hydraulic connections
24 Starting hydraulic circuit
24 Flue exhaust
25 Front door opening
25 ASGX EN 3000 ÷ 7000
25 ASGX EN 8000 ÷ 17000
26 Turbulator assembly
27 Electrical connections
28 Burner assembly
29 Water characteristics
30 Frequency of analysis
Use
31 Preliminary checks
31 Thermal expansion
32 Commissioning
33 Checks after commissioning
34 Stop periods
Maintenance
35 Routine maintenance
36 Periodic verifications
37 Methods for checking the safety devices
37 Check of the safety pressure switch
37 Extraordinary maintenance
38 Any anomalies and remedies
38 Protecting the environment
38 Decommissioning and disposal
Residual Risk Management
Useful information and declarations
43 QR code
Notes
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information 3
1 General information
INTRODUCTION
Dear Customer,
Thank you for having chosen an appliance of the series ASGX EN , 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.
mIMPORTANT
This manual refers to boilers with “standard accessories”.
For boilers that “do not require continuous monitoring” by the operator refer to the specific technical manual.
RANGE
MODEL CODE
12 bar
ASGX EN3000 86803000
ASGX EN3500 86803500
ASGX EN4000 86804000
ASGX EN5000 86805000
ASGX EN6000 86806000
ASGX EN7000 86807000
ASGX EN8000 86808000
ASGX EN9000 86809000
ASGX EN10000 86810000
ASGX EN11000 86811000
ASGX EN12000 86812000
ASGX EN13000 86813000
ASGX EN14000 86814000
ASGX EN15000 86815000
ASGX EN16000 86816000
ASGX EN17000 86817000
COMPLIANCE
Superheated water heat generators Series ASGX EN comply with the following European Directives:
–Directive 2014/68/EU (PED)
–Low Voltage Directive 2014/35/EU
–Electromagnetic Compatibility Directive 2014/30/EU
NOTE
The serial number is indicated on the boiler nameplate.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information4
WARNINGS
mIMPORTANT
–The instructions manual is an integral and essential part of the product. If the body is sold or transferred to a new owner
or if you relocate and leave the system, always make sure that the manual accompanies the boiler body, so that it can be
consulted by the new owner and/or by the installer. In case of damage or loss, request a copy from Technical Assistance
Service ICI CALDAIE S.p.A. . This body must be intended for the use it was expressly designed for. The manufacturer will
be exempted from any liability, contractual and extra-contractual, for any injury/damage caused to people, animals, or
property due to the failure to perform maintenance and/or scheduled periodic checks and improper uses.
–Upon receipt of the generator, make sure that the supply is intact and undamaged and promptly contact ICI CALDAIE
S.p.A.
if it does not correspond to the order
–The installation of ASGX EN generator must be performed by a Certified Company 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.
–After long periods of inactivity of the device, the intervention of professionally qualified personnel is required to perform
the operations described in the relevant paragraph in order to preserve the boiler.
–The periodic check and maintenance of the appliance is a legislative obligation. The User must have it performed by
professionally qualified personnel.
–Make sure the safety valves properly open at the design pressure.
–Make sure the safety pressure switch intervenes properly which, by shutting down the burner, eliminates the cause of the
pressure increase.
–Check the correct connection of the accessories to the boiler body (gasket seal check).
–Pay the due attention during handling and installation.
–It is necessary to check that the operating water conductivity values are within those provided in the supplied technical
manual.
–Analyse the water when necessary, ascertaining that the values are within the limits expressed in this technical manual
and carry out the due chemical treatments. Check the intervention of the safety probes by lowering the level below the
minimum required.
–Manually check that the level switch is working properly every 6 hours.
–Do not step on or damage the protective sheath of the cable with any other mean.
–It is not necessary to consider the boiler connections as support points for the weight of the pipes.
–It is good practice to provide expansion joints and appropriate supports for the pipes connecting the boiler to the system
–Check that the panel power supply complies with the wiring diagram supplied.
–Make sure the generator is properly earthed.
–Check the plant’s electrical system.
–Before opening the manhole, check that the pressure in the boiler body is equal to the atmospheric pressure (0 relative bar).
–Before opening the door, check that the burner is off and disconnected.
–Switch off the burner and the pump before closing the shut-off valve.
–Avoid contact with the non-insulated parts of the equipment during its operation. When adjustments or checks are carried
out during operation, it is necessary to protect oneself with suitable clothing (P.P.E. according to Italian Legislative Decree
81/08).
