ICI Caldaie MONOLITE JB Series User manual

TECHNICAL MANUAL
MONOLITE GT
CONDENSING BOILER WITH PREMIX BURNER
MONOLITE JB
CONDENSING BOILER (WITHOUT BURNER)
LOW NOx STEEL CONDENSING
BOILERS

TABLE OF CONTENTS
1
1GENERAL.................................................................................................................................................. 2
2GENERAL WARNINGS............................................................................................................................. 3
3TECHNICAL SPECIFICATIONS ............................................................................................................... 4
3.1 MONOLITE 45 GT – 350 GT...............................................................................................................................4
3.2 MONOLITE 30 JB - 670 JB.................................................................................................................................6
4INSTALLATION......................................................................................................................................... 9
4.1 HEATING SYSTEM.............................................................................................................................................9
4.1.1 Boiler room..................................................................................................................................................9
4.2 FLUE...................................................................................................................................................................9
4.2.1 Condensate drain........................................................................................................................................9
4.3 WATER CONNECTIONS....................................................................................................................................9
4.3.1 Sealed hot water heating system with expansion vessel...........................................................................10
4.4 ELECTRICAL CONNECTION...........................................................................................................................12
4.5 OPTIONAL CONTROL PANEL.........................................................................................................................12
4.6 STARTING........................................................................................................................................................12
4.7 INVERTING THE DOOR APERTURE (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
5FITTING 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
6STARTING............................................................................................................................................... 18
6.1 PRELIMINARY CHECKS..................................................................................................................................18
6.2 WATER TREATMENT ......................................................................................................................................18
6.3 FILLING THE SYSTEM.....................................................................................................................................18
7OPERATION............................................................................................................................................ 19
7.1 OPERATION CHECKS.....................................................................................................................................19
7.2 TEMPORARY BOILER STOP...........................................................................................................................19
7.3 PROLONGED BOILER STOP ..........................................................................................................................19
7.4 PERIODICAL USER CHECKS..........................................................................................................................19
7.5 MAINTENANCE AND CLEANING ....................................................................................................................19

MONOLITE
2
1 GENERAL
The boilers of the MONOLITE series have a horizontal through-flame combustion chamber and a vertical
condensing section of a special design, in stainless steel type AISI 316 Ti. These elements are immersed in
water contained in a horizontal boiler drum with a vertical column to which the system inlet and outlet con-
nections are fitted.
These boilers reach very high efficiency levels (nearly 108% referred to the Lower Calorific Value LCV) as
the flue gases not only are released at a temperature little higher than that of the system return water, but
also a large part of the water vapour contained in the flue gases is condensed, recovering the latent heat of
condensation.
The particular flame path (through the combustion chamber 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 temperatures, condensation does not occur and so the recovery of the latent heat contained in the
water vapour, present in the flue gas, is impossible. The efficiency of the boiler remains in any case high
(97%) even with traditional high-temperature heating systems (t 80/65° C).
The very high efficiency due to the complete recovery of the heat content of the fuel and to heavy
thermal insulation of the boiler, using high density glass wool, allow classification of the MONOLITE
series boilers as “4-Star - very high efficiency” as to the Efficiency Directive 92/42/CEE..

MONOLITE
3
2 GENERAL WARNINGS
Each generator is provided with a data 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 pressure.
The installation must be performed in compliance with the regulations in force by professionally qualified per-
sonnel. The term “professionally qualified personnel” means persons with specific technical skills in the sec-
tor of heating system components.
Incorrect installation may cause damage to persons, animals or objects for which the manufacturer cannot be held
responsible.
At the first start up, all regulation and control devices positioned 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
Directive on Low Voltage 73/23/EEC
IMPORTANT: This boiler has been designed to heat hot water to a temperature lower than the boiling point
of water at atmospheric pressure and must be connected to a heating plant and/or a domestic hot water
plant within the limits of the boiler performance and output.
WARNING!
THE BOILER MAY ONLY BE INSTALLED IN A ROOM WHICH COMPLIES WITH THE
APPROPRIATE VENTILATION REQUIREMENTS. READ THE INSTALLATION AND
USER INSTRUCTION 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.

