Unical SuperModulex 440, SuperModulex 550, SuperModulex 660, SuperModulex 900, SuperModulex 770 Installation And Servicing Instructions

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00331587/a - 2nd edition - 02/10

SuperModulex

440 - 550 - 660 770 - 900

INSTALLATION AND SERVICING INSTRUCTIONS

MODULAR CONDENSING BOILER

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

Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accordance with the current laws in force. The end user MUST not make any alterations to the boiler. Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage.

General information

1.1 -SYMBOLS USED IN THIS GUIDE

When reading this guide particular care has to be given to the parts marked with the followings symbols:

1.2 - CORRECT USE OF THE APPLIANCE

The ALKON appliance has been designed utilizing today’s heating technology and in compliance with the current safety regulations.However, following an improper use, dangers could arise for the safety and life of the user or of other people, or damage could be caused to the appliance or other objects.The appliance is designed to be used in pumped hot water central heating systems. Any other use of this appliance will be considered improper.UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this case the risk is completely at the user’s responsibility.In order to use the appliance according to the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide.

1.3 - INFORMATION TO BE HANDED OVER TO THE USER

GENERAL INFORMATION

NOTE! Suggestions for the user

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

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

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

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

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

a safe place in

order to always have them at hand for future reference.

• Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that is absolutely

forbidden to make any alterations to the boiler.

• Inform the user how to check the system’s water pressure as well as informing him how to restore the correct

pressure.

• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure

the greatest possible fuel economy.

• Remind the user that it is obligatory to carry out a comprehensive service annually and a combustion analysis

every two years (in compliance with the national law).

• If the appliance is sold or transferred to another owner or if the present user moves home and leaves the

appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted

by the new owner and/or installer.

Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause injury to persons, animals or damage to property . The manufacturer shall not be held liable for any such injury and/ or damage.

General information

WARNING! The installation, adjustment, and servicing of this appliance must be carried out by a competent person and installed in accordance with the current standards and regulations. Failure to correctly install this appliance could cause injury to persons, animals or damage to property . The manufacturer shall not be held liable for any injury and/or damage.

DANGER!

Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL recommends drawing up a service contract. Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not be held liable.

Modifications to parts connected to the appliance

Do not carry out any modifications to the following parts:

- the boiler

- to the gas, air, water supply pipes and electrical current

- to the flue pipe, safety relief valve and its drainage pipe

- to the constructive components which influence the appliance’s safe operation

WARNING!

When tightening or loosening the screw pipe connections, use only adequate fork spanners.

The improper use and/or the use of inadequate equipment can cause damages (for example water or gas leakages).

WARNING!

Indications for appliances operating with propane gas Ensure yourself that before installing the appliance the gas tank has been purged. For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legally authorized. If the tank has not been correctly purged problems could occur during ignition.

If this occurs contact the liquid gas tank’s supplier.

Smell of gas

If you smell gas follow these safety indications:

- Do not turn on or off electrical switches

- Do no smoke

- Do not use the telephone

- Close the main gas tap

- Open all windows and doors where the gas leakage has occurred

- Inform the gas society or a company specialized in installing and servicing heating systems

Explosive and easily inflammable substances

Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room where the appliance has been installed.

1.4 -SAFETY W ARNINGS

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.

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)

LEGEND:

1 = Y ear of CE certification issue 2=

Boiler type

3=Boiler model 4=Number of stars (Directive 92/42/CEE) 5=(S.N°) Serial number 6=P.I.N. code 7=Approved fluing configurations 8=(N0x) N0x class

A = Central Heating circuit features

(Pn) Nominal output

10 = (Pcond) Condensing nominal output 11 = (Qmax) Nominal heat input

12 = (Adjusted Qn) Adjusted for nominal Heat input 13 =

(PMS) Max. pressure C.H. system

14 = (T max) Max. C.H. temperature

B = Domestic Hot Water circuit features

15 = (Qnw) Nominal heat input in D.H.W. mode (if different from Qn) 16 = (D) Specific D.H.W. flow rate according to EN 625 - EN 13203-1

17 = (R factor) N° taps based on the quantity of water declared EN

13203-1

18 = (F factor) N°stars based on the quality of water declared

EN 13203-1 19 = (PMW) Max. pressure D.H.W. system 20 = (T max) Max. temperature D.H.W system

C = Electrical features

21 = Electrical power supply 22 = Consumption 23 = Protection grade

D = Countries of destination

24 = Direct and indirect country of destination 25 = Gas family 26 = Supply pressure

E = Factory setting

27 = Adjusted for gas type X 28 = Space for national brands

7 8

21 22

C D

- 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)

General information

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. 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.

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

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

Any repairs must be carried out by Unical authorized technicians and using only original spare parts. Nonobservance of the above requirement may jeopardize the safety of the appliance.

