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INOXIA GJ
INSTALLATION AND
SERVICING MANUAL
00335290 - 1
st
edition - 04/11
2
General Information
CONTENTS
1 GENERAL INFORMATION .................................................................................................................................................................................... 3
1.1 Symbols used in this manual ...............................................................................................................................................................................3
1.2 Correct use of the appliance ................................................................................................................................................................................3
1.3 Water treatment ................................................................................................................................................................................................... 3
1.4 Information to be handed over to the user ..........................................................................................................................................................3
1.5 Safety warnings .................................................................................................................................................................................................. 4
1.6 Data badge ......................................................................................................................................................................................................... 5
1.7 General warnings ...............................................................................................................................................................................................6
2 TECHNICAL FEATURES AND DIMENSIONS .....................................................................................................................................................7
2.1 Technical features ............................................................................................................................................................................................... 7
2.2 Main components ................................................................................................................................................................................................7
2.3 Dimensions ..........................................................................................................................................................................................................8
2.4 Performance data according to the Standard UNI 10348 ...................................................................................................................................9
3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 10
3.1 General warnings .............................................................................................................................................................................................10
3.2 Standard codes for installation .........................................................................................................................................................................11
3.3 Handling ...........................................................................................................................................................................................................12
3.4 Heating plant location ....................................................................................................................................................................................... 12
3.5 Burner ............................................................................................................................................................................................................... 12
3.5.1Burner’s choice ............................................................................................................................................................................................... 12
3.5.2 Burner’s installation .......................................................................................................................................................................................13
3.6 Connection flame spy control to the burner .....................................................................................................................................................13
3.7 Flue connection ................................................................................................................................................................................................14
3.8 Condensate drain .............................................................................................................................................................................................14
3.9 Furnace door : regulation, opening, closing .....................................................................................................................................................15
3.9.1 Boilers INOXIA GJ 150÷ INOXIA GJ 350 ....................................................................................................................................................15
3.9.2 Boilers INOXIA GJ 450÷ INOXIA GJ 1000 ..................................................................................................................................................15
3.9.3 Important note ...............................................................................................................................................................................................16
3.10 Connection boiler to the plant .........................................................................................................................................................................16
3.11 Filling the system .............................................................................................................................................................................................17
3.12 Gas connection ................................................................................................................................................................................................17
3.13 Packaging ........................................................................................................................................................................................................ 19
3.14 Shell assembly ................................................................................................................................................................................................20
3.15 Electric connections.........................................................................................................................................................................................22
3.16 Tools panel MASTER MODULANTE cod. 37892 ............................................................................................................................................23
3.17 Thermoregulator programming with single boiler ............................................................................................................................................23
3.18 Electric and hydraulic connection to the plant with tools panel cod. 37892 ..................................................................................................... 27
3.19 thermoregulator programming with boiler cascade .........................................................................................................................................29
3.20 Tools panel modulating cascade cod. 37900 ................................................................................................................................................... 33
3.21 Electric and hydraulic connection to the plant with boilers cascade tools panels cod. 37892 and 37900 ....................................................... 35
3.22 Tools panel MASTER BISTADIO cod. 38778 ...................................................................................................................................................37
3.22 Thermoregualtors programming with single boiler ...........................................................................................................................................37
3.24 Electric and hydraulic connection to the plant with tools panel cod.38778 ......................................................................................................41
3.25 thermoregulator programming with boiler cascade .........................................................................................................................................43
3.26 Tools panel CASCATA BISTADIO cod. 37901 .................................................................................................................................................47
3.27 Electric and hydraulic connection to the plant with boilers cascade tools panels cod 38778 and 37901 ........................................................ 49
3.28 Initial lighting ....................................................................................................................................................................................................51
3.29 Burner regulation ............................................................................................................................................................................................. 52
4 SERVICING SCHEDULE .....................................................................................................................................................................................52
Instructions for inspecting and servicing the appliance .......................................................................................................................................... 52
Shell servicing ......................................................................................................................................................................................................... 53
Burner servicing ......................................................................................................................................................................................................53
Checking the electrode lighting ...............................................................................................................................................................................53
Components to verify during the annual inspection .................................................................................................................................................53
3
General Information
1.1 - SYMBOLS USED IN THIS MANUAL
When reading this manual particular care has to be given to the parts marked with the followings symbols:
NOTE! Suggestions for the
user
WARNING! Indicates a potentially
dangerous situation for the pro-
duct and the environment
DANGER! Indicates serious
danger for your personal safety
and for your life
1.2 - A CORRECT USE OF THE APPLIANCE
The INOXIA GJ appliance has been designed utilizing today’s heating technology and in compliance with
the current safety regulations.
However, following an improper use, dangers could arise for the safety and life of the user or of other people,
or damage could be caused to the appliance or other objects.
The appliance is designed to be used in pumped hot water central heating systems.
Any other use of this appliance will be considered improper.
UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this case
the risk is completely at the user’s responsibility.
In order to use the appliance according to the foreseen scopes it is necessary to carefully follow the in-
structions indicated in this manual.
1.3 - WATER TREATMENT (refer to specific guide)
• The hardness of the mains water supply conditions the frequency with which the heat exchanger is cleaned.
• In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is recommen-
ded. The choice of this device has to be made taking into consideration the characteristics of the water.
• We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the
first year and subsequently every two years; in this occasion check the state of wear of the anode.
