ARES 440 TEC ERP ARES 550 TEC ERP ARES 660

Instructions and warnings
Installer
Maintenance technician
IE
ARES 440 TEC ERP
ARES 550 TEC ERP
ARES 660 TEC ERP
ARES 770 TEC ERP
ARES 900 TEC ERP
*1.039293ENG*
Modular condensing boiler
Warning this manual contains the exclusive instructions for use for professionally qualified
installers and/or maintenance technicians, in compliance with laws in force.
The individual in charge of the system is NOT authorised to work on the boiler.
The manufacturer will not be held liable in the case of damage to people, animals or property
due to the failure to observe the instructions contained in the manuals supplied with the boiler.
INDEX
1
General information....................................................................4
1.1 Symbols used in the manual.........................................................4
1.2 Compliant use of the appliance....................................................4
1.3 Information to be provided to the user......................................4
1.4 Safety warnings..............................................................................5
1.5 Regulations for installation..........................................................6
1.6Installation......................................................................................6
1.7 Water treatment.............................................................................7
1.8 general warnings............................................................................8
3.13
3.14
3.15
3.16
3.17
3.25
3.26
complete optional kits.................................................................23
condensate drain..........................................................................24
Connecting the flue.....................................................................25
Flue exhaust manifold connection............................................25
Electrical connections.................................................................27
General recommendations.........................................................27
230V electrical supply connection............................................28
Connection diagram...................................................................29
Power supply, gas electrovalve, INAIL, ON/OFF
pump, external probe, flow switch.............................................29
Power supply, gas electrovalve, INAIL, modulating pump,
external probe, flow switch.........................................................29
INAIL safety connection
(supplied with modulating pump)............................................30
ON/OFF thermostat connection...............................................30
Modulating room thermostats connection..............................31
Modulating zone manager connection.....................................31
Practical connection diagram....................................................32
Connections and management diagram...................................34
Examples of installation (functional diagram and
description of connections)........................................................36
System filling and emptying.......................................................41
Boiler frost protection.................................................................41
Check the adjustment of the pressure to the burner...............42
Nozzles - pressures......................................................................44
Emergency and safety operations .............................................46
First ignition.................................................................................47
4
Inspections and maintenance...................................................48
3.18
2
Technical characteristics and dimensions..................................9
2.1 Technical characteristics...............................................................9
2.2 View of main parts.......................................................................10
2.3Dimensions...................................................................................11
2.4 Operating data / general characteristics...................................12
3
Instructions for installation......................................................13
3.1 General recommendations.........................................................13
3.2Packaging......................................................................................14
3.3 Operation to unload and remove the packaging ....................15
3.4 Positioning the heating control unit.........................................16
3.5 Connecting the boiler.................................................................17
3.6 Gas connection............................................................................18
3.7 System flow and return pipe connection..................................19
3.8 Additional safety, protection and control devices...................20
3.9 Hydraulic separator.....................................................................21
3.10 Hydraulic system filter................................................................21
3.11 Determining the primary circuit pump or boiler pump........22
3.12 Ball valves......................................................................................22
3.19
3.20
3.21
3.22
3.23
3.24
CE DECLARATION OF CONFORMITY
(according to ISO/IEC 17050-1)
The company IMMERGAS S.p.A., with registered office in via Cisa Ligure 95 42041 Brescello (RE) whose design, manufacturing, and after sale
assistance processes comply with the requirements of standard UNI EN ISO 9001:2008,
DECLARES that:
The ARES 440 TEC ERP, ARES 550 TEC ERP, ARES 660 TEC ERP, ARES 770 TEC ERP, ARES 900 TEC ERP model boilers comply with the
following European Directives and Delegated European Regulations:
“Eco-design” Directive 2009/125/EC, “Energy labelling” Directive 2010/30/EC, “Gas Appliance” Directive 2009/142/EC, “Electromagnetic Compatibility” Directive 2004/108/EC, “Performance” Directive 92/42/EC and “Low Voltage” Directive 2006/95/EC.
Mauro Guareschi
Research & Development Director
Signature:
Immergas S.p.A. declines all liability due to printing or transcription errors, reserving the right to make any modifications to its technical and
commercial documents without prior notice.
General information
1
GENERAL
INFORMATION
1.1 SYMBOLS USED IN THE MANUAL
When reading this manual, pay special attention to the parts marked with these symbols:
DANGER!
Serious danger to
safety and life
ATTENTION!
Possibly dangerous situation
for the product and environment
NOTE!
Tips for the user
1.2 COMPLIANT USE OF THE APPLIANCE
The ARES Tec appliance was built based on the current technical level and recognised technical safety rules.
Nevertheless, following improper use the safety and life of the user or other people may be exposed to danger, i.e. damage
to the appliance or other objects.
The appliance is designed for operation in hot water circulating heating systems.
Any other use is considered improper.
Immergas will not be held liable for any damage resulting from improper use.
Any use in accordance with the envisioned purposes includes the strict observance of the instructions in this manual.
1.3 INFORMATION TO BE PROVIDED TO THE USER
The user must be instructed in the use and operation of his/her heating system, in particular:
- Deliver these instructions to the user, as well as the other documents relative to the appliance contained in the packaging in
an envelope. The user must keep this documentation safe so that it is available for future consultation.
- Inform the user of the importance of aeration vents and the flue exhaust system, highlighting how essential they are and how
it is strictly forbidden to change them.
- Inform the user on how to control the water pressure in the system as well as the operations required to restore it.
- Inform the user on how to correctly regulate the temperature, control units/thermostats and radiators in order to save energy.
- Remember it is compulsory to carry out regular maintenance on the system once a year and a combustion analysis every two
years (as per national legislation).
- If the appliance is sold or transferred to another owner or if the owner moves, leaving the appliance behind, always ensure the
handbook accompanies the appliance so that it may be consulted by the new owner and/or installer.
The manufacturer will not be held liable in the case of damage to people, animals or property due to the failure to observe the instructions
contained in this manual.
4
General information
1.4 SAFETY WARNINGS
ATTENTION!
The appliance must not be used by people with reduced physical, mental and sensorial capabilities, without experience and
knowledge. These people must be duly instructed and supervised during manoeuvring operations.
ATTENTION!
Installation, adjustment and maintenance of the appliance must be carried out by professionally qualified staff, in compliance
with regulations and provisions in force, as incorrect installation can cause damage to people, animals and property, for
which the manufacturer will not be held liable.
DANGER!
Maintenance or repair work on the boiler must be carried out by professionally qualified staff, authorised by Immergas;
it is advisable to sign a maintenance contract.
Poor or irregular maintenance can compromise the operational safety of the appliance and cause damage to people, animals
and property for which the manufacturer will not be held liable.
Changes to parts connected to the appliance
Do not make changes to the following elements:
- to the boiler
- to the gas, air, water and power supply lines
- to the flue pipe, safety valve and exhaust pipe
- to the constructive elements that affect the operational safety of the appliance.
Attention!
To tighten or loosen the screw-attached fittings, use suitable wrenches only.
Improper use and/or unsuitable tools can cause damage (for ex. water and gas leaks).
ATTENTION!
Instructions for appliances running on propane gas
Make sure that the gas tank has been deaerated prior to installing the appliance.
For a thorough deaeration of the tank contact the liquid gas supplier and in any case authorised staff, in accordance with the law.
Ignition problems can arise if the tank is not thoroughly deaerated.
In this case contact the liquid gas tank supplier.
Smell of gas
In case of the smell of gas observe the following safety instructions:
- do not use electric switches
- do not smoke
- do not use the telephone
- shut off the gas cut-off valve
- aerate the room where the gas leak occurred
- notify the gas supply company or a company specialised in the installation and maintenance of heating systems.
Explosive and easily flammable substances
Do not use or deposit explosive or easily flammable materials (for ex. petrol, paints, paper) in the room where the appliance is
installed.
ATTENTION!
The heat unit must be installed so as to avoid, under the envisioned operating conditions, the liquid contained in it from freezing
and avoid exposing the command and control parts to temperatures below -15°C and over +40°C.
The heat unit must be protected from climatic/environmental variations by:
- insulating the hydraulic and condensation exhaust pipes
- adopting specific anti-freeze products in the hydraulic system.
5
General information
1.5 REGULATIONS FOR INSTALLATION
Also observe the standards regarding the heating control unit,
construction regulations and requirements on combustion heating in
the country of installation.
ARES Tec is a gas category II2H3P heat unit.
The appliance must be installed, commissioned and subject to
maintenance in accordance with the current "state of the art". This also
applies to the hydraulic system, the flue exhaust system, the installation
room and the electrical system.
The appliance must be installed in accordance with the instructions
contained in this manual.
Installation must be carried out by an authorised professional
technician, who is in charge of enforcing observance of all local
and/or national laws published in the Official Gazette, as well as all
applicable technical regulations.
Failure to observe the above regulations will void
the warranty.
It is necessary to observe the standards, regulations and requirements
for installation provided below, constituting a rough and non-exhaustive
list, in order to follow the evolution of the "state of the art". We
would like to underline that updating the list of standards is the
responsibility of the technicians authorised to carry out installation.
1.6INSTALLATION
Attention!
If the new boiler has been replaced in an old system
without having preventively washed it as described
above, do not wash the system, as any residues of
the product in the circuit may fill the generator with
residues after replacement.
It is advisable to contact a company specialised in
water treatment.
Otherwise, if ARES Tec is being installed on a new system it is advisable
to wash it thoroughly in any case, using products that are suitable for
the entire system, and install a Y-strainer with two cut-off valves on the
return pipe to the boiler, so that it can be cleaned as needed.
This filter will protect the boiler from sediments coming from the
heating system.
When the appliance is installed on existing systems, make sure that:
-The flue is suitable for condensation appliances, for the temperatures
of the combustion products, calculated and built in accordance with
regulations in force. That is it a straight as possible, water-tight and
insulated and does not have any obstructions or constrictions.
- The flue is equipped with an attachment to evacuate the condensation.
-The heating control unit is equipped with a pipe for the evacuation
of the condensation produced by the boiler.
-The electrical system is built in accordance with specific regulations
and qualified technical personnel.
-The flow rate, head and direction of flow of the circulation pumps is
appropriate.
In both cases it is necessary to keep the head losses localised in the
primary circuit, for the correct sizing of the pump.
- The fuel feed line and any existing tanks are set up in accordance with
regulations in force.
-The expansion vessels ensure complete absorption of the dilation of
the fluid contained in the system.
-Slurry and build-up have been cleaned out of the system.
If ARES Tec is being installed on existing Systems:
If it is possible to schedule the replacement, it is necessary to wash
the system preventively, with alkaline dispersants. Washing must be
carried out four weeks prior to replacement, with a system operating
between 35°C - 40°C.
6
General information
1.7 WATER TREATMENT
To minimise corrosion, it is essential to use a corrosion inhibitor.
In order for it to work efficiently, however, the metal surfaces must
be clean.
The best inhibitors on the market also contain an aluminium
protection system that stabilises the pH levels of the filler water,
preventing sudden changes (buffer effect).
It is advisable to systematically check (at least twice a year) the
pH value of the water in the system. In order to do so a chemical
laboratory analysis is not required, but a simple check using a
analysis "kit" contained in a carry cases, easily available on the
market.
Treating the supply water allows you to prevent problems and
maintain the functionality and efficiency of the generator over time.
The purpose of this treatment is to eliminate or significantly reduce
problems that can be outlined as:
build-up
corrosion
sediments
biological growth (mould, fungus, algae, bacteria, etc.)
It will therefore be necessary to set up the devices shown in the figure
in the heating system.
The chemical analysis of the water provides a lot of information on the
state and "health" of the system.
The pH level is a numerical indication of the acidity or alkalinity of
a solution.
The pH scale goes from 0 to 14, where 7 corresponds to neutral.
Values below 7 indicate acidity, values above 7 indicate alkalinity.
The ideal pH value in heating systems with aluminium boilers is
between 6.5 and 8, with a hardness of 15°F.
Water in a system with a pH value outside of this range considerably
accelerates the destruction of the protective oxide layer which forms
naturally inside the aluminium bodies, and would not occur naturally:
if the pH level is lower than 6 it contains acid, if it is above 8 the water is
alkaline, either due to an alkaline treatment (for example phosphates or
glycols operating as antifreeze) or in some cases the natural generation
of alkalis in the system.
Vice versa, if the pH value is between 6.5 and 8, the aluminium surfaces
in the body are passivated and protected from further corrosive attacks.
THE COUPLING MUST BE SET UP ON THE
RETURN PIPE TO THE PRIMARY CIRCUIT
DOWNSTREAM OF THE PUMP.
All of the precautions required to avoid the formation and localisation of
oxygen in the water of the system. For this reason the plastic pipes used
in the under-floor heating systems must not be permeable to oxygen.
Make sure that any anti-freeze products are compatible with aliminium
and any other parts and materials in the system.
ATTENTION!
Any damage caused to the boiler, due to the formation
of build-up or corrosive water, will not be covered by
the warranty.
ATTENTION!
These appliances are designed and developed to
transfer heat to a heat carrying fluid possessing the
characteristics described here, they are not suitable to
directly heat water intended for human consumption.
Example of water treatment unit
Key:
1 -
2 -
3 -
4 -
5 -
6 -
7 -
1
2
3
4
5
2
6
7
7
1
Ball valve
Sample trap
Filling unit
Cut-off device
Water treatment unit
Litre meter (recommended)
"Y" strainer
General information
1.8 GENERAL WARNINGS
Any repairs to the products must be carried out by authorised Immergas
personnel only, using original spare parts only. Failure to observe
the above can jeopardise the safety of the appliance and will void the
warranty.
