Unical ALKON 50 kW, ALKON 70 kW Installation And Servicing Manual

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00333009/a - 3rd edition - 02/10

ALKON 70 kW

ALKON 50 kW

INSTALLATION AND SERVICING MANUAL

ENGLISH

CONTENTS

1 GENERAL INFORMATION ................................................................................................................................................................................... 3

1.1 Symbols used in this guide .......................................................................................................................................................................... 3

1.2 Correct use of the appliance ....................................................................................................................................................................... 3

1.3 Water treatment ............................................................................................................................................................................................ 3

1.4 IInformation to be passed over to the person in charge of the appliance ................................................................................................ 3

1.5 Safety warnings ............................................................................................................................................................................................ 4

1.6 Data badge .................................................................................................................................................................................................... 5

1.7 General warnings ......................................................................................................................................................................................... 6

2 TECHNICAL FEATURES AND DIMENSIONS ..................................................................................................................................................... 7

2.1 Technical features ........................................................................................................................................................................................ 7

2.2 Dimensions ................................................................................................................................................................................................... 8

2.3 Main components ....................................................................................................................................................................................... 11

2.4 Boiler water circuit ...................................................................................................................................................................................... 12

2.5 Operating performances ............................................................................................................................................................................ 13

2.6 General features......................................................................................................................................................................................... 13

3 INSTRUCTIONS FOR THE INSTALLER............................................................................................................................................................ 14

3.1 General warnings ...................................................................................................................................................................................... 14

3.2 Installation standards ................................................................................................................................................................................ 15

3.3 Packaging .................................................................................................................................................................................................. 16

3.4 Boiler location in a boiler room .................................................................................................................................................................. 16

3.5 Installation on existing systems ............................................................................................................................................................... 17

3.6 Gas connection ......................................................................................................................................................................................... 17

3.7 Connection return and flow system pipes ............................................................................................................................................... 18

3.8 Determination of primary boiler pump or boiler pump system.......................................................................................................... 19

3.9 Supplemental safety, security and control devices ................................................................................................................................ 20

3.10 Safety pressure relief valve ..................................................................................................................................................................... 21

3.11 Working pressure...................................................................................................................................................................................... 21

3.12 Mixing header filter .................................................................................................................................................................................... 22

3.13 Mixing header ............................................................................................................................................................................................ 22

3.14 Condensing drain ...................................................................................................................................................................................... 23

3.15 Water treatment ......................................................................................................................................................................................... 24

3.16 Fluing connections .................................................................................................................................................................................... 25

3.17 Electrical connections ............................................................................................................................................................................... 30

General warnings ...................................................................................................................................................................................... 30

Connection to electrical supply 230V ...................................................................................................................................................... 30

Room thermostat and/or heating controller E8 connection .................................................................................................................... 31

Electrical connection of additional safety devices .................................................................................................................................. 31

Electrical connection of additional safety devices for ALKON 50/70 in batterie ................................................................................... 32

3.18 Practical connection diagrams ................................................................................................................................................................. 33

3.19 Management connections diagram with E8 regulator ............................................................................................................................ 36

3.20 Examples of installation (functional diagram) .......................................................................................................................................... 38

3.21 Examples of installations with optional kits .............................................................................................................................................. 44

3.22 Filling the system ...................................................................................................................................................................................... 48

3.23 COMMISSIONING .................................................................................................................................................................................... 48

Preliminary checks ................................................................................................................................................................................... 49

Ignition and switching off........................................................................................................................................................................... 49

Information to be supplied to the user ..................................................................................................................................................... 49

3.24 Burner adjustment ..................................................................................................................................................................................... 50

3.25 Burner pressure adjustment .................................................................................................................................................................... 52

3.26 Gas conversions....................................................................................................................................................................................... 52

3.27 Programming of the operational parameters ........................................................................................................................................... 53

4 SERVICING SCHEDULE .................................................................................................................................................................................... 55

Instructions for checking and servicing the appliance ................................................................................................................................... 55

Table of the resistance values in function of the heating and domestic sensor temperature......................................................................55

Verification and cleaning of the condensate evacuation siphon..................................................................................................................... 55

Sealing gasket between distributor and boiler body ........................................................................................................................................ 56

5 FAULT FINDING ................................................................................................................................................................................................ 57

5.1 Error codes................................................................................................................................................................................................ 57

5.2 Servicing Request ..................................................................................................................................................................................... 57

5.3 Display off error codes on heating controller E8 .................................................................................................................................... 59

6 DECLARATION OF CONFORMITY ............................................................................................................................................................... 62

7 CE CERTIFICATE....................................................................................................................................................................................63

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.

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:

1.2 - CORRECT USE OF THE APPLIANCE

The ALKON 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 - WATER TREATMENT

• The hardness of the mains water supply conditions the frequency with which the heat exchanger is cleaned.

• In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is recommended. The choice of this device has to be made taking into consideration the characteristics of

the water.

• In order to improve the resistance to lime scale it is recommended to adjust the domestic hot water temperature

as near as possible to the one you really require.

• We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of

the first year and subsequently, on the basis of the lime scale found, this period can be extended to two years.

1.4 - INFORMATION TO BE HANDED OVER TO THE USER

GENERAL INFORMATION

NOTE! Suggestions for the user

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

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

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

• Hand over these instructions to the end user, together with any other literature regarding this appliance,

placed inside the envelope contained in the packaging. The user has to keep these documents in a 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.

General Information

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).

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.

5 - SAFETY WARNINGS

General Information

LEGEND:

1 = CE Surveillance notify body 2=

Boiler type

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

10 = (Pcond) Condensing nominal output 11 = (Qmax) Nominal heat input 12 = (Adjusted Qn) Adjusted for nominal Heat input 13 =

(PMS) Max. pressure C.H. system

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 DATA BADGE

CE Marking

- The CE marking documents that the boilers satisfy:

- The essential requirements of the Directive regarding gas appliances (Directive 90/396/CEE)

- The essential requirements of the ElectroMagnetic CompatibilityDirective (2004/108/CEE)

- The essential requirements of the BoilersEfficiency Directive ( 92/42/CEE)

- The essential requirements of the Low V oltage Directive ( 2006/95/CEE)

7 8

21 22

C D

General Information

1.7 - GENERAL WARNINGS

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.

The installations for the domestic hot water production MUST be build, in their entirety, with materials (taps, pipes, fittings, etc.) approved for drinkable water.

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.

Do not obstruct the intake/outlet terminal ducts. In the event of failure and/or faulty functioning of the appliance,

switch off the boiler. Do not attempt to make any repairs: contact qualified technicians.

Any repairs must be carried out by Unical authorized 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.

Before putting again into service an appliance which has been unused for a certain time, proceed to rinse the domestic hot water circuit, making the water flowing for the time necessary to draw the full content of the domestic circuit.

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.

Technical features and dimensions

2.1 - TECHNICAL FEATURES

The ALKON 50/70 boilers are a thermals gas fired units with an atmospheric fully pre-mixed burner.

They are supplied only in heating version.

These boilers have an input head power of: 50 or 70 kW, These boilers are designed for use on gas category II2H3P. The ALKON boilers are supplied complete with all the safety and control devices in accordance with all the current regulations and the following European directives: – Gas Directive 90/396 CEE – Efficiency Directive 92/42 CEE – Electromagnetic Compatibility Directive 2004/108 CEE – Low Voltage Directive 2006/95 CEE.

Moreover, the boilers of the ALKON range are classified as “CONDENSING BOILERS” according to the Directive 92/42 CEE appendix 2 (4 stars).

DESCRIPTION OF COMPONENTS AND FEATURES

• Aluminium heat exchanger/condenser;

• Fully premixed burner working at constant CO2;

• Electronic ignition;

• Safety high limit thermostat;

• Flow temperature sensor;

• Return temperature sensor;

615

930

266

85 110 110 132 100 78

430 107

125

179

RMG

Scf

R CH system return 1’’ (1 ¼’’ for 70 kW)

M CH flow system 1’’ (1 ¼’’ for 70 kW) G Gas Inlet Ø ¾’’ Sc Outlet condensate drain siphon (corpo alluminio)

135

180

266

Scf Outlet condensate drain siphon (proveniente dal tubo scarico fumi) SV Safety valve outlet A Air intake S Flue Outlet

TECHNICAL FEATURES AND DIMENSIONS

2.2 - DIMENSIONS

• Automatic air vent;

• Drain condensate siphon

• Control panel with electrical protection IP X4D;

• eBUS device;

• CH temperature selector switch: 30 ÷ 85°C;

• Flame modulation in function of the absorbed power;

• Pump overrun function;

• Additional functions : diagnostics of operation parameters

and troubles, antifreeze, technical functions and digital indication of failures.