MONOLITE
4
3 TECHNICAL SPECIFICATIONS
3.1 MONOLITE 45 GT – 350 GT
Characteristics
Effic. 100%
(stars) NG max flow rate G20 NG max flow rate G30 NG max flow rate G31 Max flow rate of flues
kW kcal/h kW kcal/h kW kcal/h % % % m³/h kg/h kg/h kg/h
Medium
Temp.
70°C
Temp.
flow/return
50/30°C
(Efficienty Dir.
92/42/CEE)
MONOLITE 45 GT
52,0 45.000 57,0 49.200 53,0 45.800 98,3 107,5 **** 5,64 4,18 4,14 84,04
MONOLITE 70 GT
81,0 70.000 88 76.500 82,0 71.200 98,3 107,5 **** 8,76 6,50 6,43 130,52
MONOLITE 95 GT
110,0 95.000 120 103.800 112,0 96.600 98,3 107,5 **** 11,89 8,82 8,73 177,16
MONOLITE 125 GT
145,0 125.000 158 136.700 147,0 127.200 98,3 107,5 **** 15,65 11,62 11,49 233,19
MONOLITE 160 GT
186,0 160.000 203 175.000 189,0 162.800 98,3 107,5 **** 20,03 14,87 14,71 298,45
MONOLITE 210 GT
244,0 210.000 266 229.600 248,0 213.600 98,3 107,5 **** 26,28 19,51 19,30 391,57
MONOLITE 270 GT
313,0 270.000 343 295.300 319,0 274.700 98,3 107,5 **** 33,80 25,09 24,81 503,62
MONOLITE 350 GT
406,0 350.000 445 382.800 414,0 356.100 98,3 107,5 - 43,82 32,52 32,17 652,92
Efficiency 100%
(N.C.V.)
Temp. flow/return
50/30°C
Medium Temp.
70°C
Heat output Heat input
Characteristics
Effic. 30%
(stars) NG min flow rate G20 NG min flow rate G30 NG min flow rate G31 Min flow rate of flues
kW kcal/h kW kcal/h kW kcal/h % % % m³/h kg/h kg/h kg/h
Medium
Temp.
70°C
Temp.
flow/return
50/30°C
(Efficienty
Dir.
92/42/CEE
)
MONOLITE 45 GT 17 15.000 19 16.599 17 15.228 98,5 109 **** 1,87 1,39 1,38 27,92
MONOLITE 70 GT 26 23.000 30 25.452 27 23.350 98,5 109 **** 2,87 2,13 2,11 42,81
MONOLITE 95 GT 37 32.000 41 35.411 37 32.487 98,5 109 **** 4,00 2,97 2,93 59,56
MONOLITE 125 GT
48 42.000 54 46.477 49 42.640 98,5 109 **** 5,25 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 Temp.
70°C
Temp. flow/return
50/30°C
Characteristics
Pressure losses
flue gas side Chimney available head Noise level CO emissions Nox emissions 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 Condense production Press. losses water side Design Pressure Total capacity Boiler weight Electric supply Frequency Insulation class Electric power
mbar mbar dB(A) mg/kWh mg/kWh % % % °C kg/h mbar bar lk
g
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
Temp.
flow/return
50/30°C
(ΔT=12K)
MONOLITE 45 GT
0,6 0,5 62,0 0 45 1,50 0,30 0,10 50 6,68 3,0 5 160 200 230 50 IP X0D 150
MONOLITE 70 GT
0,8 0,2 62,5 0 58 1,50 0,30 0,10 50 10,38 8 5 150 220 230 50 IP X0D 150
MONOLITE 95 GT
1,0 0,5 62,5 0 55 1,50 0,30 0,10 50 14,09 12 5 210 280 230 50 IP X0D 150
MONOLITE 125 GT
1,1 0,5 63,0 0 65 1,50 0,30 0,10 50 18,55 22 5 200 320 230 50 IP X0D 150
MONOLITE 160 GT
1,5 0,5 65,0 0 52 1,50 0,30 0,10 50 23,74 12 5 308 520 230 50 IP X0D 300
MONOLITE 210 GT
2,0 0,5 66,0 0 58 1,50 0,30 0,10 50 31,14 22 5 285 590 230 50 IP X0D 300
MONOLITE 270 GT
2,1 0,5 68,0 0 60 1,50 0,30 0,10 50 40,05 16 5 340 680 230 50 IP X0D 300
MONOLITE 350 GT
2,3 0,5 68,0 0 65 1,50 0,30 0,10 50 51,93 11 5 392 1030 230 50 IP X0D 300
Mod. 45 GT – 125 GT

