INTRODUZIONE

TECHNICAL MANUALTBXCONDENSINGLOW NOx BOILER

INDEXTOC1 GENERAL DETAILSThese condensing heating boilers allow full exploitation of heat resulted from combustion, subjecting the fumes to a considerable temperature reduction or dehumidifying boost.

The heat generator does not impose return temperature limits.The performance will increase reducing the return temperature, therefore, the floor standing heat exchange surface systems with low return temperatures will have an improved efficiency;The efficiency will remain high even with traditional heating systems operating at high temperatures (e.g. t 80/60 C).The boiler bodies whose axes are inclined in relation to the vertical axis, consist of: Entirely submerged passing flame combustion chamber; Corrugated smoke ducts whose particular shape increases the heat exchange surface, develops smoke turbulence and allows condensate formation and drainage through the rear collection chamber; Water containment casing connected to the low and medium temperature return, delivery and the control and safety accessory connections; The smoke chamber able to collect condensate through the combustion chamber nozzle from the chimney and condensate drainage tube.All surfaces that come into contact with the combustion products are made from STAINLESS steel and, therefore, are also resistant to acid condensate attacks.High efficiency due to complete exploitation of the fuel's thermal energy and to considerable insulation consisting ofself extinguishing, fire resistant reticulated polyethylene foam, label these boilers as "4 star high-efficiency" according to Efficiency Directive 92/42/EEC.Every boiler body is equipped with an air/gas pre-mix burner.Permanent lowering of combustion products in the full combustion chamber limit nitrogen oxide (NOx) formation.2 SUPPLIED EQUIPMENTThese heating units consist in one to three components to connect with supplied kits.TBX consisting of a single THERMAL UNIT:TBX 35 code 81024035 Effective output kW 35*TBX 50 code 81024050 Effective output kW 50*TBX 70 code 81024070 Effective output kW 70*TBX consisting of TWO THERMAL UNITSTBX 100 code 81024100 Effective output kW 50+50*TBX 120 code 81024120 Effective output kW 60+60*TBX 140 code 81024140 Effective output kW 70+70*TBX consisting of THREE THERMAL UNITSTBX 150 code 81024150 Effective output kW 50+50+50*TBX 170 code 81024170 Effective output kW 57+57+56*TBX 190 code 81024190 Effective output kW 63+63+64*TBX 210 code 81024210 Effective output kW 70+70+70** with 50C delivery and 30C returnIn order to optimize the operation of the modular heat generator (two or three thermal units connected in cascade) all the burners must have the fan speed adjustment potentiometers set at the same values(see the POWER ADJUSTMENT chapter).The overall power of the boiler is given by the sum of individual heating units, so in order to reach intermediate values set the trimmers properly.ASSEMBLED STANDARD COMPONENTS INAIL SafetiesInserted in the control panel: Thermometer Full scale adjustment thermometer 100 C Safety thermometer 110C ManometerMounted on the boiler: Safety valve with drainage funnel Maximum pressure regulator Minimum pressure regulator Fuel interruption valve Control panel witheterm electric components Boiler probe Fume thermostatSTANDARD ACCESSORIES AND DOCUMENTS INAIL valve with manometer connection (installed by the customer on the external manifold) External probe Cascade collector probe (for 2 or 3 boiler unit version) Thermal unit's identification plate mounted on the front cover panel. Manual of the termal unit ** In order to configure the electronic board, who's parameters depend on the loaded firmware, see the manual related to theETERM01 boiler management board. The firmware can be downloaded from the website www.icicaldaie.com:SelectDownload NEREIX ETERM Manuali IT_Manual ETERM01.pdf, Free registration is required to download the manual.The standard accessories and documents are placed on top of the boiler and contained in the cardboard package.ASSEMBLY STANDARD COMPONENTS

TBX consisting of a single THERMAL UNIT: Fumes exhaust kit TBX consisting of TWO THERMAL UNITS Fumes exhaust kit code TBX V140.50 Manifold kit code TBX V140.30 Accessories kit code 90082020TBX consisting of THREE THERMAL UNITS Fumes exhaust kit code TBX V210.50 Manifold kit code TBX V210.30 Accessories kit code 900820303 GENERAL WARNINGEach boiler is provided with a manufacturers 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 (natural gas or lpg) Max operating pressure.A manufacturers certificate is also provided which certifies the hydraulic test.The installation must be carried out in accordance with in force regulations by professional qualified staff , meaning staff specially trained in the field of heating system components used in domestic environments for hot water production, staff trained mainly by a Service Centre authorised by ICI CALDAIE.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, as a consequence, CE-marked. EEC directives are as follows: Directive on Gas 2009/142/CE Directive on Output 92/42/EEC Directive on Electromagnetic Compatibility 2004/108/CE Directive on Low Voltage 2006/95/CE

4 TECHNICAL SPECIFICATIONS

DIMENSIONSTBX consisting of a single THERMAL UNIT:

TBX consisting of TWO THERMAL UNITS:

TBX consisting of THREE THERMAL UNITS:

POS.1 ELEM. 2 ELEM.3 ELEM.