• Constant combustion ratio

• Self adapting output depending on the length of flue ducts

• Modulating pump for ALKON 70

OPTIONAL KITS:

• Kit of manidold for additional safety devices

• Kit of additional safety devices

• Krömschröder controller E8/Expansion modules and

modulating thermostats (case for wall mounting)

• Kit of boiler pump (at constant or modulating flow rate:

only for ALKON 50)

• Mixing bottle Kit

• Chimney for single, battery or cascade mounting

• Supporting frames

• Kit for D.H.W. priority

• Kit of blind flanges and hydraulic manifolds

• Kit of wiring harness for external D.H.W. tank

VIEW FROM ABOVE

VIEW FROM BELOW

Technical features and dimensions

1510

502

762

1978

712

3040

500

1500

2431

1972

1740

DIMENSIONS ALKON 50/70 + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT

DIMENSIONS ALKON 50/70 in BATTERY (n.2 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT

Technical features and dimensions

2475

1972

500

1500

1740

3726

2510

1972

500

1500

1740

4630

DIMENSIONS ALKON 50/70 in BATTERY (n.3 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT

DIMENSIONS ALKON 50/70 in BATTERY (n.4 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT

Technical features and dimensions

2.3 - MAIN COMPONENTS

N.B.: The boiler cannot work on natural circulation

ALUMINIUM HEA T EXCHANGER/ CONDENSER

CONDENSATE

DRAIN

(Ø25 mm)

AIR

VENT

VALVE

MODULATING

FAN

AIR INTAK E

OPENING

(Ø80 mm)

FLUE

OUTLET

PIPE

(Ø80 mm)

PIPE WITH

SMOKE

SAMPLING AND

CONDENSATE

EVACUATION

CONNECTION

SIPHON

GAS VALVE

SPACER PIPE

REPLACEABLE

FOR MOUNTING

OF OPTIONAL

CIRCULATOR

FLOW

TEMPERATURE

SENSOR

RETURN

TEMPERATURE

SENSOR

OVERHEAT

THERMOSTAT

IGNITION

TRANSFORMER

MIN. WATER

PRESSURE

SWITCH

IGNITION

ELECTRODE

SAFETY VALVE

ALKON 50

Technical features and dimensions

ALKON 70

ALUMINIUM HEAT EXCHANGER/ CONDENSER

CONDENSATE

DRAIN

(Ø25 mm)

AIR

VENT

VALVE

MODULATING

FAN

AIR INTAK E

OPENING

(Ø80 mm)

FLUE

OUTLET

PIPE

(Ø80 mm)

SIPHON

GAS VALVE

FLOW

TEMPERATURE

SENSOR

RETURN

TEMPERATURE

SENSOR

OVERHEAT

THERMOSTAT

IGNITION

ELECTRODE

SAFETY VALVE

MODULANTING

PUMP

MIN. WATER

PRESSURE

SWITCH

PIPE WITH

SMOKE

SAMPLING AND

CONDENSATE

EVACUATION

CONNECTION

IGNITION

TRANSFORMER

Technical features and dimensions

MRG

ATTENTION! THE PRE-FORMING FOR THE BOILER PUMP IS ONLY FOR THE PUMP KIT SUPPLIED BY UNICAL

00361320 - Kit of MODULATING PUMP, only for

ALKON 50

00361321 - Kit of CONSTANT FLOW RATE PUMP, only for

ALKON 50

2.4 - BOILER WATER CIRCUIT DIAGRAM

1 Gas valve 2 CH flow temperature sensor 3 CH return temperature sensor 4

Condensate drain siphon

5 Overheat thermostat 6 Heat exchanger 7 Burner 8 Air vent valve 9 Flue outlet / Air intake 10 Fan 11 Premix 12 Room sealed chamber 13 Replaceable pipe for insertion optional pump

(only for ALKON 50)

modulating pump only for ALKON 70 14 Safety valve 6 bar 15 Pressure switch against lack of water

M C.H flow G Gas supply R C.H. return

Technical features and dimensions

2.6 - GENERAL FEATURES

2.5 - PERFORMANCE DATA

l/min bar bar mbar l °C °C l bar l l bar bar l/min. l/min. l/min. l/min. l/min. l/min. l/min. °C V-Hz A (F) W IP kg

ALKON 50

2H3P

3,86 0,5 6 10 3,9 85 30

230/50 4 77 (172) X4D 50

ALKON 70

2H3P

5,4 0,5 6 10 3,9 85 30

230/50 4 145 (290) X4D

Appliance’s family gas category Min. water flow rate in CH circuit (Δt 20 °C) Min. pressure in CH circuit Max. pressure in CH circuit Min. dynamic gas pressure (natural gas) Water content in primary circuit Max operating temp. in CH mode Min operating temp. in CH mode Total volume CH expansion vessel Total pre-loading expansion vessel Max water content CH circuit (calculated for a max temp. of 82°C) Min flow rate DHW circuit Min. DHW inlet pressure Max DHW inlet pressure DHW specific flow rate ( t 30 °C) DHW flow restrictor DHW production in continuous operation with t 45 K DHW production in continuous operation with t 40 K DHW production in continuous operation with t 35 K DHW production in continuous operation with t 30 K (*) DHW production in continuous operation with t 25 K (*) DHW adjustable temperature Electrical supply /power consumption Fuse rating Maximum absorbed power (with optional modulating pump) Electrical protection Net weight

For information regarding the adjustment of: INJECTORS - BURNER PRESSURES – DIAPHRAGMS – OUTPUTS – GAS CONSUMPTIONS please refer to the paragraph ADAPTMENT TO THE USE OF OTHER GASES.

48,5 9,6 47,2 9,1 97,29 94,9 4 49,3 10,3 101,62 107,33 97,80 98,42 0,58 0,311 43,6 21,44 26,84 7,8

19,7 - 71,5 33,9 5 2,20

67,5 9,6 65,5 9,1 97,06 94,9 4 68,5 10,3 101,51 107,33 98,39 98,28 0,35 0,223 51,3 30,96 26,84 10,87

19,7 - 98,7 34,68 5 2,59

(Reference gas: Natural Gas G20)

Max heat input Min heat input

Nominal heat outpout 80/60 Minimum heat output 80/60 Efficiency at nominal load 80/60 Efficiency at minimal load 80/60 Number of stars (according to CEE 92/42 Nominal heat output in condensing mode 50/30 Minimal heat output in condensing mode 50/30 Efficiency at nominal load in condensing mode 50/30 Efficiency at minimal load in condensing mode 50/30 Combustion efficiency at nominal load Combustion efficiency at minimal load Stand-by losses with burner in operation Stand-by losses with burner off

(*) Flue gas temperature tf-ta (max)

Flue gas mass flow rate (max) Air excess λ

Condensate production max (**) CO2 (min - max) CO at 0% of O2 (min - max)

N0x (value according to EN 297/A3 and EN 483 N0x class Flue losses with burner in operation (max)

kW kW kW kW % % n. kW kW % % % % % % °C g/s % kg/h % mg/kWh mg/kWh % mg/kWh

(*) Room Temperature = 20°C (**) See Table Injectors - Pressures

ALKON 50

ALKON 70

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 . An out door installation could cause malfunctioning and could be dangerous. For external installations, it is recommended to use appliances which are specifically designed and predisposed for this purpose.

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, i.e. only in T ype C version.

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

WARNING! The appliance must be installed only on a closed, vertical flat wall, made of non combustible material. The appliance must be positioned so that at least the minimum operational and servicing clearances are provided.

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

Instructions for the installer

3.2 - STANDARD CODES FOR

INSTALLATION

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 out 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 revisions.

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 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 house.

Instructions for the installer

370

715

1025

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.

When selecting the position for the installation of the boiler please comply to the following safety requirements:

• Guarantee an easy access to the components of the boiler

to facilitate the possible operations of ordinary and extraordinary maintenance.

• Fit the appliance in rooms protected from frost;

• In rooms where aggressive vapours or dust are present,

the appliance must be able to operate independently from the air of the location room;

• The appliance must be installed exclusively on a vertical

and solid wall, capable of adequately supporting the weight of the boiler;

• The wall must not be made of inflammable material.

CONNECTIONS ALKON 50 ALKON 70

M =

CH system flow

1” 1’’¼

R =

CH system return

1” 1’’¼

G = Gas Supply 3/4” 3/4”

S = Condensate Drain

840

110 110

177

132

310,5

206,5

3.3 - PACKAGING

The ALKON 50/70 boiler is supplied fully assembled in a strong cardboard box.

After having unpacked the boiler check that it is intact and undamaged.

Keep the packaging material (cardboard box, plastic bags, polyester protection etc.) out of

the reach of children as they can be dangerous.

UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations.

In the packaging, in addition to the boiler, you can also find the following contents:

- Service logbook

- Instruction manual for the person in charge of the

appliance

- Instruction manual for the installer and servicing personnel

- Warranty

- Nr. 2 spare parts request coupons

- N° 3 plastic plugs for fixing boiler

- Boiler support bracket

- Condensate evacuation siphon

- Aluminum pipe Ø 80 mm for smoke evacuation

3.4 - BOILER LOCATION INSIDE A BOILER HOUSE

Instructions for the installer

- 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.

3.5 - INSTALLATION ON EXISTING

HEATING SYSTEMS

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.

3.6 - GAS CONNECTION

The gas supply pipe must be connected to the boiler via the respective pipe connection ¾” as indicated on page 13.

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.