MONOLITE
5
Mod. 160 GT – 350 GT
Dimensions H
H1 H2 H4 H5 H6 H8 H9 H10 H12 H14 L L1 L2 L5 L6
mm
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
MONOLITE 45 GT 1825
1734 1348 - - 264 837 557 432 125 987 939 756 710 272 -
MONOLITE 70 GT 1825
1734 1348 - - 264 837 557 432 125 987 939 756 710 272 -
MONOLITE 95 GT 1825
1734 1348 - - 264 837 557 432 120 991 966 756 710 279 -
MONOLITE 125 GT 1825
1734 1348 - - 264 837 557 432 120 991 966 756 710 279 -
MONOLITE 160 GT 2151
1941 1510 1952 2071 367 864 589 562 192 - 1063 853 814 - 150
MONOLITE 210 GT 2151
1941 1510 1952 2071 367 864 589 562 192 - 1063 853 814 - 150
MONOLITE 270 GT 2200
1941 1510 1955 2105 367 864 589 562 192 - 1063 853 814 - 150
MONOLITE 350 GT 2310
2008 1532 2025 2205 315 854 569 524 121 - 1201 991 932 - 200
Dimensions P P1P2P3P4P5P6P7P8ØbØcN1 N2 N3 N4 N5N6N7N8N9N10
mm mm mm mm mm mm mm mm mm mm mm DN/in DN/in DN/in DN/in DN/in DN/i
n
DN/i
n
DN/i
n
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 50 50 1" 1" - 1/2" 3/4" 1/2" 50 3/4"
MONOLITE 160 GT 2012 1296 1004 785 175 1052 450 - - 205 200 65 65 1" 1" - 1/2" 3/4" 1/2" 65 -
MONOLITE 210 GT 2087 1296 1004 860 175 1052 450 - - 205 200 65 65 1" 1" - 1/2" 3/4" 1/2" 65 -
MONOLITE 270 GT 2338 1546 1254 860 195 1283 580 - - 205 200 80 80 1"1/4 1" - 1/2" 3/4" 1/2" 80 -
MONOLITE 350 GT 2354 1577 1205 861 220 973 580 150 150 225 250 100 100 1" 1" 1"1/2 1/2" 3/4" 1/2" 100 -
KEY
N1 Boiler flow
N2 Medium temperature return
N3 Fitting for Instruments
N4 System filling/drainage
N6 Bulbs wells
N7 Boiler condensation drain
N8 Inspection well
N9 Low temperature return
N10 Gas fitting
T Inspection plugs

