Unical PK 150 X 2S, PK 230 X 2S, PK 300 X 2S, PK 348 X 2S Installation And Servicing Instructions
PK 150 X 2S
PK 230 X 2S
PK 300 X 2S
PK 348 X 2S
00334158 - 1st edition - 05/2012
INSTALLATION
AND SERVICING
INSTRUCTIONS
2
General Information
CONTENTS
1 GENERAL INFORMATIONI .................................................................................................................................................................................. 3
1.1 Symbols used in this manual ....................................................................................................................................................................... 3
1.2 Correct use of the appliance ....................................................................................................................................................................... 3
1.3 Water treatment ............................................................................................................................................................................................ 3
1.4 Information to be handed over to the user or the person in charge of the appliance ............................................................................. 3
1.5 Safety warnings ............................................................................................................................................................................................ 4
1.6 Data plate ...................................................................................................................................................................................................... 5
1.7 General warnings ......................................................................................................................................................................................... 6
2 TECNICAL FEATURES AND MACHINES ........................................................................................................................................................... 7
2.1 Tecnical featuers .......................................................................................................................................................................................... 7
2.2 Dimensions ................................................................................................................................................................................................... 8
2.3 Performance data ....................................................................................................................................................................................... 10
2.4 Main components ....................................................................................................................................................................................... 11
3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 12
3.1 General warnings ...................................................................................................................................................................................... 12
3.2 Standard codes of installation .................................................................................................................................................................. 13
3.3 Packaging .................................................................................................................................................................................................. 14
3.4 Handling and lifting .................................................................................................................................................................................... 15
3.5 Installation on existing heating system .................................................................................................................................................... 15
3.6 Boiler location ............................................................................................................................................................................................ 16
3.7 Chimney conection ................................................................................................................................................................................... 16
3.8 Condensaet drainage ................................................................................................................................................................................ 18
3.9 Boiler connection ....................................................................................................................................................................................... 19
3.10 Gas conection ........................................................................................................................................................................................... 20
3.11 System connection .................................................................................................................................................................................... 21
3.12 Determination of primary circuit pump or boiler system pump .............................................................................................................. 22
3.13 Frost protection ......................................................................................................................................................................................... 23
3.14 Mixing header and plate heat exchanger ................................................................................................................................................ 26
3.15 Water treatment ......................................................................................................................................................................................... 27
3.16 Casing assembly ....................................................................................................................................................................................... 28
3.17 Filling the system ....................................................................................................................................................................................... 28
3.18 Electrical connections ............................................................................................................................................................................... 29
3.19 Functional low wiring diagram .................................................................................................................................................................. 31
3.20 Types of installation ................................................................................................................................................................................... 32
3.21 Electrical panel .......................................................................................................................................................................................... 34
3.22 Wiring connection for electrical panel ...................................................................................................................................................... 35
3.23 Wiring connection panel within multiinox Master + Slave ....................................................................................................................... 35
3.24 Table positioning selector and cards ........................................................................................................................................................ 37
3.25 Installation examples ................................................................................................................................................................................. 38
3.26 Initial lighting ............................................................................................................................................................................................... 41
3.27 Burner pressure adjustment .................................................................................................................................................................... 42
3.28 Test mode .................................................................................................................................................................................................. 44
3.29 Programming of the operating modes ..................................................................................................................................................... 46
3.30 Operatività di emergenza e sicurezze .................................................................................................................................................... 48
4 INSPECTION AND MAINTENANCE .................................................................................................................................................................. 49
6 CE CERTIFICAT ................................................................................................................................................................................................. 52
Warning: this manual contains instructions to be used exclusively by the
installer and/or a competent person in accordance with the current laws in
force.
The end user MUST not make any alterations to the boiler.
Failure to follow the instructions indicated in this manual, which is supplied
with the boiler, could cause injury to persons, animals or damage to property.
UNICAL shall not be held liable for any injury and/or damage.
3
General Information
1.1 -SYMBOLS USED IN THIS GUIDE
When reading this guide particular care has to be given to the parts marked with the followings symbols:
1.2 - CORRECT USE OF THE APPLIANCE
The PKX appliance has been designed utilizing today’s heating technology and in compliance with the
current safety regulations.However, following an improper use, dangers could arise for the safety and life
of the user or of other people, or damage could be caused to the appliance or other objects.The appliance
is designed to be used in pumped hot water central heating systems. Any other use of this appliance will be
considered improper. UNICAL declines any responsibility for any damages or injuries caused by an improper
use; in this case the risk is completely at the user’s responsibility . In order to use the appliance according
to the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide.
1.3 - WATER TREATMENT (refer to specific guide)
1
GENERAL INFORMATION
NOTE!
Suggestions for the
user
WARNING!
Indicates a potentially dangerous
situation for the product and the
environment
DANGER!
Indicates serious danger
for your personal safety
and for your life
• The hardness of the mains water supply conditions the frequency with which the heat exchanger is
cleaned.
• In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is
recommended. The choice of this device has to be made taking into consideration the characteristics
of the water.
• We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the
end of the first year and subsequently every two years; in this occasion check the state of wear of the
anode.
1.4 - INFORMATION TO BE HANDED OVER TO THE USER
The user has to be instructed on the use and operation of his heating system, in particular:
• Hand over these instructions to the end user, together with any other literature regarding this appliance,
placed inside the envelope contained in the packaging. The user has to keep these documents in a safe
place in order to always have them at hand for future reference.
• Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that is absolutely
forbidden to make any alterations to the boiler.
• Inform the user how to check the system’s water pressure as well as informing him how to restore the correct
pressure.
• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure
the greatest possible fuel economy.
• Remind the user that it is obligatory to carry out a comprehensive service annually and a combustion analysis
every two years (in compliance with the national law).
• If the appliance is sold or transferred to another owner or if the present user moves home and leaves the
appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted
by the new owner and/or installer.
Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause injury
to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/
or damage.
4
General Information
WARNING!
The device should not be used by people with reduced physical, mental and sensory , experience and
knowledge. These people must be well-informed and supervised during the work. Children must be
supervised so they do not play with the appliance.
WARNING!
The installation, adjustment, and servicing of this appliance must be carried out by a competent person and
installed in accordance with the current standards and regulations. Failure to correctly install this appliance
could cause injury to persons, animals or damage to property . The manufacturer shall not be held liable for
any injury and/or damage.
DANGER!
Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL
recommends drawing up a service contract. Bad or irregular servicing could compromise the safe operation
of the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not
be held liable.
Modifications to parts connected to the appliance
Do not carry out any modifications to the following parts:
- the boiler
- to the gas, air, water supply pipes and electrical current
- to the flue pipe, safety relief valve and its drainage pipe
- to the constructive components which influence the appliance’s safe operation
WARNING!
When tightening or loosening the screw pipe connections, use only adequate fork spanners.
The improper use and/or the use of inadequate equipment can cause damages (for example water or gas
leakages).
WARNING!
Indications for appliances operating with propane gas
Ensure yourself that before installing the appliance the gas tank has been purged.
For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legally
authorized.
If the tank has not been correctly purged problems could occur during ignition.
If this occurs contact the liquid gas tank’s supplier.
Smell of gas
If you smell gas follow these safety indications:
- Do not turn on or off electrical switches
- Do no smoke
- Do not use the telephone
- Close the main gas tap
- Open all windows and doors where the gas leakage has occurred
- Inform the gas society or a company specialized in installing and servicing heating systems
Explosive and easily inflammable substances
Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room
where the appliance has been installed.
1.4 -SAFETY W ARNINGS
5
General Information
®
1
2
3
5
7 8
6
4
9
11
13
10
12
14
15
17
19
16
18
20
28
A
B
21 22
23
24
25
26
27
C D
E
The data plate can be found underneath the casing above
the first module's electrical box, a duplicate of the same
data plate can be found on the control instrument's inside
door.
CE Marking
The CE marking documents that the boilers satisfy:
LEGEND:
1 = Y ear of CE certification issue
2=
Boiler type
3=Boiler model
4=Number of stars (Directive 92/42/CEE)
5=(S.N°) Serial number
6=P.I.N. code
7=Approved fluing configurations
8=(N0x) N0x class
A = Central Heating circuit features
9=
(Pn) Nominal output
10 = (Pcond) Condensing nominal output
11 = (Qmax) Nominal heat input
12 = (Adjusted Qn) Adjusted for nominal Heat input
13 =
(PMS) Max. pressure C.H. system
14 = (T max) Max. C.H. temperature
B = Domestic Hot Water circuit features
15 = (Qnw) Nominal heat input in D.H.W. mode (if different from Qn)
16 = (D) Specific D.H.W. flow rate according to EN 625 - EN 13203-1
17 = (R factor) N° taps based on the quantity of water declared EN
13203-1
18 = (F factor) N°stars based on the quality of water declared
EN 13203-1
19 = (PMW) Max. pressure D.H.W. system
20 = (T max) Max. temperature D.H.W system
C = Electrical features
21 = Electrical power supply
22 = Consumption
23 = Protection grade
D = Countries of destination
24 = Direct and indirect country of destination
25 = Gas family
26 = Supply pressure
E = Factory setting
27 = Adjusted for gas type X
28 = Space for national brands
- The essential requirements of the Directive regarding gas
appliances (Directive
2009-142 EC)
- The essential requirements of the Directive regarding
electromagnetic compatibility (Directive 2004/108 EC)
- The essential requirements of the Efficiency Directive
(Directive 92/42/EEC)
- The essential requirements of the low voltage Directive
(Directive
2006/95EC).
1.7 - DATA PLATE
6
General Information
1.7 - GENERAL WARNING
This instruction manual is an integral and indispensable part
of the product and must be retained by the person in charge of
the appliance.
Please read carefully the instructions contained in this manual as they provide important indications regarding the safe
installation, use and servicing of this appliance.
Keep this manual in a safe place for future reference.
The installation and servicing must be carried out in accordance with the regulations in force according to the manufacturer's instructions and by registered engineers or installers.
