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OSA S 24

Unical Osa S 24, Osa S 28, Osa S 35 Installation And Servicing Manual

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S 24 S 28 S 35
ENGLISH
+ TOUCH CONTROL Uy BOX integrate
INSTALLATION AND SERVICING MANUAL
http://www.unicalag.it/prodotti/domestico-50/condensazione-gas/osa/1635/osa-s
Provisions for proper disposal of the product in accordance with Directive 2002/96/EC
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 .................................................................................................. 14
2.4 Operation data .......................................................................................................................................15
2.4.1 Data according to directive ErP ....................................................................................................15
2.4.2 Caratteristiche del controllo integrato Uy BOX ........................................................................... 15
2.5 General features ............................................................................................................................. 15
General information
ENGLISH
3 INSTALLATION INSTRUCTIONS ...................................................................................................................16
3.1 General warnings .................................................................................................................................. 16
3.2 Installation standards ............................................................................................................................16
3.3 Preventive system verication and adjustment operations ...................................................................16
3.4 Packaging ..............................................................................................................................................17
3.4 Positioning the boiler ............................................................................................................................. 18
3.6 Flue gas exhaust pipe connection ......................................................................................................... 19
3.7 Connections ..........................................................................................................................................22
3.8 Filling the system ...................................................................................................................................23
3.9 Electrical connections ............................................................................................................................24
3.10 Commissioning ................................................................................................................................... 26
3.11 Measurement of combustion efciency during installation .................................................................... 27
3.11.1 Calibration function activation ................................................................................................... 27
3.11.2 Probes positioning ....................................................................................................................28
3.12 Burner adjustment ................................................................................................................................. 29
3.12.1 Combustion adjustment function activation ..............................................................................30
3.12.3 Adaptation of the power to the heating system .........................................................................31
4 MAINTENANCE INSTRUCTIONS .................................................................................................................. 32
4.1 Inspection and maintenance instructions .............................................................................................. 32
4.1.1 Pannello comandi Uy BOX ......................................................................................................... 33
4.2 Parameters that can be edited from the control panel ..........................................................................35
4.3 Adaptation of the power to the heating system ..................................................................................... 38
4.3.1 GAC adjustment .......................................................................................................................... 39
4.4 Wiring diagram ................................................................................................................................43
4.5 Error Code .............................................................................................................................................44
4.5.1 Filling system ................................................................................................................................47
4.6 Important Note ....................................................................................................................................... 48
4.6.1 Service panel ................................................................................................................................49
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.
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-off devices. Do not obstruct the terminals of the intake/exhaust ducts.
In the event of failure and/or malfunctioning of the appliance, switch it off 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 boiler and void the warranty.
To guarantee appliance ef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.
Only original accessories must be used for all appli­ances with optionals or kits (including electric).
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 (*).
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
for the user
and the environment
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. Unical AG S.p.A. will not be held liable for any damage resulting from improper use. Use according to the intended purposes also includes strict compliance with the in­structions in this manual.
NOTE!
Tips
NOTE!
For more information
See Technical Info:
from site indicated at pag. 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. Insuf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 affect 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 off
- do not smoke
- do not use the telephone
- close the gas shut-off 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 af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 rating plate is placed inside the boiler, The rating plate DUPLICATE is placed under the front casing (lower-right).
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
ef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.
1.8 - BOILER ANTIFREEZE PROTECTION (*)
(*) The frost protection is always active. Even disabling the CH and DHW services.
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 OFF
OFF ON OFF OFF
< 2 °C ON
This protection can intervene only
i f the electricity and gas supplies are
connected.
I f 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 effectively from frost by using antifreeze products with inhibitor for heating systems (specific for multidmetal).
Do not use car engine antifreeze products as they could damage the water gaskets.
ANTIFREEZE FUNCTION
Actions
function
antifreeze
Only when both the power supplies are ON:
- Burner and Pump OFF until T > 5°C
- When T > 5°C then Burner and Pump ON until T > 14°C.