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

INSIDE BOILER ROOM

OUTSIDE BOILER ROOM

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

Instructions for the installer

3.7 - FLOW AND RETURN PIPE CONNEC-

TIONS

The CH flow and return circuits have to be connected to the boiler via the respective connections

1” or 1’’¼ as indicated

on page 16. 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.

GATE VALVES

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

WARNING! Before installing the boiler we recommend that the system is flushed out with a suitable product, 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.

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

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.

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 Ät of the primary circuit if the installation has a mixing header

Power supply in kW

Max flow rate demanded in l/h (

ΔΔ

ΔT 15K)

Portata nominale richiesta in l/h (

ΔΔ

Δ T 20K)

49,3

2826

2120

ALKON 50

68,5

3927

2946

ALKON 70

200 400 600 800

1000

1200 1400

1600

1800

2000

2200

2400 2600

2800 300

3200 3400

3600

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

3600

3800

4000

4200

4400

4600

4800

5000

5200

5400

5600

5800

6000

6200

6400

6600

6800

7000

7200

7400

7600

7800

8000

3800 4000 4200 4400 4600 4800 5000

ALKON 50

ALKON 70

3.8 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP

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.

For a

ΔΔ

ΔT 20 K, the max. water flow rate requested is 2120 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 1,6 mH2O.

Pressure losses (mmH2O)

Q: water flow rate (l/h)

WA TER SIDE PRESSURE LOSSES

Instructions for the installer

For the electrical connection of the additional safety devices make reference to the paragraph 3.17 - Connection of the additional safety devices.

6 7

CERTIFICATION OF THE SUPPLEMENT AL SAFETY DEVICES:

Several notified bodies prescribe supplemental safety devices. For the safety valves and on-off gas valves it is necessary to obtain the ISPESL (Institution for preventive measures and

safety at work) calibration certificate which confirms that they are free from lead or bossing.

The expansion vessels with a capacity superior to 24 litres must have be supplied with an approval booklet released by

ISPESL and a manufacturers conformity declaration. All the accessories must have an ISPESL approval certificate.

SAFETY DEVICES

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

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.

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.

PROTECTIVE DEVICES

3. 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.

4. Safety pressure switch: it has the function of shutting

down the generator if it reaches the maximum working pressure. It must be able to be reset manually.

3.9 - SUPPLEMENTAL SAFETY, PROTECTIVE AND CONTROL DEVICES PRESCRIBED BY

THE GOVERNMENT DECREE 01-12-1975 AND RELATIVE APPLICABLE TECHNICAL SPECIFICATIONS (CONTAINED IN THE “RACCOLTA R EDITION 1982”)

CONTROL DEVICES

5. Pressure indicator with shock absorber tube and pressure gauge holder valve: it indicates the effective

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

6. Thermometer: it indicates the effective water temperature contained in the generator. It must be graduated in degrees Celsius with a temperature scale not exceeding 120°C.

7. Bulb holder for a master temperature gauge: it must be fitted vertically and must have an inside dia. of 10 mm, in order to locate a mercury master thermometer.

8. Calibrated expansion vessel: it permits the absorption of the increase in volume of the system’s water following an increase in temperature and its nominal maximum working pressure must be higher than the pressure relief valve’s setting.

Instructions for the installer

3.11 - WORKING PRESSURE

The boiler’s maximum allowable working pressure is set at 3 bar; whilst the minimum pressure is pre-charged to 0,5 bar.

WARNING! The boiler doesn‘t integrate any specific device against the lack of water, because this function is performed by the high limit thermostat (overheating).

Note: On the main PCB it is alwys possible to electrically connect a minimum water pressure switch against the lack of water.

3.10 - 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,

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.

Instructions for the installer

In 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

3.12 - 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.

3.13 - MIXING HEADER (cod. 00361333-00361499-00361500)

Instructions for the installer

3.14 - CONDENSATE DRAIN

During the combustion process the boiler produces condensate which, through the “A” pipe, flows into the siphon. The condensate which forms inside the boiler has to be routed into an adequate drain by means of the pipe “B”.

DANGER! Before commissioning the appliance fill the siphon and check the correct drainage of the condensate. If the appliance is used with the condensate drain siphon empty there could be danger of intoxication resulting from the escape of flue gasses.

The connection between the appliance and the sewage system must be carried out in compliance with the specific reference standards, and in particular:

- prevent the end user utilizing the condensate produced;

- a siphon must be fitted (supplied with the boiler);

- there must be no bottlenecks;

- the connection must be made just under the bottom part of

the boiler;

- it must be installed so as to avoid freezing of the liquid

when the boiler is operating and prevent the eventual pressurization of the sewage system;

- consent the correct downflow of the appliance’s liquid di-

scharges;

- it must be made with one of the following materials which

are resistant to condensate:

- Grès, according to the Standards DIN 1230-1 and 6, EN 295-1 or 2 or 3;

- Glass (boron silicate);

- Polyvinyl chloride (PVC) , according to DIN V 19534-1 and 2, and DIN 19538;

- Polyethylene (PE) DH type, according to DIN 19535-1 and 2 and DIN 19537-1 and 2;

- Polypropylene (PP) and copolymer styrene (ABS) according to DIN V 19561;

- Polyesterific resin (GF-UP), according to DIN 19565-1;

- Stainless steel.

Condensate inlet coming from the flue outlet

Condensate drain pipe of boiler and chimney (to connect to the sewage system

Condensate inlet coming from the heat exchanger

Instructions for the installer

3.15 - WATER TREATMENT

The chemical/physical features of the heating system’s water are fundamental for the boiler’s correct operation and safety.

Among the inconvenients caused by the bad quality of the feeding water, the most frequent and the most serious is the incrustation of the boiler thermal exchange surfaces.

Less frequent, but also serious, is the hydraulic circuit surfaces.

It is ascertained that the boiler incrustations, due to their low thermal conductivity , highly reduce the thermal exchange, even if with a thickness of some millimetres and provoque a very dangerous localised overheating.

We suggest to make the water treatment of the heating circuit in the following cases: a) When the hardness of the water is higher than 15°f; b) For C.H. installations with large water content; c) Renewal of the water system due to uncontrolled leakages; d) Subsequent refilling of the system due to maintenance

works on the installation;

e) Presence of different metals in the hydraulic circuit. The scope of this treatment is finalized for eliminating or

substantially reducing the following problems:

- lime scale deposit

- corrosion sludge

- deposits

- microbiological growths (moulds, bacteria etc.)

An appropriate treatment of the supply water will prevent the above stated problems and will maintain the correct operation and efficiency of the generator in time.

For this purpose it will be necessary to fix the following chemical-physical characteristics of the water:

PH include between 6,5 and 8 Hardness 15° FR

Therefore, before filling the heating system it will be necessary to fit the devices indicated in the figure.

THE INSTALLA TION MUST BE FORESEEN ON THE RETURN PIPE OF THE PRIMARY CIRCUIT DOWNSTREAM OF THE CIRCULATING PUMP.

All necessary precautions must be taken for preventing the formation and localization of oxygen in the system’s water. For this reason, ensure yourself that the plastic piping used in underfloor heating systems is impermeable to oxygen.

If any anti-freeze solutions are used ensure that they are compatible with aluminium and any other boiler components and materials.

WARNING! Any damage caused to the boiler due to the formation of lime scale or by corrosive water will not be covered by the warranty.

1 BALL VALVE 2 INSPECTION POCKET 3 FILLING MANIFOLD 4 DISCONNECTOR

5 SCALE REDUCING DEVICE 6 LITER COUNTER (Recommended) 7 Y filter

1 2 3 4 5 2 7 16

EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FOR WA TER TREA TMENT

Instructions for the installer

3.16 - FLUE OUTLET INSTALLATION

The flue system must be installed in accordance with the local and national Standards.

We recommend using only original UNICAL flue outlet systems. Damages caused by installation errors and for non-observance of the instructions given by the manufacturer will invalidate all the supplier’s contractual or extra contractual responsibilities.

If the boiler has to be replaced ALWAYS replace the flue outlet system.

The boiler has been approved for the following flue configurations:

C13 oiler designed for connection to horizontal inlet and out-

let terminals, which admit fresh air to the burner and discharge the products of combustion to the outside through concentric or twin ducts. The minimum distance between the inlet air duct and the flue outlet duct must be of 250 mm and both terminals must be positioned within a 500 mm square section.

C33 Boiler designed for connection to vertical inlet and out-

let terminals, which admit fresh air to the burner and discharge the products of combustion to the outside through concentric or twin ducts. The minimum distance between the air inlet duct and the flue gas outlet duct must be of 250 mm and moreover both terminals must be positioned within a 500 mm square area.

C43 Boiler designed for connection to collective flue systems

including two ducts, one for the air inlet and the other for the discharge of products of combustion through concentric or twin ducts.

C53 Boiler with separate air inlet and products outlet. These

ducts can discharge into areas with different pressure.

The two terminals must not be fitted on to two opposite walls.

C83 Boiler designed for connection to a terminal for the in-

take of combustion air and to an individual or collective chimney for the discharge of the products of combustion.

The chimney must comply to the current regulations.

B23 Boiler designed to be connected to an open flue which

will terminate vertically through the roof. The combustion air is withdrawn directly from the room where the boiler is installed.

