9
Delivery
- The G100/20-30-40-50 and G100/20-30-40-50IE
boilers are delivered fully assembled in a single
package.
- The G100/70-90-110 and G100/70-90-110IE
boilers are delivered in four packages which
contain:
- Fully assembled boiler, burners and gas train
assembly.
- Outer casing.
- Smoke hood.
- Control panel
- The G100/GTA and G100IE/GTA boilers are
delivered in three packages which contain:
- Fully assembled G100 or G100 IE boiler.
- Storage cylinder.
- Cylinder casing and boiler support framework.
Installation
- Observe current regulations applicable with
regard to access to the boiler for future start-up
operations, monitoring and servicing.
- Ensure there is a 220/230V-50 Hz single- phase
earthed power point as well as a water supply
and a drain near the final installation location of
the boiler.
- It is advisable to install a non-thermosiphonic
valve in the ”heating flow” pipe to prevent the
radiators from warming up when there is no
demand for heating.
Assembly
Location
- Locate the boiler in accordance with the layout
and position of the Flow, Return and Gas inlet
pipes, flue duct, drain, etc.
- The boiler should be installed at least 0.5 m away
from any flammable material.
- If there is a wooden, cork, or similar heat-
sensitive floor, protect the supporting surface in
an area of 0.5 m around the boiler with 20 mm-
thick (minimum) glass fibre.
- The G100/70-90-110 and G100/70-90-110IE
boilers may only be installed outdoors
(protected) or in a room separate from the
inhabited rooms, suitably ventilated directly to
the outside air.
- For G100/GTA and G100IE/GTA boilers, ensure
there is enough room at the back so that future
water connections and the assembly of the
cylinder casing can be performed without
difficulty.
Boiler support framework, optional electric
heater and hydraulic unit (GTA version only)
- In the cylinder ”Return” tapping screw in the
1” x 3/4” reducing nipple (1), the 3/4” m-f elbow
(2), the check valve (3) -with the arrow pointing
towards the flexible tube adaptor- and finally
screw in the adaptor itself (4).
Fig. 1
.
- Put the cylinder cradle in its final location, with
the angle irons (5) facing the viewer.
Fig. 2
.
- Rest the cylinder on the cradle, with its metal
base facing the viewer and the prepared
assembly in the lower section, properly centred
and against the front supporting plate.
- Screw the 1/2” plug into the rear tapping on the
left-hand side of the cylinder (viewed from its
metal base) and the nipple (6) into the top
tapping.
- As an option, when required, insert the electric
heater element into the cylinder and screw it in
the plug tapping (7). Wire it to the terminals
marked on the wiring diagrams shown in the
Instructions that come with the relevant control
panel.
- Place the two vertical brackets (8), which are
identical, such that the hole which is closest to
the end of the top profile stays on the right, as
viewed from its metal base.
- Place the above vertical brackets behind the
angle irons (5) and fasten them by introducing
the M6 x 15 bolts (9) through the angle irons
by screwing them to the brackets. At the time
the brackets (8) are being screwed in, install the
tie- rods (1 0) – one on either side.
Fig. 3
and
4
.
- Rest the boiler supporting base (11) on the
brackets (8) and secure it with the M6 x 15 bolts
(12) and nuts provided.
- Put the unpacked boiler and its support (’U’
shapes) (13) on the floor so that the U-shaped
profiles come into contact with the rear legs. The
rear left leg will coincide with the U-shape which
has a hole in the welded stop (14).
Fig. 5
.
- Raise the back side of the boiler and slide the
support (13) under it until the U-shaped profiles
come into contact with the back side of the
boiler’s front legs.
- Raise the boiler through the front and slide it
over the U-shaped profiles until its rear legs
come into contact with the welded stops.
- Fasten the rear left leg of the boiler to the drilled
stop, using a nut and bolt. – Insert the rods of
both handles (15) into the end holes in the U-
shaped profiles of the boiler support (13) and
secure them with the nuts provided.
Fig. 6
.
- Lift both the support (13) and the boiler through
the handles (15) and rest them on the boiler
supporting base (11). The front of the boiler
should face in the same direction as the metal
base of the cylinder, while the hex heads of the
bolts (12) that fasten the supporting base (11)
to the vertical brackets (8) should coincide with
the holes (16) in the boiler support (13).
Figs. 4
and
5
.
- Disassemble the handles (15) and keep them
for future use (for instance, under the cylinder).
- Fasten the support (13) to the supporting base
(11) with the four nuts and bolts provided.
- Screw the adaptor (4) onto the 500 mm flexible
tube union (17).
Fig. 4
.
- Screw the cone piece (18) on the reducing T
(19). The side port should be horizontal and
facing out.
Fig. 7
.
- Screw the nipple (20) to the elbow (21).
- Screw the elbow (21) to the side port of the
reducing T(19).
