ICI Caldaie CODEX GT Series User manual

CODEX 1000-1600 GT_EN Ed. 00 - 05/2019
EN
Low NOx steel condensing boilers
CODEX 10001600 GT
INSTALLATION, USE AND MAINTENANCE MANUAL
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

2
INDEX
SYMBOLS USED IN THE MANUAL
aDANGER
To indicate actions that, if not performed correctly, can result in injury of generic origin or may generate malfunction
or damage to the appliance; therefore require particular caution and adequate preparation.
dIT IS FORBIDDEN
To indicate operations that SHOULD NOT be performed.
mIMPORTANT
To indicate particularly useful information and important.
The illustrations and data presented are not binding. The company reserves the right to make without prior notice any changes it
deems appropriate for continuous improvement and constant updating.
General information
3 Introduction
3 Range
3 Compliance
4 Warnings
4 Prohibitions
5 Hazards
5 Identification
6 Appliance description
6 Structure
7 Dimensions and connections
9 Technical data
10 Control panel (accessory)
10 Burners
Installation
11 Product receipt
12 Handling
12 Installation room
13 System cleaning
13 Hydraulic connections
14 Starting hydraulic circuit
15 Flue exhaust
15 Condensate drain
16 Door opening
16 Door opening inversion (from the right to the left)
17 Door adjustment
18 Insulating casing assembly
19 Burner assembly
19 Electrical connections
20 Water treatment
20 Limestone build-ups
20 Limestone diagram
20 Corrosion on water side
21 System filling and emptying
Use
22 Preliminary checks
22 Commissioning
22 Checks after commissioning
23 Stop periods
23 Short periods of time
23 Long periods of time
23 Decommissioning of old appliances
Maintenance
24 Boiler
24 Burner
25 Any anomalies and remedies
25 Environmental protection and disposal
25 Information for the disposal of electrical and
electronic equipment
Useful information and declarations
26 QR code
27 Declaration of Conformity
Notes
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General information 3
1 General information
INTRODUCTION
Dear Customer,
Thank you for having chosen an appliance of the series CODEX GT , a high quality and efficiency product, reliable and safe.
We recommend entrusting its maintenance to Professionally Qualied Personnel who, when necessary, uses original spare parts.
This manual contains important information and suggestions that must be observed for easier installation and best possible use
of the appliance.
mIMPORTANT
Failure to observe the instructions in this manual will void the warranty conditions.
RANGE
BOILER BOILER
MODEL CODE CODE
CODEX 1000 GT 81022203 17010195
CODEX 1200 GT 81022213
CODEX 1400 GT 81022303
CODEX 1600 GT 81022313
COMPLIANCE
CODEX GT boilers comply with the following 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 400kW comply with the Ecodesign of Energy-using Products Directive 2009/125/EC and with the delegated
Regulation (EU) no. 813/2013.
0461
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General information4
WARNINGS
mIMPORTANT
–The appliance must be used for the purposes for which it has been expressly designed and any manufacturer’s liability shall
be excluded in case of damage to persons, animals or property due to insufficient maintenance or improper use.
–This manual is an integral part of the Boiler and must be carefully read before installation and commissioning of the
appliance. Moreover, it must be carefully stored for subsequent consultations and must ALWAYS accompany the Boiler
during its entire life-cycle (from Installation to disposal). In case of damage or loss, request a copy from ICI CALDAIE S.p.A.
Technical Assistance Service.
–The appliance is delivered in several separated packages. Upon receipt, check that the supply is intact and undamaged and
promptly contact the ICI CALDAIE S.p.A. if it does not correspond to the order.
–The installation of CODEX GT boilers must be performed by a Certified Company which, at the end of the operation,
must provide the owner with the declaration of conformity certifying that the installation has been correctly carried out,
namely in compliance with the Standards and the national and local Laws in force, and with the indications included in the
instruction manuals supplied by ICI CALDAIE S.p.A. .
–The maintenance of the appliance is a legislative obligation. The User must have 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 electrical devices or appliances such as switches, household appliances, etc. if you smell fuel or unburnt materials.
In this case:
- ventilate the room by opening doors and windows
- close the fuel shut-off device
- ask the Technical Assistance Service or qualified personnel to intervene as soon as possible.
–Any technical or cleaning operation carried out before disconnecting the appliance from the power supply mains, by
positioning the system main switch and the control panel main switch to “OFF”.
–Modifying safety or adjustment devices without the Boiler manufacturer’s authorisation and indications.