MONOLITE
6
3.2 MONOLITE 30 JB - 670 JB
Characteristics
Effic. 100%
(stars) NG max flow rate G20 NG max flow rate G30 NG max flow rate G31 Max flow rate of flues
kW kcal/h k
W
kcal/h kW kcal/h % % % m³/h kg/h kg/h kg/h
Medium
Temp.
70°C
Temp.
flow/return
50/30°C
(Efficienty Dir.
92/42/CEE)
MONOLITE 30 JB
31 27.200 34,6 29.722 32 27.700 98,3 107,3 **** 3,41 2,53 2,50 50,81
MONOLITE 45 JB
52 45.000 57 49.200 53 45.800 98,3 107,5 **** 5,64 4,18 4,14 84,04
MONOLITE 75 JB
87 75.000 95 82.000 88 76.300 98,3 107,5 **** 9,39 6,97 6,89 139,91
MONOLITE 95 JB
110 95.000 120 103.800 112 96.600 98,3 107,5 **** 11,89 8,82 8,73 177,16
MONOLITE 125 JB
145 125.000 158 136.700 147 127.200 98,3 107,5 **** 15,65 11,62 11,49 233,19
MONOLITE 160 JB
186 160.000 203 175.000 189 162.800 98,3 107,5 **** 20,03 14,87 14,71 298,45
MONOLITE 210 JB
244 210.000 266 229.600 248 213.600 98,3 107,5 **** 26,28 19,51 19,30 391,57
MONOLITE 270 JB
313 270.000 343 295.300 319 274.700 98,3 107,5 **** 33,80 25,09 24,81 503,62
MONOLITE 350 JB
406 350.000 445 382.800 414 356.100 98,3 107,5 - 43,82 32,52 32,17 652,92
MONOLITE 440 JB
511 440.000 559 481.200 520 447.600 98,3 107,5 - 55,08 40,88 40,43 820,69
MONOLITE 550 JB
639 550.000 699 601.500 650 559.500 98,3 107,5 - 68,84 51,10 50,54 1025,72
MONOLITE 610 JB
709 610.000 775 667.000 721 620.500 98,3 107,5 - 76,35 56,67 56,05 1137,62
MONOLITE 670 JB
779 670.000 851 732.700 792 681.600 98,3 107,5 - 83,87 62,25 61,57 1249,66
Heat output Heat input Efficiency 100%
(N.C.V.)
Medium Temp.
70°C
Temp. flow/return
50/30°C
Characteristics
Effic. 30%
(stars) NG min flow rate G20 NG min flow rate G30 NG min flow rate G31 Min flow rate of flues
kW kcal/h kW kcal/h kW kcal/h % % % m³/h kg/h kg/h kg/h
Medium
Temp.
70°C
Temp.
flow/return
50/30°C
(Efficienty
Dir.
92/42/CEE
)
MONOLITE 30 JB
11 10.000 13 11.066 11 10.152 98,5 109,0 **** 1,25 0,93 0,92 18,61
MONOLITE 45 JB
17 15.000 19 16.599 17 15.228 98,5 109,0 **** 1,87 1,39 1,38 27,92
MONOLITE 75 JB
29 25.000 32 27.665 29 25.381 98,5 109,0 **** 3,12 2,32 2,29 46,53
MONOLITE 95 JB
37 32.000 41 35.411 37 32.487 98,5 109,0 **** 4,00 2,97 2,93 59,56
MONOLITE 125 JB
48 42.000 54 46.477 49 42.640 98,5 109,0 **** 5,25 3,89 3,85 78,18
MONOLITE 160 JB
61 53.000 68 58.650 62 53.807 98,5 109,0 **** 6,62 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
212 183.000 235 202.508 216 185.787 98,5 109,0 - 22,86 16,97 16,78 340,62
MONOLITE 610 JB
236 203.000 261 224.640 239 206.091 98,5 109,0 - 25,36 18,82 18,62 377,85
MONOLITE 670 JB
259 223.000 287 246.772 263 226.396 98,5 109,0 - 27,86 20,68 20,45 415,07
Minimum
output Minimum input Efficiency at 30% (N.C.V.)
Medium Temp.
70°C
Temp. flow/return
50/30°C
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 Condense production Press. losses water side Design Pressure Capacity Boiler
weight Electric supply Frequency Insulation
class Electric power
mbar % % % °C kg/h mbar bar lk
g
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
Temp.
flow/return
50/30°C
(ΔT=12K)
With electr.
contr.
(excluded
pump and
burner
)
Nat. gas
Lpg
MONOLITE 30 JB
0,4 1,50 0,30 0,10 50 4,04 1,4 5 160 200 230 50 IP X0D 20 X X
MONOLITE 45 JB
0,6 1,50 0,30 0,10 50 6,68 3 5 160 200 230 50 IP X0D 20 X X
MONOLITE 75 JB
0,8 1,50 0,30 0,10 50 11,13 8 5 150 220 230 50 IP X0D 20 X X
MONOLITE 95 JB
1,0 1,50 0,30 0,10 50 14,09 12 5 210 280 230 50 IP X0D 20 X X
MONOLITE 125 JB
1,1 1,50 0,30 0,10 50 18,55 22 5 200 320 230 50 IP X0D 20 X X
MONOLITE 160 JB
1,5 1,50 0,30 0,10 50 23,74 12 5 308 520 230 50 IP X0D 20 X X
MONOLITE 210 JB
2,0 1,50 0,30 0,10 50 31,14 22 5 285 590 230 50 IP X0D 20 X X
MONOLITE 270 JB
2,1 1,50 0,30 0,10 50 40,05 16 5 340 680 230 50 IP X0D 20 X X
MONOLITE 350 JB
2,3 1,50 0,30 0,10 50 51,93 11 5 392 1030 230 50 IP X0D 20 X X
MONOLITE 440 JB
2,5 1,50 0,30 0,10 50 65,27 17 5 560 1230 230 50 IP X0D 20 X X
MONOLITE 550 JB
2,7 1,50 0,30 0,10 50 81,58 27 5 523 1270 230 50 IP X0D 20 X X
MONOLITE 610 JB
3,4 1,50 0,30 0,10 50 90,47 34 5 523 1270 230 50 IP X0D 20 X X
MONOLITE 670 JB
4,1 1,50 0,30 0,10 50 99,39 41 5 523 1270 230 50 IP X0D 20 X X
Fuel

