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KONe C 28

Unical KONe C 24, KONe C 28, KONe R 24, KONe C 18, KONe R 28 Installation And Servicing Manual

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R 18 - C 18 R 24 - C 24 R 28 - C 28 R 35 - C 35
ENGLISH
INSTALLATION AND SERVICING MANUAL
http://www.unicalag.it/prodotti/domestico-50/condensazione-gas/776/kone
Provisions for proper disposal of the product.
a special recycling centre managed by the local authorities, or to a dealer who o󰀨ers this service. Separate disposal of a domestic appliance avoids possible negative consequences for the environment and human health deriving from inappropriate waste handling and allows the recovery of the materials of which it is made, in order to obtain signicant energy and resource savings.
2
Attention: this manual contains instructions for the exclusive use of the professionally qualied installer
and/or maintenance technician in compliance with current legislation.
The user is NOT qualied to intervene on the boiler.
The manufacturer will not be held liable in case of damage to persons, animals or objects resulting from failure to comply with the instructions contained in the manuals supplied with the boiler.
1 GENERAL INFORMATION .............................................................................................................................4
1.1 General warnings ....................................................................................................................................4
1.2 Symbols used in the manual ...................................................................................................................5
1.3 Appropriate use of appliance ...................................................................................................................5
1.4 Information for system manager .............................................................................................................. 5
1.5 Safety warnings ....................................................................................................................................... 6
1.6 Technical data plate ................................................................................................................................7
1.7 Water treatment .......................................................................................................................................8
1.8 Boiler antifreeze protection ...................................................................................................................... 8
2 TECHNICAL FEATURES AND DIMENSIONS ..............................................................................................9
2.1 Technical features ...................................................................................................................................9
2.2 Main components view and dimensions .................................................................................................. 9
2.3 Available ow rate / pressure diagram .................................................................................................. 12
2.4 Operation data ....................................................................................................................................... 13
2.5 General features .................................................................................................................................... 14
General information
ENGLISH
3 INSTALLATION INSTRUCTIONS ................................................................................................................ 15
3.1 General warnings ..................................................................................................................................15
3.2 Installation standards ............................................................................................................................ 15
3.3 Preventive system verication and adjustment operations ................................................................... 15
3.4 Packaging .............................................................................................................................................. 16
3.4 Positioning the boiler ............................................................................................................................. 17
3.6 Flue gas exhaust pipe connection ......................................................................................................... 18
3.7 Connections ..........................................................................................................................................21
3.8 Filling the system ................................................................................................................................... 22
3.9 Electrical connections ............................................................................................................................ 23
3.10 Commissioning ................................................................................................................................... 25
3.11 Measurement of combustion e󰀩ciency during installation ....................................................................26
3.11.1 Calibration function activation ................................................................................................... 26
3.11.2 Probes positioning .................................................................................................................... 27
3.12 Burner adjustment ................................................................................................................................. 27
3.12.1 Combustion adjustment function activation .............................................................................. 29
3.12.3 Adaptation of the power to the heating system ......................................................................... 31
4 MAINTENANCE INSTRUCTIONS ...............................................................................................................31
4.1 Inspection and maintenance instructions ..............................................................................................31
4.2 Parameters that can be edited from the control panel .......................................................................... 33
4.3 Adaptation of the power to the heating system ..................................................................................... 37
4.3.1 GAC adjustment .......................................................................................................................... 38
4.4 Important notes ..................................................................................................................................... 39
4.5 Wiring diagram ......................................................................................................................................40
4.6 Error codes ............................................................................................................................................ 41
Technical Features
Installation Instructions
Maintenance instructions
3
1
GENERAL INFORMATION
1.1 - GENERAL WARNINGS
The instruction booklet is an integral and essential part of the product and must be kept by the user.
Read the warnings contained in this instruction
booklet carefully as they provide important guidelines
regarding installation, use and maintenance safety.
Keep the booklet with care for further consultation.
Installation and maintenance must be performed in compliance with the standards in force ac­cording to the instructions of the manufacturer,
up to standard and by personnel qualied and certied in compliance with law.
Systems for the production of domestic hot wa­ter MUST be constructed entirely with compliant materials.
By professionally qualied personnel we mean: personnel with specic technical skill in the eld
of heating system components for civil use, do­mestic hot water production and maintenance.
Personnel must have the qualications provided
for by current legislation.
Incorrect installation or improper maintenance can cause damage to persons, animals or objects for which the manufacturer is not responsible.
In case of failure and/or malfunctioning of the appli-
ance, switch it o󰀨 and do not try to repair it or inter­vene on it directly. Contact only personnel qualied
in compliance with law.
Any repairs must be performed solely by personnel authorised by Unical AG S.p.A., using original spare parts only. Failure to comply with the above can
compromise the safety of the appliance and void
the warranty.
To guarantee appliance e󰀩ciency and its correct
operation, yearly maintenance must be performed
by qualied personnel.
Should you decide not to use the appliance, parts entailing potential sources of hazard must be made safe. Before commissioning an appliance that has not been used, wash the domestic hot water production
system, making the water ow until it has been fully
replaced.
Should the appliance be sold or transferred to a new
owner or if you move and leave the appliance, always
make sure that the instruction booklet accompanies it in order to be consulted by the new owner and/or installer.
Before performing any cleaning or maintenance, disconnect the appliance from the energy mains by acting on the switch of the system and/or through
the specic cut-o󰀨 devices.
Do not obstruct the terminals of the intake/exhaust ducts.
Only original accessories must be used for all appli­ances with optionals or kits (including electric).
This appliance is intended solely for the use for which it was expressly designed. Any other use is to be considered improper and therefore dangerous (*).
4
1.2 - SYMBOLS USED IN THE MANUAL
Pay special attention when reading this manual to the parts marked by the symbols:
DANGER!
Serious danger
to safety
and health
situation for the product
ATTENTION!
Possible dangerous
and the environment
DANGER!
Danger of burns!
1.3 - APPROPRIATE USE OF APPLIANCE
The boiler has been built according to the current level of engineering and acknowledged technical safety rules. Nonetheless, if improperly used, dangers could arise for the safety and life of the user and other persons or damage to the equipment or other objects.
The appliance is designed to work in heating systems, with hot water circulation, for
the production of domestic hot water. Any other use is considered improper. For any damage resulting from improper use UNICAL AG. S.p.A. assumes no respon­sibility. Use according to the intended purposes also includes strict compliance with the in­structions in this manual.
NOTE!
Tips
for the user
OBLIGATION!
wear gloves
protective
NOTE!
For further details
refer to the Technical
Information:
at the web address
indicated
on page 2
1.4 - INFORMATION PROVIDED TO THE USER
The user must be instructed concerning the use and operation of his heating system, in particular:
• Deliver these instructions to the user, as well as other documents concerning the appliance inserted in the envelope inside the packaging. The user must keep this documentation
safe for future consultation.
• Inform the user about the importance of the air vents and the ue gas exhaust system, high­lighting their essential features and the absolute prohibition of modifying them.
• Inform the user concerning controlling the system's water pressure as well as operations to
restore it.
• Inform the user concerning correct temperature control, control units/thermostats and radiators for saving energy.
• Please note that, in compliance with the standards in force, the inspection and maintenance of the appliance must be carried out in compliance with the regulations and frequency indicated
by the manufacturer.
• Should the appliance be sold or transferred to a new owner or if you move and leave the ap­pliance, always make sure that the instruction booklet accompanies it in order to be consulted by the new owner and/or installer.
The manufacturer will not be held liable in the event of damage to persons, animals or objects resulting from failure to comply with the instructions contained in this manual.
5
1.5 - SAFETY WARNINGS
ATTENTION! The boiler cannot be used by children. The boiler can be used by adults and only after having carefully read the user’s ma­nual. Children should be supervised to ensure that they do not play or tamper with the device.
ATTENTION!
The appliance must be installed, adjusted and maintained by professionally qualied
personnel, in compliance with the standards and provisions in force. Incorrect instal­lation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.
DANGER! NEVER attempt performing maintenance or repairs on the boiler on your own initiative. Any work must be done by professionally qualied personnel. We recommend stipulat­ing a maintenance contract. Insu󰀩cient or irregular maintenance can jeopardise the operating safety of the appli­ance and cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.
Changes to the parts connected to the appliance (once the appliance installation is complete)
Do not modify the following parts:
- the boiler
- the gas, air, water and electricity supply lines
- the ue gas pipe, the safety valve and the exhaust pipe
- the construction parts which a󰀨ect the operating safety of the appliance
Attention!
To tighten or loosen the screwed ttings, use only appropriate xed spanners.
Incompliant use and/or inappropriate tools can cause damage (e.g. water or gas leakage).
ATTENTION!
Indications for propane gas-red appliances
Make sure that the gas tank has been deaerated before installing the appliance.
For state-of-the-art tank venting, contact the LPG supplier or person qualied in compliance with the law requirement.
If the tank has not been professionally deaerated, ignition problems could arise. In that case, contact the supplier of the LPG tank.