1.4 - INFORMATION TO BE HANDED OVER TO THE USER OR PERSON IN CHARGE OF THE
APPLIANCE
The user or the person in charge has to instructed on the use and operation of his heating system, in particular:
- Hand over these instructions to the end user or person in charge of the appliance, together with any other literature
regarding this appliance placed inside the envelope contained in the packaging. The user has to keep these do-
cuments in a safe place in order to always have them at hand for future reference.
- Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that it is absolutely
forbidden to make any alterations to the boiler.
- Inform the user how to check the system’s water pressure as well as informing him how to restore the correct pres-
sure.
- Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure the
greatest possible fuel economy.
- Remind the user that it is obligatory to service the appliance at least annually and to carry out a combustion analysis
in compliance with the schedule indicated in the national Codes of Practice.
- If the appliance is sold or transferred to another owner or if the present user moves home and leaves the appliance
installed, ensure yourself that the manual always follows the appliance so that it can be consulted by the new owner
and/or installer.
1
GENERAL INFORMATION
Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accor-
dance with the current laws.
The end user is not qualified to carry out any service work on the boiler.
Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons,
animals or damage to property. UNICAL shall not be held liable for any injury and/or damage.
4
General Information
1.5 - SAFETY WARNINGS
WARNING!
The installation, adjustment, and servicing of this appliance must be carried out by a competent, qualified
person and installed in accordance with the current standards and regulations. Failure to correctly install
this appliance could cause injury to persons, animals or damage to property. The manufacturer shall not
be held liable for any injury and/or damage.
DANGER!
NEVER try to carry out any repairs or service work on the boiler on your own initiative.
Servicing or repairs of the appliance must be carried out by qualified service engineers;
UNICAL recommends drawing up a service contract.
Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons,
animals or damage to property for which UNICAL shall not be held liable.
Modifications to parts connected to the appliance
Do not carry out any modifications to the following parts:
- the boiler
- to the gas, air, water supply pipes and electrical current
- to the flue pipe, safety relief valve and to the central heating’s drainage pipe
- to the constructive components which influence the appliance’s safe operation
WARNING!
When tightening or loosening the screw pipe connections, use only adequate fork spanners.
The improper use and/or the use of inadequate equipment can cause damages (for example water or gas leakages).
WARNING!
Indications for appliances operating with propane gas
Ensure yourself that before installing the appliance the gas tank has been purged.
For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legally
authorized.
If the tank has not been correctly purged problems could occur during ignition.
If this occurs contact the liquid gas tank’s supplier.
Smell of gas
If you smell gas follow these safety indications:
• Do not turn on or off electrical switches
• Do not smoke
• Do not use the telephone
• Close the mains gas tap
• Open all windows and doors where the gas leakage has occurred
• Contact the gas society or a company specialized in installing and servicing heating systems
Explosive and easily inflammable substances
Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room where
the appliance has been installed.
5
General Information
CE Marking
- The CE marking documents that the boilers satisfy:
- The essential requirements of the Directive regarding gas
appliances (Directive 90/396/CEE)
- The essential requirements of the Directive regarding
electromagnetic compatibility (Directive 89/336/CEE)
- The essential requirements of the Efficiency Directive
(Directive 92/42/CEE)
1.6 - DATA BADGE
The data badge is adhesive and placed inside the documentation envelope; it must be glued on to one side of the casing, on the
external part, by the installer.
The boiler’s serial number is indicated on the plate screwed on the boiler’s front plate (front side, upper left hand side).
Mains: 230V~ 50Hz
W:
Boiler type
Serial number
Year of manufacture
Boiler water capacity
Max. operating pressure
l
Fuels
(only those with X)
Gas
Wood
Charcoal
Diesel oil
Naphtha
OUTPUTS
P.I.N. code
Furnace
Useful
kW
Capacity Max. press. Max. temp.
l °Cbar
Storage tank:
AG S.P.A.
46033 CASTELDARIO (MN) - Via Roma
tel. 0376 57001 - fax 0376 660556
www.unical.ag [email protected]
Max. operating temp. °C
bar
Category
kW
kW
Sup. m²
See serial no. on boiler body
Approval
min. max.
min.
max.
6
General Information
1.7 - GENERAL WARNINGS
This instruction manual is an integral and indispensable part
of the product and must be retained by the person in charge of
the appliance.
Please read carefully the instructions contained in this manual as
they provide important indications regarding the safe installation,
use and servicing of this appliance.
Keep this manual in a safe place for future reference.
The installation and servicing must be carried out in accordance
with the regulations in force according to the manufacturer’s
instructions and by legally competent authorized persons.
By a competent person, we imply a person who has a specific
technical qualification in the field of components for central hea-
ting systems for domestic use, domestic hot water production
and servicing. The person must have the qualifications foreseen
by the current laws in force.
Bad or irregular servicing could compromise the safe operation
of the appliance, and could cause injury to persons, animals or
damage to property. The manufacturer shall not be held liable
for any such injury and/or damage.
Before carrying out any cleaning or servicing turn off the electrical
supply to the boiler by means of the ON/OFF switch and/or by
means of the appropriate shutdown devices.
Do not obstruct the intake/outlet terminal ducts.
In the event of failure and/or faulty functioning of the appliance,
switch off the boiler. Do not attempt to make any repairs: contact
qualified technicians.
Any repairs must be carried out by Unical authorized technicians
and using only original spare parts. Non-observance of the above
requirement may jeopardize the safety of the appliance.