- Insert a 3/4” gasket into the union adaptor on
the ”Return connection” pipe (22)
Fig. 4
and
screw it to the elbow (21) through the slotted
hole in the supporting base (11).
- Place a 3/4” gasket between the 500 mm flexible
tube (17) and the nut on the ”Return connection”
pipe (22) and join them together.
- Fix the pipe (22) to the cylinder metal base with
the aid of the clamp (23) as shown in
figure 4
.
- Screw the reducing nut (24) into the ”Flow”
tapping.
Fig. 7
.
- Screw the nut (24) into an end of the ”boiler outlet
pipe” (25). The T with union should be facing
the floor.
- Install the safety valve. Where appropriate.
- Place a gasket in the vertical T union and screw
it to the pump. The arrow on the pump body
should point to the floor and the terminal box be
at the top.
- Screw the 520 mm flexible tube to the nipple (6)
on the cylinder through the hole provided in the
supporting base (11) and screw the union
adaptor on the other end of the flexible tube to
the pump, having put a gasket beforehand.
Watertight Test
For G100/70-90-110 and G100/70-90-110IE
boilers:
- Unscrew the non-return valve sensor (26) from
the control panel hydrometer and screw it into
the tapping in the front section.
Fig. 8
.
- Fill the system with water and check the
hydraulic circuit for leaks.
In all boilers:
- Install the specific safety devices as shown in
Fig. 9
. The size of the safety conduits must
conform to the dimensions given for them in the
current Regulations.
- Install a drain cock in the tapping (27), or fit a
plug if the drain cock is located elsewhere; then
make the connection of the FLOW and RETURN
circuits, i.e. tappings (28) and (29)*
respectively.
Fig. 10
.
* The assembled boilers have a 2” x 1” cone, while
G100/90-110 and G100/90-110IE are equipped
with a 2” x 2” distributor.
- With GTA version boilers, connect the cylinder
to the mains water supply and to the system
through the screwed nipples, observing their
destination as shown in
Fig. 12
; then in the
”mains water inlet” connection before the
cylinder, install the Flexbrane safety unit in
accordance with the instructions that come with
it. Route the discharge to the general drain.
- Fill the system* with water and check the
hydraulic circuit for leaks.
* With GTA version boilers, it is essential to fill
the DHW circuit (storage cylinder) before the
heating circuit and, when appropriate, empty the
latter first.
Final Assembly
For G100/70-90-110 and G100/70-90-110IE:
- Rest the smoke hood (30) on the boiler and
secure it to the front and back sections by means
of the nuts and bolts provided.
Fig. 8
.
- Place the insulating blanket over the boiler body
so that its ends overlap at the front of the boiler.
- Fasten the bracket-casing (31) to the front
section: with M8 x 10 screws through the top;
with M12 nuts and washers through the lower
right-hand side; and with MS nuts and washers
fasten it to he spacer which has been previously
screwed to the leg – through the lower left-hand
side.
Fig. 11
.
- Fasten the side bracket (32) onto the bosses at
the top of the back section by means of M8 x 20
bolts. The angles should face inwards and the
slotted hole to the right.
Fig. 10
.
- Secure the other side bracket (33) to the holes
in the back section cover using two M8 x 40
bolts. The angles should face inwards and the
slotted hole to the right.
- Temporarily hang the control panel from the
hooks (34) on the bracket casing (31).
Fig. 11
.
- Insert the thermostat and thermometer probes
through the slotted hole (35) in the top left-hand
side of the bracket-casing (31).
- Screw the hydrometer sensor to the non- return
valve situated on the front section. – Insert the
thermometer, control (2 in the G100/90-110IE)
and safety limit thermostat(s) into the pocket in
the back section and fasten the capillaries with
the clip provided for this purpose.
Fig. 12
.
- Remove the control panel from the casing
bracket hooks.
- Fix the casing side panels to the brackets (31),
(32) and (33) using the black Allen screws and
washers provided (four each).
- Rest the left-hand casing extension piece (36)
on its bottom side and secure it through the top
with a screw.
Fig. 13
.
- Hang the control panel to the front of the casing
panels and secure it through the bottom with
the two screws provided.
In all boilers:
- Insert the end of the flue duct down into the
smokehood collar and ensure that the joint is
air-tight by applying pipe jointer material, ceramic
fibre gasket or putty which does not set hard.
- Connect the end of the boiler gas train to the
gas supply pipe and with soapy water check that
the gas train is air-tight.
Electrical connections
- In boilers which are delivered disassembled,
make the connection between the control panel
and the boiler gas valve by means of the
connectors situated at the bottom left hand-side
of the control panel and at the end of the valve
wiring.
- Wire the heating pump, the optional ambient
thermostat and the mains power supply to the
terminals marked on the wiring diagrams that
come with the Instructions for the control panel.
For boilers which are delivered fully assembled,
please note that before proceeding as indicated
GB
ATC
ROC