Smell of gas
Should a smell of gas be perceived, follow these safety guidelines:
- do not turn electric switches on or o󰀨
- do not smoke
- do not use the telephone
- close the gas shut-o󰀨 valve
- air out the area where the gas leakage has occurred
- inform the gas supplier or a company specialised in installation and maintenance of heating
systems.
Explosive and easily ammable substances
Do not use or store explosive or easily ammable materials (e.g. petrol, paints, paper) in the
room where the appliance is installed.
DANGER! Do not use the appliance as a supporting base for objects.
In particular, do not place receptacles containing liquids (Bottles, Glasses, Jars or Detergents)
on top of the appliance. If the appliance is installed inside a housing, do not insert or rest other objects inside this housing.
6
1.6 - TECHNICAL DATA PLATE
The CE marking
certies the compliance of the equipment with the essential safety requirements dened in the directi­ves and applicable European regulations and that
its functioning satisfy applicable technical stan­dards.
The CE marking is a󰀩xed to each piece of equip­ment with an appropriate label.
KEY: 1 = CE monitoring body 2 = Type of boiler 3 = Boiler model 4 = Number of stars (directive 92/42 EEC) 5 = (S.N°) Serial Number
6 = P.I.N.ProductIdenticationNumber 7 = Typesofapproveduegasexhaustcongurations 8 = (NOx)NOxClass
The CE declaration of conformity issued in accor­dance with international standards by the manu­facturer, is placed in documentation envelope sup­plied with the product.
The technical data plate is located
inside the boiler on the back at the
bottom
A = Heatingcircuitcharacteristics
9 = (Pn) Effective nominal output 10 = (Pcond) Effective output in condensation
11= (Qn)Maximumheatoutput 12= (AdjustedQn)Adjustedforratedheatoutput 13= (PMS)Max.heatingoperatingpressure 14= (Tmax)Max.heatingtemperature
B = Domestichotwatercircuitcharacteristics 15= (Qnw)Ratedheatoutputindomestichotwaterfunction
(if different to Qn)
16= (D)SpecicD.H.W.owrateaccordingtoEN625 -EN
13203-1 19= (PMW)Max.domestichotwateroperatingpressure 20= (Tmax)Max.domestichotwatertemperature
C = Electricalcharacteristics 21= Electricalpowersupply
22 = Consumption 23 = Protection rating
General information
ENGLISH
D = Countries of destination 24 = Direct and indirect countries of destination 25 = Gas category 26 = Supply pressure
E = Factory settings 27 = Adjusted for gas type X 28 = Space for national brands
G = ErP
29=Seasonalspaceheatingenergyefciency 30 =EnergyefciencyinDHWproductionmode
7
1.7 - WATER TREATMENT
The treatment of the supply water allows to prevent inconveniences and maintain the functionality and
e󰀩ciency of the generator over time.
The ideal water pH in heating systems
must be within:
VALUE MIN MAX PH 6.5 8 Hardness [°fr] 9 15
To minimise corrosion, it is crucial to use a corrosion inhibitor; in order for it to work properly, the metal surfac­es must be clean. (see system protection ACCESSO­RIES sect. in domestic price list)
ATTENTION! ANY DAMAGE TO THE BOILER CAUSED BY THE FORMATION OF FOULING OR BY CORROSIVE WATER WILL NOT BE COVERED BY THE WARRANTY.
ATTENTION (*) see general warn­ings 1.1
The heating only models are NOT
suitable for the production of water
for human consumption according
to Ministerial Decree D.M. 174/2004.
NOTE!
Further details in the section
‘‘Technical Information’’ on the
boiler
page of the www.unicalag.it website
1.8 - BOILER ANTIFREEZE PROTECTION (*)
Make sure that E is lit up
on the display ( using B / C.
(*) The Antifreeze protection is always active. Even by disabling the heating and domestic hot water services,
in this mode (
active.
)only the antifreeze function is
P
O
S
1
2
(*) Sensor 11 par. 2.2
Power supplies 11 - SR (*) Status
Electric Gas
ON ON < 6 °C ON - Burner and Pump ON until T > 14°C ON ON < 2 °C ON Only when both the power supplies are ON:
ON OFF < 7 °C OFF - Pump ON till T > 10°C OFF ON OFF - Burner and Pump OFF OFF OFF OFF - Burner and Pump OFF
), select the mode
ANTIFREEZE FUNCTION
function
antifreeze
This protection can intervene only if the electricity and gas supplies are connected.
If one of the two is not available and
upon reset 11 (SR) a temperature of < 2
°C is detected, the appliance will behave
as described in tab. pos 2.
The heating system can be protected
e󰀨ectively from frost by using antifreeze
products with inhibitor for heating
systems (specic for multidmetal).
Do not use car engine antifreeze products as they could damage the water gaskets.
Actions
- Burner and Pump OFF until T > 5°C
- When T > 5°C then Burner and Pump ON until T > 14°C.
8
2
13
23
24
11
4
25
10
1 2
3 15 26 17 20
16
12
18
5
27
21
12
18
27
21
TECHNICAL FEATURES AND DIMENSIONS
2.1 - TECHNICAL FEATURES
Further details in the section
‘‘Technical Information’’ on the boiler
page of the www.unicalag.it website
NOTE!
2.2 - VIEW WITH THE INDICATION OF THE MAIN COMPONENTS AND DIMENSIONS
KONe 18 / 24 R KONe 18 / 24 C
25
10
11
4
24
23
(*)
13
22
5
(*)
22
ENGLISH
Technical Features
3
26
15
20
View from above
View from below
9
KONe 28 / 35 R KONe 28 / 35 C
24
27
24
12
13
15
20
27
(*)
25
10
11
18
23
22
4
4
25
5
10
5
11
8
18
(*)
8
13
23
22
12
3
3
1
2
26
15
17
20
16
View from above
View from below
10
KEY
NO. C.E. S.E. Description
1 db SS Domestic hot water temperature
sensor
2 FLS Flow switch with cold water lter
3 VG Gas valve
4 Fd E.
5 Burner
6 Combustion chamber
7 AF TF Flue gas anti-overow thermostat
8 Expansion vessel
9 FR
HT
10 HL TL Safety thermostat
11 Hb SR Heating temperature sensor
12 Ht P Pump
13 Lp DK Water deciency pressure switch
14 Boiler drain valve
15 Filling valve
16 Diverter valve
17 Plate heat exchanger
18 FL
FH
19 AFASPV Flue gas pressure switch
Ignition/detection electrode
ACC
/RIL
Heat exchanger
Fan
VM
20 Safety valve
21 Automatic by-pass
22 rb SRR Return temperature sensor
23 tf TLC Flue gas collector safety ther-
mostat
24 Aluminium Heat Exchanger/Ca-
pacitor
25 Vent valve
26 Condensation drain trap
27 SL Arrangement for condensate
sensor level
C Domestic hot water outlet G ½
G Gas inlet G ¾
F Cold water inlet G ½
M Heating system ow G ¾
R Heating system return G ¾
Rc Filling valve
Sc Boiler drain
Svs Safety valve drain
Scond
C.E. = ERROR CODES see
Condensation drain
par. 4.6
S.E. = WIRING DIAGRAM KEY
see par. 4.5
ENGLISH
Technical Features
11
2.3 - DIAGRAM OF FLOW RATE/PRESSURE AVAILABLE FOR INSTALLATION
MODULATING PUMP
DIAGRAM OF FLOW RATE/PRESSURE AVAILABLE FOR INSTALLATION
KONe 18 - 24 = 6m
Avaible Head (m.c.a.) metres of waterAvaible Head (m.c.a.) metres of water
Flow rate (l/h)
KONe 28 - 35 = 7m
12
Flow rate (l/h)
2.4 - OPERATING DATA
Fortheadjustmentdata:NOZZLES-PRESSURES-DIAPHRAGMS-FLOWRATES-CONSUMPTIONSrefertotheparagraphADAPTATIONTOOTHERTYPESOFGAS.
m
KON
Nominal heat input in CH / DHW mode kW 18,0 / 23,4 23,4 / 23,4 28,0 / 28,0 33,0 / 33,0 Minimum heat input with Nat. Gas / Propane kW 3,0 / 4,4 3,0 / 4,4 4,4 / 5,6 4,4 / 5,6 Nominal heat output kW 17,4 22,6 27,2 32,0 Minimum heat output kW 2,9 2,9 4,3 4,3 Nominal output in condensation 50/30 °C kW 18,4 23,6 28,9 33,8 Minimum heat output in condensation 50/30 °C kW 3,2 3,2 4,67 4,67
Combustion e󰀩ciency at full load % 97,6 97,2 97,6 97,26 Combustion e󰀩ciency at part load % 98,6 98,6 98,1 98,1
Heat losses through the casing (min.-max.) % 2,0 - 0,67 2,0 - 0,6 1,47 - 0,43 1,47 - 0,2
(*) Net ue gas temperature tf-ta (max.) °C 49,0 57,4 47,9 57,0 Flue gas mass ow rate (min.-max) g/s 1,35 - 8,1 1,35 - 10,5 2 - 12,5 2 - 14,7 Air excess λ % 24,3 24,3 23,0 23,0
CO
2
CO at 0% of O
(min. - max) ppm 22 - 95 22 - 114 11 - 93 11 - 120
2
% 9,2 - 9,2 9,2 - 9,2 9,3 - 9,3 9,3 - 9,3
Maximum production of condensate kg/h 2,9 3,8 4,5 5,3 NOx class 6 6 6 6 Chimney heat losses with burner ON (min. - max.) % 1,4 - 2,4 1,4 - 2,9 1,9 - 2,4 1,9 - 2,8 Chimney heat losses with burner OFF % 0,60 0,46 0,41 0,34
Prevalenza disponibile alla base del camino min. / max.
