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CODEX 1000-1600 GT_EN Ed. 00 - 05/2019

Low NOx steel condensing boilers

CODEX 1000-1600 GT

INSTALLATION, USE AND MAINTENANCE MANUAL

Cooke Industries - Phone: +64 9 579 2185 Email: [email protected] Web: www.cookeindustries.co.nz

Summary of Contents for 17010195

Page 1: ... GT_EN Ed 00 05 2019 EN Low NOx steel condensing boilers CODEX 1000 1600 GT INSTALLATION USE AND MAINTENANCE MANUAL Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...ry 10 Burners Installation 11 Product receipt 12 Handling 12 Installation room 13 System cleaning 13 Hydraulic connections 14 Starting hydraulic circuit 15 Flue exhaust 15 Condensate drain 16 Door opening 16 Door opening inversion from the right to the left 17 Door adjustment 18 Insulating casing assembly 19 Burner assembly 19 Electrical connections 20 Water treatment 20 Limestone build ups 20 Lim...

Page 3: ...the instructions in this manual will void the warranty conditions RANGE BOILER BOILER MODEL CODE CODE CODEX 1000 GT 81022203 17010195 CODEX 1200 GT 81022213 CODEX 1400 GT 81022303 CODEX 1600 GT 81022313 COMPLIANCE CODEX GT boilers comply with the following European Directives European Regulation on Gas Equipment GAR 2016 426 EU Low Voltage Directive 2014 35 EU Electromagnetic Compatibility Directi...

Page 4: ...ied personnel maintenance technician in compliance with the requirements of the local Standards in force Ordinary and extraordinary maintenance must be carried out by qualified personnel in order to promptly detect any damage to the boiler body under pressure and to the safety and control accessories PROHIBITIONS d IT IS FORBIDDEN Operate electrical devices or appliances such as switches household...

Page 5: ...ant with the standards in force IDENTIFICATION Each CODEX GT Boiler can be identified by means of the technical data plate inside the envelope of the documents supplied with the Boiler which includes technical efficiency informations such as serial number or identification marking nominal thermal power in kW nominal thermal flow in kW types of fuels which can be used maximum operating pressure CE ...

Page 6: ...thus ensures that the main mechanical characteristics of stainless steel are preserved as well as its capability to resist acid condensate corrosion flow flange fitting and two system return fittings to distinguish the Boiler inlet and ensure the minimum possible temperature at the lowest point thus getting the most out of condensate benefits even in the presence of medium high temperature return ...

Page 7: ...2 H12 mm 91 91 68 68 L mm 1493 1493 1573 1573 L1 mm 1310 1310 1390 1390 L2 mm 1298 1298 1378 1378 L4 mm 1060 1060 1165 1165 P mm 2443 2443 2437 2437 P2 mm 1732 1732 1725 1725 P6 mm 250 300 250 300 250 300 250 300 Øb mm 280 280 320 320 Øc mm 350 350 400 400 Attachments Description u m CODEX GT 1000 1200 1400 1600 N1 DN in 125 125 125 125 N2 DN in 100 100 100 100 N1 N2 PN 6 6 6 6 N4 DN in 1 1 1 1 N7...

Page 8: ...on u m CODEX GT 1000 1200 1400 1600 1 DN in 1 2 2 1 1 2 3 1 1 2 4 1 1 4 5 1 2 6 1 2 7 1 2 8 1 2 9 1 2 10 3 4 11 1 2 NOTE For further details see the chapter Starting hydraulic circuit Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 9: ...e kg h 34400 41280 48160 55040 Minfluidflowrate kg h 4128 4816 6192 8600 Pressuredropsonexhaustside mbar 4 2 6 2 8 3 10 8 Soundpower 5 dB A 87 7 87 7 96 0 96 0 COemissions mg kWh 0 0 0 0 NOxemissions mg kWh 50 50 50 50 NOxclass 4 6 6 6 6 Maxchimneyloss 2 1 3 1 3 1 3 1 3 Casingloss 2 0 3 0 3 0 3 0 3 LosswithburnerOff 2 0 1 0 1 0 1 0 1 Fumetemperature Ratedinput air 20 C G20 2 C 40 40 40 40 CO2 G20 ...

Page 10: ...LMCE eterm Boiler control panel QETERM01CE eterm system control panel QETERM02 eterm Easy manager panel QCTETERM BURNERS The burners are supplied together with CODEX GT Boilers and are CE marked in accordance with European Directives European Regulation on Gas Equipment GAR 2016 426 EU Low Voltage Directive 2014 35 EU Electromagnetic Compatibility Directive 2014 30 EU Efficiency Directive 92 42 EE...

Page 11: ... CONTROL PANEL 5 BURNER 6 5 3 2 4 6 1 m IMPORTANT Upon receipt of CODEX GT Boiler make sure that the supply is intact and undamaged and promptly contact ICI CALDAIE S p A if it does not correspond to the order m IMPORTANT The instruction manual is an integral part of the appliance and it MUST be carefully read before installing and commissioning the Boiler carefully stored for further consultation...

Page 12: ...g the door of the installed burner considering its opening direction towards the right or the left A P4 90 NO A P4 see Size and fittings a ATTENTION Consider the spaces necessary to access the adjustment and safety devices and to perform maintenance in compliance with the legislation in force in the place of installation If the burner is fed with gas of specific weight greater than that of the air...