MONOLITE
7
Mod. 30 JB - 125 JB
Mod. 160 JB - 270 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

MONOLITE
8
Mod. 350 JB - 670 JB
Dimensions H
H1 H2 H4 H5 H6 H8 H9 H10 H12 L L1 L2 L6
mm
mm mm mm mm mm mm mm mm mm mm mm mm mm
MONOLITE 30 JB 1825
1734 1348 - - 264 837 557 432 125 939 756 710 -
MONOLITE 45 JB 1825
1734 1348 - - 264 837 557 432 125 939 756 710 -
MONOLITE 75 JB 1825
1734 1348 - - 264 837 557 432 125 939 756 710 -
MONOLITE 95 JB 1825
1734 1348 - - 264 837 557 432 120 966 756 710 -
MONOLITE 125 JB 1825
1734 1348 - - 264 837 557 432 120 966 756 710 -
MONOLITE 160 JB 2151
1941 1510 1952 2071 367 864 589 562 192 1063 853 814 150
MONOLITE 210 JB 2151
1941 1510 1952 2071 367 864 589 562 192 1063 853 814 150
MONOLITE 270 JB 2200
1941 1510 1955 2105 367 864 589 562 192 1063 853 814 150
MONOLITE 350 JB 2310
2008 1532 2025 2205 315 854 569 524 121 1201 991 932 200
MONOLITE 440 JB 2310
2008 1532 2025 2205 315 854 569 524 121 1201 991 932 200
MONOLITE 550 JB 2310
2008 1532 2025 2205 315 854 569 524 121 1201 991 932 200
MONOLITE 610 JB 2310
2008 1532 2025 2205 315 854 569 524 121 1201 991 932 200
MONOLITE 670 JB 2310
2008 1532 2025 2205 315 854 569 524 121 1201 991 932 200
Dimensions PP1P2P3P4P5 P6P7P8ØbØcN1N2N3N4N5N6N7N8N9
mm mm mm mm mm mm mm mm mm mm mm DN/in DN/in DN/in DN/in DN/in DN/i
n
DN/i
n
DN/i
n
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 318 200 812 200-250 - - 150 180 50 50 1" 1" - 1/2" 3/4" 1/2" 50
MONOLITE 125 JB 1330 1221 1010 318 200 812 200-250 - - 150 180 50 50 1" 1" - 1/2" 3/4" 1/2" 50
MONOLITE 160 JB 1550 1296 1004 323 175 1052 250-300 - - 205 200 65 65 1" 1" - 1/2" 3/4" 1/2" 65
MONOLITE 210 JB 1550 1296 1004 323 175 1052 250-300 - - 205 200 65 65 1" 1" - 1/2" 3/4" 1/2" 65
MONOLITE 270 JB 1801 1546 1254 323 195 1283 250-300 - - 205 200 80 80 1"1/4 1" - 1/2" 3/4" 1/2" 80
MONOLITE 350 JB 1817 1577 1205 324 220 973 250-300 150 150 225 250 100 100 1" 1" 1"1/2 1/2" 3/4" 1/2" 100
MONOLITE 440 JB 2331 2092 1720 324 220 1487 250-300 150 150 225 250 100 100 1" 1" 1"1/2 1/2" 3/4" 1/2" 100
MONOLITE 550 JB 2331 2092 1720 324 220 1487 250-300 150 150 225 250 100 100 1" 1" 1"1/2 1/2" 3/4" 1/2" 100
MONOLITE 610 JB 2331 2092 1720 324 220 1487 250-300 150 150 225 250 100 100 1" 1" 1"1/2 1/2" 3/4" 1/2" 100
MONOLITE 670 JB 2331 2092 1720 324 220 1487 250-300 150 150 225 250 100 100 1" 1" 1"1/2 1/2" 3/4" 1/2" 100