Pa 2 / 70 2 / 70 2 / 70 2 / 70
Notes: (*) Room Temperature = 20°C Data obtained with appliance operated with Nat Gas (G20)
R 18 / C 18 R 24 / C 24 R 28 / C 28 R 35 / C 35
ENGLISH
2.4.1 - DATA ACCORDING TO ErP DIRECTIVE
Description Symbol Unit KONe R18 C18 R24 C24 R28 C28 R35 C35
Nominal Heat Output Pnominal kW 17 23 27 32 Seasonal space heating energy
e󰀩ciency
Seasonal e󰀩ciency class in
heating mode
For CH only and combination boilers: useful heat output
Useful Heat Output in high-tempera­ture regime (Tr 60 °C / Tm 80 °C)
Useful e󰀩ciency at nom. heat output
in high-temperature regime (Tr 60 °C / Tm 80 °C
Useful heat output at 30% of nom. heat output in low-temperature regime (Tr 30 °C)
Useful e󰀩ciency at 30% of nom. heat
output in low-temperature regime (Tr 30 °C)
Range-rated boiler: YES / NO YES YES YES YES Auxiliary electricity consumption At full load elmax kW 0,085 0,085 0,116 0,116 At part load elmin kW 0,012 0,012 0,012 0,012 In stand-by mode P
Other items
Dispersione termica in stand-by P Emissions of nitrogen oxides ref. PCI (PCS) NOx Mg/kWh 37 (33) 50 (45) 55 (50) 43 (39) Annual electricity consumption Q
For CH & DHW production boilers
Declared load prole - XL - XL - XL - XL Energy e󰀩ciency in DHW production mode ƞ
Daily electricity consumption Qelec kWh - 0,09 - 0,09 - 0,09 - 0,09 Daily fuel consumptionl Qfuel kWh - 22,07 - 22,07 - 23,05 ­Inside sound power level Lwa dB (A) - 50,7 - 51 - 55,2 - 55,2 Annual electricity consumption AEC kWh 400 400 402 402 Annual fuel consumption AFC GJ 17 17 17 18
Seasonal e󰀩ciency class
in DHW production mode
s % 93 92 93 93
ƞ
A A A A
4 kW 10,3 12,7 15,8 18,2
P
4 % 88,1 87,0 88,4 87,5
ƞ
1 kW 3,4 4,2 5,3 6,1
P
ƞ
1 % 97,8 96,7 97,5 97,5
SB kW 0,003 0,003 0,003 0,003
stb kW 0,0824 0,0824 0,1136 0,1136
HE GJ 32 40 49 56
wh % - 86 - 86 - 85 - 85
- A - A - A - A
23,13
Technical Features
13
2.5 - GENERAL FEATURES
e
KON
Appliance category Minimum heat. circuit output (∆t 20 °C) l/min Minimum heating circuit pressure bar Maximum heating circuit pressure bar Primary circuit content l Maximum operating temperature in heat. °C Minimum operating temperature in heat. °C
Expansion vessel total capacity l Expansion vessel pre-load bar
Maximum system capacity (max temp. calc.) l Minimum domestic hot water circuit ow rate l/min.
Minimum domestic hot water circuit pressure bar Maximum domestic hot water circuit pressure bar
Domestic hot water specic ow rate (∆t 30 °C) ‘‘D’’ l/min. Production of D.H.W. in continuous operation with ∆t 45 K Production of D.H.W. in continuous operation with ∆t 40 K Production of D.H.W. in continuous operation with ∆t 35 K Production of D.H.W. in continuous operation with ∆t 30 K Production of D.H.W. in continuous operation with ∆t 25 K (*)
l/min. l/min. l/min. l/min.
l/min. Adjustable DHW temperature °C Voltage/Frequency electric power supply V-Hz Fuse on the power supply A (F) Protection rating IP Net weight kg Gross weight kg
F Factor - 1 - 1 - 2 - 2 R Factor - - - -
(*) mixed
R 18 C 18 R 24 C 24 R 28 C 28 R 35 C35
2H3P
II
1,2 1,2 1,7 1,7
0,5 0,5 0,5 0,5
3 3 3 3
2,2 2,2 2,2 2,2
85 85 85 85
30 30 30 30
8 8 10 10
1 1 1 1
164 164 205 205
- 2 - 2 - 2 - 2
- 0,5 - 0,5 - 0,5 - 0,5
- 6 - 6 - 6 - 6
- 11,2 - 11,2 - 13 - 16
- 7,4 - 7,4 - 8,6 - 10,1
- 8,3 - 8,3 - 9,7 - 11,4
- 9,5 - 9,5 - 11,1 - 13,0
- 11,0 - 11,0 - 12,9 - 15,2
- 13,3 - 13,3 - 15,5 - 18,3
-
35-60
230/50 230/50 230/50 230/50
3,15 3,15 3,15 3,15
X5D X5D X5D X5D
32,5 34 32,5 34 35,5 37 35,5 37
35,5 37 35,5 37 38,5 40 38,5 40
2H3P
II
-
35-60
2H3P
II
-
35-60
2H3P
II
-
35-60
14
3
INSTALLATION INSTRUCTIONS
3.1 - GENERAL WARNINGS
ATTENTION!
This boiler is intended solely for the use for which it was expressly designed. Any other use is to be considered improper and therefore dangerous.
This boiler heats water at a temper­ature lower than the atmospheric pressure boiling temperature.
Before connecting the boiler, have pro­fessionally qualied personnel:
a) Thoroughly wash all the piping of
the system to remove any residues or impurities which could jeopard­ise proper operation of the boiler, even from a hygienic point of view.
b) Check that boiler is set up to oper-
ate with the available type of fuel. This can be seen written on the package and on the technical feature plate;
ATTENTION! If there is dust and/or if there are aggressive/corrosive vapours present in the installation room, the appliance must be protected suitably and must be able to operate independently from the air in the room.
ENGLISH
ATTENTION! Only mount the appliance on a closed
wall, made of non-ammable materi-
al, at, vertical so that the minimum
distances required for installation and
maintenance can be observed.
The boiler must be connected to a cen­tral heating system and/or domestic hot water supply network compatible with its
e󰀩ciency and output.
c) Check that the chimney/ue has an
appropriate draught, without any bottlenecks, and that no exhausts from other appliances are inserted,
unless the ue has been implement­ed to accommodate several utilities according to specic standards and
regulations in force. Only after this check can the fitting between the
boiler and chimney/ue be mounted;
3.2 - INSTALLATION STANDARDS
It must be installed by a professionally qualied
technician, who shall take the responsibility of
observing all local and/or national laws published
in the o󰀩cial journal, as well as the applicable
technical standards.
NOTE!
Further details in the section
‘‘Technical Information’’ on the boiler page of
the www.unicalag.it website
Installation Instructions
NOTE! For further details relating to the standards, rules and regulations for safe installation of the thermal unit, refer to the section "Technical Information" on the boiler page of the www.unicalag.it website
3.3 - PREVENTIVE VERIFICATION AND VERIFICATION AND AD­JUSTMENT OPERATIONS
NOTE!
Further details in the section
‘‘Technical Information’’ on the boiler page of the
www.unicalag.it website
15
H
P
L
3.4 - PACKAGING
The boiler is supplied completely assembled in a sturdy cardboard box.
After having removed the appliance from
the packaging, make sure that the supply is complete and undamaged.
The packaging elements (cardboard box, straps, plastic bags, etc.) must be
kept out of the reach of children as
they are potential sources of danger. Unical AG S.p.A. will not be held liable
for damage to persons, animals or ob-
jects due to failure to comply with the
instruction above.
OBLIGATION! wear protective gloves
• The boilers must always be lifted and carried by two people, or a carrier carriage or special transport equip­ment must be used.
As well as the appliance, the packaging contains:
A DOCUMENTATION ENVELOPE
- System booklet
- User operating instructions booklet
- Instruction booklet for the installer and maintenance engineer
- Warranty
- 2 Spare parts form
- Certicate of conformity
B - Connection predisposition paper template
C - Chimney spacer
21
P depth
380 mm 470 mm 810 mm
L width
H height
16
3.5 - POSITIONING THE BOILER
When choosing the place of the installation of the appliance, follow the safety instructions below:
- Place the appliance in rooms protected from frost.
- Avoid installation in rooms with a corrosive or very
dusty atmosphere.
- The appliance must only be installed on a vertical
and solid wall which can support its weight.
