Immergas INAIL Safety Kit with Circulator and Separator (440-770 kW)
Product Code: COD.3.023648
Document Code: 1.034900 - rev. ST.009369/000 - 07/2025
General Warnings
All Immergas products are protected with suitable transport packaging. The material must be stored in a dry place protected from the weather.
This instruction manual provides technical information for installing the Immergas kit. For other issues related to kit installation (e.g., safety in the workplace, environmental protection, accident prevention), it is necessary to comply with regulations in force and principles of good practice.
Improper installation or assembly of Immergas appliances, components, accessories, kits, and devices can cause unexpected problems for people, animals, and objects. Read the product instructions carefully for proper installation.
Installation and maintenance must be performed in compliance with regulations, according to manufacturer's instructions, and by professionally qualified staff with specific technical skills in the plant sector, as envisioned by law.
Compatible Appliances
- The entire Ares Tec range (150-900 kW)
Description
The primary ring mixing header fastens perfectly on condensing generators with low water content and very high modulation ratio.
The kit includes:
- SAFETY kit
- Hydraulic balancing circuit
- Modulating pump
- Mechanical impurity filtering system
Kit Components and Diagram Description
Figure 1 and Figure 2 illustrate the physical assembly of the safety kit. The main components include a large cylindrical separator vessel, a manifold assembly containing a modulating pump, a 'Y' filter, and various ports for safety devices, sensors, and connections. The assembly is supported by brackets and adjustable feet.
Main Kit Components:
| Ref. | Component Name | Description |
|---|---|---|
| 3 | Modulation Pump | |
| 5 | Filter "Y" DN100 PN16 | |
| 15 | Mixing Header DN100 | |
| C | Support bracket | (2 positions) |
| D | Adjustable foot | |
| E | Manifold safety Kit (DN100 PN16) | |
| F | DN65/DN100 Adapter | |
| 6 | Expansion vessel | / more expansion vessels (optional, depends on power) |
| 16 | Automatic air vent valve | |
| 17 | Dirt separator connection |
Manifold Safety Kit Components:
| Ref. | Component Name | Notes |
|---|---|---|
| 2 | Minimum water pressure switch | Certified |
| 4 | Paddle flow switch | (not supplied) |
| 7 | Predisposition for expansion vessel connection | |
| 8 | Control well for thermometer | |
| 9 | Safety pressure switch (Max) | |
| 10 | Thermometer | (scale 0°C ÷ 120°C) |
| 11 | Safety thermostat | |
| 12 | VIC bulb well | |
| 13 | Safety valve | (not supplied, max calibration pressure: 5.4 bar. Up to 580 kW = 1 valve; > 580 kW = 2 valves) |
| 14 | Pressure gauge connection | (3-way tap, shock absorber tube) |
| 23 | Manometer | (not supplied) |
Mounting Dimensions and Position Components
Figure 2 provides critical mounting dimensions and component placement. Key dimensions include overall height, width, and depth. Specific clearance requirements are indicated, such as the 10 cm screed under the boiler or the assembly. The diagram also shows the adjustable positioning of the support bracket (C).
Key Dimensions (approximate):
- Overall Height: 1230 mm
- Overall Width: 1415 mm
- Overall Depth: 770 mm (main unit)
- Clearance for Position 1: 10 cm (screed under boiler)
Note on Support Bracket (C): The support bracket can be mounted in 2 positions, with a height range of 235-255 mm.
Height Requirements for Different kW Models:
- Up to 440 kW: 1087 mm
- 550 - 660 kW: 1355 mm
- 770 - 900 kW: 1623 mm
Electrical Connections
Figure 4 and Figure 5 detail the electrical connections required for the safety kit. The diagrams show wiring from the main electrical panel (Q.E) to various terminals on the kit, including a Wieland power supply socket (D), flow switch (FL), external sensor (SE), and pump connector (C). It also illustrates connections to a Boiler Control Module (BCM) via terminal blocks.
Terminal Connections:
| Label | Description |
|---|---|
| Q.E | Main electrical panel (not supplied) |
| B | Services connection return terminal board |
| D | Wieland mobile power supply socket 230 V - 50Hz |
| FL | Terminals for Flow switch |
| SE | Terminals for external Sensor |
| SMG | Global flow sensor |
| C | Pump power connector |
Safety Detail Items (INAIL Safety Connections):
These connections are typically made to a Boiler Control Module (BCM). If terminal block "B" is not present, connections should be made directly to the BCM as indicated.
- INAIL Safety Inputs:
- Terminal 9 (Max Pressure Switch)
- Terminal 10 (Flow Switch)
- Terminal 11 (Min Pressure Switch)
- Terminal 12 (Safety Thermostat)
Note on BCM Connections: When connecting directly to the BCM without terminal block "B", remove any bridge connections and connect cables as indicated (e.g., Y2 10 to terminal block M2, Y2 11 to terminal block M2).
Analog and Digital Inputs:
The system supports analog inputs (AI 1/2) and digital inputs (DI 1/2).
- Analog Inputs (AI 1/2): Typically configured for 0-10 V or 4-20 mA / PT 1000 signals. For 0-10V, AI 1 uses terminals 13 (+In) and 12 (-GND).
- Digital Inputs (DI 1/2): Used for various sensor signals.
- Safety Extra-Low Voltage (SELV): Connections are made to specific terminals for safe operation.