The instruction handbook is an integral and essential part of the product
and must be kept safe by the individual in charge of the system.
The guarantee the efficiency of the appliance and its correct operation it
is essential for authorised personnel to carry out annual maintenance.
Read the warnings contained in the handbook carefully, as they provide
important instructions regarding installation, user and maintenance
safety.
Keep the handbook safe for future consultation.
If the appliance is put out of use for downtime, any part that is
susceptible to posing a potential source of danger must be made safe.
The appliance must be installed and maintained in accordance
with regulations in force, pursuant to the instructions of the
manufacturer, the state of the art and by authorised and qualified
personnel, in accordance with the law.
Before re-commissioning an appliance that has been put out of use,
proceed to washing the domestic hot water production system, making
water flow through it for the amount of time required to change the
water completely.
Professionally qualified personnel means staff with specific technical
skills in the sector of heating system parts for civil use, hot water
production for domestic use and maintenance. This personnel must
have the authorisations required by legislation in force.
If the appliance is sold or transferred to another owner or if the owner
moves, leaving the appliance behind, always ensure the handbook
accompanies the appliance so that it may be consulted by the new
owner and/or installer.
Incorrect installation or poor maintenance can cause injury to persons
and animals and damage to objects, for which the manufacturer is
not liable.
All appliances with optionals or kits (including electric) must only use
original spare parts.
The appliance must only be employed for its expressly foreseen use.
Any other use must be considered improper and therefore dangerous.
Before carrying out any cleaning or maintenance operations, cut the
appliance off from the power mains by acting on the switch on the
system and/or using the cut-off devices.
Do not obstruct the intake/exhaust pipe terminals.
In case of breakdown and/or poor operation of the appliance, switch it
off, and do not attempt in any way to repair it or intervene directly. Only
contact personnel that has been authorised in accordance with the law.
8
2
Technical characteristics and dimensions
TECHNICAL
CHARACTERISTICS AND
DIMENSIONS
-The entire heating unit is equipped with global temperature control
NTC sensors on the flow and return manifolds.
-Integral insulation with non-allergenic synthetic wool.
-Total premix burner, modulating, with "metal foam" radiation
combustion chamber. Premixing in the fan. Automatic separating
backflow diaphragm from the combustion chamber.
-Sound emissions at maximum power below 49 dBA.
2.1 TECHNICAL CHARACTERISTICS
-Operation during heating: determining the instantaneous power
through a control microprocessor, with preset comparison parameters
between requested temperature (or calculated by the outdoor
thermoregulation) and global flow temperature.
-Heat generator, to heat Low Nox condensation gas
-Comprised of a heat module designed to operate on its own or in a
set
-Can be set up directly outside (IP X5D)
-Logic of operation:
-Low water content
-Possibility of controlling the power of the single heating elements
for calibration and/or assistance with reserved access code.
-High response speed to load changes
-Single flue exhaust that can be positioned on 3 sides
-D.H.W. production through priority NTC probe, to control the
storage tank load through a pump or three-way deviator valve
through the supplied TGC thermoregulator.
-Unified flow and return hydraulic manifolds
-Comprised of 4 or more heating elements (between 4 and 8),
aluminium/silicon/magnesium casting
-Possibility of controlling the power of the single heating elements.
-Heat request control: temperature setpoint and modulation level.
-Including total irradiation premixing modulating burners
-Monitoring the state of operation and temperatures.
-None of the heating elements have hydraulic cut-off devices
-Alarm notification.
-Single gas supply pipe
-Modulated power between 22 ÷ 108 kW/element.
-Parameter setting.
TEMPERATURE CONTROL DEVICES:
-ROOM NTC sensor (every heating element)
-Analogue 0÷10V output to control a modulating pump.
-Control relay to switch on a pump at a fixed speed.
-Emergency operation: this allows you to avoid the system from
stopping due to an interruption in communication with the adjusting
system or possible remote management of the control unit:
-Room Limit Thermostat (every heating element)
-Flow NTC sensor (General)
-The possibility of selecting the emergency temperature through
supplied "Constant Setpoint" heating elements: 70°C, maximum
power 50%.
-Return NTC sensor (General)
-Approved safety thermostat (To be ordered and installed on INAIL
section in parag. 3.8)
-GCI global flow probe.
-Alarm management.
OTHER SAFETY DEVICES according to the R COLLECTION
see parag. 3.8
-Alarm notification Relay.
-Alarm reset input.
-Condensation collection tray with stainless steel exhaust trap.
-Easily removable integral panelling comprised of oven-painted steel
panels suitable for outdoor installation.
POP-UP control panel composed of:
-ON-OFF switch see parag. 3.25
- Condensation collection tray with stainless steel exhaust trap and flue
chamber.
-TGC boiler thermoregulation/manager
-GCI (internal cascade management board)
-Incorporated deaerator.
-Protection fuses
The request for heat can be generated by the TGC thermoregulation/
manager or alternatively by the GCI (internal cascade management
board).
The management logic envisions simultaneous operation of the
maximum number of heat elements, so as to always obtain the
maximum efficiency. Since it guarantees the maximum exchange area
based on the delivered power. The elements are made to operate so as
to equally divide the operating time.
The hot water that is produced is pushed by the pump located on the
return of the primary ring to the flow of the hydraulic separator. From
here a second pump (system - see suggested diagrams) will distribute to
the various utilities. From the system, return the cooled water is taken
in by the pump on the return, through the hydraulic separator, to start
the cycle towards the generator again.
-Any limit thermostats
-Fan air pressure switch
-Condensation water level sensor
-Gas pressure switch
-Exhaust pressure switch (anti-obstruction).
9
Technical characteristics and dimensions
2.2 VIEW OF MAIN PARTS
GAS
PIPE
TUBO
GAS
Pannello
PANEL
Valvola
GAS
VALVEgas
BURNER
COPERCHIO
BR UCIATORE
COVER
FAN
Ventilatore
Bruciatore
BURNER
AUTOMATIC
SFIATO
ARIA
AIR BLEED
AUTOMATICO
VALVE
Elettrodo
IGNITION
ELECTRODE
di
accensione
Camer a
COMBUSTION
di
CHAMBER
comb ustione
Te rmostato
SAFETY
THERMOSTAT
di sicurezza
MANDATA
HEAT.
FLOW
RISCALD
AM.
Elemento
STUDDED
ELEMENT
piolinato
RITORNO
HEAT.
RISCALD AM.
RETURN
CONDENSATE
Collettore
COLLECTION
raccogli condensa
MANIFOLD
CONDENSATION
BACINELLA
COLLECTION
RACCOGLI
PAN
CONSENSA RACCORDO
FLUE
FITTING
CAMINO
LEVEL
Sensore
di
SENSOR
livello
TELAIO
FRAME
TRAP
Sifone
Profondità
min.
mm
Min. depth
100100
mm
flue outlet LEFT, RIGHT, REAR side
flow LEFT side
return LEFT side
Gas inletLEFT side
GCI: under the front casing
10
Technical characteristics and dimensions
2.3DIMENSIONS
RIGHT SIDE VIEW
FRONT VIEW
(Supply condition for left side attachments)
L
1448
62,5
S
287
L1
24
TOP VIEW
=
LEFT SIDE VIEW
=
122
G
M
327
235
Dimensions
Heating elements
Height
Width "L"
Width "L1"
Depth
Attachment sizes
G Gas fitting
F System flow
R System return
Flue fitting
Condensate drain
Flue outlets:
Left side (supply condition)
Right side
Rear side
39 5
534
1267
R
S
946
ARES Tec
440
550
660
770
900
Unit
n°
mm
mm
mm
mm
4
1448
1087
1039
946
5
1448
1355
1307
946
6
1448
1355
1307
946
7
1448
1623
1575
946
8
1448
1623
1575
946
mm (inch)
mm (inch)
mm (inch)
mm
mm
80 (3)
100 (4)
100 (4)
250
40
80 (3)
100 (4)
100 (4)
250
40
80 (3)
100 (4)
100 (4)
300
40
80 (3)
100 (4)
100 (4)
300
40
80 (3)
100 (4)
100 (4)
300
40
11
Technical characteristics and dimensions
2.4 OPERATING DATA / GENERAL CHARACTERISTICS
ARES Tec
Boiler category
Nominal heat input on L.V.C. Qn
Minimum heat input on L.C.V. Qmin
Nominal effective power (Tr 60 / Tf 80°C) Pn
Minimum effective power (Tr 60 / Tf 80°C) Pn min
Nominal effective power (Tr 30 / Tf 50°C) Pcond
Minimum effective power (Tr 30 / Tf 50°C) Pcond min
Efficiency at nominal power (Tr 60 / Tf 80°C)
Efficiency at minimum power (Tr 60 / Tf 80°C)
Efficiency at nominal power (Tr 30 / Tf 50°C)
Efficiency at minimum power (Tr 30 / Tf 50°C)
Efficiency class according to directive 92/42 EEC
Combustion efficiency at nominal load
Combustion efficiency at minimum load
Losses from operating burner casing
Losses from burner casing when switched off
Chimney losses with burner on
Flue temperature at net of Tf-Ta (max)
Maximum flue flow rate (max)
Air excess
(**) CO2 (min/max)
NOX (weighted value according to EN 15420)
NOX class
Water flow rate at nominal power (∆T 20°C)
Minimum pressure of heating circuit
Maximum pressure of heating circuit
Water content
Methane gas consumption G20 (supp.press. 20 mbar) at Qn
Methane gas consumption G20 (supp.press. 20 mbar) at Qmin
Gas consumption G25 (supp.press. 20/25 mbar) at Qn
Gas consumption G25 (supp.press. 20/25 mbar) at Qmin
Propane gas consumption (supp.press. 37/50 mbar) at Qn
Propane gas consumption (supp.press. 37/50 mbar) at Qmin
Maximum pressure available at flue base
Max condensate production
Emissions
CO with 0% of O2 in the exhaust
NOx with 0% of O2 in the exhaust
Sound
Electrical data
Power supply voltage / Frequency
Supply fuse
Maximum power
(***) Degree of protection
Consumption in stand-by
kW
kW
kW
kW
kW
kW
%
%
%
%
-%
%
%
-%
°C
kg/h
%
%
mg/kWh
-l/h
bar
bar
l
m3/h
m3/h
m3/h
m3/h
kg/h
kg/h
Pa
kg/h
440
II2H3P
432
22
424,27
20,57
445,39
23,94
98,21
93,5
103,1
108,8
4
98,28
98,45
0,1
0,1
1,55
45,4
706,0
25,5
47
5
18243,5
0,5
6,0
73
45,68
2,33
53,13
2,71
33,53
1,71
100
69,5
550
II2H3P
540
22
530,33
20,57
557,82
23,94
98,21
93,5
103,3
108,8
4
98,28
98,45
0,1
0,1
1,55
45,5
882,5
25,5
47
5
22804,4
0,5
6,0
88
57,10
2,33
66,41
2,71
41,92
1,71
100
86,9
660
II2H3P
648
22
636,40
20,57
670,03
23,94
98,21
93,5
103,4
108,8
4
998,28
98,45
0,1
0,1
1,55
45,5
1059,1
25,5
47
5
27365,2
0,5
6,0
103
68,52
2,33
79,69
2,71
50,30
1,71
100
104,3
770
II2H3P
756
22
742,47
20,57
783,22
23,94
98,21
93,5
103,6
108,8
4
98,28
98,45
0,1
0,1
1,55
45,5
1235,6
25,5
47
5
31926,1
0,5
6,0
118
79,94
2,33
92,97
2,71
58,68
1,71
100
121,7
900
II2H3P
864
22
848,53
20,57
900,29
23,94
98,21
93,5
104,2
108,8
4
98,30
98,45
0,1
0,1
1,55
45,3
1412,1
25,5
47
5
36487,0
0,5
6,0
133
91,36
2,33
106,25
2,71
67,07
1,71
100
139,1
ppm
ppm
dBA
<95
<30
<49
<95
<30
<49
<95
<30
<49
<95
<30
<49
<95
<30
<49
V/Hz
A (F)
W
IP
W
230/50
4
626
X5D
20
230/50
4
783
X5D
20
230/50
4
940
X5D
20
230/50
4
1096
X5D
20
230/50
4
1252
X5D
20
(*) Room Temperature = 20°C
(**) See "NOZZLES - PRESSURES" table
(***) The IP X5D degree of protection is obtained with
the lid lowered.
12
3
Instructions for the installer
INSTRUCTIONS FOR
INSTALLATION
ATTENTION!
In rooms with aggressive vapour or dust, the
appliance must operate independently of the air in
the room of installation!
3.1 GENERAL RECOMMENDATIONS
ATTENTION!
The appliance must be installed by a qualified
technician possessing professional-technical
qualifications in accordance with the law, who, under
his/her own responsibility, enforces the observance of
regulations according to the rules of good practice.
ATTENTION!
This boiler must only be employed for its explicitly
intended use. Any other use must be considered
improper and therefore dangerous.
This boiler is used to heat water to below boiling
temperature in atmospheric pressure.
ATTENTION!
Assemble the appliance in observance of the minimum
required distances for installation and maintenance.
ATTENTION!
These appliances are designed exclusively for
installation inside suitable technical compartments.
The boiler must be connected to a heating system
compatibly with its specifications and power.