To guarantee the efficiency and correct functioning of the appliance it is indispensable to have the boiler serviced annually by a qualified person.

If the boiler remains unused for long periods, ensure that any dangerous parts are rendered innocuous.

If the appliance is sold or transferred to another owner or if the present user moves home and leaves the appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted by the new owner and/ or installer.

Only original accessories must be used for all appliances supplied with optionals or kits (including electrical ones). This appliance must be used only for the purposes for which it has been expressively designed. Any other use shall be considered incorrect and therefore dangerous

Technical features and dimensions

2.1 - TECHNICAL FEATURES

• 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.

4 5 6 7 8

440 550 660 770 900

• 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.

TECHNICAL FEATURES AND DIMENSIONS

Technical features and dimensions

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

920

206

171

666

232

474

974

398

460

1372

Øi 250

124

615

440

4 1372 1378

920

50 (2) 80 (3) 80 (3)

250 615

390 988

1378

2.2 - DIMENSIONS

FRONT VIEW

RIGHT HAND SIDE VIEW

LEFT HAND SIDE VIEW

UPPER VIEW

Technical features and dimensions

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

660

6 1372 1256 1520

50 (2) 100 (4) 100 (4)

300 721

770

7 1372 1390 1520

50 (2) 100 (4) 100 (4)

300 855

550

5 1372 1122 1520

50 (2) 80 (3) 80 (3)

250 615

666

232474

1372

206

171

974

398

460

350

Øi D

110

124

Øi D

425

175

920 600

FRONT VIEW RIGHT HAND SIDE VIEW

LEFT HAND SIDE VIEW UPPER VIEW

Technical features and dimensions

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 mm Condensate drain mm

900

8 1434 1674 1546

80 (3) 100 (4) 100 (4)

300 986

544

232

530

1434

1574

961 585

222

1306

488,5

472,5

364

Øi D

986

100

Øi D

410

175

FRONT VIEW RIGHT HAND SIDE VIEW

LEFT HAND SIDE VIEW UPPER VIEW

Technical features and dimensions

2.3 - PERFORMANCE DATA

BOILER TYPE

SUPERMODULEX

Appliance category II

2H3P

Nominal Heat Input on P.C.I.

Minimum Heat Input on P.C.I.

Qmin

Nominal Output (Tr 60 / Tm 80 °C)

Minimum Output (Tr 60 / Tm 80 °C)

Pn min

Nominal Output (Tr 30 / Tm 50 °C)

Pcond

Minimum Output (Tr 30 / Tm 50 °C)

Pcond min

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 m3/h Gas Consumption G25 (supply pressure 25 mbar) Qmin m3/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

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

(*) Room Temperature = 20°C (**)See paragraph ‘’

INJECTORS – PRESSURES’’

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

1399

24,25

36487

0,5

133

91,36

2,33

106,25

2,71

67,07

1,71

100

146,7

<95 <30 <49

230/50

1224

40 10

770

756

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

1224

24,25

31926

0,5

118

79,94

2,33

92,97

2,71

58,68

1,71

100

128,4

<95 <30 <49

230/50

1071

40 10

660

648

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

27365

0,5

103

68,52

2,33

79,69

2,71

50,30

1,71

100

110

<95 <30 <49

230/50

918

40 10

550

540

530,33

20,33

554,04

23,94 98,21

92,4 102,6 108,8

4 97,47 98,43

0,2 0,1

2,53

874

24,25

22804

0,5

57,10

2,33

66,41

2,71

41,92

1,71

100

91,7

<95 <30 <49

230/50

765

40 10

440

432

424,27

20,33

442,37

23,94 98,21

92,4 102,4 108,8

4 97,42 98,43

0,2 0,1

2,58

699

24,25

18243

0,5

45,68

2,33

53,13

2,71

33,53

1,71

100

73,4

<95 <30 <49

230/50

612

40 10

The Technical data plate is placed under the casing over the forehead stirrup.

Technical features and dimensions

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

2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS

AIR INTAKE CONNECTION

CONTROLL PA N E L

FAN

GAS VALVE

GAS PIPE

BURNER COVER

BURNER

ALUMINIUM/ SILICON HEAT EXCHANGER

CONDENSATE DRAIN SIPHON

CONDENSATE COLLECTING

TRAYSMOKE MANIFOLD

C.H. RETURN

C.H. FLOW

AUTOMATIC AIR VENT

Min. Depth 100 mm

BOILER FRAME

Instructions for the installer

INSTRUCTIONS FOR THE INSTALLER

3.1 - GENERAL WARNINGS

WARNING! This boiler has to be destined for the use for which it has been expressively designed for. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at a temperature inferior to boiling point at an atmospheric pressure.

