Automatic Heating Modulex EXT 440, Modulex EXT 550, Modulex EXT 660, Modulex EXT 770, Modulex EXT 900 Installation And Servicing Instructions

Modulex EXT

440 - 550 - 660 - 770 - 900

Modular Condensing Boiler

Installation and Servicing Instructions

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

CONTENTS

1 GENERAL INFORMATION ................................................................................................................................................................................... 4

1.1 Symbols used in this guide .......................................................................................................................................................................... 4

1.2 Correct use of the appliance ....................................................................................................................................................................... 4

1.3 IInformation to be passed over to the person in charge of the appliance ................................................................................................ 4

1.4 Safety warnings ............................................................................................................................................................................................ 5

1.5 Data badge .................................................................................................................................................................................................... 6

1.6 General warnings ......................................................................................................................................................................................... 7

2 TECHNICAL FEATURES AND DIMENSIONS ..................................................................................................................................................... 8

2.1 Technical features ........................................................................................................................................................................................ 8

2.2 Dimensions ................................................................................................................................................................................................... 9

2.3 Performance data ....................................................................................................................................................................................... 10

2.4 RHS view showing main components ....................................................................................................................................................... 11

3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 12

3.1 General warnings ...................................................................................................................................................................................... 12

3.2 Installation standards ................................................................................................................................................................................ 13

3.3 Packaging .................................................................................................................................................................................................. 14

3.4 Installation .................................................................................................................................................................................................. 16

3.5 Boiler location in a boiler room .................................................................................................................................................................. 17

3.6 Boiler connection ....................................................................................................................................................................................... 17

3.7 Gas connection ......................................................................................................................................................................................... 18

3.8 Connection return and flow system pipes ............................................................................................................................................... 19

3.9 Primary circuit pump or boiler pump ........................................................................................................................................................ 20

3.10 Additional safety and control devices, according to the Italian Law + primary circuit kit ..................................................................... 21

3.11 Wiring diagram for additional safety devices ........................................................................................................................................... 22

3.12 Safety pressure relief valve ..................................................................................................................................................................... 23

3.13 Mixing header filter .................................................................................................................................................................................... 23

3.14 Ballstop valves .......................................................................................................................................................................................... 23

3.15 Boiler freeze protection ............................................................................................................................................................................. 24

3.16 Mixing header and plate heat exchanger ................................................................................................................................................ 24

3.17 Condensing drain ...................................................................................................................................................................................... 25

3.18 Water treatment ......................................................................................................................................................................................... 26

3.19 Flue chimney connection .......................................................................................................................................................................... 27

3.20 Flue manifold connection .......................................................................................................................................................................... 27

3.21 Operation ................................................................................................................................................................................................... 29

3.22 Electrical connections ............................................................................................................................................................................... 31

3.23 Functional wiring diagram......................................................................................................................................................................... 32

3.24 Wiring diagram for connection and managing......................................................................................................................................... 34

3.25 Installation examples (functional wiring and connections description) .................................................................................................. 36

3.26 Cascade manager BCM ........................................................................................................................................................................... 40

Connections for boilers in cascade, controlled by outer compensators ............................................................................................... 43

3.27 Configuration with a modulating pump ..................................................................................................................................................... 44

3.28 Filling the system ...................................................................................................................................................................................... 45

3.29 Burner Adjustment .................................................................................................................................................................................... 46

3.30 Emergency functions ............................................................................................................................................................................... 49

3.31 Initial Lightning ........................................................................................................................................................................................... 50

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

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

General information

GENERAL INFORMATION

1.1 -SYMBOLS USED IN THIS GUIDE

When reading this guide particular care has to be given to the parts marked with the followings symbols:

DANGER! Indicates serious danger for your personal safety and for your life

WARNING! Indicates a potentially dangerous situation for the product and the environment

NOTE! Suggestions for the user

1.2 - CORRECT USE OF THE APPLIANCE

The MODULEX appliance has been designed utilizing today’s heating technology and in compliance with the current safety regulations.However, following an improper use, dangers could arise for the safety and life of the user or of other people, or damage could be caused to the appliance or other objects.The appliance is designed to be used in pumped hot water central heating systems. Any other use of this appliance will be considered improper. UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this case the risk is completely at the user’s responsibility.In order to use the appliance according to 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

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 safe

place 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 absolutely

forbidden 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 correct

pressure.

• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure

the greatest possible fuel economy.

• Remind the user that it is obligatory to carry out a comprehensive service annually and a combustion analysis

every 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 the

appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted by the new owner and/or installer.

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

1.4 -SAFETY W ARNINGS

WARNING! The device should not be used by people with reduced physical, mental and sensory , experience and knowledge. These people must be well-informed and supervised during the work. Children must be supervised 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 and installed in accordance with the current standards and regulations. Failure to correctly install this appliance could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any injury and/or damage.

DANGER!

Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL recommends drawing up a service contract. Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not be held liable.

Modifications to parts connected to the appliance

Do 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 gas leakages).

General information

WARNING!

Indications for appliances operating with propane gas Ensure 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 legally authorized. 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 gas

If 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 substances

Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room where the appliance has been installed.

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 temperature

lower 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.

General information

1.5 - DATA PLATE

CE Marking

The CE marking documents that the boilers satisfy:

- The essential requirements of the Directive regarding gas

appliances (Directive 2009-142 EC)

- The essential requirements of the Directive regarding

electromagnetic 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).

7 8

C D

21 22

LEGEND:

1 = Y ear of CE certification issue

Boiler type

2= 3=Boiler model 4=Number of stars (Directive 92/42/CEE) 5=(S.N°) Serial number 6=P.I.N. code 7=Approved fluing configurations 8=(N0x) N0x class

A = Central Heating circuit features

(Pn) Nominal output

9= 10 = (Pcond) Condensing nominal output 11 = (Qmax) Nominal heat input 12 = (Adjusted Qn) Adjusted for nominal Heat input

(PMS) Max. pressure C.H. system

13 = 14 = (T max) Max. C.H. temperature

B = Domestic Hot Water circuit features

15 = (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 EN

13203-1

18 = (F factor) N°stars based on the quality of water declared

EN 13203-1 19 = (PMW) Max. pressure D.H.W. system 20 = (T max) Max. temperature D.H.W system

C = Electrical features

21 = Electrical power supply 22 = Consumption 23 = Protection grade

D = Countries of destination

24 = Direct and indirect country of destination 25 = Gas family 26 = Supply pressure

E = Factory setting

27 = Adjusted for gas type X 28 = Space for national brands

1.6 - GENERAL WARNINGS

General information

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

of the appliance.

Please read carefully the instructions contained in this manual as they provide important indications regarding the safe installation, use and servicing of this appliance.

Keep this manual in a safe place for future reference.

The installation and servicing must be carried out in accordance with the regulations in force according to the manufacturer’s instructions and by legally competent authorized persons.

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

Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/or damage.

Before carrying out any cleaning or servicing turn off the electrical supply to the boiler by means of the ON/OFF switch and/or by means of the appropriate shutdown devices.

In the event of failure and/or faulty functioning of the appliance, switch off the boiler. Do not attempt to make any repairs: contact qualified technicians.

Any repairs must be carried out by Unical authorized technicians and using only original spare parts. Nonobservance of the above requirement may jeopardize the safety of the appliance.

To guarantee the efficiency and correct functioning of the appliance it is indispensable to have the boiler serviced annually by a qualified person.

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

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

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

This appliance must be used only for the purposes for which it has been expressively designed. Any other use shall be considered incorrect and therefore dangerous

(*).

Do not obstruct the intake/outlet terminal ducts.

Technical features and dimensions

TECHNICAL FEATURES

AND DIMENSIONS

2.1 - TECHNICAL FEATURES

• MODULEX is a compact, gas fired, Low NOx, condensing boiler, made up by one sectional boiler body, This boiler body consists of two or more modules (from 4 to

8), which cannot be separated from each other, being under the same protecting casing, and are set to operate separately or in cascade. These modules are connected to a single smoke exhaust manifold and are controlled by a single microprocessor (BMM), which manages completely the temperatures from the point of view, both operational and safety. This version is suitable for only central heating

CAUTION: These devices are not suitable for the production 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 temperature = 107,2%.

• Efficiency Class:

• Each module, is composed of a combustion chamber, metallic fiber pre-mix burner, modulating fan, gas valve, ignition electrode, flame detection, NTC sensor for management control (BMM), local temperature control and afety thermostat.

