Automatic Heating Global | Commercial Heating & …...A = Central Heating circuit features 9=(Pn) Nominal output 10 = (Pcond) Condensing nominal output 11 = (Qmax) Nominal heat input

Modular Condensing Boiler

Modulex EXT440 - 550 - 660 - 770 - 900

Installation and Servicing Instructions

3

CONTENTS

1 GENERAL INFORMATION ................................................................................................................................................................................... 41.1 Symbols used in this guide .......................................................................................................................................................................... 41.2 Correct use of the appliance ....................................................................................................................................................................... 41.3 IInformation to be passed over to the person in charge of the appliance ................................................................................................ 41.4 Safety warnings ............................................................................................................................................................................................ 51.5 Data badge .................................................................................................................................................................................................... 61.6 General warnings ......................................................................................................................................................................................... 7

2 TECHNICAL FEATURES AND DIMENSIONS ..................................................................................................................................................... 82.1 Technical features ........................................................................................................................................................................................ 82.2 Dimensions ................................................................................................................................................................................................... 92.3 Performance data ....................................................................................................................................................................................... 102.4 RHS view showing main components ....................................................................................................................................................... 11

3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 123.1 General warnings ...................................................................................................................................................................................... 123.2 Installation standards ................................................................................................................................................................................ 133.3 Packaging .................................................................................................................................................................................................. 143.4 Installation .................................................................................................................................................................................................. 163.5 Boiler location in a boiler room .................................................................................................................................................................. 173.6 Boiler connection ....................................................................................................................................................................................... 173.7 Gas connection ......................................................................................................................................................................................... 183.8 Connection return and flow system pipes ............................................................................................................................................... 193.9 Primary circuit pump or boiler pump ........................................................................................................................................................ 203.10 Additional safety and control devices, according to the Italian Law + primary circuit kit ..................................................................... 213.11 Wiring diagram for additional safety devices ........................................................................................................................................... 22

3.12 Safety pressure relief valve ..................................................................................................................................................................... 233.13 Mixing header filter .................................................................................................................................................................................... 233.14 Ballstop valves .......................................................................................................................................................................................... 233.15 Boiler freeze protection ............................................................................................................................................................................. 243.16 Mixing header and plate heat exchanger ................................................................................................................................................ 243.17 Condensing drain ...................................................................................................................................................................................... 253.18 Water treatment ......................................................................................................................................................................................... 263.19 Flue chimney connection .......................................................................................................................................................................... 273.20 Flue manifold connection .......................................................................................................................................................................... 273.21 Operation ................................................................................................................................................................................................... 293.22 Electrical connections ............................................................................................................................................................................... 313.23 Functional wiring diagram ......................................................................................................................................................................... 323.24 Wiring diagram for connection and managing ......................................................................................................................................... 343.25 Installation examples (functional wiring and connections description) .................................................................................................. 363.26 Cascade manager BCM ........................................................................................................................................................................... 40

Connections for boilers in cascade, controlled by outer compensators ............................................................................................... 433.27 Configuration with a modulating pump ..................................................................................................................................................... 443.28 Filling the system ...................................................................................................................................................................................... 453.29 Burner Adjustment .................................................................................................................................................................................... 463.30 Emergency functions ............................................................................................................................................................................... 493.31 Initial Lightning ........................................................................................................................................................................................... 50

4 SERVICING SCHEDULE .................................................................................................................................................................................... 51

5 CE CERTIFICATE ............................................................................................................................................................................................... 56

Warning: this manual contains instructions to be used exclusively by theinstaller and/or a competent person in accordance with the current laws inforce.The end user MUST not make any alterations to the boiler.Failure to follow the instructions indicated in this manual, which is suppliedwith the boiler, could cause injury to persons, animals or damage to property.UNICAL shall not be held liable for any injury and/or damage.

4

General information

1.1 - SYMBOLS USED IN THIS GUIDEWhen reading this guide particular care has to be given to the parts marked with the followings symbols:

1.2 - CORRECT USE OF THE APPLIANCE

The MODULEX appliance has been designed utilizing today’s heating technology and in compliance with thecurrent safety regulations.However, following an improper use, dangers could arise for the safety and lifeof the user or of other people, or damage could be caused to the appliance or other objects.The applianceis designed to be used in pumped hot water central heating systems. Any other use of this appliance will beconsidered improper. UNICAL declines any responsibility for any damages or injuries caused by an improperuse; in this case the risk is completely at the user’s responsibility.In order to use the appliance accordingto the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide.

1.3 - INFORMATION TO BE HANDED OVER TO THE USER

1 GENERAL INFORMATION

NOTE!Suggestions for theuser

WARNING!Indicates a potentially dangeroussituation for the product and theenvironment

DANGER!Indicates serious dangerfor your personal safetyand for your life

The user has to be instructed on the use and operation of his heating system, in particular:

• Hand over these instructions to the end user, together with any other literature regarding this appliance,placed inside the envelope contained in the packaging. The user has to keep these documents in a safeplace in order to always have them at hand for future reference.

• Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that is absolutelyforbidden to make any alterations to the boiler.

• Inform the user how to check the system’s water pressure as well as informing him how to restore the correctpressure.

• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensurethe greatest possible fuel economy.

• Remind the user that it is obligatory to carry out a comprehensive service annually and a combustion analysisevery two years (in compliance with the national law).

• If the appliance is sold or transferred to another owner or if the present user moves home and leaves theappliance installed, ensure yourself that the manual always follows the appliance so that it can be consultedby the new owner and/or installer.

Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause injuryto persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/or damage.

5

General information

WARNING!The device should not be used by people with reduced physical, mental and sensory, experience andknowledge. These people must be well-informed and supervised during the work. Children must besupervised so they do not play with the appliance.

WARNING!The installation, adjustment, and servicing of this appliance must be carried out by a competent person andinstalled in accordance with the current standards and regulations. Failure to correctly install this appliancecould cause injury to persons, animals or damage to property. The manufacturer shall not be held liable forany injury and/or damage.

DANGER!Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICALrecommends drawing up a service contract. Bad or irregular servicing could compromise the safe operationof the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall notbe held liable.

Modifications to parts connected to the applianceDo not carry out any modifications to the following parts:- the boiler- to the gas, air, water supply pipes and electrical current- to the flue pipe, safety relief valve and its 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 gasleakages).

WARNING!Indications for appliances operating with propane gasEnsure yourself that before installing the appliance the gas tank has been purged.For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legallyauthorized.If the tank has not been correctly purged problems could occur during ignition.If this occurs contact the liquid gas tank’s supplier.

Smell of gasIf you smell gas follow these safety indications:- Do not turn on or off electrical switches- Do no smoke- Do not use the telephone- Close the main gas tap- Open all windows and doors where the gas leakage has occurred- Inform the gas society or a company specialized in installing and servicing heating systems

Explosive and easily inflammable substancesDo not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the roomwhere the appliance has been installed.

1.4 - SAFETY WARNINGS

WARNINGS

The boiler has to be installed in such way to avoid,under the foreseen operation conditions, the congelation of the water and

to prevent that the control devices are exposed to a temperaturelower than -15°C and higher than 40°C.

The boiler has to be protected against environmental variations with:

- The insulation of the hydraulic pipelines and the condensate evacuation- The adoption of specific antifreeze products in the C.H. installation.

6

General information

® 1

2

3

5

7 8

6

4

9

11

13

10

12

14

15

17

19

16

18

20

28

A

B

21 22

23

24 25 26

27

C D

E

CE MarkingThe CE marking documents that the boilers satisfy:- The essential requirements of the Directive regarding gas

appliances (Directive 2009-142 EC)

LEGEND:1 = Year of CE certification issue2 = Boiler type3 = Boiler model4 = Number of stars (Directive 92/42/CEE)5 = (S.N°) Serial number6 = P.I.N. code7 = Approved fluing configurations8 = (N0x) N0x class

A = Central Heating circuit features9 = (Pn) Nominal output10 = (Pcond) Condensing nominal output11 = (Qmax) Nominal heat input12 = (Adjusted Qn) Adjusted for nominal Heat input13 = (PMS) Max. pressure C.H. system14 = (T max) Max. C.H. temperature

B = Domestic Hot Water circuit features15 = (Qnw) Nominal heat input in D.H.W. mode (if different from Qn)16 = (D) Specific D.H.W. flow rate according to EN 625 - EN 13203-1

17 = (R factor) N° taps based on the quantity of water declared EN13203-1

18 = (F factor) N°stars based on the quality of water declaredEN 13203-1

19 = (PMW) Max. pressure D.H.W. system20 = (T max) Max. temperature D.H.W system

C = Electrical features21 = Electrical power supply22 = Consumption23 = Protection grade

D = Countries of destination24 = Direct and indirect country of destination25 = Gas family26 = Supply pressure

E = Factory setting27 = Adjusted for gas type X28 = Space for national brands

- The essential requirements of the Directive regardingelectromagnetic compatibility (Directive 2004/108 EC)

- The essential requirements of the Efficiency Directive(Directive 92/42/EEC)

- The essential requirements of the low voltage Directive(Directive 2006/95EC).

1.5 - DATA PLATE

7

General information1.6 - GENERAL WARNINGS

This instruction manual is an integral and indispensable partof the product and must be retained by the person in charge

of the appliance.

Please read carefully the instructions contained in this manualas they provide important indications regarding the safeinstallation, use and servicing of this appliance.

Keep this manual in a safe place for future reference.

The installation and servicing must be carried out inaccordance with the regulations in force according to themanufacturer’s instructions and by legally competentauthorized persons.

By a competent person, we imply a person who has aspecific technical qualification in the field of componentsfor central heating systems for domestic use, domestichot water production and servicing. The person must havethe qualifications foreseen by the current laws in force.

Bad or irregular servicing could compromise the safeoperation of the appliance, and could cause injury to persons,animals or damage to property. The manufacturer shall notbe held liable for any such injury and/or damage.

Before carrying out any cleaning or servicing turn off theelectrical supply to the boiler by means of the ON/OFF switchand/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 authorizedtechnicians and using only original spare parts. Non-observance of the above requirement may jeopardize thesafety of the appliance.

To guarantee the efficiency and correct functioning of theappliance it is indispensable to have the boiler servicedannually by a qualified person.

If the boiler remains unused for long periods, ensure that anydangerous parts are rendered innocuous.

If the appliance is sold or transferred to another owner or ifthe present user moves home and leaves the applianceinstalled, ensure yourself that the manual always follows theappliance so that it can be consulted by the new owner and/or installer.

Only original accessories must be used for all appliancessupplied with optionals or kits (including electrical ones).

This appliance must be used only for the purposes for whichit has been expressively designed. Any other use shall beconsidered incorrect and therefore dangerous (*).

8

Technical features and dimensions

45678

440550660770900

2.1 - TECHNICAL FEATURES

• MODULEX is a compact, gas fired, Low NOx, condensingboiler, made up by one sectional boiler body,This boiler body consists of two or more modules (from 4 to8), which cannot be separated from each other, being un-der the same protecting casing, and are set to operate se-parately or in cascade. These modules are connected to asingle smoke exhaust manifold and are controlled by asingle microprocessor (BMM), which manages completelythe temperatures from the point of view, both operationaland safety. This version is suitable for only central heatingCAUTION: These devices are not suitable for theproduction of water for human consumption

• Efficiency at full load with temperature 30/50°C = 101,1%.At part load (30% of the nominal) with 30°C return tempe-rature = 107,2%.

• Efficiency Class:• Each module, is composed of a combustion chamber, me-

tallic fiber pre-mix burner, modulating fan, gas valve, igni-tion electrode, flame detection, NTC sensor for manage-ment control (BMM), local temperature control and afetythermostat.