8
2
TECHNICAL FEATURES AND DIMENSIONS
For more information
2.1 - TECHNICAL FEATURES
2.2 - VIEW WITH THE INDICATION OF THE MAIN COMPONENTS AND DIMENSIONS
OSA S 24
See Technical Info
from site indicated at pag. 2
NOTE!
ENGLISH
Technical Features
9
OSA S 28 - OSA S 35
10
OSA S 24 - OSA S 28 - OSA S 35
View from below
View from above
11
KEY
N° 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.
Ignition/detection electrode
ACC
/RIL
5 Burner
8 Expansion vessel
10 HL TL Safety thermostat
11 Hb SR Heating temperature sensor
12 Ht P Pump
13 Lp DK Water deciency pressure switch
16 Diverter valve
17 Plate heat exchanger
18 FL
VM
Fan
FH
20 Safety valve
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
33 Uy BOX (retractable)
34 Gateway (external links)
35 Emergency panel
Aves Connection for additional
expansion vessel
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
Condensation drain
Ufp Smoke rear output optional
C.E. = ERROR CODES see
par. 4.6
S.E. = WIRING DIAGRAM
KEY see par. 4.5
12
2.3 - DIAGRAM OF FLOW RATE/PRESSURE AVAILABLE FOR INSTALLATION
MODULATING PUMP
DIAGRAM OF FLOW RATE/PRESSURE AVAILABLE FOR INSTALLATION
OSA S 24
ENGLISH
Avaible Head (m.c.a.) metres of waterAvaible Head (m.c.a.) metres of water
OSA S 28 - OSA S 35
Technical Features
Flow rate (l/h)
Flow rate (l/h)
13
2.4 - OPERATING DATA ACCORDING TO UNI 10348
Fortheadjustmentdata:NOZZLES-PRESSURES-DIAPHRAGMS-FLOWRATES-CONSUMPTIONSrefertotheparagraphADAPTATIONTOOTHERTYPESOFGAS.
OSA S 24 OSA S 28 OSA S 35
Nominal heat input in CH / DHW mode kW 23,4 28,0 / 33,0 33,0 Minimum heat input with Nat. Gas / Propane kW 3,0 / 3,0 4,4 / 4,4 4,4 / 4,4 Nominal heat output kW 23,02 27,3 32,2 Minimum heat output kW 2,96 4,3 4,3 Nominal output in condensation 50/30 °C kW 23,7 28,9 33,8 Minimum heat output in condensation 50/30 °C kW 3,22 4,68 4,68 Combustion efciency at full load % 97,2 97,8 97,3 Combustion efciency at part load % 98,6 98,2 98,1 Heat losses through the casing (min.-max.) % 1,4 - 1,0 1,1 - 0,2 1,1 - 0,2 (*) Net ue gas temperature tf-ta (max.) °C 56,8 45,1 54,8 Flue gas mass ow rate (min.-max) g/s 1,35 - 10,5 2,0 - 12,5 2,0 - 14,7 Air excess λ % 24,3 23,0 23,0
CO
2
CO at 0% of O Maximum production of condensate kg/h 3,8 4,5 5,3 NOx class 5 5 5 Chimney heat losses with burner ON (min. - max.) % 1,4 - 2,8 1,8 - 2,2 1,9 - 2,7 Chimney heat losses with burner OFF % 0,35 0,34 0,34 Max. available pressure at the chimney base min. / max. Notes: (*) Room Temperature = 20°C Data obtained with appliance operated with Nat Gas (G20)
(min. - max) ppm 22 - 114 14 - 88 14 - 94
2
% 9,2 - 9,2 9,2 - 9,3 9,2 - 9,3
Pa 2 / 70 2 / 70 2 / 70
2.4.1 - DATA ACCORDING TO ErP DIRECTIVE
Description Symbol Unit OSA S 24 OSA S 28 OSA S 35
Nominal Heat Output Pnominale kW 23 27 32 Seasonal space heating energy
efciency Seasonal efciency class in
heating mode Integrated Weather compensator and
room sensor Seasonal space heating energy
efciency of package
Seasonal space heating energy
efciency class of package
For CH only and combination boilers: useful heat output
Useful Heat Output in high-tempera­ture regime (Tr 60 °C / Tm 80 °C)
Useful ef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 efciency at 30% of nom. heat output in low-temperature regime (Tr 30 °C)
Range-rated boiler: YES / NO YES YES YES
Auxiliary electricity consumption
At full load elmax kW 0,085 0,093 0,093 At part load elmin kW 0,012 0,015 0,015 In stand-by mode P
Other items
Stand-by heat loss P Emissions of nitrogen oxides NOx Mg/kWh 41 36 39