Before connecting the boiler, have professionally
qualified personnel:
a)Accurately washing all of the pipes in the system
to remove any residues or sediments could stop
the boiler form running efficiently, even in terms
of health and hygiene.
b)Making sure the boiler is set up to operate with the
available type of fuel. The type of fuel is stated on the
packaging and technical characteristics plate.
c)Make sure that the chimney/flue has an adequate
draught, that it is not choked, and that there are no
other exhausts for other appliances, unless the flue
is designed for multiple utilities, in accordance with
standard specifications and requirements in force.
Only once this check has been carried out can the
fitting between boiler and chimney/flue be set up.
13
Instructions for the installer
3.2PACKAGING
Composition of packaging:
The ARES Tec boiler is supplied assembled in a sturdy cardboard box.
on the left side of the boiler:
-The flue exhaust manifold.
-A cardboard box containing:
Once the two straps have been removed, slide the box
off from the top and make sure the contents are intact.
-Gasket between pan and terminal
-Collar gasket (Ø 250) Ø 300
-Two bends + one T + plastic cap for condensate drain
Packaging materials (cardboard box, straps, plastic bags,
etc.) constitute a potential hazard and must be kept
out of the reach of children.
Immergas will not be held liable in case of damage
caused to people, animals or property due to failure to
observe the above.
-Screws required to secure the flue terminal
-The probes: external, flow, storage tank.
-Flue inspection cap.
-Kit of resistances.
-Plate and fairlead for power output.
To take the boiler off of the pallet it is necessary to use a jib crane, to
avoid damaging it.
- Remove the casings and harness it using slings "A" fig. 3 being careful
to pass the slings through the load bearing crossbeams of the frame
-A cardboard box containing:
-Flanges
Inside the rear side of the casing:
-Condensate drain trap pipes (1 m).
-Tie the slings to the jib "B". Perform these operations with caution.
Above the boiler cover:
-A plastic bag containing:
-Installer and maintenance technician instructions handbook
-System manager instructions handbook
-TGC control unit user handbook
-Warranty certificate
-Hydraulic test certificate
-Control unit handbook
-Spare parts stub
C
A
B
Model
A (mm)
B (mm)
C (mm)
Gross
Weight (kg)
440
550
660
770
900
1263
1531
1531
1799
1799
1120
1120
1120
1120
1120
1515
1515
1515
1515
1515
585
643
707
806
858
14
Instructions for the installer
3.3 OPERATION TO UNLOAD AND
REMOVE THE PACKAGING
ATTENTION!
Handle using forklift or hoist and sling.
ATTENTION!
Sling slotting points for lifting. The slings must be
assembled on the load bearing crossbeams.
4
To take the boiler off of the pallet it is necessary to use a jib crane, to
avoid damaging it.
-Remove the casings and harness it using slings, being careful to pass
the slings through the load bearing crossbeams of the frame.
-Tie the slings to the jib. Perform these operations with caution.
T ma x
50°C/122° F
T min
-5°C/23° F
Max. admitted boilers
stacked
Do not turn upside down
Do not expose to rain
Fragile
Do not expose to sunlight
Do not store at
temperature:
lower than - 5 ° C / 23 °F
superior than 50 °C / 122 °F
1
T max
50°C/122°F
T min
-5°C/23°F
Max. admitted boilers
stacked
Do not turn upside down
Do not expose to rain
Fragile
Do not expose to sunlight
Do not store at
temperature:
lower than - 5 ° C / 23 °F
superior than 50 °C / 122 °F
2
T ma x
50°C/122°F
T min
-5°C/23°F
Max. admitted boilers
stacked
Do not turn upside dow
n
Do not expose to rain
Fragile
Do not expose to sunlight
Do not store at
temperature:
lower than - 5 ° C / 23 °F
superior than 50 °C / 122 °F
3
15
Instructions for the installer
3.4 POSITIONING THE HEATING
CONTROL UNIT
The boiler can be placed on a flat platform that is sufficiently sturdy
in size, in plan, no smaller than the boiler measurements and with a
minimum height of at least 100 mm so that the trap for condensate
drainage can be installed. Alternatively, a trap can be built from this
platform, next to the boiler, at a depth of 100 mm so that the trap can
be placed in it (Parag. 3.16).
When installation is complete the boiler should be perfectly horizontal
and firmly stable (to reduce vibrations and noise).
Special attention must be paid to local standards and regulations
regarding heating control units, especially the minimum distances
that must be observed.
Installation must be comply with the requirements contained in the
most recent standards and legislation regarding heating control units,
heating system installation and hot water production, ventilation, flues
suitable for condensation boiler combustion product exhaust, and any
other applicable regulation.
B
A
D
A > 400 mm
B > 400 mm
C = 100 mm
D = 500 mm
C
Sifone
Trap
Observe the minimum clearance distances required to
perform normal maintenance and cleaning operations.
16
Instructions for the installer
3.5 CONNECTING THE BOILER
Diaphragms and gaskets.
Diaphragm installed on the first and last element of the flow manifold
Ø 18 (A), internal Ø 27 (B).
Gaskets installed on all of the other elements (C).
The ARES Tec boiler leaves the factory set up for
the hydraulic (flow and return) and gas connections
located on the left side of the boiler.
To fasten the flue exhaust manifold use the screws
and gaskets contained in the accessory kit box and a
10 mm socket key.
A
The flue exhaust manifold is set up on the LEFT SIDE.
It is also possible to set up the outlet on the RIGHT
and REAR SIDE.
B
A
F
G
R M
F
F
C
17
Instructions for the installer
3.6 GAS CONNECTION
Before installation it is advisable to clean the inside
of the fuel intake pipe thoroughly, in order to remove
any residues that could stop the boiler from operating
smoothly.
The gas intake pipe must be connected to the boiler using the respective
G 3" fitting as indicated in parag. 2.3.
The supply pipe must have a section equal to or larger than the one used
in the boiler and must nevertheless provide the correct gas pressure.
If you notice the smell of gas:
a)Do not work the electrical switches, the telephone
or any other object that can generate sparks;
It is nevertheless advisable to adhere to the standard specifications
and requirements in force, setting up a cut-off valve, gas filter, antivibration joint, etc.
b) Immediately open doors and windows to create an
air current that purifies the room;
Before commissioning an internal gas distribution system and therefore,
before connecting it to the meter, it is necessary to thoroughly check
the seal.
c) Close the gas valves;
d)Seek the assistance of professionally qualified
personnel.
If any part of the system is not in view, the sealing test must be carried
out before covering the pipe.
In order to prevent any gas leaks it is advisable to install
a surveillance and protection system composed of a gas
leak detector combined with a cut-off electrovalve on
the fuel supply line.
Danger!
The gas connection must be set up by an authorised
installation technician who must observe and apply
the contents of the legislation in force and the local
requirements of the gas supply company, as incorrect
installation can cause damage to people, animals
and property, for which the manufacturer will not
be held liable.
EXAMPLE OF GAS INTAKE SYSTEM
ESTERNO OF
EXTERIOR
CENTRALE
THE
HEATING
TERMICA UNIT
CONTROL
INTERNOOF
INTERIOR
CENTRALE
THE
HEATING
TERMICAUNIT
CONTROL
1
Key:
1 -
2 -
3 -
4 -
5 -
6 -
2
3
4
6
Fuel shut-off valve
Double membrane regulator
Gas filter
Anti-vibration joint
Gas electrovalve
Cut-off valve
18
5
6
Instructions for the installer
3.7 SYSTEM FLOW AND RETURN PIPE
CONNECTION
Make sure the pipes in the system are not used as
earthing connections for the electrical or telephone
system. They are absolutely not suitable for this purpose.
Serious damage to pipes, boiler and radiators could
occur in a short amount of time.
The heating flow and return must be connected to the boiler by the
respective 4" fittings F and R as indicated in parag. 2.3.
ATTENTION!
IT IS ABSOLUTELY FORBIDDEN TO SET UP CUTOFF DEVICES ON THE GENERATOR BEFORE
THE SAFETY DEVICES.
For heating circuit pipe sizing it is necessary to take into account
the head losses induced by the components of the system and its
configuration.
The layout of the pipes must be set up taking every necessary precaution
to avoid air pockets and to facilitate continuous degassing of the system.
ATTENTION!
Before connecting the boiler to the system proceed
by thoroughly washing the pipes terminating at the
boiler with a suitable product, in compliance with
standards, in order to eliminate metal residues from
machining and welding, any oil and grease that could
affect its operation.
Do not use solvents to wash the system, as they might
damage the system and/or its components.
Failure to observe the instructions in this manual
can cause damage to people, animals and property,
for which the manufacturer will not be held liable.
GCI
G
M
R
19
Instructions for the installer
3.8 ADDITIONAL SAFETY, PROTECTION
AND CONTROL DEVICES
Protection devices.
10Safety thermostat: this is designed to stop the generator if the safety
thermostat installed on the boiler fails to operate correctly. It must
have an IMMOVABLE calibration of < 100°C.
15Minimum pressure switch: this is designed to stop the generator if
the minimum operating pressure drops (can be calibrated between
0.5 ÷ 1.7 bar). It must be manually re-armed.
16Extra sleeve G1".
18Safety pressure switch: this is designed to stop the generator if the
maximum operating pressure is reached (can be calibrated between
1 ÷ 5 bar).
Certificate of additional safety devices: closely consult the legislative
regulations and safety provisions in force in the country of installation
of the appliance.
Use the fuel safety and cut-off valves suitable for application and
compliant with provisions in force.
The boiler is not equipped with an expansion vessel on the system. It
is mandatory to install a closed expansion vessel to guarantee correct
boiler operation. The expansion vessel must be compliant with standard
requirements in force. The dimensions of the expansion vessel depend
on the data for the central heating system. Install a vessel with a capacity,
determined by an authorised designer, that responds to the requisites
of the standards in force.
Control devices.
13(Pressure indicator - not supplied by Immergas) with (12) damper
pipe and (11) pressure gauge valve: it indicates the existing effective
pressure in the generator, it must be graduated in "bar", its full scale
must match the maximum operating pressure and be equipped with
a three-way valve with an attachment for the control pressure gauge.
14Thermometer: this indicates the effective temperature of the water
contained in the generator, it must be graduated in centigrade with
a full scale of no more than 120°C.
17Inspection traps: approved for the inclusion of control devices.
19G1 ¼" stub pipes: for the inclusion of safety valves.
20Flow switch: this is designed to stop the generator in case of poor
water circulation inside the primary ring.
3 Approved expansion vessel: this absorbs the increase in volume
of water in the system following an increase in temperature. Not
supplied by Immergas.
8 Y strainer.
7 Modulation pump (Not included in the kit).
5 Hydraulic separator (Not included in the kit).
4 Bleeder valve. Not supplied by Immergas.
6 Draining valve. Not supplied by Immergas.
Safety devices.
1 Gas cut-off valve: this has the function of directly cutting-off the
gas supply if the limit value of the water temperature is reached.
The detection element must be installed as close as possible to the
generator output (flow pipe) at a distance of < 500 mm, and must
not have a cut-off device installed on it. Not supplied by Immergas.
2 Safety valve: this has the function of unloading the fluid contained
in the generator into the atmosphere when it reaches the maximum
operating temperature for any reason. Not supplied by Immergas.
2aVisible draining funnel. Not supplied by Immergas.
Set up a safety valve, on the flow pipe, sized for boiler capacity, within
0.5 m of the boiler, and in compliance with regulations in force.
Attention!
Remember it is forbidden to set up any type of cut-off
device between the boiler and the safety valve, and it
is also advisable to use valves for operation that does
not exceed the maximum allowed operating pressure.
Attention!
Set up a runoff pipe with funnel and trap on the
heating safety valve, that lead to a suitable drain. The
drain must be visually controlled.
The manufacturer will not be held liable in the case of
failure to observe this precaution, where any work on
the safety valve may cause damage to people, animals
and property.
20
Instructions for the installer
Recommended installation
3
1a
1
GCI
2
4
2a
17
13
18
19
15
16
14
12
11
10
6
3.9 HYDRAULIC SEPARATOR
3.10 HYDRAULIC SYSTEM FILTER
To ensure good operation it is necessary to use a hydraulic separator
that guarantees:
-separation and collection of impurities in the circuits
It is advisable to install a Y strainer in the boiler return
pipe.
This filter will protect the boiler from sediments
coming from the heating system.
-optimal deaeration
-hydraulic decoupling between the two hydraulic circulation rings
mod.Ø
ARES Tec 440 ÷ 900 kW
DN 100
-balancing the circuits
Circuito
Primary
Primario
Boiler
Caldaia
Circuit
FM
17
FM
R
R
Circuito
Secondary
Secondario
System
Impianto
Circuit
Hydraulic separator 440 ÷ 900 kW
F = DN 100 - (G 4")
R = DN 100 - (G 4")
21
Instructions for the installer
3.11 DETERMINING THE PRIMARY
CIRCUIT PUMP OR BOILER PUMP
The pumps must be determined by the installer or
designer based on the data for the boiler and system.
The resistance curve on the water side of the boiler is
represented in the table provided below.
The pump is not an integral part of the boiler.
It is advisable to choose a pump with a flow rate and
head of approximately 2/3 of its typical curve.
Immergas provides a series of primary rings complete with an accurately
sized pump, if alternative solutions are being used, the boiler pump
must have a head that is capable of ensuring the flow rates represented
in the "Water side head losses" graph.
The table below roughly indicates the flow rates of the pump based
on the Δt of the primary circuit if the installation is equipped with a
hydraulic separator.