MONOLITE
9
4 INSTALLATION
Before connecting the boiler, carry out the following operations:
Clean carefully all the system pipework to remove any residues that could damage impede correct boiler
operation;
Check that the flue has sufficient draught, has no restrictions, is free of all soot and residues, and is per-
fectly gas tight in particular to the water vapour contained in the flue gas. Check further that no other de-
vices are connected to the flue. Take account of applicable regulations in this regard.
4.1 HEATING SYSTEM
4.1.1 Boiler room
The system must correspond to current applicable regulations. In all cases, the boiler must be installed in
adequately ventilated rooms that also allow routine maintenance and repairwork.
4.2 FLUE
The pressurised boiler that is now a part of your heating system uses this denomination as the boiler in-
cludes a burner with a blower that supplies, to the combustion chamber, the quantity of air needed for the
fuel, at a pressure equivalent to the sum of the air-flow pressure drops caused by the flue gas path.
The boiler flue gas connection to the chimney base must be inclined, rising in the direction of flow, with a
suggested slope not less than 10%. The path of this connection shall be as short and straight as possible,
any bends being designed taking account of the rules used in designing air ducts.
Chimneys must in any case be dimensioned according to Standard UNI 13384-1.
WARNING
The flue 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 boiler is not supplied with acid condense neutralizer, a siphon must
be fitted on the condensate drain in order to avoid flue gas leakage.
4.3 WATER CONNECTIONS
Make sure that the water pressure downstream of the water supply pressure reducer is lower than the work-
ing pressure shown on the boiler data plate.
During operation, the water in the heating system increases in pressure; make sure therefore, that the
maximum pressure reached does not exceed the maximum admissible pressure for the component as
shown on the component number plate.
Make sure that the safety valve discharge fittings of the boiler and of any sanitary water heater are con-
nected to the drains via an open funnel, so that if the safety valves open, the boiler room will not be
flooded.
Make sure that the water and heating system pipework are not used as a ground for the electrical sys-
tem: if so, serious damage can be caused in a short time to the boiler, pipework, water heater and radia-
tors.
Once the heating system has been filled with water, close the water supply valve, and keep it closed. Any
water leaks from the system will then appear as pressure drops, as shown by the system pressure
gauge.
NOTE: IF ONLY ONE RETURN IS REQUIRED, ALWAYS USE THE LOW TEMPERATURE ONE

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4.3.1 SEALED HOT WATER HEATING SYSTEM WITH EXPANSION VESSEL
Mod. 45 - 125
Mod. 160 - 270

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Mod. 350 - 670
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 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
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
40 Safety valve n° 2 (heating capacity above 580 kW)

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4.4 ELECTRICAL CONNECTION
The electrical system in a heating plant that is for building heating only, is the object of numerous regula-
tions, some of which are general in character, others being specific to the type of application or type
of fuel.
4.5 OPTIONAL CONTROL PANEL
The control panel (optional) with the boilers is made of self-extinguishing plastic and houses the regulation
and safety instruments:
Fig. 1
LEGEND
1 PANEL LIVE
2 BURNER SWITCH N. 1
4 HEATIN PUMP SWICTH
7 BOILER THERMOMETER
8 BOILER LIMIT THERMOSTAT
9 SAFETY LIMIT THERMOSTAT
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 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 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.
NB.
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).