For CH & DHW production boilers
Declared load prole L XL XL Energy efciency in DHW production
mode
Daily electricity consumption Qelec kWh 0,0644 0,0813 0,0813
Daily fuel consumptionl Qfuel kWh 14,41 22,97 22,97 Inside sound power level Lwa dB (A) 53 54 54
Seasonal efciency class
in DHW production mode
14
ƞ
s % 94 94 94
A A A
Classe VI % 4 4 4
ƞ
s
Packaging
% 98 98 98
A+ A+ A+
4 kW 13 16 18,4
P
ƞ
4 % 88,7 88,9 88,7
1 kW 4,3 5,3 6,1
P
ƞ
1 % 99,2 98,1 98,2
SB kW 0,003 0,001 0,001
stb kW 0,0824 0,113 0,113
wh % 84 86 86
ƞ
A A A
2.4.2 - FEATURES OF INTEGRATED Uy BOX
Uy BOX control panel, togheter with room sensor temperature and outer sensor temperature
provided as standard, performs the environmental thermoregulation work as described in the document 2014/C 207/02, section 6.1.
Class VI – Weather compensator and room sensor, for use with modulating heaters: A heater ow tem­perature control that varies the ow temperature of water leaving the heater dependant upon prevailing outside temperature and selected weather compensation curve. A room temperature sensor monitors room temperature and adjusts the compensation curve parallel displacement to improve room comfort. Control is achieved by modulating the output of the heater.
2.5 - GENERAL FEATURES
ENGLISH
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. Domestic hot water ow rate limiter 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. Voltage/Frequency electric power supply °C Fuse on the power supply V-Hz Maximum absorbed output A (F) Protection rating IP Net weight boiler kg Gross weight boiler kg Net weight front case (shell) kg Gross weight front case (shell) kg
OSA S 24 OSA S 28 OSA S 35
2H3P
II
2,1 3,06 3,08
0,5 0,5 0,5
3 3 3
2,2 2,2 2,2
85 85 85
30 30 30
9 (6+3) 6 6
1 1 1
185 123 123
2 2 2
0,5 0,5 0,5
6 6 6
11,2 16 16
10 15 15
7,3 10,3 10,3
8,3 11,6 11,6
9,4 13,3 13,3
11,0 15,5 15,5
13,2 18,6 18,6
35-60 35-60 35-60
230/50 230/50 230/50
3,15 3,15 3,15
X4D X4D X4D
41 41 41
45,7 45,7 45,7
3 3 3
4,9 4,9 4,9
2H3P
II
II
F factor 1 2 2 R factor
(*) mixed
2H3P
Technical Features
15
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;
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;
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.
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 efciency and output.
NOTE!
For more information
See Technical Info
from site indicated at pag. 2
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 ofcial journal, as well as the applicable
technical standards.
3.3 - PREVENTIVE VERIFICATION AND VERIFICATION AND AD­JUSTMENT OPERATIONS
16
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
NOTE!
For more information
See Technical Info
from site indicated at pag. 2
3.4 - PACKAGING
The OSA 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
1
for damage to persons, animals or objects due to failure to comply with the instruction above.
As well as the appliance, the packaging contains:
A DOCUMENTATION ENVELOPE
- User operating instructions booklet
- Instruction booklet for the installer and maintenance engineer
- Warranty
- 2 Spare parts form
- Certicate of conformity
- Gas conversion label
B - Connection predisposition paper template
D - Chimney spacer
E - Bracket for xing
F - Uy BOX
G - Outer sensor + Remote temperature sensor
ENGLISH
2
BOILER
OSA S P
Depth
200 mm 540 mm 1010 mm
L
Width
H
Height
3
SHELL
OSA S P
L
Depth
62 mm 592 mm 1000 mm
Width
H
Height
Installation Instructions
17
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.