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

• Integral, non allergic, synthetic wool insulation.

• Total premix burner, modulating burner with a radiant “metal sponge” (NIT). Premix antechamber combustion. Automatic backflow valve, preventing gas in the place of installation.

• Fully pre-mixed, radiating, modulating, metallic sponge burner, Automatic no return diaphragm for separation from combustion 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 presetting between the requested temperature (or calculated by the outer compensator) and the global flow tem- perature.

• 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 each module to guarantee the best homogeneous use. C) D.H.W. production, via a storage tank loading pump or a three way diverting valve, controlled by a priority sensor through the E 8 heating controller. D) Output check of each module for any calibration and/or assistance 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 boiler plant’s automation system: : (in case of remote control of the 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

5 6 7 8

440 550 660 770 900

• 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

144

2.2 - DIMENSIONS

Technical features and dimensions

287

FRONT VIEW

62,5

LEFT HAND SIDE VIEW

122

RIGHT HAND SIDE VIEW

UPPER VIEW

327

1267

534

235

946

MODULEX

Dimension

No. of Modules Height mm Width ‘’L’’ mm Width ‘’L1’’ mm Depth mm

395

Smoke outlet:

Left side (standard condition) Right side Back side

440

1448 1087 1039

946

550

1448 1355 1307

946

660

1448 1355 1307

946

770

1448 1623 1575

946

900

8 1448 1623 1575

946

Connections

300

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

300

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

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

300

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

300

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

300

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

Technical features and dimensions

2.3 - PERFORMANCE DATA

BOILER TYPE

Appliance category II Nominal Heat Input on P.C.I. Minimum Heat Input on P.C.I.

Qmin

Nominal Output (Tr 60 / Tm 80 °C) Minimum Output (Tr 60 / Tm 80 °C) Nominal Output (Tr 30 / Tm 50 °C) Minimum Output (Tr 30 / Tm 50 °C)

MODULEX

Pn min

Pcond

Pcond min

2H3P

kW kW kW kW kW

kW Efficiency 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 CEE Combustion 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) °C Flue gas mass flow rate (max) kg/h Excess of air λ % (**) CO2 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/h Minimum pressure in CH circuit bar Maximum pressure in CH circuit bar Water content l Gas Consumption Natural gas G 20 (20 mbar) Qn m3/h Gas Consumption Natural gas G 20 (20 mbar) Qmin m3/h Gas Consumption G25 (supply pressure 25 mbar) Qn m Gas Consumption G25 (supply pressure 25 mbar) Qmin m

Gas Consumption G31 (supply pressure 37/50 mbar) Qn kg/h Gas Consumption G31 (supply pressure 37/50 mbar) Qmin kg/h Max. available pressure at the chimney base Pa Condensate production max kg/h

Emissions

CO with 0% of O2 in the flue system ppm NOx with 0% of O2 in the flue system ppm Sound level dBA

Electrical Data

Voltage / Frequency V/Hz Fuse on main supply A (F) Max power absorbed W (***) Insulation degree IP Standby Consumption W

440

432

424,35

20,57

446,93

23,59 98,23

93,5

102,3

107,22

97,7 98,5

0,2

0,1 2,58 46,7

693

24,25

18247

0,5

45,68

2,33

53,13

2,71

33,53

1,71

100

73,4

<95 <30 <49

230/50

626

X5D

550

540

530,44

20,57

552,42

23,59 98,23

93,5

102,3

107,22

97,7 98,5

0,2

0,1 2,53 46,7

866

24,25

22809

0,5

57,10

2,33

66,41

2,71

41,92

1,71

100

91,7

<95 <30 <49

230/50

783

X5D

660

648

636,53

20,57

662,90

23,59 98,23

93,5

102,3

107,22

97,8 98,5

0,2

0,1 2,51 46,7

1040

24,25

27371

0,5

68,52

2,33

79,69

2,71

50,30

1,71

100

110

<95 <30 <49

230/50

940

X5D

770

756

742,62

20,57

773,38

23,59 98,23

93,5

102,3

107,22

97,8 98,5

0,2

0,1 2,58 46,7

1213

24,25

31933

0,5

108

79,94

2,33

92,97

2,71

58,68

1,71

100

128,4

<95 <30 <49

230/50

1096

X5D

900

864

849,05

20,57

873,93

23,59 98,27

93,5 101,15 107,22

4 97,8 98,5

0,2

0,1 2,58 45,8

1386

24,25

36509

0,5

122

91,36

2,33

106,25

2,71

67,07

1,71

100

146,7

<95 <30 <49

230/50

1252

X5D

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

SURES’’

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

cap down.

INJECTORS – PRES

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

Technical features and dimensions

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

GAS PIPE

GAS VALVE

FAN

AUTOMATIC AIR VENT

C.H. FLOW

C.H. RETURN

CONTROLL PA N E L

BURNER COVER

IGNITION ELECTRODE

H. LIMIT THERMOSTAT

BURNER

ALUMINIUM/ SILICON HEAT EXCHANGER

CONDENSATE COLLECTING

TRAYSMOKE MANIFOLD

BOILER FRAME

Min. Depth 100 mm

Smoke outlet on the L.H. side, on R.H. side, on the BACK side

C.H. flow connection on the L.H. side C.H. return connection on the L.H. side Gas connection on the L.H. side

BCM: under the frontal panel

Instructions for the installer

INSTRUCTIONS FOR

THE INSTALLER

3.1 - GENERAL WARNINGS

WARNING! This boiler has to be destined for the use for which it has been expressively designed for. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at a temperature inferior to boiling point at an atmospheric pressure.

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

Before installing the boiler the following points have to be carried out by a competent engineer: a) The whole system should be thoroughly flushed in order to remove any residual dirt or grime which could compromise the correct boiler operation. b) Check that the boiler has been preset for operating with the gas type available. This is verifiable via the indication on the packaging and on the data badge; c) Check that the chimney/flue pipe has an adequate draught,does not have any constrictions, and that no other appliance’s flue outlets have been fitted, unless the chimney is serving more than one heating appliance, according to the specific standards and regulations in force. The connection between the boiler and chimney/flue outlet can be made only after this verification has been carried out.

WARNING! In rooms where there is the presence of aggressive vapours or dust the appliance must operate independently from the air present in the boiler’s location room!

WARNING! The appliance must be installed by a qualified engineer, who complies to the technicalprofessional requirements according to the national applicable law and who, under his own responsibility, guarantees the compliance with the standards according to the latest regulations.

WARNING!

Install the appliance respecting the minimum

clearances for operation and servicing.

The boiler must be connected to a heating system which is compatible to its performances and output.

3.2 - STANDARD CODES FOR

INSTALLATION

Instructions for the installer

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

The installation must be carried out by a competent qualified engineer, whom will assume the responsibility of complying to all the local and/or national regulations published in the official publications, as well as all the applicable codes of practice.

Before installing the appliance please contact the gas supply company.

The installation must be carried in accordance to the codes of practice, the regulations and the requirements hereby indicated which constitute an indicative list, but not a complete one, as these continue to undergo evolve devolpments.

Moreover, the boiler must be installed in accordance to all the regulations regarding the boiler room, the building regulations and the prescriptions regarding central heating plants in force in the country where the boiler is installed.

The appliance must be installed, commissioned and serviced according to the regulations in force. This is also valid for the hydraulic system, the flue outlet system and the boiler location room.

Instructions for the installer

3.3 - PACKING

The boiler MODULEX is delivered assembled and protected by a plastic bag inside a strong cardboard box and fixed on pallet. This allows the boiler to be handled also by forklift. The boiler, with the packaging, can go through a door of 800 mm, whereas, without packaging, it can go through a door of 700 mm.

Remove both straps and finally the cardboard box from above, making sure the product is intact. The packing elements (cardboard box, straps, plastic bags, etc…) shall not be left to

children’s hand since they may be dangerous.