–Plug or dimensionally reduce the ventilation openings of the installation room. The ventilation openings are essential for
proper combustion.
–Exposing the Boiler to atmospheric agents. It is not designed to operate outdoor and it does not feature automatic anti-
freeze systems.
–Leave flammable substances and containers in the room where the appliance is installed.
–Disperse the packaging material in the environment and leave it within the reach of children as it may be a potential source
of danger. It must be disposed of in accordance with the legislation in force.
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General information 5
HAZARDS
aDANGER
–In case of water leakages, disconnect the Boiler from the power supply mains, close the water supply and contact, as soon
as possible, the Technical Assistance Service Authorised by ICI CALDAIE S.p.A. or qualified personnel.
–Sensing the presence of fuel in the thermal power plant, it is appropriate to follow the precautions below to avoid the risk
of explosions and fires:
- do not smoke or cause sparks
- do not turn on lights or electrical devices in general (mobile phones)
- open doors and windows
- close the fuel shut-off valve normally placed outside the thermal power plant
- disconnect the power supply by means of the switch which is usually located outside of the plant room.
–During the normal operation, the appliance has hot parts, such as the channel and the flue gas box, which in case of
accidental contact without appropriate personal protection can cause severe burns.
–An incorrect adjustment of the closing door or an insufficient chimney draught can cause the presence of smoke inside
the heating plant room, leading to fatal intoxications due to carbon monoxide, which is by nature colourless and odourless.
Therefore, make sure that the Boiler is correctly adjusted and installed and that the heating plant room features vents
compliant with the standards in force.
IDENTIFICATION
Each CODEX 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 fuels which can be used
–maximum operating pressure.
–CE marking
mIMPORTANT
The installer of the Boiler MUST apply the technical data plate (1) mandatorily , once the installation is complete, in a
position which is visible and legible with the appliance installed
. In case of deterioration or loss, request a duplicate
from ICI CALDAIE S.p.A. Technical Assistance Service providing the Boiler serial number.
1
The appliance is also accompanied by construction certicate attesting the successful result of the hydraulic test.
mIMPORTANT
The installation must be performed in compliance with the local standards by qualied personnel , namely by
personnel with specific technical skills in the field of the heating system components. An incorrect installation may
cause damage to persons or property for which the manufacturer will not be liable.
During commissioning check the effectiveness of all adjustment and control devices in the control panel.
The warranty validity is subject to compliance with the instructions in this manual.
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General information6
APPLIANCE DESCRIPTION
The CODEX GT appliances by ICI Caldaie S.p.A. are condensing Boilers made in AISI 316 Ti STAINLESS steel with three-pass furnace
for the production of hot water at a maximum temperature of 110°C. They are provided with pre-mixed, modulating burner for
gaseous fuels with cylindrical, heat radiating body and low NOx emissions.
They are equipped with two-stage progressive or premixed modulating gas burner, with cylindrical combustion head and
radiation with low emissions of NOx. The Nominal Efficiency of the CODEX GT reaches 108% (REF. NCV) e  (in compliance
with Directive 92/42/EEC).
The control panel suitable for the Boiler can be indifferently installed either on the right side or on the left side of the appliance.
Some of the main characteristics of the Boiler are listed below:
– chassis made of steel vertical profile structure, complete with base
– large-size cylindrical furnace made of TIG welded AISI 316 Ti stainless steel, able to withstand condensate attacks
–The CODEX GT appliances by ICI Caldaie S.p.A. are condensing Boilers made in AISI 316 Ti STAINLESS steel with three-pass
furnace for the production of hot water at a maximum temperature of 110°C. They are provided with pre-mixed, modulating
burner for gaseous fuels with cylindrical, heat radiating body and low NOx emissions
– 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 stainless steel are preserved, as well as its capability to resist acid condensate corrosion
– ow ange tting and two system return ttings , to distinguish the Boiler inlet and ensure the minimum possible temperature
at the lowest point, thus getting the most out of condensate benefits, even in the presence of medium-high temperature
return
– smokebox which can collect the produced condensate, which is then drained through a trap to be connected to the
neutraliser (where provided) and thus to the domestic hot water drain line
– very high water content and low thermal load
– ”hot” surfaces insulated with extra-thick glass wool mats, protected by painted steel panels which are easy to disassemble
– front door with reversible opening , made of steel sheet, thermally insulated with ceramic fibre
–radiant premixed modulating burner , which can provide any power output between the min and the max, according to the
instant load request; it allows maximum acoustic comfort and low polluting emissions.