Page 13: ...sure measured downstream of the pressure regulator on the supply line does not exceed the operating pressure indicated on the Boiler plate Make sure that the drains of the safety valves of the Burner and of the heater if any are connected to a drain funnel so that the valves do not flood the room in case of intervention Make sure that the water and heating system pipes are not used as earthing poi...

Page 14: ...ing thermostat probe no 1 14 Setting thermostat probe no 2 15 Fuel shut off valve probe 16 Shock absorbing pipe 17 Safety valve no 1 no 2 with thermal power above 580 kW 18 Fuel shut off valve 19 Manual shut off valve 20 Gas manual shut off valve 21 Expansion vessel 22 Level probe glow plug optional 23 System flow 24 Probe holding sheaths inside the boiler 25 Natural gas inlet 26 Low temperature r...

Page 15: ...ints must be ensured with materials resistant to the temperatures of the drain flue gases we recommend at least 250 C check that the chimney has an adequate draught and that is free from bottlenecks and waste CONDENSATE DRAIN CODEX GT Boilers are equipped with a condensate drain pipe derived from the appliance and the flue gas drain The condensate is acid and MUST be treated by the installer in co...

Page 16: ...ew and extract the ring nuts 5 of the two hinges on the opening side of the door and pull it carefully 4 3 5 1 2 Hinge of rotation door side Hinge of opening door side DOOR OPENING INVERSION FROM THE RIGHT TO THE LEFT Dx Sx 2 4 1 5 3 7 6 8 Left hinge screw the ring nuts 1 of the left side with the lever 2 in such a way that the distance of the door from the appliance front plate is the same and th...

Page 17: ...een the appliance front plate and the door wall is the same on both sides If not with the door ajar loosen the locking nuts 4 of the hinge units work on ring nuts 5 to adjust the distance of the door from the appliance front plate tighten the nuts 4 locking the conical washers in the pipes 6 a DANGER When cross changing ferrules always make sure that the other two ferrules are fastened so that the...

Page 18: ...pporting slat 5 using the supplied screws and nuts fasten the front 6 and rear 9 pillars to the base and to the plates 6 using the supplied screws and nuts insert the slats 2 on the lateral side m IMPORTANT The panel supporting slat 5 must be the ninth one on the side featuring the control panel 9 5 4 7 6 6 8 2 2 fasten the two cross beams 10 to the plates 6 insert the upper slats 11 fasten the en...

Page 19: ... to the wiring diagrams supplied with the Boiler with the control panel and with the burner Moreover it must operate in compliance with the Technical Standards and the national and local Laws in force Once the work is complete the Authorised Company must issue the Declaration of Conformity of the system built m IMPORTANT It is mandatory to use an omnipolar thermal magnetic line circuit breaker com...

Page 20: ...uction of the Boiler service life Limestone gathers in the points where the wall temperature is higher and the best defence against it at the construction level is to eliminate the superheating areas Scale build ups form an insulating layer which decreases the heat exchange of the boiler penalising its efficiency This means that a significant part of the heat obtained from the combustion is not fu...

Page 21: ...ack to the preset value and close the manual and or automatic supply tap After the initial filling it is necessary to prevent oxygen and untreated water from entering the system The entry of oxygen causes corrosion while untreated water causes the formation of limestone Both conditions must be avoided NOTE The system venting will be completed if necessary upon the first commissioning of the Boiler...

Page 22: ...nd activate a heat request The Boiler will perform the ignition phase and will operate until the adjusted temperatures will be reached m IMPORTANT In case of LOCK OUT STOP of the burner refer to its technical manual CHECKS AFTER COMMISSIONING Once the start up has been performed check that the appliance stops and then restarts by modifying the Boiler thermostat calibration by operating on the cont...

Page 23: ...commended to position the central panel switches and the control panel switch to OFF close the fuel and water interception valves of the hydraulic system m IMPORTANT If the external temperature is below ZERO empty the thermal system use anti freeze liquid propylene glycol until a maximum percentage of 3 DECOMMISSIONING OF OLD APPLIANCES Decommissioned appliances contain materials which can be recy...

Page 24: ...ed with water mixed with denatured alcohol or specific non abrasive detergents Dry the surfaces thoroughly after cleaning Boiler internal cleaning To perform the internal cleaning disconnect from the burner anything which may hinder the door opening e g gas train loosen the 4 nuts or the two ring nuts with the lever 1 and open the door 2 1 2 3 clean the combustion chamber surfaces with a suitable ...

Page 25: ... Check the door tightness Gas smell Gas supply circuit Check sealing possible obstructions combustion quality Frequent safety valve triggering Excessive pressure in the system circuit Check load pressure Check pressure regulator Check calibration Malfunction of the system expansion vessel Check the efficiency ENVIRONMENTAL PROTECTION AND DISPOSAL Protection and respect for the environment is a fun...

Page 26: ...f your appliance and system by completing the indicated spaces 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 Registration e...

Page 27: ...ITY 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 conform to the type described in the EC certification and comply with the following Council Directives European Regulation on Gas Equipment GAR 2016 426 EU Efficiency Directive 92 42 EEC Ele...

Page 28: ...Notes 28 6 Notes Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 29: ...Notes 29 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 30: ...Notes 30 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 31: ...Notes 31 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 32: ... 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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