WARNING! These appliances are exclusively designed to be installed inside adequate boiler rooms. Therefore these appliances must not be installed and operated externally .

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.

Instructions for the installer

3.2 - STANDARD CODES FOR

INSTALLATION

The appliance must be installed in compliance to the instructions contained in this manual.

The installation must be carried out by a competent qualified engineer, whom will assume the responsibility of complying to all the local and/or national regulations published in the official publications, as well as all the applicable codes of practice.

Before installing the appliance please contact the gas supply company.

The installation must be carried 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.

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.

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

1650 1650 1650 1650 1480

440 550 660 770 900

1200 1550 1700 1840 2000

512 kg 608 kg 692 kg 770 kg 925 kg

1020 1020 1020 1020 1100

Instructions for the installer

PALLET REMOVAL

BOILER UNLOADING AND PACKAGE REMOVAL

Instructions for the installer

A > 400 mm B > 400 mm C = 100 mm D = 500 mm

Give the boiler the minimum clearances as shown in the drawing, in order to be able to make the normal service and cleaning operations.

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.

3.4 - BOILER LOCATION INSIDE A BOILER HOUSE

Instructions for the installer

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.

When the appliance is installed on existing systems, ensure yourself that:

- The flue outlet pipe is suitable for condensing boilers, for

the temperature of the products of combustion, calculated and manufactured according to the regulations in force. It must be installed as much as possible in a straight line, tested for soundness, insulated and must not have any occlusions or restrictions.

- The flue outlet pipe has a connection for the discharge of

condensate.

- The boiler room has a suitable outlet for the discharge of

condensate 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.

When a Modulex boiler is installed onto an existing heating system:

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.

3.5 - INSTALLATION ON EXISTING HEATING SYSTEMS

Instructions for the installer

3.7 - GAS CONNECTION

The gas supply pipe must be connected to the boiler via the respective pipe connection

R 2‘‘ - 3” as indicated on page 8-

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.

Before installing the boiler it is recommended to thoroughly clean all the supply piping in order to remove any eventual residual grime which could compromise the boilers correct functioning.

If you smell gas: a. Do not turn on or off electrical switches, use

the telephone or any other object which can

provoke sparks; b. Open all doors and windows in order to allow fresh air to enter and purify the room; c. Close all gas cocks d. Contact a service engineer, qualified installer or the gas supply company.

As a safety measure against gas leaks, Unical recommends installing a surveillance and protective system made up of a gas leakage detector combined with an on-off selenoid valve on the gas supply line.

1 2 3 4 5 66

INSIDE BOILER ROOM

OUTSIDE BOILER ROOM

1. On-off gas supply valve

2. Double membrane regulator

3. Gas filter

4. Anti-vibrating joint

5. Selenoid valve

6. On-off cock

EXAMPLE OF A GAS SUPPL Y SYSTEM

Instructions for the installer

3.8 - FLOW AND RETURN PIPE CONNEC-

TIONS

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

3’’- 4” M and R as

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! IT IS ABSOLUTEL Y FORBIDDEN TO FIT ON-OFF VALVES ON THE GENERATOR TO THE FORE OF THE SAFTEY DEVICES

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.

Non-observance of these instructions could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/or damage.

Ensure yourself that the system’s piping is not used as the earth clamps for the electrical or telephonic system. They are absolutely unsuitable for this use. In a short time this could cause serious damage to the piping, boiler and radiators.

Instructions for the installer

WATER FLOW m³/h

Pressure Losses (m/H

0,2

0,4

0,6

0,8

1,2

1,4

1,6

1,8

2,2

2,4

2,6

2,8

0 2 4 6 8 101214161820222426283032343638404

44 46 48 50 52

Super

Modulex

440

Super

Modulex

550

Super

Modulex

660

Super

Modulex

770

Super

Modulex

900

3,2

3,4

3,6

3,8

4,2

4,4

4,6

4,8

5,2

5,4

5,6

5,8

3.9 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP

The size of the pumps must be determined by installers or technical engineers according to boiler data and system design.

The water side resistance curve of the boiler is shown in the following diagram. The pump is not an integral part of the boiler.

It is recommended to choose a pump with the rate and delivery head at about 2/3 of its characteristic heating curve.

The boiler pump must have a delivery head which can ensure the water flow rate as shown in the diagram “Water pressure losses”.

The following table gives an indication of the pump’s flow rate in function of the Δt of the primary circuit if the installation has a mixing header.

NOTE: The use of a mixing header fitted between the boiler circuit and the system circuit is always advisable. It becomes INDISPENSABLE if the system requires flow rates superior to the maximum permitted boiler flow rates, which is to say lower than 15K.

For a

ΔΔ

ΔT 20 K, of a MODULEX 660 boiler, the max. water flow rate requested is 27,2 m³/h.