For the removal of the boiler from the pallet it is necessary to 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 bars

frame

- Tie the belts to thearm ‘’ B ‘’; during these operationsact

with 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

440 550 660 770 900

1263 1531 1531 1799 1799

1120 1120 1120 1120 1120

1515 1515 1515 1515 1515

kg 551 kg kg 806 kg kg

BOILER UNLOADING AND PACKAGE REMOVAL

Instructions for the installer

WARNING! Handling with forklift or hoist bands,

T max 50°C/122°F T min

Max. admitted b oilers

Do not turn upside down Do not expose to r ain Fragile Do not expose to sunligh t Do not store at

stacked

temperature: lower than - 5 ° C / 23 °F superior than 50 °C / 122 °F

-5°C/23°F

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

Max. admitted boilers

Do not turn upside down Do not expose to rain Frag ile Do n ot expose to sunlight Do not store at

stacked

Max. admitted bo ilers

Do not turn u pside down Do n ot expose to rain Fragile Do not expose to sunlight Do no t store at

stacked

temperature: lower than - 5 ° C / 23 °F superior than 50 °C / 122 °F

T max 50°C/1 22°F

T min

-5°C/23°F

T max 50°C/122°F T min

-5°C/23°F

Instructions for the installer

3.4 - BOILER LOCATION INSIDE A BOILER HOUSE

Special attention shall be paid to local regulations and laws about boiler houses and particularly to the obligation of keeping minimum clearances and empty space around the boiler. The installation shall be in compliance with all latest regulations and laws about boiler houses, installations of heating and hot-water systems, ventilation, chimneys capable of evacuating the flue gases of condensing boilers and any other applicable requirement.

The boiler can be put on a flat and sufficiently strong base with the same dimensions as the boiler ones and at least 100mm high (see fig. 25), in order to assemble the condensate drain siphon. An alternative to this base may be a 100mm deep well next to the boiler as siphon housing (see fig. 25). After installation the boiler shall be perfectly horizontal and stable, to reduce any possible vibrations or noises.

A > 400 mm B > 400 mm

C = 100 mm D = 500 mm

Sifone

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

3.5 - INSTALLATION

Instructions for the installer

When the appliance is installed on existing systems, ensure yourself that:

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

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

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

- The electrical system has been fitted in compliance to the specific norms and the work has been carried out by a competent person.

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

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

- The expansion vessels assure the total absorption of the dilatation 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 existing heating system:

In case the replacement of an existing boiler in an old system can be programmed, it

out the system with a basic solution. The system must be cleaned 4 weeks before the substitution, with the system firing 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 having first performed what said in the previous paragraph, Do not wash now the system, as residual products, present in the circuit, could lead to system gathering in the boiler body, causing damage. UNICAL recommends contacting a specialised company for water treatment.

Instead, if installing a Modulex boiler in a new system, it is still recommended to thoroughly clean out the system with an adequate product and fit a Y filter with two isolating valves onthe boiler’s return pipe, so that, when necessary, it can be cleaned. This filter will protect the boiler from the dirt coming from the heating system.

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

is necessary to thoroughly clean

3.6 - BOILER CONNECTION

The boiler Modulex leaves the factory predisposed for the hydraulic / gas connection and smoke outlet on the Left side of the boiler.

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

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

G RM

Diaphragm Gaskets

The sealing gasket with diaphragm Ø18 (A) are fitted only in the flow connection seat of the first and last aluminium section of the boiler. The sealing gasket with diaphragm Ø 27 (B) are fitted in the other 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.

Instructions for the installer

3.7 - GAS CONNECTION

The gas supply pipe must be connected to the boiler via the respective pipe connection

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

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

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

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

DANGER!

The gas connection must be carried out by a registered engineer who will have to respect and comply to the regulations in force and to the requirements indicated by the local gas supplier. An incorrect installation could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any injury and/or damage.

R 3” as indicated on page 9.

Before installing the boiler it is recommended to thoroughly clean all the supply piping in order to remove any eventual residual grime which could compromise the boilers correct functioning.

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

the telephone or any other object which can

provoke sparks; b. Open all doors and windows in order to allow fresh air to enter and purify the room; c. Close all gas cocks d. Contact a service engineer, qualified installer or the gas supply company.

As a safety measure against gas leaks, Unical recommends installing a surveillance and protective system made up of a gas leakage detector combined with an on-off selenoid valve on the gas supply line.

1 2 3 4 5 66

1. On-off gas supply valve

2. Double membrane regulator

3. Gas filter

4. Anti-vibrating joint

5. Selenoid valve

6. On-off cock

EXAMPLE OF A GAS SUPPL Y SYSTEM

INSIDE BOILER ROOM

OUTSIDE BOILER ROOM

3.8 - FLOW AND RETURN PIPE CONNEC-

TIONS

Instructions for the installer

The CH flow and return circuits have to be connected to the boiler via the respective connections on page 9.

When determining the size of the CH circuit pipes it is essential to bear in mind the pressure losses induced by any of the system’s components and by the configuration of the same system.

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

WARNING! Before installing the boiler we recommend that the system is flushed out with a suitable product in compliance to the norm UNI-CTI 8065, in order to eliminate any metallic tooling or welding residues, oil and grime which could reach the boiler and affect the proper running of the boiler.

Non-observance of these instructions could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/or damage.

4” M and R as indicated

WARNING! IT IS ABSOLUTEL Y FORBIDDEN TO FIT ON-OFF VAL VES ON THE GENERA TOR TO THE FORE OF THE SAFTEY DEVICES

Ensure yourself that the system’s piping is not used as the earth clamps for the electrical or telephonic system. They are absolutely unsuitable for this use. In a short time this could cause serious damage to the piping, boiler and radiators.

Instructions for the installer

Pressur

e Losse

(m/H)

3.9 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP

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

The following table gives an indication of the pump’s flow rate in function of the Δt of the primary circuit if the installation has a mixing header.

Boiler Model

440 550 660 770

Max water flow rate Demanded in l/h ( t=15 K)

Max water flow rate Demanded in l/h ( t=20 K)

The size of the pumps must be determined by installers or technical engineers according to boiler data and system design.

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

It is recommended to choose a pump with the rate and delivery head at about 2/3 of its characteristic heating curve.

900

24326

30404

18243 22804 27365 31926 36487

36487 42570 48647

6 5,8 5,6 5,4 5,2

5 4,8 4,6 4,4 4,2

4 3,8 3,6 3,4

3,2

3 2,8 2,6 2,4

2,2

2 1,8 1,6 1,4 1,2

1 0,8 0,6 0,4 0,2

4000 6000 8000 100 00 12000 14000 16000 20000 22000 24000

2000

28000 30000 32000 34000 36000 38000 40000 42000 44000 46000 48000 50000 52000 5400018000

WATER FLOW

(l/h)

440 EXT

550 EXT

660 EXT

770 EX T

900 EXT

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 able to guarantee a delivery head of at least 1,8 m/H2O.

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

Instructions for the installer

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

pressure existing in the generator. It must be graduated in

CERTIFICATION OF THE ADDITIONAL SAFETY DEVICES:

DISPOSITIVI DI SICUREZZA

1. On-off gas valve: a device which has the function of cut-

ting off the gas supply when the water temperature reaches the max. predetermined value. The sensible element has to be installed as nearest as possible to the generator (flow pipe) at a distance which has to be < 500 mm and

must not be able to be cut-off.

Not supplied by Unical.

2 Pressure relief valve: it has the function of discharging in

the atmosphere the fluid contained in the generator when this has, for whatever motive, reached the maximum

working pressure. Not supplied by Unical.

2a Visible drain funnel. Not supplied by Unical.

PROTECTIVE DEVICES

10 Overheat thermostat: it has the function of shutting down

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

15 Minimum pressure switch: it has the function of shutting

down the generator In case of low pressure (can be cali-

brated from 0.5 to 1.7 bar). It must be able to be reset

manually.

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

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

“bar” and must have the maximum operating pressure in scale and be equipped with a 3-way valve with the connection for the manometer.

14 Thermometer: it indicates the effective water temperatu-

re contained in the generator. It must be graduated in degrees Celsius with a temperature scale not exceeding 120°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 of

the increase in volume of the system’s water following an increase in temperature; The pressure must not exceed

the safety valve set pressure.

Not supplied by Unical.

8 Y filter

7 Modulating pump ( Not supplied in kit ISPELS)

Mixing bottle (Not supplied in kit ISPELS)

Automatic air vent. Not supplied by Unical

6 Drain cock. Not supplied by Unical.

kit ISPELS

CONTROL DEVICES

11. Pressure indicator with shock absorber tube (12) and pressure gauge holder valve (13): it indicates the effective

181013

1214

MODULEX 440 - 550 - 660 - 770: 00361998

MODULEX 900: 00361999

Instructions for the installer

PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETY DEVICES

MODULEX 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.