• Each single boiler is equipped with NTC sensors for globaltemperature control on the flow and return manifolds.

• Integral, non allergic, synthetic wool insulation.• Total premix burner, modulating burner with a radiant “me-

tal sponge” (NIT). Premix antechamber combustion. Auto-matic backflow valve, preventing gas in the place of instal-lation.

• Fully pre-mixed, radiating, modulating, metallic spongeburner, Automatic no return diaphragm for separation fromcombustion chamber.

• Nominal input, per module: max. 108 kW, min. 22 kW.• Noise level at maximum output: lower than 50 dBA.• Modules configuration possibilities:• Possible cascade installation of 2 or more Modulex• Heating Operation: setting of instantaneous output by a

main microprocessor, with a comparison parameters pre-setting between the requested temperature (or calcula-ted by the outer compensator) and the global flow tem-perature.

2 TECHNICAL FEATURESAND DIMENSIONS

• Logic of operation:A) Output sharing on as many modules as possible at min.load (down to 22 kW) for the max. efficiency..B) Automatic operation hour splitting-up system for eachmodule to guarantee the best homogeneous use.C) D.H.W. production, via a storage tank loading pump or athree way diverting valve, controlled by a priority sensorthrough the E 8 heating controller.D) Output check of each module for any calibration and/orassistance by secret access code.

• Possibility of controlling the output of each single module.• Heating request control: temperature set point

andmodulation level.• Monitoring of boiler and temperature status.• Alarm control.• Parameters setting.• Relay for control of the operation of a pump at constant

flow rate.• 0÷10V analogical output for control of a modulating pump.• Emergency operation: it avoids C.H. system shut down

caused byan interruption in communication with the boilerplant’s automation system: : (in case of remote control ofthe complete boiler house):

• Input for “Constant setpoint”: 82°C, maximum output 50%.• Alarm reset input.• Alarm relay signal.• Gas connecting pipes, flow/return water pipes, arranged

for any connection (by the opposite end).• Integral easily removable panel set (painted steel panels).• Smoke exhaust pipe, adjustable on the right, the left and

behind the heating system.• Condensate collecting tank equipped with drain siphon

and stainless steel smoke chamber.• Built-in air vent.• Weights and dimensions are limited (see table at par. 1.2)• Instrument panels secreted (POP-UP)

SENSORS supplied with the boiler:• 00262208 outdoor temperature sensor• 00262209 flow temperature sensor for mixed zone• 00262210 boiler temperature sensor• 00262211 D.H.W. storage temperature sensor

Optional accessories:• 00262603 Sensor (Solar) PT1000• 00262829 Acid condensate inhibitor 1500 kW• 00361044 Cleaning kit bodies• 00361332 Kit thermoregulation E8• 00361358 Remote control kit BM8• 00361359 Kit custody thermoregulation• 00361545 Kit expansion module E8

• Primary circuits: COMPO S - PREMO S - PREMO C -COMPO S RING BOX COVER. - Safety devices - , see cap.3.10

• 00361997 Mixing header• 0036..... gas terminal Support kit• 0036....... Boiler support Kit 10 cm

9


MODULEXDimensionNo. of ModulesHeight mmWidth ‘’L’’ mmWidth ‘’L1’’ mmDepth mm

ConnectionsGas mm (inch)C.H. system Flow M mm (inch)C.H. system Return R mm (inch)Chimney connection mmCondensate drain diameter mm

440

4144810871039946

80 (3)100 (4)100 (4)

30040

395

946235 S

1267

534

327

R

M

G

122

660

6144813551307946

80 (3)100 (4)100 (4)

30040

770

7144816231575946

80 (3)100 (4)100 (4)

30040

550

5144813551307946

80 (3)100 (4)100 (4)

30040

900

8144816231575946

80 (3)100 (4)100 (4)

30040

Smoke outlet:Left side (standard condition)Right sideBack side

1448

L1287

L

62,5

24

S

2.2 - DIMENSIONSFRONT VIEW RIGHT HAND SIDE VIEW

LEFT HAND SIDE VIEW UPPER VIEW

= =

10


2.3 - PERFORMANCE DATA

900

86422

849,05 20,57873,9323,5998,2793,5

101,15107,22

497,898,50,20,1

2,5845,81386

24,25-

645

365090,5

6122

91,362,33

106,252,71

67,071,71100

146,7

<95<30<49

230/504

1252X5D

20

770

75622

742,62 20,57773,3823,5998,2393,5

102,3107,22

497,898,50,20,1

2,5846,71213

24,25-

645

319330,5

6108

79,942,33

92,972,71

58,681,71100

128,4

<95<30<49

230/504

1096X5D

20

660

64822

636,5320,57

662,9023,5998,2393,5

102,3107,22

497,898,50,20,1

2,5146,71040

24,25-

645

273710,5

694

68,522,33

79,692,71

50,301,71100110

<95<30<49

230/504

940X5D

20

550

54022

530,44 20,57552,4223,5998,2393,5

102,3107,22

497,798,50,20,1

2,5346,7866

24,25-

645

228090,5

680

57,102,33

66,412,71

41,921,7110091,7

<95<30<49

230/504

783X5D

20

440

43222

424,35 20,57446,9323,5998,2393,5

102,3107,22

497,798,50,20,1

2,5846,7693

24,25-

645

182470,5

667

45,682,33

53,132,71

33,531,7110073,4

<95<30<49

230/504

626X5D

20

(*) Room Temperature = 20°C(**) See paragraph ‘’INJECTORS – PRES

SURES’’(***) The protection IP X5D is obtained with

cap down.

The Technical data plate is placed under thecasingand is positioned near to the BCM.

BOILER TYPE MODULEXAppliance category II

2H3P

Nominal Heat Input on P.C.I. Qn kWMinimum Heat Input on P.C.I. Qmin kWNominal Output (Tr 60 / Tm 80 °C) Pn kWMinimum Output (Tr 60 / Tm 80 °C) Pn min kWNominal Output (Tr 30 / Tm 50 °C) Pcond kWMinimum Output (Tr 30 / Tm 50 °C) Pcond min kWEfficiency at max. output (Tr 60 / Tm 80°C) %Efficiency at min. output (Tr 60 / Tm 80°C) %Efficiency at max. output (Tr 30 / Tm 50°C) %Efficiency at min. output (Tr 30 / Tm 50°C) %Efficiency Class acc. to Directive 92/42 CEECombustion efficiency at nominal load %Combustion efficiency at part load %Stand-by losses with burner in operation %Flue losses with burner with burner off %Flue losses with burner with burner in operation %Flue gas temperature tf-ta (max) °CFlue gas mass flow rate (max) kg/hExcess of air λ %(**) CO

2 at min/max. output) %

NOX (value according EN 297/A3 + EN 483) mg/kWh

NOX class

Min. water flow rate in CH circuit (ΔT 20°C) l/hMinimum pressure in CH circuit barMaximum pressure in CH circuit barWater content lGas Consumption Natural gas G 20 (20 mbar) Qn m3/hGas Consumption Natural gas G 20 (20 mbar) Qmin m3/hGas Consumption G25 (supply pressure 25 mbar) Qn m3/hGas Consumption G25 (supply pressure 25 mbar) Qmin m3/hGas Consumption G31 (supply pressure 37/50 mbar) Qn kg/hGas Consumption G31 (supply pressure 37/50 mbar) Qmin kg/hMax. available pressure at the chimney base PaCondensate production max kg/hEmissionsCO with 0% of O2 in the flue system ppmNOx with 0% of O2 in the flue system ppmSound level dBAElectrical DataVoltage / Frequency V/HzFuse on main supply A (F)Max power absorbed W(***) Insulation degree IPStandby Consumption W

11


Smoke outlet on the L.H. side, on R.H. side, on the BACK sideC.H. flow connection on the L.H. sideC.H. return connection on the L.H. sideGas connection on the L.H. sideBCM: under the frontal panel

2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS

GAS PIPE

H. LIMITTHERMOSTAT

IGNITION ELECTRODE

CONTROLL PANEL

FAN

GAS VALVE

BURNER COVER

BURNER

ALUMINIUM/SILICON HEAT EXCHANGER

CONDENSATE COLLECTING TRAY-SMOKEMANIFOLD

C.H.RETURN

C.H. FLOW

AUTOMATIC AIR VENT

Min. Depth 100 mm

BOILER FRAME

12

Instructions for the installer

3 INSTRUCTIONS FORTHE INSTALLER

3.1 - GENERAL WARNINGS

WARNING!This boiler has to be destined for the use forwhich it has been expressively designed for.Any other use shall be considered improperand therefore dangerous.This boiler is designed to heat water at atemperature inferior to boiling point at anatmospheric pressure.

WARNING!These appliances are exclusively designedto be installed inside adequate boiler rooms.Therefore these appliances must not beinstalled and operated externally.

Before installing the boiler the following pointshave to be carried out by a competent engineer:a) The whole system should be thoroughlyflushed in order to remove any residual dirt orgrime which could compromise the correctboiler operation.b) Check that the boiler has been preset foroperating with the gas type available.This is verifiable via the indication on thepackaging and on the data badge;c) Check that the chimney/flue pipe has anadequate draught,does not have anyconstrictions, and that no other appliance’sflue outlets have been fitted, unless the chimneyis serving more than one heating appliance,according to the specific standards andregulations in force.The connection between the boiler andchimney/flue outlet can be made only after thisverification has been carried out.

WARNING!In rooms where there is the presence ofaggressive vapours or dust the appliancemust operate independently from the airpresent in the boiler’s location room!

WARNING!The appliance must be installed by a qualifiedengineer, who complies to the technical-professional requirements according to thenational applicable law and who, under hisown responsibility, guarantees thecompliance with the standards according tothe latest regulations.

WARNING! Install the appliance respecting the minimum clearances for operation and servicing.

The boiler must be connected to a heatingsystem which is compatible to its performancesand output.

13

Instructions for the installer3.2 - STANDARD CODES FOR

INSTALLATION

The appliance must be installed in compliance to theinstructions contained in this manual.

The installation must be carried out by a competent qualifiedengineer, whom will assume the responsibility of complyingto all the local and/or national regulations published in theofficial publications, as well as all the applicable codes ofpractice.

Before installing the appliance please contact the gas supplycompany.

The installation must be carried in accordance to the codesof practice, the regulations and the requirements herebyindicated which constitute an indicative list, but not a completeone, as these continue to undergo evolve devolpments.

Moreover, the boiler must be installed in accordance to all theregulations regarding the boiler room, the building regulationsand the prescriptions regarding central heating plants in forcein the country where the boiler is installed.

The appliance must be installed, commissioned and servicedaccording to the regulations in force. This is also valid for thehydraulic system, the flue outlet system and the boiler locationroom.

14


15151515151515151515

440550660770900

12631531153117991799

kg551 kg kg806 kg kg

11201120112011201120

3.3 - PACKING

The boiler MODULEX is delivered assembledand protected by a plastic bag inside a strongcardboard box and fixed on pallet. This allowsthe boiler to be handled also by forklift. The boi-ler, with the packaging, can go through a door of800 mm, whereas, without packaging, it can gothrough a door of 700 mm.

Remove both straps and finally the cardboardbox from above, making sure the product isintact. The packing elements (cardboard box,straps, plastic bags, etc…) shall not be left tochildren’s hand since they may be dange-rous.

For the removal of the boiler from the pallet it is necessaryto have a jib crane, to avoid to damage, during the removal.- Remove the casings and make the sling with the belts

‘’A‘’ fig. 3, having care to pass the belts bearing barsframe

- Tie the belts to thearm ‘’ B ‘’; during these operationsactwith caution.

On the L.H. side of the boiler:- There is the terminal of the smoke chamber, fixed.