To guarantee the efficiency and correct functioning of the ap-
pliance it is indispensable to have the boiler serviced annually
by a qualified person.
If the boiler remains unused for long periods, ensure that any
dangerous parts are rendered innocuous.
If the appliance is sold or transferred to another owner or if the
present user moves home and leaves the appliance installed,
ensure yourself that the manual always follows the appliance
so that it can be consulted by the new owner and/or installer.
Only original accessories must be used for all appliances sup-
plied with optional accessories or kits (including electrical ones).
This appliance must be used only for the purposes for which it has
been expressively designed. Any other use shall be considered
incorrect and therefore dangerous
7
Technical features and dimensions
2.1 - TECHNICAL FEATURES
The boilers of the INOX series consist of a firebox GJ
horizontal direct-fired and a bundle consisting 316L stainless
steel tubes and aluminum fins immersed in a vertical plating.
The building meets all the requirements set in EN 303 part 1 ª.
The components of the part under pressure, such as sheets
and tubes, are constructed in 316L stainless steel, under the
tables EURONORM and EURONORM 25 and 28.
The welders and welding procedures are approved by TÜV
(D) - UDT (PL) - SA (S) and ISPESL (I).
For all models, the fireplace is bound to the tube plate back.
The boilers are equipped with a door opening to the right with
the possibility of changing the rotation.
The outer shell is covered with a wool mattress 100 mm thick
glass in turn protected by a fabric mineral fiber.
The upper shell is fitted with holes (mod. 150/ 300) and hooks
for the lifting of the boiler.
Note: The stainless steel tank are designed to operate with
GJ Burner ON / OFF; two stage or modulating, provided that
thermal power reached minimum is lower specified on the
rating plate.
The boilers are equipped with 2 ½ “sheathing with internal
diameter of 15 mm (suitable for housing 3 bulbs each).
The sides of the mantle are fitted with holes for cable glands
power cables, pump, burner and every other auxiliary device.
2
TECHNICAL FEATURES
AND DIMENSIONS
2.2 - MAIN COMPONENTS
The INOXIA GJ are equipped with a cylindrical furnace blind,
in which the central flame burner goes to the fund and then
distributed in the flue, the ends of the tubes combustion gases
are collected in the smoke chamber and here sent to the
fireplace.
During the burner operation, within the field power of the
boiler, the combustion chamber is always under pressure.
For the value of this pressure see table page. 8, the column
“Pressure drop gas side.”
The furnace must be calculated so that its base not detected
any positive pressure
1 Furnace
2 Smoke pipe with smoke deflectors
3 Door with Flame inspection
4 Smokebox
5 Insulation body
- Tool panel (not visible)
M System delivery
Rbt system return low Temperature
Rmt System return medium temperature
Ve Expansion tank
fig. 1
2
1
4
5
3
M
Rmt
Rbt
Ve
8
Technical features and dimensions
L
mm
2.3 - DIMENSIONS
1 Control panel
2 burner flange
3 Flame inspection
T1 Heating flow
T2 Low-temperature heating return
T3 Return heating medium temperature
T4 Expansion tank connection
T5 Boiler drain
T6 Chimney connection
T7 Burner connection
T8 Drain condense
fig. 2
Useful
output
(50°-30°C)
kW
150
200
270
350
450
600
800
1000
CONNECTIONS
T1, T2, T3
UNI 2278 PN16
T4
ISO 7/1
UNI 2278 PN16
T5
ISO 7/1
T6
Øi
mm
65
65
80
80
100
100
125
125
1½
1½
2
2
65
65
80
80
¾
¾
¾
¾
1
1
1
1
180
180
200
200
250
250
300
300
150
200
270
350
450
600
800
1000
INOXIA GJ
Models
Furnace
output
kW
140
186
253
327
420
560
746
934
Boiler
capacity
l
248
248
380
380
533
533
907
907
Water side
pressure
drop(**)
m c.a.
0,27
0,45
0,35
0,55
0,30
0,50
0,37
0,60
10
15
14
23
18
32
30
45
Flue gas
pressure
drop
mm c.a.
M
aximum
operating
pressure
boiler
bar
5
5
5
5
5
5
5
5
W
eight
kg
480
480
675
675
1090
1090
1650
1650
INOXIA GJ
Models
150
200
270
350
450
600
800
1000
DIMENSIONS
A
mm
766
766
866
866
896
896
1076
1076
(*) Dimensione minima di passaggio attraverso la porta della centrale termica.
(**) Perdite di carico corrispondenti ad un salto termico di 15K.
