ICI Caldaie ASGX EN Series User manual
ASGX EN_3000_17000_en_00 - 10/2019
EN
Superheated water heat generator
ASGX EN
2
INDEX
SYMBOLS USED IN THE MANUAL
aDANGER
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.
dIT IS FORBIDDEN
To indicate operations that SHOULD NOT be performed.
mIMPORTANT
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
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 Qualied 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.
mIMPORTANT
Failure to observe the instructions in this manual will void the warranty conditions.
mIMPORTANT
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.
General information4
WARNINGS
mIMPORTANT
–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.
General information 5
mIMPORTANT
–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
dIT 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
aDANGER
–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 qualied personnel
with the purpose of
promptly detecting any damage to the generator's pressurised body and the safety and control accessories.
General information6
aDANGER
–
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
mIMPORTANT
The installation must be performed in compliance with the local standards by
qualied 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.
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.
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
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.
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.
General information 11
BURNERS
The burners that can be installed on the
ASGX EN
boilers must be CE marked according to European Directives:
–Gas Directive 2009/142/EC
–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 burner to be combined with the boiler must be of two-stage or modulating type; so that excessive flow temperature
variations can be avoided.
–The burner firing range must include the point of operation of the boiler (flow rate-back pressure in combustion chamber
considering also any resistance/draught of the smoke duct)
–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 length and shape of the flame must be suitable to the flame inversion combustion chambers. The burner manufacturers
have this information as they are required by certification.
Øb
P6
mIMPORTANT
The gap between the mouthpiece and door must be filled with flame-resistant thermoceramic material.
Dimensions u.m. ASGX EN
3000 3500 4000 5000 6000 7000
P6 mm 300-400 300-400 300-400 300-400 300-400 300-400
Øb mm 400 400 450 450 450 450
Dimensions u.m. ASGX EN
8000 9000 10000 11000 12000 13000 14000 15000 16000 17000
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
General information12
PAPERWORK
These generators, supplied in single-block, are CE marked according to the Directive 2014/68/EU "PED".
The documentation supplied with the generator is:
–declaration of conformity of the whole
–use and maintenance manual (always housed in the electrical panel)
–safety valve certificate, declaration of conformity, use and maintenance manual
–feed pump characteristic curve
–Machinery Directive 2006/42/EC (for liquid fuel burners)
–wiring diagram (always housed in the electrical panel).
mUSER OBLIGATIONS
Check which pressure equipment commissioning and use regulations are in force in the country of use.
FIRE PREVENTION
Refer to the Regulations in force in the Unit Installation Country.
General information 13
COMPONENTS
The superheated water boilers
ASGX EN
feature a series of components that can be divided into:
–Safety components (safety valves, safety pressure switch, safety thermostat).
–Indicator components (temperature indicator, pressure gauge, flame warning light).
–Adjustment components (Thermostat).
In the descriptions below, accessories are divided based on the values they control.
PRESSURE
PRESSURE GAUGE
The pressure gauge is of Bourdon type and it consists of a very flat arch-shaped elliptical metal tube and shows the design pressure
on the graduated scale (marked in red). One of the ends is open and it communicated with the inside of the generator whose
pressures is to be measured; the other end, closed and free to move, is connected to the index by a toothed sector lever system.
The pressure gauge is mounted on a three-way valve that allows performing the following operations:
–Communication between generator and pressure gauge (normal operating position).
–Communication between pressure gauge and the outside (position needed to purge the siphon).
–Communication between generator, pressure gauge and sample pressure gauge (position needed for pressure gauge
comparison).
2
0
4
6
12
16
bar
8
10
14
Indicative figure for 12 bar boiler.
General information14
OPERATING PRESSURE SWITCH
Device that controls the generator pressure and keeps it within the preset value.
Instructions for calibration
The electric switch has three screws (1-2-4 from left to right). Upon reaching the set pressure the contact 1-2 is switched into
contact 1-4.
Pressure switch calibration
–Rotate the knob (1) until setting the index of the scale (2) to the pressure value at which you wish the burner to restart.
–Remove the cover of the pressure switch and set the drum (3) to the value selected for the differential (burner stop) based on
the “Scale of the differential regulation disc”.
Scale of the differential regulation disc
Example
Pressure switch type: RT 5
Scale index: 9 bar
Drum index: 4 corresponding to 2.1 bar
Burner start: 9 bar
Burner stop: 11.1 bar
1
2
3
General information 15
SAFETY PRESSURE SWITCH
It is set at a pressure higher than the maximum one of the regulation pressure switch, but always lower than safety valve opening
value.