3.11 - WIRING DIAGRAM FOR ADDITIONAL SAFETY DEVICES

ON-OFF PUMP

Pump management via E8

to the terminal 4 (A 1 0)

LINE

from the IV connector

Safety devices

kit

RELAY

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

Boile r main s

supply

230 V

LINE

230

PREMO S.

PREMO C.

LINE

MODULATING PUMP

Terminals EXT-MIN

interface WILO

modu la ti ng pu m p

Safety devices

kit

In case of safety devices intervention, the Modulating pump continues to work at the minimum in order to decrease the high temperature

RELAY

Boile r m ain s

supply

230 V

LINE

230

3.12- PRESSURE RELIEF VALVE DRAIN

PIPE

A pressure relief valve must be fitted on the flow pipe, within 0,5 m from the boiler. It must be dimensioned for the capacity of the boiler and must comply to the regulations in force,

Instructions for the installer

Note: Modulex 660 - 770 - 900 need 2 security valve.

WARNING! Please remember that it is forbidden to interpose, between the boiler and the pressure relief valve, any type of cutting-off device. Moreover it is recommended to use cutting-off valves which do not exceed the maximum allowable operating pressure.

WARNING! In correspondence to the heating pressure relief valve foresee the installation of a discharge pipe with a funnel and a siphon which lead to an adequate drainage. The drainage has to be controllable by sight. If this precaution is not made, an eventual intervention of the pressure relief valve could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any injury and/or damage.

3.13 - MIXING HEADER FILTER

UNICAL suggests the installation of a Y filter on the return pipe so that it can be cleaned if necessary. This filter will protect the boiler from the heating system dirt.

VISIBLE DRAIN FUNNEL

SAFETY V ALVE

3.14 - BALLSTOP VALVES

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

WARNING! IT IS NOT ALLOWED TO ISOLATE THE SAFETY DEVICES, as the safety valve and the expansion vessel, FROM THE BOILER.

Secondary

circuit

Instructions for the installer

3.15 - BOILER FREEZE PROTECTION

Should the flow temperature (measured at global flow temperature NTC) decrease under 7°C, the system pump is set up. Shoul temperature 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 protection of the system, a second freeze protection thermostat is necessary to switch on the heating system pump. To protect the C.H. system from freezing when boiler is not in operation 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

3.16 - MIXING HEADER AND PLATE HEAT EXCHANGER

materials present in the system, and mainly with the aluminum.

THIS CAN BE ALLOWED ONLY IF YOU ARE SURE THAT AN ANTIFREEZE SOLUTION HAS BEEN ADDED, IN THE PROPER PERCENTAGE , TO THE C.H. WATER.

WARNING AFTER A LONG INOPERATION PERIOD OF THE BOILER, IN CASE THE BOILER TEMPERATURE IS BELOW 3°C, START THE BOILER.

ABSOLUTELY DO NOT TRY TO

n order to ensure correct boiler operation it is necessary to use 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

Boiler Circuit

Heating System

Circuit

he plate heat exchanger, conveniently dimensioned, has the advantage to keep hydraulically the two circuits (primary and secondary),protecting the boiler heat exchanger water / smo-

ke. allows subsequently, by adding or removing additional plates to adjust the system as needed.

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

Mixing HeaderModulex Ext 440 - 900

cod. 00361997 M = DN 100 - (G 4’’) R = DN 100 - (G 4’’)

See the Unical catalogue and the price list to identify the most convenient mixing header and primary circuit.

Plate Heat exchanger:

High temperature: Boiler Circuit M = 80 °C - R = 65 °C Heating System Circuit M = 70 °C - R = 60 °C

Low Temperature:

Boiler Circuit M = 70 °C - R = 55 °C Heating System Circuit M = 50 °C - R = 40 °C

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

* = G2

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’’)

3.17 - CONDENSATE DRAIN

Instructions for the installer

Discharge of condensate must be:

- Built in order to prevent the escape of gas products of the

combustion in the location or sewer (siphon).

- Dimensioned and constructed as to allow the proper flow

of 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 to be neutralized, neutralisation which can be obtained by mixing the drain water coming from washing maschines, dish washing maschines, etc., which normally have a basic pH.

Avoid the condensate stagnation inside the combustion products evacuation system, (for this reason the evacuation duct must have an inclination toward the drain of at least 30 mm/m (3/8 in. / ft) except the liquid column, inside the condensate siphon, which needs to be filled with water after

installation: its minimum height, when all the fans are in operation, must be at least 25 mm (1 in.).

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

The outlet of the condensate drain pipe will be on the same side of the smoke chamber, passing below the smoke chamber.

The recommended material must be PE (polyethylene) or PPI (polypropylene).

Before commissioning the boiler fill the condensate siphon with water, from the dedicated filling-up plug.

150

PAV I M E N TO DELLA C.T.

* Min. height of the condensate column, with all fans

operating at max. speed, requested by the EN standards.

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

150

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

Instructions for the installer

3.18 - WATER TREATMENT

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

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

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

- lime scale deposit

- corrosions

- deposits

- biological growths (moulds, bacteria, algae, fungi, etc)

The chemical treatment of the network water enables the prevention of these problems and guarantees safe boiler operation and economical advantages, in terms of maintenance and global thermal efficiency.

The chemical analysis of the water enables us to obtain a lot of 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 indicate alkalinity.

The ideal pH value for water in heating systems fitted with aluminium boilers is between 6,5 and 8, with a hardness of 15°F.

In heating systems where the water has a value outside this range, this considerably accelerates the destruction of the protective oxidized layer which naturally develops inside the aluminium bodies: if the pH is below 6, acidity is present, if it is above 8, the water is alkaline or it is caused by an alkaline treatment (for example phosphate or glycol used as an antifreeze) or in several cases it is due to the natural formation of alkaline in the system.

Vice versa, if the pH value is between 6,5 and 8, the aluminium surfaces of the boiler body are passivated and protected from further corrosive attacks.

To minimize corrosion it is essential to use a scale inhibitor, however in order for this to function correctly, the metallic surfaces have to be clean.

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

We recommend that the heating system’s water pH value is systematically controlled (minimum twice a year). In order to do this, it is not necessary to run a chemical analysis in a 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 will be necessary to fit the devices indicated in the figure below

THE CONNECTION MUST BE FITTED ON THE PRIMARY CIRCUIT’S RETURN PIPE DOWNSTREAM OF THE CIRCULATING PUMP

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

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

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

3.19 - CONNECTION TO THE CHIMNEY

Instructions for the installer

In a condensing boiler the smokes are evacuated at a very low temperature (Max about 84°C). Then it is necessary that the chimney is perfectly impermeble to the condensate of the combustion products and is made of materials corrosion resistant. The different spigot joints must be well sealed and equipped with suitable gaskets, in order to prevent the outlet of condensate and the inlet of air. Concerning the cross section and the height of the chimney, it is necessary to make reference to the national and local rules in 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 product evacuation system, in all its length, has not to be below 0°C. For condensation operating conditions of the appliance at the external design temperature, it will be necessary to foresee a condensate evacuation system, discharging, according to the installation condition, in the boiler condensate tray or in another dishpan separated from it.

In the construction of the flue duct it is necessary to use materials resistant to the combustion products, in class W1, according to EN 1443, as stainless steel or plastic certified materials.