440
550
660
770
900
Maximum flow rate in l/h (Δt = 15 K)
24326
30404
36487
42570
48647
Nominal requested flow rate in l/h (Δt = 20 K)
18243
22804
27365
31926
36487
Pe rdite
d loss
i caric
o 2(m/H
Head
(m/H
O) 2 O )
Power in kW
6
5,8
5,6
5,4
5,2
5
4,8
4,6
4,4
4,2
4
3,8
3,6
3,4
3,2
3
2,8
2,6
2,4
2,2
2
1,8
1,6
1,4
1,2
1
0,8
0,6
0,4
0,2
0
440
550
660
770
900
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
24000
Portata
(l/h)
Flow
rate (l/h)
EXAMPLE:
For a ΔT 20K, of an ARES 900 Tec the maximum
required flow rate is 36,289 l/h.
From the head loss graph it is possible to deduce that
the pump must ensure a head of at least 1.8 m/H2O.
28000
30000
32000
34000
36000
38000
40000
42000
44000
46000
48000
50000
52000
54000
NOTE: It is always advisable to set up a hydraulic compensator
between the boiler circuit and the system circuit. It becomes
ESSENTIAL if the system requires greater flow rates than the
maximum allowed by the boiler, i.e. ∆t below 15K.
3.12 BALL VALVES
Secondary circuit
It is advisable to install cut-off ball valves on the flow and return pipes
of the system.
ATTENTION!
NEVER CUT OFF SAFETY DEVICES FROM THE
GENERATOR, such as the safety valve and expansion
vessel.
In this way the boiler, during scheduled/unscheduled
maintenance, can be disconnected or emptied without
emptying the entire system.
22
Instructions for the installer
3.13 COMPLETE OPTIONAL KITS
Safety kits including pump and plate exchanger.
Safety kits including pump and hydraulic separator.
External covering kit for plate exchanger kit.
External covering kit for hydraulic separator.
23
Instructions for the installer
3.14 CONDENSATE DRAIN
It is forbidden to drain the condensate towards rain pipes, given the
risk of ice and degradation of materials normally used to build the rain
pipes themselves.
The condensate drain into the sewer must be:
- built to avoid gaseous combustion products from leaking out into the
environment or the sewer (trap).
The drain fitting must be visible.
Given the degree of acidity of the condensate (pH between 3 and 5)
suitable plastic materials must be used to build the drain pipes.
- sized and built to allow liquid discharge to runoff correctly, preventing
any leaks (gradient of 3%).
The condensate drain pipe outlet is set up towards the connection
side of the flue box manifold, removing the pre-sectioned part on the
cover panel.
-installed to avoid the liquid contained in it from freezing, under the
envisioned operating conditions.
-can be easily inspected from the relative trap
The recommended material for use must be PE (polyethylene) or PPI
(polypropylene).
-mixed with household wastewater, for example, (washing machine
and dish washer drains etc.) with a mainly alkaline pH so as to form
a buffer solution to send it into the sewers.
Before igniting the generator, fill the trap through
the relative cap.
The condensate must not be left to stagnate in the combustion product
drainage system (for this very reason the evacuation pipe must be set
up at an inclination of at least 30 mm/m, running towards the drain)
except for any liquid head, in the drain trap of the combustion product
evacuation system (which must be filled after installation and at a
minimum height with all of the fans operating at maximum speed of
at least 25 mm) - see figure.
INITIAL TRAP FILLER CAP
La
generatrice
superiore
del tubo
scarico
The
top generator
of the drain
pipedimust
not
non dovrˆ trovarsi ad un livello superiore
higher
thanbacinella.
the bottom of the
albefondo
della
150
150
pan
FLOOR
OF THE
PAVIMENTO
H.C.U.
DELLA C.T.
PLATFORM (H min 100 mm)
* Minimum safety trap enforced by regulation
** Minimum head with boiler operating at maximum power.
If you do not want to or are able to create a platform, it is possible to
install the boiler on the floor and set up the trap at a depth of 100 mm.
24
TO THE
CONDENSATION
DRAIN
Instructions for the installer
3.15 CONNECTING THE FLUE
Such as PVDF (polyvinyldimethylfluoride) or PPS (simple translucent
polypropylene) or aluminium or other materials with the same features,
in observance of regulation in force.
Exhaust is discharged at very low temperatures (Max 84°C approx) in
condensation boilers. It is therefore necessary for the flue to be perfectly
impermeable to combustion product condensate and built with suitable
corrosion-resistant materials.
The various slip on joints must be well-sealed and equipped with suitable
gaskets to stop condensation from leaking out and air from getting in.
In terms of flue section and height, it is necessary to refer to national
and local regulations in force.
Refer to regulations in force for sizing.
In order to avoid the formation of ice during operation, the temperature
of the inside wall at every point in the combustion product evacuation
system, for its entire length, must not drop below 0°C.
For condensation operating conditions of the appliance at project
outdoor temperatures, it will be necessary to build a confluent
condensate drainage system, based on the installation conditions, either
to the boiler collection tank or separate from it.
The supplier is excluded from any contractual and
extra-contractual liability for damage caused by
errors in installation and use and nevertheless due
to failure to observe the instructions provided by
the manufacturer.
The flue exhaust pipe must comply with local and national
regulations.
The evacuation pipe must be built using materials that are resistant
to the combustion products, typically class W1 certified stainless
steel or plastic materials.
3.16 FLUE EXHAUST MANIFOLD
CONNECTION
To secure the flue exhaust manifold use the 10 nuts +
CH 10 washers contained in the bag.
The flue point must be positioned on the first straight
section, within 1 meter of the boiler.
To set up the flue inspection point, cut a Ø 21 mm hole
in the flue exhaust pipe, and install the inspection point
following the sequence provided.
Ø21 mm
25
Model
Modules
Ø Attachment
440
4
250
550
5
250
660
6
300
770
7
300
900
8
300
ERRATA CORRIGE
Instructions for the installer
Dimensionamento
camini
Flue
sizing
secondo DIN
47054705
according
to DIN
Tenore
di CO 2
CO2 content
40°C
40°C
40PaPa
40
kg/h
kg/s
6%
8%
10%
2520
0,700
778
1037
1400
2160
0,600
667
889
1200
1800
0,500
555
1440
0,400
445
741
668
593
1000
900
800
1260
0,350
389
519
700
1080
0,300
333
444
600
900
0,250
277
370
500
720
606
0,200
222
296
400
540
0,150
167
222
300
360
324
288
0,100
0,090
0,080
111
100
89
148
133
119
200
180
160
252
0,070
78
104
140
140
216
0,060
67
89
120
120
180
0,050
144
126
0,040
0,035
56
50
44
39
74
66
59
52
100
90
80
70
d160
a
100
90
80
70
108
0,030
34
44
60
37
50
d125
a
60
28
90
5
10
15
20
25
30
1400
1200
d400
a
1000
900
800
700
d315
a
600
500
400
d250
a
300
200
180
160
50
0,020
22
30
40
54
0,015
17
22
30
36
32
29
25
0,010
0,009
0,008
0,007
9
8
12
10
20
18
16
14
20
18
16
14
22
0,006
7
9
12
12
14,4
12,0
10,8
0,005
0,004
0,003
0,002
5,6
5,0
4,4
3,9
8
7,4
6,6
5,9
10
9
8
7
9,0
0,001
3,4
4,4
6
Po rtat a termica
(kW)
Nominal
heatnomina
input le(kW)
72
11
40
d110
a
30
10
9
8
7
d75
a
5
10
15
Table of max flue flow rate
ARES Tec
Max flue flow rate (max) kg / h
440
706,0
550
882,5
660
1059,1
770
1235,6
900
1412,1
20
Example:
ARES 660 Tec
Maximum flue flow rate Height of flue
Diameter 25
=
=
=
30
6
2
d200
a
Po rtat a termica
nomina
(kW)(kW)
co n teno
re di
CO content
al 10 % at 10%
Nominal
thermal
flowle rate
with
CO
2
Po rtata
Flue
flowfum
ratei
Temperatura
fumi
Flue
temperature
Pressione pressure
disponibile
Available
1040 Kg/h
25 m
315 mm
NOTE:
The diagram provides rough values: in any case, the
flue must be designed by a qualified professional in
compliance with legislation and technical standard
in force.
26
Instructions for the installer
3.17 ELECTRICAL CONNECTIONS
Have professionally qualified personnel make sure the electrical system
is suitable for the maximum power absorbed by the appliance, as stated
on the plate, making sure in particular that the section of the system's
cables is suitable for the power absorbed by the appliance.
GENERAL RECOMMENDATIONS
Electrical safety of the appliance is only ensured when it is correctly
connected to an efficient earthing system as specified by current safety
standards: gas, water and heating system pipes are not suitable in any
way whatsoever as earthing connections.
For the main power supply to the appliance, never use adapters, multiple
sockets and/or extension leads.
The use of components involving use of electrical power requires some
fundamental rules to be observed such as:
-do not touch the appliance with wet and/or moist parts of the body
and/or barefoot;
It is necessary to check this fundamental safety requirement; In case
of doubt, have an accurate inspection of the electrical system carried
out by professionally qualified personnel, as the manufacturer is not
responsible for any damage caused by the lack of a earthing connection
in the system.
-do not pull the electric cables;
-the appliance may not be used by children or unskilled individuals.
TGC Terminal board (rear side)
GCI Terminal board (rear side)
3
4
7
6
5
4
Y2
3
2
1
2
1
4
Jp1
3
2
Y4
Y3
3
IX
BU S
2
1
3
+ 24 V
eB US -
eB US +
3
A1
Y1
4
5
6
9
IMP
FB R
2
1
2
1
10
F1 4 F1 3 F1 2 F11
V
VIII
PT100 0
SP F
VF
8
9
F8
F9
AF
7
6 I 5
F6
4
KF / S PF
2
3
VF
FA
n
T1 T2 T3 T4
4
5
6
7
8
M
A6
9
10
5 6
N L1 L1 1 2
1
VI A7
1
2
2
3
4
A8 A9 IV A1 0 A 11
1
1
VII
FB R
A1 A2 A3 A4 A5
2
1
F2 F1
e BUS
0-10 V
1
II
2
F3
M
1
3
F5
1
TGC
GCI
Power supply
27
DL3
0 1
7 8
F1 5
0-10 V
N L1 L 1’
2
4
2 III 1
F1 7
L H
3
1
DL1 DL2
GCI
2 3
NEUTRAL S
ION
CONNECT
REAR SIDE
A
1
SW1
2
3
4
5
Instructions for the installer
230V ELECTRICAL SUPPLY CONNECTION
The electrical connections are illustrated in section "PRACTICAL
CONNECTION DIAGRAM".
The installation of the boiler requires an electrical connection to a 230
V - 50 Hz network: This connection must be set up by state of the art,
as envisioned by IEC regulations in force.
ATTENTION!
Also bear in mind that, upstream of the supply,
it will be necessary to set up a service relay (NOT
SUPPLIED) that, when the electrical safety devices
are triggered, cuts off the electrical supply to the fuel
cut-off valve installed on the gas supply circuit, but
not to electrical supply the boiler, so as to ensure
pump operation and therefore boiler cooling.
Danger!
Electrical installation must only be carried out by an
authorised technician.
Before setting up the connections or any operation on
the electrical parts, always cut-off the electrical supply
and make sure it cannot be accidentally re-connected.
Remember that it is necessary to install a bipolar switch on the electrical
supply to the boiler with a max distance between the contacts of 3
mm, easy to access, so that maintenance operations can be carried out
quickly and safely. The electrical supply to the boiler, 230 V - 50 Hz
single phase, must be carried out on point A, included, with a H05VV-F
(PHASE - NEUTRAL - GROUND) three-pole cable with a section
between 0.75 mm and 1.5 mm.
ATTENTION:
Cables carrying a voltage of 230 V must travel
separately from cables carrying a voltage of 24 V.
FL = Flow switch Connection
28
Instructions for the installer
3.18 CONNECTION DIAGRAM
POWER SUPPLY, GAS ELECTROVALVE, INAIL, ON/OFF
PUMP, EXTERNAL PROBE, FLOW SWITCH.
GENERAL
ELECTRICAL
CONTROL
PANEL
Boiler supp.
If the safety devices are
triggered, the ON/OFF pump
continues operating to lower
the high temperature.
Press. max
NOT
SUPPLIED
Thermostat
Press. min
Flow switch
RELAY
Terminal
board on the
boiler panel
TGC
External
Probe
GCI
POWER SUPPLY, GAS ELECTROVALVE, INAIL,
MODULATING PUMP, EXTERNAL PROBE, FLOW SWITCH.
If the safety devices
are triggered, the
MODULATING pump is
placed on the minimum
speed and continues
operating to lower the high
temperature.
GENERAL
ELECTRICAL
CONTROL
PANEL
Boiler supp.
Press. max
Thermostat
Press. min
NOT
SUPPLIED
Flow switch
Terminal
board on the
boiler panel
External
Probe
Interface
board
IF-EXT.
MIN 0-10V
RELAY
TGC
GCI
29
Instructions for the installer
INAIL SAFETY CONNECTION
(SUPPLIED WITH MODULATING PUMP).
Thermostat
Min pressure switch
Gas
electrovalve
Max pressure switch
INAIL SECTION
RELAY
Boiler supp.
RELAY
Terminal
board on the
boiler panel
Flow switch
GENERAL
ELECTRICAL
CONTROL
PANEL
S
U
P
N P
O L
T I
E
D
Interface board
IF-EXT.MIN 0-10V
External
Probe
GCI
TGC
ON/OFF THERMOSTAT CONNECTION.