- The wall must not be made of ammable material.
e
KON
Since the temperature of the wall on which the boil­er is installed and the temperature of the coaxial exhaust pipe do not exceed, in normal operating conditions, a room temperature beyond 60 K, it is
not necessary to observe the minimum distances from ammable walls.
For boilers with double intake and exhaust pipes, in
the event of crossing ammable walls, insert insula­tion between the wall and the ue gas exhaust pipe.
Clearance
ENGLISH
KONe 24 C
KONe 35 C
Installation Instructions
17
3.6 - FLUE GAS EXHAUST PIPE CONNECTION
FOR BOILERS WITH FORCED DRAUGHT
To connect the ue gas exhaust pipe, local and na­tional standards must be observed
In the event the boiler is replaced, ALWAYS re-
C13x C13
% Slope towards inlet = 3%
TOTAL LENGTH (LA intake + L Exhaust)
COAXIAL Ø60/100 DOUBLE Ø80
FROM [m] TO [m] FROM [m] TO [m]
1 5,5 1 + 1
COAXIAL Ø80/125 DOUBLE Ø60
FROM [m] TO [m] FROM [m] TO [m]
1 8 1 + 1
Distance between air
inlet pipe and ue gas
exhaust pipe: min 250 mm - max 500
Horizontal exhaust and intake terminals directed outside via coaxial or double pipes..
40
(20A+20S)
20
(10A+10S)
place the ue gas pipe as well.
The boiler is type approved for the exhaust congu­rations listed below:
C43x C43
Collective chimney ue system, consisting of two pipes, one for combustion air intake and the other
one for combustion products evacuation, coaxial
or double.
C53x C53
C33x C33
TOTAL LENGTH (LA intake + L Exhaust)
COAXIAL Ø60/100 DOUBLE Ø80
FROM [m] TO [m] FROM [m] TO [m]
1 7 0,5 + 0,5
COAXIAL Ø80/125 DOUBLE Ø60
FROM [m] TO [m] FROM [m] TO [m]
1 9 1 + 1
ertical exhaust and intake terminals directed out-
side via coaxial or double pipes.
18
40
(20A+20S)
20
(10A+10S)
C53
NOT ALLOWED C53
TOTAL LENGTH (LA intake + L Exhaust)
DOUBLE Ø80 DOUBLE Ø60
FROM [m] TO [m] FROM [m] TOA [m]
1 + 1
Separate combustion air intake and combustion
products evacuation pipes. These pipes can discharge into areas with di󰀨erent
pressure.
40
(max 30 S)
1 + 1
(max 15 S)
20
C63x C63
Boiler intended for connection to a combustion air
intake and combustion products evacuation system, approved and sold separately
ATTENTION: The ue must comply with standards
in force.
C83x C83
Connection to a terminal for combustion air intake
and ue gas exhaust via a single or collective
chimney.
B23P
TOTAL LENGTH (LS)
DOUBLE Ø80
FROM [m] TO [m]
1 30
Connection to a combustion products evacuation
pipe outside the room; the combustion air is tak­en directly from the room where the appliance is installed.
ATTENTION:
For the type of connection B23P the room follows the same installation rules for boilers with natural draught.
ENGLISH
C93x C93
Air / ue gas through concentric pipes in the boiler
room and single pipes in the chimney (combustion air with counterlow in the chimney)
CAUTION LT total length is a reference value
for the dimensioning of the ducts of A (intake) and S (Exhaust). Subtracting
the values of LT reported, at values of
bends* / terminals* / extensions* you
get the value:
if > 0 = OK - POSSIBLE conguration if < 0 = NO - WRONG conguration
Installation Instructions
(*) Values in the MT018 available on the website.
Please note: these values relate to exhausts/made by means of rigid pipes and smooth original UNICAL.
19
GENERAL INFORMATION ON THE FLUE GAS EXHAUST SYSTEM
Attention:
For all drain congurations
mount the chimney
spacer supplied with the boiler
NOTE! For further details relating to pres­sure drops of the individual compo­nents, for information on standards,
rules and regulations for proper ue
gas exhaust, refer to the “Technical Information” section on the boiler page of the www.unicalag.it website
Concentric start
Rubber closure plugs
(DO NOT REMOVE)
20
It is recommended to only use original Unical exhaust pipes. The supplier will have no contractual or extra-contractual liability for damage caused due to incorrect installation and use and in any case failure to comply with the instructions provided by the manufacturer.
Adapter for double systems
3.7 - CONNECTION
G GAS 3/4’’
Danger!
The gas connection must be carried out
only by a qualied installer who must re­spect and apply that foreseen by relevant
laws in force in the local prescriptions of the supply company. Incorrect installation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.
If you smell gas:
a) Do not operate electric switches, the telephone or any other object that may cause sparks; b) Immediately open doors and windows to create air current to purify the room; c) Shut the gas cocks.
M FLOW 3/4’’ R RETURN 3/4’’
Condensation drain
The boiler, during the combustion process, pro-
duces condensation that, through pipe “A”, ows
into the trap.
The condensation that forms inside the boiler ows into a suitable drain via pipe “B”.
Danger! Before commissioning the boiler
- check that the trap is assembled properly
- check the trap and that the conden­sation is drained properly If the appliance is used with an empty condensation drain trap, there is an intoxication hazard due to the release of exhaust gasses.
ENGLISH
C HOT 1/2’’ F COLD 1/2’’
Sc BOILER DRAIN S.cond CONDENSATION DRAIN Rc FILLING VALVE Svs SAFETY VALVE DRAIN
Provide a drain pipe with funnel and a
trap that lead to a suitable drain, in cor-
respondence of Svs.
This drainage must be controlled on sight.
If this precaution is not taken, trigger­ing of the safety valve can cause dam­age to persons, animals and objects, for which the manufacturer cannot be held responsible.
The mains pressure must be within 1 and 3
bar (in the event of greater pressure install
a pressure reducer).
Installation Instructions
Condensation outlet, pipe to be connected to the drainage system
21
The connection between the appliance and the domestic waste system must
be made in compliance with the specic
reference standards.
NOTE!
Further details in the section
‘‘Technical Information’’ on the
boiler page of the Unical AG S.p.A.
website.
3.8 - FILLING THE SYSTEM
Attention! Do not mix the heating water with in­correct concentrations of antifreeze or anti-corrosion substances! This could
damage the gaskets and cause noise
during operation. La Unical AG S.p.A. will not be held liable for damage to persons, animals or objects due to failure to comply with the above instruction.
When the system connections have been completed, the circuit can be lled.
This operation must be performed carefully, respect­ing the following phases:
- open the radiator vent valves and make sure the automatic valve is working properly in the boiler.
- open the lling tap gradually, making sure that the automatic air release valves installed on the
system work properly.
- close the radiator air release valves as soon as
water comes out.
- check the pressure gauge until pressure reaches approximately 0.8/1 bar.
- close the lling tap and bleed air once again through the radiator air release valves.
22
Danger of burns!
Attention to contact with ow pipe M
and (if boiler combi) with hot water outlet pipe C.
- make sure that all the connections are watertight.
- after commissioning the boiler (see par. 3.10) and bringing the system to the operating temperature, stop the boiler and repeat the air bleed operations.
- let the system cool down and, if necessary, return the water pressure to 0.8/1 bar.
(See par. 4.4).
A3
4
3 2 1
6
5
SE
TA 1/OT TA 2
WH
WH
Y
Y
BK
BK
TA
ON-OFF
3.9 - ELECTRICAL CONNECTIONS
Danger! Only a qualied technician may per­form the electrical installation. Before performing connections or
any type of operation on electrical parts, always
disconnect electrical power and make sure that
it cannot be reconnected accidentally.
ENGLISH
ON/OFF room thermostat connection (*)
- Remove the jumper and connect the room ther­mostat wires between terminals TA 2.
ON/OFF room thermostat connection RT/OT (*)
Installation Instructions
- Connect the modulating thermostat wire between
terminals TA1/OT after having removed the jumper.
23
- Predisposed on the terminal board, terminals
SE
Electric power supply connectionExternal probe connection (*)
See par. 4.5 positioning on the board
(*) Optional
The boiler is equipped with a power cable, boiler installation requires electric al con-
nection to the mains power supply. This connection must be made up to standard,
as required the regulations in force.
Remember that a bipolar switch must be
nstalled on the boiler power line with over
3 mm between contacts, easy to access,
making maintenance quick and safe.
The power cable must be replaced by technical personnel authorised by UNI- CAL AG S.p.A., using original spare parts
only. Failure to comply with the above can
jeopardise the safety of the appliance.
NOTE!
Further details in the section
‘‘Technical Information’’ on the boiler page of
the www.unicalag.it website
24
3.10 - COMMISSIONING
Commissioning must be done by profes-
sionally qualied personnel. Unical AG
S.p.A. will not be held liable for damage to persons, animals or objects due to fail-
ure to comply with the above instruction.
does the installation meet the specic standards and regulations in force, both relating to the
gas part as well as the electrical part?
do the combustion air intake and ue gas exhaust take place properly according to what is dened by the specic rules and regulations in force?
is the fuel supply system sized according to the capacity required by the boiler? Is it equipped with all safety and control devices required by the standards in force?
is the power supply of the boiler 230V - 50Hz?
has the system been lled with water (approximately 0.8/1 bar pressure on the pressure gauge
with the pump stopped)?