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4.7 INVERTING THE DOOR APERTURE (MOD. 45 GT/125 GT)
The door can be opened in either direction (RH or LH). For the door height adjustment see Fig. 2.
Fig. 2 – Door clamping arm
4.8 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.

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4.9 PRESSURISED BOILER CONNECTION
Before installation, clean the inside of all the fuel supply pipes, to remove any residues that might compro-
mise correct boiler operation. Check the maximum combustion chamber pressure, as shown in the technical
characteristics table. The observed value can increase by 20 % if the fuel used is not gas or light fuel oil, but
heavy oil; further, make the following checks:
a) check the internal and external fuel supply system for any leaks;
b) adjust the fuel supply rate as to the required boiler heat rating;
c) check that the boiler is supplied with the type of fuel for which it has been arranged;
d) check that the fuel supply pressure is within the values shown on the burner data plate;
e) check that the fuel supply system is dimensioned adequately for the fuel supply rate that the boiler re-
quires, and that the fuel supply system is complete with all the safety and control devices foreseen by
current applicable regulations.
In particular for the use of gas:
f) check that the gas line and collector pipes conform to current applicable standards and 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.
IMPORTANT: check that the spaces between the burner sleeve and the boiler door are filled with
thermal insulation (Fig. 3). A piece of ceramic fibre insulation rope is provided with the boiler. If this is not
suited to the specific burner fitted, use a rope of another diameter, of the same type of material.
All details on the draught tube lenght (P6), the diameter of the burner hole (Øb) and the pressurization are
included in the par. Technical Specifications.
4.10 WIRING DIAGRAM
See wiring diagram inside the boiler control panel supplied:
Control panel with thermostats (standard)
Control panel with RVA 43 digital controller for high/low burners (optional)
Control panel with RVA 63 digital controller for modulating burners (optional)
REMARK: specific instruction are provided along the digital controllers control panels.
1
4
3 2
Fig. 3
KEY:
1. Burner
2. Manhole
3. Thermoinsulating material
4. Flange
P6
Ø
b

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5 FITTING THE BOILER CASING
5.1 BOILER BODY INSULATION (Fig. 4-5-6)
Wrap glass wool (A) around the column and attach with the clips.
Wrap glass wool (B) around the upper cylindrical boiler body without covering the shaft/bulb holder located near
the flanged outlet pipe and fix in position with the clips supplied.
Then insulate the rear boiler plate, attaching the wool (C) to the springs on the edge of the plate (see figure).
5.2 BOILER CASING MOD. 45 GT/125 GT – 30 JB/125 JB (Fig. 4)
Fit the panel (1D) by hooking the upper profile to the square tube and the lower to the boiler longheron. Re-
peat the same procedure for panel (1S).
Fit the panel (2D) by hooking the upper profile to the square section tube and the lower to the boiler longheron,
making sure that the side panels are joined by the specific coupling pins. Repeat the procedure for panel (2S) with
the burner-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 profile; insert the cable grommets in the panel holes (6S),
hook the panel to the side panel and feed through the supply cable, then connecting the cable to the junction
box. Hook on the panel (6D) and then fasten both using the screws at the top, and close the holes with the
specific plugs provided (see figure).
Fix the front/upper panel supports (7) to the boiler plate (excluded JB) and put on the upper panels (8S) and
(8D). Hook on the front/lower panel (9) and the front/upper panel (10). For JB models, hook the front/central
panel (10a) and the front/upper panel (10b). Finally, screw the document holder (11) on to the opposite side of
the control panel (excluded mod. 30/45/75).
Fig. 4