DETAIL FOR DOOR DRILLING
INOXIA GJ 150 / 350
DETAIL FOR DOOR DRILLING
INOXIA GJ 800 / 1000
fig. 3
fig. 5
T7
Øi
mm
180
180
180
180
210
210
270
270
Useful
output
(80°-60°C)
kW
135
180
244
316
406
541
720
902
T8
Øe
mm
40
40
40
40
40
40
40
40
B
mm
1295
1295
1530
1530
1952
1952
2250
2250
C
mm
1558
1558
1649
1649
1790
1790
2075
2075
D
mm
190
190
190
190
190
190
190
190
E
mm
112
112
112
112
125
125
140
140
F
mm
75
75
91
91
66
66
78
78
G
mm
1243
1243
1309
1309
1415
1415
1629
1629
H
mm
283
283
300
300
328
328
345
345
I
mm
489
489
536
536
590
590
655
655
J
mm
719
719
809
809
845
845
940
940
K
mm
1545
1545
1635
1635
1893
1893
2178
2178
278
278
287
287
312
312
341
341
M
mm
200
200
220
220
320
320
340
340
N
mm
1004
1004
1226
1226
1511
1511
1787
1787
O
mm
1482
1482
1733
1733
2143
2143
2468
2468
P
mm
299
299
353
353
288
288
364
364
Q
mm
1005
1005
1205
1205
1666
1666
1866
1866
R
mm
178
178
175
175
189
189
238
238
S*
mm
665
665
765
765
795
795
975
975
T
mm
85
85
85
85
85
85
85
85
U
mm
328
328
355
355
400
400
490
490
V*
mm
1645
1645
1745
1745
1893
1893
2178
2178
G
T7
A
S
Q
H
U
I
J
K
BE F
O
C
D
T3
T2
T6
T4
R
P
T
T8
T7
T5
L N
V
T1-T4
M
T1
T1-T4
1
2
3
DETAIL FOR DOOR DRILLING
INOXIA GJ 450 / 600
fig. 4
Lana di roccia
Fibra ceramica
Piastra porta-bruciatore cieca 250x250
Guarnizione piastra porta-bruciatore 250x250
ø 180
ø 150
120
Lana di roccia
Fibra ceramica
Piastra porta-bruciatore cieca 330x330
Guarnizione piastra porta-bruciatore 330x330
ø 270
ø 270
130
Lana di roccia
Fibra ceramica
Piastra porta-bruciatore cieca 280x280
Guarnizione piastra porta-bruciatore 280x280
ø 210
ø 210
130
Blind burner plate 250x250
Burner plate insulation gasket 250x250
Mineral wool
Ceramic fibre
Blind burner plate 280x280
Burner plate insulation gasket 280x280
Mineral wool
Ceramic fibre
Blind burner plate 330x330
Burner plate insulation gasket 200x200
Mineral wool
Ceramic fibre
9
Technical features and dimensions
Heat output nominal (80°-60°C)
Heat output nominal (50°-30°C)
Thermal power of the hearth
Efficiency at nominal load (80°-60°C)
Efficiency at nominal load (50°-30°C)
Heat efficiency at 30% load
Combustion efficiency (80°-60°C)
Combustion efficiency (50°-30°C)
Losses to the mantle (80°-60°C)
Losses to the mantle (50°-30°C)
Losses with burner on (80°C)
Losses with burner on (30°C)
Losses with burner off
Flue gas temperature tf-ta (80°-60°C)
Flue gas temperature tf-ta (50°-30°C)
CO2 content
Flue gas mass flow
Condensate production max, (natural gas)
INOXIA GJ 800
732,8
800
746
98,2
107,2
109
98,3
99,1
0,11
0,07
1,66
0,92
0,10
36
20
10,5
1056,5
111,3
INOXIA GJ 1000
917,5
1000
934
98,2
107
109
98,3
99,1
0,10
0,07
1,66
0,92
0,10
36
20
10,5
1322,7
139,4
kW
kW
kW
%
%
%
%
%
%
%
%
%
%
°C
°C
%
kg/h
l/h
INOXIA GJ 270
247,5
271
253
97,8
107,1
109
97,9
99,1
0,14
0,10
2,03
0,92
0,10
44
20
10,5
353,8
37,7
GAS OPERATION
INOXIA GJ 350
320,5
350
327
98
107
109
98,1
99,1
0,14
0,10
1,85
0,92
0,10
40
20
10,5
463,1
48,8
INOXIA GJ 450
412,5
450
420
98,2
107,1
109
98,3
99,1
0,12
0,09
1,66
0,92
0,10
36
20
10,5
594,8
62,7
INOXIA GJ 600
550
600
560
98,2
107,1
109
98,3
99,1
0,12
0,09
1,66
0,92
0,10
36
20
10,5
793,1
83,6
2.4 - PERFORMANCE DATA ACCORDING TO STANDARD UNI 10348
INOXIA GJ 200
181,5
200
186
97,5
107,5
109
97,8
99,1
0,25
0,17
2,17
0,95
0,11
46
20
10,2
270,1
27,7
INOXIA GJ 150
136,5
150
140
97,5
107,1
109
97,7
99,1
0,23
0,16
2,27
0,95
0,10
48
20
10,2
203,3
20,9
10
Instructions for the installer
3
INSTALLATION
INSTRUCTIONS
3.1 - GENERAL WARNINGS
WARNING!
This boiler is to be destined only to the use
for which it has expressly been designed for.
Every other use is to be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.
WARNING!
These appliances are exclusively designed
for indoor installations or installed in ade-
quate sitings. Therefore these appliances
must not be installed and operated out-
doors. An outdoor installation could cause
malfunctioning and could be dangerous. For
outdoor installations, it is recommended to
use appliances which have been specifically
designed for this purpose.
Before installing the boiler the following points
have to be carried out by a professionally
qualified person:
a) The whole system should be thoroughly
flushed in order to remove any residual dirt or
grime which could compromise correct boiler
operation.
b) Check that the boiler has been preset for
operating with the gas type available.
This is verifiable via the indication on the
packaging and on the data badge;
c) Check that the chimney/flue pipe has
an adequate draught, does not have any
constrictions, and that no other appliance’s flue
outlets have been fitted, unless the chimney
is serving more than one heating appliance,
according to the specific standards and
regulations in force.