Has the condensation drain trap been lled with water as indicated in chapter 3.7?
are any system shut-o󰀨 gate valves open?
Before commissioning the boiler, check that:
ENGLISH
does the gas to be used correspond to the boiler calibration gas?: otherwise, perform the boiler
conversion in order to use the gas available (see section: 4.3”); this operation must be carried out by technical sta󰀨 qualied in compliance with the standards in force;
is the gas supply valve open?
has the system been checked for gas leaks?
is the outside main switch ON?
is the system safety valve e󰀩cient and is it connected to the drains?
is the condensation drain trap connected to the drains?
has the system been checked for water leaks?
are the ventilation conditions and minimum distances to perform any maintenance
ensured?
have the GAS, HEATING and DOMESTIC HOT WATER pipes been cleaned thoroughly with
products suitable for each circuit?
has a surveillance and protection system against gas leaks been installed? (Optional)
are the system pipes NOT used as the electrical system earthing?
Installation Instructions
has the system been sized properly bearing in mind the radiator pressure drops?
thermostatic valves, radiator stop valves
has the operator been trained and has the documentation been supplied?
Please tick the operations performed
Switching boiler on and off
NOTE!
Further details in the section
‘‘Technical Information’’ on the boiler
page of the unicalag.ag website
25
3.11 - MEASUREMENT OF COMBUSTION EFFICIENCY DURING INSTALLATION
3.11.1- ACTIVATION OF THE CALIBRATION FUNCTION
ATTENTION! Function reserved for Authorised Assistance Centres only.
1 ACTIVATION
Press the key (D) for at least 5 seconds, until
SErvice appears.
The user is NOT authorised to activate the func­tion described below.
3 MINIMUM OUTPUT
Press the key (C-), when the low ame symbol is xed on the display.
All the symbols ash on the display.
2 MAXIMUM OUTPUT
When the high ame symbol is xed on the display
and it alternates between SP and the ow temper- ature, the boiler operates at maximum output. Perform combustion analyses.
and it alternates between SP and the ow tem- perature, the boiler operates at minimum output. Perform combustion analyses.
4 DISABLING
The “calibration” function stays active for 15 min­utes.
To disable the CALIBRATION function before the time elapses press the key (D) for 5 seconds, until
SErvice
disappears.
26
3.11.2 - POSITIONING THE PROBES
To determine the combustion e󰀩ciency one must
make the following measurements:
- measurement of the combustion air temperature
taken in the relevant hole 1.
- measurement of the ue gas temperature and
content of CO2 taken in the relevant hole 2.
COAXIAL PIPES
A
SEPARATE PIPES
B
2
1
Air probe
NOTE:
Do not insert the analyser probe in the sample point immediately, in order to
prevent saturating the analyser.
Flue gas probe
Flue gas probe
Take the measurements with the generator in
steady state conditions (see par. 3.11.1).
PIPES Ø 80 TYPE B23
C
1
1
2
Air probe
Flue gas probe
It is important to perform the combustion analysis on the combustion air as well, (Making sure that the concentration of oxygen is within O2 = 20.8% tolerance 0.2 - 0.4 %). This is to prevent any ue gas recircu­lation.
2
ENGLISH
Air probe
3.12 - ADJUSTING THE BURNER
In order for the boiler to work properly
the content of CO
must comply with
2
the tolerance eld of the table below.
PRESSURE - FLOW RATE TABLE
E󰀨ective
Ouput
[kW]
E󰀨ective
Ouput
[kW]
Heating
Thermal
[kW]
Capacity
Heating
Thermal
[kW]
Capacity
Supply Press. [mbar]
Supply Press. [mbar]
Fan
speed
[rpm]
min max min max min max
Fan
speed
[rpm]
min max min max min max
Collector
diaphragm
[Ø/n.
holes]
Collector
diaphragm
[Ø/n.
holes]
CO2 levels
[%]
CO2 levels
[%]
Con-
sumption
Con-
sumption
Con-
sumption
Con-
sumption
Start-up
power
IG [%]
Start-up
power
IG [%]
KONe R 18 - KONe C 18
Type of
Gas
Gas nat. (G20) 2,9 - 17,4 3,0 - 18 20 - - - 9,2 9,2 0,32 m³/h 1,9 m³/h -
Gas nat. (G25) 2,9 - 17,4 3,0 - 18 25 - - - 9,2 9,2 0,37 m³/h 2,21 m³/h -
Propane (G31) 2,9 - 17,4 3,0 - 18 37 - - - 10,5 10,5 0,23 kg/h 1,4 kg/h -
A.P. (G230) 2,9 - 17,4 3,0 - 18 20 - - - 9,6 9,0 0,32 m³/h 1,78 m³/h
(*) ± 0,2 Acceptable range for G20 / G25 (+) ± 0,2 Acceptable range for G31 / G230
KONe R 24 - KONe C 24
Type of
Gas
Gas nat. (G20) 2,9 - 22,6 3,0 - 23,4 20 - - - 9,2 9,2 0,32 m³/h 2,48 m³/h -
Gas nat. (G25) 2,9 - 22,6 3,0 - 23,4 25 - - - 9,2 9,2 0,37 m³/h 2,88 m³/h -
Propane (G31) 2,9 - 22,6 3,0 - 23,4 37 - - - 10,5 10,5 0,34 kg/h 1,82 kg/h -
A.P. (G230) 2,9 - 22,6 3,0 - 23,4 20 - - - 9,6 9,0 0,32 m³/h 1,82 m³/h
(*) ± 0,2 Acceptable range for G20 / G25 (+) ± 0,2 Acceptable range for G31 / G230
Installation Instructions
27
Ouput
[kW]
Heating
Thermal
[kW]
Capacity
Sup-
ply Press. [mbar]
Fan
speed
[rpm]
min max min max min max
Collector
diaphragm
[Ø/n.
holes]
CO2 levels
[%]
Con-
sumption
Con-
sumption
Start-up
power
IG [%]
KONe R 28 - KONe C 28
Type of
Gas
Gas nat. (G20) 4,3 - 27,2 4,4 - 28,0 20 - - - 9,3 9,3 0,47 m³/h 2,96 m³/h -
Gas nat. (G25) 4,3 - 27,2 4,4 - 28,0 25 - - - 9,3 9,3 0,54 m³/h 4,06 m³/h -
Propano (G31) 5,5 - 27,2 5,6 - 28,0 37 - - - 10,5 10,5 0,43 kg/h 2,17 kg/h -
A.P. (G230) 4,3 - 27,2 4,4 - 28,0 20 - - - 9,6 9,0 0,34 m³/h 2,18 m³/h
(*) ± 0,2 Acceptable range for G20 / G25 (+) ± 0,2 R Acceptable range for G31 / G230
E󰀨ective
E󰀨ective
Ouput
[kW]
Heating
Thermal
[kW]
Capacity
Supply Press. [mbar]
Fan
speed
[rpm]
min max min max min max
Collector
diaphragm
[Ø/n.
holes]
CO2 levels
[%]
Con-
sumption
Con-
sumption
KONe R 35 - KONe C 35
Type of
Gas
Gas nat. (G20) 4,3 - 32,0 4,4 - 33,0 20 - - - 9,3 9,3 0,47 m³/h 3,49 m³/h -
Gas nat. (G25) 4,3 - 32,0 4,4 - 33,0 25 - - - 9,3 9,3 0,54 m³/h 4,06 m³/h -
Propano (G31) 5,5 - 32,0 5,6 - 33,0 37 - - - 10,5 10,5 0,43 kg/h 2,56 kg/h -
A.P. (G230) 4,3 - 32,0 4,4 - 33,0 20 - - - 9,6 9,0 0,34 m³/h 2,57 m³/h
(*) ± 0,2 Acceptable range for G20 / G25 (+) ± 0,2 Acceptable range for G31 / G230
Note: for operation with Propane air (A.P.) follow the procedure to adapt to another gas at Par.
4.3 setting the parameter for operation with Propane (1) and follow the GAC Automatic Cali­bration procedure in Par. 4.3.1.
If the CO2 value detected is beyond the recommended range, check the integrity of the electrode. If needed, replace the electrode.
If the problem persists one can use the function described below.
INCONVENIENCES SOLUTIONS
KONe 18 - 24 - 28 - 35
Flame noisy in cold ignition
Flame noisy in steady-state conditions
Flame noisy in modulation
Act on parameter ‘’IG’’ using the RCh section ‘’TECHNICAL MENU’’ TSP parameters increasing the value by 5 ÷ 10 % max
e
KON
18 - 24 KONe 28 - 35
increase the CO
- max value for methane gas = 9.4 % (min value > 9.0 %)
- max value for propane = 10.7 % (min value > 10.3 %)
- max value for A.P. = 9,2 % (min value > 9.4 %)
value
2
increase the CO2 value
- max value for methane gas = 9.5 % (min value > 9.1 %)
- max value for propane = 10.7 % (min value > 10.3 %)
- max value for A.P. = 9,2 % (min value > 9.4 %)
Start-up
power
IG [%]
28
3.12.1 - COMBUSTION ADJUSTMENT FUNCTION ACTIVATION
This function allows a partial adjustment of the CO2 value on the following modulation points: Maximum output 100 % Start-up output xx % Minimum output 0 %
1 ACTIVATION
Press the keys (B- and B+) at the same time for
at least 10 seconds, SErvice APPEARS.