By a competent person, we imply a person who has a specific
technical qualification in the field of components for central
heating systems for domestic use, domestic hot water production and servicing. The person must have the qualifications foreseen by the current laws in force.
Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property. The manufacturer shall not be
held liable for any such injury and/or damage.
Before carrying out any cleaning or servicing turn off the electrical supply to the boiler by means of the ON/OFF switch and/or
by means of the appropriate shutdown devices.
Do not obstruct the intake/outlet terminal ducts.
In the event of failure and/or faulty functioning of the appliance, switch off the boiler. Do not attempt to make any repairs:
contact qualified technicians.
Any repairs must be carried out by Unical authorized service
engineers and using only original spare parts. Non-observance of the above requirement may jeopardize the safety of
the appliance.
To guarantee the efficiency and correct functioning of the appliance it is indispensable to have the boiler serviced annually by a qualified person.
If the boiler remains unused for long periods, ensure that any
dangerous parts are rendered innocuous.
If the appliance is sold or transferred to another owner or if the
present user moves home and leaves the appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted by the new owner and/or
installer.
Only original accessories must be used for all appliances
supplied with optionals or kits (including electrical ones).
This appliance must be used only for the purposes for which
it has been expressively designed. Any other use shall be
considered incorrect and therefore dangerous
WARNING
If the boiler operates with a forced draught gas burner, the appliance, not appertaining to any category contemplated in the
annexe II of the legislative decree n°93 dated 25/02/2000 (implementation of the PED Directive 97/23/EC), and moreover
also being contemplated in the Gas Appliances Directive 90/396/EEC), to which the art. 1, comma 3 paragraph "f.5" refers
to, results as being excluded from the scope of the same decree.
7
Technical features and dimensions
2.1 - TECHNICAL FEATURES
The PK series ... X is made up of gas heating units and very
low condensing temperature according to dir. 92/42, made
??entirely of stainless steel, high water content, complete with
modulating burner premix.
Efficiency class:
(4) stars
Power supplye 150 to 348 kW
Performance in condensation, more than 107% to 100% and
109% load at 30% load, thanks to the special pipes patented
progressive.
The components of the parts under pressure, such as steel
plates and pipes, are built in stainless steel 316L, according
to the tables EURONORM 25 and EURONORM 28.
The welders and the welding processes have been approved
by TUV (GE) - UDT (PL) - SD (S) and ISPESL (IT).
2
Optional kits:
Neutral Kit NH300 - part number: 00262827 for appliances
up to 300 kW
Neutral Kit NH1500-P part number: 00262829 for appliances upto 300 kW
MODULE MANAGER CASCADE BCM - code 00361602
MODULE SHC (slave heating controller) - code 00362317
TECHNICAL FEATURES
AND DIMENSIONS
- Horizontal direct-fired hearth;
- Tube bundle consisting of armored tubes patented progressive 316L stainless steel exterior with aluminum inner blades, placed in vertical tube bundle 1: functional drainage of
condensate, the absence of acid deposition wet cleaning
severity of heat transfer surfaces;
- Double return for medium and low temperature in the lower
back;
- Smoke chamber with stainless steel condensate drain
connection and condensate level sensor;
- Opening the door to the left with the possibility of change of
rotation;
- Control panel and electronic HSCP Master (Heating
System Control Panel), external to the mantle, with tempe
rature control unit eBus placed vertically at the side door,
single boiler code:
00362322 for PK150X 2S
00362321 for PK230X 2S
00362320 for PK300X 2S
00362318 for PK348X 2S
- For boilers in battery (up to 7), control panel and electronic
slave, external to the mantle, placed vertically at the side
door code:
00362326 for PK150X 2S
00362325 for PK230X 2S
00362324 for PK300X 2S
00362323 for PK348X 2S
- External shell covered with a layer of mineral wool 80 mm
thick in turn protected by a tissue mineral fiber;
- Attack 2 ½ "conduit with an inner diameter of 15 mm
(suitable for housing 3 bulbs each);
- Sides of the coat fitted with holes for cable glands for power
cables and any other assistive device;
- Total premix burner built in AISI 441 and coated with
special fiber:
- Mixing air / gas ratio of 1:1 range of modulation
(modulation ratio greater than 1:4);
- mixing system upstream of the fan, which ensures proper
operation even with low gas supply pressures
(up to 13 mbar);
- reduced power consumption compared to a
conventional forced draft burner;
- Very low emission combustion.
8
Technical features and dimensions
2.2 - MAIN COMPONENTS AND
FUNCTIONING
The PKX boilers are built with a blind furnace, in which the
burner's central flame travels towards the bottom and then is
distributed in the flue pipes; at the terminal part of the pipes
the combustion gas is collected in the flue chamber and then
sent to the chimney. During burner operation, within the boiler's output range, the combustion chamber is always under
positive pressure.
For this pressure value refer to the table on page 8, to the
column "Heating losses flue side".
2
4
5
M
Rmt
Ve
Rbt
1
3
6
7
1. Furnace
2. Flue pipes with flue deflectors
3. Door complete with flame control light
4. Smoke chamber
5. Body insultation
-- Control panel (not visible)
M System flow
Rbt Low temperature system return
Rmt Average temperature system return
Ve Expansion vessel
9
Technical features and dimensions
150
230
300
348
2.3 - DIMENSIONS
1 Control box
2 Flame control sight glass
T1 C.H flow
T2 Average temperature system return
T3 Low temperature system return
T4 Expansion vessel connection
T5 Boiler drainage
T6 Cable sheathing leads bulbs
T7 Cable sheathing leads bulbs
T8 Chimney connection
T9 Burner connection
T10 Condensate drain
Heat
output
(50°-30°C)
kW
150
230
300
348
CONNECTIONS
T 1,T2 ,T3
UNI 2278 PN16T4ISO 7/1
T5
ISO 7/1
T8
Øi
mm
65
65
80
80
1½
1½
2
2
¾
¾
¾
¾
180
180
200
200
150
230
300
348
PKX
2S
Model
Furnace
Output
kW
140
215
279,3
5324
Boiler
Volume
l
151
257
317
389
Water
side
losses (**)
m c.a.
0,27
0,32
0,55
0,60
35
40
45
50
Flue
side
losses
mm c.a.
Max
boiler
working
pressure
bar
5
5
5
5
Weight
without
burner
kg
310
447
540
661
PKX
2S
Model
DIMENSIONS
A
mm
700
830
880
960
(
*) Minimum dimensions for boiler room access requirements.
(**) Hydraulic resistance for delta T 15K.
(***) Minimum pressure gas train entrance (natural gas - G20)
T9
Øi
mm
163
163
163
163
Heat
output
(80°-60°C)
kW
136,5
209,2
273,6
317,7
T10
Øe
mm
40
40
40
40
B
mm
1570
1670
1830
1860
C (*)
mm
625
755
795
785
D
mm
150
150
160
160
E
mm
270
270
305
332
F
mm
491
491
556
586
G
mm
230
230
250
250
H
mm
929
1044
1024
1114
I
mm
685
815
855
965
L
mm
1147
1277
1329
1429
M
mm
433
503
526
576
N
mm
364
454
483
533
O
mm
350
320
320
320
P
mm
150
170
170
170
R
mm
107
107
109
109
S
mm
1183
1209
1300
1333
T (*)
mm
1650
1765
1920
1950
U
mm
80
95
90
90
Gas
pressure
(***)
mbar
20
20
20
20
T6,T7
Øi
mm
163
163
163
163
2
1
10
Technical features and dimensions
PK348X 2S
324
70
317,7
68,5
348
76,1
98,0
97,8
107,4
108,7
109
4
98,20
96,81
98,0
98,5
0,6
0,1
30
50
11,4
529,5
25,53
9,1
9,1
83,8
4
1,5
2
0,1
13660
0,5
5
389
34,26
7,40
39,85
8,61
25,15
5,43
100
52,16
10
58
230/50
6,3
370
20
18
PK300X 2S
280
70
273,6
68,4
300
76,1
97,9
97,7
107,4
108,7
109
4
98,20
96,81
97,5
98,5
0,7
0,1
30
50
114,4
457,6
25,53
9,1
9,1
89,7
4
1,5
2,5
0,1
11781
0,5
5
317
29,61
7,40
34,43
8,61
21,73
5,43
100
45,08
10
61
230/50
6,3
315
20
18
PK150X 2S
140
35
136,5
34,3
150
38,1
97,5
98,0
107,1
108,8
109
4
97,27
95,41
97,5
98,5
0,5
0,1
30
50
57,2
228,8
25,53
9,1
9,1
47,83
5
1,5
2,5
0,1
5870
0,5
5
151
14,8
3,70
17,22
4,30
10,87
2,72
100
22,54
19
45
230/50
6,3
280
20
18
BOILER TYPE
Boiler family gas category II 2H3P I
2H
Nominal heat input on LCV Qn kW
Minimum heat input on LCV Qmin kW
Nominal heat output (Tr 60/Tm 80°C) Pn kW
Minimum heat output (Tr 60/Tm 80°C) Pn min kW
Nominal heat output (Tr30/Tm 50°C) Pcond kW
Minimum heat output (Tr 630/Tm 50°C) Pcond minkW
Efficiency at nominal output (Tr 60/Tm 80°C) %
Efficiency at minimum output (Tr 60/Tm 80°C) %
Efficiency at nominal output (Tr30/Tm 50°C) %
Efficiency at minimum output (Tr30/Tm 50°C) %
Efficiency at partial load 30% (Tr 30°C) %
Efficiency Class
Efficiency at 100% %
Efficiency at partial load 100% (30%) %
Combustion efficiency at nominal load %
Combustion efficiency at reduced load %
Flue losses with burner On %
Flue losses with burner Off %
Flue gas temperature tf-ta (min) °C
Flue gas temperature tf-ta (max) °C
Flue gas mass flow rate (min) kg/h
Flue gas mass flow rate (max) kg/h
Air excess %
CO2 (min) %
CO2 (max) %
N0x (value according to EN 297/A3)
mg/kWh
N0x class
Heat loss at chimney with burner on (min) %
Perdite al camino con bruciatore funzionante (max) %
Heat loss at chimney with running burner (max) %
Water flow rate at nominal output (delta T 20°C) l/h
Minimum pressure CH circuit bar
Maximum pressure CH circuit bar
Water content l
Natural gas consumption G20 (20mbar) at Qn m3/h
Natural gas consumption G20 (20mbar) at Qmin m3/h
G25 gas consumption (20/25 mbar) at Qn m3/h
G25 gas consumption (20/25 mbar) at Qmin m3/h
Propane gas consumption (37/50 mbar) at Qn kg/h
Propane gas consumption (37/50 mbar) at Qmin kg/h
Max. available pressure at chimney base Pa
Max. condensate production (15°C) kg/h
Emissions
C0 at 0% of 02 in the flue gasses ppm
NOx with 0% of 02 in the flue gasses ppm
Electrical data
Electrical supply V/Hz
Fuse rating A (F)
Maximum/Minimum absorbed power W
Electrical protection IP
Stand-by consumption W
PK230X 2S
214
50
209,2
49
230
54,5
97,7
98,0
107,4
109
109
4
98,20
96,81
97,9
98,5
0,5
0,1
30
50
80,97
346,5
24,25
9,2
9,2
68,65
5
1,48
2,1
0,1
8994
0,5
5
257
22,63
5,29
26,32
6,15
16,61
3,88
100
34,45
19
76
230/50
6,3
300
20
18
(*) Room temperature = 20°C
(**) See table "INJECTORS-PRESSURES"
2.4 - PERFORMANCE DATA
11
Instructions for the installer
3
INSTRUCTIONS FOR
THE INSTALLER
3.1 - GENERAL WARNINGS
AThis boiler has to be destined for the use for
which it has been expressively designed for.