The connection between the boiler and
chimney/flue outlet can be made only after this
verification has been carried out.
WARNING!
In rooms where aggressive vapours or
dust is present the appliance must operate
independently from the air present in the
boiler’s location room!
WARNING!
The appliance must be installed by a qualified,
registered engineer, whom, under his own
responsibility, guarantees the compliance
of the standards according to the latest re-
gulations.
NOTE:
The boiler must be connected to a heating system
which is compatible to its performance and output.
11
Instructions for the installer
3.2 - INSTALLATION CODES OF PRACTICE
The INOXIA GJ is a boiler foreseen for operation with firewood.
The appliance must be installed in compliance with all applicable
laws and regulations.
12
Instructions for the installer
x = not less than the length of the boiler body
(dimensions in mm); in any case, never less than 1300 mm.
xx = see instructions to the side.
3.4 - HEATING PLANT LOCATION
The boiler must be installed in accordance with the rules and
regulations in force.
The room must be well ventilated with openings having an
area of not less than 1 / 30 of the floor area of the boiler room
with a minimum of 0.5 m².
The ventilation openings must be permanent, communicating
directly with the outside and be positioned at a level high and
low in accordance with the regulations in force.
The location of the vents, the supply circuits Fuel, power
distribution and lighting must comply with the applicable laws
in force in relation to the type of fuel used
You should install the boiler as close as possible to connection
of the chimney.
To facilitate the cleaning of the smoke circuit in front of the
boiler, it must have a clear space not less than the length the
boiler , and in any case, never less than 1300mm and it must
verify that with the door open to 90 ° the distance between
the door and the adjacent wall, is at least equal to the length
burner.
The boiler may be placed directly on the floor, because it has
a basement.
However, it is useful to provide a concrete platform, a plan to
level and able to withstand the weight of the boiler when is
filled with water.
When placed on the hoof, this must be have at least a size of
Q x S (see size tables).
Once installed, the base must be perfectly horizontal and well
stable (to reduce vibration and the noise level).
fig. 6
3.3 - HANDLING
The boiler can be easily handled by lifting hooks
through holes or higher.
If for reasons of space was necessary, is
possible to remove the door to facilitate the
introduction in the central heating.
3.5 - BURNER
The burners in the service of boiler INOXIA GJ will be CE
certified, and in particular comply with:
- Gas Appliance Directive (90/396/EEC);
- EMC Directive - Electromagnetic Compatibility (89/336 /
EEC).
They must also be approved in accordance with the
specifications:
- UNI EN 676 - forced draft burners for fuel gas.
- Efficiency Directive (92/42 EEC)
3.5.1 - CHOICE OF THE BURNER
A proper selection and the adjustment of the burner are
fundamental for an optimal operation of the boiler and
therefore they should be accurate and not underestimated.
The burner must be chose verifying its field work (fuel flow
rate - pressure in the combustion chamber) that should
compatible with similar characteristics declared the boiler
Please note that the pressure drop gas side of the boiler, or
the back pressure in the combustion chamber, are reported at
zero pressure at the base of the chimney.
It is appropriate that the burner tube length is not less than
the minimum stated in the table below, and the flame must
be developed and adapted to the characteristics of our
combustion chamber
To exploit all the surface of the heat exchange dead-end, you
must use burners that are able to provide a flame “long and
narrow” in every
operating condition, or even at minimum power in the case of
setting up two or more stages or modulating.
Flames too short causing localized overheating the front of
the furnace and combustion products, not sufficiently cooled,
take the flue to extreme heat can cause serious damage to
the generator.
1000
X
XX
XX
600
600
13
Instructions for the installer
The construction companies of the burners are able to
provide the size of the flames that develop their products, in
particularly those approved under the rules indicated above.
Further details are given in the “First lighting”.
øA
mm
L min.
mm
fig. 7
INOXIA GJ 800 / 1000 270 350
3.6 - CONNECTION SPY CONTROL TO THE
BURNER FLAME
The light flame control is equipped of a threaded 1/8 “ (Item
1) where mounted on a outlet pressure of 9 mm. to be used
with silicone pipe for measuring pressure in the combustion
chamber.
Instead of this outlet, which must be preserved, will be
mounted a proper fitting so you can connect, through a copper
tube (item 2), the light flame control directly to the plenum
chamber downstream of the fan burner.
The air blown by the fan will cool down properly the sight
glass and prevent blackening.
Failure to link the cooling to the light can cause breakage of
the glass control.
CAUTION: The light flame monitoring can be very hot and
then pay lot attention.
fig. 8
3.5.2 - BURNER INSTALLATION
The burner installation to the boiler door, must ensure a
perfect seal to the combustion products.
The boiler is supplied with a piece of rope fiber ceramics
to be placed on the mouthpiece of the burner so as to
completely seal the space between the mouthpiece itself
and the hole in the door.
Make sure that no gaps remain between the mouthpiece and
the hole refractory inside the door.
In the event that mounted a cone with a diameter bigger than
the mouthpiece, this is must be removed before mounted the
burner on the plate and reassembled it later.
Burner installed, check that the wires have a sufficient length
to allow the opening door to 90 degrees.
For the gas burners is not allowed to use hoses connection so
that will have the possibility of removal the final section of the
outlet pipe gas, through the joint threaded or flanged.