- A carton box containing:• Gasket between smoke chamber and its terminal,• Gasket for the base of flue socket, gasket Ø 300• Two curves + a Te piece + a plastic plug, for the

condensate evacuation system• The fixing screws• The sensors (3x).• Nipple for smokes sampling test• Kit resistance• Metal plate and passage cable for power output

- A carton box containing:• The flanges

Inside the casing, on the back side:- Two pipes for the condensate evacuation system of 1 m

each.

Above the top cover of the boiler:- A plastic bag containing:- This instructions manual for the installer- Instructions manual for the user- Instruction manual for the use of the E8 controller

C

B A

15


WARNING!Handling with forklift or hoist bands,

1

M ax. adm itte d b oiler s st acked

Do not tur n up side down Do n ot ex pose to r ain Fr agile Do no t exp ose to su nligh t Do not sto re at tem per atur e:lower than - 5 ° C / 23 °Fsup erior th an 50 °C / 122 °F

T max50°C/ 122°F

T mi n-5°C /23°F

2

M ax. adm itted bo ile rs s tacked

Do no t turn u pside down Do no t exp ose t o ra in Frag ile Do n ot ex pose t o sun ligh t Do not store at t emp eratu re :l ower t han - 5 ° C / 23 °Fs uper ior tha n 50 °C / 122 °F

T max50°C/122°F

T mi n-5°C /23°F

3

Max . adm itt ed bo ilers sta cked

Do no t t urn u psid e do wn Do n ot exp ose to rain F ra gile Do n ot e xpo se to s unl igh t Do no t st ore at t emp eratu re:l ower th an - 5 ° C / 2 3 °Fsu pe rio r than 50 °C / 1 22 °F

T max50°C /122°F

T mi n-5°C /23°F

4

WARNING!Waypoints bands for lifting. Brackets must bemounted on bearing stringers.

BOILER UNLOADING AND PACKAGE REMOVAL

16


Special attention shall be paid to local regulations and lawsabout boiler houses and particularly to the obligation ofkeeping minimum clearances and empty space around theboiler. The installation shall be in compliance with all latestregulations and laws about boiler houses, installations ofheating and hot-water systems, ventilation, chimneys capableof evacuating the flue gases of condensing boilers and anyother applicable requirement.

The boiler can be put on a flat and sufficiently strong basewith the same dimensions as the boiler ones and at least100mm high (see fig. 25), in order to assemble the conden-sate drain siphon. An alternative to this base may be a 100mmdeep well next to the boiler as siphon housing (see fig. 25).After installation the boiler shall be perfectly horizontal andstable, to reduce any possible vibrations or noises.

A

C

B

D

A > 400 mmB > 400 mmC = 100 mmD = 500 mm

Sifone

Give the boiler the minimum clearances as shownin the drawing, in order to be able to make thenormal service and cleaning operations.

3.4 - BOILER LOCATION INSIDE A BOILER HOUSE

17


Diaphragm Gaskets

A

C

F

F

G

F

RM

3.6 - BOILER CONNECTION

The boiler Modulex leaves the factory predisposed for thehydraulic / gas connection and smoke outlet on the Left sideof the boiler.

For the smoke chamber fixing, use the screws and gasketsincluded into the carton box, and a 10 mm key.

The smoke collector is a standard on the left side, you canalso exit on the right side and rear side.

3.5 - INSTALLATION

F

F

G

F

R M

A

B

When the appliance is installed on existing systems, ensureyourself that:

- The flue outlet pipe is suitable for condensing boilers, forthe temperature of the products of combustion, calculatedand manufactured according to the regulations in force. Itmust be installed as much as possible in a straight line,tested for soundness, insulated and must not have anyocclusions or restrictions.

- The flue outlet pipe has a connection for the discharge ofcondensate.

- The boiler room has a suitable outlet for the discharge ofcondensate produce by the boiler.

- The electrical system has been fitted in compliance to thespecific norms and the work has been carried out by acompetent person.

- The circulation pump’s output, the head and flow directionare suitable.

- The gas feeding supply pipe and the eventual tank areconstructed according to the regulations in force.

- The expansion vessels assure the total absorption of thedilatation of the fluid contained in the system.

- The system has been cleaned of impurities and lime scale.

When a Modulex boiler is installed onto an existingheating system:In case the replacement of an existing boiler in an old systemcan be programmed, it is necessary to thoroughly cleanout the system with a basic solution. The system must becleaned 4 weeks before the substitution, with the systemfiring at a temperature of 35°C to 40°C.

WARNING!If it is noticed that a new Modulex has replaced,in an old system the existing boiler without ha-ving first performed what said in the previous pa-ragraph, Do not wash now the system, as resi-dual products, present in the circuit, could leadto system gathering in the boiler body, causingdamage. UNICAL recommends contacting a spe-cialised company for water treatment.

Instead, if installing a Modulex boiler in a new system, it isstill recommended to thoroughly clean out the system with anadequate product and fit a Y filter with two isolating valvesonthe boiler’s return pipe, so that, when necessary, it can becleaned. This filter will protect the boiler from the dirt comingfrom the heating system.

When sizing pumps, it is necessary to take into considerationthe pressure losses which occurin the primary circuit.

The sealing gasket with diaphragm Ø18 (A) are fitted only in theflow connection seat of the first and last aluminium section ofthe boiler.The sealing gasket with diaphragm Ø 27 (B) are fitted in theother fow connection seats of the remaining aluminium sections.

In all the return connection seats of the aluminium sections,only sealing gasket (C), without, is fitted.

18


3.7 - GAS CONNECTION

The gas supply pipe must be connected to the boiler via therespective pipe connection R 3” as indicated on page 9.

The gas supply pipe must have a section which is identical orgreater then the one used on the boiler and must assure acorrect gas pressure.

It is however important to comply with the specific norms andrequirements in force, foreseeing on-off valves, gas filter,anti-vibrating joint etc.

Before commissioning an internal gas distribution systemand therefore before connecting it to the gas meter, thecomplete installation must be tested for gas soundness.

If any part of the system is concealed from view the gassoundness test must be carried out before covering the pipes.

DANGER!The gas connection must be carried out by aregistered engineer who will have to respectand comply to the regulations in force and tothe requirements indicated by the local gassupplier. An incorrect installation couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any injury and/or damage.

Before installing the boiler it is recommendedto thoroughly clean all the supply piping in orderto remove any eventual residual grime whichcould compromise the boilers correctfunctioning.

If you smell gas:a. Do not turn on or off electrical switches, use

the telephone or any other object which canprovoke sparks;

b. Open all doors and windows in order toallow fresh air to enter and purify the room;c. Close all gas cocksd. Contact a service engineer, qualifiedinstaller or the gas supply company.

As a safety measure against gas leaks, Unicalrecommends installing a surveillance andprotective system made up of a gas leakagedetector combined with an on-off selenoid valveon the gas supply line.

1 2 3 4 5 66

INSIDEBOILER ROOM

OUTSIDEBOILERROOM

1. On-off gas supply valve2. Double membrane regulator3. Gas filter4. Anti-vibrating joint5. Selenoid valve6. On-off cock

EXAMPLE OF A GAS SUPPLY SYSTEM

19


3.8 - FLOW AND RETURN PIPE CONNEC-TIONS

The CH flow and return circuits have to be connected to theboiler via the respective connections 4” M and R as indicatedon page 9.

When determining the size of the CH circuit pipes it isessential to bear in mind the pressure losses induced by anyof the system’s components and by the configuration of thesame system.

The route of the piping has to be conceived taking all thenecessary precautions in order to avoid air locks and tofacilitate the continuous purging of the system.

WARNING!IT IS ABSOLUTELY FORBIDDEN TO FIT ON-OFFVALVES ON THE GENERATOR TO THE FOREOF THE SAFTEY DEVICES

WARNING!Before installing the boiler we recommendthat the system is flushed out with a suitableproduct in compliance to the norm UNI-CTI8065, in order to eliminate any metallictooling or welding residues, oil and grimewhich could reach the boiler and affect theproper running of the boiler.

Non-observance of these instructions couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any such injury and/or damage.

Ensure yourself that the system’s piping is notused as the earth clamps for the electrical ortelephonic system. They are absolutelyunsuitable for this use. In a short time this couldcause serious damage to the piping, boilerand radiators.

20


Boiler Model

Max water flow rateDemanded in l/h ( t=15 K)Δ

Max water flow rateDemanded in l/h ( t=20 K)Δ

440 550 660 770 900

18243 22804 27365 31926 36487

24326 30404 36487 42570 48647

3.9 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP

The size of the pumps must be determinedby installers or technical engineersaccording to boiler data and system design.

The water side resistance curve of the boileris shown in the following diagram.The pump is not an integral part of the boiler.

It is recommended to choose a pump withthe rate and delivery head at about 2/3 of itscharacteristic heating curve.

The boiler pump must have a delivery head which can ensurethe water flow rate as shown in the diagram “Water pressurelosses”.

The following table gives an indication of the pump’s flow ratein function of the Δt of the primary circuit if the installation hasa mixing header.

For a DT 20 K, of a MODULEX 900 boiler, the max. water flow rate requested is 36289 l/h.From the graph of the boiler’s pressure losses, it can be determined that the pump must be ableto guarantee a delivery head of at least 1,8 m/H2O.

0

0,40,20,60,8

1

1,41,21,61,8

2

2,42,22,62,8

3

3,43,2

3,63,8

4

4,44,24,64,8

5

5,45,2

5,65,8

6

0 2000 4000 6000 8000 10000 12000 14000 16000 20000 22000 24000 28000 30000 32000 34000 36000 38000 40000 42000 44000 46000 48000 50000 52000 5400018000

900 EXT

770 EXT660 EXT440 EXT 550 EXT

WATER FLOW (l/h)

Pres

sure

Los

ses

(m/H

)2O

NOTE: The use of a mixing header fitted between the boiler circuit and the system circuit isalways advisable. It becomes INDISPENSABLE if the system requires flow rates superior to themaximum permitted boiler flow rates, which is to say lower than 15K.

21


CERTIFICATION OF THE ADDITIONAL SAFETY DEVICES:

DISPOSITIVI DI SICUREZZA1. On-off gas valve: a device which has the function of cut-

ting off the gas supply when the water temperature rea-ches the max. predetermined value. The sensible elementhas to be installed as nearest as possible to the genera-tor (flow pipe) at a distance which has to be < 500 mm andmust not be able to be cut-off. Not supplied by Unical.

2 Pressure relief valve: it has the function of discharging inthe atmosphere the fluid contained in the generator whenthis has, for whatever motive, reached the maximumworking pressure. Not supplied by Unical.

2a Visible drain funnel. Not supplied by Unical.

PROTECTIVE DEVICES10 Overheat thermostat: it has the function of shutting down

the generator if the safety thermostat fitted in the boilermalfunctions. It must be calibrated to a value of < 100°C,which MUST not be changed.

15 Minimum pressure switch: it has the function of shuttingdown the generator In case of low pressure (can be cali-brated from 0.5 to 1.7 bar). It must be able to be resetmanually.

16 Additional plug G1'’:18 Safety pressure switch: it has the function of shutting

down the generator if it reaches the maximum workingpressure (can be calibrated from..

CONTROL DEVICES11. Pressure indicator with shock absorber tube (12) andpressure gauge holder valve (13): it indicates the effective

3.10 - ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW

12

2a4

6

1a

11121415

18

10

1317

3

1916

kit ISPELS

MODULEX 440 - 550 - 660 - 770: 00361998

MODULEX 900: 00361999

pressure existing in the generator. It must be graduated in“bar” and must have the maximum operating pressure inscale and be equipped with a 3-way valve with the connectionfor the manometer.

