ICI Caldaie MONOLITE 120 GT, Installation, Use And Maintenance Manual

Page 1: ...MONOLITE 120 850 GT_EN Ed 02 10 2018 EN Low NOx steel condensing boilers MONOLITE 120 850 GT INSTALLATION USE AND MAINTENANCE MANUAL ...

Page 2: ...nections 11 Technical data 12 Control panel accessory 12 Burners Installation 13 Product receipt 14 Handling 14 Installation room 15 System cleaning 15 Hydraulic connections 15 Starting hydraulic circuit 17 Flue exhaust 17 Condensate drain 18 Door opening 19 Door opening inversion from the right to the left 20 Door adjustment 22 Insulating casing assembly 23 Burner assembly 24 Electrical connectio...

Page 3: ...R BOILER BOILER MODEL CODE CODE MODEL CODE CODE MONOLITE 120 GT 81037120 17010208 MONOLITE 420 GT 81037420 17010207 MONOLITE 140 GT 81037140 17010208 MONOLITE 555 GT 81037555 17010193 MONOLITE 180 GT 81037180 17010205 MONOLITE 700 GT 81037700 17010193 MONOLITE 250 GT 81037250 17010205 MONOLITE 780 GT 81037780 17010194 MONOLITE 320 GT 81037320 17010206 MONOLITE 850 GT 81037850 17010194 COMPLIANCE M...

Page 4: ...it carried out by an Authorised Company or by qualified personnel maintenance technician in compliance with the requirements of the local Standards in force Ordinary and extraordinary maintenance must be carried out by qualified personnel in order to promptly detect any damage to the boiler body under pressure and to the safety and control accessories PROHIBITIONS d IT IS FORBIDDEN Operate electri...

Page 5: ...that the heating plant room features vents compliant with the standards in force IDENTIFICATION Each MONOLITE GT Boiler can be identified by means of the technical data plate inside the envelope of the documents supplied with the Boiler which includes technical efficiency informations such as serial number or identification marking nominal thermal power in kW nominal thermal flow in kW types of fu...

Page 6: ...hange surface and facilitate the formation of condensate drops allowing an appropriate drip drainage Moreover the vertical position of the exchange surfaces facilitates condensate discharge ensuring an effective self cleaning function of plates welding performed with TIG procedure a method which does not require any material to be added and thus ensures that the main mechanical characteristics of ...

Page 7: ... Inspection plugs 5 Control panel accessory 6 Smokebox 7 Burner 8 Flame inspection window 9 Primary heat exchanger 10 Insulating casing 11 Flue gas drain fitting N1 Boiler flow fitting N2 Boiler return fitting at medium temperature N3 Instruments fitting N4 System intake drain fitting N5 Safety valve s fitting N6 Bulb holder pockets N7 Condensate drain fitting N8 Control pocket N9 Boiler return fi...

Page 8: ...sory 6 Smokebox 7 Burner 8 Flame inspection window 9 Primary heat exchanger 10 Insulating casing 11 Flue gas drain fitting N1 Boiler flow fitting N2 Boiler return fitting at medium temperature N3 Instruments fitting N4 System intake drain fitting N5 Safety valve s fitting N6 Bulb holder pockets N7 Condensate drain fitting N8 Control pocket N9 Boiler return fitting at low temperature N10 Gas fittin...

Page 9: ...IONS 120 140 180 models N7 N4 N1 N6 N8 N3 N9 N2 N10 P2 L2 L1 P1 H1 H H2 Øc H12 H6 H10 H9 H8 L P5 P4 P3 P Øb N2 N9 N4 N7 250 320 420 models N3 N1 N6 N8 N10 L2 L1 P2 P1 H2 H1 H5 H4 H L P5 P4 P3 L6 N7 N4 N9 N2 N2 N1 N9 N4 N7 Øc H12 H6 H10 H9 H8 Øb P ...

Page 10: ...90 690 690 800 800 800 920 920 920 920 L6 mm 150 150 150 200 200 200 200 P mm 1270 1587 1760 1765 2005 2300 2452 2452 2695 2695 P1 mm 851 1106 1106 1041 1281 1536 1560 1560 1810 1810 P2 mm 679 934 934 909 1149 1404 1436 1436 1686 1686 P3 mm 525 595 768 783 783 823 955 955 948 948 P4 mm 350 200 200 195 195 195 520 520 520 520 P5 mm 395 792 792 787 1027 1282 977 977 1227 1227 P7 mm 150 150 150 150 P...