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

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

440 550 660 770 900

4 5 6 7 8

300 300 300 300 300

3.20 - FLUE MANIFOLD CONNECTION

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

Smoke plug outlet have to be positionned on the rectilinear lenght into the 1st meter of the boiler

In order to fit the combustion gases sample test nipple, drill a hole Ø 21 mm in the smoke outlet and fit the test nipple following the indicated sequence.

hole

Ø21 mm

Instructions for the installer

Chimney dimension DIN 4705

CO levels

2520

2160

1800

1440 1260 1080

900

kg/skg/h 10% 0,700

0,600

0,500

0,400 0,350 0,300

0,250

778

667

555

445 389 333

277

1037

889

741 668 593

519 444

370

1400

1200

1000

900 800

700 600

500

Flue Gas Temperature Pressure avaible

10 15 20 25 30

d400

d315

40°C 40 Pa

1400

1200

1000

900 800

700 600

500

720 606

540

360 324 288

252 216

180

144 126 108

36 32

29 25

14,4 12,0

10,8

9,0

0,200

0,150

0,100 0,090 0,080

0,070 0,060

0,050

0,040 0,035 0,030

0,020

0,015

0,010 0,009

0,008 0,007

0,006

0,005 0,004

0,003 0,002

0,001

222

167

111 100

5,6 5,0

4,4 3,9

3,4

Nominal Heat input (kW)

89 78 67

56 50

44 39 34

296

400

300

222

148

200

133

180

119

160

104

140

120

100

7,4 6,6

5,9 4,4

18 16

9 8

7 6

51015202530

d75

9 8

d200

d160

d125

d110

d250

400

300

200 180 160

140 120

100

90 80 70

20 18

16 14

9 8

7 6

Nominal Heat input (kW) with CO level at 10%

Flue gas mass flow rate

SuperModulex

440 550 660 770 900

Flue gas mass flow rate (max)

kg/h

693

866 1040 1213 1386

Example: SUPERMODULEX 660 Flue gas mass flow rate = 1040 Km/h Chimney height = 25 m Chimney connection Ø = 315 mm

NOTE: the diagram provides indicative value

3.20 - BOILER OPERATION

Instructions for the installer

The MODULEX EXT is made of inter-linked modules; each module 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 - Negative T emperatures Coef ficient - that locally checks the temperature of every single module. The flow temperature at the boiler outlet and the return temperature at the boiler inlet are controlled by global NTC temperature sensors.

Gas valve

In case of more heat request by heating or DHW systems, the boiler starts up and water will be heated by the aluminium boiler body Then the boiler pump will send the water to the mixing bottle and from here to the radiators, according to the heating system chosen. The combustion air is supplied by fans which take it from the boiler room. The combustion air is then pushed into the premixing chamber through a diaphragm. Beyond the diaphragm, the air mixes with gas and such mixture, passing through the non-return valve, is sent to the burner. Then, on leaving the burner surface, the air/gas mixture ignites electrically and the resulting combustion gases, after being transported (and cooled) through finned sections, enter the condensate collecting manifold and then are evacuated through the chimney.

Control Panel

Fan

Combustion Chamber

Burner

Ionization electrode

H.L. Thermostat

Thermic element

Condensate collectin tray smoke manifold

Siphon

Instructions for the installer

When there is a heat request from the E8 controller or from a BCM (Boiler Cascade Manager), the E8 or BCM calculates the necessary output according to the difference between the set temperature (or the temperature calculated by the outer compensator) and the global flow temperature. The number of thermal elements (each thermal element represents a maximum input of 110 kW) x 100% determines the maximum input expressed in %. When the input has been determined, the boiler pump (not supplied by Unical) is set up and the fan of one thermal element is set in motion at starting speed. The gas valve opens and ignition is to occur within 5 sec. When the ionisation electrode detects the flame, the thermal element starts operating. Subsequently other thermal elements are likely to start in the same way. One of the operation principles for this boiler is letting as many burners as possible operate simultaneously at minimum load to reach the maximum efficiency.

For example, if a 4 thermal element boiler is requested to operate 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 input sharing 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 totali ossia 25 kW per ciascun modulo.

Such principle provides clearly efficiencies much higher than those obtained in traditional groups of small boilers installed in cascade. When the input shared on each thermal element is less than 12 kW, one thermal element after the other is automatically excluded and the remaining input is shared on thermal elements having the smallest number of operation hours (by the automatic operation-time calculating system). Modulation, i.e. input reduction, is based on the difference between the set temperature (or the temperature calculated by the outer compensator) and the global flow temperature. When no ignition occurs, the ignition device repeats two more times the ignition sequence and then puts to lock out position the thermal element concerned.

% (p.c.i.)

109,6 109

104

100

4 thermal elements of 50 kW each working

at 50% of the output give = 100 kW = (200%),

i.e. 25 kW / thermal element

55 50 45

40 35 30

25 20 15 10

5 0

1 thermal

elemets

50 % = 54 kW

1 thermal

elemets

100 % = 108 kW

(kW)

108

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

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

400% : 200 kW = 200% : X

60 70 80 90 100

Efficiency of a thermal element working at full capacity 108 kW = 103,2 % (in condensation)

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

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

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

thermal elements

Input shared on 4 thermal elements : total input

All the thermal elements work in parallel at the same output, equalizing, thus, the C.H. system efficiency to the one of the thermal element.

= 216:432 = 0,5 = 50%

Instructions for the installer

3.22 - ELECTRICAL CONNECTIONS

Regulations in force

The gas and water feeding pipes and the CH system pipes cannot be used as ground plates.

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

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

It is necessary that a qualified technician verifies that the electrical system is adequate to the appliance’s maximum absorbed power, indicated on the data plate, verifying in particular that the section of the system’s cables is suitable to the appliance’s maximum absorbed power.

For the appliance’s general electrical supply the use of adaptors, multiple sockets and/or extension cords is strictly forbidden.

The use of any power supplied equipment implies the observance of several fundamental rules, such as:

- Do not touch the appliance with any wet part of your body and/or barefooted;

- Do not pull the supply cables

- Do not permit children or inexpert people to use the

appliance.

Mains electrical supply connection 230V

The electric connections of the boiler are shown in the section named “WIRING DIAGRAMS”

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

WARNING! We remind you that upstream of the electrical connection, it will be necessary to foresee a service relay (NOT SUPPLIED) which, when the electrical safety devices (ISPESL) intervene, shuts down the electrical supply to the on-off fuel valve fitted on the gas supply circuit, but not to the boiler so as to guarantee the running of the pump and permit the boiler to cool down.

DANGER! The electrical connections must be carried out only by a qualified engineer. Before carrying out the connections or any other operation on the electrical parts, always switch off and disconnect the electricity supply and ensure yourself that it cannot be accidentally turned on.

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

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

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

Instructions for the installer

3.23 - FUNCTIONAL WIRING DIAGRAM

Note: The pictures shown on the actual wiring diagram, is purely indicative.

PINK

GREY

12345678910

VII

0-10 V eBUS

CONTROL E8

J21

A B

NL1

BLUE

BROWN

F6 F5 F3 F2 F1

FBR

T3 T 4

21 3

A8 A9 A10 A11

12345

CONNECTION WIRE NEUTRAL (N)

(IG1)

(IG2)

BLACK BLACK

1b 1a

BROWN BLUE BROWN BLUE

BLACK BLUE BROWN

BROWN RED BLACK BLACK ORANGE BROWN

BLUE BLUE BLUE BROWN BROWN

F9 F8

AF KF / SPF

T1 T2

BLUE

BLUE BLUE

BLUE

1N2N

RED

F12 F1 1

SPF

67891012345

12 1NL1L1

TLG

LTLG F10A

F6.3A

III

VIII

F14 F13

0-10 V

PT1000

NL1L1’

A1 A2 A3 A4 A5 A6

BLUE

BROWN

BLACK

F17 F1 5

IMP

BUS

FBR

BLUE

Choose set point value as indicated

in the table * (IF NECESSARY) and

insert resistence between Y2 (6-7).

SE8/BCM

SRR

SR1

BROWN

WHITE

EMERGENCY

SET POINT

BLACK

WHITE

RED

BLACK

WHITE

(1)

CON TROL

MODULATION

(*)

BROWN

WHITE

(3)

PUMP

( - )

BROWN

eBUS

remote (Cascade manager)

0-10 V

+ 24 V

123

RED

WHITE

(1)

(*)

Ω Ω Ω Ω

SMG

Set point

82°C 71

°C

1° Module

Ext sens

open

PUMP

BOILER CIRCUIT

123Y44

SW1

100 K

22 10 K

Short circuit

RESET

INSERT

BCM

WHITE

BROWN

BCM

BLACK

RED

ALIM.

On board

1° module

SIGNAL

ALARM

DL1 DL2 DL3

GIA/VER BLU (N) MARRONE (L1)

230V

NERO (-) BLU (TACHO) MARRONE (PWM) ARANCIO +

RIL./REG.