WARNING: for this type of connection the room must comply with the same installation regulations valid for open chimney boilers. The chimney must comply to the current regulations.

aa aa

Instructions for the installer

L min = 1 m - L max = 30 m

KIT5790C

KIT5750C - KIT5760C

(1 m) - (0,5 m)

TSC0130C

00310012

Preliminary operations: Fit the smoke evacuation pipe Ø 80 mm, supplied in the carton, as shown in the picture.

L min = 1 m - L max = 30 m

TSC0130C

00310012

KIT5770C

TSC0130C

FLUE OUTLETS Ø 80 mm Type B23

The total allowed linear maximum length of the smoke evacuation and air intake pipes, of Ø 80 mm, is 30 m, including one wide radius curve and one evacuation terminal.

ATTENTION! In the case in which danger of freezing subsists, the insulation of the smoke evacuation pipe is recommended on the whole length, in both cases, outside or in the chimney.

Instructions for the installer

Preliminary operations:

- Insert the supplied pipe Ø 80 in the adapter for coaxial pipes Ø80/125 (code 00361255)

- Fit the assembly pipe/adapter on the boiler as shown in figure.

HORIZONTAL FLUE OUTLET WITH CONCENTRIC DUCTS Ø 80/125 mm - Type C 13

L min = 1 m - L max = 5 m

00361256

00361255

00360357

The minimum allowed length of the horizontal coaxial pipes is 1 meter. The maximum allowed length of the horizontal coaxial pipes is 5 meters. For every additional curve the maximum allowed length must be reduced by 1 meter; besides the duct has to have an upward inclination of 3% in the direction of exit, so that to allow the collection of the condensate in to the boiler.

260

Instructions for the installer

L min = 1 m - L max = 7 m

KIT5820C

KIT5730C

(1 m)

00361255

Preliminary operations:

- Insert the supplied pipe Ø 80 in the adapter for coaxial pipes Ø80/125 (code 00361255)

- Fit the assembly pipe/adapter on the boiler as shown in figure.

VERTICAL FLUE OUTLET WITH COAXIAL DUCTS Ø80/125 mm - TYPE C 33

The minimum allowed length of the horizontal coaxial pipes is 1 meter. The maximum allowed length of the horizontal coaxial pipes is 7 meters. For every additional curve the maximum allowed length must be reduced by 1 meter. Layout NOT suitable for ALKON 70

Instructions for the installer

251

Smoke evacuation by two separate ducts Ø 80 mm - Type C53

Preliminary operations:

- Fit the supplied pipe of Ø 80 mm, as shown in the picture.

The maximum allowed pressure drop, independently from the type of installation, doesn’t have to overcome the value of 60 Pa.

L min = 2 m (1 air intake. + not less than 1 smoke evacuation)

L max = 30 m (15 air intake. + 15 smoke evacuation)

KIT5780C

KIT5770C

TSC0130C

Instructions for the installer

3.17 - ELECTRICAL CONNECTIONS

Regulations in force

The elctrical safety of the appliance is assured only when it is correctly earthed, according to the electrical rules in force.

The gas, D.H.W. 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 expose the boiler to sunlight, rain, etc., unless it is explicitly foreseen;

- Do not permit children or inexpert people to use the

appliance.

Mains electrical supply connection 230V

The boiler is provided complete with a mains supply cable 1,5 m long and with a cross section area of 3x0,75 mm2.

The electric connections of the boiler are shown in the section named “ACTUAL WIRING DIAGRAM” (paragraph 3.18 page

33) 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 additional electrical safety devices (if any) 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.

FASTON BLOCKING If necessary the faston can be disconnected by slightly folding up, with a point, the blocking tongue ‘’ Á. ‘’.

Instructions for the installer

Connection of the additional safety devices

- Gain access to the Y1 terminal board

- A Room Thermostat will be connected to the terminals 1 and 2 after removal of the existing bridge wire.

- For the Heating Controller connection use the

connecting terminals 3 and 4.

Room thermostat

E8 heat ing controller

DANGER! Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts.

- For the connection remove the existing jumper.

The opening of the additional safety devices doesn’t stop the boiler pump operation.

Thermostat Pressostat

Prea rran gement for th e connection of the addi tional safety device s

LIGHTBLUE

LIGH TBLUE

LIGHTBLUE

For the connection of the E8 heating controller, to remove the “bridge wire” existing between the terminals 1 and 2.

Room thermostat and/or E8 heating controller connection

DANGER! Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts.

Instructions for the installer

DANGER! Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts.

- For the connection remove the existing jumper.

LIGHTBLUE

Supplie Relais

Boiler 1 Boiler 2 Boiler 3 Boiler 4

Thermostat Pressostat

Prearrangement for the connection of the additional safety devices

LIGHTBLUE

Attention To maintain isolated the contacts ISPESL of the different boilers suffers the ache operation of the same ones

Connection of the additional safety devices for ALKON in battery

Instructions for the installer

3.18 - ACTUAL WIRING DIAGRAM for ALKON 50

E. ACC = Ignition electrode E. RIV. = Detection electrode DK = Minimum water pressure switch SR = CH sensor SRR = CH return sensor SS = DHW sensor (optional) TL = Limit thermostat

TF = Smoke thermostat (only pre-arrangement)

VG = Gas valve VM = Modulating fan detection/adjustment

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

ORANGE +

BLACK (-)

BROWN (P WM)

BLUE (TACHO)

LIGHT-BLUE (N)12BROWN (L1)

RIL./REG.

ALIM. 230V

SRR

BROWN

BLUE

YELL/GREEN

L1N

230 V - 50 Hz

GREEN

GREE N

WHITE

LIGHT-BLUE

BROWN

E. ACC

LIGHT-BLUE

BROWN

YELL/G REEN

RED

BLACK

E. RIV.

WHITE

BLACK

WHITE

BROWN

LIGHT-BLUE

BLUE

LIGHT-BLUE

BROWN

Fs1

NERO

BLU

MA RR ON E

ARANCIO

BROWN

Prearrangement for the connection of the additional safety devices

LIGHT-BLUE

Instructions for the installer

ACTUAL WIRING DIAGRAM for ALKON 70

ORANGE +

BLACK (-)

BROWN (PWM )

BLUE (TACHO)

LIGHT-BLUE (N)12BROWN (L1)

RIL./REG.

ALIM. 230V

SRR

BROWN

BROW N

BLU E

YELL/GREEN

L1N

230 V - 50 Hz

E. ACC

GIA/VER

ROSSO

E. RIV.

WHITE

BLACK

BROWN LIGHT-BLUE

BLUE

LIGHT-BLUE

BROWN

Fs1

BLACK

BLUE

BROWN

ORANGE

LIGHT-BLUE

BROWN

YELL-GREEN

PINK

(

MODUL ATION

)

GREY (-

)

WHI TE

GREEN

WHITE

LIGHT-BLUE

BLACK

WHITE

BROWN

Prearrangement for th e connection of the additional safety devices

LIGHT-BLUE

BROWN

LIGHT-BLUE

BROWN

E. ACC = Ignition electrode E. RIV. = Detection electrode DK = Minimum water pressure switch MDV = Motor 3 way valve PM = Modulatin pump SR = CH sensor SRR = CH return sensor SS = DHW sensor (optional) TL = Limit thermostat TF = Smoke thermostat (only pre-arrangement)

VG = Gas valve VM = Modulating fan detection/adjustment

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

Instructions for the installer

Boiler pump at constant flow rate (optional cod. 00361321 ALKON 50)

Modulating pump (optional cod. 00361320 ALKON 50)

YELL-GREEN

LIGHT-BLUE

BROWN

LIGHT-BLUE (N)

BROWN (L1)

ALIM. 230V

BROWN

LIGHT-BLUE

YELL-GR EEN

LIGHT-BLUE

BROWN

LIGHT-BLUE (N)

BROWN ( L1)

ALIM. 230V

BROW N

LIGHT-BLUE

MVD

RED

GREEN

BLUE (-)

BROWN

BLUE (-)

WHITE

BROWN

LIGHT-BLUE

BROWN

YELL-GREEN

P = Boiler pump at constant flow rate, controlled

via an ON/OFF Room thermostat

P * = Boiler pump at constant flow rate, controlled

via the heating controller E8.

Instructions for the installer

3.19 - WIRING DIAGRAM AND MANAGEMENT WITH E8 REGULATOR (Optional)

12345678910

A1 A2 A3 A4 A5 A6

NL1L1’

T1 T2

T3 T4

12345

A8 A9 A10 A11

123

BUS

50 Hz 230 V

III

IMP

0-10 V

F17

F15

FBR

III

PT1000

F14

F13

SPF

F12 F11

AF KF / SPF

F9 F8 F6 F5 F3 F2 F1

FBR

eBUS

0-10 V

67891012345

NL1L112 1

Power suppl

230 V - 50 Hz

PINK

GREY

From the boiler

Primay circuit pump

D.H.W. Rec

cling pump

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.

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.