Page 11: ... 83 210 97 271 25 376 73 482 22 632 90 836 34 1054 85 1175 40 1280 90 Maxfluegasflowrate kg h 175 52 204 73 263 28 365 65 468 01 614 33 811 75 1023 78 1140 89 1243 26 Minfluegasflowrate kg h 35 10 40 96 52 66 73 13 93 59 122 86 162 34 204 75 228 18 248 65 Max fluidflowrate kg h 10320 12040 15480 21500 27520 36120 47730 60200 67080 73100 Minfluidflowrate kg h 4128 4816 6192 8600 11008 14448 19092 2...

Page 12: ...rol panel QETERM01CE eterm system control panel QETERM02 eterm Easy manager panel QCTETERM BURNERS The burners are supplied together with MONOLITE GT Boilers and are CE marked in accordance with European Directives European Regulation on Gas Equipment GAR 2016 426 EU Low Voltage Directive 2014 35 EU Electromagnetic Compatibility Directive 2014 30 EU Efficiency Directive 92 42 EEC Models up to 400k...

Page 13: ...IT 3 SLATS 4 CONTROL PANEL 5 BURNER 6 flow ELBOW 7 and thermoceramic material for burner head 7 5 3 2 4 6 1 m IMPORTANT Upon receipt of MONOLITE GT Boiler make sure that the supply is intact and undamaged and promptly contact ICI CALDAIE S p A if it does not correspond to the order m IMPORTANT The instruction manual is an integral part of the appliance and it MUST be carefully read before installi...

Page 14: ...ing the safety devices maintenance repairing any breakage opening the door of the installed burner considering its opening direction towards the right or the left 2 m 2 m 2m 2m a ATTENTION Consider the spaces necessary to access the adjustment and safety devices and to perform maintenance in compliance with the legislation in force in the place of installation If the burner is fed with gas of spec...

Page 15: ...the supply line does not exceed the operating pressure indicated on the plate del Gruppo Termico Make sure that the drains of the safety valves del Gruppo Termico and of the heater if any are connected to a drain funnel so that the valves do not flood the room in case of intervention Make sure that the water and heating system pipes are not used as earthing point of the electrical system Once the ...

Page 16: ... gauge 7 Condensate neutraliser see ICI catalogue 8 Pressure transducer 9 Pressure gauge tap 10 Shock absorbing pipe 11 Safety valve no 1 12 Manual shut off valve 13 Expansion vessel 14 Level probe glow plug optional 15 System flow 16 Fuel shut off valve probe 17 Water inlet for system refill or top up 18 Medium temperature return 19 Boiler drain 20 Acid condensate outlet 21 Neutralised condensate...

Page 17: ...rs non insulated drain pipes can lead to a potential risk and the tightness of the joints must be ensured with materials resistant to the temperatures of the drain flue gases we recommend at least 250 C check that the chimney has an adequate draught and that is free from bottlenecks and waste CONDENSATE DRAIN MONOLITE GT Boilers are equipped with a condensate drain pipe derived from the appliance ...

Page 18: ... 780 850 models 250 320 420 555 700 780 models The door is factory set with a standard opening from the left LH to the right RH m IMPORTANT The hinges of the opening side must have the nut 1 loosened and the conical washer 2 positioned towards the base of the adjustment tie rod a DANGER IT IS DANGEROUS TO UNSCREW the ring nuts 3 of the door rotation hinges Unscrewing them could cause the detachmen...

Page 19: ...o ring nuts well tightened on the side opposite to the opening one 6 4 5 DOOR OPENING INVERSION FROM THE RIGHT TO THE LEFT To invert the door opening of 120 140 and 180 models proceed as follows leave the 4 nuts 1 which lock the door tightened slide the pin 2 out move the arm 3 to allow the access to the two screws fastening the support bracket 4 and then remove the two screws fasten the support b...

Page 20: ...ten the nuts 3 Right hinge loosen the nuts 6 and disengage the conical washers 7 from the door mechanical tubes 8 DOOR ADJUSTMENT a DANGER Incorrect door adjustment with consequent damage to people and property voids the warranty conditions The door of 120 140 and 180 model requires if necessary only the adjustment of its height To make the adjustment remove the nuts 1 fastening the door unscrew t...

Page 21: ... and check that the distance between the appliance front plate and the door wall is the same on both sides If not with the door ajar loosen the locking nuts 4 of the hinge units work on ring nuts 5 to adjust the distance of the door from the appliance front plate tighten the nuts 4 locking the conical washers in the pipes 6 a DANGER When cross changing ferrules always make sure that the other two ...

