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- Page 1 Low NOx steel condensing boilers CODEX 1000-1600 GT INSTALLATION, USE AND MAINTENANCE MANUAL CODEX 1000-1600 GT_EN Ed. 00 - 05/2019 Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 2 INDEX General information Introduction Preliminary checks Range Commissioning Compliance Checks after commissioning Warnings Stop periods Short periods of time Prohibitions Long periods of time Hazards Decommissioning of old appliances Identification Appliance description Maintenance Structure Boiler Dimensions and connections Burner Technical data Any anomalies and remedies Control panel (accessory) Environmental protection and disposal...
- Page 3 General information INTRODUCTION Dear Customer, Thank you for having chosen an appliance of the series CODEX GT , a high quality and efficiency product, reliable and safe. We recommend entrusting its maintenance to Professionally Qualified Personnel who, when necessary, uses original spare parts. This manual contains important information and suggestions that must be observed for easier installation and best possible use of the appliance.
- Page 4 Moreover, it must be carefully stored for subsequent consultations and must ALWAYS accompany the Boiler during its entire life-cycle (from Installation to disposal). In case of damage or loss, request a copy from ICI CALDAIE S.p.A. Technical Assistance Service.
- Page 5 – In case of water leakages, disconnect the Boiler from the power supply mains, close the water supply and contact, as soon as possible, the Technical Assistance Service Authorised by ICI CALDAIE S.p.A. or qualified personnel. – Sensing the presence of fuel in the thermal power plant, it is appropriate to follow the precautions below to avoid the risk...
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Page 6: Appliance Description
APPLIANCE DESCRIPTION The CODEX GT appliances by ICI Caldaie S.p.A. are condensing Boilers made in AISI 316 Ti STAINLESS steel with three-pass furnace for the production of hot water at a maximum temperature of 110°C. They are provided with pre-mixed, modulating burner for gaseous fuels with cylindrical, heat radiating body and low NOx emissions. -
Page 7: Dimensions And Connections
DIMENSIONS AND CONNECTIONS Dimensions CODEX GT Description u.m. 1000 1200 1400 1600 2020 2020 2165 2165 1522 1522 1610 1610 1880 1880 2022 2022 1493 1493 1573 1573 1310 1310 1390 1390 1298 1298 1378 1378 1060 1060 1165 1165 2443 2443 2437... - Page 8 Stub N3 for accessories CODEX GT Description u.m. 1000 1200 1400 1600 1/2" 1" 1/2 1" 1/2 1” 1/4 1/2" DN/in 1/2" 1/2" 1/2" 1/2" 3/4" 1/2" NOTE For further details, see the chapter “Starting hydraulic circuit“. General information Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
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Page 9: Technical Data
TECHNICAL DATA CODEX GT DESCRIPTION u.m. 1000 1200 1400 1600 Type of appliance Fuel G30 - G31 1097 1280 1463 Effective rated kcal/h 786400 943680 1100960 1258240 1000 1200 1400 1600 Nominal power kcal/h 860000 1032000 1204000 1376000 1116 1302 1488 Max. - Page 10 They must be ordered separately from the Boiler according to their technical characteristics and to the needs of the system served; it is recommended to see also the ICI Caldaie S.p.A. CATALOGUE . For the installation, refer to the manual supplied with the panel.
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Page 11: Installation
IMPORTANT PACKAGING: as for packages, ICI CALDAIE S.p.A. complies with the specific recycling systems of each country, ensuring an optimal reuse of them. All the materials used for the packaging respect the environment and can be recycled, such as wood, plastic, cardboard. -
Page 12: Installation Room
HANDLING CODEX GT Boilers are equipped with fittings for lifting operations and, in any case,they must be carefully moved with equipment suitable for their dimensions and weights. ATTENTION The Personal Protective Equipment required by current legislation must be used. INSTALLATION ROOM The room where CODEX GT Boilers are to be installed must be exclusively used for them, compliant with the Technical Standards and the Law in force and equipped with adequately dimensioned vents. -
Page 13: System Cleaning
The components shall be charged to the installer that, at the end of the works, must issue a declaration of conformity. IMPORTANT ICI CALDAIE S.p.A. is not liable for any harm to people, animals or property damage caused by errors in the choice of components or in the construction of the plant. - Page 14 STARTING HYDRAULIC CIRCUIT 6 16 2 19 NOTE If only one return is required, always use the low temperature one. Hydraulic backflow preventer Safety thermostat probe System flow Y-shaped filter Setting thermostat probe no.1 Probe holding sheaths inside the Flow switch Setting thermostat probe no.2 boiler Filling unit...
