ICI Caldaie MONOLITE GT Series, Technical Manual

Page 1: ...TECHNICAL MANUAL MONOLITE GT CONDENSING BOILER WITH PREMIX BURNER MONOLITE JB CONDENSING BOILER WITHOUT BURNER LOW NOx STEEL CONDENSING BOILERS ...

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Page 3: ...URE MOD 45 GT 125 GT 13 4 8 INVERTING THE DOOR APERTURE mod 160 GT JB 350 GT 670 JB 13 4 9 PRESSURISED BOILER CONNECTION 14 4 10 WIRING DIAGRAM 14 5 FITTING THE BOILER CASING 15 5 1 BOILER BODY INSULATION Fig 4 5 6 15 5 2 BOILER CASING MOD 45 GT 125 GT 30 JB 125 JB Fig 4 15 5 3 BOILER CASING mod 160 GT JB 270 GT JB Fig 5 16 5 4 BOILER COVERING mod 350 GT JB 670 JB Fig 6 17 6 STARTING 18 6 1 PRELIM...

Page 4: ...r without inversion limits as much as possible the formation of Nitrogen Oxides NOx that form when the flame remains at high temperature in the combustion chamber for long periods The MONOLITE series boilers place no limit on the return water temperature and reach the highest per formance when used with floor panel heating systems in which the return temperature is lower than 58C At higher tempera...

Page 5: ...sitioned on the control panel should be checked for efficiency The guarantee shall be valid only upon compliance with the instruction given in this manual Our boilers have been built and tested in observance of EEC requirements and consequently CE marked EEC direc tives are as follows Directive on Gas 90 396 EEC Directive on Output 92 42 EEC Directive on Electromagnetic Compatibility 89 336 EEC Di...

Page 6: ...5 3 89 3 85 78 18 MONOLITE 160 GT 61 53 000 68 58 650 62 53 807 98 5 109 6 62 4 91 4 86 98 65 MONOLITE 210 GT 81 70 000 90 77 462 82 71 066 98 5 109 8 74 6 49 6 42 130 29 MONOLITE 270 GT 104 90 000 116 99 594 106 91 371 98 5 109 11 24 8 34 8 25 167 52 MONOLITE 350 GT 136 117 000 151 129 472 138 118 782 98 5 109 14 62 10 85 10 73 217 77 Minimum output Minimum input Efficiency at 30 N C V Medium Tem...

Page 7: ...N9 N10 mm mm mm mm mm mm mm mm mm mm mm DN in DN in DN in DN in DN in DN inDN inDN in DN in DN in MONOLITE 45 GT 1267 1210 670 595 350 322 715 150 150 50 50 1 1 1 2 3 4 1 2 50 3 4 MONOLITE 70 GT 1267 1210 670 595 350 322 715 150 150 50 50 1 1 1 2 3 4 1 2 50 3 4 MONOLITE 95 GT 1607 1550 1010 595 200 812 715 150 180 50 50 1 1 1 2 3 4 1 2 50 3 4 MONOLITE 125 GT 1607 1550 1010 595 200 812 715 150 180 ...

Page 8: ...2 4 91 4 86 98 65 MONOLITE 210 JB 81 70 000 90 77 462 82 71 066 98 5 109 0 8 74 6 49 6 42 130 29 MONOLITE 270 JB 104 90 000 116 99 594 106 91 371 98 5 109 0 11 24 8 34 8 25 167 52 MONOLITE 350 JB 136 117 000 151 129 472 138 118 782 98 5 109 0 14 62 10 85 10 73 217 77 MONOLITE 440 JB 170 147 000 189 162 670 173 149 239 98 5 109 0 18 36 13 63 13 48 273 61 MONOLITE 550 JB 212 183 000 235 202 508 216 ...

Page 9: ...70 JB KEY N1 Boiler flow N2 Medium temperature return N3 Fitting for Instruments N4 System filling drainage N5 Safety valve s fitting N6 Bulbs wells N7 Boiler condensation drain N8 Inspection well N9 Low temperature return T Inspection plugs ...

Page 10: ...P8 Øb Øc N1 N2 N3 N4 N5 N6 N7 N8 N9 mm mm mm mm mm mm mm mm mm mm mm DN in DN in DN in DN in DN in DN inDN inDN in DN in MONOLITE 30 JB 990 881 670 318 350 322 200 250 150 150 50 50 1 1 1 2 3 4 1 2 50 MONOLITE 45 JB 990 881 670 318 350 322 200 250 150 150 50 50 1 1 1 2 3 4 1 2 50 MONOLITE 75 JB 990 881 670 318 350 322 200 250 150 150 50 50 1 1 1 2 3 4 1 2 50 MONOLITE 95 JB 1330 1221 1010 318 200 8...