L
Ø A
INOXIA GJ 450 / 600 210 320
INOXIA GJ 150 / 350 180 280
1
BOILER TYPE
DIMENSIONS OF BURNER BLAST TUBE
14
Instructions for the installer
For the connection of the flue pipe must be respected the
local and national regulations (see UNI-CIG 7129 4 point and
7131 point 5).
The INOXIA GJ boiler lends itself to different solutions for
connecting the chimney, it is possible, by pipe line or straight
curves, leaving the rear, left, right, or vertical
to take in the flue in a higher level.
It is recommended to isolate the connecting pipe to the
chimney to reduce heat loss and noise
In the stretch between the boiler and the chimney, it
must have suitable measuring points for the smokes
temperature and the analysis of combustion products.
WARNING: The temperature of the smoke produced from
burning are lower than the other non-condensing boilers
and have a content of high humidity
For this reason, the flue must be of a suitable material,
waterproof and resistant to the acid condense.
It must also be sized to ensure adequate draft.
We recommend using only conducted drain
suitable for the type of fuel used.
Does not accept any responsibility
contractual and non- contractual of the
supplier for damages caused by errors during
the installation and the using and for the not
observances of the instructions given by the
manufacturer.
In the case of installation or replacement, replace
ALWAYS also the accessory exhaust fumes.
The chimney must comply with current standards.
3.7 - FLUE CONNECTION
The discharge of condensate drain must be:
- designed to prevent the escape of the gas products or
combustion in the environment or sewer (siphon);
- Designed and realized in order to allow proper flow of the
liquid waste by preventing leaks;
- Installed in order to prevent freezing of the liquid that it
contains during the intended operating conditions;
- For example, mixed with domestic sewage (waste washing
machines, dishwasher, etc.). for the most basic pH in order
to form a buffer solution so that it can then enter sewage
system.
Should be avoid the stagnation of the condense in the system
exhaust of combustion products (which is why the flue must
have an inclination towards the discharge of at least 30 mm
/ m) with the exception of any swing of liquid in the siphon
discharge system for the evacuation of the combustion
products (which must be filled after installation and the
minimum height with the boiler activated, it must be at least 25
mm-see Fig. 9).
You must not discharge the condensate through the rain
gutters, because the risk of ice and degradation materials
normally used in the creation of the rain gutter
themselves (see the local health regulations).
The connection to the discharge must be visible.
The level of condensate acidity (pH 3 to 5) as materials for
drain pipes must be used only plastics for (Special kits are
available with optional salt neutralizers of acid condensate).
* Minimum Siphon of safety required by the standard
**Minimum ledge with working boiler at the maximum power.
In the event that you would or would not create a socket, the
boiler can be fitted at the floor level and create a deep pit at
least 100 mm to store the siphon.
fig. 9
PAVIMENTO
DELLA C.T.
150
150
TAPPO DI RIEMPIMENTO
INIZIALE DEL SIFONE
La di scarico
non dovrà trovarsi ad un livello superiore
al .
generatrice superiore del tubo
fondo della camera fumo
CAMERA FUMO
3.8 - CONDENSATE DRAIN
SMOKE CHAMBER
PLINTH (H min 100 mm)
TO
CONDENSATION
DRAIN
SIPHON INITIAL
FILLING CAP
The upper generator of the drain pipe
must be higher at the bottom of the smoke
chamber.
BOILER
ROOM FLOOR
15
Instructions for the installer
3.9 - FURNACE DOOR, REGOLATION,
OPEINING, CLOSING.
IMPORTANT
- You must open the door when boiler is cold to prevent fiber
damage for the thermal shock.
- The fiber insulation door may have some cracks after a
short period of operation, this, however, does not reduce
the insulating capacity and not impede the duration.
3.9.1 - BOILERS INOXIA GJ 150 ÷ INOXIA GJ 350
For all these models, the hinge and fixing the door made
according to the scheme of fig. 10.
In these cases, the door is fitted with two rotation hinges on
the left side, and two locking pins on the right side, the two
hinges on the left side allow the closure
the door on this side, which is close by 4 screws (C).
It will have exactly the opposite, however, where the door will
open from left to right.
To perform the inversion of the rotation, just reverse the
hinges.
On the door of these models is possible the following
adjustment:
A) adjustment in the axial direction: You can tighten more or
less the screws “C”.
fig. 10
- The fiber port is easily replaceable and is covered by 2
year warranty.
3.9.2 - BOILERS INOXIA GJ 450 ÷ INOXIA GJ 1000
For all these models, the hinge and fixing the door
made according to the scheme of fig. 11.
In these cases, the door is fitted with four equal
hinges : the two on the left side, with pin
added, are normally used as hinges rotation
(from right to left), while the two on the right are
used as hinges closing; the door is then locked
with four screws.
It will have exactly the opposite, however, where
the door will open from left to right.
To perform the inversion of the rotation, just move
the pins on the opposite side.
On the door of these models are possible the following
adjustments:
A) Vertical adjustment: it is possible only with the inserting
of washers with suitable thickness under the hinge on which
rotates the door.
B) Transversal Adjustment: it is possible loose the hinges
fixed on the plate to the front of the boiler and moving them to
the side.
C) Axial adjustment: you can tighten more or less the nuts.
fig. 11
C
C
C
C
C
C
C
C
A
B
C
A
B
16
Instructions for the installer
3.9.3 - IMPORTANT
Before opening the furnace door is necessary to take following
security measures:
- Close the fuel supply to the burner.