– Check that the acid condensate that can form during the system start-up is drained outside of the plant room after a
neutralisation process in compliance with the standards in force.
– Check that there is no danger of frost inside the heating plant room.
–The boiler must be operated at reduced power (max 50%) until reaching the water operating temperature in order to avoid
thermal shocks and thermal expansions between the various parts of the body.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information 5
mIMPORTANT
–Pay attention to sharp edges on the generator and its accessories.
–The boiler must be kept sheltered from adverse weather conditions, with regard to the minimum temperature (-10 ° C) and
from the rain.
–The user is responsible for considering the seismic degree of the user area in the design of the heating plant.
–After an earthquake, have technical personnel assess any damage by carrying out NDCs (non-destructive checks), if
necessary.
–The manufacturer shall not be held liable in the event of accidents caused by incorrect decommissioning.
–The personnel in charge must be able to prove to have sufficient knowledge and experience relating to the safety and
control / regulation accessories supplied with the generator and good familiarity with the instructions contained in the use
and maintenance manual and be capable and physically suitable.
–During handling, always maintain a distance of at least 5 m from the projection of the appliance to the ground
–In case of violent impact during handling, visually check the integrity of the appliance, all over; run the hydraulic test again.
– The generators are sized only for loads due to pressure, temperature and contained uid.
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
–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 dimensionally reduce the ventilation openings of the installation room. The ventilation openings are essential for
proper combustion.
–Perform any welding/repairs. If necessary, contact the manufacturer/verifying party for operation (in Italy according to MD
329/04).
–Expose the generator to atmospheric agents.
–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.
HAZARDS
aDANGER
–Dangers due to water leaks . Disconnect the boiler from the electrical power supply, close the water supply and promptly
contact the Technical Assistance Service Authorised ICI CALDAIE S.p.A. or professionally qualified personnel.
–Routine and extraordinary maintenance must be entrusted to professionally qualied personnel with the purpose of
promptly detecting any damage to the generator's pressurised body and the safety and control accessories.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information6
aDANGER
– Danger deriving from the fuel. 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 electrical power supply by using the switch normally placed outside the thermal power plant.
– Danger of burns. During normal operation, the generator has hot parts that, upon accidental contact without suitable
personal protection, can cause serious burns. Potentially hot parts include:
- accessories and valves connected to the generator
- door and smoke chamber
- upper tread walkway.
– Danger from fumes. An incorrect adjustment of the closing door or an insufficient draught in the flue can leave fumes
inside the thermal power plant, causing fatal intoxication deriving from carbon monoxide which, by its nature, is colourless
and odourless. 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.
IDENTIFICATION
Each generator ASGX EN 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 data relating to the boiler complete with the accessories, which may vary from
those of the boiler body only.
TENSIONE
QUADRO
AUT.0MAN.
POMPA POMPA
P1P2
RESET
ALLARMI
1
MINIMO
LIVELLO
2
MINIMO
LIVELLO
PROTEZIONE
POMPA
ALTA
PRESSIONE
01
BRUCIATORE
TACITAZIONE
ALLARME
1
2
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 superheated water boiler 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.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information 7
APPLIANCE DESCRIPTION
The ASGX EN range provides super-heated water boilers with three flue gas passes and completely wet furnace back.
Manufactured from steel, quality tested according to the prevailing standards and welded with automatic submerged arc welding
processes.
Suitable for liquid and gaseous fuels.
Complete with regulation and safety accessories for automatic operation.
Intended for heating or technological systems with operating temperature above 110°C.
The single front door is thermally insulated with refractory materials and is mounted on adjustable hinges, easily opened without
having to remove the burner; it is equipped with visor for flame control.
The smoke box is fixed with bolts to the back of the generator. It is equipped with smoke duct fitting, cleaning door and can be
dismantled.
The body is thermally insulated with high density rock wool mat, protected with stainless steel panels.
They are equipped with lower water side inspection opening (flanged hatch)
They use a single control panel in which the entire electrical wiring converges.
The control panel includes all the equipment required for a correct management of the boiler with fail-safe devices and circuits,
built with redundant technology in order to ensure maximum safety.