From the graph of the boiler’s pressure losses, it can be determined that the pump must be able to guarantee a delivery head of at least 1,7 m/H2O.

440 550 660 770

900

18152 22686 27223 31760 36298

24202 30248

36297 42346 48397

Boiler Model

Max water flow rate Demanded in l/h ( t=15 K)

Max water flow rate Demanded in l/h ( t=20 K)

Instructions for the installer

PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETY DEVICES

SUPERMODULEX 360 - 450 cod. 0036137561374 SUPERMODULEX 540 - 660 cod. 0036137500361375 SUPERMODULEX 770 - 900 cod. 0036156000361377

CONTROL DEVICES

7. Pressure indicator with shock absorber tube

(7a) and

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.

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.

3.10 - ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW

CERTIFICATION OF THE ADDITIONAL SAFETY 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.

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.

Instructions for the installer

3.11 - WIRING DIAGRAM FOR ADDITIONAL SAFETY DEVICES

SAFETY V AL VE

VISIBLE DRAIN FUNNEL

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.

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.

Pump management via E8

to the terminal 4 (A10)

from the IV connector

LINE

230

Safety devices

kit

RELAY

LINE

Boile r main s

supply

230 V

Terminals EXT-MIN

interface WILO

modu lating pump

LINE

230

Safety devices

kit

RELAY

LINE

Boiler m ain s

supply

230 V

ON-OFF PUMP MODULATING PUMP

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

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

30.000

50.000

100.000

150.000

200.000

250 300 400 500 600

440 550

0 - 900

power supply

over > 340 kW

125 150 200 250 300

200 250 250 300 300

1.000

1.500

1.800

300 300 300 400 400

150 150 200 300 300

1.650

1.700

2.250

2.500

2.800

200 200 200 200 200

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.

3.16 - MIXING HEADER AND PLATE HEAT EXCHANGER

1/2’’

CH FLOW

CH RETURN

I L T E R

CH FLOW

CH RETURN

Boiler

Circuit

Heating System Circuit

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

Boiler

Circuit

Heatin

System Circuit

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.

WARNING AFTER A LONG INOPERATION PERIOD OF THE BOILER, IN CASE THE BOILER TEMPERATURE IS BELOW 3°C,

ABSOLUTELY DO NOT TRY TO

START THE BOILER.

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.

See the Unical catalogue and the price list to identify the most convenient mixing header and primary circuit.

TABLE FOR THE RECOMMENDED DIMENSION OF THE HYDRAULIC COMPENSAT OR

Instructions for the installer

3.17 - CONDENSATE DRAIN

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.

* Min. height of the condensate column, with all fans

operating at max. speed, requested by the EN standards.

** 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.

150

BOILER HOUSE FLOOR

INITIAL SIPHON FILLING-UP PLUG

The upper part of the drain pipe shall not be higher than the tray bottom.

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.

The ideal pH value for water in heating systems fitted with aluminium boilers is between 6,5 and 8, with a hardness of 15°F.

In heating systems where the water has a value outside this range, this considerably accelerates the destruction of the protective oxidized layer which naturally develops inside the aluminium bodies: if the pH is below 6, acidity is present, if it is above 8, the water is alkaline or it is caused by an alkaline treatment (for example phosphate or glycol used as an antifreeze) or in several cases it is due to the natural formation of alkaline in the system.

Vice versa, if the pH value is between 6,5 and 8, the aluminium surfaces of the boiler body are passivated and protected from further corrosive attacks.

To minimize corrosion it is essential to use a scale inhibitor, however in order for this to function correctly, the metallic surfaces have to be clean.

The best corrosion inhibitors on sale also contain a protective system for aluminium which acts by stabilizing the water’s pH value, preventing unforeseen variations.

We recommend that the heating system’s water pH value is systematically controlled (minimum twice a year). In order to do this, it is not necessary to run a chemical analysis in a laboratory, but it is sufficient to use a simple analytical ‘kit’ contained in portable cases, easily found on sale.

Therefore, prior to filling the heating system with water it will be necessary to fit the devices indicated in the figure below.

THE CONNECTION MUST BE FITTED ON THE PRIMARY CIRCUIT’S RETURN PIPE DOWNSTREAM OF THE CIRCULATING PUMP

All the necessary precautions must be taken in order to avoid the formation and localization of oxygen in the system’s water. For this reason, the plastic pipes used in underfloor heating systems must be impermeable to oxygen.

If any antifreeze solutions are used ensure yourself that they are compatible with aluminium and with any other components and materials fitted on the system.

WARNING! ANY DAMAGE CAUSED BY THE BOILER, DUE TO THE FORMATION OF LIME SCALE OR DUE TO CORROSIVE WATER WILL INVALIDATE THE APPLIANCE WARRANTY.