14 Thermometer: it indicates the effective water temperatu-re contained in the generator. It must be graduated in de-grees Celsius with a temperature scale not exceeding120°C.

17 Inspection pocket: approved for inserting the control ther-mometer

19 Plug ¼’’: for the safety valves connection

3 Calibrated expansion vessel: it permits the absorption ofthe increase in volume of the system’s water following anincrease in temperature; The pressure must not exceedthe safety valve set pressure. Not supplied by Unical.

8 Y filter

7 Modulating pump (Not supplied in kit ISPELS)

5 Mixing bottle (Not supplied in kit ISPELS)

4 Automatic air vent. Not supplied by Unical

6 Drain cock. Not supplied by Unical.

22


In case of safety devices intervention, thepump ON / OFF continues to work in order todecrease the high temperature..

In case of safety devices intervention, theModulating pump continues to work at theminimum in order to decrease the hightemperature

PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETYDEVICESMODULEX 440 - 550 - 660 - 700:(COMPO S. 00361994) (PREMO S. 00362065) (PREMO C. 00362067)

MODULEX 900(COMPO S. 00361995) (PREMO S. 00362066) (PREMO C. 00362068)

COMPO S.

PREMO S.

PREMO C.

3.11 - WIRING DIAGRAM FOR ADDITIONALSAFETY DEVICES

Pump management via E8 to the terminal 4 (A10) from the IV connector

LINE 230 V

Safety deviceskit

RELAY

L

N

LINE

Boiler mainssupply230 V

NL1

L

N

NL1

Terminals EXT-MINinterface WILO

modulating pump

LINE 230 V

Safety deviceskit

RELAY

LINE

Boiler mainssupply230 V

ON-OFF PUMP

MODULATING PUMP

23


Note:Modulex 660 - 770 - 900 need 2 securityvalve.

17

SAFETY VALVEVISIBLEDRAINFUNNEL

3.12- PRESSURE RELIEF VALVE DRAINPIPE

A pressure relief valve must be fitted on the flowpipe, within 0,5 m from the boiler. It must bedimensioned for the capacity of the boiler andmust comply to the regulations in force,

WARNING!Please remember that it is forbidden tointerpose, between the boiler and thepressure relief valve, any type of cutting-offdevice. Moreover it is recommended to usecutting-off valves which do not exceed themaximum allowable operating pressure.

WARNING!In correspondence to the heating pressurerelief valve foresee the installation of adischarge pipe with a funnel and a siphonwhich lead to an adequate drainage. Thedrainage has to be controllable by sight.If this precaution is not made, an eventualintervention of the pressure relief valve couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any injury and/or damage.

3.14 - BALLSTOP VALVES

The installation of ballstop gate valves, on the C.H. flow andreturn connection, is recommended.Doing so, in case of normal or extraordinary service, the boi-ler can be drained without emptying the whole C.H. sistem.

WARNING!IT IS NOT ALLOWED TO ISOLATE THE SAFETYDEVICES, as the safety valve and the expan-sion vessel, FROM THE BOILER.

3.13 - MIXING HEADER FILTER

UNICAL suggests the installation of a Y filteron the return pipe so that it can be cleaned ifnecessary.This filter will protect the boiler from the heatingsystem dirt.

Secondarycircuit

24


3.16 - MIXING HEADER AND PLATE HEAT EXCHANGERn order to ensure correct boiler operation it is necessary touse a mixing header which guarantees:

- the separation and collection of circuit dirt- optimal air venting- hydraulic de-coupling of the two hydraulic circulation

circuits- balancing of the circuits

he plate heat exchanger, conveniently dimensioned, has theadvantage to keep hydraulically the two circuits (primary andsecondary),protecting the boiler heat exchanger water / smo-ke. allows subsequently, by adding or removing additionalplates to adjust the system as needed.

M

MR

R

Boiler Circuit

Heating SystemCircuit

Mixing HeaderModulex Ext 440 - 900cod. 00361997M = DN 100 - (G 4’’)R = DN 100 - (G 4’’)

Modulex ModulexExt 440 code 00362093* Ext 440 code 00362098Ext 550 code 00362094* Ext 550 code 00362099Ext 660 code 00362095 Ext 660 code 00362100Ext 770 code 00362096 Ext 770 code 00362101Ext 900 code 00362097 Ext 900 code 00362102

80°C (ht)

65°C (ht)

70°C (ht)

60°C (ht)

70°C (bt)50°C (bt)

40°C (bt)55°C (bt)

High temperature:Boiler CircuitM = 80 °C - R = 65 °CHeating System CircuitM = 70 °C - R = 60 °C

Low Temperature:Boiler CircuitM = 70 °C - R = 55 °CHeating System CircuitM = 50 °C - R = 40 °C

Plate Heat exchanger:

COLD OUT CH FLOW to System circuit (G 4’’)COLD IN CH RETOUR from System circuit (G 4’’)HOT IN CH FLOW from boiler (G 4’’)HOT OUT CH RETOUR to boiler (G 4’’)

3.15 - BOILER FREEZE PROTECTIONShould the flow temperature (measured at global flow tempera-ture NTC) decrease under 7°C, the system pump is set up. Shoultemperature decrease to under 3°C, all modules will start at min.output until the return temperature reaches 10°C.Such protection device is exclusively for the boiler. For the pro-tection of the system, a second freeze protection thermostat isnecessary to switch on the heating system pump.To protect the C.H. system from freezing when boiler is not inoperation during cold season, it is necessary to add to the C.H.system water an anti freezing solution.NB: The antifreezing solution must be compatible with the

materials present in the system, and mainly with thealuminum.

WARNINGAFTER A LONG INOPERATION PERIOD OF THEBOILER, IN CASE THE BOILER TEMPERATUREIS BELOW 3°C, ABSOLUTELY DO NOT TRY TOSTART THE BOILER.

THIS CAN BE ALLOWED ONLY IF YOU ARE SURE THAT ANANTIFREEZE SOLUTION HAS BEEN ADDED, IN THE PROPERPERCENTAGE, TO THE C.H. WATER.

See the Unical catalogue and the price list toidentify the most convenient mixing header andprimary circuit.

* = G2

25


3.17 - CONDENSATE DRAIN

Discharge of condensate must be:- Built in order to prevent the escape of gas products of thecombustion in the location or sewer (siphon).- Dimensioned and constructed as to allow the proper flowof liquid discharges by preventing leaks (3% slope).- Installed in order to prevent freezing of the liquid contents,in function of the operating conditions.- Easily inspected

The condensate, before being evacuated to the sewer, has tobe neutralized, neutralisation which can be obtained by mixingthe drain water coming from washing maschines, dishwashing maschines, etc., which normally have a basic pH.

Avoid the condensate stagnation inside the combustionproducts evacuation system, (for this reason the evacuationduct must have an inclination toward the drain of at least 30mm/m (3/8 in. / ft) except the liquid column, inside thecondensate siphon, which needs to be filled with water afterinstallation: its minimum height, when all the fans are in oper-ation, must be at least 25 mm (1 in.).

Is forbidden discharge the condensate through the raingutters, given the risk of ice and degradation of thematerials normally used.The connection discharge should be visible.due to the level of condensate acidity (pH 3 to 5) as amaterial piping must be used only suitable plastics.

The outlet of the condensate drain pipe will be on the sameside of the smoke chamber, passing below the smoke cham-ber.

The recommended material must be PE (polyethylene) orPPI (polypropylene).

Before commissioning the boiler fill the con-densate siphon with water, from the dedica-ted filling-up plug.

PAVIMENTO DELLA C.T.

150

150

La generatrice superiore del tubo di scarico non dovrà trovarsi ad un livello superiore al fondo della bacinella.

* Min. height of the condensate column, with all fansoperating at max. speed, requested by the EN stan-dards.

** Min. height of the condensate column, with all fans opera-ting at max. speed. In the case it is not possible to create a100 mm basement, install the boiler on the floor and fore-see a min. 100 mm well to lodge the siphon.

26

Instructions for the installer3.18 - WATER TREATMENT

The chemical-physical characteristics of the filling water andreinstatement water in heating systems are of fundamentalimportance for guaranteeing correct and safe boiler operation.

Before filling the CH circuit with water, it is necessary to analysethe water and decide for a proper treatment.

The purpose of this treatment is finalized to eliminate orsubstantially reduce the following problems:

- lime scale deposit- corrosions- deposits- biological growths (moulds, bacteria, algae, fungi, etc)

The chemical treatment of the network water enables theprevention of these problems and guarantees safe boileroperation and economical advantages, in terms ofmaintenance and global thermal efficiency.

The chemical analysis of the water enables us to obtain a lotof information on the system’s condition and state of “health”.

It is essential to avoid any problems with the boiler.The pH is a measure of the acidity or alkalinity of a solution.The pH scale has a range of 0-14, where 7 is neutral.Values inferior to 7 indicate acidity, values above 7 indicatealkalinity.

The ideal pH value for water in heating systems fitted withaluminium boilers is between 6,5 and 8, with a hardness of15°F.

In heating systems where the water has a value outside thisrange, this considerably accelerates the destruction of theprotective oxidized layer which naturally develops inside thealuminium bodies: if the pH is below 6, acidity is present, if it isabove 8, the water is alkaline or it is caused by an alkalinetreatment (for example phosphate or glycol used as anantifreeze) or in several cases it is due to the natural formationof alkaline in the system.

Vice versa, if the pH value is between 6,5 and 8, the aluminiumsurfaces of the boiler body are passivated and protected fromfurther corrosive attacks.To minimize corrosion it is essential to use a scale inhibitor,however in order for this to function correctly, the metallicsurfaces have to be clean.

The best corrosion inhibitors on sale also contain aprotective system for aluminium which acts by stabilizingthe water’s pH value, preventing unforeseen variations.

We recommend that the heating system’s water pH valueis systematically controlled (minimum twice a year). In orderto do this, it is not necessary to run a chemical analysis ina laboratory, but it is sufficient to use a simple analytical‘kit’ contained in portable cases, easily found on sale.

Therefore, prior to filling the heating system with water it willbe necessary to fit the devices indicated in the figure below

THE CONNECTION MUST BE FITTED ON THEPRIMARY CIRCUIT’S RETURN PIPEDOWNSTREAM OF THE CIRCULATING PUMP

All the necessary precautions must be taken in order to avoidthe formation and localization of oxygen in the system’s water.For this reason, the plastic pipes used in underfloor heatingsystems must be impermeable to oxygen.

If any antifreeze solutions are used ensure yourself that theyare compatible with aluminium and with any other componentsand materials fitted on the system.

WARNING!ANY DAMAGE CAUSED BY THE BOILER, DUETO THE FORMATION OF LIME SCALE OR DUETO CORROSIVE WATER WILL INVALIDATE THEAPPLIANCE WARRANTY.

27


45678

440550660770900

300300300300300

For fixing the flue manifold use the 6 x nutsCH 10 and washers supplied in the plastic bag.

Smoke plug outlet have to be positionned on therectilinear lenght into the 1st meter of the boilerIn order to fit the combustion gases sampletest nipple, drill a hole Ø 21 mm in the smokeoutlet and fit the test nipple following theindicated sequence.

holeØ21 mm

3.20 - FLUE MANIFOLD CONNECTION

3.19 - CONNECTION TO THE CHIMNEY

In a condensing boiler the smokes are evacuated at a verylow temperature (Max about 84°C). Then it is necessary thatthe chimney is perfectly impermeble to the condensate of thecombustion products and is made of materials corrosion resi-stant.The different spigot joints must be well sealed and equippedwith suitable gaskets, in order to prevent the outlet of conden-sate and the inlet of air.Concerning the cross section and the height of the chimney, itis necessary to make reference to the national and local rulesin force.For the dimensioning follow the instruction in pr EN 13384.In order to prevent, during the operation, the formation of ice,the temperatureof the internal wall of the combustion productevacuation system, in all its length, has not to be below 0°C.For condensation operating conditions of the appliance at theexternal design temperature, it will be necessary to foresee acondensate evacuation system, discharging, according to theinstallation condition, in the boiler condensate tray or inanother dishpan separated from it.