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.
OSA S 24 - OSA S 28 - OSA S 35
Clearance
18
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
ENGLISH
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.
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
40
(max 30 S)
1 + 1
(max 15 S)
20
Separate combustion air intake and combustion products evacuation pipes. These pipes can discharge into areas with different pressure.
Installation Instructions
19
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
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.
Connection to a terminal for combustion air intake and ue gas exhaust via a single or collective chimney.
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)
ATTENTION:
(*) Values in the MT018 available on the website.
For the type of connection B23P the room follows the same installation rules for boilers with natural draught.
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
Please note: These values relate to exhausts/ made by means of rigid pipes and smooth original UNICAL.
20
NOTE!
For more information
See Technical Info
from site indicated at pag. 2
GENERAL INFORMATION ON THE FLUE GAS EXHAUST SYSTEM
Rear smoke outlet not possible
ENGLISH
Rubber sealing caps
(Remove according to the type Exhaust used:
HIGHER
- Split (remove both)
- Coaxial (leave only one shown)
REAR NOT VISIBLE (rear in the boiler)
installation instructions in the kit. it is possible only with coax (Leave 2 above).
(+) Adapter for double systems
Departure Coaxial
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.
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
Installation Instructions
21
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, pro­duces 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 appliance:
- check that the trap is assembled properly
- ll the trap and check 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.
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 cor­respondence 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.
Aves
Connection for additional expansion vessel.
22
The mains pressure must be within 1 and 3 bar (in the event of greater pressure install a pressure reducer).
Condensation outlet, pipe to be connected to the drainage system
The connection between the appliance and the domestic waste system must be made in compliance with the specic reference standards.
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.
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.
- ONLY FOR FIRST FILL - normally the lling is
automatic - open the lling tap gradually Rc (me­diante cacciavite) 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 U-y until pressure
reaches approximately 0.8/1 bar.
- close the lling tap Rc and bleed air once again
through the radiator air release valves.
- 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. 4.5).
NOTE!
For more information
See Technical Info
from site indicated at pag. 2
ENGLISH
Note: The rst ll of the boiler must
be made manually.
FILLING VALVE Screw in load position LOAD
FILLING VALVE Screw in position of NORMAL OPERATION.
Unical will not be held liable for dam­age to persons, animals or objects due to failure to comply with the above instruction.
Installation Instructions
Rc
The lling valve RC is positioned
behind the siphon.
23
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.
The external connections have to be made on the GATEWAY (connector Y3), the cable exits wil be made in groves on cover A.
OT/TA = ON-OFF room thermostat (*) OT (OpenTherm) is not enabled
- Arranged on GATEWAY connector, Y 3 5-6. Remove the jumper and connect the wires of the room thermostat between terminals.
(*) Optional
SA = Room sensor supplied
- Arranged on GATEWAY connector, Y3 9-10, Remove the bridge between terminals 5-6.
24
SE = Outside sensor supplied
SHC = Multifunction module (*)
ENGLISH
- Arranged on GATEWAY connector, Y3 7-8.
Electric power supply connection
Modulation Board
INSIDE
BOILER
- Arranged on GATEWAY connector, Y3 4-3.
The boiler is equipped with a power cable, boiler installation requires elec­tric al connection 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 installed 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 UNICAL AG S.p.A., using original spare parts only. Failure to comply with the above can jeopardise the safety of the appliance.
Installation Instructions
If necessary the shield of the sensor cable, can be connected to the termi­nal. (Ground connections - modulation board).
See par. 4.5 positioning on the board
(*) Optional
25
3.10 - COMMISSIONING
Commissioning must be done by profes­sionally qualied personnel. Unical AG S.p.A. will not be held liable for damage to persons, animals or objects due to
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-off gate valves open?
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 staff qualied in compliance with the standards in force;
is the gas supply valve open?
failure to comply with the above instruction. Before commissioning the boiler, check that:
has the system been checked for gas leaks?
is the outside main switch ON?
is the system safety valve ef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?
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?