Power terminal assignments (230 V)

Power terminal block

Sensor terminal block

Terminal II

A1 A2 A3 A4 A5 A6

NL1L1’

T1 T2

67891012345

NL1L112 1

N: L1: L2: : : : : :

Neutral conductor, mains

Power supply, unit Power supply to relay

heating circuit pump HK 1 heating circuit pump HK 2 Storage tank charging pum p

Mixer open, heati ng circuit 2 Mixer closed, heating circuit 2

T3 T4

Te rminal VI

12345

A8 A9

A10 A11

21 3

Terminal IV

: :

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

Multifunction relay

Multifunction relayRecycle pump /

Instructions for the installer

Sensor terminal assignments

Connection to BCM

For connection to remote control devices

Terminal VII

VII

eBUS

0-10 V

VII

Pin 1: Pin 2:

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

Terminal I

12345678910

AF KF / SPF

F9 F8 F6 F5 F3 F2 F1

FBR

Pin 4: Pin 5: Pin 6: D.H.W. Pin 7: Pin 8: Pin 9: Pin 10:

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)

SPF SPF

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)

SPF

F12 F11

Terminal V

SPF

Pin 1: C.H. Flow senso r circuit 1 / sensor Multifunction 1 Pin 2: D.H.W. Tank low sensor / se nsor Multifunction 2

VIII

PT1000

F14 F13

Terminal VI II

F13 F14

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

Terminal III

III

123

III

IMP

0-10 V

F17 F15

FBR

Pin 1: Pin 2:

FBR heating ci rcuit 2 (room sensor) / 0-10V IN / (to be enabled) FBR heating circuit 2 (ground)

F15

F17

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

1234

BUS

Morsetto IX

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

Instructions for the installer

M R

< 1 m

Filter

Expansion vessel (optional)

Safety devices kit

Mixing Header

Heating Circuit 1

Outside Sensor

NOTE! THE CONFIGURATIONS, SHOWN IN THIS MANUAL, ARE DOABLE BY USING THE E8 REGULATOR, SUPPLIED AS AN OPTION.

BEFORE USING OTHER MODELS OF REGULATORS, MAKE SURE THEY ARE COMPATIBLE

3.20 - INSTALLATION EXAMPLES (functional wiring and connections description)

INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE

(9-10) outdoor sensor

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(4) Collector pump

Instructions for the installer

F Ric.

SPF

< 1 m

Filter

Heating Circuit 1

Heating Circuit 2

Mixing Header

Safety devices kit

Expansion vessel (optional)

Outside Sensor

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

(9-10) outdoor sensor

(6-7) Storage tank sensor

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

SPF

(5) Re-circulation pump storage tank

(4-5) Flow sensor heating circuit 2

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Instructions for the installer

F Ric.

SPF

M R G

< 1 m

Filter

Heating Circuit 1

Heating Circuit 2

Mixing Header

Safety devices kit

Expansion vessel (optional)

Outside Sensor

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

(5) Re-circulation pump storage tank

(9-10) outdoor sensor

(6-7) Storage tank sensor

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

SPF

(4-5) Flow sensor heating circuit 2

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Instructions for the installer

F Ric. C

VF VF

SPF

Sonda di caldaia

< 1 m

Filter

Heating Circuit 1

Heating Circuit 2

Mixing Header

Safety devices kit

Expansion vessel (optional)

Outside Sensor

PT1000

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

(9-10) outdoor sensor

(4-5) Flow sensor heating circuit 2 (6-7) Storage tank 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

SPF

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

(5) Re-circulation pump storage tank

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

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

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

Instructions for the installer

SPF

A11

PT1000

F14

F12

< 1 m

Filter

Heating Circuit 1

Heating Circuit 2

Mixing Header

Safety devices kit

Expansion vessel (optional)

Outside Sensor

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

(9-10) outdoor sensor

(4-5) Flow sensor heating circuit 2 (6-7) Storage tank sensor

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

SPF

(5) Re-circulation pump storage tank

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

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

PT1000

(4) Collector 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

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

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

F Ric.

SPF

M R

< 1 m

Boiler sensor

Filter

Heating Circuit 1

Heating Circuit 2

Mix ing He ader

Safety devices kit

Expansion vessel (optional)

Outside Sensor

Expansion vessel (optional)

Connection of severa ALKON 50 o 70

123

ALKO N 50/1

ALKON 50/ 2

ALKO N 50/3

The E8 regulator (OPTIONAL) will recognise automatically the number of boilers connected and their output .

For the connection of several ALKON 90 (Max 8 boilers) it is necessary to change some parameters of prearrangement (see table Regulator E8 on page 6: TIPE CR1 from ‘’2’’ to ‘’6’’

CR1 BUS prearranged ‘’03’’

Attention!

Respect the polarity: BUS - / BUS -

BUS + / BUS +

Set the E8 in cascade System (see

Input of the basic

setting

, parameter list cascade) Set the parameter SC in the ALKON 50: 1st master ((sc = 00), 2nd slave (sc = 01), 3rd slave (sc = 02), 4th slave (sc = 03)

Connections on to the MASTER controller

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

(5) Re-circulation pump storage tank (4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(9-10) outdoor sensor

(4-5) Flow sensor heating circuit 2 (6-7) Storage tank 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

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

The electrical connection of several ALKON 50 in cascade must be done in parallel between the terminals 3 of Y1

(ALKON 50 or 70 / 1) e 3 of Y1 (ALKON 50 or 70 / 2) ....etc;

from 4 of Y1 (ALKON 50 or 70 / 1) al 4 di Y1 (ALKON 50 or 70

/ 2) ....etc, of the PCBs .

Instructions for the installer

1 - 00361366 = Supporting frame for one boiler 2 - 00361314 = Manifold kit for Alkon 50/70 3 - 00361313 = Pipe kit for additional safety devices 4 - 00361316 = Safety devices kit 5 - 00361333 = Mixing bottle kit 9 - 00361320 = Modulating pump (only for Alkon 50)

- 00361321 = Constant flow rate pump (only for Alkon 50)

11 - 00361450 = Blind flanges kit

3.21 - EXAMPLES OF CONNECTION WITH OPTIONAL KITS

REGULATION ACCESSORIES

00361332 = E8 regulator kit 00361359 = Box for E8 regulator kit 00361358 = BM8 remote control kit

DN 50

CONNECTION OF AN EXTERNAL D.H.W. TANK

00361668 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 50

00361736 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 70

INSTALLATION OF A SINGLE ALKON 50/70

1 - 00361366 = Supporting frame for one boiler 2 - 00361314 = 3 - 00361313 = 4 - 00361316 = 5 - 00361333 = 9 - 00361320 = Modulating pump (only for Alkon 50)

- 00361321 = Constant flow rate pump (only for Alkon 50)

11 - 00361450 = Blind flanges kit

Instructions for the installer

1 - 00361363 = Supporting frame for two boilers 2 - 00361314 = Manifold kit for Alkon 50/70 3 - 00361313 = Pipe kit for additional safety devices 4 - 00361316 = Safety devices kit 5 - 00361499 = Mixing bottle kit 6 - 00361414 = Pipes kit for connection of mixing bottle 8 - 00361361 = Smoke outlet for two boilers 9 - 00361320 = Modulating pump (only for Alkon 50)

- 00361321 = Constant flow rate pump (only for Alkon 50)

11 - 00361450 = Blind flanges kit

SMOKE ACCESSORIES

00262430 = Elbow 45° Ø 160

00262431 =

Elbow

87° Ø 160 00262432 = Extension Ø 160 L = 250 00262433 = Extension Ø 160 L = 500 00262434 = Extension Ø 160 L = 1000 00262435 = Extension Ø 160 L = 2000 00262438 = Inspection terminal Ø 160

REGULATION ACCESSORIES

00361332 = E8 regulator kit 00361359 = Box for E8 regulator kit 00361358 = BM8 remote control kit

DN 65

DN 50

DN 65

Note:

The insulation of the battery flow and return manifolds is suggested.

INSTALLATION OF TWO ALKON 50/70 IN BATTERY

CONNECTION OF AN EXTERNAL D.H.W. TANK

00361668 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 50

00361736 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 70

Instructions for the installer

1 - 00361363 = Supporting frame for two boilers 1a - 00361365 = Added supporting frame for one boiler 2 - 00361314 = Manifold kit for Alkon 50/70 3 - 00361313 = Pipe kit for additional safety devices 4 - 00361316 = Safety devices kit 5 - 00361499 = Mixing bottle kit 6 - 00361414 = Pipes kit for connection of mixing bottle 8 - 00361361 = Smoke outlet for two boilers Alkon 8a - 00361362 = Added smoke outlet for one

boiler Alkon 50

9 - 00361320 = Modulating pump (only for Alkon 50)

- 00361321 = Constant flow rate pump (only for Alkon 50)

10 - 00361450 = Blind flanges kit

SMOKE ACCESSORIES

00262430 = Elbow 45°

160

00262431 =

Elbow

87° Ø 160 00262432 = Extension Ø 160 L = 250 00262433 = Extension Ø 160 L = 500 00262434 = Extension Ø 160 L = 1000 00262435 = Extension Ø 160 L = 2000 00262438 = Inspection terminal Ø 160

Note:

The insulation of the battery flow and return manifolds is suggested.