1 - FUMES EXHAUST80160160

2 - COND. DRAIN. PIPE-2525

3 - GAS3/4"1-1/2"1-1/2"

4 - DELIVERY1-1/4"DN65DN65

5 - RETURN MEDIUM TEMP.1"DN50DN50

6 - RETURN LOW TEMP.1-1/4"DN65DN65

7 - CONDENSATE DRAINAGE284040

INAIL ACCESSORIES

POS.NAMECODEQ.TY'

1INTERMEDIATE TBX V70.00 BODY710280701

2COND. DRAINAGE RUBBER TUBE L=1500 "STELT"140001951

3DISCHARGE VALVE M 1/2" - WITH HOSE CONNECTION180228101

5PRESSURE SWITCH M 1/4 (0.2 - 6 BAR)L45534901

6ADAPTER MF 1/2" X 1/4"70500511

7SAFETY PRESSURE SWITCH R.M. (1-5 BAR) F1/4"160310081

8T-JOINT 1/2"70400132

9SAFETY VALVE 3,5 BAR - F 1/2" 130915691

10NIPPLE =4 L=33400003201

11FUNNEL DRAIN 3/4"130520451

12HOSE CONNECTION 3/4" X TUBE 20140004141

13NIPPLE 1/2" 600002551

14CHECK VALVE X TERMOID. 1/2" - 1/4"200000701

15HOSE CLAMP 15-25-9100501021

16REDUCING NIPPLE 1/2" X 1/4" GALVANIZED IRON70251521

17RUBBER TUBE 20X28 (V.SCAR.WALL)140004461

5 INSTALLATION WARNINGSBefore 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 release into the flue (unless designed to serve several utilities). See the regulations in force.THERMAL PLANTBOILER ROOMAs 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.EXTERNAL INSTALLATIONIt is possible to utilise a special base (optional) for external installation to further weatherproof the thermal plant. CHIMNEYThe pressurised boiler, is so-called, because it uses a burner provided with fan. The fan introduces into the combustion chamber, the exact amount of air necessary in relation to the fuel and maintains an pressurisation in the furnace equivalent to all the internal resistances of the flue gas path as far as the boiler exhaust. At this point the fan pressure should have dropped to zero to prevent the flue connection pipe and the lower area of the flue itself from being under pressure and combustion gas leaks occurring in the boiler room.The connection pipe from the boiler to the flue must slope incline in the direction of the flue gas flow with recommended gradient of no less than 10%. Its path must be as short and straight as possible with the bends and fittings rationally designed in accordance with air duct criteria.WARNING The flue gas temperature of this boiler (between 35 and 120C) 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.HYDRAULIC CONNECTIONSEnsure 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 (5 bar). 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.In case the single unit boiler's condensate neutralisation (optional) is not being used, check if a siphon is connected to the condensate drainage tube, inside the boiler, in order to facilitate fume output.NOTE: if only one return is required, always use the low temperature oneELECTRICAL CONNECTIONSElectrical 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.Please refer to this manual's wiring diagram when connecting the control panel.PRE-MIX BURNERThe boiler is supplied with a pre-mix burner already mounted on the boiler, suitably calibrated for a 20mbar gas pressure.Check combustion parameters before assembly (CO e CO2).Please refer to the BURNER chapter for burner information.BOILER BODY INSULATIONThe boiler's body and upper door side's insulation consists of a layer of insulating, reticulated, fire resistant, self extinguishing, polyethylene foam.6 SET-UPCASING DISMANTLING

CONTROL PANEL TURNOVER AND FASTENING

TBX accessories kit for three thermal units code 90082030 (image)TBX accessories kit for two thermal units code 90082020

AExpansion tank connectionBScrews and nuts for lever blockCOpened valvePOS.NAMECODEQ.TY'

9008202090082030

1T-JOINT 3/4"07040004(3-4)11

2GALVANIZED ADAPTER 3/4"X3/8" MF 07050013 (MF 3-4 X 3-8)11

3ADAPTER MF 1" X 3/4"07050014 (MF 1 X 3-4)23

4STRAIGHT CONICAL BRASS NOZZLE 1"1/2" MF 706010411

5STRAIGHT NOZZLE MF 1''07060251 (MF 1)23

6CAST IRON F/331 STRAIGHT NOZZLE 1"1/4 FF07060260 (FF 1-1.4)23

7GALVANIZED IRON PLUG 3/4" M707020411

8GALVANIZED IRON PLUG 1"1/2" F 07070355 (1-1.2 F)11

9HOSE GAS MF L=130-220 mm YELLOW708020123

10HOSE AVC32 1''1/4 L=245 ATT. MF708021723

11HOSE AVC32 1''1/4 L=480 ATT. MM708021823

12HOSE AVC25 1'' L=550 ATT. MM708021923

13GASKET 3/4 - 38 X 29 X SP.2906004623

14CAP NUT 5M1003104023

15ADJUSTABLE SUPPORT 30 M101005002044

16TUBE FASTENING COLLAR X TUBE 1"1/2"1005030322

17THREADED SOCKET M10X19 FTT/C HOLE12 ACC.1005051844

18BEAD 8X20 C/GALVAN. TIP UNI59231005071622

19POLISHED ZN WASHER 8X14 C60 1006001022

20FLAT GALVANIZED WASHER 5X10 UNI65921006004223

21CROSS GALVANIZED SCREWS M5X16 TC DIN79851007151623

22ELECTRIC ACTUATOR 220V - FOR BALL VALVE1302009023

233 WAY PORTAMAN ACC VALVE MF 3/8 MOD.6903001303204011

24GAS BALL VALVE M/F 3/4"1308003623

25BALL VALVE 1"1/4 MF1308005723

26MOTORISED BALL VALVE MM 1"1/4"1308006223

273 WAY "T-JOINT" VALVE 1"1308007123

28HOSE CONNECTION 3/4" X TUBE 201400041423

29PROBE SHEATH H1/2 X 3 TUBES L=90 D=81400203022

30WASHER 1 44X34X3 ECOL.005 RACC.11/21805005023

31WASHER 11/4 56X42X3 ECOL.0051805012023

32WASHER 23,5X15,5XSP.2 - CON.3/4"5000082023

33BLACK PAINTED MANIFOLD ENSEMBLE TBX V210 TBX V210.3011

34YELLOW PAINTED GAS MANIFOLD TBX V210 RAL 1004TBX V210.3311

35MANIFOLD SHELL i75 L= 1000 TBX V210.3544

36MANIFOLD SHELL i 60 L= 1000TBX V210.3722

PHASE 1Position the gas and hydraulic manifolds.Mount the manifolds on the wall and fasten using supplied screws and slots (1)

PHASE 2Insulate the manifolds.

