Immergas ARES 440 TEC ERP Product manual

*1.039293ENG*
ARES 440 TEC ERP
ARES 550 TEC ERP
ARES 660 TEC ERP
ARES 770 TEC ERP
ARES 900 TEC ERP
Modular condensing boiler
IE
Instructions and warnings
Installer
Maintenance technician

Warning this manual contains the exclusive instructions for use for professionally qualied
installers and/or maintenance technicians, in compliance with laws in force.
e individual in charge of the system is NOT authorised to work on the boiler.
e manufacturer will not be held liable in the case of damage to people, animals or property
due to the failure to observe the instructions contained in the manuals supplied with the boiler.
1 General information...................................................................4
1.1 Symbols used in the manual........................................................4
1.2 Compliant use of the appliance...................................................4
1.3 Information to be provided to the user .....................................4
1.4 Safety warnings .............................................................................5
1.5 Regulations for installation..........................................................6
1.6 Installation.....................................................................................6
1.7 Water treatment ............................................................................7
1.8 general warnings...........................................................................8
2 Technical characteristics and dimensions.................................9
2.1 Technical characteristics..............................................................9
2.2 View of main parts......................................................................10
2.3 Dimensions..................................................................................11
2.4 Operating data / general characteristics ..................................12
3 Instructions for installation.....................................................13
3.1 General recommendations........................................................13
3.2 Packaging.....................................................................................14
3.3 Operation to unload and remove the packaging ...................15
3.4 Positioning the heating control unit.........................................16
3.5 Connecting the boiler ................................................................17
3.6 Gas connection............................................................................18
3.7 System ow and return pipe connection.................................19
3.8 Additional safety, protection and control devices ..................20
3.9 Hydraulic separator....................................................................21
3.10 Hydraulic system lter ...............................................................21
3.11 Determining the primary circuit pump or boiler pump .......22
3.12 Ball valves.....................................................................................22
3.13 complete optional kits................................................................23
3.14 condensate drain.........................................................................24
3.15 Connecting the ue ....................................................................25
3.16 Flue exhaust manifold connection ...........................................25
3.17 Electrical connections................................................................27
General recommendations........................................................27
230V electrical supply connection ...........................................28
3.18 Connection diagram ..................................................................29
Power supply, gas electrovalve, INAIL, ON/OFF
pump, external probe, ow switch............................................29
Power supply, gas electrovalve, INAIL, modulating pump,
external probe, ow switch........................................................29
INAIL safety connection
(supplied with modulating pump). ..........................................30
ON/OFF thermostat connection..............................................30
Modulating room thermostats connection.............................31
Modulating zone manager connection....................................31
3.19 Practical connection diagram ...................................................32
3.20 Connections and management diagram..................................34
3.21 Examples of installation (functional diagram and
description of connections).......................................................36
3.22 System lling and emptying......................................................41
3.23 Boiler frost protection................................................................41
3.24 Check the adjustment of the pressure to the burner..............42
Nozzles - pressures. ....................................................................44
3.25 Emergency and safety operations ............................................46
3.26 First ignition................................................................................47
4 Inspections and maintenance ..................................................48
INDEX
Immergas S.p.A. declines all liability due to printing or transcription errors, reserving the right to make any modications to its technical and
commercial documents without prior notice.
Mauro Guareschi
Research & Development Director
Signature:
CE DECLARATION OF CONFORMITY
(according to ISO/IEC 17050-1)
e company IMMERGAS S.p.A., with registered oce in via Cisa Ligure 95 42041 Brescello (RE) whose design, manufacturing, and aer sale
assistance processes comply with the requirements of standard UNI EN ISO 9001:2008,
DECLARES that:
e ARES 440 TEC ERP, ARES 550 TEC ERP, ARES 660 TEC ERP, ARES 770 TEC ERP, ARES 900 TEC ERP model boilers comply with the
following European Directives and Delegated European Regulations:
“Eco-design” Directive 2009/125/EC, “Energy labelling” Directive 2010/30/EC, “Gas Appliance” Directive 2009/142/EC, “Electromagnetic Com-
patibility” Directive 2004/108/EC, “Performance” Directive 92/42/EC and “Low Voltage” Directive 2006/95/EC.

4
General information
1.2 COMPLIANT USE OF THE APPLIANCE
e ARES Tec appliance was built based on the current technical level and recognised technical safety rules.
Nevertheless, following improper use the safety and life of the user or other people may be exposed to danger, i.e. damage
to the appliance or other objects.
e appliance is designed for operation in hot water circulating heating systems.
Any other use is considered improper.
Immergas will not be held liable for any damage resulting from improper use.
Any use in accordance with the envisioned purposes includes the strict observance of the instructions in this manual.
1.3 INFORMATION TO BE PROVIDED TO THE USER
e user must be instructed in the use and operation of his/her heating system, in particular:
- Deliver these instructions to the user, as well as the other documents relative to the appliance contained in the packaging in
an envelope. e user must keep this documentation safe so that it is available for future consultation.
- Inform the user of the importance of aeration vents and the ue exhaust system, highlighting how essential they are and how
it is strictly forbidden to change them.
- Inform the user on how to control the water pressure in the system as well as the operations required to restore it.
- Inform the user on how to correctly regulate the temperature, control units/thermostats and radiators in order to save energy.
- Remember it is compulsory to carry out regular maintenance on the system once a year and a combustion analysis every two
years (as per national legislation).
- If the appliance is sold or transferred to another owner or if the owner moves, leaving the appliance behind, always ensure the
handbook accompanies the appliance so that it may be consulted by the new owner and/or installer.
e manufacturer will not be held liable in the case of damage to people, animals or property due to the failure to observe the instructions
contained in this manual.
1GENERAL INFORMATION
1.1 SYMBOLS USED IN THE MANUAL
When reading this manual, pay special attention to the parts marked with these symbols:
DANGER!
Serious danger to
safety and life
ATTENTION!
Possibly dangerous situation
for the product and environment
NOTE!
Tips for the user

5
General information
1.4 SAFETY WARNINGS
ATTENTION!
e appliance must not be used by people with reduced physical, mental and sensorial capabilities, without experience and
knowledge. ese people must be duly instructed and supervised during manoeuvring operations.
ATTENTION!
Installation, adjustment and maintenance of the appliance must be carried out by professionally qualied sta, in compliance
with regulations and provisions in force, as incorrect installation can cause damage to people, animals and property, for
which the manufacturer will not be held liable.
DANGER!
Maintenance or repair work on the boiler must be carried out by professionally qualied sta, authorised by Immergas;
it is advisable to sign a maintenance contract.
Poor or irregular maintenance can compromise the operational safety of the appliance and cause damage to people, animals
and property for which the manufacturer will not be held liable.
Changes to parts connected to the appliance
Do not make changes to the following elements:
- to the boiler
- to the gas, air, water and power supply lines
- to the ue pipe, safety valve and exhaust pipe
- to the constructive elements that aect the operational safety of the appliance.
Attention!
To tighten or loosen the screw-attached ttings, use suitable wrenches only.
Improper use and/or unsuitable tools can cause damage (for ex. water and gas leaks).
ATTENTION!
Instructions for appliances running on propane gas
Make sure that the gas tank has been deaerated prior to installing the appliance.
For a thorough deaeration of the tank contact the liquid gas supplier and in any case authorised sta, in accordance with the law.
Ignition problems can arise if the tank is not thoroughly deaerated.
In this case contact the liquid gas tank supplier.
Smell of gas
In case of the smell of gas observe the following safety instructions:
- do not use electric switches
- do not smoke
- do not use the telephone
- shut o the gas cut-o valve
- aerate the room where the gas leak occurred
- notify the gas supply company or a company specialised in the installation and maintenance of heating systems.
Explosive and easily ammable substances
Do not use or deposit explosive or easily ammable materials (for ex. petrol, paints, paper) in the room where the appliance is
installed.
ATTENTION!
e heat unit must be installed so as to avoid, under the envisioned operating conditions, the liquid contained in it from freezing
and avoid exposing the command and control parts to temperatures below -15°C and over +40°C.
e heat unit must be protected from climatic/environmental variations by:
- insulating the hydraulic and condensation exhaust pipes
- adopting specic anti-freeze products in the hydraulic system.

6
General information
1.5 REGULATIONS FOR INSTALLATION
ARES Tec is a gas category II2H3P heat unit.
e appliance must be installed in accordance with the instructions
contained in this manual.
Installation must be carried out by an authorised professional
technician, who is in charge of enforcing observance of all local
and/or national laws published in the Ocial Gazette, as well as all
applicable technical regulations.
It is necessary to observe the standards, regulations and requirements
for installation provided below, constituting a rough and non-exhaustive
list, in order to follow the evolution of the "state of the art". We
would like to underline that updating the list of standards is the
responsibility of the technicians authorised to carry out installation.
Also observe the standards regarding the heating control unit,
construction regulations and requirements on combustion heating in
the country of installation.
The appliance must be installed, commissioned and subject to
maintenance in accordance with the current "state of the art". is also
applies to the hydraulic system, the ue exhaust system, the installation
room and the electrical system.
Failure to observe the above regulations will void
the warranty.
Attention!
If the new boiler has been replaced in an old system
without having preventively washed it as described
above, do not wash the system, as any residues of
the product in the circuit may ll the generator with
residues aer replacement.
It is advisable to contact a company specialised in
water treatment.
Otherwise, if ARES Tec is being installed on a new system it is advisable
to wash it thoroughly in any case, using products that are suitable for
the entire system, and install a Y-strainer with two cut-o valves on the
return pipe to the boiler, so that it can be cleaned as needed.
is lter will protect the boiler from sediments coming from the
heating system.
In both cases it is necessary to keep the head losses localised in the
primary circuit, for the correct sizing of the pump.
1.6 INSTALLATION
When the appliance is installed on existing systems, make sure that:
- e ue is suitable for condensation appliances, for the temperatures
of the combustion products, calculated and built in accordance with
regulations in force. at is it a straight as possible, water-tight and
insulated and does not have any obstructions or constrictions.
- e ue is equipped with an attachment to evacuate the condensation.
- e heating control unit is equipped with a pipe for the evacuation
of the condensation produced by the boiler.
- e electrical system is built in accordance with specic regulations
and qualied technical personnel.
- e ow rate, head and direction of ow of the circulation pumps is
appropriate.
- e fuel feed line and any existing tanks are set up in accordance with
regulations in force.
- e expansion vessels ensure complete absorption of the dilation of
the uid contained in the system.
- Slurry and build-up have been cleaned out of the system.
If ARES Tec is being installed on existing Systems:
If it is possible to schedule the replacement, it is necessary to wash
the system preventively, with alkaline dispersants. Washing must be
carried out four weeks prior to replacement, with a system operating
between 35°C - 40°C.

7
1 2 3 4 5 2 7 16
General information
1.7 WATER TREATMENT
Treating the supply water allows you to prevent problems and
maintain the functionality and eciency of the generator over time.
e purpose of this treatment is to eliminate or signicantly reduce
problems that can be outlined as:
build-up
corrosion
sediments
biological growth (mould, fungus, algae, bacteria, etc.)
e chemical analysis of the water provides a lot of information on the
state and "health" of the system.
e pH level is a numerical indication of the acidity or alkalinity of
a solution.
e pH scale goes from 0 to 14, where 7 corresponds to neutral.
Values below 7 indicate acidity, values above 7 indicate alkalinity.
e ideal pH value in heating systems with aluminium boilers is
between 6.5 and 8, with a hardness of 15°F.
Water in a system with a pH value outside of this range considerably
accelerates the destruction of the protective oxide layer which forms
naturally inside the aluminium bodies, and would not occur naturally:
if the pH level is lower than 6 it contains acid, if it is above 8 the water is
alkaline, either due to an alkaline treatment (for example phosphates or
glycols operating as antifreeze) or in some cases the natural generation
of alkalis in the system.
Vice versa, if the pH value is between 6.5 and 8, the aluminium surfaces
in the body are passivated and protected from further corrosive attacks.
To minimise corrosion, it is essential to use a corrosion inhibitor.
In order for it to work eciently, however, the metal surfaces must
be clean.
The best inhibitors on the market also contain an aluminium
protection system that stabilises the pH levels of the ller water,
preventing sudden changes (buer eect).
It is advisable to systematically check (at least twice a year) the
pH value of the water in the system. In order to do so a chemical
laboratory analysis is not required, but a simple check using a
analysis "kit" contained in a carry cases, easily available on the
market.
It will therefore be necessary to set up the devices shown in the gure
in the heating system.
THE COUPLING MUST BE SET UP ON THE
RETURN PIPE TO THE PRIMARY CIRCUIT
DOWNSTREAM OF THE PUMP.
All of the precautions required to avoid the formation and localisation of
oxygen in the water of the system. For this reason the plastic pipes used
in the under-oor heating systems must not be permeable to oxygen.
Make sure that any anti-freeze products are compatible with aliminium
and any other parts and materials in the system.
ATTENTION!
Any damage caused to the boiler, due to the formation
of build-up or corrosive water, will not be covered by
the warranty.
ATTENTION!
These appliances are designed and developed to
transfer heat to a heat carrying uid possessing the
characteristics described here, they are not suitable to
directly heat water intended for human consumption.
Key:
1 - Ball valve
2 - Sample trap
3 - Filling unit
4 - Cut-o device
5 - Water treatment unit
6 - Litre meter (recommended)
7 - "Y" strainer
Example of water treatment unit