STRUCTURE
3
6
2
1
5
4
7 8 9 10
1920
13 14 151211 1816 17
1 Door opening handle
2 Upper door
3 Burner support flange
4 Burner
5 Hinges
6 Lower door
7 Flame inspection window
8 Combustion chamber pressure test
connection
9 Control panel (accessory)
10 Insulating casing
11 Inspection fitting
12 Smokebox
13 Medium-temperature return
14 Condensate drain
15 Available fitting
16 Boiler drain
17 Available fitting
18 Low-temperature return
19 System flow
20 Flue gas drain fitting
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General information 7
DIMENSIONS AND CONNECTIONS
N1
L2
L1
P2
H2
H
L
P4
N2
N9
N2
N1
N9
T
N4
N7
Øc
H9
H6
H10
H5
P
H8
H12
N3
Dimensions
Description u.m.
CODEX GT
1000 1200 1400 1600
H mm 2020 2020 2165 2165
H2 mm 1522 1522 1610 1610
H5 mm 1880 1880 2022 2022
H6 mm 450 450 427 427
H8 mm 202 202 205 205
H9 mm 202 202 205 205
H10 mm 62 62 62 62
H12 mm 91 91 68 68
L mm 1493 1493 1573 1573
L1 mm 1310 1310 1390 1390
L2 mm 1298 1298 1378 1378
L4 mm 1060 1060 1165 1165
P mm 2443 2443 2437 2437
P2 mm 1732 1732 1725 1725
P6 mm 250-300 250-300 250-300 250-300
Øb mm 280 280 320 320
Øc mm 350 350 400 400
Attachments
Description u.m.
CODEX GT
1000 1200 1400 1600
N1 DN/in 125 125 125 125
N2 DN/in 100 100 100 100
N1/N2 PN 6 6 6 6
N4 DN/in 1" 1" 1" 1"
N7 DN/in 1" 1" 1" 1"
N9 DN/in 125 125 125 125
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General information8
Stub N3 for accessories
910 4
8 8 6 3 1
7 5 4 112
Description u.m.
CODEX GT
1000 1200 1400 1600
1
DN/in
1/2"
2 1" 1/2
3 1" 1/2
4 1” 1/4
5 1/2"
6 1/2"
7 1/2"
8 1/2"
9 1/2"
10 3/4"
11 1/2"
NOTE
For further details, see the chapter “Starting hydraulic circuit“.
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General information 9
TECHNICAL DATA
DESCRIPTION u.m.
CODEX GT
1000 1200 1400 1600
Type of appliance B23
Fuel
G20
G30 - G31
Effective rated
[1]
kW 914 1097 1280 1463
kcal/h 786400 943680 1100960 1258240
Nominal power
[2]
kW 1000 1200 1400 1600
kcal/h 860000 1032000 1204000 1376000
Max. thermal flow rate
kW 930 1116 1302 1488
kcal/h 800.000 960.000 1.120.000 1.280.000
Min. thermal flow rate
kW - - - -
kcal/h - - - -
Efficiency at 100% (ref. P.C.I.)
[1]
% 98,3 98,3 98,3 98,3
100% efficiency (ref. NCV)
[2]
% 107,5 107,5 107,5 107,5
30% efficiency (ref. NCV)
[1]
% 98,5 98,5 98,5 98,5
30% efficiency (ref. NCV)
[2]
% 108,5 108,5 108,5 108,5
Efficiency of 100% (stars)
[3]
% **** **** **** ****
Efficiency of 30% (stars)
[3]
% **** **** **** ****
Max gas flow rate - G20 Stm3/h 98,44 118,12 137,81 157,5
Max gas flow rate - G30 kg/h 73,06 87,67 102,28 116,89
Max gas flow rate - G31 kg/h 72,27 86,72 101,17 115,63
Max air flow rate kg/h 180,83 210,97 271,25 376,73
Max flue gas flow rate kg/h 1466,76 1759,99 2053,37 2346,75
Max. fluid flow rate kg/h 34400 41280 48160 55040
Min fluid flow rate kg/h 4128 4816 6192 8600
Pressure drops on exhaust side mbar 4,2 6,2 8,3 10,8
Sound power
[5]
dB(A) 87,7 87,7 96,0 96,0
CO emissions
mg/
kWh 0000
NOx emissions
mg/
kWh 50 50 50 50
NOx class
[4]
6666
Max chimney loss
[2]
% 1,3 1,3 1,3 1,3
Casing loss
[2]
% 0,3 0,3 0,3 0,3
Loss with burner Off
[2]
% 0,1 0,1 0,1 0,1
Fume temperature (Rated input - air=20°C) - G20
[2]
°C 40 40 40 40
CO 2 - G20 %9999
CO 2 - G30 %----
CO 2 - G31 %----
Condense production kg/h 116,65 139,97 163,3 186,64
Fluid pressure drop (ΔT=12K) mbar 34 48 66 86
Rated pressure bar 5 5 5 5
Total capacity l 1900 1900 1828 1828
Total weight Kg 2100 2100 2570 2570
Power supply V ~ Hz 230 ~ 50 230 ~ 50 230 ~ 50 230 ~ 50
Electric protection rating IP 40 40 40 40
Maximum absorbed power W 3000 3000 5500 5500
[1] Average temperature 70°C.