PHASE 3Mount drainage ensemble onto the delivery manifold using the 3/4'' T-joint:- Valve for the INAIL sample manometer- 3/4'' connection for the expansion tank

PHASE 4Connect the manifolds to the boiler's connections using the supplied valves. PHASE 5

AGAS TUBE: 11/2 mount the ingoing brass nozzle and the F 11/2 plug on its extremity BSelect RH or LH for the condensate drainage tube output and remove the base tray's precut slot plugs.CInsert the boiler's condensate drainage tubeDInsert the safety valve drainage hosePHASE 6Connect the fume exhaust to each individual thermal unit.

EInsert the fume thermostat's bulb into the fume exhaust tube's nozzleMount the supplied fume collector for two or three TBX units.

7 ELECTRICAL WIRINGTERMINALSTERMINAL NAMEFUNCTION

HIGH VOLTAGE

X 1 LCONTROL PANEL MAIN POWER SUPPLYL

TT

NN

1EXTERNAL SAFETIESIN

2OUT

X 2 3BURNER POWER SUPPLYL

TT

4N

5BURNER CONSENTT1

6T2

X 3 7STAGE 1 SIGNALB4

8STAGE 2 SIGNAL (UNUSED)B5

9BLOCK SIGNALS3

103 POINT COMMAND (CONFIGURABLE FOR MIXING VALVE)T6

11T7

12T8

X 4 13UNUSED

14

15VOLTAGE FREE CONTACT OUT R2IN

16OUT

X VM BR(BROWN)MOTORIZED VALVE POWER SUPPLYL

BU(BLUE)N

GN(GREEN)MOTORIZED VALVE COMMANDL1

WH(WHITE)MOTORISED VALVE LIMIT SWITCHFC

PN(RED)FC

LOW VOLTAGE / SIGNAL

X 5 17PT1 Boiler Probe (PT1000)1

182

19PT21

202

21PT31

222

23NTC1

242

25IN 0-10 V+

26-

X 6 27OUT 0-10 V (BURNER MODULATION)+

28-

29RS485 (RS1)A

30B

31RS485 (RS2)A

32B

33C

8 CONTROL PANEL

SAFETY THERMOSTAT WITH MANUAL RESET

STANDARD EQUIPMENT AND CODES OF THE MAIN CONTROL PANEL SPARE PARTS- Manual of the electronic board for ETERM01 boiler management ....................................................Spare part cod. 93120332- Electronic board ..Spare part cod. 17120273- LCD Display .Spare part cod. 17120274- Main switchSpare part cod. -Burner mode switch (Manual / Off / Automatic)..Spare part cod. - Operation switch of the 2 programmable outputs (Manual / Off / Automatic) ..Spare part cod. - PT1000 boiler probe ..Spare part cod. 16111247- CE / ISPESL full scale regulating thermostat 100CSpare part cod. 16090029- CE / ISPESL 110 C safety thermostat ...Spare part cod. 16090032- Fumes safety thermostat 110 CSpare part code - CE / ISPESL thermostat .Spare part cod. 16080209- Pressure gauge .Spare part cod. - External probe .Spare part cod. 17120012(Optional) Accessories for the control panelSystem management panel for input / output implementation .Cod. QETERM02 Temperature probe PT1000 .Cod. 16111247PT1000 immersion probe for water heaters, mixed zone, solar panels, etc..NTC Temperature probe .Cod. 18022218Immersion probe for water heaters, mixed zone, etc..Fumes temperature probe PT1000.Cod. CB1093Duct temperature probe PT1000.Cod. CB1091Air duct probeDuct temperature probe NTC . CB1092Air duct probeModem KIT with antenna and 1,5 meter cable .Cod. CB876Installed inside the boiler's panel Modem antenna with 10 meter cable ....Cod. CB913PC modem ....Cod. CB916For remote computer - system modem communication9 CONTROL PANEL QUICK CONFIGURATIONThe firmware loaded on the electronic board can be upgraded and the operations can be implemented.For additional information please consult the manual regarding the ETERM01 boiler management board downloadable from www.icicaldaie.com:related to the ETERM01 boiler management board downloadable from www.icicaldaie.com:SelectDownload NEREIX ETERM Manuali IT_Manual ETERM01.pdf, Free registration is required to download the manual.