The safety pressure switch is triggered in case of regulation pressure switch fault and permanently stops the burner.
The burner will be switched on again only after the water pressure value has decreased and the control panel has been manually
reset.
The calibration of this pressure switch is carried out with a procedure similar to that used for the regulation pressure switch, with
the only requirement of setting the drum indicator to 1, practically with a zero differential.
21 5 6
4 43
1
Sealed anti-tampering cap
2
Polyamide cover
3
Stainless steel bellows
4
Pressure connection G 1/2 A
5
Protection class IP 66
6
2 x PG 13.5 cable diameter 6 - 14 mm
7
SPDT interchangeable contact system
mIMPORTANT
The safety pressure switch is calibrated and sealed during generator construction.
Operation
When the pressure exceeds the set value, contacts 1-4 close and contacts 1-2 open. Contacts go back to their initial position when
the pressure drops below the set value, minus the differential value (fixed at 1.2 bar).
I II
14
2
IS
DM
14
2
14
2
I
Alarm triggered by the increase of the pressure above the set value.
II
Alarm triggered by the decrease of the pressure below the set value, minus the differential value.
IS
Scale setting.
DM
Mechanical differential.
Intrinsic safety operation for increasing pressure
The figure shows a section of the intrinsic safety bellows for increasing pressure.
When pressure increases, the contact lever interrupts the connection between
terminals 1 and 2. Should the internal bellows pierce, the pressure will be sent to the
external bellows.
The external bellows surface is three times higher than the one of the internal bellows.
The connection between terminals 1 and 2 is interrupted. Should the external bellows
pierce, atmospheric pressure will be present between the two bellows.
The contact system interrupts the connection between terminals 1 and 2. Thanks
to the double bellows structure, in case of breakage, fluid will not leak into the
environment.
General information16
SAFETY VALVES
The safety valves are able to maintain the pressure in the generator to the design pressure (save temporary peaks of 10% max of
the max PS of the whole) even if all other pressure control devices (pressure switches and transmitters) are out of use.
These valves are regulated by specific national and international standards, therefore they are sized, tested, installed and maintained
in compliance with the applicable regulations and the contents of this manual.
The
use and maintenance manual
is supplied with the safety valves.
The main components of the safety valve are:
1
Lifting lever
2
Hat
3
Spring
4
Valve body
5
Cap
6
Drainage hole (if any)
SC
Drain
IF
Fluid inlet
aATTENTION
Drainage hole placed at the bottom of the valve body (6).
Drainage hole with diameter ¼”BSP-f until DN80.
For higher DN sizes, the hole diameter is equal to ½”BSP-f.
Remove the red plastic cap (if any) and provide for collecting draining suitably. (provided by the customer).
For further information, refer to the supplier’s manual.
mIMPORTANT
Before starting the generator, remove the steel wire that blocks the lever during transport. Make sure that the lifting
lever is free to move.
In case of conveyed drain, bracket the conveying pipe to compensate the reaction force generated when the fluid is drained.
Make one or more draining holes in the conveying pipe to drain any condensate.
Drain must take place in the atmosphere, direct the valve so as not to harm people or damage property.
Interception valves must not be provided.
The exhaust pipe must be designed in such a way that any
low temperatures do not create ice that ob-structs the
outlet.
N.B.: Bracket at no more than 1 m away
mIMPORTANT
The operation of the safety valves is sensitive to pressure losses that occur in the drain conveying pipe during their
opening. The pressure losses in the drain conveying pipe of the safety valves must be 0. The nominal diameter of the
exhaust pipe must be greater than or equal to the size of the safety valve outlet connection. A diameter ≥ 1.5 DN
(PSV) is suggested.
General information 17
VALVE MAINTENANCE
The valve is a very delicate mechanism, so the system operator must check its efficiency. If necessary, contact a technician
authorised by the manufacturer.
It is good practice for the safety valves installed to protect the plant:
–to be operated (once a week) with system pressurised, by activating the manual lifting lever of the shutter
–to have their calibration checked once a year, directly on the system or with bench test
–to be subjected to overhaul every two years
–to be replaced after ten years of operation
mIMPORTANT
The safety valves are designed and built to operate without lubricant; simply keep them clean and efficient. Always
refer to the specific manual.
TEMPERATURE
THERMOREGULATION AND MESSAGE DISPLAY
Thermoregulator front
1
Instructions:1 =2nd stage of burner on (enabled to work)2 =Burner on (enabled to work)
2
Display of flow temperature measured or indication of the variable during the thermoregulator parametrization phase (HSET
- SP - AL2 - HAL2)
3
Display of the burner AL2 (ON-OFF variable) or of the sets of variables during the thermoregulator parametrization phase
(HSET - SP - AL2 - HAL2)
4
Enter key, its pressure allows accessing variable parametrization and if you push it again it scrolls the sequence of variables(HSET
- SP - AL2 - HAL2)
5
Up and down keys for the variables during the thermoregulator parametrization
Variable functions
HSET = Set Point hysteresis(working temperature hysteresis, burner 2nd stage control)
SP= Set Point(working temperature, burner 2nd stage control)
AL2= Limit temperature set(burner ON-OFF control)
HAL2= Limit Set hysteresis(limit temperature hysteresis, burner ON-OFF control)
General information18
Thermoregulator parametrization example
Push the enter key (4), field 2 to display the HSET variable and field 3 to display the variable parametrization (example: working
temperature hysteresis 2°C); to modify the variable push the up and down keys (5).
Attention: HSET hysteresis affects both above and below the Set Point; this means that, for example, if the desired Set Point
temperature is 110°C and hysteresis 2°C, the control at 2nd stage burner will be interrupted at 112°C and activated again at 108°C.
When the enter key (4) is pushed again, the system goes to the SP variable (example: working temperature 110°C, burner 2nd
stage control); to modify the variable push the up and down keys (5).
By doing it again, the system goes to the AL2 variable (example: limit temperature 120°C, burner ON-OFF), to modify the variable
push the up and down keys (5).
At last the system goes to the HAL2 variable (example: limit temperature hysteresis 2°C), to modify the variable push the up and
down keys (5).
Attention: HAL2 hysteresis only affects above the limit set; this means that, for example, if the desired temperature limit is 120°C
and hysteresis 2°C, the burner ON-OFF control will be interrupted at 122°C and activated again at 120°C.
At the end of the parametrization wait a few seconds, the thermoregulator goes automatically to normal visualization.
Message display front (Alarms)
1
Alarm output connected - Buzzer on electric panel enabled
2
Alarm indicator
3
Indication of several alarms - There is more than one alarm
4
Alarm/s indicator - Alarm indicator box, see the type below, if there are several alarms the display will display them alternately
every 4 seconds
5
Alarm silencing key - Press to mute the buzzer, when a new alarm appears it will switch back on automatically
6
Key to reset the alarms in the memory - If signal 2 is not on and the display is flashing, alarm/s in the memory but not present,
the button can be used to clear it/them.
Alarm indications
A.01 = (Minimum or maximum) pressure alarm, check the system pressure, the settings of the loading system and of the expansion
system
A.02 = High temperature alarm, check the flow water temperature and the parametrization of the control thermoregulator
A.03 = Safety circuit alarm, indicates a fault inside the control panel
A.04 = Burner shut off alarm, indicates an incorrect operation of the burner
General information 19
THERMOMETER
It is of the inert gas recessed type, 0/120°C range, boiler with 100 mm diameter and 4000 mm long temperature detection
capillary tube.
REGULATION THERMOSTAT
The regulation thermostat stops the burner when the required temperature is reached and restarts it automatically at a pre-set
value.It also features a contact to activate the second flame of a two-stage burner.
SAFETY THERMOSTAT
The safety thermostat stops the burner when the required temperature value is reached and sends an alarm signal.
The restart is performed only after the alarm cause has been removed and the system has been reset by using the reset button
on the control panel.
NOTE
Calibration and sealing at the manufacturer’s premises
For further information, see the specific instructions supplied with the boiler.
Installation20
2 Installation
PRODUCT RECEIPT
The
ASGX EN
generators are supplied complete with accessories.
The combustion chamber contains:
–turbulator unit to be inserted in the smoke pipes during installation
–thermoceramic material to be inserted in the gap between burner mouthpiece and door insulation
The control panel contains the following documentation:
–declaration of conformity
–use and maintenance manual
–safety valve certificate, with declaration of conformity and use and maintenance manual
–electrical diagram
mIMPORTANT
The instruction manual is an integral part of the appliance and so MUST be carefully read before installing and
commissioning the generator, carefully stored for future consultation and MUST always accompany the appliance.
This manual suits for next models
16
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