Unical INOXIA GJ 1000 Installation And Servicing Manual Download | Manualshive

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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

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Summary of Contents for INOXIA GJ 1000

Page 1: ...INOXIA GJ INSTALLATION AND SERVICING MANUAL 00335290 1st edition 04 11 ...

Page 2: ...m 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...

Page 3: ...heck the state of wear of the anode 1 4 INFORMATIONTO BE HANDED OVERTOTHE USER OR PERSON IN CHARGE OFTHE 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 cont...

Page 4: ...lve 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 yo...

Page 5: ...lued 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 k...

Page 6: ...ing 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 ...

Page 7: ... two stage or modulating provided that thermal power reached minimum is lower specified on the rating plate The boilers are equipped with 2 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 INO...

Page 8: ...52 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...

Page 9: ... 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 ...

Page 10: ...n 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 fitt...

Page 11: ...uctions 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 ...

Page 12: ...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 Electromagneti...

Page 13: ...ause 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 mouthpi...

Page 14: ...lled 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 h...

Page 15: ... 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 hinge...

Page 16: ...es 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 radiato...

Page 17: ...nt 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 ga...

Page 18: ...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 ...

Page 19: ...ing 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 addit...

Page 20: ...er 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...

Page 21: ...21 Instructions for the installer fig 12 5 24 4 8 10 12 13 6 3 1 2 7 23 20 14 19 17 21 18 1 2 11 9 16 12 15 ...

Page 22: ...plied equipment implies the observance of several fundamental rules such as Do not touch the appliance with any wet part of your body and or barefooted Do not pull the supply cables Do not expose the boiler to sunlight rain etc unless it is explicitly foreseen Do not permit children or inexpert people to use the appliance Connection to mains supply 230V The electrical connections are shown at ch 3...

Page 23: ...ect zone PZ1 21 switch system pump mixed zone Pz2 33 thermostat operation 35 Safety thermostat The probes of the temperature controller boiler water heater external delivery are included in the supply environmental probes 1 and 2 are optional the mixing valve and its engine command are not supplied If you fit the room temperature sensors optional temperature environments will be determined only un...

Page 24: ...R2 85 C 01 08 ADDRESS BUS BOILER 10 C 80 C MIN T CR2 10 C 0 11 VOLTAGE CURVE 11 0 00 10 00V CURVE 11 U2 0V 0 00 10 00V CURVE 11 U2 10V 00 120 C CURVE 11 T1 0 C 00 120 C CURVE 11 T2 100 C 0 00 10 00V CURVE 11 UA 0V 10 C 85 C WASTE START 10 Only display BOILER FOUND 00 1000kW POWER LEVEL see notes 00 01 disins ins NEW CONFIGURATION 00 100 MINIMUM MODULATION 00 00 08 ACS LEVELS 00 K DIFFERENCE REGULA...

Page 25: ...truction manual controller E8 5064 Default Personal values Value range Designation DOMESTIC HOT WATER PRODUCTION 00 01 OFF ON CHARGE PUMP 01 ON 00 01 02 03 PARALLEL PUMP OPERATION 01 00K 50K TAC 20K 5K 30K AC HYSTERESIS 5 gradi 00 min 30 min DELAY AC 00 min 00 01 OFF ON INLET THERMOSTAT 00 OFF 00 01 OFF ON FUNC THERMOSTAT 00 OFF Exit level using BACK 00 01 OFF ON LOADING 00 OFF Default Personal va...

Page 26: ...S 1 4 MF 5 C 5 25 FUNCTION F 15 0 Exit level using C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 PROGRAMMABLE PARAMETERS FOR TECHNICIANS OF THERMOREGULATOR type Lago Basic 0201 RV 1 1 2 3 1 1 Set the switch on the burner 1 2 Press the OK key 2 3 Turn the knob 3 until it appears on the display mm modulating burner 4 Press the OK key 2 2 1 Move the selector 1 the symbol of the mixing valve 2 Press...

Page 27: ...irect area and a zone low temperature controlled by mixing valve engine hot sanitary water Key Vmix2 mixing valve area motorized PZ1 pump heating zone HIGH TEMPERATURE Pz2 pump heating zone LOW EV vessel expansion IR AT distribution of the heating HIGH TEMPERATURE IR BT distribution of the heating LOW Ps hot water recirculation pump Pb charge pump hot water producer SPF tank sensor KF boiler tempe...

Page 28: ...the boiler for the production of acs will be put into operation automatically and will be switched off when will reach the temperature of delivery through the controller For practical connections electrical and probes refer to the diagram supplied with the panel instruments cod 37892 The panel is designed for the management of burners in operation modulator With this plant configuration the contro...

Page 29: ...ODE NUMBER FOR THERMOREGULATOR type E8 5064 00 01 OFF ON MASTER TEMPERATURE 30 C 110 C MAX T MAX CR1 COLLECTOR 10 C 80 C MIN MIN T CR1 COLLECTOR 01 ON 85 C 10 C 0 01 BUS CONNECTION 01 00 01 disins ins POWER BUS 01 ON 2K 20K HYSTERESIS 00 30 min TIME HYSTERESIS 00 01 02 MINIMUM 5 00 min 00 30 C 110 C MAX T CR2 85 C 01 08 ADDRESS BUS BOILER 10 C 80 C MIN T CR2 10 C 0 11 VOLTAGE CURVE 11 0 00 10 00V ...

Page 30: ... BURNER 2K 01 06 SEQUENCE MODE 01 Set the value of the first stage of the first boiler to 1 in the second to leave the dashes Set the value of the first stage of the second boiler 1 the second to leave the dashes In the case of more than 2 boilers in cascade to enable the early stages of the boilers in cascade See instruction manual controller E8 5064 Default Personal values Value range Designatio...

Page 31: ...e range Designation HEATING CIRCUIT 2 00 04 CIRCUIT OPERATION 0 00 03 PUMP OPERATION 0 5 25 MIXER OPEN 18 5 25 MIXER CLOSED 12 20 C 110 C MAX TEMPERATURE DISCHARGE 45 C 10 C 110 C MINIMUM DELIVERY TEMPERATURE 10 C 15 C 5 C ANTIFREEZE 0 C 0 00 24 00 RIT TEMP EST 0 00 00K 50K DIST CUR RIS 5 C 00 01 OFF ON OBLIDGE REDUCTION 01 Exit level using BACK Default Personal values Value range Designation SOLA...

Page 32: ...3 until it appears on the display mm modulating burner 4 Press the OK key 2 2 1 Move the selector 1 the symbol of the mixing valve 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 15 the time of the servo burner 4 Press the OK key 2 3 1 Move the selector 1 on the BUS ID 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 1 identification of the boiler...

Page 33: ...n the case of boiler cascade The temperature controller adjusts the temperature Boiler No 2 To achieve this the thermostat will be located in scale up pos 32 The possible modulation of the burner will be managed by the thermoregulatory On the boiler power line control panel must be provided with a switch fuses protection To use the instrument panel see instruction manual for the plant manager As f...

Page 34: ...3 until it appears on the display mm modulating burner 4 Press the OK key 2 2 1 Move the selector 1 the symbol of the mixing valve 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 15 the time of the servo burner 4 Press the OK key 2 3 1 Move the selector 1 on the BUS ID 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 2 identification of the boiler...

Page 35: ...g 20 shows the typical pattern of connection of the boiler to the heating system it consists of two boilers with cascade function at the service of an area high temperature and a low temperature zone controlled by motorized mixing valve production of hot water The boiler No 1 is equipped with an instrument panel code 37892 boiler No 2 is equipped with an instrument panel code 37900 Vmix2 mixing va...

Page 36: ... charge pump of the boiler for the production of acs will be put into operation automatically and will be switched off when will reach the temperature of delivery through the controller For practical connections electrical and probes refer to the diagram supplied with the panel instruments cod 37892 and 37900 The panel is designed for the management of burners in operation modulator With this plan...

Page 37: ...1 21 switch system pump area mixed Pz2 33 thermostat operation 35 Safety thermostat The probes of the temperature controller boiler water heater external delivery are included in the supply environmental probes 1 and 2 are optional the mixing valve and its engine command are not supplied If you fit the room temperature sensors optional temperature environments will be determined only under the cur...

Page 38: ...R2 85 C 01 08 ADDRESS BUS BOILER 10 C 80 C MIN T CR2 10 C 0 11 VOLTAGE CURVE 11 0 00 10 00V CURVE 11 U2 0V 0 00 10 00V CURVE 11 U2 10V 00 120 C CURVE 11 T1 0 C 00 120 C CURVE 11 T2 100 C 0 00 10 00V CURVE 11 UA 0V 10 C 85 C WASTE START 10 Only display BOILER FOUND 00 1000kW POWER LEVEL see notes 00 01 disins ins NEW CONFIGURATION 00 100 MINIMUM MODULATION 00 00 08 ACS LEVELS 00 K DIFFERENCE REGULA...

Page 39: ...uction manual controller E8 5064 Default Personal values Value range Designation DOMESTIC HOT WATER PRODUCTION 00 01 OFF ON CHARGE PUMP 01 ON 00 01 02 03 PARALLEL PUMP OPERATION 01 00K 50K T AC 20K 5K 30K AC HYSTERESIS 5 degrees 00 min 30 min DELAY AC 00 min 00 01 OFF ON INLET THERMOSTAT 00 OFF 00 01 OFF ON FUNC THERMOSTAT 00 OFF Exit level using BACK 00 01 OFF ON LOADING 00 OFF Default Personal v...

Page 40: ...RESIS 1 4 MF 5 C 5 25 FUNCTION F 15 0 Exit level using BACK C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 PROGRAMMABLE PARAMETERS FOR TECHNICIANS OF THERMOREGULATOR type Lago Basic 0201 RV 1 1 2 3 1 1 Set the switch on the burner 1 2 Press the OK key 2 3 Turn the knob 3 until it appears on the display mm modulating burner 4 Press the OK key 2 2 1 Move the selector 1 the symbol of the mixing valv...

Page 41: ... controlled by mixing valve engine hot sanitary water Keys Vmix2 mixing valve area motorized PZ1 pump heating zone HIGH TEMPERATURE Pz2 pump heating zone LOW EV vessel expansion IR AT distribution of the heating HIGH TEMPERATURE IR BT distribution of the heating LOW Ps hot water recirculation pump Pb charge pump hot water producer SPF tank sensor KF boiler temperature control probe E8 5064 KF1 boi...

Page 42: ...the boiler for the production of acs will be put into operation automatically and will be switched off when will reach the temperature of delivery through the controller For practical connections electrical and probes refer to the diagram supplied with the panel instruments cod 38778 The panel is designed for the management of burners in operation modulator With this plant configuration the contro...

Page 43: ...CODE NUMBER FOR THERMOREGULATOR type E8 5064 00 01 OFF ON MASTER TEMPERATURE 30 C 110 C MAX T MAX CR1 COLLECTOR 10 C 80 C MIN MIN T CR1 COLLECTOR 01 ON 85 C 10 C 0 01 BUS CONNECTION 01 00 01 disins ins POWER BUS 01 ON 2K 20K HYSTERESIS 00 30 min TIME HYSTERESIS 00 01 02 MINIMUM 5 00 min 00 30 C 110 C MAX T CR2 85 C 01 08 ADDRESS BUS BOILER 10 C 80 C MIN T CR2 10 C 0 11 VOLTAGE CURVE 11 0 00 10 00V...

Page 44: ... 2 BURNER 2K 01 06 SEQUENCE MODE 01 Set the value of the first stage and the second stage of the first boiler 1 Set the value of the first stage and the second stage of the second boiler 1 In the case of more than 2 boilers in cascade to enable the early stages and second stages of the boilers in cascade See instruction manual controller E8 5064 Default Personal values Value range Designation DOME...

Page 45: ...e range Designation HEATING CIRCUIT 2 00 04 CIRCUIT OPERATION 0 00 03 PUMP OPERATION 0 5 25 MIXER OPEN 18 5 25 MIXER CLOSED 12 20 C 110 C MAX TEMPERATURE DISCHARGE 45 C 10 C 110 C MINIMUM DELIVERY TEMPERATURE 10 C 15 C 5 C ANTIFREEZE 0 C 0 00 24 00 RIT TEMP EST 0 00 00K 50K DIST CUR RIS 5 C 00 01 OFF ON OBLIDGE REDUCTION 01 Exit level using BACK Default Personal values Value range Designation SOLA...

Page 46: ...3 until it appears on the display mm modulating burner 4 Press the OK key 2 2 1 Move the selector 1 the symbol of the mixing valve 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 15 the time of the servo burner 4 Press the OK key 2 3 1 Move the selector 1 on the BUS ID 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 1 identification of the boiler...

Page 47: ... P1 in the case of boiler cascade The temperature controller adjusts the temperature Boiler No 2 To achieve this the thermostat will be located in scale up pos 32 The possible modulation of the burner will be managed by the thermoregulatory On the boiler power line control panel must be provided with a switch fuses protection To use the instrument panel see instruction manual for the plant manager...

Page 48: ...3 until it appears on the display mm modulating burner 4 Press the OK key 2 2 1 Move the selector 1 the symbol of the mixing valve 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 15 the time of the servo burner 4 Press the OK key 2 3 1 Move the selector 1 on the BUS ID 2 Press the OK key 2 3 Turn the knob 3 until the display shows the number 2 identification of the boiler...

Page 49: ...R AT distribution of the heating HIGH TEMPERATURE IR BT distribution of the heating LOW Ps hot water recirculation pump fig 27 P1 circulator pump Pb charge pump hot water producer SPF tank sensor KF boiler temperature control probe E8 5064 KF 1 boiler temperature control probe Lake Basic 0201 RV 1 VF outlet probe AF external probe P1 C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 3 1 4 2 11 4 1 1...

Page 50: ... The charge pump of the boiler for the production of acs will be put into operation automatically and will be switched off when will reach the temperature of delivery through the controller The panel is designed for the management of burners in operation modulator For practical connections electrical and probes refer to the diagram supplied with the panel instruments cod 38778 and 37901 With this ...

Page 51: ... procedures For lighting and shutting down the boiler refer to the USER S INSTRUCTIONS GUIDE Information to be passed on to the user The user must be instructed on the use and operation of his boiler and in particular detail Hand over to the end user the booklet USER S INSTRUCTIONS GUIDE as well as all the other literature relative to the appliance and placed in the envelope contained in the packa...

Page 52: ...uency of servicing will be determined by the service engineer and will depend on the appliance s state of condition These adjustments can be performed only by Service Centres authorized by UNICAL INSTRUCTIONS FOR INSPECTION AND SERVICING To ensure a long life to all your boiler components and in order not to alter the conditions of the approved product only original UNICAL spare parts must be used...

Page 53: ...s of the seal which must not show signs of deterioration otherwise need to be replaced using Only original spare parts Check the status of the inspection cover gasket smoke chamber In case of deterioration should be replaced using Only original spare parts Burner Maintenance The burner maintenance of the must be carried out by central assistance authorized by Unical punishment void the warranty Ch...

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Page 56: ... of transcript or press Also reserves the right to bring those changes that it will hold necessary to it own products or profits without jeopardizing its essential characteristics AG S P A 46033 casteldario mantova italia tel 0376 57001 r a fax 0376 660556 www unical eu info unical ag com ...

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