[2] Flow/ret. temperature 50/30°C.
[3] Efficiency Directive 92/42/EEC
[4] Ref. Standard UNI/EN 15502-1; 2015.
[5] Ref. EN 15036.
G20 (PCI - Hi). 9.45 kW/m3 (15°C, 1013 mbar)
G30 (PCI - Hi). 12.68 kW/kg (15°C, 1013 mbar)
G31 (PCI - Hi). 12.87 kW/kg (15°C, 1013 mbar)
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General information10
CONTROL PANEL ACCESSORY
The control panels which can be installed on CODEX GT Boilers are mentioned in the table.
They must be ordered separately from the Boiler according to their technical characteristics and to the needs of the system served;
it is recommended to see also the ICI Caldaie S.p.A. CATALOGUE .
For the installation, refer to the manual supplied with the panel.
Description Code
Thermostatic control panel QACC10ELMCE
eterm Boiler control panel QETERM01CE
eterm system control panel QETERM02
eterm Easy manager panel QCTETERM
BURNERS
The burners are supplied together with CODEX 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.
mIMPORTANT
To fit the burners on the CODEX GT Boilers refer to the specific chapter “BURNER ASSEMBLY” and to the relevant
manual of the appliance.
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Installation 11
2 Installation
PRODUCT RECEIPT
Each phase of the appliance installation must be carried out by Qualied Personnel , wearing appropriate Personal Protective
Equipment (PPE)
, in compliance with the national and local Laws in force.
An incorrect installation of the appliance or the failure to use PPE can cause severe damage to persons or property for which the
Manufacturer DECLINES ANY RESPONSIBILITY.
CODEX GT Boilers are supplied in six packages, indicated below, positioned on one pallet:
– BOILER BODY (1)
–thermally insulating mineral wool MATS (2) and fastening springs
– SLAT SUPPORT KIT (3)
– SLATS (4)
– CONTROL PANEL (5)
– BURNER (6)
5
3
2
4
6
1
mIMPORTANT
Upon receipt of CODEX 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 installing and
commissioning the Boiler, carefully stored for further consultations and it MUST always accompany Boiler.
mIMPORTANT
PACKAGING: as for packages, ICI CALDAIE S.p.A. complies with the specific recycling systems of each country, ensuring
an optimal reuse of them. All the materials used for the packaging respect the environment and can be recycled, such
as wood, plastic, cardboard.
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Installation12
HANDLING
CODEX GT Boilers are equipped with fittings for lifting operations and, in any case,they must be carefully moved with equipment
suitable for their dimensions and weights.
aATTENTION
The Personal Protective Equipment required by current legislation must be used.
INSTALLATION ROOM
The room where CODEX GT Boilers are to be installed must be exclusively used for them, compliant with the Technical Standards
and the Law in force and equipped with adequately dimensioned vents.
The spaces around the Boiler and towards the ceiling must be suitable for:
–installing the appliance
–reaching the safety devices
–maintenance
–repairing any breakage
–opening the door of the installed burner, considering its opening direction (towards the right or the left).
A (*)
P4
≤90°
NO!
(*) A ≥ P4 (see “Size and fittings*)
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 specific weight greater than that of the air, the electrical parts must be positioned at least
500 mm from the ground.
mIMPORTANT
COMBUSTION AIR: CODEX GT Boilers MUST be installed in rooms which are permanently vented with adequately
dimensioned vents, according to the appliance’s thermal power, and which comply with the Technical Standards and
the national and local Laws in force at the place of installation.
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Installation 13
SYSTEM CLEANING
Before connecting the Boiler to the system, it is MANDATORY to wash the pipes thoroughly in order to remove any residues which
may compromise the correct operation of the Boiler.