Any other use shall be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.
WARNING!
These appliances are exclusively designed
to be installed inside adequate boiler rooms.
Before installing the boiler the following
points have to be carried out by a competent
engineer:
a) The whole system should be thoroughly
flushed in order to remove any residual
dirt or grime which could compromise the
good operation of the boiler, even from a
hygienical point of view.
b) Check that the boiler has been preset for
operating with the gas type available.
This is verifiable via the indication on the
packaging and on the data badge;
c) Check that the chimney/flue pipe has an
adequate draught, does not have any
constrictions, and that no other applian
ce's flue outlets have been fitted, unless
the chimney is serving more than one
heating appliance, according to the spe
cific standards and regulations in force.
The connection between the boiler and chimney/flue outlet can be made only after this verification has been carried out.
WARNING!
In rooms where aggressive vapours or dust
is present, the appliance must operate
independently from the air present in the
boiler's location room!
WARNING!
The appliance must be installed by a registered engineer or gas installer.
The boiler must be connected to a heating
system which is compatible to its performance
and output.
12
Instructions for the installer
3.2 - STANDARD CODES FOR
INSTALLATION
This appliance must be installed in compliance to the manufacturer's instructions and
the national regulations in force. Read the instructions fully
before installing or using the appliance
In the interests of safety, a competent installer should be employed to effect the installation of the appliance.
Moreover, the installation of the boiler MUST be in accordance with the latest wiring regulations local buildings regulations and any relevant requirements regarding central heating plants in force in the country the boiler is installed.
The MULTIINOX boilers are a range of heating units in stainless steel foreseen for the II2H3P family gas category.
3
INSTRUCTIONS FOR
THE INSTALLER
3.1 - GENERAL WARNINGS
AThis boiler has to be destined for the use for
which it has been expressively designed for.
Any other use shall be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.
WARNING!
These appliances are exclusively designed
to be installed inside adequate boiler rooms.
Before installing the boiler the following
points have to be carried out by a competent
engineer:
a) The whole system should be thoroughly
flushed in order to remove any residual
dirt or grime which could compromise the
good operation of the boiler, even from a
hygienical point of view.
b) Check that the boiler has been preset for
operating with the gas type available.
This is verifiable via the indication on the
packaging and on the data badge;
c) Check that the chimney/flue pipe has an
adequate draught, does not have any
constrictions, and that no other applian
ce's flue outlets have been fitted, unless
the chimney is serving more than one
heating appliance, according to the spe
cific standards and regulations in force.
The connection between the boiler and chimney/flue outlet can be made only after this verification has been carried out.
WARNING!
In rooms where aggressive vapours or dust
is present, the appliance must operate
independently from the air present in the
boiler's location room!
WARNING!
The appliance must be installed by a registe-
red engineer or gas installer.
The boiler must be connected to a heating
system which is compatible to its performance
and output.
13
Instructions for the installer
3.3 - PACKAGING
The PKX boilers are delivered fully complete with door and
smoke chamber already
fitted, whilst the casing with the insulation mattress is contained in separate cardboard
packaging(s). The control panel and accessories are inside
the combustion chamber.
Before starting the installation make sure that the length and
the width of the boiler body received, indicated in the table on
page 8, correspond to the dimensions of the ordered boiler,
and that the cartons, containing the casing, or part of it, are
marked as indicated below.
The casing of the boilers PK X complete with the insulation
mattress, is contained in n°2 cartons.
(1 carton for the PK 150 X S2).
In addition to the above indicated control panel, packaged in
its own carton, in the combustion chamber as accessories,
there are also:
- a carton containing the flanges for flow, return and safety
connections (if applicable) with relevant gaskets and bolts;
- ceramic fibre rope for the insulation between the door and
burner blast tube;
- 1 bag containing the condensate drain kit
After having unpacked the boiler check that it is
intact and undamaged.
Keep the packaging material (cardboard box,
plastic bags, polyester protection etc.) out of
the reach of children as they can be dangerous.
UNICAL refuses all liability for injury to persons, animals or damage to property deriving
from not having respected the above mentioned recommendations.
In the packaging, in addition to the boiler, you can also find
the following contents:
- Hydraulic test certificate
- Service logbook
- Instruction manual for the person in charge of the
appliance
- Instruction manual for the installer and servicing
personnel
- Warranty certificate
- Adhesive sticker indicating local venting regulations
ISOLATION AND CASING
N.B. For the model PK150X 2S, mantle and isolation are
contained in 1 package marked:
38353 (casing insulation PK150X + 2S)
N.B. For models PK230X 2S, PK300X 2S PK348X 2S the
casing and insulation are contained in 2 packages
marked:
37462 (casing side + isolation PK230X 2S)
37463 (casing front. + back + cover PK230X 2S)
38355 (casing side + isolation PK300X 2S)
38354 (casing front. + back + cover PK300X 2S)
37464 (casing side + isolation PK348X 2S)
37465 (casing front. + back + cover PK348X 2S)
CONTROL PANEL
N.B. For the model PK150X 2S the control panel is contai-
ned in a package marked:
00362322 (control panel with control unit + exter
nal probe EBUS)
00362326 (PK150X 2S control panel "Slave")
N.B. For models PK230X 2S the control panel is contained
in a package marked:
00362321 (control panel with control unit EBUS + ex
ternal probe)
00362325 (control panel "Slave")
N.B. For models PK300X 2S the control panel is contained
in a package marked:
00362320 (control panel with control unit + exter-
nal probe EBUS)
00362324 (control panel "Slave")
N.B. For models PK230X 2S the control panel is contained
in a package marked:
00362318 (control panel with control unit EBUS +
external probe )
00362323 (control panel "Slave")
ACCESSORIES
N.B. The hydraulic connection flanges with gaskets and bolts
are contained in a package marked:
36372 (accessories PK150X S2 PK230X S2)
36373 (accessories PK300X S2 PK348X S2)
N.B. The condensate drain kit is contained in a package
labeled: 27982
14
Instructions for the installer
When the appliance is installed on existing systems, ensure
yourself that:
- The flue outlet pipe is suitable for condensing boilers, for
the temperature of the products of combustion, calculated
and manufactured according to the regulations in force. It
must be installed as much as possible in a straight line,
tested for soundness, insulated and must not have any
occlusions or restrictions.
- The flue outlet pipe has a connection for the discharge of
condensate.
- The boiler room has a suitable outlet for the discharge of
condensate produced by the boiler.
- The electrical system has been fitted in compliance to the
specific standards and the work has been carried out by a
competent person.
- The circulation pump's output, the head and flow direction are suitable.
- The gas feed supply pipe and eventual tank are constructed according to the regulations in force.
- The expansion vessels assure the total absorption of the
expansion of the fluid contained in the system.
- The system has been cleaned of impurities and lime scale.
3.5 - INSTALLATION ON EXISTING
HEATING SYSTEMS
3.4 - HANDLING AND LIFTING
The boiler can be moved by lifting, via the holes
or upper hooks.
If necessary, due to the dimensions of the boiler,
it is possible to remove the front door to facilitate
the introduction in the boiler house.
A
A
15
Instructions for the installer
3.7 - CHIMNEY FLUE CONNECTION
In condensing boilers the flue gases are evacuated at a very
low temperature (max about 84°C). Therefore the chimney
must be perfectly impermeable to the condensate of products
of combustion and built with suitable materials which are resistant to corrosion.
The different spigot joints must be well sealed and equipped
with suitable gaskets, in order to prevent the outlet of condensate and the inlet of air.
Furthermore ensure that the possible condensate or rain water coming from the chimney does not
enter the boiler's flue chamber.
Refer to applicable regulations while determining the size
and height of the flue.
In order to prevent the formation of ice during normal boiler
operation, the temperature of the internal wall of the combustion product evacuation system, in all its length, has not to be
below 0°C.
The flue must be installed in accordance with the recommendations of local and national codes of practice.
The flue pipe must be built using materials resistant to products of combustion, in Class W1, in accordance to EN 1443,
in stainless steel or certified plastic. This can be PVDF
(polyvinylidene fluoride) or PPS (Polyphenylene sulfide) or
otherwise aluminium or different materials but with equivalent characteristics which comply to the regulations in force.