Page 11: ...gas temperatures produced by MONOLITE boilers are considerably lower than in the case of non condensing boilers and have therefore very high relative humidity For these reasons the chim ney must be completely watertight must withstand corrosion attack by acid condensate and must be adequately heat insulated to guarantee sufficient draught 4 2 1 Condensate drain Connect condensate drain If the boil...

Page 12: ...MONOLITE 10 4 3 1 SEALED HOT WATER HEATING SYSTEM WITH EXPANSION VESSEL Mod 45 125 Mod 160 270 ...

Page 13: ...gulation thermostat n 1 19 Regulation thermostat n 2 20 Manual reset safety thermostat 21 Shock absorbing pipe 22 Safety valve n 1 the 2 nd has a heating capacity above 580 kW 23 Fuel shut off valve 24 Manual shut off valve 25 Manual shut off valve for gas 26 Expansion vessel 27 Level probe glow plug optional 28 System flow 29 Probe sleeves inside the boiler 30 Gas inlet 31 Low temperature return ...

Page 14: ...ol thermostats TR1 TR2 have an operating range from 0 to 90 and can be set by the user by means of the front dial Safety limit thermostats TS has a fixed setting of 100 0 6 C and can be manually reset For correct installation refer to the boiler casing assembly instructions 4 6 STARTING Open the gas tap check if there is any gas leakage Switch on the burner and heating pump on the control panel At...

Page 15: ...INVERTING THE DOOR APERTURE mod 160 GT JB 350 GT 670 JB If the door is to be opened to the opposite side act as follows 1 Switch the outside nut or bush of one hinge with the diametrically opposite closure bush then at the hinge side fasten the cone to the door with the inside nut 2 Repeat the operation for the other hinge 3 For any adjustment needed act on the specific hinge nuts ...

Page 16: ...nd regulations g check that all gas connections are perfectly gas tight h check that the boiler room ventilation openings are dimensioned to guarantee an air flow as foreseen by applicable regulations and in any case sufficient for perfect combustion i check that the gas pipes are not used as a ground earth for electrical devices If the boiler will not be used for some time close the fuel supply I...

Page 17: ...er control panel connection cables passing through the aperture for the wiring harness please refer to the control panel diagram and to the standard plugs connection kit Unwind the thermostat capillaries fit the control panel 3 to the side RH or LH fastening with the screw then insert the bulbs in the pocket Hook the upper rear panel 4 to the sides Fasten the support bracket 5 to the frame base L ...

Page 18: ...g harness please refer to the control panel diagram and to the standard plugs connection kit Unwind the thermostat capillaries fit the control panel to the side fastening with the screw then insert the bulbs in the pocket Fit the upper panels 4S and 4D Mount the panel 5 attach the support bracket 6 to the corner of the frame base position the panel 7D and then the panel 7S with fairlead attached t...

Page 19: ...he existing opening for the wiring harness please refer to the control panel diagram and to the standard plugs connection kit Unwind the thermostat capillaries attach the control panel 3 to the side with a screw then insert the bulbs into the shaft Mount the upper panels 4P 4D and 4S with screws and plug the holes with the caps Mount the panel 5 attach the support bracket 6 to the frame base posit...

Page 20: ...posed to the flame and reducing considerably the boiler life Furring concentrates where the boiler wall temperature is higher and the best defence against this phenomenon is a boiler design that eliminates high temperature spots Furring represents an insulation layer that decreases heat exchange penalising boiler efficiency This means that a large part of the combustion heat is not transferred to ...

Page 21: ...ler WARNING during long stoppages in winter and in order to avoid frost damage drain both the sanitary wa ter and the heating system water drainage of the latter can be avoided by adding antifreeze Boiler with water heater 7 4 PERIODICAL USER CHECKS Check periodically that there is no air in the heating system and if necessary open the blow off valve at the top of the boiler Periodically check the...

Page 22: ...uarted in via G Pascoli 38 37059 Campagnola di Zevio VR Italia DECLARE THAT BOILERS MONOLITE 45 GT 70 GT 95 GT 125 GT with burner MONOLITE 160 GT 210 GT 270 GT 350 GT body only MONOLITE JB comply with the CE certificate and with the following regulations or harmonised regula tions EN 60335 1 EN 303 1 pr EN 303 3 In accordance with the boards regulations Gas Directive 90 396 CEE Low Voltage Directi...

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Page 24: ...ascoli 38 Zevio fraz Campagnola VERONA ITALIA Tel 045 8738511 Fax 045 8731148 info icicaldaie com www icicaldaie com The data reported are indicative only and are not binding Our company reserves the right to introduce alterations at any time as it deems fit and proper for the development of the product ...