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Page 15: Flue Exhaust
FLUE EXHAUST The smoke duct and the connection to the chimney must be built in compliance with the Standards and the Laws in force, with rigid pipes, suitable for the temperature, resistant to condensate, mechanical stresses and sealed. IMPORTANT The smoke duct must have a diameter equal to or larger than the Boiler fitting. Indicative scheme CODEX GT Description... -
Page 16: Door Opening
DOOR OPENING The door is adjusted in the factory with standard opening to the left (Sx) and hinges on the right (Dx). IMPORTANT The hinges of the opening side must have the nut (1) loosened and the conical washer (2) positioned towards the base of the adjustment tie-rod. -
Page 17: Door Adjustment
DOOR ADJUSTMENT DANGER Incorrect door adjustment with consequent damage to people and property voids the warranty conditions. VERTICAL ADJUSTMENT To make the adjustment: – with the door ajar, loosen the counter-nuts (1) of the hinge units – act on the adjustment nuts (2) to lift or lower the door by centring the gasket on the stop plate, then block the counter-nuts (1). - Page 18 INSULATING CASING ASSEMBLY To fit the insulating casing proceed as follows: – wrap the thermally insulating mats around the Boiler body and lock them with the supplied springs (1) – prepare all the slats (2) inserting the locking plugs (3) in the corners of each one of them, as shown in the figure below –...
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Page 19: Burner Assembly
2 cm – connect the earth cable to an effective earthing system. ICI Caldaie S.p.A. is not liable for any damage caused by the lack of the earthing system and the failure to comply with the instructions of the wiring diagrams. -
Page 20: Water Treatment
WATER TREATMENT The thermal system water must comply with the Laws in force, therefore it is good practise to use treatment units when the line water is particularly rich in calcium carbonate, which causes scale build-ups and corrosion. The table includes some indicative values: Characteristics Scale Filling water... -
Page 21: System Filling And Emptying
SYSTEM FILLING AND EMPTYING FILLING – Before filling the system, disconnect the power supply by positioning the system main switch to “ OFF ” and check that the Boiler drain valve is closed – open the Boiler filling valve and the shut-off valve of the hydraulic system and make the water enter slowly, in quantities proportional to the venting capacity of the automatic or manual air separators, and until the expansion vessel pre-filling static pressure value can be read on the manometer –... -
Page 22: Preliminary Checks
PRELIMINARY CHECKS Before commissioning the Boiler and carrying out the functional tests, check that: – the system has been filled and the hydraulic circuit pressure, in a cold state, is correct – the flue gases are correctly discharged and there are correctly dimensioned vents –... - Page 23 STOP PERIODS SHORT PERIODS OF TIME In case of system switch-off for a short period of time: – position the central panel switches and the control panel switch to “ OFF ” IMPORTANT If the external temperature is below ZERO: –...
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Page 24: Maintenance
Maintenance Periodic maintenance is prescribed by Law and must be performed only by qualified personnel, at least once a year or more frequently, depending on the Boiler output and on the fuel used. The boiler maintenance and cleaning operations are essential for its safety and to keep its efficiency high, extending its service life. IMPORTANT Before performing any maintenance or cleaning: –... -
Page 25: Any Anomalies And Remedies
Check the efficiency ENVIRONMENTAL PROTECTION AND DISPOSAL Protection and respect for the environment is a fundamental principle for ICI CALDAIE S.p.A. . The quality of products, lower costs and protection of the environment are of equal importance for the company. ICI CALDAIE S.p.A. , also through ISO 14001 certification, strictly adheres to European laws and standards for the protection and preservation of the environment. - Page 26 Once registered, authenticate your e-mail address by clicking on the link that will be sent by e-mail to the provided inbox. Then an additional e-mail will be received with the credentials to access all the services that ICI CALDAIE S.p.A. has developed specifically for those who will register its Boiler through the QR Code.
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Page 27: Declaration Of Conformity
Company certified according to ISO 9001, OHSAS 18001 & ISO 14001 icicaldaie.com DECLARATION OF CONFORMITY WITH EUROPEAN COMMUNITY STANDARDS The undersigned Emanuela Lucchini, CEO of ICI CALDAIE S.p.A., with registered office in Via G. Pascoli, 38 - 37059 Campagnola di Zevio (VR), Italy. Declares that the boilers: CODEX GT... - Page 28 Notes Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 29 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 30 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 31 Notes Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
- Page 32 ICI CALDAIE SpA 37059 Fraz. Campagnola di Zevio ( Verona) Italy Via G. Pascoli 38 Phone: +39 0458738511 Fax:+39 0458731148 info@icicaldaie.com www.icicaldaie.com Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
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