Page 22: ...6 using the supplied screws and nuts insert the slats 2 on the lateral and front side m IMPORTANT The panel supporting slat 5 must be the seventh one on the side featuring the control panel The cross beam 9 must be fastened to the two square tubes to support the upper slats 8 7 5 6 6 4 9 2 2 2 insert the control panel probes in the pockets 10 located in the Boiler and properly route the electrical...

Page 23: ...d and the door The strip must be wrapped around the combustion head for at least one entire circumference without having to fill the whole thickness of the gap 1 4 5 3 2 6 1 Burner 2 Flange 3 Gasket 4 Door 5 Thermoceramic material 6 Combustion head m IMPORTANT To assemble the burner of the 420 Boiler model proceed as follows insert the gasket and the flange 3 of the burner 1 in the four stud bolts...

Page 24: ... Conformity of the system built m IMPORTANT It is mandatory to use an omnipolar thermal magnetic line circuit breaker complying with the Standards CEI EN contact opening of at least 3 mm observe the connection L Phase N Neutral Keep the earth conductor longer than the power supply conductors by approximately 2 cm connect the earth cable to an effective earthing system ICI Caldaie S p A is not liab...

Page 25: ...he flame and thus to a significant reduction of the service life del Gruppo Termico Limestone gathers in the points where the wall temperature is higher and the best defence against it at the construction level is to eliminate the superheating areas Scale build ups form an insulating layer which decreases the heat exchange of the boiler penalising its efficiency This means that a significant part ...

Page 26: ...parators once the air has been expelled bring the pressure back to the preset value and close the manual and or automatic supply tap After the initial filling it is necessary to prevent oxygen and untreated water from entering the system The entry of oxygen causes corrosion while untreated water causes the formation of limestone Both conditions must be avoided NOTE The system venting will be compl...

Page 27: ...te on the ambient thermostat or chronothermostat and activate a heat request The Boiler will perform the ignition phase and will operate until the adjusted temperatures will be reached m IMPORTANT In case of LOCK OUT STOP of the burner refer to its technical manual CHECKS AFTER COMMISSIONING Once the start up has been performed check that the appliance stops and then restarts by modifying the Boil...

Page 28: ...iler is not used for a long period of time it is recommended to position the central panel switches and the control panel switch to OFF close the fuel and water interception valves of the hydraulic system m IMPORTANT If the external temperature is below ZERO empty the thermal system use anti freeze liquid propylene glycol until a maximum percentage of 3 DECOMMISSIONING OF OLD APPLIANCES Decommissi...

Page 29: ...th water mixed with denatured alcohol or specific non abrasive detergents Dry the surfaces thoroughly after cleaning Boiler internal cleaning To perform the internal cleaning disconnect from the burner anything which may hinder the door opening e g gas train loosen the 4 nuts or the two ring nuts with the lever 1 and open the door 2 1 2 3 clean the combustion chamber surfaces with a suitable tool ...

Page 30: ...k the tightness of boiler flue gas pipe and chimney Check the door tightness Gas smell Gas supply circuit Check sealing possible obstructions combustion quality Frequent safety valve triggering Excessive pressure in the system circuit Check load pressure Check pressure regulator Check calibration Malfunction of the system expansion vessel Check the efficiency ENVIRONMENTAL PROTECTION AND DISPOSAL ...

Page 31: ... a web page on which to register the data of your appliance and system by completing the indicated spaces Once registered authenticate your e mail address by clicking on the link that will be sent by e mail to the provided inbox Then an additional e mail will be received with the credentials to access all the services that ICI CALDAIE S p A has developed specifically for those who will register il...

Page 32: ... I VR 02245640236 DECLARATION OF CONFORMITY WITH THE EUROPEAN COMMUNITY REGULATIONS I undersigned Emanuela Lucchini Managing Director of ICI CALDAIE S p A headquarted in via G Pascoli 38 37059 Campagnola di Zevio VR Italia DECLARE THAT BOILERS MONOLITE GT comply with the CE certificate and in accordance with the boards regulations S Maria di Zevio li 07 02 2018 European Regulation on Gas Equipment...

Page 33: ...Notes 33 6 Notes ...

Page 34: ...Notes 34 ...

Page 35: ...Notes 35 ...

Page 36: ...ICI CALDAIE SpA 37059 Fraz Campagnola di Zevio Verona Italy Via G Pascoli 38 Phone 39 0458738511 Fax 39 0458731148 info icicaldaie com www icicaldaie com ...