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5.3 BOILER CASING mod. 160 GT/JB-270 GT/JB (Fig. 5)
Fit the panel (1D) by hooking the upper profile to the square tube and the lower to the boiler longheron.
Repeat the same procedure for panel (1S).
Fit the panel (2D) by hooking the upper profile to the square section tube and inserting it in the slots in the lower
panel. Repeat the procedure for panel (2S) with the burner-control panel connection cables passing through the ap-
erture (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 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 to its side panels. Screw on tightly and plug the pas-
sage holes with the appropriate caps. Attach the front/central panel with fairlead (8) and the front/lower
panel (9). Finally, screw the document holder (10) on to the opposite side of the control panel.
Fig. 5

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5.4 BOILER COVERING mod. 350 GT/JB-670 JB (Fig. 6)
Mount the panels (1D) fixing the lower folds on to the metal strut on the boiler and attaching the upper
ones to the centre with the appropriate screws. Repeat the same procedure for the panels (1S).
Mount the panels (2D) fixing the upper folds to the rectangular tube and inserting them into the appropri-
ate slits in the lower panels. Repeat the same procedure for the panels (2S) leaving the burner-control
panel connection cables sticking out from the 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, position the panel (7D) and then
the panel (7S) with fairlead attached to its side panels. Screw on tightly and plug the passage holes with
the appropriate caps.
Attach and screw on the front/central (8) and front/lower (9) panels.
Finally, screw the document holder (10) on to the opposite side of the control panel.
Fig. 6

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6 STARTING
IMPORTANT: before starting insert the flue gas baffles completely in the flue gas pipes, pushing
them in by at least 100 mm.
6.1 PRELIMINARY CHECKS
Before starting the boiler, make sure that:
- The number plate data corresponds to the electrical, water and liquid or gas fuel supply data;
- The burner rating is compatible with that of the boiler;
- The burner and boiler instructions are available in the boiler room;
- The chimney operates correctly;
- The ventilation openings are adequately dimensioned and free of all obstacles;
- The door, the combustion chamber and the burner plate are closed so that the boiler is gas tight at all
positions;
- The system has been filled with water and that any air locks have been eliminated;
- There is frost protection;
- The water circulation pumps operate correctly;
- The expansion tank and the safety valve(s) are correctly connected (with no valves) and operative.
- Check the electrical system and that the thermostats are operative.
6.2 WATER TREATMENT
If the boiler is to be installed in an existing system where there could be frequent losses from the
system or if the hardness of the water is greater than 10 F, it will be necessary to use a filter and a
softener for system water and control the pH above 8-9.
The most common phenomena in heating systems are:
- Furring (calcareous deposits of Calcium Carbonate)
Furring impedes heat exchange between the flue gases and the water, thereby increasing the tempera-
ture of parts exposed 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 the water, but leaves the system via
the chimney.
Calcium Carbonate Diagram
Legend
%% unused fuel
mm mm furring
- Water-side corrosion
Corrosion of metallic boiler surfaces,
waterside, is due to Iron dissolving to
form ions (Fe+). In this process, the
presence of any dissolved gas plays a
major role, in particular oxygen and
carbon dioxide. Often there are corro-
sion phenomena with softened and
demineralised water, which are by their nature aggressive to iron (acid water, that is with pH < 7): in
these cases though clearly there will be no furring, corrosion remains a risk and it will be necessary to
condition the feedwater with corrosion inhibitors.
6.3 FILLING THE SYSTEM
The water must enter the system as slowly as possible, and in proportion to the rate of air purge from the
components involved. In the case of a system with a closed expansion tank, water is injected until the pres-
sure gauge reaches the static pressure for the tank. Then proceed to heat the water to the maximum allowed
plant temperature, but not higher than 90°C. During this operation, the air in the system purges from the
automatic or manual air separators fitted to the system. On completion of the air purge, bring the pressure to
the set value and close the manual and/or automatic water supply valve.