HYDRAULIC CONNECTIONS
The hydraulic circuit must be built by an authorised company or by qualified personnel, in compliance with theTechnical Standards
and the Law in force.
The components shall be charged to the installer that, at the end of the works, must issue a declaration of conformity.
mIMPORTANT
ICI CALDAIE S.p.A. is not liable for any harm to people, animals or property damage caused by errors in the choice of
components or in the construction of the plant.
mIMPORTANT
–Make sure that the hydraulic pressure measured downstream of the pressure regulator on the supply line does not
exceed the operating pressure indicated on the Boiler plate.
–Make sure that the drains of the safety valves of the Burner 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 heating system has been filled, it is recommended to close the supply tap and keep it closed so that any
system losses can be signalled by an hydraulic pressure drop detected on the system manometer.
–For reasons of technical expertise, the system components must be chosen and installed by the installer, that must
operate in accordance with good practice regulations and Laws in force.
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Installation14
STARTING HYDRAULIC CIRCUIT
23
25
33
18 20
26
28
32
14
3
2 1919
26
27
31
30 7
29
5 5
17 17
10
9
13
14
8
24
11
12
6 16
22
A
A
15
19
NOTE
If only one return is required, always use the low temperature one.
1 Hydraulic backflow preventer
2 Y-shaped filter
3 Flow switch
4 Filling unit
5 Drain funnel with articulated elbow
pipe
6 Pressure gauge
7 Condensate neutraliser (see ICI
catalogue)
8 Control pocket
9 Pressure transducer
10 Pressure gauge tap
11 Thermometer probe
12 Safety thermostat probe
13 Setting thermostat probe no.1
14 Setting thermostat probe no.2
15 Fuel shut-off valve probe
16 Shock-absorbing pipe
17 Safety valve no.1 (no. 2 with thermal
power above 580 kW)
18 Fuel shut-off valve
19 Manual shut-off valve
20 Gas manual shut-off valve
21 Expansion vessel
22 Level probe glow plug (optional)
23 System flow
24 Probe holding sheaths inside the
boiler
25 Natural gas inlet
26 Low-temperature return
27 Water inlet for system refill or top up
28 Medium-temperature return
29 Boiler drain
30 Acid condensate outlet
31 Neutralised condensate outlet
32 Chimney fitting combustion flue gas
outlet
33 Air bleed valve
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Installation 15
FLUE EXHAUST
The smoke duct and the connection to the chimney must be built in compliance with the Standards and the Laws in force, with
rigid pipes, suitable for the temperature, resistant to condensate, mechanical stresses and sealed.
mIMPORTANT
The smoke duct must have a diameter equal to or larger than the Boiler fitting.
Ø C
Indicative scheme
H6
Description u.m.
CODEX GT
1000 1200 1400 1600
H6 mm 450 450 427 427
Ø C mm 350 350 400 400
aDANGER
–the chimney must ensure the draught necessary for the Boiler operation and provided by the Technical Standards in
force, considering a “zero” pressure at the connection with the smoke duct
–unsuitable or badly dimensioned chimneys and smoke ducts can cause problems and adversely affect the combustion
parameters
–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
CODEX GT Boilers are equipped with a condensate drain pipe, derived from the appliance and the flue gas drain.
The condensate is acid and MUST be treated, by the installer, in compliance with the national and local Laws in force in the
country of installation.
The condensate acidity can be periodically checked using litmus test paper to determine the pH.
For the choice of the condensate neutraliser, which is system ACCESSORY to be ordered and purchased separately, use the ICI
catalogue.
mIMPORTANT
–The condensate drain pipe must be sealed and have dimensions ≥ than those of the appliance drain pipe and of the trap
and it must not have bottlenecks and reductions.
–It is recommended that it always has a slope ≥ than 3% towards the drain.
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Installation16
DOOR OPENING
The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx).
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
detachment of the door, with possible severe damages to persons and property.
Before opening the door:
–close the gas line shut-off valves and disconnect the pipes
–use the lever (4) to unscrew and extract the ring nuts (5) of the two hinges on the opening side of the door and pull it
carefully.
4
35 12
Hinge of rotation
door side
Hinge of opening
door side
DOOR OPENING INVERSION (FROM THE RIGHT TO THE LEFT)
Dx
Sx
2
4
1 5 3
7 6
8
Left hinge:
–screw the ring nuts (1) of the left side with the lever (2) in such a way that the distance of the door from the appliance front
plate is the same and the sealing gasket is uniformly pressed.
–screw the nuts (3), of the left tie-rods, until the conical washers (4) are inserted into the door mechanical tubes (5). Properly
tighten the nuts (3).
Right hinge:
–loosen the nuts (6) and disengage the conical washers (7) from the door mechanical tubes (8).
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Installation 17
DOOR ADJUSTMENT
aDANGER
Incorrect door adjustment with consequent damage to people and property voids the warranty conditions.
Dx
Sx
65 46
1 2
4
3
1 2
VERTICAL ADJUSTMENT
To make the adjustment:
–with the door ajar, loosen the counter-nuts (1) of the hinge units
–act on the adjustment nuts (2) to lift or lower the door by centring the gasket on the stop plate, then block the counter-nuts
(1).
HORIZONTAL ADJUSTMENT
Close the door with the lever (3) 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 ferrules are fastened, so that they hold the door.
Check the proper adjustment in depth ensuring that the door, manually pushed up to the stop plate, naturally returns remaining
ajar. This is to ensure the hinge side fume seal.
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Installation18
INSULATING CASING ASSEMBLY
To fit the insulating casing proceed as follows:
–wrap the thermally insulating mats around the Boiler body and lock them with the supplied springs (1)
–prepare all the slats (2) inserting the locking plugs (3) in the corners of each one of them, as shown in the figure below
1
2
3
–open the control panel (4) and fasten it to the panel supporting slat (5) using the supplied screws and nuts
–fasten the front (6) and rear (9) pillars to the base and to the plates (6) using the supplied screws and nuts
–insert the slats (2) on the lateral side
mIMPORTANT
The panel supporting slat (5) must be the ninth one on the side featuring the control panel.
9
5
4
76
6
8
2
2
–fasten the two cross beams (10) to the plates (6), insert the upper slats (11), fasten the end profiles (12) using the supplied self-
threading screws.
10
10
12
12
11
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

Installation 19
BURNER ASSEMBLY
For the activities listed below, concerning the burner:
–installation and fastening to the Boiler
–the connection to the fuel supply
–the electrical connections
–the adjustments to be made
–maintenance
–the necessary checks.
refer to the Manual supplied with the appliance.
mIMPORTANT
Insert the thermoceramic material strip, supplied with the insulating casing, into the gap between the burner
combustion head 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
ELECTRICAL CONNECTIONS
The electrical system of CODEX GT Boilers must be built by an Authorised Company that must refer to the wiring diagrams
supplied with the Boiler, with the control panel and with the burner. Moreover, it must operate in compliance with the Technical
Standards and the national and local Laws in force.
Once the work is complete, the Authorised Company must issue the Declaration of 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 liable for any damage caused by the
lack of the earthing system and the failure to comply with the instructions of the wiring diagrams.
dPROHIBITION
Do not use the water and heating system pipes for the earthing connections .
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

Installation20
WATER TREATMENT
The thermal system water must comply with the Laws in force, therefore it is good practise to use treatment units when the line
water is particularly rich in calcium carbonate, which causes scale build-ups and corrosion.
The table includes some indicative values:
Characteristics Scale Filling water Circuit water
pH* - 7-8
Hardness (CaCo2) °Fr < 15 -
Iron (Fe)** mg/kg - < 0.5
Copper (Cu)** mg/kg - < 0.1
Oxygen (O2) mg/l < 0.05*** -
Appearance Clear Possibly clear
* 8 is the maximum acceptable pH value in case of radiators in aluminium or light alloys.
** Higher values indicate on-going corrosion phenomena.
*** In case of agents which form oxygen film and/or surplus, do not observe this value with intermittent operation or operation
without deaerator, but use the additive.
LIMESTONE BUILD-UPS
Limestone build-ups reduce the heat exchange between the combustion gases and water, leading to an abnormal increase of
temperature of the parts exposed to the flame and thus to a significant reduction of the Boiler service life.
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 of the heat obtained from the combustion is not fully transferred to the system water, but is lost through the
chimney.
LIMESTONE DIAGRAM
Lost heat
0 5 10 15 20 30
10
20
30
%
limestone mm
CORROSION ON WATER SIDE
The corrosion of the Boiler metal surfaces on the water side is due to the iron transit into solution through its ions (Fe+). In this
process, the presence of dissolved gases, in particular oxygen and carbon dioxide, is very important. Corrosion phenomena often
occur with softened and/or demineralised water, which by nature is more aggressive against iron (acid water with Ph < 7); in these
cases, even when scale build-ups are prevented, corrosions can occur and it is necessary to treat the water with corrosive process
inhibitors.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz