Unical SuperModulex 440-550-660-770-900 INSTALLATION AND SERVICING INSTRUCTIONS (00331587/a - 2nd edition - 02/10)
Page 1
SuperModulex
440 - 550 - 660 770 - 900
MODULAR CONDENSING
BOILER
00331587/a - 2nd edition - 02/10
INSTALLATION
AND SERVICING
INSTRUCTIONS
Page 2
2
Page 3
Warning: this manual contains instructions to be used exclusively by the
installer and/or a competent person in accordance with the current laws in
force.
The end user MUST not make any alterations to the boiler.
Failure to follow the instructions indicated in this manual, which is supplied
with the boiler, could cause injury to persons, animals or damage to property.
UNICAL shall not be held liable for any injury and/or damage.
CONTENTS
1 GENERAL INFORMATION ................................................................................................................................................................................... 4
1.1 Symbols used in this guide .......................................................................................................................................................................... 4
1.2 Correct use of the appliance ....................................................................................................................................................................... 4
1.3 IInformation to be passed over to the person in charge of the appliance ................................................................................................ 4
1.4 Safety warnings ............................................................................................................................................................................................ 5
1.5 Data badge .................................................................................................................................................................................................... 6
1.6 General warnings ......................................................................................................................................................................................... 7
2 TECHNICAL FEATURES AND DIMENSIONS ..................................................................................................................................................... 8
2.1 Technical features ........................................................................................................................................................................................ 8
2.2 Dimensions ................................................................................................................................................................................................... 9
2.3 Performance data ....................................................................................................................................................................................... 12
2.4 RHS view showing main components ....................................................................................................................................................... 13
3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 14
3.1 General warnings ...................................................................................................................................................................................... 14
3.2 Installation standards ................................................................................................................................................................................ 15
3.3 Packaging .................................................................................................................................................................................................. 16
3.4 Boiler location in a boiler room .................................................................................................................................................................. 18
3.5 Installation on existing systems ............................................................................................................................................................... 19
3.6 Boiler connection ....................................................................................................................................................................................... 19
3.7 Gas connection ......................................................................................................................................................................................... 20
3.8 Connection return and flow system pipes ............................................................................................................................................... 21
3.9 Primary circuit pump or boiler pump ........................................................................................................................................................ 22
3.10 Additional safety and control devices, according to the Italian Law + primary circuit kit ..................................................................... 23
3.11 Wiring diagram for additional safety devices ........................................................................................................................................... 24
3.12 Safety pressure relief valve ..................................................................................................................................................................... 24
3.13 Mixing header filter .................................................................................................................................................................................... 25
3.14 Ballstop valves .......................................................................................................................................................................................... 25
3.15 Boiler freeze protection ............................................................................................................................................................................. 26
3.16 Mixing header and plate heat exchanger ................................................................................................................................................ 26
3.17 Condensing drain ...................................................................................................................................................................................... 27
3.18 Water treatment ......................................................................................................................................................................................... 28
3.19 Flue chimney connection .......................................................................................................................................................................... 29
3.20 Operation ................................................................................................................................................................................................... 31
3.21 Electrical connections ............................................................................................................................................................................... 33
3.22 Functional wiring diagram......................................................................................................................................................................... 34
3.23 Wiring diagram for connection and managing......................................................................................................................................... 36
3.24 Installation examples (functional wiring and connections description) .................................................................................................. 39
3.25 Cascade manager BCM ........................................................................................................................................................................... 42
Connections for boilers in cascade, controlled by outer compensators............................................................................................... 43
3.26 Configuration with a modulating pump ..................................................................................................................................................... 46
3.27 Filling the system ...................................................................................................................................................................................... 47
3.28 Verifica regolazione della pressione al bruciatore ................................................................................................................................... 44
3.29 Emergency functions ............................................................................................................................................................................... 51
3.30 Lighting and shutting down procedures ................................................................................................................................................... 52
4 SERVICING SCHEDULE .................................................................................................................................................................................... 53
3
Page 4
General information
1
GENERAL INFORMATION
1.1 -SYMBOLS USED IN THIS GUIDE
When reading this guide particular care has to be given to the parts marked with the followings symbols:
DANGER!
Indicates serious danger
for your personal safety
and for your life
WARNING!
Indicates a potentially dangerous
situation for the product and the
environment
NOTE!
Suggestions for the
user
1.2 - CORRECT USE OF THE APPLIANCE
The ALKON appliance has been designed utilizing today’s heating technology and in compliance with the
current safety regulations.However, following an improper use, dangers could arise for the safety and life
of the user or of other people, or damage could be caused to the appliance or other objects.The appliance
is designed to be used in pumped hot water central heating systems. Any other use of this appliance will be
considered improper.UNICAL declines any responsibility for any damages or injuries caused by an improper
use; in this case the risk is completely at the user’s responsibility.In order to use the appliance according
to the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide.
1.3 - 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
Page 5
1.4 -SAFETY W ARNINGS
WARNING!
The installation, adjustment, and servicing of this appliance must be carried out by a competent person and
installed in accordance with the current standards and regulations. Failure to correctly install this appliance
could cause injury to persons, animals or damage to property . The manufacturer shall not be held liable for
any injury and/or damage.
DANGER!
Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL
recommends drawing up a service contract. Bad or irregular servicing could compromise the safe operation
of the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not
be held liable.
Modifications to parts connected to the appliance
Do not carry out any modifications to the following parts:
- the boiler
- to the gas, air, water supply pipes and electrical current
- to the flue pipe, safety relief valve and its drainage pipe
- to the constructive components which influence the appliance’s safe operation
WARNING!
When tightening or loosening the screw pipe connections, use only adequate fork spanners.
The improper use and/or the use of inadequate equipment can cause damages (for example water or gas
leakages).
General information
WARNING!
Indications for appliances operating with propane gas
Ensure yourself that before installing the appliance the gas tank has been purged.
For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legally
authorized.
If the tank has not been correctly purged problems could occur during ignition.
If this occurs contact the liquid gas tank’s supplier.
Smell of gas
If you smell gas follow these safety indications:
- Do not turn on or off electrical switches
- Do no smoke
- Do not use the telephone
- Close the main gas tap
- Open all windows and doors where the gas leakage has occurred
- Inform the gas society or a company specialized in installing and servicing heating systems
Explosive and easily inflammable substances
Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room
where the appliance has been installed.
WARNINGS
The boiler has to be installed in such way to avoid,
under the foreseen operation conditions, the congelation of the water and
to prevent that the control devices are exposed to a temperature
lower than -15°C and higher than 40°C.
The boiler has to be protected against environmental variations with:
- ALL WETHER protection and covering KIT foreseen by the manufacturer .
- The insulation of the hydraulic pipelines and the condensate evacuation
- The adoption of specific antifreeze products in the C.H. installation.
5
Page 6
General information
1.5 - DATA PLATE
CE Marking
The CE marking documents that the boilers satisfy:
- The essential requirements of the Directive regarding gas
appliances (Directive 90/396/CEE)
®
3
5
7 8
A
B
9
11
13
15
17
19
- The essential requirements of the Directive regarding
electromagnetic compatibility (Directive 89/336/CEE)
- The essential requirements of the Efficiency Directive
(Directive 92/42/CEE)
- The essential requirements of the low voltage Directive
(Directive 73/23/CEE)
1
2
4
6
10
12
14
16
18
20
C D
21 22
E
27
LEGEND:
1 = Y ear of CE certification issue
Boiler type
2=
3=Boiler model
4=Number of stars (Directive 92/42/CEE)
5=(S.N°) Serial number
6=P.I.N. code
7=Approved fluing configurations
8=(N0x) N0x class
A = Central Heating circuit features
(Pn) Nominal output
9=
10 = (Pcond) Condensing nominal output
11 = (Qmax) Nominal heat input
12 = (Adjusted Qn) Adjusted for nominal Heat input
(PMS) Max. pressure C.H. system
13 =
14 = (T max) Max. C.H. temperature
24
23
25
28
26
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
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
6
E = Factory setting
27 = Adjusted for gas type X
28 = Space for national brands
Page 7
1.6 - GENERAL WARNINGS
This instruction manual is an integral and indispensable
part of the product and must be retained by the person in
charge of the appliance.
Please read carefully the instructions contained in this manual
as they provide important indications regarding the safe
installation, use and servicing of this appliance.
Keep this manual in a safe place for future reference.
General information
Do not obstruct the intake/outlet terminal ducts.
In the event of failure and/or faulty functioning of the appliance,
switch off the boiler. Do not attempt to make any repairs:
contact qualified technicians.
Any repairs must be carried out by Unical authorized
technicians and using only original spare parts. Nonobservance of the above requirement may jeopardize the
safety of the appliance.
The installation and servicing must be carried out in
accordance with the regulations in force according to the
manufacturer’s instructions and by legally competent
authorized persons.
By a competent person, we imply a person who has a specific
technical qualification in the field of components for central
heating systems for domestic use, domestic hot water
production and servicing. The person must have the
qualifications foreseen by the current laws in force.
Bad or irregular servicing could compromise the safe
operation of the appliance, and could cause injury to persons,
animals or damage to property. The manufacturer shall not
be held liable for any such injury and/or damage.
Before carrying out any cleaning or servicing turn off the
electrical supply to the boiler by means of the ON/OFF switch
and/or by means of the appropriate shutdown devices.
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
7
Page 8
Technical features and dimensions
TECHNICAL FEATURES
2
AND DIMENSIONS
2.1 - TECHNICAL FEATURES
• MODULEX is a compact, gas fired, Low NOx, condensing
boiler, made up by one sectional boiler body,
This boiler body consists of two or more modules (from 4 to
8), which cannot be separated from each other, being under the same protecting casing, and are set to operate separately or in cascade. These modules are connected to a
single smoke exhaust manifold and are controlled by a
single microprocessor, which manages completely the temperatures from the point of view, both operational and safety.
• Efficiency at full load with temperature 30/50°C = 103%.
At part load (30% of the nominal) with 30°C return temperature = 108,3%.
• Efficiency Class:
• Each module, is composed of a combustion chamber, metallic fiber pre-mix burner, modulating fan, gas valve, ignition ele ctrode, flame detection, NTC sensor for management control (BMM), local temperature control and afety
thermostat.
• Each single boiler is equipped with NTC sensors for global
temperature control on the flow and return manifolds.
• Integral, non allergic, synthetic wool insulation.
• Fully pre-mixed, radiating, modulating, metallic sponge
burner, Automatic no return diaphragm for separation from
combustion chamber.
• Nominal input, per module: max. 108 kW, min. 22 kW.
• Noise level at maximum output: lower than 49 dBA.
• Modules configuration possibilities:
• Possible cascade installation of 2 or more Supermodu-
lex
•Heating Operation: setting of instantaneous output by a
main microprocessor, with a comparison parameters presetting between the requested temperature (or calculated by the outer compensator) and the global flow tem-
perature.
• Logic of operation:
A) Output sharing on as many modules as possible at min.
load (down to 22 kW) for the max. efficiency..
B) Automatic operation hour splitting-up system for each
module to guarantee the best homogeneous use.
C) D.H.W. production, via a storage tank loading pump or a
three way diverting valve, controlled by a priority sensor
through the E 8 heating controller.
D) Output check of each module for any calibration and/or
assistance by secret access code.
• Possibility of controlling the output of each single module.
•
Heating request control: temperature set point
andmodulation level.
•
Monitoring of boiler and temperature status.
•
Alarm control.
•
Parameters setting.
•
Relay for control of the operation of a pump at constant
flow rate.
•
0÷10V analogical output for control of a modulating pump.
•
Emergency operation: it avoids C.H. system shut down
caused byan interruption in communication with the boiler
plant’s automation system: : (in case of remote control of
the complete boiler house):
•
Input for “Constant setpoint”: 55°C, maximum output 50%.
•
Alarm reset input.
•
Aalarm relay signal.
• Gas connecting pipes, flow/return water pipes, arranged
for any connection (by the opposite end).
• Integral easily removable panel set (painted steel panels).
• Smoke exhaust pipe, adjustable on the right, the left and
behind the heating system.
• Condensate collecting tank equipped with drain siphon
and stainless steel smoke chamber.
• Built-in air vent.
• Weights and dimensions are limited (see table at par. 1.2)
SENSORS supplied with the boiler:
• outdoor temperature sensor
• flow temperature sensor for mixed zone
• boiler temperature sensor code N. 00262210
• D.H.W. storage temperature sensor, code N. 00262211
Optional accessories
•
Acid condensate inhibitor
•
Primary circuits: hydraulic system interface
with additional safety devices and modulating
pump.
•
Mixing header
•
“all weather”: stainless steel protection for
outdoor installation.
4
5
6
7
8
8
440
550
660
770
900
Page 9
0
2.2 - DIMENSIONS
Technical features and dimensions
FRONT VIEW
390 988
1378
LEFT HAND SIDE VIEW
460
460
RIGHT HAND SIDE VIEW
920
S
UPPER VIEW
11
1372
666
232
474
171
G
206
M
R
398
974
SuperModulex
Dimension
No. of Modules
Height mm
Width mm
Depth mm
Connections
Gas mm (inch)
C.H. system Flow M mm (inch)
C.H. system Return R mm (inch)
Chimney connection ''D'' mm
Chimney width ''H'' mm
Condensate drain diameter mm
Øi 250
615
124
440
4
1372
1378
920
50 (2)
80 (3)
80 (3)
250
615
40
9
Page 10
Technical features and dimensions
B
FRONT VIEW RIGHT HAND SIDE VIEW
1372
L
666
232474
LEFT HAND SIDE VIEW UPPER VIEW
460
206
460
G
171
398
110
920 600
S
175
Øi D
425
M
Øi D
R
350
SuperModulex
Dimension
No. of Modules
Height mm
Width ''L'' mm
Depth mm
Connections
Gas mm (inch)
C.H. system Flow M mm (inch)
C.H. system Return R mm (inch)
Chimney connection ''D'' mm
Chimney width ''B'' mm
Condensate drain diameter mm
974
124
550
1372
1122
1520
50 (2)
80 (3)
80 (3)
250
615
40
660
5
6
1372
1256
1520
50 (2)
100 (4)
100 (4)
300
721
40
770
7
1372
1390
1520
50 (2)
100 (4)
100 (4)
300
855
40
10
Page 11
1434
544
232
530
Technical features and dimensions
FRONT VIEW RIGHT HAND SIDE VIEW
1574
LEFT HAND SIDE VIEW UPPER VIEW
961 585
S
488,5
G
222
M
Øi D
R
364
472,5
SuperModulex
Dimension
No. of Modules
Height mm
Width mm
Depth mm
986
175
Øi D
100
410
1306
900
8
1434
1674
1546
Connections
Gas mm (inch)
C.H. system Flow M mm (inch)
C.H. system Return R mm (inch)
Chimney connection ''D'' mm
Chimney width mm
Condensate drain mm
80 (3)
100 (4)
100 (4)
300
986
40
11
Page 12
Technical features and dimensions
2.3 - PERFORMANCE DATA
BOILER TYPE
Appliance category II
Nominal Heat Input on P.C.I.
Minimum Heat Input on P.C.I.
Qn
Qmin
Nominal Output (Tr 60 / Tm 80 °C)
Minimum Output (Tr 60 / Tm 80 °C)
Nominal Output (Tr 30 / Tm 50 °C)
Minimum Output (Tr 30 / Tm 50 °C)
SUPERMODULEX
Pn
Pn min
Pcond
Pcond min
2H3P
kW
kW
kW
kW
kW
kW
Efficiency at max. output (Tr 60 / Tm 80°C) %
Efficiency at min. output (Tr 60 / Tm 80°C) %
Efficiency at max. output (Tr 30 / Tm 50°C) %
Efficiency at min. output (Tr 30 / Tm 50°C) %
Efficiency Class acc. to Directive 92/42 CEE
Combustion efficiency at nominal load %
Combustion efficiency at part load %
Stand-by losses with burner in operation %
Flue losses with burner with burner off %
Flue losses with burner with burner in operation %
Flue gas temperature tf-ta (max) °C
Flue gas mass flow rate (max) kg/h
Excess of air λ %
(**) CO2 at min/max. output) %
NOX (value according EN 297/A3 + EN 483)
mg/kWh
NOX class
Min. water flow rate in CH circuit (ΔT 20°C) l/h
Minimum pressure in CH circuit bar
Maximum pressure in CH circuit bar
DHW specific flow rate l
Gas Consumption Natural gas G 20 (20 mbar) Qn m3/h
Gas Consumption Natural gas G 20 (20 mbar) Qmin m3/h
Gas Consumption G25 (supply pressure 25 mbar) Qn m
Gas Consumption G25 (supply pressure 25 mbar) Qmin m
3
/h
3
/h
Gas Consumption G31 (supply pressure 37/50 mbar) Qn kg/h
Gas Consumption G31 (supply pressure 37/50 mbar) Qmin kg/h
Max. available pressure at the chimney base Pa
Condensate production max kg/h
B
Emissions
CO with 0% of O2 in the flue system ppm
NOx with 0% of O2 in the flue system ppm
Sound level dBA
Electrical Data
Voltage / Frequency V/Hz
Fuse on main supply A (F)
Max power absorbed
Insulation degree IP
Standby Consumption W
440
432
22
424,27
20,33
442,37
23,94
98,21
92,4
102,4
108,8
97,42
98,43
0,2
0,1
2,58
52
699
24,25
47
18243
0,5
73
45,68
2,33
53,13
2,71
33,53
1,71
100
73,4
<95
<30
<49
230/50
612
40
10
900
864
22
848,53
20,33
894,24
23,94
98,21
92,4
103,5
108,8
4
97,42
98,43
0,2
0,1
2,58
52
1399
24,25
-
47
5
36487
0,5
7
133
91,36
2,33
106,25
2,71
67,07
1,71
100
146,7
<95
<30
<49
230/50
4
1224
40
10
-
770
756
22
742,47
20,33
780,95
23,94
98,21
92,4
103,3
108,8
4
97,42
98,43
0,2
0,1
2,58
52
1224
24,25
-
47
5
31926
0,5
7
118
79,94
2,33
92,97
2,71
58,68
1,71
100
128,4
<95
<30
<49
230/50
4
1071
40
10
550
540
22
530,33
20,33
554,04
23,94
98,21
92,4
102,6
108,8
4
4
97,47
98,43
0,2
0,1
2,53
51
874
24,25
-
-
47
5
5
22804
0,5
7
7
88
57,10
2,33
66,41
2,71
41,92
1,71
100
91,7
<95
<30
<49
230/50
4
4
765
40
10
660
648
22
636,40
20,33
667,44
23,94
98,21
92,4
103,0
108,8
4
97,49
98,43
0,2
0,1
2,51
50,6
1049
24,25
47
5
27365
0,5
7
103
68,52
2,33
79,69
2,71
50,30
1,71
100
110
<95
<30
<49
230/50
4
918
40
10
(*) Room Temperature = 20°C
(**)See paragraph ‘’
12
INJECTORS – PRESSURES’’
The Technical data plate is placed under the
casing over the forehead stirrup.
Page 13
Technical features and dimensions
2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS
FAN
GAS VALVE
AIR INTAKE
CONNECTION
CONTROLL
PA N E L
GAS PIPE
AUTOMATIC
AIR VENT
C.H. FLOW
C.H.
RETURN
CONDENSATE
COLLECTING
TRAYSMOKE
MANIFOLD
BOILER FRAME
BURNER
COVER
BURNER
ALUMINIUM/
SILICON HEAT
EXCHANGER
CONDENSATE
DRAIN
SIPHON
Min. Depth 100 mm
Smoke outlet on the L.H. side (per modulex 348 e 440) - on the BACK side (per modulex 550 - 660 - 770 - 900)
C.H. flow connection on the L.H. side
C.H. return connection on the L.H. side
Gas connection on the L.H. side
BCM: under the frontal panel
13
Page 14
Instructions for the installer
INSTRUCTIONS FOR
3
THE INSTALLER
3.1 - GENERAL WARNINGS
WARNING!
This boiler has to be destined for the use for
which it has been expressively designed for.
Any other use shall be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.
WARNING!
These appliances are exclusively designed
to be installed inside adequate boiler rooms.
Therefore these appliances must not be
installed and operated externally .
Before installing the boiler the following points
have to be carried out by a competent engineer:
a) The whole system should be thoroughly
flushed in order to remove any residual dirt or
grime which could compromise the correct
boiler operation.
b) Check that the boiler has been preset for
operating with the gas type available.
This is verifiable via the indication on the
packaging and on the data badge;
c) Check that the chimney/flue pipe has an
adequate draught,does not have any
constrictions, and that no other appliance’s
flue outlets have been fitted, unless the chimney
is serving more than one heating appliance,
according to the specific standards and
regulations in force.
The connection between the boiler and
chimney/flue outlet can be made only
after this
verification has been carried out.
WARNING!
In rooms where there is the presence of
aggressive vapours or dust the appliance
must operate independently from the air
present in the boiler’s location room!
WARNING!
The appliance must be installed by a qualified
engineer, who complies to the technicalprofessional requirements according to the
national applicable law and who, under his
own responsibility, guarantees the
compliance with the standards according to
the latest regulations.
WARNING!
Install the appliance respecting the minimum
clearances for operation and servicing.
The boiler must be connected to a heating
system which is compatible to its performances
and output.
14
Page 15
3.2 - STANDARD CODES FOR
INSTALLATION
Instructions for the installer
The appliance must be installed in compliance to the
instructions contained in this manual.
The installation must be carried out by a competent qualified
engineer, whom will assume the responsibility of complying
to all the local and/or national regulations published in the
official publications, as well as all the applicable codes of
practice.
Before installing the appliance please contact the gas supply
company.
The installation must be carried in accordance to the codes
of practice, the regulations and the requirements hereby
indicated which constitute an indicative list, but not a complete
one, as these continue to undergo evolve devolpments.
Moreover, the boiler must be installed in accordance to all the
regulations regarding the boiler room, the building regulations
and the prescriptions regarding central heating plants in force
in the country where the boiler is installed.
The appliance must be installed, commissioned and serviced
according to the regulations in force. This is also valid for the
hydraulic system, the flue outlet system and the boiler location
room.
15
Page 16
Instructions for the installer
3.3 - PACKING
The boiler MODULEX is delivered assembled
and protected by a plastic bag inside a strong
cardboard box and fixed on pallet. This allows
the boiler to be handled also by forklift. The boiler, with the packaging, can go through a door of
800 mm, whereas, without packaging, it can go
through a door of 700 mm.
Remove both straps and finally the cardboard
box from above, making sure the product is
intact. The packing elements (cardboard box,
straps, plastic bags, etc…) shall not be left to
children’s hand since they may be dangerous.
For the removal of the boiler from the pallet it is necessary
to have a jib crane, to avoid to damage, during the removal,
the pressure switches, the valves gas or the electric wirings.
- Remove the casings andmake the sling with the belts ‘’ Á.
‘’ fig. 3, having care to pass the belts inside the flow,
return and gas manifolds.
- Tie the belts to thearm ‘’ B ‘’; during these operationsact
with caution.
C
On the L.H. side of the boiler, for Modulex 440, and
on the R.H. side of the boiler for Modulex 550 - 660 - 770 900 there is the terminal of the smoke chamber, inside
which there are:
- A plastic bag containing:
• Tre gaskets (gasket between smoke chamber and its
terminal, gasket for the base of flue socket, gasket Ø 250
or 300, according to the models, to be put inside the flue
socket)
• Tre curves + a Te piece + a plastic plug, for the
condensate evacuation system
• The fixing screws
- The sensors (3x).
- The flanges
- The flue socket
Inside the casing, on the L.H. side:
- Two pipes for the condensate evacuation system of 1 m
each.
Inside the condensate tray:
• One aluminium painted steel plate for closing the space
below the flue terminal, only for models 550 - 660 - 770 900
• Kit of supports for the flue terminal.
Above the top cover of the boiler:
- A plastic bag containing:
- This instructions manual for the installer
- Instructions manual for the user
- Instruction manual for the use of the E8 controller
- Certificate of guarantee
- A label for spare parts order
440
550
660
770
900
1650
1650
1650
1650
1480
A
512 kg
608 kg
692 kg
770 kg
925 kg
B
1200
1550
1700
1840
2000
1020
1020
1020
1020
1100
16
Page 17
BOILER UNLOADING AND PACKAGE REMOVAL
Instructions for the installer
1
PALLET REMOVAL
B
A
2
3
4
17
Page 18
Instructions for the installer
3.4 - BOILER LOCATION INSIDE A BOILER HOUSE
Special attention shall be paid to local regulations and laws
about boiler houses and particularly to the obligation of
keeping minimum clearances and empty space around the
boiler. The installation shall be in compliance with all latest
regulations and laws about boiler houses, installations of
heating and hot-water systems, ventilation, chimneys capable
of evacuating the flue gases of condensing boilers and any
other applicable requirement.
When selecting the position for the installation of the
boiler it has to be considered that, for the cleaning and
washing operations of the boiler body, one of the boiler
sides must be accessible for the removal of a special
baffle placed under the aluminum sections.
This baffle can be fixed, indifferently, from the R.H or L.H.
side of the condensate tray. If no modification has been
made, the boiler must have its R.H. side accessible, with the
chimney connection fitted on the R.H or L.H. side. But, if the
smoke chamber terminal, with the flue socket, is left to the
R.H. side and if, from this same side, the baffle has to be removed, then the flue socket must have the possibility to be
also removed.
If it is preferred, the baffle can be moved in order to have its
fixation screw on the opposite side, regardless the position
of the smoke chamber terminal.
The boiler can be put on a flat and sufficiently strong base
with the same dimensions as the boiler ones and at least
100mm high (see fig. 2), in order to assemble the condensate drain siphon. An alternative to this base may be a
100mm deep well next to the boiler as siphon housing (see
fig. 2). After installation the boiler shall be
perfectly horizontal and stable, to reduce any possible vibrations or noises.
A > 400 mm
B > 400 mm
C = 100 mm
D = 500 mm
B
A
D
C
Give the boiler the minimum clearances as shown
in the drawing, in order to be able to make the
normal service and cleaning operations.
18
Page 19
Instructions for the installer
3.5 - INSTALLATION ON EXISTING HEATING SYSTEMS
When the appliance is installed on existing systems, ensure
yourself that:
When a Modulex boiler is installed onto an existing
heating system:
- The flue outlet pipe is suitable for condensing boilers, for
the temperature of the products of combustion, calculated
and manufactured according to the regulations in force. It
must be installed as much as possible in a straight line,
tested for soundness, insulated and must not have any
occlusions or restrictions.
- The flue outlet pipe has a connection for the discharge of
condensate.
- The boiler room has a suitable outlet for the discharge of
condensate produce by the boiler.
- The electrical system has been fitted in compliance to the
specific norms and the work has been carried out by a
competent person.
- The circulation pump’s output, the head and flow direction
are suitable.
- The gas feeding supply pipe and the eventual tank are
constructed according to the regulations in force.
- The expansion vessels assure the total absorption of the
dilatation of the fluid contained in the system.
- The system has been cleaned of impurities and lime scale.
In case the replacement of an existing boiler in
an old system can be programmed, it
is
necessary to thoroughly clean out the system
with a basic solution. The system must be
cleaned 4 weeks before the substitution, with
the system firing at a temperature of 35°C to
40°C.
WARNING!
If it is noticed that a new Modulex has replaced, in an old
system the existing boiler without having first performed what
said in the previous paragraph, Do not wash now the system,
as residual products, present in the circuit, could lead to system gathering in the boiler body, causing damage. UNICAL
recommends contacting a specialised company for water treatment.
Instead, if installing a Modulex boiler in a new system, it is
still recommended to thoroughly clean out the system with an
adequate product and fit a Y filter with two isolating valves
onthe boiler’s return pipe, so that, when necessary, it can be
cleaned. This filter will protect the boiler from the dirt coming
from the heating system.
When sizing pumps, it is necessary to take into consideration
the pressure losses which occurin the primary circuit.
3.6 - BOILER CONNECTION
The boiler Modulex leaves the factory predisposed for the
hydraulic and gas connection on the back side of the boiler.
The smoke outlet is placed on the back side of the boiler
for MODULEX 440;
it's placed on the R.H. side of the boiler for MODULEX 550 660 - 770 - 900.
For the smoke chamber fixing, use the screws and gaskets
included into the instruction bag, and a cross screwdriver at
least 300 mm of length.
19
Page 20
Instructions for the installer
3.7 - GAS CONNECTION
The gas supply pipe must be connected to the boiler via the
respective pipe connection
9-11.
The gas supply pipe must have a section which is identical or
greater then the one used on the boiler and must assure a
correct gas pressure.
It is however important to comply with the specific norms and
requirements in force, foreseeing on-off valves, gas filter,
anti-vibrating joint etc.
Before commissioning an internal gas distribution system
and therefore before connecting it to the gas meter, the
complete installation must be tested for gas soundness.
If any part of the system is concealed from view the gas
soundness test must be carried out before covering the pipes.
DANGER!
The gas connection must be carried out by a
registered engineer who will have to respect
and comply to the regulations in force and to
the requirements indicated by the local gas
supplier. An incorrect installation could
cause injury to persons, animals or damage
to property. The manufacturer shall not be
held liable for any injury and/or damage.
R 2‘‘ - 3” as indicated on page 8-
Before installing the boiler it is recommended
to thoroughly clean all the supply piping in order
to remove any eventual residual grime which
could compromise the boilers correct
functioning.
If you smell gas:
a. Do not turn on or off electrical switches, use
the telephone or any other object which can
provoke sparks;
b. Open all doors and windows in order to
allow fresh air to enter and purify the room;
c. Close all gas cocks
d. Contact a service engineer, qualified
installer or the gas supply company.
As a safety measure against gas leaks, Unical
recommends installing a surveillance and
protective system made up of a gas leakage
detector combined with an on-off selenoid valve
on the gas supply line.
1 2 3 4 5 66
1. On-off gas supply valve
2. Double membrane regulator
3. Gas filter
4. Anti-vibrating joint
5. Selenoid valve
6. On-off cock
EXAMPLE OF A GAS SUPPL Y SYSTEM
INSIDE
BOILER
ROOM
OUTSIDE
BOILER
ROOM
20
Page 21
3.8 - FLOW AND RETURN PIPE CONNEC-
TIONS
The CH flow and return circuits have to be connected to the
boiler via the respective connections
indicated on page 9-11.
When determining the size of the CH circuit pipes it is
essential to bear in mind the pressure losses induced by any
of the system’s components and by the configuration of the
same system.
The route of the piping has to be conceived taking all the
necessary precautions in order to avoid air locks and to
facilitate the continuous purging of the system.
WARNING!
Before installing the boiler we recommend
that the system is flushed out with a suitable
product in compliance to the norm UNI-CTI
8065, in order to eliminate any metallic
tooling or welding residues, oil and grime
which could reach the boiler and affect the
proper running of the boiler.
3’’- 4” M and R as
Instructions for the installer
Non-observance of these instructions could
cause injury to persons, animals or damage
to property. The manufacturer shall not be
held liable for any such injury and/or damage.
Ensure yourself that the system’s piping is not
used as the earth clamps for the electrical or
telephonic system. They are absolutely
unsuitable for this use. In a short time this could
cause serious damage to the piping, boiler
and radiators.
WARNING!
IT IS ABSOLUTEL Y FORBIDDEN T O FIT ON-OFF
VALVES ON THE GENERATOR TO THE FORE
OF THE SAFTEY DEVICES
21
Page 22
Instructions for the installer
2
3.9 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP
The boiler pump must have a delivery head which can ensure
the water flow rate as shown in the diagram “Water pressure
losses”.
The size of the pumps must be determined
by installers or technical engineers
according to boiler data and system design.
The following table gives an indication of the pump’s flow rate
in function of the Δt of the primary circuit if the installation has
a mixing header.
The water side resistance curve of the boiler
is shown in the following diagram.
The pump is not an integral part of the boiler.
It is recommended to choose a pump with
the rate and delivery head at about 2/3 of its
characteristic heating curve.
Boiler Model
Max water flow rate
Demanded in l/h ( t=15 K)
Max water flow rate
Demanded in l/h ( t=20 K)
6
5,8
5,6
5,4
5,2
5
4,8
4,6
4,4
4,2
4
O)
2
3,8
3,6
3,4
3,2
3
2,8
2,6
2,4
2,2
2
1,8
Pressure Losses (m/H
1,6
1,4
1,2
1
0,8
0,6
0,4
0,2
0
0 2 4 6 8 101214161820222426283032343638404
Δ
Δ
440 550 660 770
24202 30248
18152 22686 27223 31760 36298
Super
Super
Modulex
440
Modulex
550
Super
Modulex
660
WATER FLOW m³/h
900
36297 42346 48397
Super
Modulex
900
Super
Modulex
770
44 46 48 50 52
54
ΔΔ
For a
ΔT 20 K, of a MODULEX 660 boiler, the max. water flow rate requested is 27,2 m³/h.
ΔΔ
From the graph of the boiler’s pressure losses, it can be determined that the pump must be able
to guarantee a delivery head of at least 1,7 m/H2O.
NOTE: The use of a mixing header fitted between the boiler circuit and the system circuit is
always advisable. It becomes INDISPENSABLE if the system requires flow rates superior to the
maximum permitted boiler flow rates, which is to say lower than 15K.
22
Page 23
Instructions for the installer
3.10 - ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW
CERTIFICATION OF THE ADDITIONAL SAFETY DEVICES:
CONTROL DEVICES
SAFETY DEVICES
1. On-off gas valve: a device which has the function of cutting
off the gas supply when the water temperature reaches the
max. predetermined value. The sensible element has to be
installed as nearest as possible to the generator (flow pipe)
at a distance which has to be < 500 mm and must not be able
to be cut-off.
7. Pressure indicator with shock absorber tube
pressure gauge holder valve
(7b): it indicates the effective
pressure existing in the generator. It must be graduated in
“bar” and must have the maximum operating pressure in
scale and be equipped with a 3-way valve with the connection
for the manometer.
(7a) and
2. Pressure relief valve: it has the function of discharging
in the atmosphere the fluid contained in the generator when
this has, for whatever motive, reached the maximum working
pressure.
2a Visible drain funnel
PROTECTIVE DEVICES
3. Overheat thermostat: it has the function of shutting down
the generator if the safety thermostat fitted in the boiler
malfunctions. It must be calibrated to a value of < 100°C,
which MUST not be changed.
6. Safety pressure switch: it has the function of shutting
down the generator if it reaches the maximum working
pressure. It must be able to be reset manually.
PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETY
DEVICES
SUPERMODULEX 360 - 450 cod. 0036137561374
SUPERMODULEX 540 - 660 cod. 0036137500361375
SUPERMODULEX 770 - 900 cod. 00361560 00361377
12
5. Thermometer: it indicates the effective water temperature
contained in the generator. It must be graduated in degrees
Celsius with a temperature scale not exceeding 120°C.
4. Inspection pocket: approved for inserting the control
thermometer
8. Calibrated expansion vessel: it permits the absorption
of the increase in volume of the system’s water following an
increase in temperature.
9 Y filter
10 Modulating pump
11 Mixing bottle
12 Automatic air vent. Not supplied by Unical
13 Drain cock. Not supplied by Unical.
8
1a
2
2a
13
1
23
Page 24
Instructions for the installer
V
V
3.11 - WIRING DIAGRAM FOR ADDITIONAL
SAFETY DEVICES
ON-OFF PUMP MODULATING PUMP
Pump m a nagement via E8
to the terminal 4 (A10)
LINE
Safety devices
L
N
kit
from the IV connector
RELAY
Boile r main s
supply
230 V
L1
N
LINE
230
3.12- PRESSURE RELIEF VALVE DRAIN
PIPE
A pressure relief valve must be fitted on the flow
pipe, within 0,5 m from the boiler. It must be
dimensioned for the capacity of the boiler and
must comply to the regulations in force,
WARNING!
Please remember that it is forbidden to
interpose, between the boiler and the
pressure relief valve, any type of cutting-off
device. Moreover it is recommended to use
cutting-off valves which do not exceed the
maximum allowable operating pressure.
LINE
VISIBLE
DRAIN
FUNNEL
Safety devices
L
N
kit
Terminals EXT-MIN
interface WILO
modu la ti ng pu m p
RELAY
SAFETY V AL VE
Boile r m ain s
supply
230 V
L1
N
LINE
230
WARNING!
In correspondence to the heating pressure
relief valve foresee the installation of a
discharge pipe with a funnel and a siphon
which lead to an adequate drainage. The
drainage has to be controllable by sight.
If this precaution is not made, an eventual
intervention of the pressure relief valve could
cause injury to persons, animals or damage
to property. The manufacturer shall not be
held liable for any injury and/or damage.
24
Page 25
3.13 - MIXING HEADER FILTER
UNICAL suggests the installation of a Y filter
on the return pipe so that it can be cleaned if
necessary.
This filter will protect the boiler from the heating
system dirt.
Instructions for the installer
3.14 - BALLSTOP VALVES
The installation of ballstop gate valves, on the C.H. flow and
return connection, is recommended.
Doing so, in case of normal or extraordinary service, the boiler can be drained without emptying the whole C.H. sistem.
WARNING!
IT IS NOT ALLOWED TO ISOLATE THE SAFETY
DEVICES, as the safety valve and the expansion vessel, FROM THE BOILER.
Secondary
circuit
25
Page 26
Instructions for the installer
g
3.15 - BOILER FREEZE PROTECTION
Should the flow temperature (measured at global flow temperature NTC) decrease under 7°C, the system pump is set up. Shoul
temperature decrease to under 3°C, all modules will start at min.
output until the return temperature reaches 10°C.
Such protection device is exclusively for the boiler. For the protection of the system, a second freeze protection thermostat is
necessary to switch on the heating system pump.
To protect the C.H. system from freezing when boiler is not in
operation during cold season, it is necessary to add to the C.H.
system water an anti freezing solution.
NB: The antifreezing solution must be compatible with the
materials present in the system, and mainly with the
aluminum.
THIS CAN BE ALLOWED ONLY IF YOU ARE SURE THAT AN
ANTIFREEZE SOLUTION HAS BEEN ADDED, IN THE PROPER
PERCENTAGE, TO THE C.H. WATER.
3.16 - 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
D
1/2’’
1/2’’
The plate heat exchanger, conveniently dimensioned, has the
advantage to keep hydraulically the two circuits (primary and
secondary), thus allowing the installation of the MODULEX
boiler also in industrial processes.
MM
WARNING
AFTER A LONG INOPERATION PERIOD OF THE
BOILER, IN CASE THE BOILER TEMPERATURE
IS BELOW 3°C,
START THE BOILER.
ABSOLUTELY DO NOT TRY TO
HR
1/2’’
HV
c
b
a
e
h
250
300
400
500
600
CH FLOW
CH RETURN
125
150
200
250
300
CH FLOW
Boiler
Circuit
F
I
CH RETURN
L
T
E
R
TABLE FOR THE RECOMMENDED DIMENSION OF THE
HYDRAULIC COMPENSA TOR
66
power supply
over > 340 kW
KV
KR
440
550
0 - 900
g
g
1/2’’
30.000
50.000
100.000
150.000
200.000
Heating
System
Circuit
Boiler
Circuit
Heatin
System
Circuit
RR
See the Unical catalogue and the price list to
identify the most convenient mixing header and
primary circuit.
125
150
200
250
300
200
250
250
300
300
300
300
300
400
400
1.000
1.000
1.500
1.500
1.800
150
150
200
300
300
1.650
1.700
2.250
2.500
2.800
200
200
200
200
200
26
Page 27
3.17 - CONDENSATE DRAIN
Instructions for the installer
Avoid the condensate stagnation inside the combustion
products evacuation system, (for this reason the evacuation
duct must have an inclination toward the drain of at least 30
mm/m (3/8 in. / ft) except the liquid column, inside the
condensate siphon, which needs to be filled with water after
installation: its minimum height, when all the fans are in operation, must be at least 25 mm (1 in.).
In order to avoid ice formation while the boiler is operating,
which can cause the stop of the boiler, the whole condensate
evacuation system has to be well insulated. It is forbidden to
evacuate the condensate through a gutter: risk of ice forming
and corrosion.
The condensate, before being evacuated to the sewer, has to
be neutralized, neutralisation which can be obtained by
mixing the drain water coming from washing maschines,
dish washing maschines, etc., which normally have a basic pH.
The connection to the sewer will be through a visible drain.
Given the high acidity degree (pH 3 to 5) only plastic material can be used for the condensate evacuation pipes.
Moreover it must be dimensioned and constructed so as
to allow the correct out-flow of drains, preventing any bottleneck and any leakage.
BACK SIDE
The outlet of the condensate drain pipe will be on the same
side of the smoke chamber, passing below the smoke chamber.
Before commissioning the boiler fill the condensate siphon with water, from the dedicated filling-up plug.
INITIAL SIPHON
FILLING-UP PLUG
BOILER
HOUSE
FLOOR
* Min. height of the condensate column, with all fans
150
operating at max. speed, requested by the EN standards.
The upper part of the drain
pipe shall not be higher
than the tray bottom.
150
** Min. height of the condensate column, with all fans operating at max. speed. In the case it is not possible to create a
100 mm basement, install the boiler on the floor and foresee a min. 100 mm well to lodge the siphon.
27
Page 28
Instructions for the installer
3.18 - WATER TREATMENT
The chemical-physical characteristics of the filling water and
reinstatement water in heating systems are of fundamental
importance for guaranteeing correct and safe boiler operation.
Before filling the CH circuit with water, it is necessary to analyse
the water and decide for a proper treatment.
The purpose of this treatment is finalized to eliminate or
substantially reduce the following problems:
- lime scale deposit
- corrosions
- deposits
- biological growths (moulds, bacteria, algae, fungi, etc)
The chemical treatment of the network water enables the
prevention of these problems and guarantees safe boiler
operation and economical advantages, in terms of
maintenance and global thermal efficiency.
The chemical analysis of the water enables us to obtain a lot
of information on the system’s condition and state of “health”.
It is essential to avoid any problems with the boiler.
The pH is a measure of the acidity or alkalinity of a solution.
The pH scale has a range of 0-14, where 7 is neutral.
Values inferior to 7 indicate acidity, values above 7 indicate
alkalinity.
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.
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.
WARNING!
ANY DAMAGE CAUSED BY THE BOILER, DUE
TO THE FORMATION OF LIME SCALE OR DUE
TO CORROSIVE WATER WILL INVALIDATE THE
APPLIANCE WARRANTY.
28
Page 29
Instructions for the installer
EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FOR WATER TREATMENT
1 2 3 4 5 2 7 16
1. Ball valve
2. Inspection pocket
3. Filling-up group
4. Disconnector
5. Scale reducing device
6. Litre counter
(recommended)
7. “Y” filter
440
550
660
770
900
4
5
6
7
8
250
250
300
300
300
29
Page 30
Instructions for the installer
Chimney dimension
DIN 4705
CO levels
22
6%
2520
2160
1800
1440
1260
1080
900
kg/skg/h 10%
0,700
0,600
0,500
0,400
0,350
0,300
0,250
778
667
555
445
389
333
277
8%
1037
889
741
668
593
519
444
370
1400
1200
1000
900
800
700
600
500
5
Flue Gas Temperature
Pressure avaible
10 15 20 25 30
d400
a
d315
a
40°C
40 Pa
1400
1200
1000
900
800
700
600
500
720
606
540
360
324
288
252
216
180
144
126
108
90
72
54
36
32
29
25
22
14,4
12,0
10,8
9,0
0,200
0,150
0,100
0,090
0,080
0,070
0,060
0,050
0,040
0,035
0,030
0,020
0,015
0,010
0,009
0,008
0,007
0,006
0,005
0,004
0,003
0,002
0,001
222
167
111
100
5,6
5,0
4,4
3,9
3,4
Nominal Heat input (kW)
89
78
67
56
50
44
39
34
28
22
17
11
400
296
300
222
200
148
180
133
160
119
140
104
120
89
100
74
90
66
80
59
70
52
60
44
50
37
40
30
30
22
20
9
8
7
7,4
6,6
5,9
4,4
18
16
12
14
10
12
9
10
8
9
8
7
6
51015202530
d75
a
d200
d160
a
d125
a
d110
a
a
d250
a
400
300
200
180
160
140
120
100
90
80
70
60
50
40
30
2
20
18
16
14
12
10
9
8
7
6
Nominal Heat input (kW) with CO level at 10%
Flue gas mass flow rate
SuperModulex
440
550
660
770
900
30
Flue gas mass
flow rate (max)
kg/h
700
874,5
1049
1224
1399
Example:
SUPERMODULEX 550
Flue gas mass flow rate = 1049 Km/h
Chimney height = 25 m
Chimney connection Ø = 315 mm
NOTA:
Il diagramma
fornisce valori indicativi
Page 31
3.20 - BOILER OPERATION
The SuperModulex is made of inter-linked modules; each
module is made of:
- Combustion Chamber
- Burner
- Fan
- Gas valve
- Local NTC ((Negative Temperature Coefficient) sensor
(checks the flow temperature of each aluminium section)
- Scheda di controllo BMM (Burner Modular Manager)
- BMM (Burner Modular Manager) control PCB.
- High Limit thermostat
- Ignition electrode
- Ionization electrode
- Air pressure switch
Max. output of a module is 108 kW. So, a SuperModulex 440
(Nom. Input 432 kW) consists of 4 modules.
Each module has its own temperature sensor NTC - Negative
Temperature Coefficient - called local NTC, which locally
checks the flow temperature of each aluminium section.
Instructions for the installer
The flow temperature at the boiler outlet and the return
temperature at the boiler inlet are controlled by global NTC
temperature sensors.
In case of more heat request by heating or DHW systems, the
boiler starts up and water will be heated by the aluminium
boiler body
Then the boiler pump will send the water to the mixing bottle
and from here to the radiators, according to the heating
system chosen.
The combustion air is supplied by fans which take it from the
boiler room. The combustion air is then pushed into the premixing chamber through a diaphragm. Beyond the diaphragm,
the air mixes with gas and such mixture, passing through the
non-return valve, is sent to the burner. Then, on leaving the
burner surface, the air/gas mixture ignites electrically and the
resulting combustion gases, after being transported (and
cooled) through finned sections, enter the condensate
collecting manifold and then are evacuated through the
chimney.
Fan
Gas valve
Burner
Combustion
Chamber
Air intake
connection
Ignition
electrode
Ionization
electrode
H.L.
Thermostat
Thermic
element
Smoke outlet
Condensate
collecting
tray smoke
manifold
31
Page 32
Instructions for the installer
4
When there is a heat request from the E8 controller or from a
BCM (Boiler Cascade Manager), the E8 or BCM calculates
the necessary output according to the difference between the
set temperature (or the temperature calculated by the outer
compensator) and the global flow temperature. The number
of thermal elements (each thermal element represents a maximum input of 110 kW) x 100% determines the maximum
input expressed in %.
When the input has been determined, the boiler pump (not
supplied by Unical) is set up and the fan of one thermal element is set in motion at starting speed. The gas valve opens
and ignition is to occur within 5 sec. When the ionisation electrode detects the flame, the thermal element starts operating.
Subsequently other thermal elements are likely to start in the
same way. One of the operation principles for this boiler is
letting as many burners as possible operate simultaneously
at minimum load to reach the maximum efficiency.
For example, if a 4 thermal element boiler is requested to
operate at its max input, this shall be 400% i.e. :
108 kW x 4 thermal elements = 432 kW = 400%.
If it is requested to operate at 200% input, thanks to the input
sharing system on the highest number of thermal elements,
each thermal element will operate at 50% output i.e. :
kW
4 thermal elements of 108 kW each working
at 50% of the output give = 216 kW = (200%),
i.e. 54 kW / thermal element
60
55
50
45
40
35
30
25
20
15
10
5
0
200% : 4 thermal elements = 50%
equal to a total of 216 kW, that is 54 kW for each thermal
element.
Such principle provides clearly efficiencies much higher than
those obtained in traditional groups of small boilers installed
in cascade.
When the input shared on each thermal element is less than
22 kW, one thermal element after the other is automatically
excluded and the remaining input is shared on thermal
elements having the smallest number of operation hours (by
the automatic operation-time calculating system).
Modulation, i.e. input reduction, is based on the difference
between the set temperature (or the temperature calculated
by the outer compensator) and the global flow temperature.
When no ignition occurs, the ignition device repeats two more
times the ignition sequence and then puts to lock out position
the thermal element concerned.
1 Thermal element (module) = 108 kW = 100%
4 Thermal elem. = 108 kW x 4 = 432 kW = 400%
400% : 332kW = 200% : X
X = (432x200) : 400 = 216 kW input shared on 4
thermal elements
% (p.c.i.)
109,6
108,8
103,2
100
1 Thermal
element
50 % = 54 kW
1 Thermal
element
100 % = 108 kW
20
22
30
60 70 80 90 100
50
5
10
Efficiency of a thermal element working at full capacity 108 kW
= 103,2 % (in condensation)
Efficiency of a thermal element working at reduced capacity 54
kW = 106,7 % (in condensation)
Efficiency of a thermal element working at minimum capacity
22 kW = 108,8 % (in condensation)
40
110
108
P
(kW)
Input shared on 4 thermal elements : total input = 216:432
= 0,5 = 50%
32
All the thermal elements work in parallel at the same output, equalizing, thus, the C.H. system efficiency to the one
of the thermal element.
Page 33
3.21 - ELECTRICAL CONNECTIONS
Regulations in force
The gas and water feeding pipes and the CH system pipes
cannot be used as ground plates.
Ensure that the above safety electrical requirements subsist;
in case of doubt, ask for a professionally qualified technician
to check the appliance’s electrical system.
UNICAL refuses responsibility for any damages arising from
failure to earth the boiler correctly.
Instructions for the installer
Mains electrical supply connection 230V
The boiler is provided complete with a mains supply cable
1,5 m long and with a cross section area of 3x0,75 mm2.
The electric connections of the boiler are shown in the section
named “WIRING DIAGRAMS” (paragraph 3.19 page 30)
A mains supply of 230 V – 50 Hz is required. The wiring to the
boiler must be in accordance with the current CEI regulations.
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.
WARNING!
We remind you that upstream of the electrical
connection, it will be necessary to foresee a
service relay (NOT SUPPLIED) which, when
the electrical safety devices (ISPESL)
intervene, shuts down the electrical supply
to the on-off fuel valve fitted on the gas supply
circuit, but not to the boiler so as to
guarantee the running of the pump and permit
the boiler to cool down.
DANGER!
The electrical connections must be carried
out only by a qualified engineer.
Before carrying out the connections or any
other operation on the electrical parts,
always switch off and disconnect the
electricity supply and ensure yourself that it
cannot be accidentally turned on.
It is necessary to fit a double pole switch on the electrical
supply line, having a 3 mm contact separation in both poles,
in an easy accessible position in order to make quick and
safe the servicing operations.
The boiler electrical supply (230 V – 50 Hz – single phase) is
to be done directly on the three pole plug supplied with the
boiler.
A
It is necessary to fit a double pole switch on the supply line in
an easy accessible position in order to make quick and safe
the service operations.
WARNING!
230 V cables shall be separated from 24 V
ones, using the two plastic conduits supplied
within the boiler casing L.H. side panel.
33
Page 34
Instructions for the installer
3.22 - FUNCTIONAL WIRING DIAGRAM
KF
PINK
GREY
123
2
12345678910
1
VII
0-10 V
eBUS
FA
n
3
4
CONTROL E8
SL
VT
MAIN SUPPLY
230 V - 50Hz
I
F6 F5 F3 F2 F1
VF
FBR
T3 T4
M
21
A7
A8 A9 A10 A11
VI
12
12345
CONNECTION
WIRE NEUTRAL (N)
ORANGE
ORANGE
1
2
BROWN
M3
BLUE
M1
BROWN
1
BLUE
2
BLUE
3
BROWN
IV
BROWN
BROWN
BROWN
4
BROWN
BROWN
BROWN
BLUE
BROWN
BLUE
BLUE
BLUE
5
6
7
8
9
10
11
12
F9 F8
AF KF / SPF
T1 T2
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BROWN
RED
BLACK
ORANGE
BROWN
BLUE
LIGHT- BLUE
BROWN
LIGHT-BLUE
BROWN
2
1
V
F12 F1 1
VF
SPF
M
67891012345
M2
BROWN
2
1
5
RELE’
12
VIII
A1 A2 A3 A4 A 5 A 6
12 1NL1L1
BLACK
F10A
F6A
F14F13
PT1000
RED
3
1a
1b
III
0-10 V
L1 L1’
N
II
2
1
1
F17 F15
IMP
31
FBR
TLG
234
IX
LH
BUS
C
IG
1N 4L
2N
BROWN (L1)
BROWN
5L
SE8/BCM
I
1b
1
O
1a
II
LIGHT-BLUE (N)
SR
SRR
SR1
EMERGENCY
Choose set point value as indicated
in the tab le * (IF NECESSARY) a nd
insert resistence between Y2 (6-7).
SET POINT
WHITE
BROWN
VM1
BLACK
WHITE
RED
RED
BLACK
WHITE
PG
PV1
CONTROL
MODULATION
PUMP
(*)
( - )
67
BROWN
WHITE
eBUS
remote
(
external
Cascade manager)
PLC /
BMS
Modbus - B
0-10 V
3
45
Y2
+ 24 V
eBUS -
eBUS +
Y1
23
45 6
1
BLACK
BROWN
RED
BROWN
Modbus - A
12
WHITE
Jp1
WHITE
BCM
WHITE
LIGHT BLUE
(*)
Ω
Ω
Ω
Ω
SMG
Set point
82°C
71
°C
60
°C
49
°C
38
°C
27
°C
ROSA
GRIGIO
Ext sens
open
BOILER CIRCUIT
123Y44
100 K
K
47
K
22
10 K
Short circuit
INSERT
BCM
RESET
IS
PR
SIGNAL
ALARM
123
Y3
ALIM.
DL1 DL2 DL3
YEL-GRE EN
PE
LIGHT BLUE (N)
BROWN (L1)
L1 N
230V
BLACK (-)
BLUE (TACHO)
4125
BROWN (PWM)
ORANGE +
RIL./RE G.
PUMP
SW1
BLACK
BROWN
RED
A1
1° Modulo
LIGHT B LUE
LIGHT B LUE
LIGHT BLUE
BROWN
LIGHT BLUE
YEL-GREEN
YEL-GREEN
TLTL1
WHITE
E.RIL.1
34
BLU E
BROWN
YEL-GRE EN
Page 35
Instructions for the installer
V
E.ACC 1....8
E.RIL 1....8
IG
IS
KF
LTL G
PG
PR
PV 1....8
SMG
SL
SE8/BCM
SR
SR
1....8
SRR
TL
TL 1....8
TLG
VG
1....8
TRA.ACC 1....8
VM 1....8
RED
BLACK
BROWN
Ignition electrode
Ionization electrode
Main switch
Inserit BCM Board
Global Flow Temperature Sens or E8
Warning lampe for the General Limit Ther m ostat
Minimum Gas pressure swich (not supplied)
Reset push button
Fan pressur e swich
Global Flow Temperature Sens or BCM
Condensate lev el sen sor
E8/BCM selector
Flow NTC Temperature sensor
Local Flo w N TC Temperature sensor
Global Return NTC Temperature sens or
High limit thermostat
Local High li m it thermostat
High limit th ermostat
Global
Gas Valve
Ignition Transformer
Modulating Fan
( )
#
YEL-GR EEN
3
LIGH T BLU E (N)
BROWN (L1)
12
ALIM.
230V
BLACK (-)
BLUE (TACHO)
412
BROWN (PWM)
ORANGE +
5
RIL./R EG.
VG1
( )
#
BROWN
LIGHT BLUE
VM (A)
ST 2
123
L1
BROWN
PINK
4
5
6
7
8
YEL-G REEN
3
4
5
6
1-2 / 2-3 / 3-4 / 4-5 / 5-6 / 6-7 / 7-8
7
12345
N
LIGHT BLUE
FILTER
BLACK
BROWN
BROWN
1-2 / 2-3 / 3-4
1-2 / 2-3 / 3-4 / 4-5
1-2 / 2-3 / 3-4 / 4-5 / 5-6
1-2 / 2-3 / 3-4 / 4-5 / 5-6 / 6-7
M (A)
234
1
5
ST 2
BLACK
123
L1
BROWN
N
LIGHT BLUE
YEL-G REEN
BROWN
LIGHT BLUE
3° - 8° MODULES
GREY
PINK
GREY
VG2...VG8
+ 24 V
1
eBUS +
Y1
432
LIGHT BLUE
BROWN
LIGHT BLUE
BROWN
BROWN
eBUS -
LIGHT BLUE
TR.ACC.1
BLUE
BROWN
SR2...SR8
2° - 8° Modulo
VG1
BROW N
BLUE
BLUE
BROWN
RED
YEL-GREEN
PV2...PV8
BROWN
BLACK
WHITE
WHITE
TL2...TL8
BLU
BLUE
BROWN
LIGHT BLUE
BROWN
LIGHT B LUE
LIGHT B LUE
LIGHT BLUE
YEL-GRREN
YEL-GRREN
BROWN
LIGHT BLUE
BROWN
TR.ACC.2...TR.ACC.8
WHITE
BLUE
BROWN
VG2...VG8
MARRONE
BLUE
BROWN
RED
YEL -G RRE N
E.RIL.2...E.RIL8
Setting of modules selectors
Module 1
(Pos 0)
Module 2
(Pos 1)
3
2
4
1
5
0
6
9
7
8
Module 3
(Pos 2)
3
2
4
1
5
0
6
9
7
8
Module 4
(Pos 3)
3
2
4
1
5
0
6
9
7
8
Module 5
(Pos 4)
3
2
4
1
5
0
6
9
7
8
Module 6
(Pos 5)
3
2
4
1
5
0
6
9
7
8
Module 7
(Pos 6)
3
2
4
1
5
0
6
9
7
8
Module 8
(Pos 7)
3
2
4
1
0
9
7
8
3
2
4
1
5
6
5
0
6
9
7
8
3° - 8° MODULES
35
Page 36
Instructions for the installer
V
V
V
V
V
V
3.23 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGING
On the back side of the E8 regulator there are two terminal
blocks, of which one is for the mains (230 V) connections and
the other one is for the low tension connections.
Power supply
BROWN
BLUE
Power
NL1L112 1
terminal
block
II
The main controls, necessary for the C.H. system management and for the boiler control, as well some components
which are part of the boiler house, must be connected to the
terminal blocks.
BLACK
67891012345
A1 A2 A3 A4 A5 A6
12
I
A7
M
12345
IV
A8 A9 A10 A11
21 3
M
4
Sensor
terminal
block
Power terminal assignments
Terminal II
NL1L1’
T1 T2
II
A1 A2 A3 A4 A5 A6
67891012345
M
II
NL1L112 1
N:
Neutral conductor, mains
Power supply, unit
L1:
L2:
Power supply to relay
:
heating circuit pump HK 1
:
heating circuit pump HK 2
:
Storage tank charging pump
:
Mixer open, heating circuit 2
:
Mixer closed, heating circuit 2
50 Hz 230 V
BUS
LH
IX
12
34
N
FBR
3
IMP
0-10 V
F17 F15
III
23
L1 L1’
1
PT1000
F14 F13
1
T1 T2
T3 T4
SPF
F12 F11
III
1
2
AF KF / SPF
VF
F9 F8 F6 F5 F3 F2 F1
V
12
F
I
FBR
n
12345678910
GREY
From BCM
FA
eBUS
0-10 V
II
12
PINK
Te rminal VI
T3 T4
I
A7
12
Terminal IV
A8 A9
M
n
36
12345
21 3
I
A10 A11
4
VI
IV
:
Mixer open, heating circuit 1
:
Mixer closed, heating circuit 1
Multifunction relay
Multifunction relayRecycle pump /
1
2
3
4
Page 37
Sensor terminal assignments
Instructions for the installer
Terminal VII
12
VII
FA
eBUS
0-10 V
Terminal I
12345678910
FBR
VF
I
F9 F8 F6 F5 F3 F2 F1
AF KF / SPF
Terminal V
12
VF
V
SPF
F12 F11
T e r m inal VIII
12
VIII
PT1000
F14 F 13
VII
Connection to BCM
Pin 1:
Pin 2:
I
VF
Pin 4:
VF
Pin 5:
SPF
Pin 6:
SPF
Pin 7:
KF
Pin 8:
AF
Pin 9:
AF
Pin 10:
V
VF
SPF
F13
F14
eBUS (FA) or 0-10V output
(Ground)
Buffer storage tank low sensor
Buf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor)
Buf. stor. tank top sensor / FBR heat. circ. 1 (set value)
Flow sensor, heating circuit 2 (ground)
Flow sensor, heating circuit 2
Storage tank sensor
Storage tank and boiler sensor (ground)
Boiler sensor
Outdoor sensor
Outdoor sensor (ground)
Pin 1: Flow sensor heating circuit 1 / sensor multifunction 1
Pin 2: Service water low sensor / sensor multifunction 2
Pin 1: Sensor HS2 / Solar 2 / Multifuncti on relay 3
Pin 2: Sensor Solar 1 / Sensor multifunction relay 4
T e r m in a l III
1
FBR
3
123
0-10 V
III
IMP
F17 F15
Morsetto IX
1234
LH
IX
BUS
III
F15
Pin 1:
Pin 2:
F17
Pin 3: FBR heating circuit 2 (set value) / Pulse counter for
For connection to remote control devices
IX
H
CAN Bus Pin 1 = H (Data)
CAN Bus Pin 2 = L (Data)
L
CAN Bus Pin 3 = - (ground, Gnd)
-
CAN Bus Pin 4 = + (12V supply)
+
FBR heating circuit 2 (room sensor) / 0-10V IN / Light
FBR heating circuit 2 (ground)
37
Page 38
Instructions for the installer
1
V
V
V
3.24 - INSTALLATION EXAMPLES (functional wiring and connections description)
INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE
AF
(9-10) outdoor sensor
(4) Pump heating circuit 1
(4) Collector pump
Heating Circuit
VF
VF
VF
1
Mixing Header
AF
F
(1) Flow sensor heating circuit 1
I
(10) Ground outdoor sensor
10
Outside
Sensor
Safety devices kit
1-2
123Y44
BCM
Primary
system pump
Filter
M
R
INSTALLATION OF A BOILER WITH CONNECTION TO TWO DIRECT HEATING ZONES + D.H.W. PRODUCTION
F
F Ric.
(4-5) Flow sensor heating circuit 2
SPF
(6-7) Storage tank sensor
C
Heating Circuit 2
4
Heating Circuit 1
F
(1) Flow sensor heating circuit 1
I
(10) Ground outdoor sensor
10
AF
(9-10) outdoor sensor
(4) Pump heating circuit 1
n
SPF
VF
VFVF
VF
VF
2
1
AF
(5) Pump heating circuit 2
(6) Cylinder charging pump
(5) Re-circulation pump storage tank
n
(4) Collector pump
Outside
Sensor
Safety devices kit
Mixing Head er
3
Primary
system pump
Filter
M
R
38
Page 39
Instructions for the installer
V
V
V
V
INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD.
F
(4-5) Flow sensor heating circuit 2
SPF
(6-7) Storage tank sensor
F Ric.
C
4
n
SPF
Heating Circuit 1Heating Circuit 2
F
(1) Flow sensor heating circuit 1
I
(10) Ground outdoor sensor
10
AF
(9-10) outdoor sensor
(4) Pump heating circuit 1
(5) Pump heating circuit 2
(6) Cylinder charging pump
(7) Mixer motor heating circuit 2 OPEN
(8) Mixer motor heating circuit 2 CLOSE
(5) Re-circulation pump storage tank
n
(4) Collector pump
AF
Outside
Sensor
Safety devices kit
Primary
system pump
3
Filtro
VF
VFVF
VF
VF
2
1
Mixing Header
INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION
F
(4-5) Flow sensor heating circuit 2
SPF
(6-7) Storage tank sensor
F Ric.
C
4
n
SPF
Heating Circuit 2
Heating Circuit 1
F
(1) Flow sensor heating circuit 1
I
(10) Ground outdoor sensor
10
AF
(9-10) outdoor sensor
(4) Pump heating circuit 1
(5) Pump heating circuit 2
(6) Cylinder charging pump
(7) Mixer motor heating circuit 2 OPEN
(8) Mixer motor heating circuit 2 CLOSE
(1) Mixer motor heating circuit 1 OPEN
VF
VF
2
VF
VF
VF
1
(2) Mixer motor heating circuit 1CLOSE
(5) Re-circulation pump storage tank
n
(4) Collector pump
M
R
AF
Outside
Sensor
Safety devices kit
Mixing Header
3
Primary
system pump
Filter
M
R
39
Page 40
Instructions for the installer
V
V
INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION BY SOLAR PANELS
F
(4-5) Flow sensor heating circuit 2
SPF
(6-7) Storage tank sensor
AF
(9-10) outdoor sensor
(4) Pump heating circuit 1
(5) Pump heating circuit 2
(6) Cylinder charging pump
(7) Mixer motor heating circuit 2 OPEN
(8) Mixer motor heating circuit 2 CLOSE
(1) Mixer motor heating circuit 1 OPEN
(2) Mixer motor heating circuit 1CLOSE
(5) Re-circulation pump storage tank
n
(4) Collector pump
F
(1) Flow sensor heating circuit 1
I
(10) Ground outdoor sensor
10
V
(2) Hot water tank low / Multifunction relay sensor 2
PT1000
(2) PT1000 sensor solar 1 / Multifunction relay sensor 4
PT1000
F14
4
A11
2+
5
F12
2+
C
F
SPF
Heating Circuit 2
Heating Circuit 1
VF
2
VFVF
VF
VF
1
AF
Outside
Sensor
Safe ty devices kit
Mixing Header
Primary
system pump
3
Filter
M
R
For the connection to a solar installation it is
necessary to change some parameters. See
Table:
Expert AREA ⇒ Level SOLAR / MF ⇒ MF 4
FUNCTION = ‘’23’’
40
Page 41
Instructions for the installer
V
V
INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION
F Ric.
C
Heating Circuit 2
4
n
SPF
VF
Heating Circuit 1
VF
2
AF
VF
VF
VF
1
Mixing Header
Outside
Sensor
KF
Boiler
Sensor
Safety devices kit
3
Primary
system pump
Safety devices kit
3
Primary
system pump
Filter
Filter
M
R
M
R
Remote
E8
Master
Slave 1
Slave 2
ATTENTION!
In this type of installation it is necessary to adjust,
in the E8 controller, the parameter BUS-ID HS.
The external regulator E8 (MASTER) has to be set to:
----,
the boiler regulators E8 (SLAVES) have to be set to:
01 to 08.
Connections on to the MASTER controller
The connections of the secondary circuit have to be done on
to the MASTER controller.
F
(4-5) Flow sensor heating circuit 2
SPF
(6-7) Storage tank sensor
AF
(9-10) outdoor sensor
(4) Pump heating circuit 1
(5) Pump heating circuit 2
(6) Cylinder charging pump
(7) Mixer motor heating circuit 2 OPEN
(8) Mixer motor heating circuit 2 CLOSE
(1) Mixer motor heating circuit 1 OPEN
(2) Mixer motor heating circuit 1CLOSE
(5) Re-circulation pump storage tank
n
(4) Collector pump
F
(1) Flow sensor heating circuit 1
I
(10) Ground outdoor sensor
10
41
Page 42
Instructions for the installer
3.26 - CASCADE MANAGER (BCM)
Application:
The BCM completes the range of functions offered by the
Modulex boilers:
- ON/OFF alarm control
- Control of a modulating header pump with the aim of
significantly increasing efficiency at low heating loads.
- Possibility of integrating the Modulex boilers in PLC
controlled boiler plants
- Thanks to LonWorks/Modbus protocol converters been
readily available also opens the road to installing
Modulex boilers in the most advanced Building
Automation Systems.
Features:
The BCM can be connected to the automation system of
a boiler plant via one of its interfaces:
- eBUS: for connection to the series of E8 heating
controllers or to an additional BCM
- Modbus: application in PLC controlled boiler plants
The communication protocols enable complete system
management:
- Control of heating request: temperature set point and
modulation level
- Monitoring of boiler operation and temperature status
- Alarm control
- Functional parameters setting
Special functions
Emergency: it avoids system shutdown caused by an
interruption in communication with the boiler plant’s
automation system:
- Input for “Constant setpoint” request: 55°C, maximum
output 50%
- Alarm reset input
- Alarm relay signal
Monitor:
a BCM connected to a group of heating generators
managed by a E8 heating controller, automatically selects
the “monitor” mode.
In this condition the following services are supplied:
- Acquisition of all the operating data and diagnostics via
the Modbus interface.
- Control of the modulating pump
- Control of the Alarm relays and control of the header
pump
- If the E8 malfunctions, the BCM automatically resets
normal boiler operation control and can enable the
emergency function previously described.
Management of the header pump:
- Relay command for running a pump at fixed rate
- 0÷10 analogical output for control of a modulating pump
42
Page 43
Instructions for the installer
Connection for boilers in a cascade arrangement managed by a E8 heating controller with PLC supervision.
MASTER
E8
CanBUS
SLAVE 1
BCM
(Pos 1)
3
2
4
1
0
9
7
8
SLAVE 2
BCM
(Pos 2)
3
2
1
0
9
7
8
5
6
4
5
6
- Cascade Manager
Scheda PLC/BM S
Modbus
- System Supervisor
Switch ‘’C’’ (see pag. 47)
in Position II
(for each boilers)
I = Comunication
by MODBUS
The applications in
a cascade
arrangement
managed with a
PLC (Modbus) require the
correct boiler address setting
(within the cascade formation)
via the BCM’s internal SWI
selector: 1....7, all different
and in sequence, (exactly as
requested by the single burner
modules).
12NL1L1
E8
II = Comunication
by E8
In this configuration,
BCM (modulex 2)
Y2 (1-2)
System Supervisor
PLC/BMS boards
Modbus
34
12
IX
LH
BUS
Cascade Manager
0-1 0 V
LH
67
Y2
45
3
12
Jp1
Y3
4
DL1 DL2 DL3
3
Y4
12
V
2
F12 F11
12
VIII
F14 F13
123
III
F17 F15
1
234
IX
Modbus - B
Modbus - A
123
1
+ 24 V
23
eBUS eBUS +
Y2
456
BCM
A1
SW1
612345
A1 A2 A3
II
L1 L1’
N
SPF
PT1000
FBR
31
IMP
BUS
switch ‚‘‘C‘‘ must be
positionned on II.
E8 (modulex 2)
BUS (+ - L H)
WARNING!
In this connection the “BUS-ID HS„
parameter must be set on the E8 heating
controller
The external E8 heating controller (MASTER) must be set
to: - - - -,
The E8 heating controllers fitted on each boiler (SLAVE)
must be set from: 01 to 08.
43
Page 44
Instructions for the installer
y
Connection for boilers in a cascade arrangement connected to an external BCM optional and managed by
PLC/BMS (E8 disconnected).