26
Please tick the operations performed
Switching boiler on and off
NOTE!
For more information
See Technical Info
from site indicated at pag. 2
3.11 - MEASUREMENT OF COMBUSTION EFFICIENCY DURING INSTALLATION
3.11.1- ACTIVATION OF THE CALIBRATION FUNCTION
ATTENTION! Function reserved for Authorised Assistance Centres only.
ENGLISH
3
1 - Inserit psw and select the function
4
4 - Activation
2
2 - Activation
3 - Available choice generator indicated by es: usually 1 / modulex 1÷8
Installation Instructions
27
5 - Generator active modulation max 100%.
6 - Change the % modulation to minimum 10%, and select the generator
7 - Generator active modulation min.
3.11.2 - POSITIONING THE PROBES
To determine the combustion efciency one must make the following measurements:
- measurement of the combustion air temperature
taken in the relevant hole 2.
COAXIAL PIPES
A
Air probe
1
Air probe
2
Flue gas probe
SEPARATE PIPES
B
Flue gas probe
8 - Disable function Chimney sweep
- measurement of the ue gas temperature and content of CO2 taken in the relevant hole 1.
Take the measurements with the generator in
steady state conditions (see par. 3.11.1).
PIPES Ø 80 TYPE B23
C
1
Air probe
1
2
2
Flue gas probe
28
NOTE:
Do not enter immediately the analyzer probe in the sampling point, to avoid the saturation analyzer.
It’s important to perform also the combustion air of combustion analysis, (Observing that the concentration of oxygen falls O tolerance 0.2 - 0.4%). This is to prevent there being any recirculation of the fumes.
= 20.8%
2
3.12 - ADJUSTING THE BURNER
Check the levels of CO2 often, especially with low ow rates. They refer to the boiler with a closed combustion chamber.
PRESSURE - FLOW RATES TABLE
OSA S 24
Type of
Gas
Nat. gas (G20) 2,96 - 23,0 3 - 23,4 20 - - - 9,2 (*) 9,2 (*) 0,32 m³/h 2,48 m³/h -
Propane (G31) 2,96 - 23,0 3 - 23,4 37 - - - 10,5(+) 10,5(+) 0,23 kg/h 1,82 kg/h -
(*) 9,0 ± 9,8 Acceptable range for G20 (+) 10,0 ± 11,0 Acceptable range for G31
OSA S 28
Type of
Gas
Gas nat. (G20) 4,3 - 27,3 4,4 - 28,0 20 - - - 9,2 (*) 9,3 (*) 0,47 m³/h 2,96 m³/h -
Propano (G31) 4,3 - 27,3 4,4 - 28,0 37 - - - 10,4(+) 10,5(+) 0,34 kg/h 2,17 kg/h -
(*) 9,0 ± 9,8 Acceptable range for G20 (+) 10,0 ± 11,0 Acceptable range for G31
Effective
Output
[kW]
Effective
Output
[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 [%]
ENGLISH
OSA S 35
Type of
Gas
Gas nat. (G20) 4,3 - 32,2 4,4 - 33,0 20 - - - 9,2 (*) 9,3 (*) 0,47 m³/h 3,49 m³/h -
Propano (G31) 4,3 - 32,2 4,4 - 33,0 37 - - - 10,4(+) 10,5(+) 0,34 kg/h 2,56 kg/h -
(*) 9,0 ± 9,8 Acceptable range for G20 (+) 10,0 ± 11,0 Acceptable range for G31
Effective
Output
[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
If the CO2 level detected is out of recommended range, verify the integrity of the electrode. In case of necessity replace the electrode. If the problem persists you can use the functions described below.
Start-up
power
IG [%]
Installation Instructions
29
3.12.1 - COMBUSTION ADJUSTMENT FUNCTION ACTIVATION
This function allows a partial adjustment of the
value on the following modulation points:
CO
2
Maximum output 100 % Start-up output xx % Minimum output 0 %
After Auto Calibration GAC par. 4.3.1
Perform combustion adjustment calibration as indicated:
If the CO2 value is not as expected, when appears box (+/-), you can retouch the value of the Maximum Power. If the desired value has been reached, proceed to the next level by pressing: Ignition
If the CO2 value is not as expected, when appears box (+/-), you can retouch the value of the Minimum Power.