ON/OFF
ON/OFF
6
12
2
3
0
Zona
Zone 2
START/STOP contact
1
3
F3
2
1
F2 F1
2
1
VII
5
4
4
5
3
F5
2
I
1
A8 A9 IV A1 0 A 11
6
2
F6
30
1
VI A7
7
TGC
10
A6
8
9
F8
8
9
7
F9
6
10
5
1
4
A1 A2 A3 A4 A5
V
3
2
2
F1 2 F11
II
2
4
3
IX
2
1
3
F1 7
E8
1
F1 4 F 13
VIII1
N L1 L1 1 2
TGC
F 15
Zona
Zone 11
2 III 1
1
0
3
3
F1 7
2
1
1
2
18
IX
6
12
3
18
NOT
SUPPLIED
24
4
24
2 III 1
F 15
2
F1 4 F13
VIII1
2 V1
F1 2 F11
10
9
F9
8
F8
7
6 I 5
F6
F5
4
3
F3
2
1
F2 F1
2
1
VII
Instructions for the installer
MODULATING ROOM THERMOSTATS CONNECTION.
Zona
Zone 11
Zona
Zone 22
NOT
SUPPLIED
1
1
2
2
N L1 L1 1 2
4
1
II
2
3
4
1
5
6
7
8
9
A1 A2 A3 A4 A5
10
A6
1
2
VI A7
1
2
3
4
5
A8 A9 IV A10 A11
3
IX
2
TGC
3
1
F1 7
2 III 1
F 15
2
F1 4 F13
VIII1
2
V
1
10
9
F9
F1 2 F11
8
7
6
F8
F6
I
5
4
3
F5
2
F3
1
2
F2 F1
1
VII
E8
MODULATING ZONE MANAGER CONNECTION.
24
18
24
6
18
12
NOT
SUPPLIED
6
12
1
2
3
1
0
2
3
0
Zona
Zone 22
Zona
Zone 11
N L1 L1 1 2
1
II
2
3
4
5
4
3
IX
31
6
7
8
A1 A2 A3 A4 A5
TGC
2
1
3
F1 7
E8
1
9
10
A6
1
2
VI A7
1
2
3
4
5
A8 A9 IV A1 0 A 11
2 III 1
F 15
2
1
2
1
F1 4 F 13 F1 2 F11
VIII
V
10
9
F9
8
F8
7
6
F6
I
5
F5
4
3
F3
2
1
F2 F1
2
1
VII
Instructions for the installer
3.19 PRACTICAL CONNECTION DIAGRAM
3
1
2
3
2
1
2
4
4
3
1
DL1 DL2
A1
5
2
Y4
Y3
GCI
Y1
MANIFOLD POMPA
CIRCUIT
COMANDO
PUMP CONTROL
CIRCUITO
COLL ETTORE
SEG
NALAZIONE
ALARM SIGNAL
ALLARME
1
Jp1
SMG
DL3
9 0 1
6
7 8
eB US +
3
+ 24 V
O
1a
II
4
Y2
2 3
3
IX
BUS
2
1
3
2 III 1
F1 7
L H
F 15
0-10 V
IMP
3
FB R
2
2
1
F1 4 F13 F1 2 F11
VIII
V
1
PT10 00
10
SPF
9
8
7
F8
F9
VF
AF
6 I 5
F6
F5
KF / SPF
4
SW1
2
1
VII
2
3
n
M
A1 A2 A3 A4 A5
4
5
6
7
1
FA
FB R
T1 T2 T3 T4
1
II
2
F2 F1
e BUS
0-10 V
M
WHITE
BIANCO
1
3
F3
VF
1
N L1 L 1’
1
WHITE
BIANCO
5
eB US -
4
STGC/GCI
I1b
6
4 5 6
7
IG
SBRELEASE
LOCCO
BROWN
MARRONE
Modbus
Modbus --BB
Modbu
s --AA
Modbus
PR
PLC /
BMS
0-10 V
(-)
(+)
(-)
GRIGIO
GREY
RED
ROSSO
CONTROLLO
MODULATING
POMPA
PUMP
MODULANTE
CONTROL
ext.
probe
ingresso
est.
orsonda
emergency
oset
setpoint
point
emergenza
input
PINK
ROSA
BLACK
NERO
remote
eBUS
eBUS
remoto
(External
cascade
(Gestore
di cascata
esterno)
manager)
BOARD
INSER
IMENTO
SCINSERTION
HEDA
KF
WHITE
BIANCO
8
9
A6
VI A7
10
1
2
3
2
4
A8 A9 IV A10 A11
1
2
3
4
5
BROWN
MARR
ONE
BLACK
NER O
BROWN
MARR
ONE
N L1 L1 1 2
RO
SSO
RED
1
BLUE
BLU
BLUE
BL
U
BLACK
NERO
NEUTRAL
COLLEGAMENT
O
CONNECTIONS
NEUTRI (N (N)
)
BROWN
MARRONE
TGC THERMOREGULATION
CENTRALINA
DI
CONTROL UNIT
TERMOREGOLAZIONE
TGC
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
SR
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
NER O
BLACK
BLUE
BLU
BIANCO
WHITE
BLUE
BLU
GIA/VER
YEL/GRN
BLU
BLUE(N)
(N)
MARR
ONE
BROWN
(L1)(L1)
NER
O (-)
BLACK
(-)
BLU
BLUE(TACHO)
(TACHO)
MARRONE
(PWM)
BROWN (PWM)
ORANGE ++
ARANCIO
GREY
BLUE
BLU
BLUE
BLU
PINK
ALIM. ALIM.
(SUPP.)
RIL./REG
. 230V
RIL./REG.
(DET./REG.)
230V
BLUE
BLU
BLUE
BLU
BLUE
BLU
C
0 1
9
1N
2
ROSSO
RED
1
1a
ROSSO
RED
IG
SR1
TLG
LTLG
F10A
c
3 (c )
NER O
BLACK
BL
WHITE
BIANCO
MA
(3)
YEL/GRN
YEL/GRN
BLUE
BROWN
LIGHT O
BLUE
AZZURR
L1 N
1
J6
LIGHT BLUE
AZZURRO
PG
BLACK
NERO
LIGHT BLUE
AZZURRO
J3
1
BLACK
NERO
MARR ONE
BROWN
BLUE
BL U
BROWN
MARRONE
BL
MA
TL1
N
MARR
ONE
BROWN
WHITE
BIANCO
BIANCO
WHITE
F6.3A
(1)
VT
st
Module
1°1 Modulo
1 (nc)
BLUE
BLU
BLUE
BLU
BLUE
BLU
BROWN
MARRONE
BROWN
MARRONE
A
B
Only su
on
Solo
Scheda
1st
Module
1° modulo
Board
PF
ROSSO
RED
LIGHT O
BLUE
AZZURR
J2
1
J3
1
J4
1
4L
1b
BROWN
MARRONE
RED
ROSSO
BLACK
NERO
BLACK
NERO
ORANGE
ARANCIONE
BROWN
MARRONE
7 8
NERO
BLACK
BLUE
BLU
BROWN
MARRONE
5 6
5L
MARRONE
BROWN
(IG1)
BLU
BLUE
2N
BROWN
MARRONE
(IG2)
BLU
BLUE
2 3
4
SRR
M2
TL
BIANCO
WHITE
L1
E.RIL. 1
POWER SUPPLY
ALIMENTAZIONE
230VV--50Hz
50Hz
230
YEL/GRN
Key:
E.ACC 1...8
E.RIL 1...8
FL
IG
KF
LTGL
-
-
-
-
-
-
Ignition electrode
Detection electrode
Blade flow switch (optional)
Main switch
TGC global flow probe
Limit thermostat lamp
PF
PG
PV1...8
SL
SMG
SR
SR 1...8
-
-
-
-
-
-
-
Flue pressure switch
Gas pressure switch
Fan pressure switch
Condensate level sensor
GCI global flow probe
Flow sensor
Local flow sensor
32
SRR
TL
TL 1...8
TLG
VG 1...8
TRA.ACC 1...8
VM 1...8
-
-
-
-
-
-
-
Heating return sensor
Safety thermostat
Local safety thermostat
General limit thermostat
Gas valve
Ignition transformer
Modulating fan
Instructions for the installer
MODULI INTERMEDI
INTERMEDIATE
MODULES
VM (A)
4
3
2
5
1
ST 2
VM (A)
4
3
2
1
5
ST 2
L1
MARR
ONE
BROWN
BROWN
MARR ONE
1
3
N
2
3
1
N
L1
MARR
ONE
BROWN
2
YELLOW/GREEN
GIALLO /VE RDE
BLACK
NERO
1
L1
BLACK
NE RO
NER O
BLACK
2
1
2
3
N
NER
O
BLACK
BLU
BLUE
BROWN
MARR
ONE
3
FILTRO
FILTER
BL U
BLUE
BLUE
BL
U
BLACK
NERO
FILTRO
FILTER
BROWN
MARRONE
YELLOW/GREEN
GIALLO/VERDE
BLUE
AZZURR
O
VM (A)
4
ST 2
YELLOW/GREEN
GIALLO
/VER DE
BLUE
BL
U
5
ULTIMO
MODULO
LAST MODULE
YELLOW/GREEN
GIALLO
/VER DE
BLUE
BL
U
st
MODULE
1° 1MODUL
O
BLU
BLUE
( )
BLUE
BLU
MARRONE
BROWN (L1)(L1)
+ 24 V
90 1
2 3
SR2...SR8
VG2...V G8
4 5 6
nd
22°
8thModulo
Module
- 8°
eB US -
eB US +
PINK
ROSA
Optional
Optional
VG1
Modulo
GREY
GR
IGIO
GREY
GR
IGIO
NER
O (-)
BLACK
(-)
BLU
BLUE(TACHO)
(TACHO)
MARRONE
(PWM)
BROWN (PWM)
ORANGE ++
ARANCIO
ROSA
PINK
ALIM. (SUPP.)
ALIM.
. 230V
RIL./REG.RIL./REG
(DET./REG.)
230V
BLACK
NERO
RED
ROSSO
GIA/VER
YEL/GRN
BLU(N)
BLUE (N)
7 8
MARR
ONE
BROWN
rd
33°
- 88°th MODULO
MODULE
BIANCO
WHITE
connessione
Connection
con GCI
with
GCI
WHITE
BIANCO
BROWN
MARR ONE
NER O
BLACK
BIANCO
WHITE
BLU
BLUE
BROWN
MARRONE
WHITE
BIANCO
E. ACC. 1
BL
U
BLUE
RED
RO
SSO
MARR
ONE
BROWN
YEL/GRN
GIA/VER
YEL/GRN
GIA/VER
YEL/GRN
GIA/VER
BL
U
BLUE
Only
the
Soloon
sul
2°2nd
modulo
Module
BROWN
MARR
ONE
AZZURRO
LIGHT BLUE
GIA/VER
YEL/GRN
MARRONE
BROWN
RED O
ROSS
BLBLUE
U
BROWN
MARR
ONE
SL
BLU
BLUE
AZZURRO
LIGHT BLUE
ORANGE
ARANCIONE
BROWN
MARR
ONE
ORANGE
ARANCIONE
BLUE
BLU
MARRONE
BROWN
Soloon
sulthe
Only
2°
2ndmodulo
Module
TR. ACC. 1
E. ACC. 2...E.A CC.8
BLU
BLUE
FL Optional
Optional
MARR
ONE
BROWN
TR. ACC. 2...TR. ACC. 8
TL2...TL8
BIANCO
WHITE
E.RIL.2...E.RIL 8
33°rd--8°
8thMODULO
MODULE
9 0 1
9 0 1
9 0 1
9 0 1
7 8
7 8
9 0 1
7 8
7 8
9 0 1
7 8
7 8
9 0 1
2 3
7 8
7 8
9 0 1
Module 88
Modulo
(Pos7)
7)
(Pos
4 5 6
2 3
4 5 6
2 3
4 5 6
33
2 3
4 5 6
2 3
4 5 6
2 3
4 5 6
2 3
4 5 6
2 3
4 5 6
Board /Posizionamento
module selector
positioning
selettore schede/moduli
Module 11 Modulo
Module 22 Modulo
Module 33 Modulo
Module 44 Modulo
Module 55 Modulo
Module 66 Modulo
Module 77
Modulo
(Pos 0)
0)
(Pos 1)
(Pos2)
2)
(Pos3)
3)
(Pos 4)
4)
(Pos 5)
5)
(Pos6)
6)
(Pos
(Pos
(Pos
(Pos
(Pos
(Pos
(Pos
Instructions for the installer
3.20 CONNECTIONS AND MANAGEMENT
DIAGRAM
On the rear of the control unit, there are two terminal boards: one
dedicated to the network connections, the other dedicated to the
low voltage connections. The main controls, required for generator
management and control, some parts are part of the heating control
unit and must be connected to the terminal boards.
BLACK
NERO
N L1 L1 1 2
1
2
II
3
4
1
5
6
7
8
9
A1 A2 A3 A4 A5
10
A6
1
2
1
VI A7
2
1
BUS
4
3
IX
L H
IMP
F17
2
1
FBR
3
2
F15
2 III 1
3
4
n
FBR
1
0-10 V
5
T1 T2 T3 T4
N L1 L1 ’
3
4
M
M
50 Hz 230 V
3
A8 A9 IV A10 A11
PT1000
SPF
VF
F14 F13 F1 2 F 11
V
VIII
2
1
2
1
AF
10
F9
F8
9
8
F6
7
FA
eBUS
0-10 V
VF
KF / SPF
F5
6 I 5
F3 F2 F1
4
3
2
1
VII
2
1
PINK
ROSA
Network
terminal
board
GRIGIO
GREY
BROWN
MARRONE
BLUE
BLU
Alimentazione
Boiler supply
della caldaia
Low voltage
terminal board
External Global Storage
Heating
Heating
tank
Probe flow
Probe 1
probe probe Probe 2
Description of terminal board for network connections.