BCM
(Pos 0)
3
2
4
1
0
9
7
8
BCM
(Pos 1)
3
2
1
0
9
8
BCM board
eBUS
- Cascade Manager
- System Monitor
5
6
Modbus
BCM
(Pos 1÷7)
3
2
4
1
5
0
6
9
7
8
PLC/BMS board
Modbus
- System Manager
- System Supervisor
Switch ‘’C’’ (see pag. 47)
in Position 0
(for each boilers)
I = Comunication
by MODBUS
II = Comunication
4
5
6
7
by E8
In this configuration,
switch ‚‘‘C‘‘ must be
positionned on 0.
1
23
45 6
SW1
+ 24 V
eBUS eBUS +
Y1
A1
The applications in a cascade arrangement
managed with an additional BCM require the
correct boiler address setting (within the
cascade formation) via the BCM’s internal
SWI selector: 0....7, all different and in
sequence, (exactly as requested by the single
burner modules).
BCM (modulex 2)
Y2 (3-4)
- Cascade Manager
7
6
Y2
45
3
12
Jp1
BCM
Y3
4
DL1 DL2 DL3
Y4
123
eBUS remoto
eBUS remoto
123
- System Monitor
BCM board
eBUS
Modbus
- System Manager
- System Supervisor
PLC/BMS board
Modbus
- System Manager
stem Supervisor
- S
44
Page 45
Instructions for the installer
Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected)
Scheda PLC/BMS
SLAVE 1
BCM
(Pos 1)
3
2
4
1
0
6
9
7
8
SLAVE 2
5
Modbus
- System Supervisor
- Cascade M anager
Switch ‘’C’’ (see pag. 47)
in Position 0
(for each boilers)
I = Comunication
by MODBUS
1
+ 24 V
23
eBUS eBUS +
Y1
45 6
BCM
(Pos 2)
3
2
1
0
9
7
8
4
5
6
II = Comunication
by E8
In this configuration,
switch ‚‘‘C‘‘ must be
positionned on 0.
The applications in a cascade arrangement
managed with Modbus require the correct
boiler address setting (within the cascade
formation) via the BCM’s internal SWI
selector: 1....7, all different and in sequence,
(exactly as requested by the single burner
modules).
BCM (modulex 2)
Y2 (3-4)
System Supervisor
Cascade Manager
67
Y2
45
3
12
BCM
Jp1
eBUS remoto
eBUS remoto
Scheda PLC/BMS
Modbus
A1
DL1 DL2 DL3
SW1
123
Y3
4
Y4
123
45
Page 46
Instructions for the installer
3.26 - CONFIGURATION WITH A:
MODULATING PUMP
he BCM board elaborates the data concerning the thermal
head (Ät between primary flow and return and supplied
heat output). When the supplied heat output diminishes,
the number of the pump’s revolutions decreases and
subsequently the hourly rate, maintaining the thermal head
practically constant. Thus obtaining a higher efficiency in
condensing mode and reducing energy costs.
The 0÷10 Volt modulation signal is preset to:
-3 for minimum speed
-10 Volt for maximum speed
These values can be changed according
to the type of pump fitted. For further
information on the 0÷10 Volt signal, please
also refer to the pump’s manual.
MODULATING PUMP
TERMINALS 0-10 V
INTERFACE
WILO MODULATING PUMP
(-)
(0 - 10 V)
3
6
45
7
Y2
+ 24 V
eBUS -
eBUS +
123
12
Y1
456
Jp1
BCM
Mains supply
230 V -50 Hz
N
L1
ALARM
3
12
3
12
4
Y4
Y3
DL1 DL2 DL3
A1
SW1
L1
N
APM
Supply
Modulating
Pump
POWER TERMINALS E8
3
6
45
7
Y2
+ 24 V
eBUS -
eBUS +
Y1
456
123
ON-OFF PUMP
3
12
12
Jp1
BCM
Y3
A1
Mains sup ply
230 V - 50 Hz
N
ALARM
3
4
Y4
DL1 DL2 DL3
SW1
Mains supply
230 V - 50 Hz
N
L1
L1
RELAY
L
N
12
P
PUMP
46
Page 47
3.27 - FILLING THE SYSTEM
Instructions for the installer
Warning!
Do not mix the CH system’s water with antifreeze or anti-corrosion solutions using wrong
concentrations! It could cause damage to the
washers and could provoke noise during
normal boiler operation.
UNICAL refuses all liability for injury to persons,
animals or damage to property deriving from
not having respected the above mentioned
recommendations.
For filling-up the system a filling tap has to be foreseen on
the system return pipe.
The filling-up can also be made through the draining tap on
the boiler return manifold.
Never use such a tap to drain the system, since the system dirt
could gather in the boiler and compromise its operation. The
EXAMPLE OF FILLING-UP SYSTEM MANIFOLD
system itself shall be equipped with its own draining tap, whose
size depends on the system capacity. The application of a
filter on the return pipe to the boiler is advisable.
Filling group with PRV
IMPORT ANT NOTE
Once the system has been filled up
at the right filling pressure, the filling
group has to be closed.
47
Page 48
Instructions for the installer
3.28 - BURNER ADJUSTMENT
WARNING!
All the instructions indicated below are for the
exclusive use of qualified UNICAL service
technicians or installers.
A ) Max output adjustment
Remove the cap of the combustion gases sampling point
- Connect a suitable C02 gas analyser to the sampling
point in the flue inlet/outlet terminal.
- Force the desired burner working at nominal output
(CASCADE MAN 100%)
- Check that the C0
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.
Follow this procedure also for the other burners
values are within the values
2
All the boilers are supplied already calibrated
and tested. If it is necessary to change the
calibration due to gas conversion or adaptation
to the mains supply system, the gas valve must
be re-calibrated.
B) REGOLAZIONE ALLA POTENZA MINIMA
- Force the desired burner working at minimum output
(CASCADE MAN 10%)
- Check that the C0
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 decrea
se it.
Follow this procedure also for the other burners
values are within the values
2
48
MAXIMUM OUTPUT
ADJUSTMENT SCREW
MINIMUM OUTPUT
ADJUSTMENT
SCREW
Page 49
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 3 turns.
Verify the boiler ignition; if the boiler goes
into lockout slacken the screw “A” again of
one turn, than retry the ignition. If the boiler
goes into lockout again, carry out the above
indicated operations until the boiler is
lighted.
At this point carry out the burner adjustment
as previously indicated.
If the actual flow rate is too low ascertain that
the flue duct is not obstructed. Il the flue duct is
free, it means that the burner surface and/or
the boiler body need to be cleaned.
Instructions for the installer
INJECTORS – PRESSURES
Gas type
SUPERMODULEX
440 - 550
660 - 770 - 900
Nat. gas (G20)
Nat. gas (G25)
Propan (G31)
Supply
pressure
(mbar)
20
25
37
Supply
pressure
(mbar)
8,8
8,8
8,8
Check the C0
Diaphragm
-
-
-
Smokes sampling point
levels often, especially at low flow rate
2
Fan speed
min
(rpm)
1800
1800
1800
max
(rpm)
6300
6300
6300
CO2 levels
(%)
min
9,2
8,7
10,3
max
9,0
8,9
10,1
Starting
power
IG
(%)
60
60
60
49
Page 50
Instructions for the installer
A
SERVICE MODE FUNCTION
Befo re open the oper ating flap
turn clock-wise Shaft encoder,
to symbol
O
pen the operating flap,
displayed
DISPLAY
RELAY TEST
Turn
clok-wise
Turn
anticlok-wise
GENERAL
fter
2 sec
is displayed
level
DATA/TIME
Turn
anticlok-wise
SERVICE
Press
to open
the level
Press
to open
the level
SW NO XXXX
CASCATA MANU
ATTENTION!
The chimney sweeper mode remains active for 15 minutes.
Past this period, the standard parametre will be restored.
Repeat this operation for each burner:
BOILER 01
BOILER 02
BOILER 03
BOILER 04
BOILER 05
BOILER 06
BOILER 07
Per caldaia 01 ... 02 etc. si intende il numero
dell’elemento termico che si desidera analizzare.
Turn
clok-w ise
Press
to open
the level
BOILER 01 - 00%
BOILER 02 - 00%
BOILER 03 - 00%
BOILER 04 - 00%
BOILER 05 - 00%
BOILER 06 - 00%
BOILER 07 - 00%
BOILER 08 - 00%
CHANGE
PER CENT
0 % = MIN
TO 100% = MAX
BOILER 01 - 100%
50
Page 51
3.29 - EMERGENCY FUNCTIONS
It avoids system shutdown in case the main boiler
plant’s system management is out of use.
Instructions for the installer
A) In position I the plant will operate when requested
at “CONSTANT SETPOINT”: 70°C – Max heat
output 50%
B) Enables burner reset in case of lock-out
C) TLG General Limit Thermostat: when it acts, it cuts the
power supply to the boiler, the warning lamp D light s.
T o reset, remove the cap and push the reset button.
D ) Warning lamp of the thermostatic lockout of TLG
E) Change-over
0 = Emergency is active
I = Series connection (the cascade is managed
by the BCM)
II = Parallel connection (the cascade is managed
by the E8)
F) Relay of the condensate level sensor: when the led is
On it means every thing is OK;
when the led is Off it means that the condensate level
sensor has cut the power supply to the boiler, and the
boiler stays Off till the level of the condensate
decreases under a certain level.
D
C
II
I
E
F
B
A
Yellow LED = Blinking
(communication between BMM and BCM)
OK
Green LED = ON (Pump enabled)
Red LED = ON (Failure code detected)
Note: The switches are positioned under
the front panel.
Note: The emergency function enables the
boiler’s burners to fire only at 50% and at
50°C in system return. All the system’s
heating loads, including the header pump,
must be controlled manually.
51
Page 52
Instructions for the installer
3.30 INITIAL LIGHTING
PRELIMIARY CHECKS
The first ignition must be carried out by a
qualified technician. Failure to do so could
cause injury to persons, animals or damage
to property. UNICAL shall not be held liable
for any injury and/or damage.
Before lighting the boiler check that:
- the boiler installation has been carried out in accordance
with the specific Standards.
- the combustion air inlet and the discharge of the products
of combustion occur in the correct way in accordance to
the specific Standards in force;
- the gas supply system is correctly dimensioned for the boiler’s output;
- the boiler’s electrical supply is 230 V - 50 Hz;
- the system has been filled with water (pressure registered
on the gauge 0,8/1 bar with pump not running);
- any of the system’s on-off valves are open;
- the mains supply gas corresponds to the one which the
boiler has been calibrated for: otherwise convert the boiler
to use the available gas (refer to section: “GAS CONVERSION”); this operation must be carried out by a qualified
technician in compliance to the regulations in force;
- the gas supply cock is open;
- there are no gas leaks;
- the external mains supply switch is on;
- the boiler system’s safety valve is not blocked and that it is
connected to the sewage system;
- the condensate drain siphon has been filled with water
and that it is connected to the sewage system;
- there are no water leaks;
- all the necessary ventilation conditions and minimum clearance distances are guaranteed for subsequent servicing in case the boiler is sited in a cupboard compartment.
Information to be passed on to the user
The user of the appliance must be instructed on the use
and operation of his boiler and in particular detail:
- Hand over to the end user the booklet: “USER’S INSTRUCTIONS GUIDE”, as well as all the other literature relative to
the appliance and placed in the envelope contained in the
packaging. The
literature for any future reference.
- Inform The user of the importance of the air vents and of
the flue outlet system, stressing the fact that absolutely no
alteration can be made.
- Inform the user regarding the control of the system’s water
pressure and how to restore it to the correct value.
- Explain and demonstrate to The user the correct function
and adjustment of the temperature, thermostats and radiators for the economic use of the system.
- Remind the user that in order to comply to the regulations
in force the boiler has to be inspected and serviced regularly as indicated by the manufacturer.
- If the appliance is sold or transferred to another owner or if
the present user moves home and leaves the appliance
installed, ensure yourself that the manual always follows
the appliance so that it can be consulted by the new owner
and/or installer.
user of the appliance must retain this
52
DANGER!
Before firing the appliance fill up the siphon
through the filling hole and check the correct
drainage of the condensate.
If the appliance is used with the condensate
drain siphon empty this could cause
poisoning caused by the leakage of the flue
gasses.