If the CO2 value is not as expected, when appears box (+/-), you can retouch the value of the Ignition. If the desired value has been reached, proceed to the next level by pressing: Minimum
The combustion adjustment is nished.
30
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.: OSA S 24 to decrease the output of the boiler to 18 kW, edit parameter
792 on Uy BOX (about 70)
E.g.: OSA S 28 to decrease the output of the boiler to 20 kW, edit parameter
792 on Uy BOX (about 65)
E.g.: OSA S 35 to decrease the output of the boiler to 24 kW, edit parameter
792 on Uy BOX (about 68)
.
.
.
The user is NOT authorised to activate the func­tion described below.
Act on parameter 792 (par. 4.2 SE parameters list) to achieve the value corresponding to the desired output.
ENGLISH
parameter 792 (HP %)
Installation Instructions
31
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 MAINTE­ NANCE 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-off valve upstream the boiler.
• If needed, and depending on the intervention to be carried out, close any shut-off valves on the ow and return line of the heating system, as well as the cold water inlet valve.
Failure to perform Inspections and Main­tenance can entail material and personal damage.
• 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 pres­sure until reaching a pressure of 0.8/1.0 bar.
• Open the gas shut-off valve.
• Switch the boiler back on.
• Make sure the appliance is gas tight and water­tight.
• 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
32
4.1.1- CONTROL PANEL Uy BOX
Uy BOX is hidden inside the boiler, to
access it, rotate as indicated.
General Operating Instructions for Uy­BOX, are contained in specic manual
provided with the boiler.
This section only lists the steps requi-
red to Adjustment / maintenance of the boiler:
- Chimney sweep function (Par. 3.11.1)
- Calibration (Par. 3.12.1)
- Edit parameters (Par. 4.2)
- Automatic calibration GAC Adaptive Calibration Gas (Par. 4.3.1)
ENGLISH
Maintenance instructions
33
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 inter­venes at 95°.
Does the pressure switch block the boiler if the water pressure is below 0.4 bar?
Without request: close the shut­off 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 expansion 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 (26) 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 ( 24 ) 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 the products purposely created by Unical (see system protection ACCESSORIES sect. in the domestic price list), being care­ful to wash the area with most
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
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
34
4.2 - PROGRAMMING OF THE OPERATION PARAMETERS
WARNING! Function reserved exclusively to authorized service centers.
ENGLISH
At every boiler lighting UFLY scans devices, if new devices are recognized, such as:
hcm / bcm
shc
bmm
Heating / Burner Control Manager
Slave Heating Controller Multifunction module
Burner Modul Manager
They are displayed on the next screen, and is prompted to save the new conguration.
Icon scanning devices
icon save new conguration
Device detected
Not installed device
previously recognized device, but not de­tected.
Maintenance instructions
35
To change the parameters is required password.
Parametri
Code Description
803
322
787
789
807
792
31
36
Enabled Services: 0: CH & DHW disabled 1: CH enabled 2: DHW enabled 3: CH & DHW enabled
Pump: Post-circulation 0: overrun 5 min. 1: continuous
Outdoor minimum temp °C
Night shift °C 0: T.A. 5÷30: Value night shift
ACS Preheating
CH: Modulation max
CH#1 Minimum Set point
Set. Min. 3 0 3
0 0 1
10 0 30
0 0/5 30
0 0 1 100 0 100 30 20 45
Max.
39
650
385 48 832
CH#1 Max. Set point
ACS Set point Min.
ACS Set point Max.
CH#1 Set point °C
Access Code (#)
85 50 85 35 25 45
60 50 65 70 20 85 0 0 199
To change the following parameters you must enable the access code.
778
341
313
312
775
309
771
Burner: 0: G20 - 1 GPL
Pump: Minimum Control
Pump: Maximum Control
Pump: temp. diff. °C
Valvola Dev.: Stroke time sec.