Instructions for the installer

4 5 6 7 8

440 550 660 770 900

250 250 300 300 300

1. Ball valve

2. Inspection pocket

3. Filling-up group

4. Disconnector

5. Scale reducing device

6. Litre counter

(recommended)

7. “Y” filter

1 2 3 4 5 2 7 16

EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FOR WATER TREATMENT

Instructions for the installer

SuperModulex

440 550 660 770 900

Flue gas mass flow rate (max)

kg/h

700

874,5

1049 1224 1399

Flue gas mass flow rate

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

CO levels

d125

d400

d315

d250

d200

d160

d110

d75

100

120

140

160

180

200

300

400

500

600

700

800

900

1000

1200

1400

4,4

5,9

6,6

7,4

104

119

133

148

222

296

370

444

519

593

668

741

889

1037

3,4

3,9

4,4

5,0

5,6

100

111

167

222

277

333

389

445

555

667

778

0,001

0,002

0,003

0,004

0,005

0,006

0,007

0,008

0,009

0,010

0,015

0,020

0,030

0,035

0,040

0,050

0,060

0,070

0,080

0,090

0,100

0,150

0,200

0,250

0,300

0,350

0,400

0,500

0,600

0,700

9,0

10,8

12,0

14,4

108

126

144

180

216

252

288

324

360

540

720

900

1080

1260

1440

1800

2160

2520

100

120

140

160

180

200

300

400

500

600

700

800

900

1000

1200

1400

Chimney dimension DIN 4705

kg/skg/h 10%

10 15 20 25 30

51015202530

Pressure avaible

Flue Gas Temperature

40 Pa

40°C

606

Nominal Heat input (kW)

Nominal Heat input (kW) with CO level at 10%

Instructions for the installer

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.

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.

3.20 - BOILER OPERATION

Air intake connection

Smoke outlet

Fan

Gas valve

Burner

Ionization electrode

Ignition electrode

Combustion Chamber

H.L. Thermostat

Thermic element

Condensate collecting tray smoke manifold

Instructions for the installer

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

Input shared on 4 thermal elements : total input = 216:432

= 0,5 = 50%

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)

100

103,2

% (p.c.i.)

109,6 108,8

(kW)

60 70 80 90 100

110

50 % = 54 kW

1 Thermal

element

100 % = 108 kW

1 Thermal

element

108

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.

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. :

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.

4 thermal elements of 108 kW each working

at 50% of the output give = 216 kW = (200%),

i.e. 54 kW / thermal element

Instructions for the installer

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.

It is necessary that a qualified technician verifies that the electrical system is adequate to the appliance’s maximum absorbed power, indicated on the data plate, verifying in particular that the section of the system’s cables is suitable to the appliance’s maximum absorbed power.

For the appliance’s general electrical supply the use of adaptors, multiple sockets and/or extension cords is strictly forbidden.

The use of any power supplied equipment implies the observance of several fundamental rules, such as:

- Do not touch the appliance with any wet part of your body

and/or barefooted;

- Do not pull the supply cables

- Do not expose the boiler to sunlight, rain, etc., unless it is

explicitly foreseen;

- Do not permit children or inexpert people to use the

appliance.

Mains electrical supply connection 230V

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

The electric connections of the boiler are shown in the section named “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.

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.

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.

Instructions for the installer

3.22 - FUNCTIONAL WIRING DIAGRAM

CONTROL

MODULATION

PUMP

SIGNAL

ALARM

PUMP

BOILER CIRCUIT

eBUS

remote

(

Cascade manager)

external

CONTROL E8

CONNECTION

WIRE NEUTR AL (N)

TLTL1

4125

L1 N

RIL./RE G.

ALIM.

230V

PV1

VM1

RED

BLACK

WHITE

BROWN

WHITE

ROSA

GRIGIO

1° Modulo

RED

E.RIL.1

SR1

SRR

12345678910

A1 A2 A3 A4 A 5 A 6

L1 L1’

T1 T2

T3 T4

12345

A8 A9 A10 A11

4M21

234

BUS

123

III

IMP

0-10 V

F17 F15

FBR

VIII

PT1000

F14F13

SPF

F12 F1 1

AF KF / SPF

F9 F8

F6 F5 F3 F 2 F1

FBR

eBUS

0-10 V

VII

67891012345

12 1NL1L1

BLUE

123

Jp1

123Y44

DL1 DL2 DL3

45 6

SW1

0-10 V

Modbus - B

Modbus - A

PLC /

BMS

BCM

eBUS -

eBUS +

+ 24 V

GREY

PINK

WHITE

BLACK

BROWN

BLACK

RED

( - )

WHITE

SE8/BCM

BROWN

BLUE

230 V - 50Hz

F10A

BROWN

RED

BLUE

LIGHT-BLUE

BROWN

BLUE

BLUE BLUE

BROWN

ORANGE

BROWN

BLACK

RELE’

BLUE

BLUE BLUE

BLUE

BROWN

BLACK

BROWN

LIGHT-BLUE (N)

BROWN (L1)

BROWN

LIGHT-B LUE

F6A

ORANGE

BROWN

RED

BLUE

1N 4L

TLG

SMG

EMERGENCY

(*)

SET POINT

Choose set point value as indicated

in the tabl e * (IF NECESSARY) a nd insert resistence between Y2 (6-7).