MINIMUM OUTPUT
When the display alternates CO - 0
SELECTION
2
ENGLISH
CO ...scrolls on the display
MAXIMUM OUTPUT
When the display alternates CO - 100
START-UP OUTPUT
Select the modulation point on which to perform the adjustment, (max output / start-up output / min output) with key B+
Press key S
3
EDITING THE VALUE
When the ame ashes, correct the value with
keys C- or C+
VALUES
FROM TO DEFAULT
-3 *
+3 *
(*) corresponds to about ± 0.5 points of CO
4 CONFIRM VALUE
4
Press key D
0
2
Installation Instructions
When the display alternates CO - with value XX.
The ame is xed
again.
DISABLING
5
Press the keys (B- and B+) at the same time for
at least 10 seconds, SErvice DISAPPEARS.
29
3.12.3 - ADAPTATION OF THE POWER TO THE HEATING SYSTEM
ATTENTION! Function reserved for Authorised Assistance Centres only.
It is possible to adjust the maximum thermal capacity in heating mode, by decreasing the burner pressure
value.
E.g.: KONe 24 to decrease the output of the boiler to 18 kW, edit parameter
HP (about 70)
E.g.: KONe 28 to decrease the output of the boiler to 20 kW, edit parameter
HP (about 65)
E.g.: KONe 35 to decrease the output of the boiler to 24 kW, edit parameter
HP (about 68)
.
.
.
The user is NOT authorised to activate the func­tion described below.
Act on parameter HP (par. 4.2 SE parameters list)
to achieve the value corresponding to the desired
output.
30
4
INSPECTIONS AND MAINTENANCE
Inspections and maintenance performed professionally and according to a regular schedule, as well as the use of original spare parts, are of the utmost importance for fault-free operation of the boiler and to guarantee its long life. Yearly maintenance of the appliance is mandatory in compliance with Laws in force.
4.1 - INSPECTION AND MAINTENANCE INSTRUCTIONS
To assure long-term functioning of your appliance
and to avoid altering its approved status, only original
Unical AG S.p.A. spare parts must be used.
If a component needs to be replaced:
• Disconnect the appliance from the electrical mains
and make sure that it cannot be reconnected accidentally.
• Close the gas shut-o󰀨 valve upstream the boiler.
• If needed, and depending on the intervention to be carried out, close any shut-o󰀨 valves on the ow and return line of the heating system, as well
Failure to perform Inspections and Main­tenance can entail material and personal damage.
ENGLISH
as the cold water inlet valve.
• Remove the front casing from the appliance.
Once all maintenance operations are complete resume boiler operation
• Open the heating ow and return pipes, as well as the cold water inlet valve (if closed previously).
• Vent and, if necessary, restore the heating pres-
sure until reaching a pressure of 0.8/1.0 bar.
• Open the gas shut-o󰀨 valve.
• Switch the boiler back on.
• Make sure the appliance is gas tight and water-
tight.
• Remount the front casing of the appliance.
TABLE OF RESISTANCE VALUES, ACCORDING TO THE TEMPERATURE, TO THE HEATING PROBE 11 (SR) AND TO THE DOMESTIC HOT WATER PROBE 1 (SS) AND ANY HEATING RETURN PROBE 22 (SRR) see par. 4.5.
T°C 0 1 2 3 4 5 6 7 8 9
0 32755 31137 29607 28161 26795 25502 24278 23121 22025 20987
10 20003 19072 18189 17351 16557 15803 15088 14410 13765 13153
20 12571 12019 11493 10994 10519 10067 9636 9227 8837 8466
30 8112 7775 7454 7147 6855 6577 6311 6057 5815 5584
40 5363 5152 4951 4758 4574 4398 4230 4069 3915 3768
50 3627 3491 3362 3238 3119 3006 2897 2792 2692 2596
60 2504 2415 2330 2249 2171 2096 2023 1954 1888 1824
70 1762 1703 1646 1592 1539 1488 1440 1393 1348 1304
80 1263 1222 1183 1146 1110 1075 1042 1010 979 949
90 920 892 865 839 814 790 766 744 722 701
Relation between the temperature (°C) and the nom. resistance (Ohm) of the heating probe SR and of the domestic hot water probe SS
Example: At 25°C, the nominal resistance is 10067 Ohm At 90°C,the nominal resistance is 920 Ohm
Maintenance instructions
31
ROUTINE YEARLY VERIFICATION OPERATIONS
COMPONENT: VERIFY: CONTROL/INTERVENTION
METHOD:
FL (domestic hot water
Is the minimum domestic hot water
ow rate 3 l/min.?
The burner must ignite with an
intake above or equal to: 3 l/min.
priority ow switch ( 2 )
VG
(Gas valve) ( 3 )
SR (heating sensor)( 11 ) SS (domestic hot water sensor)
( 1 )
SSR (return sensor) ( 22 )
E ACC/RIV. (ignition/detection electrode) ( 4 )
TL (anti-overheating
limit thermostat) ( 10 )
DK (safety pressure switch
against water deciency) ( 13 )
Does the valve modulate properly? Open a hot water tap at maxi-
mum ow rate and then at min­imum. Make sure that the ame
modulates.
Do the sensors maintain the original characteristics?
12571 ohm at 20° C / 1762 ohm at 70° C. Measurement to be taken with the wires disconnected (see table Res/Temp).
Does the discharge of sparks before putting the boiler in safe conditions last less than 10 sec.?
Does the TL put the boiler in safety
conditions when overheating?
Detach the electrode ionisation wire and check the securing time.
Heat the TL until it intervenes
at 95°C and check that it inter-
venes at 95°.
Does the pressure switch block the boiler if the water pressure is below
0.4 bar?
Without request: close the shut­o󰀨 valves of the heating circuit, open the drain valve to make the
water pressure decrease. Be­fore pressurising again, check the pressure of the expansion
vessel.
Expansion vessel ( 8 ) Does the vessel contain the right
amount of air?
Check the pressure in expen-
sion vessel (1 bar when the
boiler is empty). Pressurise the boiler (open the pump automatic
vent valve). Open the heating circuit closing valves.
Condensation drain trap (27) Has the trap got deposits on the
Clean the trap with water.
bottom?
Domestic hot water ow rate Filter in cold water inlet ( 2 ) Clean the lter with limescale
remover.
Heat exchanger body ( 9 ) 1) Measure the Thermal Capacity
using a meter and compare the val­ue with that contained in table 3.12. The data measured indicates if the exchanger needs cleaning.
It is recommended to use prod­ucts purposely created by Uni­cal AG S.p.A. (see system protection ACCESSORIES sect. in the domestic price list), being careful to wash the area
2) Check that the space between the rungs of the exchanger are not clogged
Burner ( 5 ) Check the state of cleanliness of the
burner mesh
with most rungs rst (lowest part visible from above) and then the
upper part if necessary.
Remove any deposits using
compressed air, blowing from the mesh side.
( Num ) = see key Par. 2.2
32
4.2 - PARAMETERS THAT CAN BE EDITED FROM THE CONTROL PANEL
ATTENTION! Function reserved for Authorised As­sistance Centres only.
Menu access:
InF InFormation Hi Errors Log SE SErvice FA Factory
1 ACTIVATION - SELECTION
DISPLAY
2
Press the key (B+) to display the parameters list InF
PARAMETERS LIST InF
ENGLISH
Press the key (S) for 5 seconds Press the key (B+)
INFORMATION
to access the menus
The display alternates the Parameter and Value
CODE DESCRIPTION
Heating temperature, - - if the heat­ing sensor is faulty
External temperature, - - if there is no external probe or if it is faulty
Domestic hot water temperature, - - if there is no sensor or if it is faulty
Return temperature, - - if there is no auxiliary sensor or if it is faulty
Di󰀨erential ∆t between ow and
return.
Heating temperature calculated,
(been ‘‘room zone’’ ON-OFF and ‘‘remote zone’’ OT+.)
Press the key (S) to access the Inf parameters unit
Instantaneous fan speed _ _ rpm x 100
Water pressure, is there is not pres­sure sensor, - - is displayed
Firmware version (Factory)
Maintenance instructions
Firmware version (Servicing)
33
(Hi) Errors Log
3
DISPLAY - FAULT
ACTIVATION - SELECTION See section 1 (4.2)
Press the key (S) to access the Hi parameters unit,
The display alternates H and the number of the position (01) in which the error is stored.
2
DISPLAY
Press the key (C+) to display the fault code (see chap.5).