EGULATION ACCESSORIES

00361332 = E8 regulator kit 00361359 = Box for E8 regulator kit 00361358 = BM8 remote control kit

DN 65

DN 50

INSTALLATION OF THREE ALKON 50/70 IN BATTERY

CONNECTION OF AN EXTERNAL D.H.W. TANK

00361668 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 50

00361736 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 70

Instructions for the installer

1 - 00361363 = Supporting frame for two boilers 1a - 00361365 = Added supporting frame for one boiler 2 - 00361314 = Manifold kit for Alkon 50/70 3 - 00361313 = Pipe kit for additional safety devices 4 - 00361316 = Safety devices kit 5 - 00361500 = Mixing bottle kit 6 - 00361415 = Pipes kit for connection of mixing bottle 8 - 00361361 = Smoke outlet for two boilers 8a - 00361362 = Added smoke outlet for one

boiler Alkon 50

9 - 00361320 = Modulating pump (only for Alkon 50)

- 00361321 = Constant flow rate pump (only for Alkon 50)

11 - 00361450 = Blind flanges kit

SMOKE ACCESSORIES

00262430 = Elbow 45°

160

00262431 =

Elbow

87° Ø 160 00262432 = Extension Ø 160 L = 250 00262433 = Extension Ø 160 L = 500 00262434 = Extension Ø 160 L = 1000 00262435 = Extension Ø 160 L = 2000 00262438 = Inspection terminal Ø 160

Note:

The insulation of the battery flow and return manifolds is suggested.

REGULATION ACCESSORIES

00361332 = E8 regulator kit 00361359 = Box for E8 regulator kit 00361358 = BM8 remote control kit

DN 100

DN 50

INSTALLATION OF FOUR ALKON 50/70 IN BATTERY

CONNECTION OF AN EXTERNAL D.H.W. TANK

00361668 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 50

00361736 = Kit of electrical wiring for an ext. D.H.W.

tank for ALKON 70

Instructions for the installer

3.22 - FILLING THE SYSTEM

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.

Once all the connections are made, it is possible to fill the circuit. This operation has to be performed very carefully, by observing the following steps (boiler in Off position):

- open the radiator bleeds and make ascertain the good operation of the automatic air vent fitted in the boiler .

- open progressively the filling valve and make sure the automatic air vent, in the system, work properly.

- close the bleeders of the radiators when water starts to come out.

- control via the manometer (bargraph) that the water pressure has reached a minimum value of 0.8/1 bar.

- close the filling valve and bleed again all the radiators.

- inspect for the soundness all the hydraulic connections.

- after the commissioning of the boiler and the reaching of the normal operation temperature, switch off the operation of the boiler and the pump and repeate the bleed operation.

- let the installation cool down and, if necessary, add water in order to reach the minimum presure of 0.8/1 bar.

EXAMPLE OF FILLING-UP SYSTEM MANIFOLD

Filling group

Instructions for the installer

3.23 - 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 and regulations in force for the gas part and for the electrical part;

- the air supply and the discharge of the products of combustion are carried out in the correct way in accordance to the specific Standards and regulations in force;

- the gas supply system is correctly dimensioned for the boiler’s output and is fitted with all the safety and control devices prescribed by the regulations in force;

- the electrical supply must be 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 on-off valves of the system 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 system’s safety valve on the boiler is not blocked and that it is connected to the sewage system;

- the condensate drain siphon has been filled with water;

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 lead to danger of

- there are no water leaks;

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

LIGHTING AND SHUTTING DOWN PROCEDURES For lighting and shutting down the boiler refer to the

“INSTRUCTIONS GUIDE FOR THE PERSON IN CHARGE OF THE APPLIANCE”

Information to be passed on to the user.

The usert be instructed on the use and operation of the boiler and in particular:

- Hand the booklet: “USER’S OPERATING

INSTRUCTIONS”, as well as all the other literature relative to the appliance, and placed in the envelope contained in the packaging, to the user.

The user must retain this 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 modification can be made.

- Inform theuser regarding the control of the system 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 a comprehensive service and the

measurement of thecombustion efficiency should be carried out regularly (as requested by 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.

Instructions for the installer

V I

L A

I A L L

Z Z

R R

B L

V I

L L

A Z Z U R R O

B L U

L L

Z Z

R R

B L

3.24 - 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.

A) Max output adjustment

- Connect a suitable C0

gas analyser to the sampling

point in the flue inlet/outlet terminal.

- Pressing simultaneously the keys + (plus) and – (minus) for at least 3 seconds the boiler will operate in the CH mode at the maximum output (led 1 illuminated).

B) Min output adjustment

- By pressing the key “- decrease” again the boiler will operate at the minimum output (led 1 blinking).

MAXIMUM OUTPUT ADJUSTMENT SCREW (A)

- Check that the C0

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.

- To disenable the CHIMNEY SWEEPER MODE press the keys + (increase) and – (decrease) simultaneously (led 1 off).

- Check that the C0

values are within the values indicated

in the table “Burner pressures”

Instructions for the installer

ALKON 50

20 37

1,02 m³/h 0,75 kg/h

5,13 m³/h 3,76 kg/h

48,5-9,6 48,5-9,6

9,5

11,0

95 92

26 24

5,6 5,6

9,5

11,0

40 45

FL e FH = parameter

ALKON 70

20 37

1,02 m³/h 0,75 kg/h

7,14 m³/h

5,24 kg/h

67,5-9,6 67,5-9,6

9,5

11,0

99 90

20 20

9,0 9,0

9,5

11,0

50 60

C) COMPLETION OF THE BASIC ADJUSTMENTS

- Check the C0

values at the minimum and maximum

outlet

- If necessary make the required adjustments

To ensure correct operation the C0

values have to be adjusted with extreme care respecting the values indicated in the table.

- Close the sampling test point in the flue inlet/outlet terminal with the appropriate cap C.

MINIMUM OUTPUT ADJUSTMENT SCREW (B)

Tighten the maximum adjustment screw “A” in a clockwise direction until you arrive to the abutting end, than slacken for 7 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.

- If necessary correct the value by turning the adjustment screw “B” in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrease it.

INJECTORS – PRESSURES

Nat. Gas (G20) LPG (G31)

Gas Type

Supply

pressure

(mbar)

Min.

gas

consump-

tion

Collector

Diaphragm

(Ø and n°

holes )

Heat

input

(kW)

Mixer

injectors

(Ø mm)

Flue outlet diaphragm

(Ø mm)

Fan

speed

FL (min) FH (max)

levels

(%)

min

Start

out-

put

levels

(%)

max

Max gas

consump-

tion

Gas Type

Supply

pressure

(mbar)

Min.

gas

consump-

tion

Collector

Diaphragm

(Ø and n°

holes )

Heat

input

(kW)

Mixer

injectors

(Ø mm)

Flue outlet diaphragm

(Ø mm)

Fan

speed

FL (min) FH (max)

levels

(%)

min

Start

out-

put

levels

(%)

max

Max gas

consump-

tion

Check the C0

levels often, especially at low flow rate

Instructions for the installer

The boilers are specifically produced for the type of gas requested at the ordination phase.

DANGER! The transformation of the boiler for the operation with a type of gas different than that specifically requested when the order has been placed, must be performed by professionally qualified personnel, in conformity to the norms and rules in force. The manufacturer cannot be considered responsible for any damages consequential to the transformation not correct or not performed in conformity with the norms in force or instructions given by the manufacturer.

ATTENTION! After having performed the transformation for the operation of the boiler with a type of gas, different (e.g. gas propane) than that specifically requested at the order stage. the appliance can work only with such new type of gas.

ATTENTION! Indications for appliances working on Propane Be sure that, before the installation of boiler , the reservoir of Propane has been bleeded. For a correct bleeding of the reservoir revert to supplier of the gas and, however, to trained personnel.

If the reservoir has not been properly bleeded lighting problems can rise. In such a case revert your self to the supplier of the reservoir. For the conversion of the boiler from a gas to an other one it is necessary to proceed as follows:

1. Remove the front casing

2. Set the maximum pressure adjusting screw (A.) at approximately half range and screw of a turn the minimum pressure adjusting screw (B), as shown on page 50.

3. Try to ignite the boiler: if it fails proceed unscrewing of a turn the maximum pressure adjusting screw (A) and retry the ignition. Repeat more times the operation, till the ignition of the boiler.

4. Adjust the CO

value according to the type of gas as described in the paragraph “3.24 - Adjustment of the burner.”

3.26 - ADAPTATION FOR THE USE OF OTHER GASES

3.25 - VARIATION OF OUTPUT RANGE

It is possible to adjust the maximum input by reducing the fan speed.

Modify the parameter FH from the boiler panel

board:

Factory parameter (access code) For example: ALKON 50 with parameter FH set on 72 (G 20) the correspondent maximum input will be of 34,8 kW. For example: ALKON 70 with parameter FH set on 76 (G 20) the correspondent maximum input will be of 50 kW.