PLC /

BMS

Modbus - B

Modbus - A

( - )

( + )

4567

Jp1

eBUS -

eBUS +

456

WHITE

BLACK

BROWN

1 (nc)

(c 3 )

MARRONE

BIANCO

LIGHT BLUE

MAIN SUPPLY

230 V - 50Hz

TLTL1

PV1

WHITE

E.RIL.1

E.ACC 1..8

Ignit ion e lectrode

E.RIL 1..8

Ionization electrode

Main switch

Global Flow Temperature Sensor E8

LTGL

Warning lampe for the General Limit Thermostat

Smoke pressure switch

Minimum Gas pressure swich

Fan pressure swich

PV 1..8

Condensate level sensor

Sonda Mandata Globale BCM

SMG SR

Flow NTC Temperature sensor

SR 1..8

Local Flow NTC Te mp er ature sensor

SRR

Global Return NTC Temperature sensor

High limit thermostat

TL 1..8 TLG

VG 1....8

TRA. ACC 1..8 VM 1..8

Local High limit thermostat Global High limit thermostat Gas Valve Ignition Transformer Modula t in g Fan

Instructions for the installer

1° MODULE

VM (A)

12345

ST 2

123

BLUE

BROWN

YEL-GREEN

BROWN YEL-GREEN LIGHT BLUE

BROWN

BLUE

VM (A)

12345

ST 2

123

YEL-GREEN

BLUE

BROWN

FILTER

BLACK

BLUE

BLACK

BLUE

BLACK

( )

END MODULE

ST 2

123

FILTER

BLACK

BLUE

BROWN

M (A)

YEL-GREEN

12345

BLUE

3° - 8° MODULES

YEL-GREEN

BLUE(N) BROWN (L1 )

ALIM.

230V

BLACK (- ) BLUE (TACHO) BROWN (PWM) ORANGE +

RIL./REG.

PINK

GREY

PINK

RED

BROWN

BLACK

GREY

+ 24 V

eBUS +

Connection

With BCM

BLUE

BROWN

BLUE

BROWN

BLUE

BROWN

eBUS -

E.ACC.1

VG1

RED

SR2...SR7

TR.ACC.1

On board

2° module

WHITE

BROWN WHITE

ORANGE

WHITE

BROWN

(3)

(1)

LIGHT BLUE

2° - 8° Modules

BLUE

BROWN

BLUE

BROWN

BLUE

BROWN

VG2...VG8

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

RED

BLUE

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

TL2...TL8

PV1

WHITE

E.RIL.2...E.RIL8

Module 1

(Pos 0)

Setting of modules selectors

Module 2

(Pos 1)

Module 3

(Pos 2)

Module 4

(Pos 3)

Module 5

(Pos 4)

Module 6

(Pos 5)

Module 7

(Pos 6)

Module 8

(Pos 7)

3° - 8° MODULES

Instructions for the installer

3.24 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGING

On the back side of the E8 regulator there are two terminal blocks, of which one is for the mains (230 V) connections and the other one is for the low tension connections.

Power supply

BROWN

BLUE

Power

NL1L112 1

terminal block

The main controls, necessary for the C.H. system management and for the boiler control, as well some components which are part of the boiler house, must be connected to the terminal blocks.

BLACK

67891012345

A1 A2 A3 A4 A5 A6

12345

A8 A9 A10 A11

21 3

Sensor terminal block

Power terminal assignments

Terminal II

NL1L1’

T1 T2

A1 A2 A3 A4 A5 A6

67891012345

NL1L112 1

Neutral conductor, mains

Power supply, unit

L1: L2:

Power supply to relay

heating circuit pump HK 1

heating circuit pump HK 2

Storage tank charging pump

Mixer open, heating circuit 2

Mixer closed, heating circuit 2

50 Hz 230 V

BUS

FBR

IMP

0-10 V

F17 F15

III

L1 L1’

PT1000

F14 F13

T1 T2

T3 T4

SPF

F12 F11

III

AF KF / SPF

F9 F8 F6 F5 F3 F2 F1

FBR

eBUS 0-10 V

12345678910

GREY

From BCM

PINK

Te rminal VI

T3 T4

Terminal IV

A8 A9

12345

21 3

A10 A11

Mixer open, heating circuit 1

Mixer closed, heating circuit 1

Multifunction relay

Multifunction relayRecycle pump /

1 2

3 4

Sensor terminal assignments

Instructions for the installer

Terminal VII

VII

eBUS

0-10 V

Terminal I

12345678910

FBR

F9 F8 F6 F5 F3 F2 F1

AF KF / SPF

Terminal V

SPF

F12 F11

T e r m inal VIII

VIII

PT1000

F14 F 13

VII

Connection to BCM

Pin 1: Pin 2:

Pin 4:

Pin 5:

SPF

Pin 6:

SPF

Pin 7:

Pin 8:

Pin 9:

Pin 10:

SPF

F13 F14

eBUS (FA) or 0-10V output (Ground)

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

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

Outdoor sensor (ground)

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

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

T e r m in a l III

0-10 V

FBR

III

IMP

F17 F15

Morsetto IX

1234

BUS

III

123

F15

Pin 1: Pin 2:

F17

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

For connection to remote control devices

CAN Bus Pin 1 = H (Data) CAN Bus Pin 2 = L (Data)

CAN Bus Pin 3 = - (ground, Gnd)

CAN Bus Pin 4 = + (12V supply)

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

Instructions for the installer

3.25 - INSTALLATION EXAMPLES (functional wiring and connections description)

INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE

Heating Circuit 1

(9-10) outdoor sensor

(4) Pump heating circuit 1

(4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

This sensor can also remain unused

Outside Sensor

Safety devices kit

Mixing Header

1-2

123Y44

BCM

Primary system pump

Filter

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

This sensor can also remain unused

F Ric. C

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Heating Circuit 2

SPF

Heating Circuit 1

(4-5) Flow sensor heating circuit 2

not necessary to active 2° circuit

SPF

(6-7) Storage tank sensor (9-10) outdoor sensor

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

(5) Re-circulation pump storage tank

(4) Collector pump

Mixing Header

Outside Sensor

Safety devices kit

Primary system pump

Filter

Instructions for the installer

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

This sensor can also remain unused

F Ric.

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Heating Circuit 2

SPF

Heating Circuit 1

(4-5) Flow sensor heating circuit 2

SPF

(6-7) Storage tank sensor

(9-10) outdoor sensor

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

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

(5) Re-circulation pump storage tank

(4) Collector pump

Outside Sensor

Safety devices kit

Filter

Primary system pump

VFVF

Mixing Header

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

necessary for mixing valve control

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

F Ric.

Heatin

Circuit 2

Heatin

Circuit 1

(4-5) Flow sensor heating circuit 2

SPF

(6-7) Storage tank sensor

(9-10) outdoor sensor

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

SPF

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

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

Mixing Header

(5) Re-circulation pump storage tank

(4) Collector pump

Outside Sensor

devices kit

Safet

Filter

Primary system pump

Instructions for the installer

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

necessary for mixing valve control

(4-5) Flow sensor heating circuit 2

SPF

(6-7) Storage tank sensor

(9-10) outdoor sensor (4) Pump heating circuit 1

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

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

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

(5) Re-circulation pump storage tank

(4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

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

PT1000

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

PT1000

F14

A11

F12

SPF

Heating Circuit 2

Heating Circuit 1

Outside Sensor

Safety device s kit

Mixing Header

Primary system pump

Filter

For the connection to a solar installation it is necessary to change some parameters. See Table:

Expert AREA ⇒ Level SOLAR / MF ⇒ MF 4 FUNCTION = ‘’23’’

Instructions for the installer

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

F Ric.

Circuit 1

Heating Circuit 2

SPF

Heatin

Outside Sensor

VFVF

Mixing Header

Boiler Sensor

Primary system pump

Safet

devices kit

Filtro

devices kit

Filter

Remote E8 Master

Slave 1

Slave 2

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.

Connections on to the MASTER controller

The connections of the secondary circuit have to be done on to the MASTER controller.

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

SPF

(6-7) Storage tank sensor

(7-8) Cascade global sensor

(9-10) outdoor sensor

(4) Pump heating circuit 1 (5) Pump heating circuit 2

(6) Cylinder charging pump (7) Mixer motor heating circuit 2 OPEN (8) Mixer motor heating circuit 2 CLOSE

(1) Mixer motor heating circuit 1 OPEN

(2) Mixer motor heating circuit 1CLOSE

(5) Re-circulation pump storage tank

necessary for mixing valve control

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Instructions for the installer

3.26 - CASCADE MANAGER (BCM)

Application:

The BCM completes the range of functions offered by the Modulex 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 installing Modulex boilers in the most advanced Building Automation Systems.

Features: The BCM can be connected to the automation system of a 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 system management:

- Control of heating request: temperature set point and modulation level

- Monitoring of boiler operation and temperature status

- Alarm control

- Functional parameters setting

Special functions

Emergency: it avoids system shutdown caused by an interruption in communication with the boiler plant’s automation 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 generators managed by a E8 heating controller, automatically selects the “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 the emergency function previously described.