Morsetto
II
Morsetto II
II
Morsetto
Terminal
Morsetto
II
II
II
II
II
M
M
M
T2
T2
T2
T1
T1
T1
T1T2
1111
A6
A6
A6
A5
A5
A5 A6
A4
A4
A4A5
A3
A3
A3A4
A2
A2
A2A3
A1
A1
A1
A1A2
A6
A5
A4
A3
A2
A1
L1
L1 1111 2222
NN
N
NL1LLL111L1
L1
IIII
IIII
II
11111 22222 33333 44444 55555 66666 77777 88888 99999 10
10
10
10
10
1’
1’
L1’
L1
L1
L1LLL1’
NN
N
NL1
N:
Neutral
network
cable
N:
Cavo
di
rete
neutro
N:
Cavo
di
rete
neutro
N:
di
neutro
N: Cavo
Cavo
di rete
retenetwork
neutro supply
L1:
Appliance
L1
:
Alimentazione
rete
apparecchiatura
L1
L1 :: Alimentazione
Alimentazione rete
rete apparecchiatura
apparecchiatura
L1':
Relay
network
supply
L1’:
Alimentazione
rete
relè
L1’: Alimentazione
Alimentazione rete
rete relè
relè
L1’:
L1’:
Alimentazione
rete
relè
Pompa
circuito
riscaldamento
Circ.
risc.
Heatingcircuito
circuit riscaldamento
pump
Heat. Circ.
1 risc.
Pompa
circuito
riscaldamento
Circ.
risc.
:::: Pompa
Circ.
Pompa
circuito
riscaldamento
Circ.
risc.1111
Pompa
circuito
riscaldamento
Circ.
risc.222
Heatingcircuito
circuit riscaldamento
pump
Heat. Circ.
2 risc.
::: Pompa
Circ.
Pompa
circuito
riscaldamento
Circ.
risc.
Pompa
di
carico
del
bollitore
Storagedi
tank
loaddel
pump
::: Pompa
carico
bollitore
Pompa
di
carico
del
bollitore
Valvola
miscelatrice
Circ.
risc.
APERTA
Valvola
miscelatrice
Circ.2 risc.
risc.
APERTA
:::: Valvola
Circ.
2222 APERTA
Mixing miscelatrice
valve
Heat. circ.
OPEN
Valvola
miscelatrice
Circ.
risc.
APERTA
Valvola
miscelatrice
Circ.
risc.
2
CHIUSA
Valvola
miscelatrice
Circ.
risc.
2
:::: Valvola
miscelatrice
Circ.
risc.
2
CHIUSA
Valvola
miscelatrice
Circ.2 risc.
2 CHIUSA
CHIUSA
Mixing valve
Heat. circ.
CLOSED
Morsetto
VI VI
Terminal VI
VI A7
1
T3 T4
2
IV
Morsetto
IV
IV
IV
IV
Terminal
IV
IV
Morsetto
IV
IV
Morsetto
IV IV
Morsetto
Morsetto
4333
111 222 333 444
11 22 33 44
5444
555
55
IV
IV
5
4 A11
3 A10
2 IV
1 A9
A11
A11
A10
A10
A9
A9
A8
A8
A8
IV
IV A10 A11
A9
A8
A8
A11
A10 A11
A9 IVA10
A8 A9
11
11
222 IV A10
444
333 A11
111 A9
A8
22
22
M
M
M
M
M2
M
1
:Valv.
misc.
Circ.
risc.
111 APER
APER
//relè
relè
multifunzione
Mix.
Valv.
Heat.
Circ.
OPEN
/TA
multifunction
relay 1
misc.
Circ.
risc.
APER
multifunzione
: Valv.
misc.
Circ.
risc.
1 11APER
TATA
/TA
relè
multifunzione
: Valv.
Valv.
misc.
Circ.
risc.
APER
TA
relèmultifunzione
multifunzione
::Valv.
misc.
Circ.
risc.
//relè
:Valv.
misc.
Circ.
risc.
CHIUSA
//relè
relè
multifunzione
misc.
Circ.
risc.
multifunzione
Mix.
Valv.
Heat.
Circ.
CLOSED
//multifunction
relay2
: Valv.
misc.
Circ.
risc.
1 CHIUSA
/ relè
multifunzione
: Valv.
Valv.
misc.
Circ.
risc.
11CHIUSA
CHIUSA
relèmultifunzione
multifunzione
::Valv.
misc.
Circ.
risc.
111CHIUSA
relè
3
3
4
n
nn
nnn
multifunction
relay
relè
multifunzione
relè
multifunzione
relèrelè
multifunzione
3
relèmultifunzione
multifunzione
relè
multifunzione
multifunction
relay
relè
multifunzione
4
relèrelè
multifunzione
relèmultifunzione
multifunzione
33 33
44 44
34
11 11
22 22
Dalla
FromGCI
the
GCI
Instructions for the installer
Description of terminal board for low voltage connections.
To be connected to the GCI
1
Pin
0-10Uscita
V output
Pin 1:
1: eBUS
eBUS (F A)A)orrisp.
0-10 V
Pin
BUS/ /0-10
0-10V)
V)
Pin 2:
2: (ground
(massa BUS
2
VII
e BUS
0-10 V
FA
Terminal
MorsettoVII
VII VII
I
3
2
1
Tampone
sotto
sensore
Pin 1:
1: Buffer
under
sensor
Pin 2:
Tampone
centro
sensore
/ Telereg.
1 (sensore
2: Sensor
centre
buffer
/ Remote.
Heat.Circ
circ.di1risc.
(room
sensor) amb.)
3: Buffer
oversopra
sensor
/ Remote.
Heat. Circ
circ. di
1 (nom.
value) nom.)
Pin 3:
Tampone
sensore
/ Telereg.
risc 1 (valore
VF Pin 4: Massa
sondaground
di mandata
2 / Telereg
circ.1 1circ.
massa
Flow probe
heat. circ.
circ.2risc.
/ Remote
ground
VF Pin 5: Sonda
mandata
Flow probe
heat.circ.
circ.risc.
2 2
SPF Pin 6: Sonda
Storagebollitore
tank probe
SPF Pin 7: Massa
mandata
Globale
GlobalSonda
flow Probe
Ground
KF Pin 8: Sonda
Globalmandata
flow probe
globale
AF Pin 9: Sonda
External
probe
esterna
AF Pin 10: Massa
External
Probe
Ground
/ Flow
Probe
Ground Cir.
Heat.
Circ.11
sonda
esterna
/ Massa
sonda
Mandata
Risc.
8
9
10
AF
F9 F8
7
KF / S PF
F6
6 I 5
F5
VF
4
FB R
F3 F2 F1
Terminal I I
Morsetto
2 V1
SPF
Terminal
MorsettoVIII
VIII
1
F13
2
PT 1000 PT
sensor
Sensore
1000
F14
F1 4 F13
VIII
PT1000
Pin 1:
1: Sonda
Flow sensor
heat. circ.
1 /risc.
Multifunction
1
Pin
di mandata
circ.
1 / sensore sensor
multifunzione
1
Pin
2:
Probe
(under)
storage
tank
/
multifunction
sensor
2
Pin 2: Sonda (sotto) bollitore / sensore multifunzione 2
VF
F12 F11
SP F
VF
Terminal
MorsettoVV V
1: Sensore
CM2 sensor
sensor solare
2 / Multifunction
relaymultifunzione
sensor 3
Pin 1:
GC 2/ Solar
/ Sensore
2 / sensore relè
3
Pin 2: Sensore
Solar sensor
1
/
Multifunction
relay
sensor
4
solare 1 / sensore relè multifunzione 4
F17
3
F 15
2 III 1
F15
F1 7
IMP
3
FB R
1
0-10 V
Terminal III
Morsetto
III III
To be connected to remote control devices
IX
2
IX
BUS
CAN Bus Pin 1 = H (data)
CAN
CAN Bus Pin 2 = L L(data)
(data)
CAN
CAN
Gnd)
CAN Bus Pin 3 = - (ground,
(massa, Gnd)
CAN
power supply)
CAN Bus Pin 4 = + (12V
(alimentazione
12V)
H
L
1
L H
MorsettoIX
Terminal IX
Pin 1:
1: Ingresso
0-10V input
(to(da
be enabled)
Pin
0-10V
abilitare)
Pin
2:
Ground
Pin 2: Massa
4
3
+
4
3
2
Y4
1
GCI terminal board description
7
6
5
4
3
2
1
4
Jp1
3
2
Y4
1
2
Y3
3
Y2
4
eB US +
Y1
4
A1
5
6
9
COMANDO
POMP A
PUMP CONTROL
CIRCUITO
MANIFOLDCOLLETT
CIRCUIT ORE
(-)
0-10 V
(-)
(+ )
Modbus - B
Modbus - A
SET
POINT EMERGENZA
EMERGENCY
SET POINT
Inserire
in base according
alla tabellato
(*)the table (*)
Connectresistenze
the resistances
CONTROLLO
POM
PA CONTROL
MODULANTE
MODULATING
PUMP
eBUS
remoteremoto
eBUS
(Gestore
cascatamanager)
esterno)
(Externaldicascade
PLC /
BMS
(*)
Extsens
sens
Ext
open
open
100 K Ω
47 K Ω
22 K Ω
10 K Ω
Shortcircuit
circuit
Short
DL3
0 1
7 8
eB US -
3
5 6
+ 24 V
1
2
GCI
2 3
1
DL1 DL2
4
6
1
Y2
7
2
5
3
SEGNALAZIONE
ALARM SIGNAL
ALLARME
SW1
35
Setpoint
point
Set
82°C
71 °C
60 °C
49 °C
38 °C
27 °C
Instructions for the installer
3.21 EXAMPLES OF INSTALLATION
(FUNCTIONAL DIAGRAM AND
DESCRIPTION OF CONNECTIONS)
Assembly of a boiler with connection
to a direct zone.
Circuito di
Heating circuit 1
riscaldamento 1
(1) flow probe heat. circ. 1
(10) flow probe ground heat. circ. 1
(9-10) external probe
* this probe can also not be used
(4) Pump heat. circ. 1
*VF
VF
(4) Manifold pump
VF
1
AF
Sonda
External
Ester na
Probe
INAIL
Hydraulic
Separator e
idraulico
separator
1-2
Y4
GCI
1
2
3
4
Filter
Filtro
Pompa
Manifold
Collettore
pump
Assembly of a boiler with connection to two direct zones + dhw
production.
(1) flow probe heat. circ. 1
(10) flow probe ground heat. circ. 1
(4-5) flow probe heat. circ. 2
* this probe can also not be used
F Rec.
Ric.
(6-7) storage tank probe
(9-10) external probe
C
Circuito di
Heating circuit 1
riscaldamento 1
Circuitocircuit
di
Heating
2
riscaldamento 2
(4) Pump heat. circ. 1
(5) Pump heat. circ. 2
(6) Storage tank pump
4
n
SPF
(5) Storage tank recirculation pump
VF
**
VF
VF
(4) Manifold pump
*VF
VF
1
2
AF
Sonda
External
Ester na
Probe
INAIL
Separatore
Hydraulic
idraulico
separator
3
Filtro
Filter
Po mpa
Manifold
Collettore
pump
36
Instructions for the installer
Assembly of a boiler with connection to one mixed zone and one
direct zone + dhw production.
(4-5) flow probe heat. circ. 2
(1) flow probe heat. circ. 1
(10) heat. circ. flow probe ground 1
(6-7) storage tank probe
(9-10) external probe
* this probe can also not be used
F Ric.
Rec.
C
Circuito di
Heating circuit 1
riscaldamento 1
Circuitocircuit
di
Heating
2
riscaldamento 2
(4) Pump heat. circ. 1
(5) Pump heat. circ. 2
(6) Storage tank pump
4
n
SPF
VF
VF
VF
(7) Mixing valve heat. circ. 1 OPEN
(8) Mixing valve Heat. circ. 1 CLOSED
(5) Storage tank
recirculation pump
*VF
(4) Manifold pump
VF
1
2
AF
Sonda
External
Esterna
Probe
INAIL
Separ
atore
Hydraulic
idraulico
separator
3
Filtro
Filter
Po mpa
Manifold
Collettore
pump
Assembly of a boiler with connection to two mixed zones + dhw
production.
(1) flow probe heat. circ. 1
(10) heat. circ. flow probe ground 1
(4-5) flow probe heat. circ. 2
(6-7) storage tank probe
(9-10) external probe
* this probe can also not be used
F Rec.
Ric.
C
(4) Pump heat. circ. 1
(5) Pump heat. circ. 2
(6) Storage tank pump
Circuito di
Heating circuit 1
riscaldamento 1
Circuitocircuit
di
Heating
2
riscaldament o 2
4
(7) Mixing valve heat. circ. 2 OPEN
(8) Mixing valve heat. circ. 2 CLOSED
n
SPF
VF
VF
VF
VF
(1) Mixing valve heat. circ. 1 OPEN
(2) Mixing valve heat. circ. 1 CLOSED
*
(5) Storage tank
recirculation pump
VF
2
(4) Manifold pump
1
AF
External
Sonda
Esterna
Probe
INAIL
Separ atore
Hydraulic
idraulico
separator
3
Filtro
Filter
Pompa
Manifold
Collettore
pump
37
Instructions for the installer
Secondary system connection.