3.6 - BOILER LOCATION
The boiler must be installed in accordance with the relevant
requirements of the Gas Safety Regulations, current I.E.E.
Regulations, local water authority by e-laws and it should also
comply with any relevant requirements of the local gas supplier, local authority and the relevant Standard Codes of Practice and building regulations.
The boiler house must be ventilated via permanent openings
having a total surface not inferior to 1/30th of the floor area of
the boiler house, with a minimum of 0.5 m
2
It is advisable to install the boiler as close as possible to the
chimney connection on a non combustible floor (i.e. concrete
or brick).
To facilitate cleaning of the flue circuit the boiler must have
sufficient clearance space in front, not less then the length of
the boiler body and, in any case, never less then 1300 mm.
When the door is open 90° the distance between the door
and the adjacent wall must be at least equal to the burner
length.
The surface must be flat, level, and of a suitable load bearing
capacity to support the weight of the boiler (when filled with
water - see general data table).
If the boiler is mounted on a plinth then the dimensions (see
Frame 2) of the plinth must be at least CxZ (refer to the table
dimensions).
Once the boiler has been installed it must be perfectly horizontal and stable (to avoid vibrations and noise).
1000
X
XX
XX
600
600
X = not less then the length of the boiler body (dimensions
given in millimetres); in any case never less than 1300 mm.
XX = see instructions.
16
Instructions for the installer
Esemple:
PK 230X 2S
Flue gas mass flow rate = 349,6 Kg/h
Chimney height = 25 m
Chimney connect. diam. = 200 mm
Note: The diagram shows indicative values
Co level
2
d125
a
d400
a
d315
a
d 250
a
d200
a
d160
a
d110
a
d75
a
6
7
8
9
10
12
14
16
18
20
30
40
50
60
70
80
90
100
120
140
160
180
200
300
400
500
600
700
800
900
1000
1200
1400
4,4
5,9
6,6
7,4
8
9
10
12
22
30
37
44
52
59
66
74
89
104
119
133
148
222
296
370
444
519
593
668
741
889
1037
3,4
3,9
4,4
5,0
5,6
7
8
9
11
17
22
28
34
39
44
50
56
67
78
89
100
111
167
222
277
333
389
445
555
667
778
0,001
0,002
0,003
0,004
0,005
0,006
0,007
0,008
0,009
0,010
0,015
0,020
0,030
0,035
0,040
0,050
0,060
0,070
0,080
0,090
0,100
0,150
0,200
0,250
0,300
0,350
0,400
0,500
0,600
5
0,700
9,0
10,8
12,0
14,4
22
25
29
32
36
54
72
90
108
126
144
180
216
252
288
324
360
540
720
900
1080
1260
1440
1800
2160
2520
6
7
8
9
10
12
14
16
18
20
30
40
50
60
70
80
90
100
120
140
160
180
200
300
400
500
600
700
800
900
1000
1200
1400
8%
6%
kg/skg/h 10%
10 15 20 25 30
51015202530
Flue gas
mass rate
40°C
396
240
40 Pa
Chimney dimension
DIN 4705
Pressure avaible
Flue Gas Temperature
Nominal Heat input (kW)
Nominal Heat input (kW) with CO level at 10%
2
PK ... X 2S
150
230
300
348
Flue gas mass
flow rate (max)
kg/h
228,8
349,6
457,7
529,6
Flue gas mass flow rate
17
Instructions for the installer
The condensate drain system must be:
- built in order to prevent the products of combustion discharging in the ambient or in the sewage(siphon);
- sized and built so as to permit the correct flow of the liquid
discharges preventing any eventual leakages;
- installed in such a way to prevent the liquid contained
inside freezing in cold weather
- The condensate, before being evacuated to the sewer,
has to be neutralized, neutralisation which can be obtained by mixing the drain water coming from washing machines, dish washers etc., which normally have a base
pH.
To maintain proper flow of condensate the drain pipe must
have an inclination toward the drain of at least 30 mm/m
(3/8 in./ft). The liquid column inside the condensate siphon
needs to be filled with water after installation. Its minimum
height when all the fans are in operation must be at least
25 mm (1 in).
Given the acidity degree (pH 3 to 5 ) only plastic material
can be used for the condensation evacuation pipes (special optional neutralization kits are available on request).
* Minimum height safety siphon required by the Standard
** Minimum height with boiler running at maximum output
If the boiler is not installed on a plinth then it can be fitted
directly onto the boiler floor and than a deep well of at
least 100 mm will be required to house the siphon.
3.8 - CONDENSARE DRAIN
Any neutralization devices can be connected to the condensate after the trap.
For the calculation of the neutralization of the charge must be
assessed the state of wear of the neutralizer after a year of
operation.
Based on this information you can extrapolate the total duration of the charge.
For the neutralization of the condensate neutralizer kits are
available NH 300 and NH 1500-P.
KIT NEUTRALIZATION NH 300 - code 00262827
L 'NH neutralization unit 300 is designed to:
- Appliances with power up to 300 kW
- Works well with condensate drain the boiler placed lower
down the condensate drain the boiler.
This unit does not require neutralization of the electrical connections.
KIT NEUTRALIZATION NH 1500-P - code 00262829
The 'unit of neutralizing NH 1500-P is designed to:
- Appliances with power up to 1500 kW
- Works well with condensate drain the boiler placed higher
condensate drain the boiler.
This unit requires the neutralization of electrical connections.
Flue chamber
Base (H min 100 mm)
To the condensate
drain
The upper part of the drain pipe
must not be higher then the tray bottom
Boiler room floor
Initial trap
filling-up plug
18
Instructions for the installer
3.9 - FIRE DOOR: ADJUSTMENT,OPENING &
CLOSING
IMPORTANT
- The door must be opened only when the boiler
is cold to avoid causing damages to the fibre
lining due to thermal stress.
- The door's fibre lining can crack after a brief
period of boiler operation; this however does
not reduce it's insulating capacity or it's life
span.
- The door's fibre lining is easily replaceable
and is covered by a 2 years guarantee.
For these models the door is assembled according to fig. 6.
The door is therefore installed with two rotating hinges on the
left hand side; the door is shut via 4 screws (position C).
The door mounting can be reversed so that it hinges from left
to right.
Door adjustment:
A) Axial door adjustment: further adjustment to the position of
the door in relation to the chamber can be achieved through adjustment o the screws.
WARNING
Before opening the furnace door it is necessary to adopt the following precautions:
- Close the fuel cock (oil or gas) to the
burner.
- Cool down the boiler by keeping the
water circulating through it, and only then
switch off the power.
- Place a Warning sign on the boiler with
the following text: DO NOT USE , BOILER OUT OF ORDER, TO BE SERVICED.
19
Instructions for the installer
3.10 - GAS CONENCTION
DANGER!
The gas connection must be carried out only
by a qualified registered engineer who will
have to respect and comply to the regulations
in force and to the requirements indicated by
the local gas supplier. An incorrect installation could cause injury to persons, animals or
damage to property. The manufacturer shall
not be held liable for any injury and/or
damage.
Before installing the boiler it is recommended
to thoroughly clean all the supply piping in
order to remove any eventual residual grime
which could compromise the boiler's correct
functioning.
If you smell gas:
a. Do not turn on or off electrical switches,
use the telephone or any other object which
can provoke sparks;
b. Open all doors and windows in order to
allow fresh air to enter and purify the room;
c. Close all gas cocks
d. Contact a service engineer, qualified
installer or your gas supplier.
As a safety measure against gas leaks,
Unical recommends installing a surveillance
and protective system composed of a gas
leakage detector combined with an on-off
selenoid valve fitted on the gas supply line.
The gas supply pipe must have a section which is adequate
to the burner's output.
It is however important to comply with the specific standards
and requirements in force.
Before commissioning an internal gas distribution system
and therefore before connecting it to the gas meter, the
complete installation must be tested for gas soundness.
If any part of the system is concealed from view the gas
soundness test must be carried out before covering the
pipes.
Before connecting the pipework the system must be tested
with air or inert gas at a pressure of at least 100mbar.
Before commissioning the boiler ensure that the following
operations are carried out:
- Open the gas meter cock and vent the air contained in
the piping and subsequently proceed to vent device by
device.
- Check, with the gas cock turned off, that there are no gas
leaks. During the 2nd quarter of the hour from the start of
the test, no pressure drop should be detected by the
pressure gauge. Any gas leaks must be found by using
only water soap solutions, or an equivalent product, and
eliminated.
- Never look for gas leaks using a naked flame.
1 2 3 4 5 66
1 On-off gas supply valve
2 Double membrane regulator
3 Gas Filter
EXAMPLE OF A GAS SUPPLY SYSTEM
4 Anti-vibrating joint
5 Selenoid valve
6 On-off cock
20
Instructions for the installer
WARNING!
IT IS ABSOLUTELY FORBIDDEN TO FIT ONOFF VALVES ON THE BOILER BEFORE THE
SAFTEY DEVICES
CH pressure relief valve drainage
In correspondence to the CH pressure relief valve, provision should be made to install a discharge pipe with a
funnel and a siphon which lead to an adequate drainage.
The drainage has to be controllable by sight.
WARNING!
If this precaution is not taken it could lead to
injury to persons, animals or damage to
property. The manufacturer shall not be held
liable for any such injury and/or damage
Expansion vessel connection
The PK...X 2S boilers are suitable for operating with a forced water circulation with an
open or closed water tank.
An expansion vessel is always needed
because it compensates the increase in
water volume caused by heating.
Filling /drainage connection
The boiler can be filled and drained by providing an appropriate external cock on the system's return pipe T5.
3.11 - SYSTEM CONNECTION
WARNING!
Before connecting the boiler to the heating
system we recommend that the system is
flushed out with a suitable product in order to
eliminate any metallic tooling or welding
residues, oil and grime which could reach
the boiler and affect the proper running of the
boiler.