Management of the header pump:

- Relay command for running a pump at fixed rate

- 0÷10 analogical output for control of a modulating pump

Instructions for the installer

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

SLAVE 1

BCM (modulex 1)

Y2 (3-4)

+ 24 V

eBUS eBUS +

456

BCM

DL1 DL2

SW1

DL3

BCM (modulex 2)

Y2 (3-4)

123

+ 24 V

eBUS -

eBUS +

456

BCM

DL1 DL2 DL3

SW1

BCM (modulex 3)

Y2 (3-4)

123

+ 24 V

eBUS -

eBUS +

456

BCM

DL1 DL 2

SW1

DL3

CanBUS

MASTER

1 for each cascade of boiler

- Cascade Manager

Switch ‘’C’’ (see pag. 47)

in Position II

SLAVE 2

I = BCM in series II = Forniture Position

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

4567

eBUS remoto eBUS remoto

123

Jp1

123

4 3

Jp1

eBUS remoto

45 3

eBUS remoto

Removed

Cascade Manager

wiring

123

Cascade Manager

612345

12NL1L1

A1 A2 A3

612345

12NL1L1

A1 A2 A3

SPF

F12F11

VIII

PT1000

F14F13

123

L1 L1’

0-10 V

III

FBR

IMP

F17 F15

234

BUS

1234

BUS

SPF

F12 F11

VIII

PT1000

F14F13

123

L1 L1’

0-10 V

III

FBR

IMP

F17 F15

234

BUS

Cascade Manager

WARNING!

In this connection the “BUS-ID HS„ parameter must be set on the E8 heating controller

Jp1

eBUS remoto

Removed wiring

123

4 3

Cascade Manager

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

Dalla 1a caldaia portare il collegamento eBUS lato HOST BCM su eBUS 2a e 3a etc. dopo aver posizonato il selettore di questa su 0.

Instructions for the installer

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

SLAVE 1

BCM

(Pos 0)

SLAVE 2

BCM

(Pos 1)

BCM board

eBUS

- Cascade Manager

- System Monito r

Modbus

BCM

(Pos 1÷7)

PLC/BMS board

Modbus

- System Manager

- System Supervisor

Switch ‘’C’’ (see pag. 47)

in Position 0

(for each boilers)

I = BCM in series II = Forniture Position

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

- E8 not wired to the BUS -

SW1

+ 24 V

eBUS eBUS +

456

The applications in a cascade arrangement managed with an additional BCM require the correct boiler address setting (within the cascade formation) via the BCM’s internal

SWI selector: 0....7, all different and in

sequence, (exactly as requested by the single burner modules).

BCM (modulex 2)

Y2 (3-4)

- Cascade Manager

7 6

45 3

Jp1

BCM

DL1 DL2 DL3

123

eBUS remoto eBUS remoto

123

- System Monitor

Scheda BCM

eBUS

Modbus

- System Manager

- System Supervisor

Scheda PLC/BMS

Modbus

- System Manager stem Supervisor

- S

Instructions for the installer

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

Board PLC/BMS

SLAVE 1

BCM

(Pos 0)

Modbus

1 for each c ascade of bo iler

- System Superv isor

- Cascade M anager

BCM

(Pos 1÷7)

Switch ‘’C’’ (see pag. 47)

in Position 0

(for each boilers)

+ 24 V

eBUS eBUS +

456

SLAVE 2

BCM

(Pos 1)

I = BCM in series II = Forniture Position

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

The applications in a cascade arrangement managed with Modbus require the correct boiler address setting (within the cascade formation) via the BCM’s internal SWI

selector: 1....7, all different and in sequence,

(exactly as requested by the single burner modules).

BCM (modulex 2)

Y2 (1-2)

System Supervisor

45 3

BCM

Jp1

eBUS remoto eBUS remoto

Cascade Manager

Scheda PLC/BMS

Modbus

DL1 DL2 DL3

SW1

123

Instructions for the installer

3.27 - CONFIGURATION WITH A:

MODULATING PUMP

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

The 0÷10 Volt modulation signal is preset to:

-3 for minimum speed

-10 Volt for maximum speed

These values can be changed according to the type of pump fitted. For further information on the 0÷10 Volt signal, please also refer to the pump’s manual.

TERMINALS 0-10 V

INTERFACE

WILO MOD U LATING PUMP

(-)

(0 - 10 V)

+ 24 V

eBUS -

eBUS +

123

MODULATING PUMP

ALARM

123Y24567

456

Jp1

BCM

DL1 DL2 DL3

Mains supp ly 230 V -50 Hz

SW1

APM

Supply

Modulating

Pump

POWER TERMINALS E8

4567

+ 24 V

eBUS -

eBUS +

456

123

ON-OFF PUMP

Mains supply 230 V - 50 Hz

ALARM

123

Jp1

BCM

DL1 DL2 DL3

Mains supply 230 V - 50 Hz

RELAY

SW1

PUMP

3.28 - FILLING THE SYSTEM

Instructions for the installer

Warning!

Do not mix the CH system’s water with antifreeze or anti-corrosion solutions using wrong concentrations! It could cause damage to the washers and could provoke noise during normal boiler operation. UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations.

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

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

EXAMPLE OF FILLING-UP SYSTEM MANIFOLD

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

Filling group with PRV

IMPORT ANT NOTE Once the system has been filled up at the right filling pressure, the filling group has to be closed.

Instructions for the installer

3.29 - BURNER ADJUSTMENT

WARNING!

All the instructions indicated below are for the exclusive use of qualified UNICAL service technicians or installers.

All the boilers are supplied already calibrated and tested. If it is necessary to change the calibration due to gas conversion or adaptation to the mains supply system, the gas valve must be re-calibrated. (Using service mode function)

A) REGOLAZIONE ALLA POTENZA MASSIMA

- Remove the cap of the combustion gases sampling point

- Connect a suitable C02 gas analyser to the sampling point in the flue outlet terminal.

- Operate on a burner at maximum power, following the procedure described on page 46 ‘’sweep Function (CASCADE 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 value and in an ANTICLOCKWISE direction in order to increase it.

WARNING! Remove the cap 2, fix red cap 3 to the gas

outlet. Insert the CO2 analysis probe 4 on hole of the cap. Measurement. remove the cap and close the outlet exhaust smoke cap 2.

B) MINIMUM OUTPUT ADJUSTMENT

- Operate on a burner at minimum power, following the procedure described on page 46 ‘’sweep Function (CASCADE MAN 10%)

- Check that the C02 values are within the values indicated

in the table “Burner pressures”

- If necessary correct the value by turning the adjust-

ment screw “B” in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrease it.

MAXIMUM OUTPUT ADJUSTMENT SCREW

MINIMUM OUTPUT ADJUSTMENT SCREW

Instructions for the installer

Follow this procedure also for the other burners

If the CO2 percentage is too low, check if the air and smoke ducts are not obstructed. If they are not obstructed, check if the burner and/or the exchanger (aluminium sections) are well cleaned.

C) COMPLETION OF THE BASIC

ADJUSTMENTS

- Check the C0

- If necessary make the required adjustments

- Close the sampling test point in the flue outlet terminal

values at the minimum and maximum outlet

To ensure correct operation the C0 have to be adjusted with extreme care

values

respecting the values indicated in the table.

Do not force the end switches of the adjusting screw.

In case of gas valve replacement or difficult ignition:

Tighten the maximum adjustment screw “A” in a clockwise direction until you arrive to the abutting end, than slacken for 9 turns. Verify the boiler ignition; if the boiler goes into lockout slacken the screw “A” again of one turn, than retry the ignition. If the boiler goes into lockout again, carry out the above indicated operations until the boiler is lighted. At this point carry out the burner adjustment as previously indicated.