Maximum imput (kW)

Output range

ALKON

R 50

100

ALKON

R 70

0 5 10 15 20

25 30 35 40 45 50 55 60 65

Parameter FH

Instructions for the installer

3.27 - PROGRAMMING OF THE OPERATING PARAMETERS

WARNING! THESE OPERA TIONS ARE ACCESSIBLE TO TRAINED INST ALLERS AND SERVICE ENGINEERS ONL Y FOR CHANGING THE P ARAMETER SETTINGS

eBUS IDENTIFICATION CODE

By pressing the YELLOW key you have access to the first adjustable parameter eBUS IDENTIFICA TION CODE (SC).

Standard setting 0

(Operation A)

By pressing the YELLOW key again the standard parameter setting is displayed.

A Z Z U R R O

L A

L L

B L U

(Operation B)

By pressing the keys + (increase) or – (decrease) a number of times the parameter can be changed.

(Operation C)

After setting the desired value pressing the YELLOW key stores this new value in the memory.

A Z Z U R R

I A L L

B L U

A Z Z U R R

I O

L A

I A L L

B L U

A Z Z U R R

L L

B L U

BURNER MODULA TION LEVEL IN IGNITION

Continue to change the parameters by pressing the – key (decrease).

The successive parameter which can be changed is: BURNER

MODULA TION LEVEL IN IGNITION (IG)

Press the YELLOW key and the LIGHT BLUE key simultaneously to enter in the service mode SE and change the values of the pre-set operating parameters.

A Z Z U R R

L A

I A L L

B L U

PUMP OVERRUN

Continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is: PUMP

OVERRUN (Po).

A Z Z U R R

V I

L A

L L

B L U

Repeat the operations A-B-C for setting the desired value from 1 to 10 minutes.

Standard setting: 5 minutes

WARNING! DO NOT CHANGE THE PARAMETER

Z U R R O

I A L L

B L

Repeat the operations A-B-C for setting the desired value from 0 to 99%.

Standard Natural Gas setting

40 % 50 %

Standard LPG setting 45 % 60 %

50 kW 70 kW

Instructions for the installer

MODULATING PUMP MINIMUM MODULA TION LEVEL

Continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is:

MODULA TING PUMP MINIMUM MODULA TION LEVEL (PL).

Repeat the operations A-B-C for setting the desired value from 0 to 99%.

Standard setting: 19 % per ALKON 50

25 % per ALKON 70

A Z Z U R R O

L A

L L

B L U

MODULA TING PUMP MODULA TING CAPACITY

Continue to change the parameters by pressing the – key (decrease). The successive parameter which can be changed is:

MODULA TING PUMP MODULA TING CAP ACITY (Pr).

A Z Z U R R

I A L L

B L U

Repeat the operations A-B-C for setting the desired value from 20 to 99%.

Standard setting: 99%

SETTING OF THE MINIMUM HEA TING TEMPERA TURE

Continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is: SETTING

OF THE MINIMUM HEA TING TEMPERATURE (HL).

A Z Z U R R

L A

L L

B L U

Repeat the operations A-B-C for setting the desired value from 20 to 60°C

Standard setting: 35°C

SETTING OF THE MAXIMUM HEATING TEMPERATURE

Continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is: SETTING

OF THE MAXIMUM HEATING TEMPERA TURE (HH

A Z Z U R R

I O L A

I A L L

B L U

Repeat the operations A-B-C for setting the desired value from 65 to 85°C

Standard setting: 80°C

A Z Z U R R

I O L A

I A L L

B L U

A Z Z U R R

I O L A

I A L L

B L U

SETTING OF THE MINIMUM DHW TEMPERA TURE (only if combined with an external storage tank)

Continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is: SETTING

OF THE MINIMUM DHW TEMPERATURE (dL).

Repeat the operations A-B-C for setting the desired value from 35 to 45°C

Standard setting: 40°C

SETTING OF THE MAXIMUM DHW TEMPERATURE (only if combined with an external storage tank)

Continue to change to the parameters by pressing the – key (decrease). The successive parameter which can be changed is: SETTING

OF THE MAXIMUM DHW TEMPERATURE (dH).

Repeat the operations A-B-C for setting the desired value from 50 to 65°C

Standard setting: 60°C.

Servicing schedule

Relationship between the temperature (°C) and the nominal resistance (Ohm) of the CH sensor and the DHW sensors.

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

TABLE OF RESISTANCE VALUES AS A FUNCTION OF THE HEATING SENSOR (SR) AND DHW (SS) TEMPERATURE SENSORS

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

At 90°C, the nominal resistance is 920 Ohm

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.

Regular attention will prolong the life of the boiler.

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

For this reason UNICAL recommends that a servicing contract should be made with our authorized After Sales Service Assistance Centre.

The boiler must have regular maintenance and cleaning in order to ensure reliable and efficient operation. Regular attention will prolong the life of the boiler.

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

INSPECTION AND SERVICING SCHEDULE

INSTRUCTIONS FOR INSPECTION AND SERVICING

To ensure a long life to all your boiler components and in order not to alter the conditions of the approved product, only

original UNICAL spare parts must be used.

Before servicing always carry out the following steps:

- Disconnect the mains electricity supply.

- Separate the appliance from the electrical supply by means of a separating device with an opening contact of at least 3 mm (for example safety devices or power switches) and ensure yourself that it cannot be accidentally reinserted.

- Close the on-off valve fitted upstream of 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 water inlet valve.

- Remove the appliance’s front panel.

After having carried out all the necessary maintenance work always follow these 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 cock.

- 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.

IMPORTANT: After having performed the maintenance of the appliance remember to reset the counter by selecting “Cr” from the parameters menù and introducing the relevant resetting code.

Servicing schedule

CLEANING THE CONDENSATE DRAIN SIPHON

SEALING GASKET BETWEEN DISTRIBUTOR AND BOILER BODY

DANGER! It is absolutely necessary to replace the gasket at any time the inspection or maintenance is made on the burner.

When refitting the mixer tighten the nuts progressively and in crossed way, by using a dynamometric wrench adjusted at 10 Nm (1 kgm).

Mixer

Gasket between mixer and boiler body.

Burner

Body

In order to check and clean the siphon carry out the following steps:

- disconnect the transparent pipe (1) check that no deposits

have accumulated inside the siphon (2).

- unscrew the plastic nuts (3) and (4) and to remove the siphon;

- Verify if there are any deposits flush them out with clean water;

- reassemble the siphon in reverse order.

Danger! Before commissioning the appliance fill the siphon via the filling hole and check the correct drainage of the condensate. If the appliance is used with the condensate drain siphon empty, the combustion adjustments could result completely wrong. Furthermore this could lead to danger of intoxication following the escape of flue gasses.

Fault finding

Code:

Description: Air in the pump (only for pump with

Sensor Logic

Corrective action: Manually bleed the air from

the circuit

Codice:

Description:

Jammed pump (only for pump with SensorLogic)

Corrective action:

After removal of the central plug of the pump body turn with a screw driver the pump rotor and replace the plug.

Code:

Description:

Failure on the pump wiring (only for pump with SensorLogic)

Corrective action:

Verify the wiring

Codice:

Description:

Insufficient water circulation

Corrective action:

Verify the installation

which could occur during boiler operation or commissioning of the boiler.

When the fault signalling led (1) is on, press the LIGHT BLUE key (2) to check the error code on the display (3).

Description: Failure of the heating return sensor (SRR)

Corrective action: Check the efficiency of the sensor and/or wiring

Description: Over high temperature detected by the heating sensor (SR) (>95°C)

Corrective action: Check the system’s water circulation

Description: Loss of flame signal during boiler operation

Corrective action: Press the reset key on the panel

FAULT FINDING

5.1 - ERROR CODES

The boiler is fitted with an integrated diagnostic readout which,

in case of malfunction, consents the immediate individuation of the type of fault directly on the control panel display

In the following fault finding table our purpose is to give some technical information regarding the solutions to any problems

A Z Z U R R

L L

B L U

Code:

Description: DHW sensor failure (only if the boiler is combined with an external storage tank)

Corrective action: Check the sensor’s efficiency and/or its wiring

Code:

Description: Mains voltage < 190 Vac

Corrective action: Check that the mains voltage is <190 V ac, if the mains voltage is correct replace the control board.

Code:

Description: Insufficient gas pressure

Corrective action: Check the pressure; if the pressure is correct check the efficiency of the gas pressure switch and/or the wiring.

Code:

Description: Difference between the heating temperature sensor (SR) and the heating return sensor (SRR) > 35°C.

Corrective action: Check the installation

Code:

Description: No flame detected during the ignition phase.

Corrective action: Press the reset key on the control panel

Fault finding

The boiler has an integrated system that, after 10.000 switching On or 2.000 hours of operation of the burner, provides to signal that the boiler needs maintenance.

Such information is indicated on the display by the lighting of the code

The flashing of the code doesn’t inhibit the normal operation of the boiler.

Service the appliance and subsequently reset the counter by selecting “Cr” from the parameters menù and introducing the relevant resetting code.