01 = last error displayed
4
EDIT VALUE - RESET
08 = fault code (LP
Water deciency)
ref. chap. 4.6
Press the key (B+) to display the sequence of
faults between 01 ÷ 12
PARAMETERS LIST (Hi) Errors Log
Position Description
01 02 03 04 05 06 07 08 09 10 11 12
last error displayed
penultimate error displayed
last but two error displayed
................error displayed
................error displayed.
................error displayed.
................error displayed.
............... error displayed
............... error displayed
third error displayed
second error displayed
rst error displayed
Press the key (D) for over 5 seconds, to reset the whole errors log.
This operation must only be performed in the
event one wants to delete the log completely (for
example, if important updates are made it may
therefore be useful to have a new chronological reference of events).
5
DISABLING
Briey press the key (S) to go back to the main menu See section 1 (4.2), or press it for over 5 seconds to exit.
34
(SE) Service parameters
EDITING THE VALUE
3
ACTIVATION - SELECTION See section 1 (4.2)
Press the key (S) to access the SE parameters unit. These parameters can be edited without restrictions, from the control panel.
2
DISPLAY
Press the key (B+) to display the parameters list
PARAMETERS LIST SE CODE RANGE DESCRIPTION
Post circulation
0 1
-20 10
0 30
0/5 30
0 1
0 100
20 45
50 85
25 45
50 65
0 = post 5’’ (default) 1 = continuous
External probe on panel
- 20÷10 °C
External probe on Regolafacile 0 = - 20 °C 30 = +10 °C (default 10)
Night reduction 0 = T.A. (default)
5 ÷ 30 = night reduction
Domestic hot water pre­heat function
0 = Not active (default) 1 = Active
Maximum heating modula-
tion level (default 100)
Minimum heating set point
level (default 30)
Maximum heating set point
level (default 85)
Minimum domestic hot water
set point level (default 35)
Maximum domestic hot water
set point level (default 60)
(default -10)
Press the key (C+) to access the parameter,
the parameter value ashes. Correct the value with the keys (C+ or C-)
4 CONFIRM VALUE
4
Press key D
ENGLISH
Maintenance instructions
35
(FA) Factory Parameters
ACTIVATION - SELECTION See section 1 (4.2)
Press the key (S) to access the FA parameters unit. These parameters can be edited by enter­ing the ACCESS CODE.
2
ACCESS CODE.
Press the key (B+) to enter the access code Conrm with the key (D)
Once the access code has been entered, 1 or 2 Factory parameter units are displayed
DISPLAY
3
1: Instantaneous boiler
2: Instantaneous boilers with
xed hysteresis
1 4
0 1
0 1
0 1
0 1
0 1
0 100
(*) Do not set values below 20!
UNIT 2 - FA PARAMETERS LIST
CODE RANGE DESCRIPTION
3: Heat. only boiler / or storage tank (1 pump +
1 3-way val.)
4: Boiler with storage tank 2 pumps
Heat. pressure sensor 0 = absent / 1 = present (default 0)
Unit: 0 = °C - bar 1 = °F - PSI (default 0)
Mains frequency
0 = 50 Hz / 1 = 60 Hz (default 0)
DHW and CH setpoint: 0 = bidirectional 1 = from remote control only (default 0)
Primary Dt protection 0 = disabled 1 = enabled (default 1)
Minimum output value
in CH and DHW (default 0)
Press the key (B+) to scroll the parameters.
UNIT 1 - FA PARAMETERS LIST
CODE RANGE DESCRIPTION
Type of Gas 0 = methane (default) 1 = GPL
Minimum pump modulation
level *
Maximum pump modulation
level Pump temperature di󰀨er-
ential Pump pause time during
CH / DHW service change and vice-versa
0 = no pause
1÷6 = Time in seconds
36
0 1
0 100
20 100
5 20
0 6
0 9
10 70
0 199
0 199
1 20
1 20
1 20
1 20
1 50
1 20
3 90
0 1
Boiler Power
Fan speed at start-up = rpmx100
Minimum fan speed (* 10+750) = rpmx100
Maximum fan speed (* 10+5000) =r pmx100
Heating control: proportional
Heating control: integrative
Heating control: derivative
Domestic hot water control: proportional
Domestic hot water control:
integrative
Domestic hot water control:
derivative
Ramp time CH (Value *10) = sec
Function antilegionella (storage tank boiler)
EDITING THE VALUE
4 5
4 CONFIRM VALUE
Press key D
Press the key (C+) to access the parameter,
the parameter value ashes. Correct the value with the keys (C+ or C-)
4.3 - ADAPTATION TO THE USE OF OTHER GAS
The boilers are produced for the type of gas speci­cally requested upon ordering.
DANGER! The conversion for the operation of the boiler with a type of gas other
than that specically required in the
order, must be performed by pro-
fessionally qualied personnel, in
compliance with the standards and regulations in force. The manufacturer cannot be held liable for any damage resulting from a conversion operation that is incor­rect or not performed in compliance with the laws in force and/or with the instructions given.
ATTENTION! After performing the conversion for the operation of the boiler with a type of gas (e.g. propane gas) other than
that specically requested when or-
dering, the appliance will only work
with this new type of gas.
ENGLISH
ally deaerated, ignition problems could arise.
In that case, contact the supplier of the LPG tank.
Gas Conversion
NOTE!
Further details in the section
‘‘Technical Information’’ on the
boiler page of the www.unicalag.it
website
In order to change the gas one must change
the Factory parameter:
FA PARAMETERS (UNIT 1) par 4.2
CODE METHANE PROPANE
0 1
Once the Gt parameter has been edited one must perform the GAC automatic calibration (Gas Adaptive Calibration) Chapter 4.3.1
- when the conversion is complete, ll in the
information required on the label supplied in the documentation envelope and apply it next to the technical data label of the boiler.
ATTENTION! Indications for propane gas-fired appliances
Make sure that the gas tank has been
deaerated before installing the appli­ance. For state-of-the-art deaeration of the
tank, contact the LPG supplier or a person qualied in compliance with
law.
If the tank has not been profession-
EXAMPLE OF COMPILATION
Maintenance instructions
37
4.3.1 - GAC AUTOMATIC CALIBRATION
One can perform the GAC in domestic hot water mode as well.
Make sure that there are no heating requests pre­sent and that all the valves of the heating system
are open.
If during this stage one wishes to disperse the heat on the domestic hot water circuit, open at least 2 hot water taps (ONLY AFTER HAVING ACTIVATED THE GAC FUNCTION).
1 ACTIVATION
Stage 2: START-UP OUTPUT CALIBRATION
When the display alternates tr - with value XX.
(1 min)
Stage 3: MINIMUM OUTPUT CALIBRATION
Press and hold the key (D) and press the keys (B- and B+) at the same time for at least 10 sec-
onds, until service appears.
StArt scrolls on the display , the function is active
when the symbols ash.
Note: After the ignition sequence, which can also take place after a few attempts, the boiler performs the calibration which consists of 3 stages:
Stage 1: MAXIMUM OUTPUT CALIBRATION
When the display alternates tr - 0
Calibration is complete when the small ame starts to ash.
DISABLING
2
See section 1 ACTIVATION
Note: If the display does not show errors it means that the system has been calibrated properly. Otherwise refer to chapter 4.6
"Error Codes".
When the display alternates tr - 100 (about 1 min.)
38
4.4 - IMPORTANT NOTES REPLACING COMPONENTS
Before replacing components one must follow the notes of chap. 4 "Inspections and maintenance".
To replace the components:
- GAS VALVE
- FAN
- BURNER,
- IGNITION/DETECTION ELECTRODE,
- MODULATION BOARD (in the event the
memory board CANNOT be reused) (*),
GAC calibration is required
MODULATION BOARD A universal
board memory
board (*)
B
(*) In the event the memory board can be re­used, there is no need to reprogram parame­ters, settings and automatic calibration.
The memory board is programmed by de­fault for METHANE gas operation.
In the event of LPG
operation the GT pa­rameter must be edited (Factory parameters), see (Chap. 4.2).
ENGLISH
A
B
Act carefully, pay attention to the inser­tion direction of the memory board.
Maintenance instructions
39
P
N
L1
1 2
A8
3
4 5
BR
Y-G
BL
1
2
3
BL
BR
BK
(DHW)
(CH)
M
MDV
A4
32
1
4
A9
32
1
BK (-)
1
3
St2
BL (TACHO)
BR (PWM)
OR (+)
2
4
5
VM (R)
CMP (*)
2
1
GR (WSC)
BL
(YONOS) (-)
BR
MODULAT
.
(+12 V) NOT USED
P
N
L1
1
2
A8
3
4 5
MDV
A1
4
3 2
1
8
76
5
9
DKWHFLS
SS SR
BRWHBR
WH
WH
R
R
1 - COM
4 - NO
A1
4
3 2
1
8
76
5
9
DK
WH
SS SR
BR
WH
WH
BR
BL
1 - COM
4 - NO
R C
R
C
T.ACC
230 V
50 Hz
L
1
N
GND
Y/G
BL
BR
1
2
A7
123
4
A5
5612345
A8
4
A9
32
1
A1
4
3
2
1
8
7 6 5
9
A2
4
3 2
176
5
A4
32
1
A3
4
32
1
6
5
A6
MEMORY CARD
VM (A)
1
2
3
St1
BL
BR
Y/G
L1
N
L1
N
C.I. A.P.S.