Do not use any solvents for flushing out the
system as they could damage the system
and/or its components.
Non-observance of these instructions could
cause injury to persons, animals or damage
to property. The manufacturer shall not be
held liable for any such injury and/or damage.
The CH flow and return circuits have to be connected to the
boiler via the respective connections as indicated on page
8.
When determining the size of the CH circuit pipes it is
essential to bear in mind the pressure losses induced by
any of the system's components and by the configuration of
the system.
The route of the piping has to be conceived taking all the
necessary precautions in order to avoid air locks and to
facilitate the continuous purging of the system
Ensure yourself that the system's piping is
not used as the earth clamps for the electrical
or telephonic system. They are absolutely
unsuitable for this use. In a short time this
could cause serious damage to the piping,
boiler and radiators.
21
Instructions for the installer
Perdita di carico lato acqua
0
0,5
1
1,5
2
2,5
3
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
Q : portata acqua (l/h)
perdita di carico (mmh2O)
PK150X 2S
230 300 348
8994
11781
13660
11992 15708
18213
150
5870
7826
Power supply in kW
Max flow rate
demanded in l/h
( t=15 K)
Δ
Nominal flow rate
requested in l/h ( t=20 K)
Δ
3.12 - DETERMINATION OF PRIMARY CIRCUIT PUMP OR BOILER SYSTEM PUMP
The boiler pump must have a delivery head which can
ensure the water flow rate as shown in the graph "Water
pressure losses".
The following table gives an indication of the pump's flow
rate in function of the ?t of the primary circuit.
The size of the pumps must be determined
by installers or technical engineers according to boiler data and system design.
The water side resistance curve of the boiler
is shown in the following graph.
The pump is not an integral part of the boiler.
We recommend you choose a pump with the
rate and discharge head at about 2/3 of its
characteristic curve.
Q: water flow rate (l/h)
WA TER SIDE PRESSURE LOSSES
Pressure losses (mmH2O)
22
Instructions for the installer
Perdita di carico lato acqua
0
0,5
1
1,5
2
2,5
3
3,5
4
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 32000 34000 36000 38000
Q : portata acqua (l/h)
perdita di carico (mmh2O)
PK230X 2S
Perdita di carico lato acqua
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 32000 34000 36000 38000 40000 42000 44000 46000 48000
Q : portata acqua (l/h)
perdita di carico (mmh2O)
PK300X 2S
Q: water flow rate (l/h)
Pressure losses (mmH2O)
WA TER SIDE PRESSURE LOSSES
Q: water flow rate (l/h)
Pressure losses (mmH2O)
WA TER SIDE PRESSURE LOSSES
23
Instructions for the installer
3.14 - MIXING HEADER AND PLATE HEAT EXCHANGER
In order to ensure correct boiler operation it is necessary to
use a mixing header which guarantees:
- the separation and collection of circuit dirt
- optimal air venting
- hydraulic de-coupling of the two hydraulic circulation
circuits
- balancing of the circuits
A suitably sized plate heat exchanger has the advantage of
separating the two circuits (primary and secondary), permitting the installation of the boiler in an industrial design.
Perdita di carico lato acqua
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6
0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000
Q : portata acqua (l/h)
perdita di carico (mmh2O)
PK348X 2S
Q: water flow rate (l/h)
Pressure losses (mmH2O)
WA TER SIDE PRESSURE LOSSES
3.13 - FROST PROTECTION
If the flow temperature (measured at global flow NTC) falls
below 7°C, the system pump circulates water around the
water circuit and all the heat modules will operate at
minimum output.
Note: The anti-freeze solution must be compatible with the
materials used on the entire heating system and tolerable
with aluminium alloys.
WARNING:
If the boiler has remained unused for a long
period, and you notice the presence of
frost (temperatures of < 3°C), do NOT fire
the boiler. Fire the boiler only of you know
that an anti-freeze solution has been
added in the proper percentage to the
primary circuit.
24
Instructions for the installer
1 2 3 4 5 2 7 16
3.15 - WATER TREATMENT
The chemical-physical characteristics of the filling water and
reinstatement water in heating systems are of fundamental
importance for guaranteeing correct and safe boiler operation.
Before filling the CH circuit with water, it is necessary to analyse
the water and decide for a proper treatment.
The purpose of this treatment is finalized to eliminate or
substantially reduce the following problems:
- lime scale deposit
- corrosions
- deposits
- biological growths (moulds, bacteria, algae, fungi, etc)
The chemical treatment of the network water enables the
prevention of these problems and guarantees safe boiler
operation and economical advantages, in terms of
maintenance and global thermal efficiency.
The chemical analysis of the water enables us to obtain a lot
of information on the system’s condition and state of “health”.
It is essential to avoid any problems with the boiler.
The pH is a measure of the acidity or alkalinity of a solution.
The pH scale has a range of 0-14, where 7 is neutral.
Values inferior to 7 indicate acidity, values above 7 indicate
alkalinity.
The ideal pH value for water in heating systems fitted with
aluminium boilers is between 6,5 and 8, with a hardness of
15°F.
In heating systems where the water has a value outside this
range, this considerably accelerates the destruction of the
protective oxidized layer which naturally develops inside the
aluminium bodies: if the pH is below 6, acidity is present, if it is
above 8, the water is alkaline or it is caused by an alkaline
treatment (for example phosphate or glycol used as an
antifreeze) or in several cases it is due to the natural formation
of alkaline in the system.
Vice versa, if the pH value is between 6,5 and 8, the aluminium
surfaces of the boiler body are passivated and protected from
further corrosive attacks.
To minimize corrosion it is essential to use a scale inhibitor,
however in order for this to function correctly, the metallic
surfaces have to be clean.
The best corrosion inhibitors on sale also contain a
protective system for aluminium which acts by stabilizing
the water’s pH value, preventing unforeseen variations.
We recommend that the heating system’s water pH value
is systematically controlled (minimum twice a year). In order
to do this, it is not necessary to run a chemical analysis in
a laboratory, but it is sufficient to use a simple analytical
‘kit’ contained in portable cases, easily found on sale.
Therefore, prior to filling the heating system with
water it will be necessary to fit the devices
indicated in the figure below.
THE CONNECTION MUST BE FITTED ON THE PRIMARY
CIRCUIT’S RETURN PIPE DOWNSTREAM OF THE
CIRCULATING PUMP
All the necessary precautions must be taken in order to avoid
the formation and localization of oxygen in the system’s water.
For this reason, the plastic pipes used in underfloor heating
systems must be impermeable to oxygen.
If any antifreeze solutions are used ensure yourself that they
are compatible with aluminium and with any other components
and materials fitted on the system.
WARNING!
ANY DAMAGE CAUSED BY THE BOILER, DUE
TO THE FORMATION OF LIME SCALE OR DUE
TO CORROSIVE WATER WILL INVALIDATE THE
APPLIANCE WARRANTY.
1. Ball valve
2. Inspection pocket
3. Filling-up group
4. Disconnector
5. Scale reducing device
6. Litrecounter
(recommended)
7. “Y” filter
EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FOR WATER TREATMENT
25
Instructions for the installer
3.16 - CASING ASSEMBLY
(con pannello comandi montato a destra)
2
1
3
A. Fit the insulation blanket (1) onto the boiler shell and secu-
re in to place using the elasticated straps (2) provided,
ensuring that the metal clips grip in to the external surface
of the insulation.
B. Fit the boiler shells top insulation blanket (3) and secure in
to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of
the boiler shell's insulation.
Make a convenient cut in the upper part of the insulation blanket to get easy access to the bulb holders
C. Fit the self-tapping screws onto the internal profiles of the 2
side panels (4 and 5 ).
D. Fit the left side panel (4) fixing it on to the front panel and
securing it to the top left squadretta on the boiler shell,
inserting the lower bend inside the bottom L profiles.
26
Instructions for the installer
E. After removal of the two side screws from the control panel
rotate its cover towards the front
and insert the cables and the capillaries of thermometer and thermostats through the slots on its base.
Fit the control panel to the right hand side panel (5).
F. Fit the right hand side panel (5) to the lower panel and fix it
to the upper squadretta on the right hand side of the boiler
body, inserting the lower bend inside the bottom L profiles.
G. Insert the thermometer and thermostat bulbs in the sensor
pockets as shown in Fig. 8
boiler sensor
termometer
sensor
HL thermostat
sensor
and connect the mains, the burner, the pump(s) and
any equipment to the control panel.
PF
SL
27
Instructions for the installer
Guide the burner plug through the side cable clamp plate(6) and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates to the casing side
panels.
Refit the upper shell of the control panel.
H. Fit the top panel (8) and fix it onto the side panels (4 & 5).
I. Fix the retaining strips (9) onto the lower left hand side
rear panel (4) and to the upper panel (8).
10
8
4
8
4
5
L. Fit the right hand side rear panel (10) onto the left hand
side rear panel (4) and to the upper rear panel (8).
10
9
Fix the platelets (pos 6) support the two sides of the conduit and the plate (pos 7) closing the lateral left side.
28
Instructions for the installer
O. Position the top panels (14 and 15) and press them
against the side panels.
M. Fit the lower right hand side rear panel (11) onto the right
hand side rear panel (5), to the left hand side rear panel
(10) and to the upper rear panel (8).
Unite the two rear panels with the retaining strips profile
(12).
N. Fit the lower front panel (13)and fix it on to the side panels
(4 and 5).
13
4
5
14
15
P. Remove the protective paper film from the data plates and
fit them on to the side panel.
The data plates are in the plastic bag containing the documents.
Warning!
In the event that the panel is mounted on the left
side, you must turn the temperature control unit
eBus.