5.2 - REQUEST OF MAINTENANCE

Code:

Description: Lack of water (only for pump equipped with SensorLogic)

Corrective action: Fill-up the water circuit

Code:

Description: Main heat exchanger frozen

Corrective action: Carefully de-frost the exchanger

Code:

Description: Intervention of the high limit thermostat (TL)

Corrective action: Press the reset key on the control panel

Code:

Description: Alteration of the operating parameters caused by EMC disturbances

Corrective action: Restore the factory parameters

Code:

Description: Flame signal detected before the ignition cycle

Corrective action: Disconnect the detection electrode’s wire from the control board; if the error code disappears replace the cable, otherwise replace the control board.

Code:

Description: Flame detected after burner OFF

Corrective action: Disconnect the gas valve’s wire from the control board; if the error code disappears replace the control board, otherwise replace the gas valve.

Code:

Description: Internal failure

Corrective action: Replace the control board

Description: Heating sensor failure

Corrective action: Check the sensor’s efficiency and/or wiring

Code:

Description: Modulating fan failure

Corrective action: Check the fan’s wiring

Code:

Description: Modulating fan failure

Corrective action: Check the fan’s wiring

Fault finding

Code:

Description:

Air in the pump (only for pump with Sensor Logic

Corrective action:

Manually bleed the air from the circuit

Code:

Description:

DHW sensor failure (SS) (only if the boiler is com-

bined with an external D.H.W. tank)

Corrective action:

Check the sensor’s efficiency and/or its wiring

Description:

Jammed pump (only for pump with SensorLogic)

Corrective action:

After removal of the central plug of the pump body turn with a screw driver the pump rotor and replace the plug.

E 41

E 13

E 14

E 2

E 15

E 42

Codice:

Description:

Failure on the pump wiring (only for pump with SensorLogic)

Corrective action:

Verify the wiring

E 43

In case of fault, on the display of the regulator a blinking trian-

gle with its error code will appear

Here below you will find the E8 error codes, the relevant meaning and corrective actions.

For the error codes related to the heating system, make reference to the paragraph “Fault finding” of the “User Instruction manual” supplied with the E8.5064 heating controller.

5.3 - DISPLAY OF ERROR CODES ON HEATING CONTROLLER E8

Code:

Description:

Insufficient gas pressure

Corrective action:

Check the pressure, if the pressure is correct control the gas switch and/or its wiring.

Code: Description:

Difference between the temperature of the CH sensor (SR) and the temperature of the heating return sensor (SRR) > 35°C.

Corrective action:

Examine the system.

Code:

E 32

Description:

Mains supply < 190 Vac

Corrective action:

Check that the mains supply is < 190Vac. If the mains supply is correct replace the control board.

Code:

E 40

E 6

E 5

E 4

Description:

Failure of the heating return sensor (SRR)

Corrective action:

Check the efficiency of the sensor and/or its wiring

Description:

Bad water circulation

Corrective action:

Examine the system

Description:

Water temperature too high detected by the CH sensor (SR) (>95°C)

Corrective action:

Check adequate flow of water through boiler

Description:

Loss of flame signal during boiler operation

Corrective action:

Press the reset button on the control panel

Description:

No flame detected during the ignition phase

Corrective action:

Press the reset button on the control panel

Code:

Fault finding

Code:

Description:

Lack of water (only for pump with SensorLogic)

Corrective action:

Fill the hydraulic circuit

Code:

Description:

Flame detected before the starting of the ignition cycle

Corrective action:

Disconnect the lead of the ionisation probe from the control PCB; if the error code disappears replace the lead,otherwise replace the control PCB.

Code:

Description:

Flame detected after burner extinction

Corrective action:

Disconnect the cable of the valve gas from the control PCB; if the error code disappears to replace the cable, otherwise replace the gas valve.

Code:

Description:

Internal fault

Corrective action:

Replace the Control PCB.

Description:

Fault at the heating flow sensor (SR)

Corrective action:

Corrective action: Check the efficiency of the sensor and/or its wiring

E 8

E 11

E 20

E 10

E 12

Code:

Description:

Alteration of the operating parameters caused by EMC disturbances

Corrective action:

Restore the factory parameters

E 30

Code:

E 16

Code:

E 26

Code:

E 24

Code:

E 1

Description:

Modulating fan failure

Corrective action:

Check the fan’s wiring

Description:

Modulating fan failure

Corrective action:

Check the fan’s wiring

Description:

Main heat exchanger frozen

Corrective action:

Carefully de-frost the exchanger

Description:

Intervention of the overheat safety thermostat (TL)

Corrective action:

Press the reset key on the control panel

PIN n° 1312BQ4306

Nota: E’ possibile che alcuni prodotti descritti, non siano commercializzati.

Note: It is possible that some of the product indicated above will not be commercialised.

DICHIARAZIONE DI CONFORMITA’ /

DECLARATION OF CONFORMITY

AG s.p.a

che tutti i modelli delle gamme / that all the models of the ranges:

Sono inoltre marcate /

All these boiler ranges have the following

non appartengono a nessuna delle categorie dell’art.9 del Decreto Legislativo n. 93 del 25 febbraio 2000, in attuazione della direttiva 97/23/CE (in materia di attrezzature a pressione) e che tutti i modelli sopra citati sono completi di tutti gli organi di sicurezza e di controllo previsti dalle norme vigenti in materia e rispondono, per caratteristiche tecniche e funzionali, alle prescrizioni delle norme: / do not belong to any of the categories specified in clause 9 of the European

Directive 97/23/EC (regarding pressure equipment) and that all the a.m. models are fully equipped with all the safety and control instruments foreseen by the latest relevant regulations, and comply, with regards to the technical and operating characteristics, to the requirements stated in the following Standards and Directives:

Castel d’ Ario, 13 Gennaio / January 2009

Unical AG s.p.a.

La Unical AG s.p.a. DECLINA ogni responsabilita’ per sinistri a persone, animali o cose derivanti da manomissioni dell’apparecchio da parte di terzi non autorizzati, ovvero da un’errata installazione, od una manutenzione o riparazione carente o irregolare.

/ Unical declines any responsibility for injuries to persons, animals or to property deriving from wrong handling of the boiler by

unauthorized third parties, or by bad installation or servicing.

92/42/EEC

Direttiva Rendimenti / Boiler Efficiency Directive

90/396/EEC

Direttiva Gas / Gas Appliances Directive

2006/95/EC 2004/108/EC

Direttiva Bassa Tensione / Low Voltage Directive Direttiva Compatibilità Elettromagnetica / Electromagnetic Compatibility Directive

con sede / with headquarters in Castel d’ Ario (MN) - via Roma, 123

in qualità di azienda costruttrice di caldaie a gas a condensazione /

as gas fired condensing boiler manufacturers

DICHIARA / DECLARE

Gli apparecchi sopra menzionati hanno ottenuto i requisiti di rendimento energetico corrispondente a 4 “Stelle”, secondo la Direttiva Rendimenti 92/42/EEC, dall’Ente Omologante CERTIGAZ /

The a.m. appliances, with output up to

400 kW, have obtained the 4 stars efficiency classification, according to the Efficiency Directive 92/42/EEC, from the notified body CERTIGAZ.

Direttore Tecnico / Technical Manager

Dino Lanza

Gli apparecchi sopra menzionati hanno un rendimento termico utile,con carico pari al 100% della potenza utile nominale, maggiore o uguale a 93 + 2log Pn, (dove log Pn è il logaritmo in base 10 della potenza ulile nominale del singolo generatore, espressa in kW), come richiesto dal comma 1a dell’art. 9.

In attuazione del decreto ministeriale 18 febbraio 2007 e successive modifiche e integrazioni,attuativo della legge Finanziaria 2007

UNI EN 483

UNI EN 625 (Dove applicabile)

(Where’s applicable)

Caldaie per riscaldamento utilizzanti combustibile gassoso - Caldaie di tipo C con portata termica nominale non superiore a 70 kW / Gas-fired central heating boilers - Type C boilers of

nominal heat input not exceeding 70 kW

Caldaie a gas per riscaldamento centrale - Prescrizioni specifiche per la funzione acqua calda sanitaria delle caldaie combinate con portata termica nominale non maggiore di 70 kW

/ Gas fired central heating boilers - Specific requirements for domestic hot water operation of combination boilers of nominal heat input not exceeding 70 kW.

UNI EN 677

Caldaie di riscaldamento centrale alimentate a combustibili gassosi. Requisiti specifici per caldaie a condensazione con portata termica nominale non maggiore di 70 kW / Gas-fired

central heating boilers - Specific requirements for condensing boilers with a nominal heat input not exceeding 70 kW.

ALKON 18 R - ALKON 24 R - ALKON 24 C - ALKON 28 C ALKON 35 R - ALKON 35 C - ALKON 35S R - ALKON 35S C - ALKON 35S ELT ALKON 50 ALKON MASTER 50 - ALKON 70 ALKON CARGO 35 - ALKON CLIPPER 28

(Questo modello viene commercializzato anche con potenza termica di 34,8 kW)

AG S.P.A.

46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - fax 0376/660556

www.unical.ag - info@unical-ag.com

The Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also reserves the right to bring those changes that it will hold necessary to it own products or profits, without jeopardizing its essential characteristics.

Unical ALKON 50 kW, ALKON 70 kW Installation And Servicing Manual

Specifications and Main Features

Frequently Asked Questions

User Manual