System congurations: 1: W1 2: W2 3: W3 4: W4
Sensore pressione Acqua 0: assente - 1 presente
0 0 1
-- 0 100
-- 20 100
-- 5 20
-- 0 6
-- 1 4
-- 0 1
896
806
848
483
672
2590 619
Unit: 0 = °C / bar 1 = °Fahrenheit / PSI
Frequency: 0: 50 Hz - 1: 60 Hz
Dis. local setpoint: 0: bidirectional 1: Only by remote
Temp. different. Max
Min modulation CH/ACS
Burner power
Modulation and ignition
0 0 1
0 0 1
0 0 1
1 0 1 0 0 100
-- 0 9
-- 10 70
346 319
353
354 478 323 324
325
(#) Enable (insert value) to change parameter
(*) ( x 10 + 750) = rpm x 100 (**) ( x 10 + 5000) = rpm x 100
Fan min speed
fan max speed
Regolation Proportional
Regolation Integrative
Regolation Derivative
ACS PID:Proportional
ACS PID:Integrative
ACS PID:Derivative
(*) 0 199 (**) 0 199
-- 1 20
-- 1 20
-- 1 20
-- 1 20
-- 1 50
--
1 20
ENGLISH
Historical Error
Clean display Error with CLEAR .
Maintenance instructions
37
4.3 - ADAPTATION TO THE USE OF OTHER GAS
The boilers are produced for the type of gas speci­cally requested upon ordering.
Gas Conversion
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.
ATTENTION! Indications for propane gas-fired appliances
Make sure that the gas tank has been
deaerated before installing the appli-
ance. 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-
ally deaerated, ignition problems
could arise. In that case, contact the supplier of
the LPG tank.
NOTE!
For more information
See Technical Info
from site indicated at pag. 2
In order to change the gas one must change the Factory parameter:
PARAMETER par 4.2
CODE GAS NAT. PROPANE
778 0 1
Once the 778 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.
EXAMPLE OF COMPILATION
38
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).
WARNING! Function reserved exclusively to authorized service centers.
ENGLISH
Start Calibration phase - Wait: Step 1 = Calibration Maximum Power Step 2 = Calibration Power Start Step 3 = Calibration Minimum Power.
Maintenance instructions
39
Step 1: CALIBRATION MAX POWER
Step 3: CALIBRATION MIN POWER
Step 2: CALIBRATION POWER START
The automatic calibration is completed.
To perform the calibration adjustment of combu­stion, see par. 3.12.1.
40
(This page is intentionally left blank)
ENGLISH
Maintenance instructions
41
KEY
BOARDBMM
A1.....A9 Services connectors
ALIM.P.sup Supply.PumpExtra
CMP Control modulating Pump E.ACC./RIL Ignition/detection electrode EVCI (*) Caricamento Impianto (Only OSA S)
FLS Domestichotwaterrequestowswitch MEMORY
Memory
CARD
42
4.4 - WIRING DIAGRAM
Practical connection board
ENGLISH
MVD Diverter valve motor MDV (**) Controlpredispositiondiverter(externalwater
heater)onlyHeatingboilers
PM Circolatore Modulante SPI Pressure Sensor System
SR Flowheatingsensor SRR Returnheatingsensor
SS
TL Limitthermostat TLC Fluegascollectorlimitthermostat
Domestichotwaterprobe(Pred.forRmodels)
VG Gas valve VM (A) Soupply modulating fan
VM(R) Rilev./Reg.ModulatingFun
SchedaGATEWAY
Y1....Y3 Services connectors
230V-50Hz Boiler Supply EXT DEVICE Externaldevices:SHC(eBUS+/eBUS-) SA TerminalRoomsensor SE Terminal Outer sensor
OT/TA TerminalTAon-off/OT disabled) UFLY
connection
U-yBOXsupply
Maintenance instructions
43
4.5 - ERROR CODES
Failure that causes the stop of the boiler:
- The error code is displayed, the boiler is in lock. After resolving the fault press Reset to restart the boiler.