Firmware update and configuration from the PC are implemented using the etermPCmanager software available at www.eterm.it and www.icicaldaie.comDISPLAY

WIRING CHECK PROCEDUREFor the R1 and R2 outputs:Set the mechanical switches to:-Manual and check if the devices connected to R1 and R2 are powered on( R1 may be connected to the cascade valve)-0 and check if the devices connected to R1 and R2 are powered-offFor burner control, when setting the switch to the manual mode:-Check if the regulating thermostat causes burner start-up.ProbesThe probes that must be connected depend on the configuration that will be implemented. The boiler probe is always necessary and it can be viewed in the upper right side (boiler temperature)Burner notifications:Make sure that when the burner's auxiliary power supply are enabled, this symbol is displayed Make sure that in case of burner block, this symbol is displayed Make sure that when the burner is lit (flame presence) this symbol is displayed In case of failure (for example a disconnected or short-circuited probe), the "alarm" icon will flash in the "menu" section Select the "Instantaneous alarms" menu to check current alarm type.ELECTRONIC BOARD CONFIGURATIONThe meaning of the keys is variable. Please refer to the corresponding icon displayed on the screen.Standard parameters are loaded in the electronic board's firmware and can be used as a starting point for the configuration of your system. The TBX's following preloaded configurations may be used:- TBX:automatically sets the appropriate parameters of a single unit TBX boiler - TBX Master:automatically sets the appropriate parameters of a cascade master TBX unit - TBX Slave 1 or 2:automatically sets the appropriate parameters of a slave TBX boilerAlways conduct a quick setup before starting a configuration (even from PC).This operation allows the cancellation of previous configurations conducted by mistake or by third parties.After a quick setup all parameters are still editable.Enter the menu and scroll using the arrow keys to the Quick setupmenu Access the menus by pressing and select the desired predefined setup.Press and hold the key until the electronic board will reset.MAINE PARAMETERS THAT MUST BE CHECKEDSome parameters can be locked to prevent configuration tampering.For this purpose, there are two levels (user and technical). The controller's default setting is "technical" and thus allows a complete freedom of configuration.Please refer to the manual of eterm boiler's electronic board (Code 93120301)."General configuration" menuContains parameters related to:- Language - Address configuration (if necessary)- The external probe (yes / no / system: if the board is slave to a master with an external probe)- Boiler mode (single / master / slave)- Cascade parameters (if the device is cascade master) - Display contrast"Burner parameters" menu-Burner type: the TBX's quick setup configures the controller to control the burner with 0-10 volt impulses- Time between maximum and minimum power: TBX's quick setup implements the correct value- Fumes probe: input enabled (off = no fumes probe) and possible burner shut-down threshold."Operation mode" menuThis menu configures the mode of setpoint determination in automatic mode.The menu expands displaying required parameters when various functions are enabled:- Fixed Point 1 or 2: requires the use of inputs with digital function (open / closed) After this feature is enabled, the system will request the temperature to be associated with the closing of the relay and possible schedule.An input may not be used as digital and analogue at the same time (temperature probe or 0-10 Volt input). The configuration via PC eliminates the posibility of configuration inconsistencies- Programmed operation: fixed temperatures (comfort / reduced / off) depending on a schedule. You must choose the associated program and the temperatures (in off mode the boiler will operate according to an antifreeze temperature).- Boiler climatic curve: Select the climatic curve (OFF = feature disabled) and then select possible digital conditions and / or schedule to associate with the request.- 0/-10 volt operation Select the function, the temperature corresponding to 10 volts and possible digital conditions and / or schedule to associate with the request (0 volts always corresponds to 0C).- Time intervals and temperature: Allows configuration of-Boiler minimum and maximum temperatures-Antifreeze temperature-Manual function and climatic curve setpoint thresholds-Pump circulation -Various probe offset (correction of the displayed reading)"Domestic water" menuConfigure if a water heater is present"Output configuration" menuAssociate the R1 and R2 outputs with:-Boiler pump (or valve)-Cascade pump-Condensate pump-Water heater pump-Solar circuit pump(by implementing this function the PT2 is associated with the solar panel and PT3 to the solar accumulation tank probe).-An alarm (the relay closes the board triggers an alarm: probe, burner, bus communication)(by configuring the board from a PC, additional alarm conditions may be configured such as relay closing / opening, temperature limits, etc.)-System pump-Direct temperature-Mixed temperature-Fixed point 1/2-1-2-3 schedule"Domestic water" menuConfigure if a mix circuit is presentForcingAllows digital and analogue output forcing in order to verify board and/or the connected user functionality.Boiler statusAllows you to view all operational and relay data.Date / time /periodCaution:- The parameters can not be modified if the device is set as slave.- Climatic operation is enabled only during winter time.Time programs3 weekly schedules are available that can be associated wit various functions:- Operation mode- Water heater- Mixing valveInstant alarmsDisplays current alarms (currently active)Alarm historyDisplays the last 50 alarms (can be reset from PC or keyboard see the eterm boiler electronic board's manual, Code 93120301).10 CASCADE BOILER CONFIGURATIONIn a cascade the master's setpoint (manual or automatic) represents the delivery manifold's setpoint.Check if the manifold's probe is connected to the master's PT2 input and if the bus connections have been carried out.Use the specific quick setup :- TBX Master- TBX Slave 1 o 2Once the quick setup has been completed for all slave devices, from the master unit access theAddress configuration menu and press the key If the configurations are correct and if the bus is correctly connected , the master unit's screen will display a list of cascaded device registration numbers.The PC configuration is conducted by typing the board's registration number in the address list.However, it is recommended that you run the quick setup even before a PC configuration.The board's serial number is printed on the transformer and is displayed on screen during the control panel's start up.After the address configuration, the master displays e the slave .If the slave device's addresses are not configured or if the bus connection is interrupted, the screen will display .The devices' cascade symbols are displayed intermittently.When displayed and cascade setpoints are switched on (determined by the master unit).When displayed and boiler setpoints are switched off.Each single boiler is then configured as described in the previous paragraph paying particular attention to burner parameters and output configuration."Operation types" will settable only by the master unit (which determines the manifold's set point).Check these fundamental parameters form the master's configuration ("General Setup" menu):- Cascade time reversal:

OFF= no priority reversal

0= priority reversal at any interruption / request reset

xx hours= priority inversion after xx houres and after any interruption / request reset- Manifold's initial dosage: initial setpoint temperature difference between boilers and manifold11 MODEM (optional) ALL THE ASSEMBLY AND WIRING OPERATIONS MUST BE PERFORMED WITHOUT VOLTAGEGENERAL CHARACTERISTICS OF THE MODEMThe modem is directly powered by the board by means of the flat.Cut off power supply when connecting the modem and when inserting the SIM card.The SIM card must be enabled for data traffic (no voice!!).The SIM must be pushed to limit switch: a click will anounce a successful insertion.Before inserting the SIM, disable the PIN by using a cellphone.

Main characteristics: Module MODEM GSM - GPRS Quad-Band LED that signals GSM network sign-in status Buzzer for acoustic signals (disabled) TTL interface Compatible with the NEREIX motherboardRADIO CHARACTERISTICS Quad-band EGSM 850/900/1800/1900 MHz Emission power: class 4 (2W) @ 850/900 MHz class 1 (1W) @ 1800/1900 MHz Sensitivity: 107 dBm (typ.) @ 850/900 MHz 106 dBm (typ.) @ 1800/1900 MHzGPRS CHARACTERISTICS GPRS class 10 Mobile station class B Encoding patterns: from 1 to 4 PBCCH supportThe green status LED stands for: FAST FLASHING= Searching for a network SLOW FLASHING= Registered in a network CONTINUOUSLY ON= Data connection in progressIn order to mount the antenna with optional extension, remove the serial antenna by pulling the connector directly from the module's connector and insert the new one.Insert the antenna in the appropriate socket (in case the extended antenna is used, use a cable socket for the extended antenna's output from the control panel).MODEM ASSEMBLYRemove the two small middle nuts that fasten the board in the lower part (adjacent to the keys).Assemble the 2 hexagonal turrets (A).Position the modem board after having removed the antenna.Fasten the board with the nuts (B) removed previously.Connect the flat onto the board and modem.

The antenna supplied can be fastened inside the panel (with its double-sided tape) or brought to the outside, compatibly with the length of the wire included in the supply.If necessary, in order to pick up the signal outside of the room, use the optional antenna with a 10 meter extension (code CB913)12 eterm PANEL UTILISATIONIf the controller is not configured or is faulty the burner can be controlled by the mechanical thermostat by setting the burner's mechanical switch to MANSimilarly the devices connected to R1 and R2 can be activated.Once the electronic control unit has been activated, all the electronic switches must be set to AUTO.The electronic board has three operating modes that can be selected with by pressing and holding the left side key(from the main page):

Standby = only the anti-freeze function is enabled.

Manual = the boiler's setpoint (or manifold if the boiler is cascade master) and can be set manually using the "+" and "-" buttons.

Automatic = the boiler's or manifold's setpoint (if the electronic board is cascade master) is determined automatically, depending on the implemented configurations (operation type - domestic water - mixing valve).If the cascade slave is in:

Standby = only the anti-freeze function is enabled.

Manual = the boiler's setpoint can be set manually by using the "+" and "-" keys and the boiler is relieved from cascade master.

Automatic = the boiler's setpoint depends exclusively on the master's commandsCascade slaves will normally be set to Automatic mode.A special menu has been provisioned for the user and it only contains the parameters useful for the current configuration.In automatic mode, from the main screen, an operator can easily access the schedules by pressing .During the operation, the following icons may appear: if a hot domestic water production request has been activated. if a mix circuit request has been activatedIf multiple requests are activated the symbols alternate.13 BURNERWarranty and liabilityThe manufacturer gives warranties regarding the burner in respect to in force regulations.Warranty and liability rights are declared void, in the event of damage to persons and/or things, where the damage itself refer to one or more of the following causes:-improper burner commissioning, use and maintenance;-improper, erroneous, and unreasonable burner use;-unauthorised personnel intervention;-unauthorized equipment modifications;-use of the burner with faulty safety devices, applied in the an improper way and/or non-functioning;-installation of additional components that are not tested together with the burner;-burner supply unsuitable fuels;-fuel system feeding defects;-use of the burner after the occurrence of an error and/or a fault;-repairs and/or revisions improperly executed;-combustion chamber modification through the introduction of inlays that prevent normal flame development constructively set;-insufficient and inappropriate supervision and care of burner components subjected to wear.-non-genuine part use (spare parts, kits, accessories and optional components);-causes of force majeure The manufacturer also declines any responsibility for failure to comply with the instructions stated in this manual.Personnel trainingThe user is the person, institution, organization or company, which has bought the machine and that means to use it for its intended purpose.The machine and personnel training is the customer's responsibility.The customer:-is required to entrusts the machine only to qualified and trained personnel;-is required to take all necessary measures to prevent access to unauthorized personnel to the machine.-is required to adequately inform their personnel to apply and comply with safety requirements. To this end, the customer must strive to ensure that all employees are knowledgeable regarding the use and security instructions;-must inform the manufacturer in case accident prevention system defects or malfunctions are discovered, as well as any allegedly dangerous situation.-The staff should always use the means of individual protection required by the legislation and follow the instructions presented in this manual.-The staff must comply with all instructions regarding danger and caution signs displayed on the machine.-The staff must follow all the signs of danger and caution reported on the machine.-The staff has the obligation to report to their superior every problem or dangerous situation that might occur.-Installing other brand components or implement possible modifications can change the characteristics of the machine and therefore compromise operational security. The Manufacturer declines any and all responsibility for any damage that may arise due to the use of parts that are not original.BURNER DESCRIPTION