Page 53
4
Servicing schedule
SERVICING
SCHEDULE
To ensure the continued safe and efficient
operation of the boiler it is highly
recommended that it is checked at regular
intervals and serviced when necessary , and
that only original spare parts are used.
The law in force states that the boiler must
be serviced annually .
If the boiler is not checked and serviced when
necessary it could cause material and
personal damages.
For this reason UNICAL recommends that a servicing contract should be made with a heating installer.
The regular inspection is useful to determine the actual state
of an appliance and to compare it with an optimum state. This
is achieved through measurement, control and observation.
The service is necessary to eliminate eventual deviations of
the actual state from the optimum state. This is normally done
through the cleaning, the parameters setting and the eventual replacement of single components subject to mechanical
wear.
The frequency of servicing will be determined by the service
engineer and will depend on appliance’s state of condition.
INSTRUCTIONS FOR SERVICING
To ensure a long life to all your boiler
components and in order not to alter the
conditions of the approved product only
original UNICAL spare parts must be used.
After having carried out all the necessary maintenance, always
follow these steps:
• Switch OFF the main switch
• Isolate the boiler from mains via a device having, at least,
a 3 mm in the switch contacts (e.g.: safety devices or power
switches) and make sure it cannot be switched ON accidentally.
• Switch off the gas gate valve upstream the boiler.
- If necessary , and in function of the type of work to be carried
out, close any on-off valves fitted on the CH flow and return
pipes, as well as the cold inlet valve.
- Remove the appliance’s front panel.
After maintenance works have been finished, follow the next
steps:
- Open the CH flow and return valves as well as the cold
inlet valve (if previously closed),
- Purge and, if necessary, proceed with restoring the heating
system’s pressure until a pressure of 0,8/1 bar is reached.
- Open the on-off gas valve.
- Reconnect the appliance to the electrical supply and
switch on the mains electrical supply.
- Test for gas soundness, on the gas side and on the water
side.
- Replace the appliance’s front panel.
.
T ABLE OF THE RESISTANCE VALUES IN FUNCTION OF THE HEA TING SENSOR (SR) AND RETURN HEATING SENSOR
TEMPERA TURE (SRR)
T°C0123456789
0 32755 31137 29607 28161 26795 25502 24278 23121 22025 20987
10 20003 19072 18189 17351 16557 15803 15088 14410 13765 13153
20 12571 12019 11493 10994 10519 10067 9636 9227 8837 8466
30 8112 7775 7454 7147 6855 6577 6311 6057 5815 5584
40 5363 5152 4951 4758 4574 4398 4230 4069 3915 3768
50 3627 3491 3362 3238 3119 3006 2897 2792 2692 2596
60 2504 2415 2330 2249 2171 2096 2023 1954 1888 1824
70 1762 1703 1646 1592 1539 1488 1440 1393 1348 1304
80 1263 1222 1183 1146 1110 1075 1042 1010 979 949
90 920 892 865 839 814 790 766 744 722 701
Relation between the temperature (°C) and the nom.
resistance (Ohm) of the heating sensor SR and the return
heating sensor SRR.
Example: At 25°C, the nominal resistance is 10067 Ohm
At 90°C, the nominal resistance is 920 Ohm
53
Page 54
Servicing schedule
We recommend that periodical service is made
by qualified technical personnel according to
the frequency stated by national rules in force.
As much as the dust present in the air will be sucked inside
the combustion chamber, the smoke side resistance will
increase, which, finally, will result in a reduced heat input
(and consequently a reduced output).Before cleaning the boiler
body sections, check the boiler input and the CO
percentage
2
(see 3.28).
Note! A reduction of the input can be caused
by the obstruction of the evacuation duct or of
the air intake. Check, first of all, that this is not
the reason.
If the actual input (with the correct CO2) is within
5% of the value shown in the chapter 3.24, the
boiler does not need to be cleaned.The
operation then, can be limited to the cleaning
of the siphon.
st
1
phase - Disassembly
• Switch off power and gas supply and ascertain the gas
cock is well closed.
• Unscrew the coupling at the gas inlet.
• Remove the front, rear and top panels of the casing.
• Remove the plug of the supply cord from the 230 V socket
Remove the electrical connections of the modules (it is
suggested to regroup separately, with tape, the harness
of each individual module)
-
-
-
-
Ignition electrode (orange)
Ionization probe (white)
Local limit thermostat)
Hearting lead (ignition transformer)
• Remove the screws “A”, fixing the burner covers, with a 13
mm socket wrengh.
A
A
A
A
• Remove the “B” fixing screws on the two sides of the bur-
ner manifold.
B
B
54
• Remove the 2 screws “C” from the front frame using a spanner of 13 mm
C
E
Page 55
• Remove the safety clip “D” of the supporting rod “E”.
• Rotate the burner assembly on its rotation axis (two
persons required).
F
F
Servicing schedule
D
• Bring up the supporting rod “E” and fix it with the safety clip
“D”.
E
55
Page 56
Servicing schedule
Dismantle burner procedure
Verify the condition of the silicone gasket s; if
they are glued to the aluminum body, before
removing them, sprinkle on them a silicone
product and leave it to act for at least 5
minutes; then proceed as indicated here after.
L
• Disjoin the burner from its seat by inserting a cutter between the red gasket and the aluminium body.
Do this on the three sides “L”, “M” and “N” of the burner.
Warning: proceed with caution,
by using gloves and a cutter.
O
• Remove the burner by lifting it only on the long sides, right
or left, as shown in fig. “O”, to avoid its deformation.
M
N
P
• Repeat the a. m. operations for each individual burner.
WARNING: AT EACH MAINTENANCE SERVICE
IT IS COMPULSORY TO REPLACE THE
SEALING GASKET OF EACH BURNER.
GASKET KIT FOR
SUPERMODULEX Code No. 95251126
56
BURNER KIT FOR
SUPERMODULEX Code No. 95262515
Page 57
2nd phase – Cleaning
• Remove from their seat the sealing gaskets and the burners and blow them with compressed air from the convex
side to the dished side.
The burner sealing gaskets, must be replaced at each cleaning of the burner.
• Wash, with a water jet, the combustion chamber: pay attention to not to wet the electrical wiring. During this operation
ascertain that the condensate evacuation pipe is always
free, so that the water cannot come out from the tray.
• Blow with compressed air in the combustion chamber, in
between the sections, so that all dirty parts are removed
from the aluminum protrusions.
• Once the cast aluminum sections have been washed, make
sure the condensate evacuation siphon is free: if necessary clean it.
• Inspect the flue duct and the smoke chamber.
3rd phase – Reassembly
• Replace the burner sealing gaskets
• Reassemble all the components previously removed by
following the reverse order.
• Before starting the boiler ascertain that the condensate siphon is filled with water.
• Before opening the gas cock on the burner manifold make
sure the coupling is well tight. To do this, open the gas cock
and check the soundness of the coupling using a soap
solution.
• As soon as a burner is put into operation check immediately the soundness between the gas valve and the relevant
premixing chamber.
• Make the combustion analysis and check the combustion
parameters.
• Make sure that all the gas pressure test nipples, previously
open, are closed and tight.
Servicing schedule
57
Page 58
DICHIARAZIONE DI CONFORMITA’ /
DECLARATION OF CONFORMITY
AG s.p.a
con sede / with headquarters in Castel d’ Ario (MN) - via Roma, 123
in qualità di azienda costruttrice di caldaie a gas a condensazione /
as gas fired condensing boiler manufacturers
DICHIARA / DECLARE
che tutti i modelli delle gamme / that all the models of the ranges:
Modulex...u: 80u - 120/16u - 120u - 160u - 200u - 240u - 280u - 300u
Modulex...p: 90p - 140p - 180p - 230p - 280p - 320p
Modulex 100: 100 - 116 - 145 - 190 - 240 - 290 - 340
Modulex: 349 - 360 - 450*- 540*- 630*
Supermodulex: 348 - 440*- 550*- 660*- 700*- 900*- 360 - 450*- 540*- 630*- 720*
(*) questi modelli non sono coperti dalla direttiva / These models are not covered by the European directive 92/42/EEC
non appartengono a nessuna delle categorie dell’art.9 del Decreto Legislativo n. 93 del 25 febbraio 2000, in attuazione
della direttiva 97/23/CE (in materia di attrezzature a pressione) e che tutti i modelli sopra citati sono completi di tutti
gli organi di sicurezza e di controllo previsti dalle norme vigenti in materia e rispondono, per caratteristiche tecniche
e funzionali, alle prescrizioni delle norme: / do not belong to any of the categories specified in clause 9 of the European
Directive 97/23/EC (regarding pressure equipment) and that all the a.m. models are fully equipped with all the safety and
control instruments foreseen by the latest relevant regulations, and comply, with regards to the technical and operating
characteristics, to the requirements stated in the following Standards and Directives:
EN 15417
EN 656
pr EN 15420
90/396/EEC
92/42/EEC
2006/95/EC
2004/108/EC
Gli apparecchi sopra menzionati hanno ottenuto i requisiti di rendimento energetico corrispondente a 4 “Stelle”,
secondo la Direttiva Rendimenti 92/42/EEC, dall’Ente Omologante CERTIGAZ / The a.m. appliances, with output up to
400 kW, have obtained the 4 stars efficiency classification, according to the Efficiency Directive 92/42/EEC, from the
notified body CERTIGAZ.
Sono inoltre marcate /
All these boiler ranges have
the following
Caldaie per riscaldamento centralizzato alimentate a combustibili gassosi. Requisiti specifici
per caldaie a condensazione con portata termica nominale maggiore di 70 kW ma non maggiore
di 1000 kW. / Gas-fired central heating boilers - Specific requirements for condensing boilers with
a nominal heat input greater than 70 kW but not exceeding 1000 kW.
Caldaie a gas per riscaldamento centrale alimentate a combustibili gassosi. Caldaie di tipo ‘’B’’
di portata termica nominale maggiore di 70 kW ma non maggiore di 300 kW. / Gas-fired central
heating boilers - Type B boilers of nominal heat input exceeding 70 kW but not exceeding 300 kW.
Caldaie per riscaldamento utilizzanti combustibile gassoso - Caldaie di tipo ‘’C’’ con portata
termica nominale superiore a 70 kW ma inferiore a 1000 kW.
/ Gas-fired central heating boilers - Type C boilers of nominal heat input exceeding 70 kW, but not
exceeding 1000 kW.
Direttiva Gas / Gas Appliances Directive
Direttiva Rendimenti / Boiler Efficiency Directive
Direttiva Bassa Tensione / Low Voltage Directive
Direttiva Compatibilità Elettromagnetica / Electromagnetic Compatibility Directive
PIN n° 1312BM3615 Modulex ...u
PIN n° 1312BR4912 Modulex ...p
PIN n° 1312BR4795 Modulex 100
PIN n° 1312BP4012 Modulex 360
PIN n° 1312BS4959 Supermodulex
IT In attuazione del decreto ministeriale 18 febbraio 2007 e successive modifiche e integrazioni,attuativo della legge Finanziaria 2007
Gli apparecchi sopra menzionati hanno un rendimento termico utile,con carico pari al 100% della potenza utile nominale, maggiore o uguale a 93 + 2log Pn,
(dove log Pn è il logaritmo in base 10 della potenza ulile nominale del singolo generatore, espressa in kW), come richiesto dal comma 1a dell’art. 9.
La Unical AG s.p.a. DECLINA ogni responsabilita’ per sinistri a persone, animali o cose derivanti da manomissioni
dell’apparecchio da parte di terzi non autorizzati, ovvero da un’errata installazione, od una manutenzione o riparazione
carente o irregolare. / Unical declines any responsibility for injuries to persons, animals or to property deriving from wrong handling
of the boiler by unauthorized third parties, or by bad installation or servicing.
Unical AG s.p.a.
Direttore Tecnico / Technical Manager
Dino Lanza
Castel d’ Ario, 13 Maggio / May 2009
Page 59
Page 60
AG S.P.A.
46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - fax 0376/660556
www.unical.ag - info@unical-ag.com
The Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also
reserves the right to bring those changes that it will hold necessary to it own products or profits, without jeopardizing
its essential characteristics.
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