- Cool the boiler circulating water system, and then remove
the power supply.
- Put a sing on the boiler with the following Text: DO NOT
USE, BOILER MAINTENANCE OUT OF SERVICE
3.10 - CENTRAL HEATING CONNECTION
WARNING!
Before installing the boiler we recommend
that the system is flushed out with a
suitable product in order to eliminate any
metallic tooling or welding residues, oil
and grime which could reach the boiler and
affect the
proper running of the boiler.
Do not use any solvents for flushing out
the system as they could damage the
system and/or its components.
Non-observance of these instructions
could cause injury to persons, animals or
damage to property.
The manufacturer shall not be held liable
for any such injury and/or damage.
Warning!
Be sure to make a connection pipes
without stress mechanics points to avoid
the danger of loss!
The flow and return circuits have to be connected to the boiler
via the respective connections as indicated on page 8.
When determining the size of the CH circuit pipes it is
essential to bear in mind the pressure losses induced by the
radiators, any eventual thermostatic radiator valves, lockshield
valves and by the system’s layout..
Ensure yourself that the system’s piping is
not used as earth clamps for the electrical
or telephonic system. They are absolutely
unsuitable for this use. In a short time this
could cause serious damage to the piping,
boiler and radiators.
Pressure relief valve drain pipe
In correspondence to the heating pressure relief valve
provision should be made to install a discharge pipe with a
funnel and a siphon which lead to an adequate drainage. The
drainage has to be controllable by sight.
WARNING!
If this precaution is not taken it could lead
to injury to persons, animals or damage to
property.
The manufacturer shall not be held liable
for any such injury and/or damage.
Expansion vessel connection
The INOXIA GJ boilers are suitable for operation with water
movement forced with open or closed expansion vessel
An expansion vessel is always necessary to compensate the
increase in water volume caused to the heating.
The piping connecting of the expansion vessel
will start by the attack T3 (see Table Size) and
should not have any interception valve
Connection the filling /discharge cock
For the filling and the discharge of the boiler an apposite cock
can be connected to the attack T5, which is located in back.
17
Instructions for the installer
3.11 - FILLING THE SYSTEM
Warning!
Do not mix the CH system’s water with
unsuitable antifreeze products or use
wrong concentrations of anti-corrosion
solutions ! This could cause damage to the
washers and could provoke noise during
normal boiler operation.
UNICAL refuses all liability for injury to
persons, animals or damage to property
deriving from not having respected the
above mentioned recommendations.
After completing all the system’s service connections the
circuits may be filled by carefully following out the following
phases:
- open the radiator’s air vents and check that the automatic
air vent in the boiler is working properly.
- gradually open the appropriate filling cock and check that
the automatic air vents fitted onto the system are working
properly.
- close the radiator’s air vents as soon as water begins to flow
out.
- using the pressure gauge check that the pressure reaches
the value of 1 bar.
- close the filling cock and then bleed off the air once again
through the radiator’s air vents.
- check all the connections for soundness.
- after having fired the boiler and the system has reached the
correct temperature , stop the pump and repeat the air
bleeding operations.
- let the system cool down and, if necessary, re-establish the
water pressure to1 bar.
NOTE:
The minimum low water pressure switch
will not give the electrical impulse to fire the
burner if the pressure is lower then 1 bar.
use the filling cock on the boiler to adjust the
pressure.
This operation must be carried out when the
system is cold.
NOTE!
If the boiler has not been fired for a long
period the pump could be jammed. Before
firing the boiler,
it is important to carry out the following un-
jamming operation:
- place a cloth underneath the pump
- remove the pump vent plug positioned in
the centre of the pump
- using a screwdriver, rotate the shaft in a
clockwise direction.
Once this operation has been concluded,
screw back the pump vent plug and check
that there have been no water leaks.
WARNING!
After removing the pump vent plug some
slight water leakage could occur.
Before replacing the front panel dry all the
wet surfaces.
3.12 - GAS CONNECTION
DANGER!
The gas connection must be carried out
only by a qualified engineer who will have
to respect and comply to the regulations in
force and to the requirements indicated by
the local gas supplier.
An incorrect installation could cause injury
to persons, animals or damage to property.
The manufacturer shall not be held liable
for any injury and/or damage.
Before installing the boiler it is
recommended to thoroughly clean all the
fuel feed pipework in order to remove
any eventual residual grime which
could compromise the boilers correct
functioning.
Warning!
Be sure to make a connection pipes without
stress mechanics points to avoid the danger
of loss!
If you smell gas:
a. Do not turn on or off electrical switches,
use the telephone or any other object
which can provoke sparks;
b. Open all doors and windows in order to
allow fresh air to enter and purify the room;
c. Close all gas cocks;
d. Contact a service engineer, qualified
installer or the gas supply company.
As a safety measure against gas
leaks, Unical recommends installing
a surveillance and protective system
composed of a gas leakage detector
combined with an on-off solenoid valve
fitted on the gas supply line.
The gas supply pipe must have an appropriate section to the
burner capacity.
The gas supply pipe must have a section which is identical or
greater then the one used on the boiler and must assure
a correct gas pressure.
It is however important to comply with the “General installation
standards” indicated in the standards UNI 7129, UNI 7131
and UNI 1137-1.