To turn the temperature control unit eBus on the control panel,
you must:
Q) remove the two screws "1" cover fixing "2" access to the
terminal unit of the "3",
Montaggio del pannello comandi sul lato sinistro
3
1
2
1
29
Instructions for the installer
R) after removing the cover disconnect the connector "4", un-
screw the 2 nuts "5" and remove the bracket "6",
4
S) Turn the Unit 180°,
5
6
5
T) to reposition the unit "3", through the bracket "6" and ti-
ghten the 2 nuts "5",
3
5
6
5
U) plug the connector "4" on the unit,
4
V) replace the cover "2" access to the terminal unit, and se-
cure with the two screws "1".
1
2
30
Instructions for the installer
3.17 - SYSTEM FILLING AND DRAINING
Warning!
Do not mix the CH system's water with antifreeze or anti-corrosion solutions using
wrong concentrations! It could cause damage to the washers and could provoke noise
during normal boiler operation.
UNICAL refuses all liability for injury to
persons, animals or damage to property
deriving from not having respected the above
mentioned recommendations.
After completing all the system's service connections the
circuits may be filled.
To fill the system it is necessary to fit a filling cock on the
system's return.
The boiler is equipped with its own drain tap, whose
position is indicated in the figure on page 17.
This tap must NEVER be used for draining of the whole
system as this could lead to system dirt gathering in the
boiler, compromising good boiler operation. Therefore, the
system has to be fitted with its own draining tap, of the right
size for the system's capacity.
GRUPPO DI
CARICAMENTO
EXAMPLE OF FILLING MANIFOLED
FILLING MANIFOLD
31
Instructions for the installer
Mains electrical supply connection 230V
The electric connections of the boiler are shown in the section
named “ACTUAL WIRING DIAGRAM” (paragraph 3.19 page
31)
The boiler installation requires a mains supply of 230 V - 50
Hz. The wiring to the boiler must conform to current CEI regulations.
The supply cable must have the following characteristics: PVC
HT CABLE H05V2V2-F 3x0,75
DANGER!
The electrical connections must be carried out
only by a qualified engineer.
Before carrying out the connections or any
other operation on the electrical parts, always
switch off and disconnect the electricity supply
and ensure yourself that it cannot be accidentally turned on.
It is necessary to fit a double pole switch on the
electrical supply line, having a 3 mm contact
separation in both poles, in an easy accessible
position in order to make quick and safe the servicing operations.
The supply cable must be replaced only by
highly qualified personnel. Failure to do so
could compromise the appliance's safety.
WARNING!
We remind you that upstream of the electrical
connection, it will be necessary to foresee a
service relay (NOT SUPPLIED) which, when
the electrical safety devices (ISPESL) intervene, shuts down the electrical supply to the onoff fuel valve fitted on the gas supply circuit,
but not to the boiler so as to guarantee the
running of the pump and permit the boiler to
cool down.
- Gain access to the Y1 terminal board
- Room thermostat: connect the thermostat's cables to the
terminals 1 and 2.
DANGER!
Switch off and disconnect the electricity supply before carrying out any operations on the
electrical parts.
Room
Thermostat
Room thermostat connection
3.18 - ELECTRICAL CONNECTIONS
General warnings
The elctrical safety of the appliance is assured only when it is
correctly earthed, according to the electrical rules in force.
The gas, D.H.W. and the CH system pipes cannot be used as
ground plates.
Ensure that the above safety electrical requirements subsist;
in case of doubt, ask for a professionally qualified technician
to check the appliance’s electrical system.
UNICAL refuses responsibility for any damages arising from
failure to earth the boiler correctly.
It is necessary that a qualified technician verifies that the
electrical system is adequate to the appliance’s maximum
absorbed power, indicated on the data plate, verifying in
particular that the section of the system’s cables is suitable
to the appliance’s maximum absorbed power.
For the appliance’s general electrical supply the use of
adaptors, multiple sockets and/or extension cords is strictly
forbidden.
The use of any power supplied equipment implies the
observance of several fundamental rules, such as:
- Do not touch the appliance with any wet part of your body
and/or barefooted;
- Do not pull the supply cables
- Do not expose the boiler to sunlight, rain, etc., unless it is
explicitly foreseen;
- Do not permit children or inexpert people to use the
appliance.
32
Instructions for the installer
- Gain access to the rear of the eBus and remove the
terminals numbered from 5 to 11.
- Outdoor sensor connection: insert the cables between
the pins 9 and 10 on the e-Bus terminal board.
DANGER!
Switch off and disconnect the electricity supply before carrying out any operations on the
electrical parts.
Outdoor sensor connection
EBUS UNIT
1234 5678 910
11
OUTDOOR
SENSOR
0
1
2
3
4
5
6
7
8
9
BUS +
Single boiler
DANGER!
Switch off and disconnect the electricity supply before carrying out any operations on the
electrical parts.
- Gain access to the Y2 terminal board on the BCM
Cascade controller
- Outdoor sensor connection: insert the cables between
the pins 6 and 7 on the terminal board.
Boilers installed in a cascade formation
OUTDOOR
SENSOR
123Y24567
Y3
123
Jp1
12
3
Y4
4
DL1 DL2 DL3
1
23
Y1
456
A1
SW1
BCM
eBUS -
eBUS +
+ 24 V
0
1
2
3
4
5
6
7
8
9
BCM
33
Instructions for the installer
The BCM (optional kit) board, elaborates the data concerning the thermal drop (Δt between primary flow and
return) and provided power.
When the provided power is reduced, the number of turns
of the pump reduces as well and therefore also the hourly
flow rate, keeping the thermal drop constant.
.
Boiler battery
IThe 0 - 10 Volt modulation signal is reset at:
- 3 Volt for minimum speed
- 10 Volt for maximum speed.
These values can be modified according to the
pump model used. For further information of
the 0 - 10 Volt signal, also refer to the pump
manual.
FIX RATE PUMP
Modulating Pump
12
3
Y2
45
67
Y3
12
3
Jp1
12
3
Y4
4
DL1 DL2 DL3
123
Y1
45 6
A1
SW1
ALLARM
SIGNAL
BCM
eBUS -
eBUS +
+ 24 V
MAIN SUPPLY
230 V - 50 Hz
N
L1
N
0-10 V termi nals
Wilo modulating
pump interface
(-)
(0 - 10 V)
L1
SUPPLY
MODULATION
PUMP
APM
MODULATING PUMP
Pump Connection
FIXED
RATE PUMP
Single Boiler
12 L1 N
MARRONE
MARRONE
BLU
BLU
GIA/VER
GIA/VER
M1
P
- For the fixed flow rate pump connection, place the ca-
bles between pin 1.2 and terminal M1.
12
3
Y2
4567
Y3
12
3
Jp1
12
3
Y4
4
DL1 DL2 DL3
123
Y1
456
A1
SW1
ALLARM
SIGNAL
PUMP
BCM
eBUS -
eBUS +
+ 24 V
MAIN SUPPLY
230 V - 50 Hz
N
L1
N
L1
MAIN SUPPLY
230 V - 50 Hz
P
RELE’
N
L
34
Instructions for the installer
BROWN
FUSE
BLUE
230 V - 50 Hz
E. RIV.
WHITE
F 6,3 A
BLU E
BROW N
VG
E. ACC
BLUE
BROWN
YEL /GRE EN
RED
2
VM
eBUS HEATING CONTROL (If foreseen)
ORANGE +
BLACK (-)
BLAC K
BROWN (PWM)
BLUE (TACHO)
45
BLU E (N)12BROWN (L1)
3
RIL./REG.
ALIM.
230V
ORAN GE
ORANGE
BROWN
BROWN
WHITE
WHITE
SR
BROWN
BLUE
PG
1 - 3 mod. 150()
SL
TL
BLUE
BLUE
BROWN
WHITE
1 (nc)
(
c 3 )
PF
IG
TR. ACC.
12 L1 N
BROWN
BLUE
123
4
567891011
M1
3.19 - FUNCTIONAL FLOW WIRING DIAGRAM
E.ACC = Ignition electrode
E.RIV = Ionization electrode
IG = Main switch
PF = Flue switch
PG = Gas switch
SR = CH sensor
SRR = CH return sensor
SL = Condensate level sensor
TL = Limit thermostat
TR.ACC = Ignition transformer
VG = Gas valve
VM = Modulating fan detection/adjustment
35
Instructions for the installer
3.20 - TYPES OF INSTALLATION
Single boiler
Control panel
fitted with an
eBus heating
controller
Boiler Cascade
Slave
Panel
BCM cascade
manager
(kit 00361602)
Control panel
fitted with an
eBus heating
controller
36
Instructions for the installer
Electrical connections for boilers installed
in a cascade formation
The cable for the connection
between the boiler and the BCM
must have the following
characteristics:
PVC HT CABLE 3x0,5
EBUS UNIT
123
4
567891011
12
3
Y2
4567
Y3
123
Jp1
12
3
Y4
4
DL1 DL2 DL3
1
23
Y1
456
A1
SW1
BCM
SMG
eBUS -
eBUS +
+ 24 V
0
1
2
3
4
5
6
7
8
9
BOILER 1
eBUS +
BOILER 2
BOILER 3
BCM
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
eBUS -
eBUS +
eBUS +
eBUS -
eBUS -
eBUS +
eBUS -
eBUS +
eBUS -
+ 24V
Board selector setting
0
1
2
3
4
5
6
7
8
9
pos.
BCM 0
Boiler 1 (with eBus UNIT) 0
Boiler 2 (Slave) 1
Boiler 3 (Slave) 2
Boiler 4 (Slave) 3
Boiler 5 (Slave) 4
Boiler 6 (Slave) 5
Boiler 7 (Slave) 6
Boiler 8 (Slave) 7
NERO
(*)
(*)
(*)
remove the
bridge between
contacts
IN and OUT
Y1 terminal
37
Instructions for the installer
3.21 - INSTALLATION EXAMPLES (Functional diagram)
Boiler connection to the heating system, with 1 direct high temperature heating zone
CH SYSTEM
HIGH TEMPEARTURE
EXPANSION
VASSEL
BOILER PKX
BOILER
SENSOR
NB: In case of a single system return (low or
medium temperature), the connection must
ALWAYS be carried out on the inlet and the
lower back of the boiler (stub "low-temperature system return").
38
Instructions for the installer
Installation of 2 boilers in a cascade arrangement functioning for 1 high temperature zone + 1 low temperature zone, managed via a motorized mixing valve + domestic hot
water production.
NB: In case of a single system return (low
or medium temperature), the connection
must ALWAYS be carried out on the inlet
and the lower back of the boiler (stub
"low-temperature system return").
VE
VE
BOILER PKX 1
(Master )
BOILER PKX 2
(Slave)
CH SYSTEM
HIGH TEMPERATURE
BOILER
SENSOR
BOILER
SENSOR
Connection for eventual
mixing header for perfect
balance of the heating
39
Instructions for the installer
The first ignition must be carried out by a qualified technician. Failure to do so could cause
injury to persons, animals or damage to property. UNICAL shall not be held liable for any
injury and/or damage.
Before lighting the boiler check that:
" the boiler installation has been carried out in accordance
with the specific Standards;
" the combustion air inlet and the discharge of the products
of combustion occur in the correct way in accordance to
the specific Standards and regulations in force;
" the gas supply system is correctly dimensioned for the
boiler's output and is fitted with all the safety and control
devices prescribed by the regulations in force;
" the boiler's electrical supply is 230 V - 50 Hz;
" the system has been filled with water (pressure registe-
red on the gauge 1 bar with pump not running);
" all of the system's on-off valves are open;
" the mains gas supply corresponds to the one which the
boiler has been calibrated for: otherwise convert the boi-
ler to use the available gas; this operation must be carried
out by a qualified technician in compliance to the regula-
tions in force;
" the gas supply cock is open;
" there are no gas leaks;
" the external mains supply switch is in the on position;
" the boiler system's safety valve is not blocked and that it is
connected to the sewage system;
" there are no water leaks;
" all the necessary ventilation conditions and minimum cle-
arance distances are guaranteed for subsequent servi-
cing.
LIGHTING AND SHUTTING DOWN PROCEDURES
For lighting and shutting down the boiler refer to the "INSTRUCTIONS GUIDE FOR THE PERSON IN CHARGE OF
THE APPLIANCE"
Information to be passed on to the person in charge of the
appliance
The person in charge of the appliance must be instructed on
the use and operation of the boiler and in particular detail:
- Hand over to the person in charge of the appliance the
booklet: "INSTRUCTIONS GUIDE FOR THE PERSON IN
CHARGE OF THE APPLIANCE", as well as all the other
literature relative to the appliance, and placed in the envelope contained in the packaging,. The person in charge
of the appliance must retain this literature for any future
reference.
- Inform the person in charge of the appliance of the importance of the air vents and of the flue outlet system, stressing the fact that absolutely no modification can be made.
- Inform the person in charge of the appliance regarding the
control of the system's water pressure and how to restore
it to the correct value.
- Explain and demonstrate to the user the correct function
and adjustment of the temperature, thermostats and radiators for the economic use of the system.
- Remind the person in charge of the appliance that in order
to comply to the regulations in force the boiler has to be
inspected and serviced annually and the measurement of
the combustion efficiency should be carried out as required by the national regulations in force.
- If the appliance is sold or transferred to another owner or
if the present user moves home and leaves the appliance
installed, ensure yourself that the manual always follows
the appliance so that it can be consulted by the new owner
and/or installer.
The PKX boilers are forced water circulation system boilers:
therefore it is necessary to ensure that the water circulates
when the burner is firing.
You must avoid the burner firing without the system pump
being activated; otherwise the safety thermostat could intervene.
The room ambient temperature will be adjusted via the mixing
valve managed by the heating controller.
When the burner fires or turns off you could hear a slight noise
caused by the structure This should not give cause for concern because these thermal expansions have been foreseen
in the developing phase.
3.26 - INITIAL LIGHTING
PRELIMINARY CHECKS
40
Instructions for the installer
MINIMUM OUTPUT
ADJUSTMENT SCREW
3.23 - BURNER PRESSURE ADJUSTMENT
PK150X 2S
WARNING!
All the instructions indicated below are for the
exclusive use of qualified UNICAL service technicians or installers.
All the boilers are supplied already calibrated
and tested. However, if it is necessary to change
the calibration, the gas valve must be re-calibrated.
Warning: during this operation do not request any
DHW draw-off .
B) Min output adjustment
- Via the e-bus controller change the "Test" mode and run
the boiler at minimum output (refer to procedure illustrated on page 43).
- Check that the C02 values are within the values indicated in the table "Burner pressures"
- If necessary correct the value by turning the adjustment
screw "B" in a CLOCKWISE direction to increase the value
and in an ANTICLOCKWISE direction in order to decrease it.
MAXIMUM OUTPUT ADJUSTMENT SCREW
A) Max output adjustment
- Remove the sampling point cap and insert a suitable C02
gas analyser in the flue outlet terminal.
- Via the e-bus controller activate the "Test" mode and run
the boiler at maximum output.
- Check that the C02 values are within the values indicated in the table "Burner pressures"
- If necessary correct the value by turning the adjustment
screw "A" in a CLOCKWISE direction to decrease the value and in an ANTICLOCKWISE direction in order to increase it.
Flue sampling point
Note: To disenable the "Test" mode press the left
key.
C) COMPLETION OF THE BASIC
ADJUSTMENTS
- Check the C02 values at the minimum and maximum
input.
- If necessary make the required adjustments
To ensure correct operation the C02 values
have to be adjusted with extreme care respecting the values indicated in the table.
- Replace the protective cap on the sampling test point on
the flue outlet terminal.
41
Instructions for the installer
3.25 - BURNER PRESSURE ADJUSTMENT
PK230X 2S - PK300X 2S - PK348X 2S
WARNING!
All the instructions indicated below are for the
exclusive use of qualified UNICAL service technicians.
All the boilers are supplied already calibrated
and tested. However, if it is necessary to change
the calibration, the gas valve must be re-calibrated.
Warning: during this operation do not request any DHW drawoff .
A) Max output adjustment
- Remove the sampling point cap and insert a suitable C02
gas analyserin the flue outlet terminal.
MAXIMUM OUTPUT ADJUSTMENT SCREW
- Via the e-bus controller activate the "Test" mode and run
the boiler at maximum output (refer to procedure indicated
on page xx).
- Check that the percentage of C02 is within the values
indicated in the table "Burner pressures"
- If necessary correct the value by turning the adjustment
screw "A" in a CLOCKWISE direction to increase the value
and in an ANTICLOCKWISE direction in order to decrease it.
Flue sampling point
Levels
CO2 (%)
min
Levels
CO2 (%)
max
Fan
speed %
Consump.
min.
Gas nat. (G20)
min max
Diafraghm
collettore
(Ø e n. fori )
PKX 150
Starting
Power
%
FL FH
20 3,7 m³/h 14,8 m³/h- 9,1 9631 9,09,1 60
In case of gas valve replacement or difficult
ignition:
Tighten the maximum adjustment screw "A"
in a clockwise direction until you arrive to
the abutting end, than slacken for 7 turns.
Verify boiler ignition; if the boiler goes into
lockout slacken the screw "A" again of one
turn, than retry to light the boiler. If the boiler
goes into lockout again, carry out the above
indicated operations until the boiler fires.
At this point carry out the burner adjustment
as previously indicated.
Check the C02 levels often, especially at low output
INJECTORS - PRESSURES
Gas
Type
Supply
Pressure
(mbar)
Ø
Injectors
(mm)
Consump.
max.
42
Instructions for the installer
C) COMPLETION OF THE BASIC ADJUSTMENTS
- Check the C02 values at the minimum and maximum
input.
- If necessary make the required adjustments
To ensure correct operation the C02 values
have to be adjusted with extreme care respecting the values indicated in the table.
- Replace the protective cap on the sampling test point on
the flue outlet terminal.
MINIMUM OUTPUT ADJUSTMENT SCREW
+
B) Min output adjustment
Via the e-bus controller Change the "Test" mode and run the
boiler at minimum output (refer to procedure illustrated on
page 43).
- Check that the C02 values are within the values indicated in the table "Burner pressures"
- If necessary correct the value by turning the adjustment
screw "B" in a CLOCKWISE direction to increase the value
and in an ANTICLOCKWISE direction in order to decrease it.
Gas nat. (G20)
min max
PKX 230
20 5,28 m³/h 22,83 m³/h- 9,2 8224 159,2 60
Gas nat. (G20)
PKX 300
20 7,4 m³/h 29,61 m³/h- 9,1 8724 159,1 50
Gas nat. (G20)
PKX 348
20 7,4 m³/h 34,26 m³/h- 9,1 9924 159,1 50
Levels
CO2 (%)
min
Levels
CO2 (%)
max
Fan
speed %
Consump.
min.
Diafraghm
collettore
(Ø e n. fori )
Starting
Power
%
FL FH
Check the C02 levels often, especially at low output
INJECTORS - PRESSURES
Gas
Type
Supply
Pressure
(mbar)
Ø
Injectors
(mm)
Consump.
max.
-
Levels
CO2 (%)
min
Levels
CO2 (%)
max
Fan
speed %
Consump.
min.
Diafraghm
collettore
(Ø e n. fori )
Starting
Power
%
FL FH
Gas
Type
Supply
Pressure
(mbar)
Ø
Injectors
(mm)
Consump.
max.
Levels
CO2 (%)
min
Levels
CO2 (%)
max
Fan
speed %
Consump.
min.
Diafraghm
collettore
(Ø e n. fori )
Starting
Power
%
FL FH
Gas
Type
Supply
Pressure
(mbar)
Ø
Injectors
(mm)
Consump.
max.
43
Instructions for HSCP calibration/adjustment
3.25 - ACTIVATION CHIMNEYSWEEPER
MODE
A
B
C
Press key B (menu)
Turn the knob C until the symbol appears
Press key A
(selection)
Turn the knob "C" until Manual Control appears on the
display
Press key ‘’A (selection) (and you enter in the menu
“Password check”)
Turn the knob ‘’C’’ to ZERO
Press key A
(1° zero) appears on the display
Press key A (2° zero) appears on the display
Press key A (3° zero) appears on the display
Press key A (4° zero) appears on the display
For activating the "CHIMNEYSWEEPER MODE" proceed as
follows:
on the display)
Turn the knob C on
Press key A (store)
Turn the C until "Manual control" appears on the
display.
1
2
3
Select the activation command of the function
Select the modulation level setting and change it as follows:
MAXIMUM OUTPUT = 100%
The system will fire at the MAXIMUM HEAT OUTPUT =
100%: Proceed with the combustion analysis
44
Instructions for HSCP calibration/adjustment
3.26 - PROGRAMMING THE OPERATOR PARAMETERS
Press key B (menu)
Rotate knob C until reaching (symbol )
Press key A
(selection)
Rotate knob C until “Parameter Settings” appears
on the display
Press key A (selection) (enter the parameter and
relative set values screenshot)
Rotate knob C to scroll the parameter list
To modify the involved parameter
Press key A (selection) (enter the password)
Rotate knob C
to ZERO
Press key A
(1st zero) appears on the display
To display/modify the “operating parameters” proceed as follows:
Press key A
(2nd zero) appears on the display
Press key A (3rd zero) appears on the display
Press key A (4th zero) appears on the display
Rotate knob C up
Press key A (save)
At this point you can modify the parameters
Rotate knob C to select the involved parameter
Press key A
(selection)
Rotate knob C to modify the parameter value
Press key A
(save) to confirm
A
B
C
ATTENTION! OPERATIONS TO BE CARRIED OUT ONLY BY TECHNICIANS TO
VERIFY AND MODIFY (IF REQUIRED) THE OPERATING PARAMETERS
45
Instructions for HSCP calibration/adjustment
Position Identification Parameter description PKX 150 PKX 230 PKX 300 PKX 348
1 31 CH: Minimum Setpoint 20 20 20 20
2 39 CH: Maximum Setpoint 85 85 85 85
3 322 Pump: Overrun 5 5 5 5
4 309 System Config. (single master) 3 3 3 3
System Config. (master in battery) 2 2 2 2
System Config. (slave) 2 2 2 2
5 619 Ignition modulation 60 60 50 65
6 314 Standby modulation 0 0 0 0
7 319 Maximum Modulation 96 99 90 99
8 346 Minimum Modulation 32 29 24 28
9 488 Fan: PWM @ Max 10 10 20 20
10 527 Fan: Set./Rev 2 2 3 3
11 161 Burner power 150 230 300 350
12 483 Max differential Temp. 0 0 0 0
13 622 Minimum flow sensor 0 0 0 0
14 34 Burner hysteresis 50 50 50 50
15 336 Temperature Gradient 10 10 10 10
16 353 Proportional adjustment 20 20 20 20
17 354 Integrative adjustment 12 12 12 12
18 478 Derivative Adjustment 10 10 10 10
19 486 Fan: Prop. Adjust. 6 6 14 14
20 487 Fan: Int. Adjust. 1 1 2 2
21 337 Modulation Gradient 1000 1000 2000 2000
22 526 Fan: Max. Speed 100 110 100 110
23 777 APS Control 0 0 0 0
24 793 Chimney obstruction sensor 1 1 1 1
DEFAULT SETTINGS
46
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.
Failure to perform Inspections and Maintenance can entail material and personal damage.
We therefore recommend stipulating an inspection or maintenance contract.
Inspections help to determine the actual status of the appliance and to compare it with the nominal status. This is done
through measuring, controls and observation.
Maintenance is required to eliminate any differences between the actual status and the nominal status. This is normally
done by cleaning, setting and replacing individual components subject to wear.
Maintenance intervals and their extent are determined by a
specialist based on the status of the appliance ascertained
through inspection.
Inspection and maintenance instructions
To assure long-term functioning of your appliance and to avoid altering its approved status, only original Unical spare parts must be
used.
Before proceeding with maintenance, always perform the following operations:
• Disconnect the electric mains switch.
• Isolate the appliance from the electric mains by means of
an isolated device with a contact opening of at least 3 mm
(e.g. safety devices or power switches) and make sure
that it cannot be re-connected accidentally.
• Close the gas shut-off valve upstream the boiler.
• Close any shut-off valves on the heating flow and return
pipes.
After having completed all maintenance work, always perform the following operations:
• Open the heating flow and return pipes.
• If necessary, restore the heating system pressure until it
reaches the static pressure relative to the highest point of
the system.
• Open the gas shut-off valve.
• Reconnect the appliance to the electric mains and engage the switch.
• Make sure the appliance is gas tight and watertight.
• Vent the heating system and restore pressure if necessary.
Should you decide to temporarily deactivate the boiler, you
must:
a) shut off the various supplies: electric, water and fuel;
b) empty the water system if antifreeze is not used.
4
INSPECTIONS AND
MAINTENANCE
47
Inspections and maintenance
Boiler body maintenance
Danger!
Before performing any maintenance, make
sure the boiler and its components have cooled off.
Disconnect the boiler from the electric mains
and shut the gas supply to the appliance.
Attention!
Before cleaning the boiler body, protect the
panel board against any water sprays.
Once a year, at the end of the heating season, the boiler must
receive a general cleaning.
Before performing any maintenance, make sure that all the precautions referred to in the previous point have been taken.
To proceed with maintenance you must:
- disconnect power by acting on the main switch;
- remove the burner, which could be overhauled at the same
time;
- open the furnace door to access the combustion chamber;
- remove the smoke chamber access door;
- make sure the internal parts are intact.
Checking status of gaskets and insulation fibres
The insulation fibre of the door can show
cracks after a short time of operation; this however does not reduce its insulation capacity nor
jeopardise its lifespan.
Check the status of the seal gasket which must
not show signs of deterioration; if so, it must be
replaced, using only original spare parts.
Check the status of the smoke chamber inspection cover gasket.
Replace it if worn, using only original spare
parts.
Components to check during yearly inspection
COMPONENT:
Ts (safety thermostat)
System expansion vessel
Door gaskets
Smoke chamber gaskets
Ignition electrode
Detection electrode
Burner
VERIFY:
Does the thermostat place the boiler in
safety when overheating?
Does the vessel contain the right amount
of air?
Does smoke seep through the door
gaskets?
Does smoke seep through the smoke
chamber gaskets?
Does ignition occur correctly?
Is the flame detection correct?
Is the burner still in optimal operating conditions?
CONTROL/INTERVENTION MEASURE:
Bring the boiler to operating temperature
with the pumps stopped.
Check pressure.
Pressurise the boiler (open the pump bleeder). Open the heating circuit closing valves.
Further tighten the door screws.
Replace the sealing gasket and possibly the
internal gasket of the door.
Further tighten the smoke chamber nuts.
Replace the sealing gaskets.
Make sure that the distance between
electrode and burner is 9-10 mm.
Make sure that the distance between the
electrode tips are 3 mm.
Check the discharge with closed gas.
Make sure that the distance between
electrode and burner is 15-18 mm.
Check ignition and detection with cold system.
Visual check the fibre; if dirty, clean using
water jet from inside out
48
Error codes
5
ERROR CODES
5.1 - ERROR CODES DISPLAY
Error codes of EBUS control unit are indicated below together
with its meaning and corrective actions.
Failure notification
Error code
Error description
Reset key
Code:
Meaning:
Presence of water inside the smoke chamber
Solution:
Verify the correct operation of the condensation
draining system
Code:
Meaning:
Sanitary sensor failure (only if the boiler is coupled with an outer storage tank)
Solution:
Make sure the sensor and/or wiring is efficient
Code:
Meaning:
Mains voltage < 190 Vac
Solution:
Check the mains voltage, if < 190 Vac, if the mains
voltage is correct replace the control board
Code:
Meaning:
Insufficient gas pressure
Solution:
Check the pressure; if pressure is correct, check
the pressure switch efficiency and/or wiring
29
13
32
2
49
Error codes
Code:
Meaning:
Excessive water temperature detected by the
heating sensor (SR) (> 95°C)
Solution:
Check water circulation in installation
Code:
Meaning:
Loss of the flame signal during operation
Solution:
Press the unblock key on the panel
Code:
Meaning:
No flame detected during the ignition phase
Solution:
Press the unblock key on the panel
6
5
4
Code:
Meaning:
Heat exchanger freezing
Solution:
Carefully defrost the heat exchanger
Code:
Meaning:
Safety thermostat intervention (TL)
Solution:
Press the unblock key on the panel
Code:
Meaning:
Heating system failure (SR)
Solution:
Make sure the sensor and/or wiring is efficient
16
1
12
Code:
Meaning:
Modulating fan failure
Solution:
Check the fan wiring
26
Code:
Meaning:
Modulating fan failure
Solution:
Check the fan wiring
24
Code:
Meaning:
Flame detected before starting the ignition cycle
Solution:
Disconnect the detection electrode cable from the
control board; if the error code disappears, replace the cable, otherwise replace the control
board
Code:
Meaning:
Flame detected once the burner has been turned
off
Solution:
Disconnect the gas valve cable from the control
board; if the error code disappears, replace the
control board, otherwise replace the gas valve
Code:
Meaning:
Inner failure
Solution:
Replace the control board
11
20
10
Code:
Meaning:
Modification of the operating parameters due to
EMC disturbances
Solution:
Restore the factory settings
30
Code:
Meaning:
Flue pressure switch intervention (PV)
Solution:
Check the flue discharge state
28
46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - telefax 0376/660556
www.unical.ag - info@unical-ag.com
Unical will not be held responsible for possible inaccuracies if due to transcription or printing errors. It also reserves the
right to modify its products as deemed necessary or useful, without jeopardising their essential features.
AG S.P.A.
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