BR
Y-G
BL
GR
WH
R
(DHW)
(CH)
E. ACC./RIL.
R
A2
4
32
1
7 6
5
TLC
TL
SRR
G
G
WH
WH
WH
BL
A6
VI
WH
R
(Mod)
(On/Off)
+-
VG
EV2
EV1
OR
+-
A3
4
32
1
6
5
SE
BK
TA 1/OT TA 2
WH
WH
Y
Y
BK
BK
MDV
PK (WSC)
(YONOS)
G
ND
WH
SL
BK
CASING
4.5 - WIRING DIAGRAM Practical connection board
C.I Systemlling
A.P.S. Additional Pump
Supply
KEY
A1.....A9 Services connectors
CMP Modulating pump control DK Waterdeciencysafetypressureswitch
E.ACC./RIL Ignition/detection electrode
FLS Domestichotwaterrequestowswitch
MVD Diverter valve motor P Pump
SR Flowheatingsensor SRR Returnheatingsensor
40
SS
TL Limitthermostat
Domestichotwaterprobe(Pred.forRmodels)
TLC Fluegascollectorlimitthermostat
VG Gas valve VM Modulating fan
SE Externalprobeconnectionterminals TA1 / OT Modulating TA connection terminals TA2 On/off TA connection terminals
4.6 - ERROR CODES
Thesymbolashesonthedisplaymonitorwhentheboilerdetectsananomaly.
1)Intheeventofananomalythatdoesnotstopboileroperation,presskey‘‘D’’to displaytheerrorcode;intheeventtheboilerisinstand-by,theerrorcodeappears andremainsxedonthedisplay.
2)Intheevent ofananomalythatcausesboilerdowntime,the errorcodeashes directlyonthedisplay. Eachfaultischaracterisedbyaprioritylevel:iftwofaultsaredetectedatthesame time,thecodewiththehighestpriorityisdisplayed.Thefaultcodesarelistedbelow:
F)Faultcodedisplayedwithcodenumber:
ThedisplayashesalternatingtheF(FAULT-ANOMALY)witherrorcode(eg23).
SYMBOL PRIO-
COD.REGO-
LAFACILE/
FAULT
HISTORY
RITY
09 0 EXTERNAL PROBE
( Num ) = see key Par. 2.2
DESCRIPTION SOLUTIONS
Check the wiring, if needed
interrupted
replace the external probe
ENGLISH
14 1
RETURN PROBE
Auxiliary (SRR) sensor inter­rupted
45 2
WATER OVERPRESSURE
detected if the H2O pressure Transducer is present with pressure > 2.5 bar; it is reset automatically when H2O pres­sure < 2 bar
30 3 SERVICE PARAMETERS
Service parameters altered due
to possible electromagnetic interferences.
21 4 POOR WATER CIRCULATION
Poor circulation in primary circuit
17 5 FLAME CONTROL FRE-
QUENCY BEYOND LIMIT
Depends on the power supply
mains (Frequency and voltage
beyond default limits)
15 6 WATER CIRCULATION IN-
SUFFICIENT
Primary circuit water circulation
insu󰀩cient (∆t > 35° C)
22 7 INCORRECT SENSOR PO-
SITIONING Flow and return
sensors inverted
24 8 SPEED OUT OF
CONTROL
Alteration of the fan speed; the speed is not reached.
Check the wiring, if needed re­place the auxiliary sensor (22)
Wait for the values to return to
default limits / Replace the Transducer
Reset the altered parameters via the panel and/or regola­facile
Check pump operation (12) and speed, if there are any obstructions or system closure.
Wait for the values to return to
the default limits
Check pump operation (12) and speed - remove any heat­ing system obstructions - clean the scaled domestic hot water exchanger
Check the wiring (21) (22)
Check fan operation (18) and the connections
Maintenance instructions
41
26 9 SPEED OUT OF
CONTROL
Alteration of the fan speed; the
speed is above that requested
6 10 HIGH TEMPERATURE
Boiler temperature too high
8
NO
WATER
11 WATER DEFICIENCY
Insu󰀩cient water pressure and consequent intervention of the
minimum water pressure - pres­sure switch ( 13 ).
44
NO
WATER
12
WATER PRESSURE
detected if the pressure Trans­ducer is present
Check fan operation (18) and the connections
Check pump operation and if needed clean the exchanger (24)
Fill the heating circuit as de­scribed in chap. 3.8 and wait
for the values to return within
default limits. If needed, check the electri­cal connections and replace the minimum water pressure switch.
Wait for the values to return
to default limits / Replace the Transducer
16 13 EXCHANGER
FREEZING ( 24 )
Exchanger freezing is detected If the heating sensor detects a temperature below 2° C, burn­er ignition is inhibited until the sensor detects a temperature
above 5°C.
13 14
DOMESTIC HOT WATER SENSOR
Domestic hot water sensor fault (1)
12 15 HEATING SENSOR (11)
Heating sensor fault
38 16 FACTORY PARAMETERS
Alteration of the factory param­eters due to possible electro­magnetic interferences.
1
LIMIT
THERM
4
BLOCK
17
SAFETY THERMOSTAT
Intervention of the safety ther­mostat (10)
18 BLOCK
No gas or failed burner ignition
Disconnect the from the power supply, close the gas
valve, defrost the exchanger
carefully.
Check the efficiency of the sensor (see table Res/Temp) (Par.4) or its connections.
Check the efficiency of the sensor (see table Res/Temp) (Par.4) or its connections.
Press the unblock key; if the anomaly persists, replace the board.
Press the unblock button on the panel and/or check that the thermostat or its connections are not interrupted.
Check the gas supply or that the ignition/detection electrode is working properly (4).
42
11 19 PARASITE FLAME
Flame detected upon ignition
20 20 PARASITE FLAME
Flame detected after swtich-o󰀨
5
CHIMNEY
21 FLUE GAS COLLECTOR
SAFETY THERMOSTAT
Intervention of the flue gas
collector safety thermostat (23)
Check the wiring of the Ign/Det.
electrode and remove any oxidation.
Check for humidity between drain wire and ceramic, if necessary, replace the electrode, press the unblock key, if the anomaly persists, replace the electrode (4).
Check the wiring and for any
leaks from the gas valve (3), if needed replace the gas valve.
Rearm the thermostat manual­ly and press the unblock button on the panel. Check the connections.
(F) 27 22
service
ERROR Flow Gradient
Check if the pump switches o󰀨
suddenly.
(F) 23 23
(F) 53 24
service
(F) 55 25
service
(F) 18 26
(F) 43 27
Detected tab panel button pres­sed for longer than 30 “
Check keypad and reset the status of the buttons. Or repla­ce the electronic board
Clogged Outlets Check the Chimneys / Check
the trap.
No Calibration GAC Calibration 4.3.1
Electrode earthed on the Burn­er or presence of moisture
Checkthedistancebetweentheburn­erandtheelectrode,checkforhumid­itybetweendrainwireandceramic,if necessary,replacetheelectrode.
During the ignition stage, ab­normal flame extinguishing
has occurred 12 "consecutive"
times in a period of about 50 sec.
Checkthe gas pressure / anyue gasrecirculationinthechimneyand
obstructions / condensation drain / electrode electrical connection /
electrodeandburnerearth/perform GACcalibrationchap.4.3.1/replace theelectrodeand its connection / replacetheelectronicboard
service
service
BLOCK 28
service
service
BLOCK 32
BLOCK 33
service
BLOCK
Control circuit problems
Gas Valve
Gas Valve opening time beyond
limit time
Flame loss with max ignition
value correction
General block for unclassied
anomalies.
Check the Gas Valve connec­tions / Replace the Gas Valve
(3) / Replace the Modulation Board
Checkthepartsthatgeneratetheheat requests(thermostats,electrovalve limitswitches,owswitch,etc.)
Checkthe gas pressure / anyue gasrecirculationinthechimneyand
obstructions / condensation drain / electrode electrical connection /
electrodeandburnerearth/perform GACcalibrationchap.4.3.1/replace theelectrodeand its connection / replacetheelectronicboard
Replace Modulation Board.
ERRORS DISPLAYED ON REGOLAFACILE ONLY
- 75 -
Regolafacile external sensor Replace the external probe /
Regolafacile
- 80 -
- 81 -
(*) if there is a condensation obstruction inside the ue gas manifold (before resetting) it is necessary to proceed to a drying operation inside of the tank especially of the level sensor electrodes.
Regolafacile Internal Sensor Replace Regolafacile Eprom Error of Regolafacile Replace Regolafacile
www.unical.eu
a
ed. 03/18
ORIGINAL INSTRUCTION - 00334659/b - 1
46033 casteldario - mantova - italia - tel. +39 0376 57001 - fax +39 0376 660556
Also reserves the right to bring those changes that it will hold necessary to it own products or prots, without jeopardizing its essential characteristics.
AG S.p.A.
info@unical-ag.com - export@unical-ag.com - www.unical.eu
Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press.
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