CONNECTION
SECTION
B (heating
circuit 1) 1)
COLLEGAMENTO
SEZIONE
B (circuito
riscaldamento
B
Circuito di
riscaldamento 1
C
riscaldamento 2
BLUE
BLU
Pompa
Recirculation
ricircolo
pump
BLUE
BLU
BLUE
BLU
GENERAL
ELECTRICAL
QUADRO
CONTROL
ELETTRICO
PANEL
GENERALE
Rec. F
Ric.
Circuito
di 2
Heating
circuit
Heating circuit 1
BLUE
BLU
BLUE
BLU
BLUE
BLU
Storage
Sonda
bollitore
tank
probe
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
Circ.
Sonda
mandata
flow
circ. Risc.
probe
Heat.11
Flow
Sonda
probe
mandata
circ. circ.
Risc. 22
heat.
Pump
Pompa
Heat.Risc.
circ.11
circ.
Pump Heat.
Pompa
Circ.2
circ.
Risc. 2
BLUE
BLU
M2
Heat.
Miscelatr
ice
Mixer1
Risc.
1
N
Heat.
Miscelatr
ice
Mixer2
Risc.
2
Pompa
Storage
bollitore
tank
pump
23 0 V
L1
RELE ’
RELAY
Opening
Apertura
Closing
Chiusura
1 2
TGC
4
5
1
6
2
IV
A8 A9
II
A1 A2 A3
2
1
F1 2 F11
V
10
9
F9
I
F8
CONNECTION
SECTION
(heating
circuit 2)
COLLEGAMENTO
SEZIONE
CC
(circuito
riscaldamento
2)
B
C
Circuito di
riscaldamento 1
Heating circuit 1
C
Circuito di
riscaldament o 2
Heating circuit 2
BLUE
BLU
Pompa
Recirculation
ricircolo
pump
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
Storage
Sonda
bollitore
tank
probe
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
Circ.
Sonda
mandat a
flow
circ. RHeat.1
isc. 1
probe
Circ.
Sonda
flow
mandat a
probe
circ.Heat.2
R isc. 2
Pump Heat.
Pompa
Circ. R1 isc. 1
circ.
Pump
Pompa
Heat.
Circ.2
BLUE
BLU
M2
GENERAL
ELECTRICAL
QUADRO
CONTROL
ELETTRICO
PANEL
GENERALE
circ. R isc. 2
Heat.
Miscelat rice
Mixer2
Heat.
Miscelat
rice
Mixer1
Risc.
1
Risc. 2
N
Aper
tu ra
Opening
Ch
iusu ra
Closing
23 0 V
L1
7
8
1 2
TGC
4
5
6
II
A1 A2 A3 A4 A5
38
Pompa
Storage
bollitore
tank
pump
Rec. F
Ric.
5
F5
4
I
Instructions for the installer
CONNECTION
SECTION
D (domestic
COLLEGAMENTO
SEZIONE
D (circuitocircuit)
sanitario)
B
C
Circuitocircuit
di
Heating
1
riscaldamento 1
D
Circuitocircuit
di 2
Heating
riscaldamento 2
BLU
BLUE
Storage
Sond a
tank
bollitore
probe
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
Rec.
Ric. F
Po mpa
Recirculation
ricircolo
Pump
BLUE
BLU
BLUE
BLU
C
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
Sonda
Circ.
mandata
flow
circ. Risc.
probe
Heat.11
Flow
Sonda
probe
mandata
heat.
circ.circ.
Risc. 22
Pump
Po mpaHeat.
circ. Risc. 1
Circ.1
Pump
Po mpaHeat.
Circ.2
circ. Risc. 2
Heat.
Miscelatr ice
Mixer1
Risc. 1
Heat.
Miscelatr
ice
Mixer2
Risc.
2
BLUE
BLU
M2
Storage
Po mpa
tank
bollitore
pump
GENERAL
ELECTRICAL
QUADRO
CONTROL
ELETTRICO
PANEL
GENERALE
N
230 V
L1
1 2
TGC
4 II 5 6
A1 A2 A3
8
7
F8
6
F6
I
CONNECTIONSEZIONE
SECTIONE E
(solar panels)
COLLEGAMENTO
(pannelli
solari)
E
C
Circuitocircuit
di
Heating
1
riscaldamento 1
F
Circuitocircuit
di
Heating
2
Pt1000
Sonda
solar
solare
probe
Pt1000
riscaldamento 2
Storage
Sonda
tank
bollitore
probe
BLUE
BLU
Flow
Sonda
probe
mandat a
circ.
Heat.
Risc.1 1
Circ.
Flow
Sonda
mandat a
probe
circ.
Heat.
Risc. 22
Circ.
Pump
Pompa
Heat.
circ.
Risc.1 1
Circ.
Pump
Pompa
Heat.
circ.
Circ. 22
Risc.
3-way
3 vi e
Heat.
circ.
Circ.
Risc.1 1
3-way
3 vi e
Heat.
circ.
Circ.
Risc. 22
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLUE
BLU
Sonda
Storage
bollitore
tank
probe
Pompa
Solar
circuito
circuit
solare
pump
BLUE
BLU
BLUE
BLU
BLUE
BLU
GENERAL
QUADRO
ELECTRICAL
ELETTRICO
CONTROL
GENERALE
PANEL
BLUE
BLU
BLUE
BLU
Storage
Pompa
tank
bollitore
pump
BLUE
BLU
BLUE
BLU
BLUE
BLU
BLU
BLUE
M2
Separatore
Hydraulic
idraulico
separator
N
23 0 V
L1
3
F1 7
2 III 1
2
F1 5
1
2
1
F1 4 F1 3 F1 2 F11
V
VIII
10
9
F9
I
Connections to solar systems require changing a
number of setting parameters see Table:
TGC
3
4
5
IV
A10 A11
Expert field →Level SOLAR / MF → MF 4 FUNCTION = "23"
39
Instructions for the installer
2 ARES Tec connected in a set, managed by an external TGC cascade
regulator.
BUS ID HS = 02
GENERAL
ELECTRICAL
CONTROL
PANEL
Thermostat
Min pressure switch
Max pressure switch
Gas
electrovalve
INAIL SECTION
POS. I
Pos. 2
Pos. 0
RELAY
Boiler supp.
BUS ID HS = 02
Terminal
board on the
boiler panel
Flow switch
RELAY
Interface board
IF-EXT.MIN 0-10V
TGC
GCI
GENERAL
ELECTRICAL
CONTROL PANEL
Thermostat
Min pressure switch
Max pressure switch
Gas
electrovalve
INAIL SECTION
POS. I
RELAY
Boiler supp.
BUS ID HS = 01
RELAY
Interface board
IF-EXT.MIN 0-10V
BUS ID HS = 01
Terminal
board on the
boiler panel
Pos. 2
Pos. 0
Flow switch
TGC
GCI
External
probe
BUS ID HS = _ _ _ _
KF boiler
probe
TGC
External Cascade
Manager
For any other system applications not included in the
instructions handbook, contact the Immergas aftersales service.
* Consult the TGC manual included.
40
Instructions for the installer
3.22 SYSTEM FILLING AND EMPTYING
To fill the system it is possible to set up a loading valve on the system's
return pipe.
Attention!
Do not mix the heating water with antifreeze or anticorrosion substances at incorrect concentrations!
This may damage the gaskets and cause noise to
develop during operation.
Immergas will not be held liable in case of damage
caused to people, animals or property due to failure
to observe the above.
It can also be filled through the drain valve installed on the boiler
return manifold.
The boiler is equipped with an emptying valve, positioned as indicated
in the figure of parag. 2.2. This valve must never be used to empty the
system, since all of the dirt contained in the system may accumulate
in the boiler, jeopardising smooth operation. Accordingly, the system
must be equipped with its own emptying valve, of a suitable size for
the flow rate of the system.
Once all of the connections for the system have been set up, it is possible
to fill the circuit.
EXAMPLE OF SYSTEM LOADING UNIT
LOADING
GRUPPO DI
CARICAMENTO
UNIT
3.23 BOILER FROST PROTECTION
If the flow temperature (measured at the global flow NTC) should fall
below 7°C the system pump starts operating.
If the temperature drops any further (under 3°C), all modules are
commissioned at the minimum power until the return temperature does
not reach 10°C. This device protects the boiler only. In order to protect
the system as well, it is necessary to add antifreeze liquid.
NB: The antifreeze liquid must be compatible with materials present
in the entire system and tolerable for aluminium alloys.
41
Instructions for the installer
3.24 CHECK THE ADJUSTMENT OF THE
PRESSURE TO THE BURNER
ATTENTION!
All of the instructions below are provided for the
exclusive use of authorised assistance personnel.
All boilers leave the factory calibrated and approved,
nevertheless, if the calibration conditions need to be
changed it is necessary to re-calibrate the gas valve.
ATTENTION!
Remove cap 2, attach the red cap 3 to the flue point 1.
Place the CO2 analysis probe 4 in the hole on the cap.
Once the measurement has been made, take the cap
out and use the relative cap 2 to close the flue exhaust
point back up.
ATTENTION!
1
To access the gas valves more easily, unhook electric
panel "A" by acting on spring "B" (right and left).
2
3
Turn electrical panel "A" slightly and lower tilting
panel "C"
4
For the amount of time required for the adjusting
operation, fix tilting panel "C" in place using 2 M4
screws + "D" washers (contained in the documentation
bag).
B
D
A
C
A
B
B
42
Instructions for the installer
Follow this procedure to adjust the other modules
as well.
A) Adjustment at maximum power.
-Unscrew the closing cap for flue exhaust analysis point.
-Place the analyser probe inside the flue analysis point.
-Make burner 1 operate at max power, following the procedure
illustrated below in "chimney sweep function " (100 % CASC
MANUAL).
If the measured flow rate is too low, make sure the supply and draining
systems (the supply and draining pipes) are not obstructed.
If they are not obstructed, make sure the burner and/or exchanger
are not dirty.
-Make sure that the CO2 level falls within the values indicated in the
"Nozzle pressure" table.
C) Completing basic calibration.
-Check CO2 values at the minimum and maximum flow rate.
- Possibly correct the value by turning adjusting screw "A" CLOCKWISE
to decrease it and COUNTER-CLOCKWISE to increase it.
-Touch up if necessary.
B) Adjustment at minimum power.
-Make burner 1 operate at min power, following the procedure
illustrated below in "chimney sweep function " (10 % CASC
MANUAL).
For smooth operation, calibrate the CO2 values taking
care to observe the values in the table.
-Close the cap for the flue inspection point back up.
-Make sure that the CO2 level falls within the values indicated in the
"Nozzle pressure" table.
- Possibly correct the value by turning adjusting screw "B" CLOCKWISE
to increase it and COUNTER-CLOCKWISE to decrease it.
NOTE: do not force the adjusting screw limit switch
limits.
ADJUSTING SCREW
MAXIMUM POWER
ADJUSTING SCREW
MINIMUM POWER
43
ERRATA CORRIGE
Instructions for the installer
When replacing the gas valve or
having difficulty with ignition:
Screw general adjusting screw "A" on clockwise until
it stops, then unscrew by 9 revolutions (methane).
Check boiler ignition. If it does not start up unscrew
screw "A" by one more revolution, then try to start it
up again. If the boiler does not start up again, follow
the operations described above until the boiler does
start up again.
At this point adjust the burner as previously
illustrated.
NOZZLES - PRESSURES.
Frequently check the CO2 levels, especially at low flow rates.
ARES 440 - 900
Tec
Type of
Gas
Supply
pressure
(mbar)
Ø
Nozzles
(mm)
Diaphragm
Min.
Max.
Min.
Max.
Power at
ignition IG
(%)
Nat. gas
(G20)
20
9
-
1700
5540
9,1
9,1
50
Nat. gas
(G25)
25
9
-
1700
5540
9,1
9,1
50
Propane
(G31)
37
9
-
1700
5290
10,2
10,4
50
44
Fan speed (rpm)
CO2 levels (%)
Instructions for the installer
Chimney sweep function.
Prima Prima
di aprire
lo sportello
di aprire
lo sportello
opening
the door
girare girare
inBefore
senso
orario
fino
in senso
orario
fino turn
clockwise
to simbol
theo
a portarsi
sul simbol
a portarsi
sul
o symbol
Open
thelodoor
Turn in
Aprire
lo sportellin
oon the
Aprire
sportellin
o Girare inGirare
senso counter
senso
sul display
compar
e
suldisplay
display
compar
e antiorario
screen
clockwise
antiorario
INSTALLAZ
SETUP
INSTALLAZ
GirareGirare
inTurn in
sensocounter
senso
antiorario
clockwise
antiorario
Trascorsi
2 sec.
Trascorsi
2 sec.