Before commissioning an internal gas distribution system and
therefore before connecting it to the gas meter, the complete
installation must be tested for gas soundness.
If any part of the system is concealed from view the gas
soundness test must be carried out before covering the pipes.
Before connecting the pipework the system must be tested
with air or inert gas at a pressure of at least 100mbar.
18
Instructions for the installer
Before commissioning the boiler ensure that the following
operations are carried out:
- Open the gas meter cock and vent the air contained in the
piping and subsequently proceed to vent device by device.
- Check, with the gas cock turned off, that there are no gas
leaks. During the 2nd quarter of the hour from the start of the
test, no pressure reduction should be detected by the
pressure gauge.
Any gas leaks must be found by using only water soap
solutions, or an equivalent product, and eliminated.
Never look for gas leaks using a naked flame
19
Instructions for the installer
3.13 - PAKAGING
The INOXIA GJ boilers are supplied with door and smokebox
fitted, while the casing with the isolation is contained in
cardboard boxes separately.
The instrument panel and accessories are within the
combustion chamber.
Before starting the installation, make sure that the length
and the width of the boiler received, listed in Table pag. 8,
correspond to the size of the boiler ordered
and that the boxes containing the casing, or part of it are
branded as the table below.
The coat of boilers from INOXIA GJ150 to INOXA GJ 350,
complete with its insulating mats, is contained in 2 cartons.
The coat of boilers from INOXIA GJ 450 to INOXA GJ 1000 is
contained in 3 boxes
In addition to the above panel, packed with its own board, as
accessories in the combustion chamber it will find also:
- 1 carton containing the flanges hydraulic connection with
related fittings and bolts.
- Ceramic fiber rope for insulation between the cylinder
burner and the door.
- 1 bag containing the kit drain.
After having unpacked the boiler check that it is
intact and undamaged.
Keep the packaging material (cardboard
box,plastic bags, polyester protection etc.)
out of the reach of children as they can be
dangerous.
UNICAL refuses all liability for injury to
persons, animals or damage to property
deriving from not having respected the
above mentioned recommendations.
In the packaging, in addition to the boiler, you can also find
the following contents:
- Service logbook
- User’s instruction guide
- Installation and servicing manual
- Warranty
- Adhesive label local ventilation standards
N.B. For the INOXIA GJ 150 model to INOXIA GJ 350 (ref. fig.
12),
the casing and insulation are contained in 2 marked
boxes
:
34059 (
top casing
INOXIA GJ 150/200)
34060 (lower casing INOXIA GJ 150/200)
34061 (
top casing
INOXIA GJ 270/350)
34062 (lower casing INOXIA GJ 270/350)
N.B. For the INOXIA GJ 450 model to INOXIA GJ 1000 (ref.
fig. 12),
the casing and insulation are contained in 3 marked
boxes:
34063 (
top casing
INOXIA GJ 450/600)
34064 (lower casing INOXIA GJ 450/600)
34065 (
front casing
/rear INOXIA GJ 450/600)
34066 (
top casing
INOXIA GJ 800/1000)
34067 (lower casing INOXIA GJ 800/1000)
34068 (
front casing
/rear INOXIA GJ 800/1000)
20
Instructions for the installer
3.14 - SHELL INSTALLATION
I) Insert the bulbs into the sheaths of the instruments as
shown in fig. 13, route the cables through the side fairlead
on the side where you want to go out and make the
electrical connection of the panel control to the power
line, to the burner and any eventual pumps, etc..
Replace the box cover of the electric board.
Fix the support plate of the fairlead (item 12) on two side
Fix the side cover plate (item 13) on the left side
J) Attach to the side panels the front panels pos. 16 and 17.
K) Put the upper front panel pos. 14 and attach it by pressing
the two side panels.
L) Fix the two crossbeams can. 19 to the rear panel pos. 18.
Fasten the panel to the rear side panel lower left .
Secure the two panel pos. 20 at the rear side panel lower
right corner.
Combine the two rear panels with reinforcing profile pos.
21.
M) Fix the top rear panel to the two side upper panels
N) Place the top rear panel pos. 23 and attach it by pressing
to the two side panels.
O) Fix the boiler labels and installation data (Item 24) to the
side panel after degreasing it with a suitable solvent.
The plates are inserted into the envelope documents
A) Fix the support brackets (item 1 and 2) of the below hip
shell to the boiler by 8 screws M 6x20 and the associated
nuts and washers.
B) Install the bottom insulation of the boiler (Item 3) and fix
the two strips joints with elastic pegs (item 5) provided in
the accessory box, hooked to the outer fabric insulation.
C) Install the upper insulation of the boiler (item 4) and fix
the two strips joints with elastic pegs (item 5) provided
in the accessory box, hooked to the outer fabric of the
bottom insulation
D) Install the front insulation (Item 6) on the hinges.
E) Install the insulation back pos. 7.
F) Put the lower side panels (item 8 and 9) with the lower
fold in the L profiles on the support basis of the boiler, and
hooking the top part in the cuts on the brackets pos. 1 and
2.
G) Lift forward the cover of the control panel after unscrew the
two side screws with a screwdriver and drive in holes on
the base the entering electrical cables and the capillaries
of output the probe.
Fasten the control panel to the right above side panel (item
11).
H) Place the side panels above (Item 10 and 11) by engaging
side panels below and fitting the upper part in the cuts
expected on the plates of the boiler.
/