INJECTORS – PRESSURES

Gas type Supply

MODULEX 440 - 550 660 - 770 - 900

Gas nat. (G20) Gas nat. (G25) Propan (G31)

pressure

(mbar)

20 25 37

Injectors

(mm)

9 9 9

Check the C0

Diaphragm

levels often, especially at low flow rate

Fan speed

min

(rpm)

1760 1760 1760

max

(rpm)

6300 6300 6300

CO2 levels (%)

max

min

9,1 9,1

10,2

9,3 8,6

10,4

Starting

power

(%)

50 50 50

Instructions for the installer

SWEEPER MODE

Before open the operating flap turn clock-wise Shaft encoder,

to symbol

pen the operating flap,

displayed

DISPLAY

RELAY TEST

Turn

clok-wise

Turn

anticlok-wise

GENERAL

Press

to open

the le v e l

After 2 sec is displayed level

SW NO XXXX

CA SC ATA MANU

DATA/TIME

clok-wise

BOILER 01 - 00%

Turn

anticlok-wise

Press

to open

the level

Turn

SERVICE

Press to open the level

CHANGE PER C EN T VALUE TO 10 %.

BOILER 01 - 10%

VA R Y THE VALU E PER CENT FROM 10 % TO 100%.

BOILER 01 - 100%

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

All modules of the boiler running and working at MINIMUM power

All modules of the boiler running and working at MAXIMUM power

For the adjustment of each individual module it is necessary to put the switch ‘’ C ‘’, in position I, as shown in the figure. In this way all the modules are switched OFF and the first module is ignited. T o pass to the following modules (after the previous one has been switched OFF) repeat the step 0 - 1 of the switch ‘’ C’ as shown in figure.

BCM

3.30 - EMERGENCY FUNCTIONS

Instructions for the installer

The BCM It avoids system shutdown in case the main boiler plant’s system E8 5064 management is out of use.

A YELLOW LED = Blinking

(communication between BMM and BCM) OK

GREEN LED = ON (Active Pump)

EFGH

L Change-over Series/Parallel

0 = Emergency is active or the control is

managed by PLC or BMS

I = Series connection (the cascade is

managed by the BCM,

II = Parallel connection condition of for

niture

C B

BCM

RED LED = ON (Failure code detected)

B Enables burner reset in case of lock-out

C In position I the plant will operate when reque

sted at “CONSTANT SETPOINT”: 70°C – Max heat output 50%

D Idrometer (optional)

E Control Panel E8

F Warning lamp of the thermostatic lockout

from TLG

G Fuse: 1 = 6.3 A 2 = 10 A

H Main Switch

I TLG General Limit Thermostat: when it acts, it

cuts the power supply to the boiler, the warning lamp E lights. To reset, remove the cap and push the reset button.

Note: The switches are positioned under the front panel.

Note: The emergency function enables the boiler’s burners to fire only at 50% and at 50°C in system return. All the system’s heating loads, including the header pump, must be controlled manually.

Condensate level sensor position

Instructions for the installer

3.31 INITIAL LIGHTING

PRELIMIARY CHECKS

The first ignition must be carried out by a qualified technician. Failure to do so could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage.

Before lighting the boiler check that:

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

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

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

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

- the system has been filled with water (pressure registered on 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 the boiler has been calibrated for: otherwise convert the boiler to use the available gas (refer to section: “GAS CONVERSION”); this operation must be carried out by a qualified technician 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 is connected to the sewage system;

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

- there are no water leaks;

- all the necessary ventilation conditions and minimum clearance distances are guaranteed for subsequent servicing 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 use

and operation of his boiler and in particular detail:

- Hand over to the end user the booklet: “USER’S INSTRUCTIONS GUIDE”, as well as all the other literature relative to the appliance and placed in the envelope contained in the packaging. The

literature for any future reference.

- Inform The user of the importance of the air vents and of the flue outlet system, stressing the fact that absolutely no alteration can be made.

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

- Explain and demonstrate to The user the correct function and adjustment of the temperature, thermostats and radiators for the economic use of the system.

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

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

user of the appliance must retain this

DANGER! Before firing the appliance fill up the siphon through the filling hole and check the correct drainage of the condensate. If the appliance is used with the condensate drain siphon empty this could cause poisoning caused by the leakage of the flue gasses.

Servicing schedule

SERVICING SCHEDULE

To ensure the continued safe and efficient operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary , and that only original spare parts are used. The law in force states that the boiler must be serviced annually .

If the boiler is not checked and serviced when necessary it could cause material and personal damages.

For this reason UNICAL recommends that a servicing contract should be made with a heating installer.

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

The service is necessary to eliminate eventual deviations of the actual state from the optimum state. This is normally done through the cleaning, the parameters setting and the eventual replacement of single components subject to mechanical wear.

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

INSTRUCTIONS FOR SERVICING

To ensure a long life to all your boiler components and in order not to alter the conditions of the approved product only original UNICAL spare parts must be used.

After having carried out all the necessary maintenance, always follow 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 power switches) and make sure it cannot be switched ON accidentally.

• 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 return pipes, as well as the cold inlet valve.

- Remove the appliance’s front panel.

After maintenance works have been finished, follow the next steps:

- 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.

T ABLE OF THE RESISTANCE VALUES IN FUNCTION OF THE HEATING SENSOR (SR) AND RETURN HEATING SENSOR TEMPERA TURE (SRR)

T°C0123456789

0 32755 31137 29607 28161 26795 25502 24278 23121 22025 20987 10 20003 19072 18189 17351 16557 15803 15088 14410 13765 13153 20 12571 12019 11493 10994 10519 10067 9636 9227 8837 8466 30 8112 7775 7454 7147 6855 6577 6311 6057 5815 5584 40 5363 5152 4951 4758 4574 4398 4230 4069 3915 3768 50 3627 3491 3362 3238 3119 3006 2897 2792 2692 2596 60 2504 2415 2330 2249 2171 2096 2023 1954 1888 1824 70 1762 1703 1646 1592 1539 1488 1440 1393 1348 1304 80 1263 1222 1183 1146 1110 1075 1042 1010 979 949 90 920 892 865 839 814 790 766 744 722 701

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

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

At 90°C, the nominal resistance is 920 Ohm

Servicing schedule

We recommend that periodical service is made by qualified technical personnel according to the frequency stated by national rules in force.

As much as the dust present in the air will be sucked inside the combustion chamber, the smoke side resistance will increase, which, finally, will result in a reduced heat input

(and consequently a reduced output).

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

Note! A reduction of the input can be caused by the obstruction of the evacuation duct or of the air intake. Check, first of all, that this is not the reason.

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

Phase - Disassembly

• Switch off power and gas supply and ascertain the gas

cock is well closed.

• Remove

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

ve the cover

- all panels of the casing.

- Rotate the screw shown to lift the cover cap

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

- Rimuovere le 2 viti di fissaggio coperchio

Servicing schedule

- Remove the red silicone pipe and then the fans room

• Screws on thermal elements

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

- Remove the screws “A”, fixing the burner covers,

(with a 13 mm socket or open wrengh)

Servicing schedule

- move up the burners block (Front)

- move up the rear burner block and remove the 2 pins with 5 mm hex key to reach the holes ‘’C’’ (left and right).

- Remove gas fittings from the gas manifold with flat key

36 mm.

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

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

then the gas flange

2nd phase – Cleaning

• Remove from their seat the sealing gaskets and the burners.

• 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 replaced at each cleaning of the burner.

Servicing schedule

Compressed air

• Wash, with a water jet, the combustion chamber: pay attention to not to wet the electrical wiring. During this operation ascertain that the condensate evacuation pipe is always free, so that the water cannot come out from the tray.

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

• Once the cast aluminum sections have been washed, make

sure the condensate evacuation siphon is free: if necessary clean it.

• Inspect the flue duct and the smoke chamber.

3rd phase – Reassembly

• After cleaning the body and / or burners reposition the

burners in their seats

• Replace the NEW burner sealing gaskets

Reassemble all the components previously removed by following the reverse order to tighten the screws of the mixer / fans to the body, with torque of 13 Nm

CAUTION FOR EACH OPERA TION OF MAINTENANCE ‘MUST BE REPLACED THE GASCKETS FOR EACH 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 siphon is filled with water.

• Before opening the gas cock on the burner manifold make sure the coupling is well tight. To do this, open the gas cock and check the soundness of the coupling using a soap solution.

• As soon as a burner is put into operation check immediately the soundness between the gas valve and the relevant premixing chamber.

• Make the combustion analysis and check the combustion parameters.

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

sure

Automatic Heating Pty Ltd

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

Telephone Facsimile Email

+61 3 9330 3300 +61 3 9310 5655

sales@automaticheating.com.au

www.automaticheating.com.au

ABN 90 446 545 923

Automatic Heating Modulex EXT 440, Modulex EXT 550, Modulex EXT 660, Modulex EXT 770, Modulex EXT 900 Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual