Immergas 900 kW Safety Kit with Circulator and Separator

Product Identification

Product Name: Safety Kit Complete with Circulator and Separator

Power Rating: 900 kW

Product Code: 3.023649

Document Code: ST.009334/000

Revision/Date: 07/2025

General Warnings and Usage Information

All Immergas products are supplied with suitable transport packaging and must be stored in a dry place, protected from the weather. This document provides technical information for installing the Immergas kit. For other installation-related matters, such as workplace safety, environmental protection, and accident prevention, it is essential to comply with current regulations and principles of good practice.

Improper installation or assembly of Immergas appliances, components, accessories, kits, or devices can lead to unforeseen problems for people, animals, or property. Users should carefully read the instructions provided with the product for correct installation. Installation and maintenance must be performed in compliance with applicable regulations, manufacturer's instructions, and by qualified, professionally skilled personnel with specific technical expertise in plant installation, as required by law.

Compatible Appliances

This kit is compatible with the entire Immergas Ares Tec range (150-900 kW).

Kit Description

The primary ring mixing header is designed to optimally interface with condensing generators that have low water content and a very high modulation ratio.

The kit includes:

Safety kit
Hydraulic balancing circuit
Modulating pump
Mechanical impurity filtering system

Kit Composition and Components

The kit comprises several key components, detailed in the figures and legends provided.

Description of Figure 1 (Page 2) and Figure 2 (Page 3): These figures illustrate the physical layout and components of the safety kit. They show the main separator unit, the modulating pump, the filter, the mixing header, and various safety and control devices connected to the manifold. Dimensions for mounting are also indicated.

Main Components (Referenced in Figures)

Separator Support (C)
Filter "Y" DN100 PN16 (5)
Modulation Pump (3)
Mixing Header DN100 (15)
Manifold Safety Kit (E/DN100 PN16)

INAIL Safety Kit Components (Referenced in Figures)

Minimun water pressure switch (certified) (2)
Paddle flow switch (4) - Not supplied
Predisposition for expansion vessel connection (7)
Control well for thermometer (8)
Safety pressure switch (Max) (9)
Thermometer (scale 0°C ÷ 120°C) (10)
Safety thermostat (11)
VIC bulb well (12)
Safety valve (13) - Not supplied. Max calibration pressure: 5.4 bar. One valve for up to 580 kW, two valves for > 580 kW.
Pressure gauge connection (14) (includes 3-way tap, shock absorber tube)
Manometer (23) - Not supplied
Automatic air vent valve (16)
Dirt separator connection (17)

Water Content: 1.87 Liters

Mounting Dimensions

The figures illustrate the required mounting dimensions and component positioning. The separator support (C) can be mounted in two positions, allowing for heights of 235-255 mm. Specific clearances and overall dimensions are provided in the diagrams.

Description of Mounting Dimensions (Page 3): This section details the physical space requirements for installing the kit. It shows the overall width, height, and depth, along with specific measurements for component placement and clearances. Different height configurations for the separator support are indicated.

Electrical Connections

The electrical connections diagram outlines the wiring required for the system. This includes connections from the main electrical panel (Q.E.) to various components and control modules.

Description of Electrical Connection Diagram (Page 4 & 5): This diagram shows the flow of electrical signals and power. It details connections to the main electrical panel, a Wieland power supply socket (230V, 50Hz), terminals for a flow switch, external sensors, and the pump power connector. It also illustrates the wiring to the Boiler Control Module (BCM), specifying connections for analog inputs (AI 1, AI 2), digital inputs (DI 1, DI 2), and power supply (+24V, GND). Specific notes are provided for connecting safety devices (pressure switches, thermostat) to the BCM, including alternative wiring if a specific terminal block is absent.

Key Electrical Components and Terminals:

Q.E.: Main electrical panel (not supplied).
B: Services connection return terminal board.
D: Wieland mobile power supply socket (230V, 50Hz).
FL: Terminals for flow switch.
SE: Terminals for external sensor.
SMG: Global flow sensor.
C: Pump power connector.

BCM (Boiler Control Module) Connections:

Analog Inputs (AI 1, AI 2): Support 0-10V, 4-20mA/PT 1000 signals. Terminal 13 is +In, Terminal 12 is -GND for AI 1.
Digital Inputs (DI 1, DI 2): For digital signals.
Power Supply: +24V, GND.
Safety Extra-Low Voltage (SELV): Connections for safety circuits.

Note on Safety Connections: If terminal block "B" is not present, connections should be made directly to the BCM as indicated in the diagrams (e.g., Y2 10 to terminal block M2, Y2 11 to terminal block M2).

Safety Details (INAIL)

This section details the specific safety features and their connections, particularly relating to INAIL requirements.

Description of INAIL Safety Details (Page 5): This diagram provides a close-up view of the safety devices and their wiring to the BCM. It highlights the maximum pressure switch (1.1 P. max.), the flow switch (FL), and the minimum pressure switch (1.2 P. min.), along with the safety thermostat (1.3 T.S.). The connections are shown to specific terminals on the BCM, with notes on how to proceed if certain terminal blocks are not present.

The INAIL safety kit includes critical components for system protection, such as pressure switches and a safety thermostat, which must be correctly wired to the control unit for proper operation and safety compliance.

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