After
2 sec.
on the
Sul display
è screen
Sul display
è
display
visualizzato
visualizzato
ASSIST
ASSIST
SERVICE
DATE/TIME
DATA/ORA
DATA/ORA
GENERALE
GENERALE
GENERAL
Premere
Premere
il pulsante
Press
theil pulsante
button to
per passare
al
per passare
al to Level
continue
il Livello
il Livello
Appears
CompareCompare
RELAY
TEST
RELE
TESTTEST
RELE
Turnin
Girare in Girare
senso
senso clockwise
orario
orario
SONDA
SENSOR
TEST
TESTTEST
SONDA
Turn
Girare in
clockwise
Girare in
senso senso
orario orario
Turnin
Girare in Girare
senso
SW
NO
XXXX
SW
NO
XXXX
senso clockwise
VER SWVER
NO
XXXX
orario orario
TA MANU
CASC
MANUAL
CASCACASCA
TA MANU
Premere
PremerePress to
perpassareto
continue
perpassare
al Livello
next
Level
al Livello
successivo
successivo
CALDAIA
01 - 00%
CALDAIA HS
01 -01-00%
00%
All of the boiler modules
are on and operating at
MINIMUM power
NUMERO
CODICE
CODE-NO
NUMERO CODICE
xtimes
5 volte
x55
volte
to
enter
the access
per
inserire
il codice
per inserire
il codice
d’accesso
(4 volte 0)
code
('0'
4 times)
d’accesso (4 volte 0)
000 0
000 0
BRING THE PERCENTAGE
POR TARE IL VALORE
VALUE
10% AL 10 %.
POR TARE
IL TO
VALORE
PERCENTUALE
PERCENTUAL E AL 10 %.
Compare
Appears
Compare
ATTENTION!
The functions stays on for 30 min., after which amount
of time the set parameters are restored.
CALDAIA
01 - 00%
HS 01-00%
CALDAIA 01 - 00%
CALDAIA
01 - 10%
HS 01-10%
CALDAIA 01 - 10%
CALDAIA 03 - 00%
CALDAIA
01 - 100%
HS 01-100%
CALDAIA 01 - 100%
Premere
Confermare
Confirm
Press to
BRING
THEIL VALOREPremere
POR TARE
Equivale
aQ
min. Confermare
per
entare
Equal
to Q
min
PO RTARE
IL VALORE
enter
to
PERCENTAGE
VALUEper entare
PERCENTUALE
a regolare Equivale a Q min.
PERCENTUAL
adjust
AL10%
10 %. E
TO
a regolare
AL 10 %.
BRING
THEILPERCENTAGE
POR TARE
VALORE
100% AL 100 %.
POR VALUE
TARE
ILTO
VALORE
PERCENTUALE
CALDAIA 02 - 00%
PERCENTUALE AL 100 %.
Equal
to Q
max
Equivale
aQ
max
Equivale a Q max
CALDAIA 04 - 00%
All of the boiler modules
are on and op erat ing at
MAXIMUM power
CALDAIA 05 - 00%
CALDAIA 06 - 00%
1To adjust every single module it is necessary to bring switch "C" (see
fig. 1) to position I.
CALDAIA 07 - 00%
CALDAIA 08 - 00%
Accordingly, all of the modules will switch off except for the first one.
C
2Change entry HS 01 to a value of 100% to calibrate the maximum and
then to 10% to calibrate the minimum.
3To move onto the next modules repeat sequence 0 - 1 of the "C" switch,
see fig. 2.
Once the last module has been calibrated:
GCI
4Bring key C to position 0.
Fig. 1
5Bring entry "HS 01" to 00% to turn off the last module that has stayed
on.
6Bring entry "HS 01" to 100% for the definitive combustion analysis,
to be noted down in the control unit handbook.
Fig. 2
45
Confermare
Confirm
Confermare
Instructions for the installer
3.25 EMERGENCY AND SAFETY
OPERATIONS
I H
1
G2 F
E
D
L C B
A
GCI
GCI
The GCI board allows you to avoid stopping the system if the main
management system of the control unit is out of order.
A YELLOW LED = flashing (communication between SDE and GCI) ok
GREEN LED = on (Pump On)
RED LED = on (Error Code detected)
B This allows you to re-arm the burners anytime they do not respond
to controls
C In position I the control unit operates on request at "SETPOINT
COSTANTE" ("CONSTANT SETPOINT"): 70°C. maximum power
50%
D Water pressure gauge (optional)
E TGC Control panel
F TLG General Limit Thermostat trigger light
GFuses:
1 = 6.3 A
2 = 10 A
H Main Switch
I When TLG General Limit Thermostat comes on it cuts off power
to the boiler and light F comes on. To re-arm it, take off the cap and
press.
L Parallel series selector:
0 = Emergency on or control managed by PLC or BMS
Condensate level sensor position (condensate collection pan
at the front of the boiler).
I = Do not use
II = Parallel (service position for extensive diagnosis).
NOTE: the devices are positioned under the casing
next to the control unit.
NOTE: the emergency function only switches the
burners on in the boiler to 50% and 70°C in flow. All
system loads, including the manifold pump, must be
controlled manually.
46
Instructions for the installer
3.26 FIRST IGNITION
Switching the boiler on and off.
To turn the boiler on and off read the handbook for the TGC regulator.
Preliminary checks.
Information for the system manager
First ignition must be carried out by professionally
qualified staff. Immergas will not be held liable in case
of damage caused to people, animals or property due
to failure to observe the above.
The individual in charge of the system must be instructed in the use
and operation of the heating system, in particular:
-Supply the system manager with the "THE SYSTEM MANAGER'S
INSTRUCTIONS FOR USE", as well as all other documents attached
the appliance contained in the envelope in the packaging. The system
manager must keep this documentation safe so that it is available
for future consultation.
Danger!
Prior to commissioning the appliance fill the trap
through the filler hole and make sure the condensate
is draining correctly.
If the appliance is used with an empty condensate
drain trap the danger of poisoning subsists following
a flue gas leak.
-Inform the system manager of the importance of aeration vents and
the flue exhaust system, highlighting how essential they are and how
it is strictly forbidden to change them.
-Inform the system manager of the requirement to check the system's
water pressure, as well as operations to restore it.
Prior to commissioning the boiler it is advisable to make sure that:
-installation fulfils the standard specifications and requirements in
force for both the gas and electrical part;
-Inform the system manager on how to correctly regulate the
temperature, control units/thermostats and radiators in order to save
energy.
-the supply of combustion air and the evacuation of flue exhaust are
carried out correctly in accordance with standard specifications and
requirements in force;
-Remember that it is compulsory to carry out regular maintenance on
the system and measure combustion output (as per national law).
- If the appliance is sold or transferred to another owner or if the owner
moves, leaving the appliance behind, always ensure the handbook
accompanies the appliance so that it may be consulted by the new
owner and/or installer.
- the fuel supply system is sized for the boiler's flow rate and is equipped
with all of the safety and control devices required by regulations in
force;
-the power supply for the boiler is 230V - 50Hz;
-the system has been filled with water;
-any cut-off dampers on the system are open;
-the required gas corresponds to the one used for boiler calibration:
otherwise have the boiler converted for use with the available gas (see
section: "ADAPTATION FOR USE WITH OTHER GASES"); this
operation must be carried out by qualified technical staff in accordance
with regulations in force;
-the gas supply valve is open;
-there are no gas leaks;
-the external main switch is engaged;
-the system safety valve on the boiler responds to operation and is
connected to the sewer drain;
-the condensate drain trap is filled with water;
-there are no water leaks;
-the conditions for aeration and minimum distances to carry out any
maintenance operations are fulfilled.
47
4
Inspections and maintenance
INSPECTIONS AND
MAINTENANCE
Instructions for inspection and maintenance.
Only original Immergas spare parts must be used
to ensure a long life for all of the functions of your
appliance, and to avoid changing the conditions of
the approved standard product.
Inspections and maintenance carried out to state
of the art and at regular intervals, as well as the
exclusive use of original spare parts, are of primary
importance for smooth operation and to guarantee
long boiler life.
Annual maintenance of the appliance is compulsory,
in accordance with Legislation in force.
Before proceeding with maintenance operations, always carry out the
procedures described below:
-Turn off the mains switch.
- Separate the appliance from the electrical network using a separation
device, with a contact opening of at least 3 mm (for ex. safety devices
or power switches), and make sure it cannot be accidentally reconnected.
Failure to carry out Inspections and Maintenance can
cause material and personal damage.
-Shut the gas cut-off valve upstream of the boiler.
- If necessary, and based on the work that needs to be carried out, close
any cut-off valves on the heating flow and return.
For this reason we recommend stipulating an inspection or maintenance
contract.
Inspection is required to determine the effective state of an appliance
and compare it with the optimal state. This is carried out through
measuring, checking, observing.
Once the maintenance work has been finished, always carry out the
operations listed below:
-If necessary, open the heating flow and return.
Maintenance is required to eliminate any deviation of the effective state
from the optimal state. This is usually carried out through cleaning,
setting and possibly replacing single parts that are subject to wear.
-Open the gas cut-off valve.
-Relieve and, if necessary, restore the pressure in the heating system.
-Re-connect the appliance to the electrical network and engage the
mains switch.
These maintenance intervals are set forth by a specialist based on the
certified state of the appliance at the time of inspection.
-Make sure the appliance is water-tight, on the gas side and the water
side.
Table of resistance values based on the heating probe (SR) and the
heating return probe (SRR) temperature.
T°C
0
1
2
3
4
5
6
7
8
9
0
32755
31137
29607
28161
26795
25502
24278
23121
22025
20987
10
20003
19072
18189
17351
16557
15803
15088
14410
13765
13153
20
12571
12019
11493
10994
10519
10067
9636
9227
8837
8466
30
8112
7775
7454
7147
6855
6577
6311
6057
5815
5584
40
5363
5152
4951
4758
4574
4398
4230
4069
3915
3768
50
3627
3491
3362
3238
3119
3006
2897
2792
2692
2596
60
2504
2415
2330
2249
2171
2096
2023
1954
1888
1824
70
1762
1703
1646
1592
1539
1488
1440
1393
1348
1304
80
1263
1222
1183
1146
1110
1075
1042
1010
979
949
90
920
892
865
839
814
790
766
744
722
701
Relation between the temperature (°C) and nom. resistance (Ohm) of
the heating probe SR and the heating return probe SRR.
Example: At 25°C, the nominal resistance is 10067 Ohm
At 90°C, the nominal resistance is 920 Ohm
48
Inspections and maintenance
We urge you to have qualified technical staff fulfil
requirements regarding periodic maintenance
checks.
Since dust is extracted from the inside, the resistance on the flue side,
through the boiler, will increase, leading to a decrease in the heat load
(and, consequentially, in the power).
Prior to cleaning, check the heat load (see parag. 3.24) and the
percentage of CO2 (see parag. 3.24). If the measured load (with a correct
CO2 level) is within 5% of the value indicated in parag. 3.24, the boiler
does not need to be cleaned.
The operation must therefore be limited to cleaning the trap.
ATTENTION!
A drop in the heat load can be caused by an obstruction
in the exhaust channel or air intake pipe. First of all
make sure that this is not the cause.
-Act on the two rear closing hinges to take out the cover.
If there is a drop in the heat load greater than 5%, check
how clean the burner condensate-collection pan is. Also
clean the trap.
First phase – Disassembly.
- Shut off the electrical and gas supplies making sure the valve is firmly
shut.
-Take out: all of the casings.
-Take out the rear, front and side casing clamping screws.
-Turn the required screw to lift the cover.
-Take out the two cover clamping screws.
49
Inspections and maintenance
-Take out the red silicone pipes and then the fan chamber.
Element screws.
A
--Unhook the fan chamber clamping spring (right/left side).
-Take out screws "A" from each element (with 13mm socket and flat
key).
50
Inspections and maintenance
-Lift the burner block (front part).
-Lift the rear burner block slightly and take out 2 pins with a 5 mm
hex key, until you reach holes "C" (left and right side).
-Take out the gas fittings from the gas manifold with a 36 mm flat key.
51
Inspections and maintenance
Third phase - Reassembly.
-Once the body and/or burners have been cleaned, put the burners
back in their places.
Second phase – Cleaning.
-Take out the gaskets and burners.
-Dry clean the burners using compressed air and operating from the
"flame side".
-Put the new graphite gaskets in place.
-Visually check the state of the welding on the angulars and burner
mesh.
Proceed in the reverse order for reassembly, being
careful to tighten the screws that clamp the mixer
unit/fans to the body, at a torque of 13 Nm.
The burner gaskets must be replaced every time
cleaning operations are carried out.
ATTENTION
IT IS NECESSARY TO CHANGE THE SEALING
GASKETS ON EACH BURNER AT EVERY
MAINTENANCE OPERATION.
-Wash the combustion chamber with water being careful not to get
the electrical cables wet.
-During this operation is necessary to make sure that the condensate
exhaust pipe is always unobstructed so that the wash water does not
leak out from the inspection opening.
-Prior to ignition, make sure the condensate drain trap is full of water.
-Before opening the gas supply valve make sure that the previously
loosened gas fitting is firmly tightened. In order to do so open the
valve and check the seal using soapy water.
- As a burner is being ignited, immediately check the seal between each
single gas valve and relative premixing chamber.
-Perform a combustion analysis and check the parameters.
-Make sure that all of the previously opened gas pressure points are
closed.
-Blow the combustion chamber with compressed air to remove any
dirt that is still attached to the studs.
-When the elements have been washed make sure that the condensate
drain trap is unobstructed: clean if necessary.
-Inspect the exhaust evacuation pipe and the flue.
Compressed
air
Aria compressa
52
Cod. 1.039293ENG - rev. ST.002264/000 - 10/15 - Inglese per IRLANDA (IE)
This instruction booklet is made of ecological paper
Follow us
Immergas Italia
immergas.com
Immergas S.p.A.
42041 Brescello (RE) - Italy
Tel. 0522.689011
Fax 0522.680617
Certified company ISO 9001