ERROR CODES (FAULT) ( Num ) = see key Par. 2.2 CODE 01
04
06
08
09 10 11
12
13
14
15
DESCRIPTION SOLUTIONS
SAFETY THERMOSTAT
Intervention of the safety thermostat (10)
BLOCK
No gas or failed burner ignition
High Temperature
Boiler temperature too high
Water Decency
Insufcient water pressure and consequent
intervention of the minimum water pressure
- pressure switch ( 13 ).
Outer Sensor Check the wiring, if needed replace outer sensor
Internal failure
Parasite Flame
Flame detected upon ignition
Heating Sensor (11)
Heating sensor fault
Domestic Hot Water Sensor
Domestic hot water sensor fault (1)
Inlet temperature Sensor
(SRR)
Water circulation insufcent
Primary circuit water circulation insufcient
(∆t > 35° C)
Failure that could NOT cause stop of the boiler:
Error code is displayed, the boiler is in CH
-
demand, Icon Reset (note that was detected a fault even if the fault was temporary. Is therefore necessary always push reset to clear the display’ ‘‘error’’
Press Reset 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).
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.
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 efciency of the sensor (see table Res/ Temp) (Par.4) or its connections.
Check the efciency of the sensor (see table Res/ Temp) (Par.4) or its connections..
Check the efciency of the sensor / and replace it
Check pump operation (12) and speed - remove any heating system obstructions - clean the scaled domestic hot water exchanger
44
16
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
20 Parasite Flame
Flame detected after swtich-off
24
Speed out of control
Check fan operation (18) and the con-
nections
25 26
28 30
31
32
38
44
45
47 49 50 56 57 58 60 62 66 74 75
Exhaust smoke overheating
Speed out of control
Alteration of the fan speed; the speed is
above that requested
Scambiatore Ostruito
Service Parameter
Service parameters altered due to possible
electromagnetic interferences.
System conguration invalid or
corrupted
Low line voltage Correction: if the line voltage is <190 Vac: the
Factory Parameters
Alteration of the factory parameters due to
possible electromagnetic interferences.
Water sensor pressure
detected if the pressure Transducer is
present
Water Overheater
detected if the H
present with pressure > 2.5 bar; it is reset
automatically when H
Communication error
HCM, SHC: host controller missing
Room1: temperature sensor
Host controller missing
Burners NOT detected
Global ow temperature sensor
Date and Time not valid
Actuators SGV
Missing calibration
Temp. sensors swap
Temperature slope exceeds the limit
O pressure Transducer is
2
O pressure < 2 bar
2
Disconnect the from the power supply, close the gas valve, defrost the exchanger carefully.
Check the wiring and for any leaks from the gas valve (3), if needed replace the gas valve.
Check fan operation (18) and the connections
ENGLISH
Check fan operation (18) and the connections
Reset and via Uy restore the altered parameters
line voltage is really below the minimum limit, otherwise the line monitor error: replace BMM
Press RESET; if the anomaly persists, replace the board.
Wait for the values to return to default limits / Re­place the Transducer
Wait for the values to return to default limits / Replace the Transducer
Maintenance instructions
45
94 95 99 100 101 102 103
Gas valve wiring
Frequent loss of ame
Internal error
General Lockout not listed
Ignition failure
Short circuit of the iono electrode
Gas valve open delay
46
4.5.1 - FILL THE SYSTEM
By pressing reset icon, start the automatic lling, up to a pressure of 1.2 bar (60 sec. max).
If the system does not reach 1.2 bar pressure within 60 seconds, activate the ll manually by pressing LOAD icon.
47
4.6 - 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 778 pa­rameter must be edited (Factory parameters), see (Chap. 4.2).
A
B
Act carefully, pay attention to the inser­tion direction of the memory board.
48
4.6.1 - SERVICE PANEL
The boiler can be programmed also by
means of the service inner panel. Remove the screws indicated to ex­tract the panel and turn.
Indications related to programming with the emergency panel, can be found at the address indicated on page 2, or on the user / installation manual and maintenance of KONE model boiler.
49
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ed. 06/15
st.
00336315 - 1
46033 casteldario - mantova - italia - tel. +39 0376 57001 - fax +39 0376 660556
AG S.p.A.
info@unical-ag.com - export@unical-ag.com - www.unical.eu
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.
Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press.
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