The appliance rests on a carbon steel profile base that ensures its stability.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information8
TECHNICAL DATA
DESCRIPTION u.m. ASGX EN
3000 3500 4000 5000 6000 7000
Nominal power kW 3000 3500 4000 5000 6000 7000
Thermal capacity kW 3333 3888 4444 5555 6666 7777
100% efficiency (ref. NCV) % 90 90 90 90 90 90
NG max flow rate G20 Stm3/h 352,65 411,47 470,28 587,92 705,43 822,94
NG max flow rate G30 kg/h 261,74 305,39 349,04 436,35 523,56 610,78
NG max flow rate G31 kg/h 258,9 302,08 345,26 431,62 517,89 604,16
Max flue gas flow rate kg/h 5254,49 6130,9 7007,17 8760,01 10510,91 12261,81
100% efficiency (ref. NCV) % 92 92 92 92 92 92
Pressure drop mbar 15 18 15 20 13 15
Heat losses through the chimney % 9,7 9,7 9,7 9,7 9,7 9,7
Heat losses through the casing % 0,3 0,3 0,3 0,3 0,3 0,3
Heat losses with burner off % 0,1 0,1 0,1 0,1 0,1 0,1
Flue gas temp. at boiler output and air
at 20 deg. C
°C 240 240 240 240 240 240
CO 2% 10 10 10 10 10 10
Hydraulic pressure drop mbar 55 75 98 154 91 123
Rated pressure bar 12 12 12 12 12 12
Total capacity l 4520 5300 6650 8600 9150 10200
Total weight kg 7000 7800 9000 11000 13000 14500
Electric supply Volt ~ 230 230 230 230 230 230
Frequency Hz 50 50 50 50 50 50
Insulation class IP IP55 IP55 IP55 IP55 IP55 IP55
Electric power W 1000 1000 1000 1000 1000 1000
Allowed fuels Methane - LPG - Diesel - Naphtha
DESCRIPTION u.m. ASGX EN
8000 9000 10000 11000 12000 13000 14000 15000 16000 17000
Nominal power kW 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000
Thermal capacity kW 8791 9890 10989 12087 13157 14285 15384 16339 17486 18681
100% efficiency (ref. NCV) % 91 91 91 91 91,2 91 91 91,8 91,5 91
NG max flow rate G20 Stm3/h 930,23 1046,51 1162,91 1279,19 1392,4 1511,75 1628,03 1729,05 1850,38 1976,87
NG max flow rate G30 kg/h 690,41 776,71 863,11 949,41 1033,42 1122,01 1208,31 1283,29 1373,33 1467,21
NG max flow rate G31 kg/h 682,93 768,29 853,75 939,11 1022,22 1109,85 1195,21 1269,38 1358,45 1451,31
Max flue gas flow rate kg/h 13860,43 15593 17327,36 19059,93 20746,76 22525,08 24257,65 25762,85 27570,66 29455,36
100% efficiency (ref. NCV) % 93 93 93 93 93,2 93 93 93,8 93,5 93
Pressure drop mbar 17,5 22,5 15 19 22 26 23,5 19,5 22 23
Heat losses through the chimney % 8,7 8,7 8,7 8,7 8,5 8,7 8,7 7,9 8,2 8,7
Heat losses through the casing % 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3
Heat losses with burner off % 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1
Flue gas temp. at boiler output and air
at 20 deg. C
°C 212 212 212 212 208 212 212 195 201 212
CO 2% 10 10 10 10 10 10 10 10 10 10
Hydraulic pressure drop mbar 161 98 66 79 94 111 128 86 98 111
Rated pressure bar 12 12 12 12 12 12 12 12 12 12
Total capacity l 14950 16200 20200 20200 21800 21800 23800 33000 33000 35100
Total weight kg 15400 16300 24940 24940 25400 25400 28050 37500 37500 45000
Electric supply Volt ~ 230 230 230 230 230 230 230 230 230 230
Frequency Hz 50 50 50 50 50 50 50 50 50 50
Insulation class IP IP55 IP55 IP55 IP55 IP55 IP55 IP55 IP55 IP55 IP55
Electric power W 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Allowed fuels Methane - LPG - Diesel - Naphtha
Water delivery ΔT max 30°C
Design data
Minimum/maximum temperature -10°C / 191,7 °C
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information 9
DIMENSIONS AND CONNECTIONS
ASGX EN 3000-7000
1 Electrical panel
2 Pressure gauge
3 Thermometer
4 Pressure gauge valve
5 regulation thermostat
6 Safety thermostats
7 Safety pressure switch fitting (not supplied)
8 Upper inspection hatch
9 Lower inspection hatches
N1 Boiler flow line
N2 Boiler return line
N3 Instruments fittings
N4 System intake/drain fitting
N5 Safety valve fittings
N6 Bulb-holder pockets
N7 Condensate drain
N8 Control pocket
NOTE
Drawing, legend and data refer to standard models. For specific models refer to the supplied accessory manual.
Dimensions u.m. ASGX EN
3000 3500 4000 5000 6000 7000
H mm 2460 2460 2700 2700 2820 2820
H1 mm 2210 2210 2420 2420 2570 2570
H2 mm 1230 1230 1335 1335 1410 1410
H4 mm 2400 2400 2610 2615 2765 2765
H6 mm 1230 1230 1335 1335 1410 1410
H10 mm 125 125 125 125 125 125
L mm 2200 2200 2410 2410 2560 2560
L1 mm 1960 1960 2170 2170 2320 2320
L2 mm 1300 1300 1400 1400 1600 1600
P mm 3879 4379 4379 5373 5389 5889
P2 mm 3430 3930 3930 4930 4930 5430
P3 mm 1012 1012 1012 1006 1264 1264
P4 mm 1500 2000 2000 3000 2700 3200
P5 mm 1367 1367 1367 1367 1425 1425
P6 mm 300-400 300-400 300-400 300-400 300-400 300-400
Øb mm 400 400 450 450 450 450
Øc mm 550 550 600 600 700 700
N1 DN/in 200 200 200 200 250 250
N2 200 200 200 200 250 250
N1/N2 PN 16 16 16 16 16 16
N4
DN/in
40 40 40 40 40 40
N7 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4
N8 3/4" 3/4" 3/4" 3/4" 3/4" 3/4"
[1] Tb=Turbulators size and quantity.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

General information10
ASGX EN 8000-17000
1 Electrical panel
2 Pressure gauge
3 Thermometer
4 Pressure gauge valve
5 Upper inspection hatch
6 Lower inspection hatches
N1 Boiler flow line
N2 Boiler return line
N3 Instruments fittings
N4 System intake/drain fitting
N5 Safety valve fittings
N6 Safety and regulation thermostat fittings
N7 Condensate drain
N8 Control pocket
N9 Safety pressure switch fitting (not supplied)
N11 Minimum level probe fitting (not supplied)
NOTE
Drawing, legend and data refer to standard models. For specific models refer to the supplied accessory manual.
Dimensions u.m. ASGX EN
8000 9000 10000 11000 12000 13000 14000 15000 16000 17000
H mm 3050 3050 3400 3400 3400 3400 3500 3960 3960 3960
H1 mm 2850 2850 3200 3200 3200 3200 3276 3700 3700 3700
H2 mm 1600 1600 1730 1730 1730 1730 1764 1975 1975 1975
H4 mm 3050 3050 3400 3400 3400 3400 3500 3960 3960 3960
H6 mm 1600 1600 2450 2450 2450 2450 2530 2840 2840 2840
H10 mm 171 171 105 105 105 105 128 200 200 200
L mm 2700 2700 3140 3140 3140 3140 3265 3650 3650 3650
L1 mm 2490 2490 2940 2940 2940 2940 3065 3450 3450 3450
L2 mm 1700 1700 2000 2000 2000 2000 2000 2250 2250 2250
P mm 7035 7535 7735 7735 8235 8235 8183 8820 8820 9320
P2 mm 4750 5250 5400 5400 5900 5900 5900 6500 6500 7000
P3 mm 1548 1548 1800 1800 1800 1800 1673 1706 1706 1706
P4 mm 3885 4255 4135 4135 4635 4635 4670 5144 5144 5644
P5 mm 1602 1732 1800 1800 1800 1800 1840 1970 1970 1970
P6 mm 600-700 600-700 650-800 650-800 650-800 650-800 650-800 600-700 600-700 600-700
Øb mm 500 500 580 580 580 580 580 740 740 740
Øc mm 800 800 900 900 900 900 1000 1100 1100 1100
N1 DN/in 250 300 350 350 350 350 350 400 400 400
N2 250 300 350 350 350 350 350 400 400 400
N1/N2 PN 16 16 16 16 16 16 16 16 16 16
N4
DN/in
40 40 40 40 40 40 40 40 40 40
N7 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4 1"1/4
N8 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4"
N11 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"
[1] Tb=Turbulators size and quantity.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz