ICI Caldaie CODEX User manual

TECHNICAL MANUAL EN
CODEX
THREE PASS CONDENSING
BOILER WITH
LOW NOx

2
1INTRODUCTION...................................................................................................................................................3
2SAFETY WARNINGS ...........................................................................................................................................3
3GENERAL.............................................................................................................................................................5
4GENERAL WARNINGS........................................................................................................................................6
5HANDLING AND LIFTING....................................................................................................................................7
6TECHNICAL SPECIFICATIONS ..........................................................................................................................8
6.1TECHNICAL DATA ........................................................................................................................................8
6.2DIMENSIONS AND FITTINGS ......................................................................................................................9
7INSTALLATION ..................................................................................................................................................10
7.1THERMAL PLANT........................................................................................................................................10
7.1.1BOILER ROOM.....................................................................................................................................10
7.2BASE............................................................................................................................................................10
7.3CHIMNEY.....................................................................................................................................................10
7.4HYDRAULIC CONNECTIONS.....................................................................................................................11
7.4.1SEALED Hot water heating system with expansion vessel..................................................................11
7.5INSULATION OF THE BOILER BODY........................................................................................................11
7.6HOW TO ASSEMBLE THE CASE AND THE CONTROL PANEL ..............................................................12
7.7ELECTRICAL CONNECTIONS ...................................................................................................................16
7.8OPTIONAL CONTROL PANEL....................................................................................................................16
7.9STARTING...................................................................................................................................................16
7.10DOOR...........................................................................................................................................................17
7.10.1DOOR OPENING..................................................................................................................................17
7.10.2DOOR OPENING REVERSAL (to the right).........................................................................................17
7.10.3DOOR ADJUSTMENT (opening on the right).......................................................................................18
7.11BURNER CONNECTION.............................................................................................................................19
8START UP...........................................................................................................................................................20
8.1 PRELIMINARY CHECKS.............................................................................................................................20
8.2 WATER TREATMENT .................................................................................................................................20
8.3 FILLING THE SYSTEM................................................................................................................................20
9OPERATION .......................................................................................................................................................21
9.1 Operation checks .........................................................................................................................................21
9.2 Temporary boiler stop ..................................................................................................................................21
9.3 Prolonged boiler stop ...................................................................................................................................21
9.4 Periodical user checks.................................................................................................................................21
10MAINTENANCE..................................................................................................................................................22
10.1 PREPARATION FOR INSPECTION AND MAINTENANCE........................................................................22
10.2 cleaning........................................................................................................................................................22
10.3 fURNACE DRAWER....................................................................................................................................23
11PROTECTING THE ENVIRONMENT.................................................................................................................23
12DECOMMISSIONING AND DISPOSAL.............................................................................................................23
13QR Code .............................................................................................................................................................24

3
1 INTRODUCTION
Dear Customer,
Thank you for having chosen our generator.
In your interests, we invite you to follow and observe the instructions in this manual to ensure the highest
level of efficiency and duration of the unit.
IMPORTANT: failure to observe the instructions in this manual will void the warranty conditions.
2 SAFETY WARNINGS
IMPORTANT
For safety and for proper operation, carefully read this TECHNICAL MANUAL before installing and starting
the generator.
The manual is an integral and essential part of the generator and must accompany it from installation until
disposal. The generator must be used for the purpose for which it was strictly intended and any liability by
the Manufacturer for damages to people, animals or property due to lack of maintenance or for improper
use, is excluded.
Safety of the thermal power plant
For safety purposes, the qualified technical personnel in charge of running the system must consider the following
requirements:
-Follow the accident prevention and environmental safety regulations in force.
-Ensure the generator installation in the thermal power plant complies with the standards in force.
-Ensure that the electrical and hydraulic system complies with the standards in force.
-Ensure that the boiler room complies with the standards in force and is sufficiently ventilated.
-Ensure that the boiler fumes are conveyed outside the thermal power plant through a flue compliant with
the standards in force.
-Ensure that the acidic condensation that may develop during system start-up, is evacuated outside the
thermal power plant after a neutralisation process in compliance with the standards in force.
-Ensure that there is no danger due to frost inside the thermal power plant.
System check
Before switching on the generator for the first time, a duly qualified technician must perform a check at the central
heating plant and update the system log once the check is over.
Periodic verifications
The generator must be periodically checked by a duly qualified technician (maintenance worker), who should up-
date the system log once the check is over.
Danger of explosion
Routine and extraordinary maintenance must be entrusted to professionally qualified personnel with the pur-
pose of promptly detecting any damage to the generator's pressurised body and the safety and control accesso-
ries.
Danger deriving from the fuel
Sensing the presence of fuel in the thermal power plant, it is appropriate to follow the precautions below to avoid
the risk of explosions and fires:
-Do not smoke or cause sparks.
-Do not turn on lights or electrical devices in general (mobile phones).
-Open doors and windows.
-Close the fuel shut-off valve normally placed outside the thermal power plant.
-Disconnect the electrical power supply by using the switch normally placed outside the thermal power plant.

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Danger of burns
During normal operation, the generator has hot parts that, upon accidental contact without suitable personal pro-
tection, can cause serious burns. Potentially hot parts include:
-Accessories and valves connected to the generator.
-Door and smoke chamber.
Danger from fumes
An incorrect adjustment of the closing door or an insufficient draught in the flue can leave fumes inside the thermal
power plant, causing fatal intoxication deriving from carbon monoxide which, by its nature, is colourless and odour-
less. Therefore, ensure the generator is properly installed and adjusted and the presence of ventilation openings in
the thermal power plant are compliant with the regulations in force.
Repairs
Any generator repair must be carried out or authorised by the manufacturer in order to avoid risks to people and
property, as well as to prevent voiding the Warranty Conditions being . Generator maintenance must be en-
trusted to competent personnel.
Spare parts
In order to ensure maximum safety and reliability, it is essential that all removable defective accessories and parts
are replaced with Original Spare Parts supplied by the Manufacturer.
ORIGINAL
SPARE
PARTS

5
3 GENERAL
This is a commercial condensing boiler patented. The boiler condenses and utilises the latent heat absorbed from
the flue gases and is designed for operation with natural gas and LPG.
This boiler has no limit on boiler return temperature so the best boiler performance (efficiency 107%) is reached
when the boiler is fitted to an under floor heating circuit or when the return temperature is under 58 deg. C . Above
this temperature, the condensation phenomenon does not take place and so it is not possible take the latent heat
from the vapour of the flue. The boiler efficiency is still very high (97%) even when the boiler is fitted in a traditional
heating circuit plant working at delta T 80/65 deg. C.
The body that is slightly inclined, is composed of:
-single pass wet back furnace
-large diameter pipes connected directly to the furnace and the front tube plate (two-pass)
-corrugated horizontal flue passages, whose special surface increases: the heat exchange area, the flue gas
turbulence and the formation of condense, the easy drainage of same (three-pass).
-boiler shell complete with boiler flow, constant temperature return, variable temperature return, fittings for con-
trol thermostats and safety devices.
-rear smoke box has the function to drain the condense and an chimney connection to drain any condense from
the chimney.
All the parts of the boiler are manufactured in stainless steel AISI 316 Ti.
The high volume of the furnace reduces the thermal NOx production.
The high boiler efficiency is due to optimum combustion efficiency combined high density rock wool insu-
lation, which puts the boiler in the top position in European regulation “4 stars” according the Efficiency
Directive 92/42/EEC.

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4 GENERAL WARNINGS
Each boiler is provided with a manufacturer’s plate that can be found in the envelope with the boiler documents.
The plate lists:
Serial number or identification code
Rated thermal output in kcal/h and in kW
Furnace thermal output in kcal/h and in kW
Types of fuels that can be used
Max operating pressure.
A manufacturer’s certificate is also provided which certifies the hydraulic test.
The installation must be in compliance with local regulations in force by professionally qualified personnel. The
term “professionally qualified personnel” means persons with specific technical skills in the sector of heating sys-
tem components.
Incorrect installation may cause damage to persons, animals or objects for which the manufacturer cannot be held respon-
sible.
At the first start up, all regulation and control devices positioned on the control panel should be checked for effi-
ciency. 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.
IMPORTANT: This boiler has been designed to heat water to a temperature less than the boiling temperature of
water at atmospheric pressure and must be connected to a heating plant and/or a domestic hot water plant within
the limits of its performance and output.
WARNING!
THE BOILER MAY ONLY BE INSTALLED IN A ROOM WHICH COMPLIES WITH THE AP-
PROPRIATE VENTILATION REQUIREMENTS. READ THE INSTALLATION AND USER IN-
STRUCTION BEFORE INSTALLING AND LIGHTING THE BOILER.
Systems must be cleaned in accordance with British Standard Code of Practice BS
7593:1992, Code of practice for treatment of water in central heating systems.

7
5 HANDLING AND LIFTING
ATTENTION: Only the special eye bolts on the top of the boiler must be used for lifting
The above picture is only for reference.
When using a forklift, the weight of the boiler must be balanced before proceeding. This can be achieved
by positioning the forks equidistantly from the centre of gravity marked on the sides.

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6 TECHNICAL SPECIFICATIONS
6.1 TECHNICAL DATA
Characteristics NG max flow
rate G20 NG max flow rate G30 NG max flow rate G31 Max flow rate of flues Max fluid flow Min. fluid flow
kW kcal/h kW kcal/h kW kcal/h % % Stm³/h k
g
/h k
g
/h k
g
/h k
g
/h k
g
/h % %
Medium
Temp.
70°C
Temp.
flow/return
50/30°C
Medium
Temp.
70°C
Temp.
flow/return
50/30°C
CODEX 801 732 629.120 800 688.000 744 640.000 98,3 107,5 78,75 58,45 57,81 1173,38 68800 27520 98,50 108,50
CODEX 1000 914 786.400 1000 860.000 930 800.000 98,3 107,5 98,44 73,06 72,27 1466,76 86000 34400 98,50 108,50
CODEX 1200 1.097 943.680 1200 1.032.000 1116 960.000 98,3 107,5 118,12 87,67 86,72 1759,99 103200 41280 98,50 108,50
CODEX 1400 1.280 1.100.960 1400 1.204.000 1302 1.120.000 98,3 107,5 137,81 102,28 101,17 2053,37 120400 48160 98,50 108,50
CODEX 1600 1.463 1.258.240 1600 1.376.000 1488 1.280.000 98,3 107,5 157,50 116,89 115,63 2346,75 137600 55040 98,50 108,50
Efficiency at 30%
(N.C.V.)
Efficiency 100%
(N.C.V.)
Temp. flow/return
50/30°C
Medium Temp.
70°C
Heat output Heat input
Characteristics
Pressure losses
flue gas side Heat losses through the chimney Heat losses through the casing
Heat losses
with
burner off
Flue gas temp.
at boiler output
and air at 20 deg. C CO2 Condense
production Press. losses fluid side Design Pressure Total capacity Weight Electric supply Frequency Insulation class Electric power
Modello mbar % % % °C % kg/h mbar bar lkg Volt ~ Hz IP W
For condensing
Temp. flow/return
50/30°C
For condensing
Temp. flow/return
50/30°C
For condensing
Temp.
flow/return
50/30°C
GAS
For condensing
Temp. flow/return
50/30°C
GAS
For condensing
Temp. flow/return
50/30°C
Temp. flow/return
50/30°C (ΔT=12K)
With electr.
contr. (excluded
pump and burner)
Nat. gas Lpg
CODEX 801
3,7 1,30 0,30 0,10 40 11 93,32 22 5 1900 1661 230 50 IP40 20 X X
CODEX 1000
4,2 1,30 0,30 0,10 40 11 116,65 34 5 1900 1661 230 50 IP40 20 X X
CODEX 1200
6,2 1,30 0,30 0,10 40 11 139,97 48 5 1900 1661 230 50 IP40 20 X X
CODEX 1400
8,3 1,30 0,30 0,10 40 11 163,30 66 5 1828 2023 230 50 IP40 20 X X
CODEX 1600
10,8 1,30 0,30 0,10 40 11 186,64 86 5 1828 2023 230 50 IP40 20 X X
Fuel

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6.2 DIMENSIONS AND FITTINGS
KEY
N1 Boiler flow
N2 Medium temperature return
N3 Accessory socket
1.Level probe with integrated glow plug (not supplied as standard) - G1/2“
2.Available connection - G1“1/2
3.Expansion vessel fitting - G1“1/2
4.Safety valve fitting - G1“1/4
5.Available connection - G1/2“
6.Temperature control fitting - G1/2“
7.Pressure switch fitting - G1/2“
8.Termometers/termostats fitting - G1/2“
9.Fuel shut-off valve fitting- G1/2“
10. Air vent fitting - G3/4“
11. Minimum level probe fitting - G1/2“
N4 System filling/drainage
N7 Boiler condensation drain
N9 Low temperature return
T Inspection plugs
Dimensions H
H2 H5 H6 H8 H9 H10 H12 L L1 L2 L4 P P2 P6 Øb Øc N1 N2 N1/N2 N4 N7 N9
mm
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm DN/in DN/in PN DN/in DN/in DN/in
CODEX 801 2020
1522 1880 450 202 202 62 91 1493 1310 1298 1060 2443 1732 250-300 280 350 125 100 6 3/4" 1" 125
CODEX 1000 2020
1522 1880 450 202 202 62 91 1493 1310 1298 1060 2443 1732 250-300 280 350 125 100 6 3/4" 1" 125
CODEX 1200 2020
1522 1880 450 202 202 62 91 1493 1310 1298 1060 2443 1732 250-300 280 350 125 100 6 3/4" 1" 125
CODEX 1400 2165
1610 2022 427 205 205 62 68 1573 1390 1378 1165 2437 1725 250-300 320 400 125 100 6 3/4" 1" 125
CODEX 1600 2165
1610 2022 427 205 205 62 68 1573 1390 1378 1165 2437 1725 250-300 320 400 125 100 6 3/4" 1" 125

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7 INSTALLATION
Before connecting the boiler, the following operations must be completed:
-Thoroughly clean all the system pipes in order to remove any foreign matter that could affect correct operation
of the boiler;
-Check that the flue has an adequate draught, that there is no narrowing of passages and that it is free from
debris; also check that other appliances do not discharge into the flue (unless designed to serve several utili-
ties). See the regulations in force.
7.1 THERMAL PLANT
7.1.1 BOILER ROOM
As a rule, regulations in force should be always observed.
Premises in which boilers will be installed should be sufficiently ventilated and guarantee access for ordinary and
extraordinary maintenance operations.
7.2 BASE
The boiler should be installed on a stand, 100/200 mm high, in order to create an air trap in the condensate drain,
which is designed to retain fumes and evacuate water.
IMPORTANT
Make sure the boiler supporting base is perfectly horizontal. The door must be at a uniform slope to pro-
vide a proper drainage of the condensate to the smoke box.
7.3 CHIMNEY
The smokestack must be dimensioned as to applicable regulations.
WARNING
The flue gas temperature of this boiler is very low compare to the traditional non-condensing boilers,
therefore, there is a very high humidity density. For this reason the boiler chimney must be water resistant,
acid condense resistant and insulated to warrant sufficient draught.

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7.4 HYDRAULIC CONNECTIONS
7.4.1 SEALED HOT WATER HEATING SYSTEM WITH EXPANSION VESSEL
KEY
1 Hydraulic disconnect switch
2 Filter a y
3 Water flow switch
4 Filling unit
5 Tundish with articulated joint
6 Pressure gauge
7 Acid condense neutralizer
8 Boiler switchboard
9 Inspection well
10 Safety pressure switch
11 Pressure gauge cock
12 Termometer probe
13 Safety termostat probe
14 Regulation termostat probe n°1
15 Regulation termostat probe n°2
16 Fuel shut-off valve probe
17 Termometer
18 Regulation thermostat n°1
19 Regulation thermostat n°2
20 Manual reset safety thermostat
21 Shock absorbing pipe
22 Safety valve (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
32 Return water inlet from the plant
33 Medium temperature return
34 Boiler exhaust
35 Acid condense outlet
36 Neutralized condense outlet
37 Outlet flue gas
38 Air vent valve
39 Burner

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Ensure that the hydraulic pressure measured after the reduction valve on the supply pipe does not exceed
the operating pressure specified on the rating plate of the component (boiler, heater etc.).
As the water contained in the heating system increases in pressure during operation, ensure that its
maximum value does not exceed the maximum hydraulic pressure specified on the component rating
plate.
Ensure that the safety valve outlets of the boiler and hot water tank, if any, have been connected to drain
in order to prevent the valves from flooding the room if they open.
Ensure that the pipes of the water and heating system are not used as an earth connection for the
electrical system as this can seriously and very rapidly damage the pipes, boiler, heater and radiators.
Once the heating system has been filled, you are advised to close the supply cock and keep it closed so
that any leaks from the system will be identified by a drop in hydraulic pressure indicated on the system
pressure gauge.
IMPORTANT!
If the boiler is not supplied with acid condense neutralizer, a siphon must be fitted on
the condensate drain in order to avoid flue gas leakage.
NOTE: IF ONLY ONE RETURN IS REQUIRED, ALWAYS USE THE LOW TEMPERATURE ONE

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7.5 INSULATION OF THE BOILER BODY
The boiler is supplied fixed to a wooden supporting base (1) to allow handling and to facilitate the insulation
process.
The glass wool insulation, consisting of 3 layers, must be wrapped on the parts shown in the figure and fixed
to the connection sides by the appropriate clamps supplied.
The above picture is only for reference.
Once the glass wool is attached, the wooden support can be removed and the boiler can be placed in its fi-
nal position.
1
1

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7.6 HOW TO ASSEMBLE THE CASE AND THE CONTROL PANEL
1) Prepare the staves by inserting the four stoppers, as shown in the figure.
2) Secure the front struts to the plate using the appropriate screws and nuts.
The above picture is only for reference.
3) Fix the two items (1 and 2), which form the “stave steering” strut, to the front/back plate. Fit the internal
item (1), right and left, paying attention to the hole that is closer to the edge and also on the lower side.
1
2

13
4) Fix the special “stave steering” struts to the upper/lower plate proceeding as described above.
5) Then, in the same way, fix the two (front and back) beams.
NB: only models 1400/1600 kW require previous installation of the “spacer” staves, by applying the reverse
technique: the larger part to the front side and the straight part to the back.

14
6) Insert the 4 short staves (previously prepared with the stoppers) between the struts, on each side.
The above picture is only for reference.
7) Insert the staves, including the one designed for the installation of the control panel.
HOW TO ASSEMBLE THE CONTROL PANEL
The control panel supplied in the boiler kit can be installed either to the right-hand side or the left-hand side
of the wall.
The panel must be fixed to the corresponding stave (1) which has pre-prepared holes for the screws and
slots for the capillary inlets.
The above picture is only for reference.
8) Fix the control panel (2) to the supporting stave and pass the capillaries (3) through the stave slot until
they reach the bulb basins in the equipped socket (4), fitted on the boiler delivery line (inside the fur-
nace).
2
3
1
4

15
9) After you have finished installing all the staves, proceed with the assembly of the closing frame, us-
ing the 4 self-threading screws.
10) View of the boiler with the case and control panel in position.
The above picture is only for reference.

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7.7 ELECTRICAL CONNECTIONS
Electrical systems of thermal plants designed only for heating purposes must comply with numerous legal
regulations which apply to in general as well as specifically to each application or fuel type.
7.8 OPTIONAL CONTROL PANEL
The control panel (optional) with the boilers is made of self-extinguishing plastic and houses the regulation
and safety instruments:
LEGEND
1 PANEL LIVE
2 BURNER SWITCH N. 1
4 HEATING PUMP SWITCH
7 BOILER THERMOMETER
8 BOILER LIMIT THERMOSTAT
9 SAFETY THERMOSTAT N° 1
11 2nd FLAME THERMOSTAT
The upper part of the control panel can be rotated to gain access to the terminal board and uncoil the ther-
mostat and thermometer capillaries. A copy of the wiring diagram is contained inside the control panel cover.
The control thermostats (TR1-TR2) have an operating range from 0° to 100° and can be set by the user by
means of the front dial.
Safety limit thermostats (TS) has a fixed setting of 110°C and can be manually reset.
For correct installation, refer to the boiler casing assembly instructions.
WIRING DIAGRAM
Refer to the diagram supplied with the specific switchboard.
7.9 STARTING
Open the gas tap (check if there is any gas leakage).
Switch on the burner and heating pump on the control panel.
At this point if the water temperature inside the boiler is less that the value set up on the control thermostat
and the room thermostat/timer (if present) is closed, the burner and the pump will run.
WARNING
It is common to find air inside the gas pipe-work, especially during the initial start up or after a long period of
without use. So if the flame failure occurs, repeat the same operation as previously explained.
NOTE: control pumps are running.
CONNECTION LIVE/NEUTRAL
If the connections of the live and the neutral are not correct, the burner will stop at the end of the
safety time (even if the burner is running).

17
7.10 DOOR
7.10.1 DOOR OPENING
The door is adjusted in the factory with standard opening to the left (s) and with hinges on the right (d).
CAUTION: it is dangerous to unscrew the ring nuts (8d) on the side of the hinges to avoid
causing the door to detach, with possible serious damage to people and property.
7.10.2 DOOR OPENING REVERSAL (to the right)
Proceed as follows to reverse the opening direction of the door:
Door with ferrules perforated on both sides
1. Screw the left perforated ferrules (8s) so that the door seal gasket is pressed in the same way as the
right part. Bring the conical washers (10s) of the left tie-rods close to the mechanical tubes (9s) of the
door and tighten the nuts (7s) using a suitable wrench.
2. On the right opening side, loosen the nuts (7d) and free the conical washers (10d) from the mechanical
tubes (9d) of the door.
Door with wrench ferrules, hinge side
IMPORTANT NOTE: In models equipped with wrench-adjustable ferrules (8d), these must always be
mounted on the hinges to prevent the door from being accidentally opened through the lever (12).
In this case, proceed as follows:
3. Proceed as indicated in point 1.
4. Cross-change the wrench ferrule of a hinge (8d) with the opposite perforated ferrule (8s), after loosening
the locking nuts on the tie rods and freeing the conical washers.
5. On the left hinge side, fasten the conical washer (9s) onto the door using the nut (10s).
6. Proceed with the other two ferrules following the procedure described in points 4 and 5.
CAUTION: When cross-changing ferrules, always make sure that the other two ferrules
are fastened, so that they hold the door.
7. Check the correct adjustment of the tie-rods and hinges ensuring that, during closure, the seal gasket is
evenly pressed in the centre on the whole circumference (see figure).
If necessary, adjust as described in the next par.

18
7.10.3 DOOR ADJUSTMENT (opening on the right)
Vertical adjustment
1. With the door ajar, loosen the counter-nuts (5s) of the hinge units.
2. Act on the adjustment nuts (4s) to lift or lower the door by centring the gasket on the stop plate (see fig-
ure), then block the counter-nuts (5s).
3. Close the door and centre the tie-rod (1d) on the mechanical tube (9d), proceeding as in point 2.
Horizontal adjustment
Close the door using the lever and check that there is equal distance on both sides, between the stop plate
and the band.
Otherwise, proceed as follows:
1. With the door ajar, loosen the locking nuts (7s) of the hinge units.
2. Act on the ferrule (8s) to adjust the distance depth-wise.
3. Screw the nuts (7s) and block the conical washers on the mechanical tubes.
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.
For any problems related to the reversal and adjustment of the door, we recommend contacting our
local Authorised Technical Assistance Centre.
IMPORTANT: Incorrect door adjustment with consequent damage to people and property
voids the warranty conditions.
OPENINGUNIT The above picture is only for reference HINGE UNIT
KEY
1. Tie-rod with pin
2. Upper bracket
3. Lower bracket
4. Vertical adjustment nut
5. Locking counter nut
6. Vertical tie-rod plain washer
7. Horizontal locking nut
8. Perforated ferrule for opening (s)
Wrench ferrule for hinge (d)
9. Door mechanical tube
10. Conical centring washer
11. Opening lever washer
12. Opening lever