In the construction of the flue duct it is necessary to usematerials resistant to the combustion products, in classW1, according to EN 1443, as stainless steel or plastic cer-tified materials.

As PVDF (polyvinildimethylfluorure) or PPS (polypropylenetransparent simple) certified for this use. Other materials antthicknesses are also autorized provided they can guarantee,at least, equivalent characteristics.

Any contractual or extra-contractual respon-sibility of the supplier, for damages caused bymistakes in the installation and in the use, and,in any case, due to the non respect of the in-structions given by the suplier, is excluded.

28


SuperModulex

440550660770900

Flue gas massflow rate (max)

kg/h693866104012131386

Flue gas mass flow rate Example:SUPERMODULEX 660Flue gas mass flow rate = 1040 Km/hChimney height = 25 mChimney connection Ø = 315 mm

NOTE:the diagram provides indicativevalue

CO levels2 2

d125a

d400a

d315a

d250a

d200a

d160a

d110a

d75a

6

78

910

12

14

161820

30

40

50

60

70

8090

100

120

140

160180200

300

400

500

600

700

800900

1000

1200

1400

4,4

5,96,6

7,48

9

10

12

22

30

37

44

52

596674

89

104

119133148

222

296

370

444

519

593668741

889

1037

3,4

3,94,4

5,05,6

7

8

9

11

17

22

28

34

39

445056

67

78

89100111

167

222

277

333

389

445

555

667

778

0,001

0,0020,003

0,0040,005

0,006

0,007

0,0080,0090,010

0,015

0,020

0,030

0,035

0,040

0,050

0,060

0,070

0,0800,0900,100

0,150

0,200

0,250

0,300

0,350

0,400

0,500

0,600

50,700

9,0

10,812,0

14,4

22

25

293236

54

72

90

108

126

144

180

216

252

288324360

540

720

900

1080

1260

1440

1800

2160

2520

6

78

910

12

14

161820

30

40

50

60

70

8090

100

120

140

160180200

300

400

500

600

700

800900

1000

1200

1400

8%6%

Chimney dimensionDIN 4705

kg/skg/h 10%10 15 20 25 30

5 10 15 20 25 30

Pressure avaibleFlue Gas Temperature

40 Pa40°C

606

Nom

inal

Hea

t inp

ut (

kW)

Nom

inal

Hea

t inp

ut (

kW)

with

CO

leve

l at 1

0%

2

29


In case of more heat request by heating or DHW systems, theboiler starts up and water will be heated by the aluminiumboiler bodyThen the boiler pump will send the water to the mixing bottleand from here to the radiators, according to the heatingsystem chosen.The combustion air is supplied by fans which take it from theboiler room. The combustion air is then pushed into the pre-mixing chamber through a diaphragm.Beyond the diaphragm, the air mixes with gas and suchmixture, passing through the non-return valve, is sent to theburner.Then, on leaving the burner surface, the air/gas mixture igniteselectrically and the resulting combustion gases, after beingtransported (and cooled) through finned sections, enter thecondensate collecting manifold and then are evacuatedthrough the chimney.

Condensatecollectingtray smokemanifold

Control Panel

Burner

Siphon

Fan

IonizationelectrodeCombustion

ChamberH.L. Thermostat

Thermicelement

Gas valve

The MODULEX EXT is made of inter-linked modules; eachmodule is made of:- Combustion Chamber- Burner- Fan- Gas valve- Local NTC ((Negative Temperature Coefficient) sensor

(checks the flow temperature of each aluminium section)- BMM (Burner Modular Manager)- High Limit thermostat- Ignition electrode- Ionization electrode- Air pressure switch

A module is able to supply a maximum power of 110 kW. So,for instance, a boiler model 440 is constituted by 4 modules.Each module has its temperature sensor NTC - NegativeTemperatures Coefficient - that locally checks the temperatureof every single module.The flow temperature at the boiler outlet and the returntemperature at the boiler inlet are controlled by global NTCtemperature sensors.

3.20 - BOILER OPERATION

30


When there is a heat request from the E8 controller or from aBCM (Boiler Cascade Manager), the E8 or BCM calculatesthe necessary output according to the difference between theset temperature (or the temperature calculated by the outercompensator) and the global flow temperature. The numberof thermal elements (each thermal element represents a ma-ximum input of 110 kW) x 100% determines the maximuminput expressed in %.When the input has been determined, the boiler pump (notsupplied by Unical) is set up and the fan of one thermal ele-ment is set in motion at starting speed. The gas valve opensand ignition is to occur within 5 sec. When the ionisation elec-trode detects the flame, the thermal element starts operating.Subsequently other thermal elements are likely to start in thesame way. One of the operation principles for this boiler isletting as many burners as possible operate simultaneouslyat minimum load to reach the maximum efficiency.

For example, if a 4 thermal element boiler is requested tooperate at its max input, this shall be 400% i.e. :

110 kW x 4 thermal elements = 440 kW = 400%.If it is requested to operate at 200% input, thanks to the inputsharing system on the highest number of thermal elements,each thermal element will operate at 50% output i.e. :

200% : 4 moduli = 50 %corrispondente a 100 kW totaliossia 25 kW per ciascun modulo.

Such principle provides clearly efficiencies much higher thanthose obtained in traditional groups of small boilers installedin cascade.When the input shared on each thermal element is less than12 kW, one thermal element after the other is automaticallyexcluded and the remaining input is shared on thermalelements having the smallest number of operation hours (bythe automatic operation-time calculating system).Modulation, i.e. input reduction, is based on the differencebetween the set temperature (or the temperature calculatedby the outer compensator) and the global flow temperature.When no ignition occurs, the ignition device repeats two moretimes the ignition sequence and then puts to lock out positionthe thermal element concerned.

4 thermal elements of 50 kW each working at 50% of the output give = 100 kW = (200%),

i.e. 25 kW / thermal element

0

5

1015

20

2530

3540

kW

4550

5560

10

100

104

% (p.c.i.)

20 5030 4022

109,6109

P (kW)60 70 80 90 100 108

50 % = 54 kW

1 thermalelemets

100 % = 108 kW

54

1 thermalelemets

400% : 200 kW = 200% : X

X = (432x200) : 400 = 216 kW input shared on 4thermal elements

Input shared on 4 thermal elements : total input= 216:432 = 0,5 = 50%

Efficiency of a thermal element working at full capacity108 kW = 103,2 % (in condensation)

Efficiency of a thermal element working at reducedcapacity 54 kW = 106,7 % (in condesation)

Efficiency of a thermal element working at minimumcapacity 22 kW = 108,8 % (in condesation)

All the thermal elements work in parallel at the same ou-tput, equalizing, thus, the C.H. system efficiency to the oneof the thermal element.

1 Thermal element (module) = 108 kW = 100%

4 Thermal elem. = 108 kW x 4 = 432 kW = 400%

31


A

3.22 - ELECTRICAL CONNECTIONS

Regulations in force

The gas and water feeding pipes and the CH system pipescannot be used as ground plates.

Ensure that the above safety electrical requirements subsist;in case of doubt, ask for a professionally qualified technicianto check the appliance’s electrical system.

UNICAL refuses responsibility for any damages arising fromfailure to earth the boiler correctly.

It is necessary that a qualified technician verifies that theelectrical system is adequate to the appliance’s maximumabsorbed power, indicated on the data plate, verifying inparticular that the section of the system’s cables is suitableto the appliance’s maximum absorbed power.

For the appliance’s general electrical supply the use ofadaptors, multiple sockets and/or extension cords is strictlyforbidden.

The use of any power supplied equipment implies theobservance 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 permit children or inexpert people to use the

appliance.

Mains electrical supply connection 230VThe electric connections of the boiler are shown in the sectionnamed “WIRING DIAGRAMS”

A mains supply of 230 V – 50 Hz is required. The wiring to theboiler must be in accordance with the current CEI regulations.

WARNING!We remind you that upstream of the electricalconnection, it will be necessary to foresee aservice relay (NOT SUPPLIED) which, whenthe electrical safety devices (ISPESL)intervene, shuts down the electrical supplyto the on-off fuel valve fitted on the gas supplycircuit, but not to the boiler so as toguarantee the running of the pump and permitthe boiler to cool down.

DANGER!The electrical connections must be carriedout only by a qualified engineer.Before carrying out the connections or anyother operation on the electrical parts,always switch off and disconnect theelectricity supply and ensure yourself that itcannot be accidentally turned on.

It is necessary to fit a double pole switch on the electricalsupply line, having a 3 mm contact separation in both poles,in an easy accessible position in order to make quick andsafe the servicing operations.

The boiler electrical supply (230 V – 50 Hz – single phase) isto be done directly on the three pole plug supplied with theboiler.

WARNING!230 V cables shall be separated from 24 Vones, using the two plastic conduits suppliedwithin the boiler casing L.H. side panel.

32

Instructions for the installer3.23 - FUNCTIONAL WIRING DIAGRAM

Note: The pictures shown on theactual wiring diagram, is purelyindicative.

Smoke pressure switch

Ignition electrodeIonization electrodeMain switchGlobal Flow Temperature Sensor E8Warning lampe for the General Limit Thermostat

Minimum Gas pressure swich

E.ACC 1..8E.RIL 1..8IGKFLTGLPFPG

PV 1..8SLSMGSRSR 1..8SRRTL

Fan pressure swichCondensate level sensor

Flow NTC Temperature sensorLocal Flow NTC Temperature sensorGlobal Return NTC Temperature sensorHigh limit thermostat

Sonda Mandata Globale BCM

TL 1..8TLGVG 1....8TRA. ACC 1..8VM 1..8

Local High limit thermostatGlobal High limit thermostatGas ValveIgnition TransformerModulating Fan

RED

SMG

230 V - 50Hz

1 2 3 4 5 6 7 8 9 10

IIA1A2A3A4A5A6

NL1L1’

M

T1T2

12A7

T3T4

VI12345A8A9A10A11 IV

4

M2 13

n

1 2 3 4IX

LHBUS

1 2 3III

IMP0-10 V

F17F15

31 FBR

1 2VIII

PT1000

F14F131 2V

SPF

F12F11

VFAFKF / SPFVF

F9F8F6F5F3F2F1

FBR

eBUSFA

0-10 V

1 2 IVII

678910 12345

121 NL1L1

M2

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

123Y24567

Y3

123

Jp1123

Y44

DL1 DL2 DL3

1 2 3Y14 5 6

A1

SW1

0-10

V

Mod

bus

- BM

odbu

s - A

PLC /BMS

BCM

eBU

S -

eBU

S +

+ 24

V

PR IG

GREY

PINK

WHITE

WHITE

BLACK

BROWN

BR

OW

N

BLA

CK

RE

D( - )

( - )

( + )

II

I

O1

1a

1b

SE8/BCM

BROWN

WHITE

BLA

CK

BR

OW

N

BLU

E

BLU

E

TLTL1

ARANCIO +

NERO (-)

MARRONE (PWM)

BLU (TACHO)

BLU (N)

MARRONE (L1)

RIL

./RE

G.

ALI

M.