POS.NAMECODEQ.TY'

1REDUCED NIPPLE 3/4"X1/2" 70253091

2LOCK NUT 3/4" 180303101

3GAS BURNER AIR DUCT - TBX V70TBX V70.371

4BURNER FAN G 70 MXH PREMIX-UNIT 17010190P11

5FUEL INTERRUPTION VALVE130520481

6BURNER TUBE G 70 MXH PREMIX-UNIT 17010190P21

7NIPPLE =4 L=33400003201

8YELLOW HOSE MF 3/4X 3/4 GAS L=750007080203 (MF 3-4)1

9SCREWS 8X25 TE CL8.8-ZN GALVANIZED ALL THREADED100708354

10FLAT GALVANIZED WASHER 8X15 UNI6592100600094

11FLAT GALVANIZED WASHER 5X10 UNI6592100600424

12SCREWS TBEI CL-10.9-ZN GALVANIZED100705194

13NUT 5M HIGH CL8-ZN GALVANIZED100310514

14BURNER GASKETR3020294 2

15GASKET 23,5X15,5XSP.2 CONNECTION 3/4"180500201

16CERAMIC MATTRESS L= 610 INSULFRAX-S BLANKET920706001

17DOORTBX V70.051

18GALVANIZED FLAME VISOR (AQ-3001)70808011

19GASKET 30X22X1,5 OMNIA BLU DOOR VISOR90600402

20GAS PRESSURE INLET EN 150180521141

21FLAME CONTROL VISOR GLASS D=30X5 MM160102011

FUEL SUPPLYThe burners are matched with pneumatic proportional monolithic gas valves, that allow delivered gas amount modulation, thus modulating developed power.A pressure signal detected in the air circuit is led to the pneumatic gas valve, which delivers a quantity of gas proportional to the flow of air processed by the fan.In order to optimize the dimensions, the gas ramp is assembled directly on the body of the burner.GAS RAMP GROUP The valve-manifold connection allows the compensation of suction accidental blocking by reducing the amount of delivered gas.

AIR/GAS MIXER The mixing of gas and combustion air is performed inside the ventilation circuit (mixer), starting with the suction inlet entrance.The fuel is inserted through the gas ramp into the air intake and with the help of a mixer starts an optimum mixing.GAS VALVE

IONISATION CURRENTThe minimum equipment operating current is 5A.The burner produces a significantly higher current, so that normally it does not require any control.If, however, we want to measure the ionization current, the connector (CN1) inserted into the red wire must be opened and then a microammeter must be inserted.

Optimal calibration values

Safety Notes for the first commissioningThe first commissioning of the burner should be carried out by authorised personnel and authorized by ICI CALDAIE SpA, as shown in this manual and in accordance with in force rules and regulations.

Verify regulating, control and safety device correct operation .ADJUSTMENTS PRIOR TO IGNITIONThe adjustments that need to be executed are:- Open the manual valves located upstream of the gas ramp.- Vent the air from the gas pipe by suing the P1 plug screw.- Check the equipment's potentiometer settings.BURNER STARTClose the thermostat and electrically power the burner.The burner starts in pre-ventilation mode at maximum value. After 30 seconds, it reaches START speed and the ignition occurs.If, on the other hand, the fan starts but at the end of the safety time the flame does not appear, the equipment allows the repetition of the start-up program for maximum 2 attempts.At the third attempt, if not the lighting does not occur, the burner will be blocked.Unlock and wait for a new start attempt.If the lighting still does not occur, it may be possible that the gas does not arrive at the combustion head within a safety time of 5s.Slightly rotate clockwise (no more than 360 ) the V1 screw placed on the gas valve mixer.Once lighting has occurred, move on to the full adjustment of the burner.POWER ADJUSTMENTThe modulation is based on variable speed technology.The combustion air flow is adjusted through the variation in the number of engine revolutions, The proportional gas ramp delivers the correct amount of fuel depending on the pressure sensed in the ventilation circuit, So, the engine speed rotation variation adjusts the delivered power.The engine speed can be adjusted by acting on the burner's three potentiometersAdjustments may be necessary based on the installation.The thermal capacity of the burner should not exceed the capacity of the boiler.MIN Determines the speed of the fan when the modulation is minimalMAX Determines the speed of the fan when the modulation is at its peakSTART Determines the speed of the fan during the starting phase"MIN" adjustment is replaced instantly at the end of the pre-ventilation outlined by the opening of the valve and the presence of the vent.Maximum modulation enabling with "MAX" occurs approximately 10 sec from the valve opening.

Boiler rated effective output* kWMIN timer calibrationMAX timer calibrationSTART timer calibration

3523.55

40244.5

50254

60263.5

70273

* with 50C delivery temperature and 30C return temperatureIn order to optimize the operation of the modular heat generator (two or three thermal units connected in cascade) all the burners must have the fan speed adjustment potentiometers set at the same values.The overall power of the boiler is given by the sum of individual heating units, so in order to reach intermediate values set the trimmers properly.GAS VALVE ADJUSTMENTThe adjustment of the gas flow rate is obtained by using the two screws V1 and V2.In order to vary the maximum flow rate of gas operate screw V1.- In order to increase the flow rate: turn the screw counter-clockwise (not more than 360 with respect to the default calibration).- In order to decrease the flow rate: turn the screw clockwise (not more than 360 with respect to the default calibration).In order to vary the minimum gas flow rate operate the gas valve's V2 screw.Remove protection screw and operate the inner screw using Torx key.- In order to increase the flow rate: turn the screw clockwise (not more than 360 with respect to the default calibration).- In order to decrease the flow rate: turn the screw counter-clockwise (not more than 360 with respect to the default calibration).