8
General information
1.8 GENERAL WARNINGS
e instruction handbook is an integral and essential part of the product
and must be kept safe by the individual in charge of the system.
Read the warnings contained in the handbook carefully, as they provide
important instructions regarding installation, user and maintenance
safety.
Keep the handbook safe for future consultation.
e appliance must be installed and maintained in accordance
with regulations in force, pursuant to the instructions of the
manufacturer, the state of the art and by authorised and qualied
personnel, in accordance with the law.
Professionally qualied personnel means sta with specic technical
skills in the sector of heating system parts for civil use, hot water
production for domestic use and maintenance. is personnel must
have the authorisations required by legislation in force.
Incorrect installation or poor maintenance can cause injury to persons
and animals and damage to objects, for which the manufacturer is
not liable.
Before carrying out any cleaning or maintenance operations, cut the
appliance o from the power mains by acting on the switch on the
system and/or using the cut-o devices.
Do not obstruct the intake/exhaust pipe terminals.
In case of breakdown and/or poor operation of the appliance, switch it
o, and do not attempt in any way to repair it or intervene directly. Only
contact personnel that has been authorised in accordance with the law.
Any repairs to the products must be carried out by authorised Immergas
personnel only, using original spare parts only. Failure to observe
the above can jeopardise the safety of the appliance and will void the
warranty.
e guarantee the eciency of the appliance and its correct operation it
is essential for authorised personnel to carry out annual maintenance.
If the appliance is put out of use for downtime, any part that is
susceptible to posing a potential source of danger must be made safe.
Before re-commissioning an appliance that has been put out of use,
proceed to washing the domestic hot water production system, making
water ow through it for the amount of time required to change the
water completely.
If the appliance is sold or transferred to another owner or if the owner
moves, leaving the appliance behind, always ensure the handbook
accompanies the appliance so that it may be consulted by the new
owner and/or installer.
All appliances with optionals or kits (including electric) must only use
original spare parts.
e appliance must only be employed for its expressly foreseen use.
Any other use must be considered improper and therefore dangerous.

9
Technical characteristics and dimensions
2TECHNICAL CHARACTERISTICS AND
DIMENSIONS
2.1 TECHNICAL CHARACTERISTICS
- Heat generator, to heat Low Nox condensation gas
- Comprised of a heat module designed to operate on its own or in a
set
- Can be set up directly outside (IP X5D)
- Low water content
- High response speed to load changes
- Single ue exhaust that can be positioned on 3 sides
- Unied ow and return hydraulic manifolds
- Comprised of 4 or more heating elements (between 4 and 8),
aluminium/silicon/magnesium casting
- Including total irradiation premixing modulating burners
- None of the heating elements have hydraulic cut-o devices
- Single gas supply pipe
- Modulated power between 22 ÷ 108 kW/element.
TEMPERATURE CONTROL DEVICES:
- ROOM NTC sensor (every heating element)
- Room Limit ermostat (every heating element)
- Flow NTC sensor (General)
- Return NTC sensor (General)
- Approved safety thermostat (To be ordered and installed on INAIL
section in parag. 3.8)
- GCI global ow probe.
OTHER SAFETY DEVICES according to the R COLLECTION
see parag. 3.8
POP-UP control panel composed of:
- ON-OFF switch see parag. 3.25
- TGC boiler thermoregulation/manager
- GCI (internal cascade management board)
- Protection fuses
- Any limit thermostats
- Fan air pressure switch
- Condensation water level sensor
- Gas pressure switch
- Exhaust pressure switch (anti-obstruction).
- e entire heating unit is equipped with global temperature control
NTC sensors on the ow and return manifolds.
-Integral insulation with non-allergenic synthetic wool.
- Total premix burner, modulating, with "metal foam" radiation
combustion chamber. Premixing in the fan. Automatic separating
backow diaphragm from the combustion chamber.
- Sound emissions at maximum power below 49 dBA.
- Operation during heating: determining the instantaneous power
through a control microprocessor, with preset comparison parameters
between requested temperature (or calculated by the outdoor
thermoregulation) and global ow temperature.
- Logic of operation:
- Possibility of controlling the power of the single heating elements
for calibration and/or assistance with reserved access code.
- D.H.W. production through priority NTC probe, to control the
storage tank load through a pump or three-way deviator valve
through the supplied TGC thermoregulator.
- Possibility of controlling the power of the single heating elements.
- Heat request control: temperature setpoint and modulation level.
- Monitoring the state of operation and temperatures.
- Alarm notication.
- Parameter setting.
- Control relay to switch on a pump at a xed speed.
- Analogue 0÷10V output to control a modulating pump.
- Emergency operation: this allows you to avoid the system from
stopping due to an interruption in communication with the adjusting
system or possible remote management of the control unit:
- e possibility of selecting the emergency temperature through
supplied "Constant Setpoint" heating elements: 70°C, maximum
power 50%.
- Alarm management.
-Alarm reset input.
-Alarm notication Relay.
- Condensation collection tray with stainless steel exhaust trap.
- Easily removable integral panelling comprised of oven-painted steel
panels suitable for outdoor installation.
- Condensation collection tray with stainless steel exhaust trap and ue
chamber.
- Incorporated deaerator.
e request for heat can be generated by the TGC thermoregulation/
manager or alternatively by the GCI (internal cascade management
board).
The management logic envisions simultaneous operation of the
maximum number of heat elements, so as to always obtain the
maximum eciency. Since it guarantees the maximum exchange area
based on the delivered power. e elements are made to operate so as
to equally divide the operating time.
e hot water that is produced is pushed by the pump located on the
return of the primary ring to the ow of the hydraulic separator. From
here a second pump (system - see suggested diagrams) will distribute to
the various utilities. From the system, return the cooled water is taken
in by the pump on the return, through the hydraulic separator, to start
the cycle towards the generator again.

10
Ventilatore
Valvola gas
Bruciatore
Camer a
di
comb ustione Te rmostato
di sicurezza
Elemento
piolinato
Collettore
raccogli condensa
Elettrodo
di accensione
Pannello
Sifone
TUBO GAS
BACINELLA
RACCOGLI
CONSENSA -
RACCORDO
CAMINO
TELAIO
Profondità min. 100 mm
COPERCHIO
BR UCIATORE
MANDATA
RISCALD AM.
RITORNO
RISCALD AM.
SFIATO ARIA
AUTOMATICO
Sensore di
livello
Technical characteristics and dimensions
2.2 VIEW OF MAIN PARTS
ue outlet LEFT, RIGHT, REAR side
ow LEFT side
return LEFT side
Gas inletLEFT side
GCI: under the front casing
PANEL
GAS VALVE
FAN
GAS PIPE
BURNER
COVER
BURNER
LEVEL
SENSOR
CONDENSATION
COLLECTION
PAN
FLUE FITTING
FRAME
Min. depth 100 mm
HEAT.
RETURN
HEAT. FLOW
AUTOMATIC
AIR BLEED
VALVE IGNITION
ELECTRODE
COMBUSTION
CHAMBER
STUDDED
ELEMENT
TRAP
SAFETY
THERMOSTAT
CONDENSATE
COLLECTION
MANIFOLD