230V

RED

RED

BLACK

WHITE

BLACK

WHITE

BROWN

WHITE

LIG

HT

BLU

E

LIG

HT

BLU

E

LIG

HT

BLU

E

LIG

HT

BLU

E

GIA/VER

1° Module

E.RIL.1

SR1

SRR

SR

WHITE

PG

PF

BIANCO

MARRONE

(3) (1)

1 (nc)

(c 3 )

01

2 3 45

6

789

0 1 23

456

78

9

BLACK

BLACK

ABVT N

L1

J61

J31

BLUEBLUEBLUEBROWNBROWN

J41 BROWN

BROWN

BLACKBLACK

RED

ORANGE

J31

BROWN

BLACKBLUE

J21

BROWN

BROWNBLUE

BLUE IG(IG1)

(IG2)

5L 4L

1N2N

C 2

1RED

1b 1aTLGLTLGF10A

F6.3A

BRO

WN

BLU

E

N L1

KF

On board

1° moduleof

CONTROL E8

CONNECTIONWIRE NEUTRAL (N)

MAIN SUPPLY

SIG

NA

LA

LAR

M

PUM

P B

OIL

ER C

IRCU

IT

RES

ETIN

SER

TB

CM

eBUSremote

(Cascademanager)

CONTROLMODULATION

PUMP EMERGENCY

(*)

SET POINTChoose set point value as indicated

in the table * (IF NECESSARY) andinsert resistence between Y2 (6-7).

(3) (1)

BR

OW

N

WH

ITE

PV1

Ext sensopen

100 K4722

Short circuit

Ω K K

10 K

ΩΩΩ

Set point82°C7160493827

°C°C°C°C°C

(*)

33


0 0 0 0 0 0 0

1 1 1 1 1 1 1

2 2 2 2 2 2 23 3 3 3 3 3 34 4 4 4 4 4 4

5 5 5 5 5 5 5

6 6 6 6 6 6 67 7 7 7 7 7 78 8 8 8 8 8 89 9 9 9 9 9 9

Module 1(Pos 0)

Module 2(Pos 1)

Module 3(Pos 2)

Module 4(Pos 3)

Module 5(Pos 4)

Module 6(Pos 5)

Module 7(Pos 6)

01

2 3 45

6789

Module 8(Pos 7)

Setting of modules selectors

FILTER

BL

UE

BL

AC

K

BL

UE

BR

OW

N

L1 N1 2 3

VM (A)12345

ST 2

3° - 8° MODULES

3° - 8° MODULES

TR.ACC.1E.ACC.1

VG1

TL2...TL8

SR2...SR7

RIL

./RE

G.

ALI

M.

230V

ORANGE +

BLACK (-)

BROWN (PWM)

BLUE (TACHO)

BLUE(N)

BROWN (L1)

BLUE

BROWN

BLUE

BROWN

BLU

E

BR

OW

N

RE

D

WHITE

WHITE

LIG

HT

BLU

E

LIG

HT

BLU

E

E.RIL.2...E.RIL8

PIN

K

GR

EY

PIN

K

GR

EY

BLU

E

BR

OW

N

WHITE

2° - 8° Modules

TR.ACC.2...TR.ACC.8

E.ACC.2...E.ACC.8

VG2...VG8

BLUE

BROWN

BLUE

BROWN

BLU

E

BR

OW

N

RE

D

SL

OR

AN

GE

OR

AN

GE

BROWNWHITE

+ 24

V

eBU

S +

eBU

S -

RE

D

BR

OW

N

BLA

CK

( )

01

2 3 45

6

789

BROWN

BLUE

BROWN

LIGHT BLUE

BL

UE

BR

OW

NY

EL

-GR

EE

N

L1 N1 2 3

VM (A)12345

ST 2

BL

AC

K

BLU

E

YEL-GREEN

1° MODULE

BLACK

BLUE

FILTER

BL

UE

BR

OW

N

YE

L-G

RE

EN

L1 N1 2 3

VM (A)12345

ST 2

END MODULE

BLACK

BLUE

YE

L-G

RE

EN

YEL-GREEN

ConnectionWith BCM

On board

2° moduleof

(3) (1)

BR

OW

N

WH

ITE

PV1

34


3.24 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGINGOn the back side of the E8 regulator there are two terminalblocks, of which one is for the mains (230 V) connections andthe other one is for the low tension connections.

The main controls, necessary for the C.H. system manage-ment and for the boiler control, as well some componentswhich are part of the boiler house, must be connected to theterminal blocks.

Power terminal assignments

Powerterminalblock

Sensorterminalblock

12345678910

II A1 A2 A3 A4 A5 A6

N L1 L1’

M

T1 T2

1 2A7

T3 T4

VI1 2 3 4 5A8 A9 A10 A11IV

4

M21 3

n

1234IX

L HBUS

50 Hz 230 V

123 III

IMP 0-10 V

F17 F15

3 1FBR

12 VIII

PT1000

F14 F1312 V

SPF

F12 F11

VF AF KF / SPF VF

F9 F8 F6 F5 F3 F2 F1

FBR

eBUSFA

0-10 V

12IVII

6 7 8 9 101 2 3 4 5

N L1 L1 1 2 1

Power supply

PIN

K

GR

EY

From BCM

BLU

E

BR

OW

N

BLA

CK

Terminal IIII

A1

A2

A3

A4

A5

A6

NL1

L1’

M

T1T2

67

89

101

23

45

NL1

L11

21

II

N: L1: L2: : : : : :

Neutral conductor, mainsPower supply, unitPower supply to relayheating circuit pump HK 1heating circuit pump HK 2Storage tank charging pump

Mixer open, heating circuit 2Mixer closed, heating circuit 2

12

A7

T3T4

VI

Terminal VI VI

12

34

5A

8A9

A10

A11IV

4

M2

13

n

Terminal IV IV

: :

Mixer open, heating circuit 1Mixer closed, heating circuit 1

Multifunction relayMultifunction relayRecycle pump /

21

43

35

Instructions for the installerSensor terminal assignments

Connection to BCM

For connection to remote control devices

Terminal VII VII

eBUSFA 0-10

V 12

VII Pin 1:

Pin 2: eBUS (FA) or 0-10V output(Ground)

Terminal I I

12

34

56

78

910A

FKF

/ SP

FVF

F9F8

F6F5

F3F2

F1

FBR

I

Pin 4: Pin 5: Pin 6: Pin 7: Pin 8: Pin 9: Pin 10:

Flow sensor, heating circuit 2 (ground)Flow sensor, heating circuit 2Storage tank sensorStorage tank and boiler sensor (ground)Boiler sensorOutdoor sensorOutdoor sensor (ground)

VFVF

SPFSPFKFAFAF

Buffer storage tank low sensorBuf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor)Buf. stor. tank top sensor / FBR heat. circ. 1 (set value)

12

V

SPF

F12

F11

VF

Terminal V V

VFSPF

Pin 1: Flow sensor heating circuit 1 / sensor multifunction 1Pin 2: Service water low sensor / sensor multifunction 2

12

VIII

PT10

00

F14

F13

Terminal VIIIF13F14

Pin 1: Sensor HS2 / Solar 2 / Multifunction relay 3 Pin 2: Sensor Solar 1 / Sensor multifunction relay 4

Terminal III III

12

3III

IMP

0-10 V

F17

F15

31

FBR

Pin 1: Pin 2:

FBR heating circuit 2 (room sensor) / 0-10V IN / LightFBR heating circuit 2 (ground)

F15

F17 Pin 3: FBR heating circuit 2 (set value) / Pulse counter for

12

34

IX

LH

BUS

Morsetto IX IX

H CAN Bus Pin 1 = H (Data)CAN Bus Pin 2 = L (Data)CAN Bus Pin 3 = - (ground, Gnd)CAN Bus Pin 4 = + (12V supply)

L-+

36


VF

1

VFVF

AF

1 2 3

Y44BCM

1-2

*

Safety devices kit

Mixing Header

Filter

Primarysystem pump

Heating Circuit 1

OutsideSensor

SPF

AF

n

VF

not necessary to active 2° circuit**

*

*

3.25 - INSTALLATION EXAMPLES (functional wiring and connections description)

INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE

INSTALLATION OF A BOILER WITH CONNECTION TO TWO DIRECT HEATING ZONES + D.H.W. PRODUCTION

(9-10) outdoor sensor

(4) Pump heating circuit 1

AF (1) Flow sensor heating circuit 1VF

10I (10) Ground outdoor sensor

(4) Collector pump


(6-7) Storage tank sensor

(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump

(5) Re-circulation pump storage tank

(4-5) Flow sensor heating circuit 2

(4) Collector pump

(1) Flow sensor heating circuit 1VF


F Ric. C

VFVF

SPF

12

n

4

VFVF

VF

AF

3

***

Filter

Heating Circuit 1Heating Circuit 2

OutsideSensor

Mixing Header

Safety devices kit

Primarysystem pump

This sensor can also remain unused


37


F Ric. C

VFVF

SPF

12

n

4

VFVF

VF

AF

3

*

Filter


OutsideSensor

Mixing Header

Safety devices kit

Primarysystem pump

*

n

*

INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD.




SPF

AF

VF(4-5) Flow sensor heating circuit 2(1) Flow sensor heating circuit 1VF


(7) Mixer motor heating circuit 2 OPEN(8) Mixer motor heating circuit 2 CLOSE

n(5) Re-circulation pump storage tank

(4) Collector pump

INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION

F Ric. C

VFVF

SPF

12

n

4

VFVF

VF

AF

3

*


Mixing Header

Primarysystem pump

OutsideSensor

Safety devices kit

Filter






SPF

AF

(1) Mixer motor heating circuit 1 OPEN(2) Mixer motor heating circuit 1CLOSE

(5) Re-circulation pump storage tank

VF

(4) Collector pump




necessary for mixing valve control

38


*

Filter

VFVF

12

VFVF

VF

AF

SPF

C F

A115

4

PT1000

2+F14

F122+

3

*


OutsideSensor

Mixing Header

Safety devices kit

Primarysystem pump

INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION BY SOLAR PANELS





SPF

AF

n(5) Re-circulation pump storage tank

VF

V (2) Hot water tank low / Multifunction relay sensor 2

(2) PT1000 sensor solar 1 / Multifunction relay sensor 4

PT1000

For the connection to a solar installation it isnecessary to change some parameters. SeeTable:Expert AREA ⇒ Level SOLAR / MF ⇒ MF 4FUNCTION = ‘’23’’

(4) Collector pump





necessary for mixing valve control

39


F Ric. C

VFVF

SPF

12

n

4

VFVF

VF

AF

Filtro

3

3

KF

* Slave 1

Slave 2

Heating Circuit 1

OutsideSensor

Filter

Heating Circuit 2

Remote E8Master

Mixing Header

Primarysystem pump

Safety devices kit

BoilerSensor

Primarysystem pump

Safety devices kit

INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION

Connections on to the MASTER controllerThe connections of the secondary circuit have to be done onto the MASTER controller.

n (5) Re-circulation pump storage tank

ATTENTION!In this type of installation it is necessary to adjust,in the E8 controller, the parameter BUS-ID HS.

The external regulator E8 (MASTER) has to be set to: ----,the boiler regulators E8 (SLAVES) have to be set to:01 to 08.




(4-5) Flow sensor heating circuit 2 (optional)



SPF

AF

VF



necessary for mixing valve control*

(7-8) Cascade global sensorKF

40


3.26 - CASCADE MANAGER (BCM)

Application:The BCM completes the range of functions offered by theModulex boilers:- ON/OFF alarm control- Control of a modulating header pump with the aim of

significantly increasing efficiency at low heating loads.- Possibility of integrating the Modulex boilers in PLC

controlled boiler plants- Thanks to LonWorks/Modbus protocol converters been

readily available also opens the road to installingModulex boilers in the most advanced BuildingAutomation Systems.

Features:The BCM can be connected to the automation system ofa boiler plant via one of its interfaces:- eBUS: for connection to the series of E8 heating

controllers or to an additional BCM- Modbus: application in PLC controlled boiler plants

The communication protocols enable complete systemmanagement:- Control of heating request: temperature set point and

modulation level- Monitoring of boiler operation and temperature status- Alarm control- Functional parameters setting

Management of the header pump:- Relay command for running a pump at fixed rate- 0÷10 analogical output for control of a modulating pump

Special functionsEmergency: it avoids system shutdown caused by aninterruption in communication with the boiler plant’sautomation system:- Input for “Constant setpoint” request: 55°C, maximum

output 50%- Alarm reset input- Alarm relay signal

Monitor:a BCM connected to a group of heating generatorsmanaged by a E8 heating controller, automatically selectsthe “monitor” mode.In this condition the following services are supplied:- Acquisition of all the operating data and diagnostics via

the Modbus interface.- Control of the modulating pump- Control of the Alarm relays and control of the header

pump- If the E8 malfunctions, the BCM automatically resets

normal boiler operation control and can enable theemergency function previously described.

41


SLAVE 1

SLAVE 2

E8

CanBUS

- Cascade Manager

MASTER

1 for each cascade of boiler

IIA

1A2

A3

NL1

L1’

12

34

IX

LH

BUS

12

3III

IMP

0-10 V

F17

F15

31

FBR

12

VIII

PT10

00

F14

F13

2V

SPF

F12

F11

61

23

45

12

NL1

L1

1 2 3 4IX

LHBUS

E8Cascade Manager

IIA1

A2

A3

NL1

L1’

12

34

IX

LH

BUS

12

3III

IMP

0-10 V

F17

F15

31

FBR

12

VIII

PT10

00

F14

F13

2V

SPF

F12

F11

61

23

45

12

NL1

L1

E8Cascade Manager1

23

Y2 45

67

Y3

12

3

Jp11

23Y4

4DL1

DL2

DL3

12

3Y14

56

A1

SW1

eBUS remoto

BC

M

eBUS -

eBUS +

+ 24 V

eBUS remoto

12

3Y2 4

56

7

Y3

12

3

Jp11

23

Y44D

L1D

L2D

L3

12

3Y14

56

A1

SW1

eBUS remoto

BC

M

eBUS -

eBUS +

+ 24 V

eBUS remoto

BCM (modulex 1)Y2 (3-4)


12

3Y2 4

56

7

Y3

12

3

Jp11

23Y4

4DL1DL2

DL3

12

3Y14

56

A1

SW1

eBUS remoto

BC

M

eBUS -

eBUS +

+ 24 V

eBUS remoto


Cascade Manager

Cascade Manager Dalla 1a caldaia portare il collegamento eBUSlato HOST BCM su eBUS 2a e 3a etc. dopo averposizonato il selettore di questa su 0.

Removedwiring

Removedwiring

Connection for boilers in a cascade arrangement managed by a external E8

WARNING!In this connection the “BUS-ID HS„parameter must be set on the E8 heatingcontroller

The external E8 heating controller (MASTER) must be setto: - - - -,The E8 heating controllers fitted on each boiler (SLAVE)must be set from: 01 to 08.

I = BCM in seriesII = Forniture Position

Switch ‘’C’’ (see pag. 47)in Position II

In this configuration,switch ‚‘‘C‘‘ must bepositionned on II.

42


- Cascade Manager- System Monitor

eBUS Modbus

- System Manager- System Supervisor

Modbus

01

2 3 45

6

789

BCM(Pos 1÷7)

SLAVE 1

01

2 3 45

6

789

BCM(Pos 0)

SLAVE 2

01

2 3 45

6789

BCM(Pos 1)

BCM board PLC/BMS board

eBUS Modbus


Scheda PLC/BMS

Modbus

- Cascade Manager- System Monitor


Scheda BCM

12

3Y2 4

56

7

Y3

12

3

Jp11

23Y4

4DL1

DL2

DL3

12

3Y14

56

A1

SW1

eBUS remoto

BC

M

eBUS -

eBUS +

+ 24 V

eBUS remoto


Connection for boilers in a cascade arrangement connected to an external BCM optional and managed byPLC/BMS (E8 disconnected).

The applications in a cascade arrangementmanaged with an additional BCM require thecorrect boiler address setting (within thecascade formation) via the BCM’s internalSWI selector: 0....7, all different and insequence, (exactly as requested by the singleburner modules).

Switch ‘’C’’ (see pag. 47)in Position 0

(for each boilers)

In this configuration,switch ‚‘‘C‘‘ must bepositionned on 0.

- E8 not wired to the BUS -


43


- System Supervisor- Cascade Manager

Board PLC/BMS

ModbusSLAVE 1

01

2 3 45

6

789

BCM(Pos 0)

SLAVE 2

01 2 3 4

56

789

BCM(Pos 1)

1 for each cascade of boiler

01

2 3 45

6

789

BCM(Pos 1÷7)

System Supervisor

Scheda PLC/BMS

Modbus

Cascade Manager

12

3Y2 4

56

7

Y3

12

3

Jp11

23Y4

4DL1

DL2

DL3

12

3Y14

56

A1

SW1

eBUS remoto

BC

M

eBUS -

eBUS +

+ 24 V

eBUS remoto


Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected)

The applications in a cascade arrangementmanaged with Modbus require the correctboiler address setting (within the cascadeformation) via the BCM’s internal SWIselector: 1....7, all different and in sequence,(exactly as requested by the single burnermodules).

In this configuration,switch ‚‘‘C‘‘ must bepositionned on 0.

Switch ‘’C’’ (see pag. 47)in Position 0

(for each boilers)


44


he BCM board elaborates the data concerning the thermalhead (Ät between primary flow and return and suppliedheat output). When the supplied heat output diminishes,the number of the pump’s revolutions decreases andsubsequently the hourly rate, maintaining the thermal headpractically constant. Thus obtaining a higher efficiency incondensing mode and reducing energy costs.

3.27 - CONFIGURATION WITH A:

The 0÷10 Volt modulation signal is preset to:-3 for minimum speed-10 Volt for maximum speedThese values can be changed accordingto the type of pump fitted. For furtherinformation on the 0÷10 Volt signal, pleasealso refer to the pump’s manual.

MODULATING PUMP

ON-OFF PUMP

MODULATING PUMP

123Y24567

Y3

123

Jp1123

Y44

DL1 DL2 DL3

1 2 3Y14 5 6

A1

SW1

PUMP

BCM

eBU

S -

eBU

S +

+ 24

V

N L1 NL1

P

N

L

POWER TERMINALS E8A

LARM

Mains supply 230 V - 50 Hz

RELAY

Mains supply 230 V - 50 Hz

123Y24567

Y3

123

Jp1123

Y44

DL1 DL2 DL3

1 2 3Y14 5 6

A1

SW1

BCM

eBU

S

-

eBU

S +

+ 2

4 V

NL1

N

TERMINALS 0-10 VINTERFACE

WILO MODULATING PUMP

(-) (0 -

10 V

)

L1

SupplyModulating

Pump

APM

ALA

RM

Mains supply 230 V -50 Hz

45


3.28 - FILLING THE SYSTEM

Warning!Do not mix the CH system’s water with anti-freeze or anti-corrosion solutions using wrongconcentrations! It could cause damage to thewashers and could provoke noise duringnormal boiler operation.UNICAL refuses all liability for injury to persons,animals or damage to property deriving fromnot having respected the above mentionedrecommendations.

For filling-up the system a filling tap has to be foreseen onthe system return pipe.

The filling-up can also be made through the draining tap onthe boiler return manifold.

Never use such a tap to drain the system, since the system dirtcould gather in the boiler and compromise its operation. Thesystem itself shall be equipped with its own draining tap, whosesize depends on the system capacity. The application of afilter on the return pipe to the boiler is advisable.

EXAMPLE OF FILLING-UP SYSTEM MANIFOLD

Filling group with PRV

IMPORTANT NOTEOnce the system has been filled upat the right filling pressure, the fillinggroup has to be closed.

46


B) MINIMUM OUTPUT ADJUSTMENT

- Operate on a burner at minimum power, following the pro-cedure described on page 46 ‘’sweep Function (CASCA-DE MAN 10%)

- Check that the C02 values are within the values indicatedin the table “Burner pressures”

- If necessary correct the value by turning the adjust-ment screw “B” in a CLOCKWISE direction to increasethe value and in an ANTICLOCKWISE direction in or-der to decrease it.

A) REGOLAZIONE ALLA POTENZA MASSIMA

- Remove the cap of the combustion gases sampling point- Connect a suitable C0

2 gas analyser to the sampling point

in the flue outlet terminal.- Operate on a burner at maximum power, following the pro-

cedure described on page 46 ‘’sweep Function (CASCA-DE MAN 100%)

- Check that the C02 values are within the values indicated

in the table “Burner pressures”- If necessary correct the value by turning the adjustment

screw “A” in a CLOCKWISE direction to decrease the va-lue and in an ANTICLOCKWISE direction in order to incre-ase it.

3

12

4

WARNING!Remove the cap 2, fix red cap 3 to the gasoutlet. Insert the CO2 analysis probe 4 onhole of the cap.Measurement. remove the cap and close theoutlet exhaust smoke cap 2.

MAXIMUM OUTPUTADJUSTMENT SCREW MINIMUM OUTPUT

ADJUSTMENTSCREW

3.29 - BURNER ADJUSTMENT

WARNING!All the instructions indicated below are for theexclusive use of qualified UNICAL servicetechnicians or installers.

All the boilers are supplied already calibratedand tested. If it is necessary to change thecalibration due to gas conversion or adaptationto the mains supply system, the gas valve mustbe re-calibrated. (Using service mode function)

47


CO2 levels (%)Gas type Supplypressure

(mbar)min

(rpm)

Startingpower

IG(%)

20

25

37

ØInjectors

(mm)

9

9

9

Gas nat. (G20)

Gas nat. (G25)

Propan (G31)

Fan speed

max(rpm)

1760

1760

1760

6300

6300

6300

50

50

50

min

9,1

9,1

10,2

max

9,3

8,6

10,4

MODULEX440 - 550660 - 770 - 900

Diaphragm

-

-

-

Follow this procedure also for the other bur-ners

If the CO2 percentage is too low, check if the air and smoke

ducts are not obstructed. If they are not obstructed, check if theburner and/or the exchanger (aluminium sections) are wellcleaned.

Check the C02 levels often, especially at low flow rateINJECTORS – PRESSURES

C) COMPLETION OF THE BASICADJUSTMENTS

- Check the C02 values at the minimum and maximum outlet- If necessary make the required adjustments

To ensure correct operation the C02 valueshave to be adjusted with extreme carerespecting the values indicated in the table.

- Close the sampling test point in the flue outlet terminal

Do not force the end switches of theadjusting screw.

In case of gas valve replacement or difficultignition:

Tighten the maximum adjustment screw “A”in a clockwise direction until you arrive tothe abutting end, than slacken for 9 turns.Verify the boiler ignition; if the boiler goesinto lockout slacken the screw “A” again ofone turn, than retry the ignition. If the boilergoes into lockout again, carry out the aboveindicated operations until the boiler islighted.At this point carry out the burner adjustmentas previously indicated.

48

Instructions for the installerSWEEPER MODE

C

BCM

For the adjustment of each individual module it isnecessary to put the switch ‘’ C ‘’, in position I, asshown in the figure. In this way all the modulesare switched OFF and the first module is ignited.To pass to the following modules (after the previousone has been switched OFF) repeat the step 0 - 1of the switch ‘’ C’ as shown in figure.

The function is active for a time of 15 min,after that the planned parameters arerestored.

SW NO XXXX

CASCATA MANU

BOILER 01 - 00%

CHANGE PER CENTVALUE TO 10 %.