BURNER ADJUSTMENTIn order to obtain an optimum burner adjustment, the analysis of gas exhausted from the boiler's combustion must be conducted. When installing the burner onto the boiler, adjustments and tests must be carried out in compliance with the boiler instruction manual, including the control of CO and CO2 concentration in flue gases and their temperature.Sequentially check:- Maximum power- Minimum power- Ignition powerThemaximum power should match the one required by the used boiler. In order to increase or decrease its value operate the equipment's MAX potentiometer.Measure the meter's gas flow to find exactly the amount of power burned.Using an fume analyser, measure the value of CO2 or O2 in order to optimize the calibration of the burner.The correct values are: CO2 8.5 9% or O2 55.5%.To correct these values operate the gas valve (no more than 360 from default calibration) as follows:-To increase the gas flow rate and CO2: rotate screw V1 counter-clockwise.-To decrease the gas flow rate and CO2: rotate screw V1 clockwise.Theminimum power should match the one required by the used boiler. In order to increase or decrease its value operate the equipment's MIN potentiometer.Measure the meter's gas flow to find exactly the amount of power burned.Using an fume analyser, measure the value of CO2 or O2 in order to optimize the calibration of the burner.The correct values are: CO2 8 8.2% or O2 5.5 6%.To correct these values operate the gas valve (no more than 360 from default calibration) as follows:-To increase the gas flow rate and CO2: rotate screw V2 clockwise.-To decrease the gas flow rate and CO2: rotate screw V2 counter-clockwise.The ignition power can be varied by operating the equipment's START trimmer.Combustion headThe combustion head consists of a high thermal resistant cylinder. Its surface is interspersed with several holes and shrouded with a metallic mesh.The air-gas mixture is pushed inside the cylinder and escapes through the outer holes toward the exterior of the head.The combustion starts when the air-gas mixture is ignited by the electrode's spark.The metallic mesh is the fundamental element of the combustion head as it greatly improves the performance of the burner.The flame developed on the head's surface is perfectly attached and adheres to the mesh during maximum operation.This allows high modulation ratios up to 6:1, thus avoiding the danger of backfiring to minimum modulation.The flame is characterized by an extremely compact shape that avoids any risk of contact between the flame and boiler components and consequently the risk of poor combustion phenomenon.The structure of the flame allows the development of compact combustion chambers, designed to take advantage of this feature.EmissionsThe burners' emission values are much lower than the limits imposed by the most stringent regulations. Flame distribution and its expansion on a large surface, allows thermal NOx containment, mainly responsible for emissions.NORMAL OPERATION

BLOCK DUE TO MISFIRE

BLOCK DUE TO FLAME PRESENCE OR FLAME SIMULATION DURING PRE-VENTILATION

BLOCK TYPES AND INTERVENTION TIMES IN CASE OF BURNER FAILURE

RECYCLING FUNCTION IN CASE OF FLAME DISAPPEARANCE DURING OPERATIONThe equipment allows the recycling, namely the complete repeat of the ignition programIf the flame is not present after the safety time of the last restart has passed, the burner will block. RE-IGNITION FUNCTION DUE TO MISFIREThe equipment allows start-up repeat for maximum 3 attempts, if at the end of the safety time there is no flame.A further lack of flame after the fourth ignition attempt determines the block of the burner at the end of the safety time.CHECK OF THE NUMBER OF ENGINE REVOLUTIONSVerification of engine operation if it exceeds the minimum number of rotations per minute (900 rpm).If the engine does not exceed the minimum number of revolutions, check the block after 20 seconds.EQUIPMENT UNLOCKING (INTEGRATED PUSH-BUTTON)To unlock of equipment proceed as following:Press the release button for 1 or 2 seconds.EQUIPMENT UNLOCKING (FROM REMOTE CONNECTION)Use input RS from the X1 terminal strip to remotely unlock the equipment.MAINTENANCE SAFETY NOTES Periodic maintenance is essential for the proper operation, safety, efficiency and the lifespan of the burner.This allows a power consumption and pollutant emissions decrease and also allows to maintain a reliable product over time.Before performing any maintenance, cleaning, or control operation:MAINTENANCE PROGRAMDANGERMaintenance and burner calibration interventions should be carried out by trained and authorized personnel by ICI CALDAIE SpA, as shown in this manual and in accordance with in force rules and regulations.DANGERremove the burner's power supply using the system's main switch;DANGERclose the fuel interruption valveMaintenance frequencyThe combustion system should be checked at least once a year by an ICI BOILERS SpA representative or other specialist.Flexible tubesMake sure that the fuel lines, air intake and combustion products evacuation do not have blockages or bottlenecks.Electrical wiringCheck the correct execution of burner and gas ramp electrical connections.Gas leaksCheck that there are no gas leaks in the following areas:- the meter-burner pipe- the valve-mixer coupling - the burner sealing flange.Combustion headView the combustion head and check that the fabric is intact, free of holes or wide and deep corrosion.Also check that there are no deformations due to high temperature.Gas rampCheck the valve calibration and operation proportionality using exhaust gas analysis.Check the valve/manifold compensation tube.Electrode groupIn case of electrode verification and/or replacement, check that the electrodes and the probe do not show pronounced deformations and surface oxidation. Check that the distances indicated in the figure are still met, possibly reset them.

If necessary, eliminate the oxide from the probe's surface using an abrasive paper.

Do not rotate the electrode. Place it as shown in the figure; if the electrode is placed near the ionization probe, the equipment's amplifier could be damaged.CombustionLeave the burner running at full speed for about ten minutes, correctly calibrating all the elements listed in this manual.Then perform a combustion analysis and check: CO2 percentage (%); CO content (ppm); NOx content (ppm); Ionisation current (A); Chimney fume temperature.Adjust the burner if the combustion values recorded at the beginning of the operation do not meet in force regulations or, in any case, do not correspond to a good combustion.Write the new combustion values in a suitable form, they will be useful for the subsequent checks.FAULTS / REMEDIESThis is a listing of some causes and possible remedies to a series of faults that may occur and lead to burner failure or non-regular operation. A fault, in most cases, leads to lighting of the equipment's command and control release button.After this signal is enabled, the burner will work again only after the release push-button is pressed; after this has been done, if there is a regular ignition, you can allocate the arrest to a transient and non dangerous anomaly. If the block persists, you will have to search for the cause of fault and implement the remedies shown in the following tables.Operation faults

Ignition difficulties

Safety warningsIn order to ensure a combustion with a minimum rate of pollutant emissions, the size and the type of the heat generator's combustion chamber must match clearly defined values.Therefore, you should consult the Assistance Technical Service before choosing this type of burner for this generator generator. Qualified staff has the technical professional requirements specified by the law no. 46 of 5 March 1990 The commercial organization has an extensive network of agencies and technical services, who's staff regularly attends courses of instruction and update at the corporate Training Centre.This burner must be used only for its intended purpose.Any contractual and non-contractual liability of the manufacturer for any damage caused to people, animals or things, errors of installation, adjustment, maintenance and improper use are excluded.Basic safety rules-This equipment may not be used by children or unauthorised personnel.-Plunging with rags, cards or other things of the intake or dissipation gratings and the ventilation opening of the area where the equipment is installed it is strictly forbidden.-Any attempt of equipment repair by unauthorized personnel is strictly forbidden.-Pulling or twisting of electrical cables is dangerous.-Any cleaning operation before disconnecting the equipment's power supply is strictly forbidden.-Do not carry out cleaning operations of the burner or its parts using flammable substances (e.g. , gasoline, alcohol, etc. ). Cleaning of the casing must be carried out using only soapy water.-Do not place objects on the burner.-Do not cap or reduce vent dimensions of the establishment where the generators is installed.-Do not leave containers and flammable substances in the establishment where the equipment is installed.Notes regarding electrical wiring safety-Default electrical wiring must not be altered-Any checks must be performed in the absence of electrical power.-The manufacturer declines any responsibility for changes or connections other than those represented in the wiring diagrams.-Do not switch the power supply line's neutral conductor with the phase conductor The possible reversal would induce a stop due to misfire.-The equipment's electrical safety is reached only when the machine is correctly connected to an effective grounding system, executed as required by the in force regulations. This fundamental security requirement must be verified. In case of doubt, an authorised staff should carry out an accurate control of the electric system .-The electrical system must be adequate for the maximum power absorbed by equipment, displayed by the identification in plate and in the manual, in particular making sure that the cable section is suitable for the power absorbed by the unit.Electrical schematics legendA1

ESYS S4965V2208-HSI electrical equipmentFCSRotor speed controlG

Signal converter 0-10 V / 4-20 mAMVFan motorRS Remote release buttonSB Unlock signalSOIonisation probeTA

Ignition transformerTB

Burner earth connectionTL

Limit thermostat/pressure switchTS

Safety thermostat/pressure switchT6AMono phase power supply fuseY

Valve groupY1

Valve 1Y2

Valve 2X1

10-pin connectorX2

6-pin connectorX3

18-pin connectorXMBTerminal stripXP77-pin socketXS77-pin plug

14 START UP WARNINGSPRELIMINARY CHECKSBefore starting the boiler, check that: The rating plate specifications and power supply network (electricity, water, gas) specifications correspond; The burner power range is compatible with the power of the boiler; The boiler room also contains the instructions for the burner; The flue gas exhaust pipe is operating correctly; The air inlet supply is well dimensioned and free from any obstacle; The boiler door, the smoke box and the burner plate are closed in order to provide a complete flue gas seal; The system is full of water and that any air pockets have therefore been eliminated; The anti-freeze protections are operative; The water circulation pumps are operating correctly. The expansion vessel and the safety valve(s) have been connected correctly (with no interception) and are properly operating. Check the electrical parts and thermostat operation.WATER TREATMENTIf 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 that occur in heating systems are:- ScalingScale obstructs heat transfer between the combustion gases and the water, causing an abnormal increase in the temperature of the metal and therefore reducing the life of the boiler. Scale is found mostly at the points where the wall temperature is highest and the best remedy, at construction level, is to eliminate areas that overheat. Scale creates an insulating layer, which reduces the thermal transfer of the boiler, affecting system efficiency. This means that the heat produced by burning the fuel is not fully transferred and is lost to the flue.

Scale diagramKey%

% fuel not usedmmmm scale- Corrosion on the water sideCorrosion of the metal surfaces of the boiler on the water-side is due to the passage of dissolved iron through its ions (Fe+). In this process the presence of dissolved gases and in particular of oxygen and carbon dioxide is very important. Corrosion often occurs with softened or de-mineralised water, which has a more aggressive effect on iron (acid water with Ph