BOILER 01 - 10%

VARY THE VALUE

FROM 10 % TO 100%.PER CENT

BOILER 01 - 100%

RELAY TEST

Turnanticlok-wise

Odisplayed

pen the operating flap,

DISPLAY GENERALAfter 2 sec is displayedlevel

DATA/TIME SERVICEPress

to open the level

Before open the operating flapturn clock-wise Shaft encoder,

to symbol

Turnanticlok-wise

Turnclok-wise

Pressto open the level

Turnclok-wise

Pressto open the level

All modules of theboiler running andworking at MINIMUMpower

All modules of theboiler running andworking at MAXIMUMpower

49


C B

BCM

DEFGHI AL1 2

The BCM It avoids system shutdown in case the mainboiler plant’s system E8 5064 management is out ofuse.

A YELLOW LED = Blinking(communication between BMM and BCM) OK

GREEN LED = ON (Active Pump)

RED LED = ON (Failure code detected)

C In position I the plant will operate when requested at “CONSTANT SETPOINT”: 70°C –Max heat output 50%

B Enables burner reset in case of lock-out

F Warning lamp of the thermostatic lockoutfrom TLG

I TLG General Limit Thermostat: when it acts, itcuts the power supply to the boiler, thewarning lamp E lights. To reset, remove thecap and push the reset button.

Note: The switches are positioned underthe front panel.

Note: The emergency function enablesthe boiler’s burners to fire only at 50%and at 50°C in system return. All thesystem’s heating loads, including theheader pump, must be controlledmanually.

Condensate level sensor position

D Idrometer (optional)

E Control Panel E8

G Fuse: 1 = 6.3 A 2 = 10 A

H Main Switch

3.30 - EMERGENCY FUNCTIONS

L Change-over Series/Parallel

0 = Emergency is active or the control ismanaged by PLC or BMS

I = Series connection (the cascade ismanaged by the BCM,

II = Parallel connection condition of forniture

50


3.31 INITIAL LIGHTING

PRELIMIARY CHECKS

The first ignition must be carried out by aqualified technician. Failure to do so couldcause injury to persons, animals or damageto property. UNICAL shall not be held liablefor any injury and/or damage.

Before lighting the boiler check that:

- the boiler installation has been carried out in accordancewith the specific Standards.

- the combustion air inlet and the discharge of the productsof combustion occur in the correct way in accordance tothe specific Standards in force;

- the gas supply system is correctly dimensioned for the boi-ler’s output;

- the boiler’s electrical supply is 230 V - 50 Hz;

- the system has been filled with water (pressure registeredon the gauge 0,8/1 bar with pump not running);

- any of the system’s on-off valves are open;

- the mains supply gas corresponds to the one which theboiler has been calibrated for: otherwise convert the boilerto use the available gas (refer to section: “GAS CONVER-SION”); this operation must be carried out by a qualifiedtechnician in compliance to the regulations in force;

- the gas supply cock is open;

- there are no gas leaks;

- the external mains supply switch is on;

- the boiler system’s safety valve is not blocked and that it isconnected to the sewage system;

- the condensate drain siphon has been filled with waterand that it is connected to the sewage system;

DANGER!Before firing the appliance fill up the siphonthrough the filling hole and check the correctdrainage of the condensate.If the appliance is used with the condensatedrain siphon empty this could causepoisoning caused by the leakage of the fluegasses.

- there are no water leaks;

- all the necessary ventilation conditions and minimum cle-arance distances are guaranteed for subsequent servi-cing in case the boiler is sited in a cupboard compartment.

Information to be passed on to the user

The user of the appliance must be instructed on the useand operation of his boiler and in particular detail:

- Hand over to the end user the booklet: “USER’S INSTRUC-TIONS GUIDE”, as well as all the other literature relative tothe appliance and placed in the envelope contained in thepackaging. The user of the appliance must retain thisliterature for any future reference.

- Inform The user of the importance of the air vents and ofthe flue outlet system, stressing the fact that absolutely noalteration can be made.

- Inform the user regarding the control of the system’s waterpressure and how to restore it to the correct value.

- Explain and demonstrate to The user the correct functionand adjustment of the temperature, thermostats and radia-tors for the economic use of the system.

- Remind the user that in order to comply to the regulationsin force the boiler has to be inspected and serviced regu-larly as indicated by the manufacturer.

- If the appliance is sold or transferred to another owner or ifthe present user moves home and leaves the applianceinstalled, ensure yourself that the manual always followsthe appliance so that it can be consulted by the new ownerand/or installer.

51

Servicing schedule

To ensure the continued safe and efficientoperation of the boiler it is highlyrecommended that it is checked at regularintervals and serviced when necessary, andthat only original spare parts are used.The law in force states that the boiler mustbe serviced annually.

If the boiler is not checked and serviced whennecessary it could cause material andpersonal damages.

For this reason UNICAL recommends that a servicing con-tract should be made with a heating installer.

The regular inspection is useful to determine the actual stateof an appliance and to compare it with an optimum state. Thisis achieved through measurement, control and observation.

The service is necessary to eliminate eventual deviations ofthe actual state from the optimum state. This is normally donethrough the cleaning, the parameters setting and the even-tual replacement of single components subject to mechanicalwear.

The frequency of servicing will be determined by the serviceengineer and will depend on appliance’s state of condition.

4

INSTRUCTIONS FOR SERVICING

To ensure a long life to all your boilercomponents and in order not to alter theconditions of the approved product onlyoriginal UNICAL spare parts must be used.

After having carried out all the necessary maintenance, alwaysfollow these steps:• Switch OFF the main switch• Isolate the boiler from mains via a device having, at least,

a 3 mm in the switch contacts (e.g.: safety devices or powerswitches) and make sure it cannot be switched ON acci-dentally.

• Switch off the gas gate valve upstream the boiler.- If necessary, and in function of the type of work to be carried

out, close any on-off valves fitted on the CH flow and returnpipes, as well as the cold inlet valve.

- Remove the appliance’s front panel.

After maintenance works have been finished, follow the nextsteps:- Open the CH flow and return valves as well as the cold

inlet valve (if previously closed),- Purge and, if necessary, proceed with restoring the heating

system’s pressure until a pressure of 0,8/1 bar is reached.- Open the on-off gas valve.- Reconnect the appliance to the electrical supply and

switch on the mains electrical supply.- Test for gas soundness, on the gas side and on the water

side.- Replace the appliance’s front panel..

SERVICINGSCHEDULE

Relation between the temperature (°C) and the nom.resistance (Ohm) of the heating sensor SR and the returnheating sensor SRR.

T°C 0 1 2 3 4 5 6 7 8 90 32755 31137 29607 28161 26795 25502 24278 23121 22025 20987

10 20003 19072 18189 17351 16557 15803 15088 14410 13765 1315320 12571 12019 11493 10994 10519 10067 9636 9227 8837 846630 8112 7775 7454 7147 6855 6577 6311 6057 5815 558440 5363 5152 4951 4758 4574 4398 4230 4069 3915 376850 3627 3491 3362 3238 3119 3006 2897 2792 2692 259660 2504 2415 2330 2249 2171 2096 2023 1954 1888 182470 1762 1703 1646 1592 1539 1488 1440 1393 1348 130480 1263 1222 1183 1146 1110 1075 1042 1010 979 94990 920 892 865 839 814 790 766 744 722 701

TABLE OF THE RESISTANCE VALUES IN FUNCTION OF THE HEATING SENSOR (SR) AND RETURN HEATING SENSORTEMPERATURE (SRR)

Example: At 25°C, the nominal resistance is 10067 OhmAt 90°C, the nominal resistance is 920 Ohm

52

Servicing schedule

- Act on the two closing hinges (on both sides) to remo-ve the cover

- Remove the screws panel left, right and back side.

- Rotate the screw shown to lift the cover cap

- Rimuovere le 2 viti di fissaggio coperchio

We recommend that periodical service is madeby qualified technical personnel according tothe frequency stated by national rules in force.

As much as the dust present in the air will be sucked insidethe combustion chamber, the smoke side resistance willincrease, which, finally, will result in a reduced heat input(and consequently a reduced output).

efore cleaning the boiler body sections, check the boiler inputand the CO2 percentage (see 3.24).

Note! A reduction of the input can be causedby the obstruction of the evacuation duct orof the air intake. Check, first of all, that thisis not the reason.

If the actual input (with the correct CO2) is within 5% of thevalue shown in the chapter 3.24, the boiler does not need tobe cleaned.The operation then, can be limited to the cleaningof the siphon.

- all panels of the casing.

1st Phase - Disassembly• Switch off power and gas supply and ascertain the gas

cock is well closed.• Remove

53

Servicing schedule

- Sganciare la molla di fissaggio camera ventilatori(lato destro/sinistro).

- Remove the red silicone pipe and then the fans room

- Remove the screws “A”, fixing the burner covers,(with a 13 mm socket or open wrengh)

A

• Screws on thermal elements

54

Servicing schedule

- move up the rear burner block and remove the 2 pins with5 mm hex key to reach the holes ‘’C’’ (left and right).

C

- move up the burners block (Front)

- Remove gas fittings from the gas manifold with flat key36 mm.

- Remove the screws gas collector (left and right side).

- Remove the four screws with a 36 mm socket wrengh,then the gas flange

55

Servicing schedule

2nd phase – Cleaning• Remove from their seat the sealing gaskets and the bur-

ners.• Make a dry-cleaning by blowing compressed air on the “

flame” side of the burner• Visually check the condition of the welds of the metal spon-

ge burner.

The burner sealing gaskets, must be repla-ced at each cleaning of the burner.

• Wash, with a water jet, the combustion chamber: pay atten-tion to not to wet the electrical wiring. During this operationascertain that the condensate evacuation pipe is alwaysfree, so that the water cannot come out from the tray.

• Blow with compressed air in the combustion chamber, inbetween the sections, so that all dirty parts are removedfrom the aluminum protrusions.

• Once the cast aluminum sections have been washed, makesure the condensate evacuation siphon is free: if neces-sary clean it.

• Inspect the flue duct and the smoke chamber.

Compressed air

3rd phase – Reassembly

Reassemble all the components previouslyremoved by following the reverse order sureto tighten the screws of the mixer / fans to thebody, with torque of 13 Nm

CAUTIONFOR EACH OPERATION OF MAINTENANCE‘MUST BE REPLACED THE GASCKETS FOREACH BURNER.

Spare code:

95251632 - GASKETS KIT for BURNER MODULEX EXT 348-900 (5 pz.)

95262961 - BURNER KIT MODULEX EXT 348-900

• Before starting the boiler ascertain that the condensate si-phon is filled with water.

• Before opening the gas cock on the burner manifold makesure the coupling is well tight. To do this, open the gas cockand check the soundness of the coupling using a soap so-lution.

• As soon as a burner is put into operation check immedia-tely the soundness between the gas valve and the relevantpremixing chamber.

• Make the combustion analysis and check the combustionparameters.

• Make sure that all the gas pressure test nipples, previouslyopen, are closed and tight.

• After cleaning the body and / or burners reposition theburners in their seats

• Replace the NEW burner sealing gaskets

DISTRIBUTED BY

Autom

atic Heating P

tyLtd

AB

N 90 446 545 923

51 Assembly Tullamarine Vic 3043 AustraliaPO Box 356 Tullamarine Vic 3043 Australia

+61 3 9330 3300 +61 3 9310 [email protected]

Telephone FacsimileEmailwww.automaticheating.com.au

Automatic Heating Global | Commercial Heating & …...A = Central Heating circuit features 9=(Pn) Nominal output 10 = (Pcond) Condensing nominal output 11 = (Qmax) Nominal heat input

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