BROWN

YEL-GREEN

BLACK

YEL-GREEN

BROWN

WHITE

LIGHT BLUE

BROWN

WHITE

LIGHT B LUE

LIGHT BLUE

WHITE

MAIN SUPPLY

ORANGE +

BLACK (-)

BROWN (PWM)

LIGHT BLUE (N) BROWN (L1)

YEL-GREEN

BLUE (TACHO)

RESET

INSERT

BCM

Ext sens

open

100 K

47 22

Short circuit

K K

10 K

Ω Ω Ω

Set point

82°C 71 60 49 38 27

°C °C °C °C °C

(*)

Instructions for the installer

Module 1

(Pos 0)

Module 2

(Pos 1)

Module 3

(Pos 2)

Module 4

(Pos 3)

Module 5

(Pos 4)

Module 6

(Pos 5)

Module 7

(Pos 6)

Module 8

(Pos 7)

Setting of mo dules selectors

Ignition electrode Ionization electrode Main switch Inserit BCM Board Global Flow Temperature Sensor E8 Warning lampe for the Ge neral Limit Ther m ostat Minimum Gas pressure swich (not supplied)

Fan pressur e sw ich Global Flow Temperature Sensor BCM Condensate lev el sensor E8/BCM selector Flow NTC Temperature sensor Local Flo w NTC T emperature sensor Global Return NTC Temperature sensor High limit thermostat Local High li m it thermostat

High limit thermostat Gas Valve Ignition Transformer Modulating Fan

Reset push button

Global

PG PR

SR SR SRR TL

TL 1....8

E.ACC 1....8

E.RIL 1....8

IG IS KF LTL G

PV 1....8

SMG SL SE8/BCM

1....8

TLG

1....8

TRA.ACC 1....8

VM 1....8

BLACK

3° - 8° MODULES

BLUE

LIGHT BLUE

BROWN

LIGHT BLUE

BROWN

YEL-GREEN

BROWN

WHITE

LIGHT B LUE

YEL -G RRE N

RED

BROWN

BLACK

LIGHT BLUE

BROWN

WHITE

BROWN

BLUE

BROW N

BLUE

BROWN

TR.ACC.1

TL2...TL8

PV2...PV8

SR2...SR8

412

RIL./R EG.

ALIM.

230V

RED

WHITE

432

+ 24 V

eBUS +

eBUS -

E.RIL.2...E.RIL8

PINK

GREY

PINK

GREY

2° - 8° Modulo

TR.ACC.2...TR.ACC.8

VG2...VG8

BLUE

VG2...VG8

BLU

MARRONE

VG1

( )

4 5 6 7 8

3 4 5 6 7

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

1-2 / 2-3 / 3-4 / 4-5 / 5-6 / 6-7 / 7-8

BROWN

123

VM (A)

12345

ST 2

FILTER

BLACK

123

M (A)

234

ST 2

RED

BROWN

LIGHT BLUE

BROWN

BLUE

BROWN

BLUE

BROWN

ORANGE +

BLACK (-)

BROWN (PWM)

LIGH T BLUE (N) BROWN (L1)

YEL-GREEN

BLUE (TACHO)

YEL-GRREN

BROWN

LIGHT BLUE

3° - 8° MODULES

LIGHT BLUE

BROWN

LIGHT BLUE

BROWN

LIGHT BLUE

YEL-G REEN

BROWN

LIGHT BLUE

YEL-G REEN

LIGHT BLUE

BROWN

( )

Instructions for the installer

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.

The main controls, necessary for the C.H. system management and for the boiler control, as well some components which are part of the boiler house, must be connected to the terminal blocks.

Power terminal assignments

Power terminal block

Sensor terminal block

12345678910

A1 A2 A3 A4 A5 A6

L1 L1’

T1 T2

T3 T4

12345

A8 A9 A10 A11

21 3

BUS

50 Hz 230 V

III

IMP

0-10 V

F17 F15

FBR

III

PT1000

F14 F13

SPF

F12 F11

AF KF / SPF

F9 F8 F6 F5 F3 F2 F1

FBR

eBUS

0-10 V

67891012345

NL1L112 1

Power supply

PINK

GREY

From BCM

BLUE

BROWN

BLACK

Terminal II

A1 A2 A3 A4 A5 A6

NL1L1’

T1 T2

67891012345

NL1L112 1

N: L1: L2: : : : : :

Neutral conductor, mains

Power supply, unit Power supply to relay

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

Mixer open, heating circuit 2 Mixer c losed, hea ting circuit 2

T3 T4

Te rminal VI

12345

A8 A9

A10 A11

21 3

Termina l IV

: :

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

Multifunction relay

Multifunction relayRecycle pump /

Instructions for the installer

Sensor terminal assignments

Connection to BCM

For connection to remote control devices

Terminal VII

VII

eBUS

0-10 V

VII

Pin 1: Pin 2:

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

Terminal I

12345678910

AF KF / SPF

F9 F8 F6 F5 F3 F2 F1

FBR

Pin 4: Pin 5: Pin 6: Pin 7: Pin 8: Pin 9: Pin 10:

Flow sensor, heating circuit 2 (ground) Flow sensor, heating circuit 2 Storage tank sensor Storage tank and boiler sensor (ground) Boiler sensor Outdoor sensor

Outdoor sensor (ground)

SPF SPF

AF AF

Buffer storage tank low sensor Buf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor)

Buf. stor. tank top sensor / FBR heat. circ. 1 (set value)

SPF

F12 F11

Terminal V

SPF

Pin 1: Flow sensor heating circuit 1 / sensor multifunction 1 Pin 2: Service water low sensor / sensor multifunction 2

VIII

PT1000

F14 F13

Te rminal VIII

F13 F14

Pin 1: Sensor HS2 / Solar 2 / Multifunction relay 3 Pin 2: Sensor Solar 1 / Sensor multifunct ion relay 4

Te rminal III

III

123

III

IMP

0-10 V

F17 F15

FBR

Pin 1: Pin 2:

FBR heating circuit 2 (room sensor) / 0-10V IN / Light FBR heating circuit 2 (ground)

F15

F17

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

1234

BUS

Morsetto IX

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

Instructions for the installer

F Ric.

VFVF

SPF

Filter

Heating Circuit 1

Heating Circuit 2

Outside Sensor

Mixing Head er

Safety devices kit

Primary system pump

123Y44

BCM

1-2

Safety devices kit

Mixing Header

Filter

Primary system pump

Heating Circuit

Outside Sensor

3.24 - INSTALLATION EXAMPLES (functional wiring and connections description)

INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE

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

(9-10) outdoor sensor

(6-7) Storage tank sensor

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

SPF

(5) Re-circulation pump storage tank

(4-5) Flow sensor heating circuit 2

(9-10) outdoor sensor

(4) Pump heating circuit 1

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Instructions for the installer

F Ric.

SPF

Filter

Heating Circuit 1

Heating Circuit 2

Outside Sensor

Mixing Header

Safety devices kit

Primary system pump

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

(9-10) outdoor sensor

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

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

(7) Mixer motor heating circuit 2 OPEN (8) Mixer motor heating circuit 2 CLOSE

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

SPF

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

(5) Re-circulation pump storage tank

(7) Mixer motor heating circuit 2 OPEN (8) Mixer motor heating circuit 2 CLOSE

(5) Re-circulation pump storage tank

(9-10) outdoor sensor

(6-7) Storage tank sensor

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

SPF

(4-5) Flow sensor heating circuit 2

(4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Filtro

F Ric.

VFVF

SPF

Heating Circuit 1Heating Circuit 2

Outside Sensor

Mixing Header

Safety devices kit

Primary system pump

Instructions for the installer

VFVF

SPF

A11

PT1000

F14

F12

Mixing Header

Filter

Heating Circuit 1

Outside Sensor

Heating Circuit 2

Safe ty devices kit

Primary system pump

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

(9-10) outdoor sensor

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

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

SPF

(5) Re-circulation pump storage tank

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

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

PT1000

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’’

(4) Collector pump

(7) Mixer motor heating circuit 2 OPEN (8) Mixer motor heating circuit 2 CLOSE

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

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Instructions for the installer

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

Connections on to the MASTER controller

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

(5) Re-circulation pump storage tank

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.

(4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(9-10) outdoor sensor

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

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

SPF

(7) Mixer motor heating circuit 2 OPEN (8) Mixer motor heating circuit 2 CLOSE

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

Filter

Heating Circuit 1

Outside Sensor

Filter

Heating Circuit 2

Remote E8 Master

Mixing Header

Safety devices kit

Primary system pump

Safety devices kit

Primary system pump

Boiler Sensor

F Ric.

SPF

Slave 1

Slave 2

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

Management of the header pump:

- Relay command for running a pump at fixed rate

- 0÷10 analogical output for control of a modulating pump

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.

Instructions for the installer

Connection for boilers in a cascade arrangement managed by a E8 heating controller with PLC supervision.

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.

123

Jp1

DL1 DL2 DL3

1 23

456

SW1

Modbus - B Modbus - A

BCM

eBUS eBUS +

+ 24 V

System Supervisor

PLC/BMS boards

Modbus

A1 A2 A3

L1 L1’

234

BUS

123

III

IMP

0-1 0 V

F17 F15

FBR

VIII

PT1000

F14 F13

SPF

F12 F11

612345

12NL1L1

BUS

Cascade Manager

BCM (modulex 2)

Y2 (1-2)

E8 (modulex 2)

BUS (+ - L H)

SLAVE 1

SLAVE 2

- System Supervisor

CanBUS

- Cascade Manager

Scheda PLC/BM S

Modbus

MASTER

BCM

(Pos 1)

BCM

(Pos 2)

I = Comunication

by MODBUS

II = Comunication

by E8

Switch ‘’C’’ (see pag. 47)

in Position II

(for each boilers)

In this configuration, switch ‚‘‘C‘‘ must be positionned on II.

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).

Instructions for the installer

Connection for boilers in a cascade arrangement connected to an external BCM optional and managed by PLC/BMS (E8 disconnected).

eBUS

Modbus

- System Manager

- S

stem Supervisor

PLC/BMS board

Modbus

- Cascade Manager

- System Monitor

- System Manager

- System Supervisor

BCM board

123

Jp1

123

DL1 DL2 DL3

1 23

45 6

SW1

eBUS remoto

BCM

eBUS eBUS +

+ 24 V

eBUS remoto

BCM (modulex 2)

Y2 (3-4)

- Cascade Manager

- System Monitor

BCM board

eBUS

Modbus

- System Manager

- System Supervisor

PLC/BMS board

Modbus

BCM

(Pos 1÷7)

BCM

(Pos 0)

BCM

(Pos 1)

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).

I = Comunication

by MODBUS

II = Comunication

by E8

Switch ‘’C’’ (see pag. 47)

in Position 0

(for each boilers)

In this configuration, switch ‚‘‘C‘‘ must be positionned on 0.

Instructions for the installer

Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected)

- System Supervisor

- Cascade Manager

Scheda PLC/BMS

Modbus

SLAVE 1

SLAVE 2

BCM

(Pos 1)

BCM

(Pos 2)

System Supervisor

Scheda PLC/BMS

Modbus

Cascade Manager

123

Jp1

123

DL1 DL2 DL3

1 23

45 6

SW1

eBUS remoto

BCM

eBUS eBUS +

+ 24 V

eBUS remoto

BCM (modulex 2)

Y2 (3-4)

I = Comunication

by MODBUS

II = Comunication

by E8

Switch ‘’C’’ (see pag. 47)

in Position 0

(for each boilers)

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).

Instructions for the installer

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.

3.26 - CONFIGURATION WITH A:

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

ON-OFF PUMP

MODULATING PUMP

4567

Jp1

DL1 DL2 DL3

123

456

SW1

PUMP

BCM

eBUS -

eBUS +

+ 24 V

POWER TERMINALS E8

ALARM

Main s suppl y 230 V - 50 Hz

RELAY

Mains supply 230 V - 50 Hz

4567

Jp1

DL1 DL2 DL3

123

456

SW1

BCM

eBUS -

eBUS +

+ 24 V

TERMINALS 0-10 V

INTERFACE

WILO MODULATING PUMP

(-)

(0 - 10 V)

Supply

Modulatin g

Pump

APM

ALARM

Mains supply 230 V -50 Hz

Instructions for the installer

3.27 - FILLING THE SYSTEM

Warning!

Do not mix the CH system’s water with antifreeze or anti-corrosion solutions using wrong concentrations! It could cause damage to the washers and could provoke noise during normal boiler operation. UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations.

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

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.

EXAMPLE OF FILLING-UP SYSTEM MANIFOLD

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.

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

values are within the values

indicated in the table “Burner pressures”

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

Follow this procedure also for the other burners

B) REGOLAZIONE ALLA POTENZA MINIMA

- Force the desired burner working at minimum output (CASCADE MAN 10%)

- Check that the C0

values are within the values

indicated in the table “Burner pressures”

- If necessary correct the value by turning the adjustment screw “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

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.

MAXIMUM OUTPUT ADJUSTMENT SCREW

MINIMUM OUTPUT ADJUSTMENT SCREW

Instructions for the installer

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.

20 25 37

8,8 8,8 8,8

1800 1800 1800

6300 6300 6300

60 60 60

9,2 8,7

10,3

9,0 8,9

10,1

SUPERMODULEX 440 - 550 660 - 770 - 900

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.

Smokes sampling point

Check the C0

levels often, especially at low flow rate

INJECTORS – PRESSURES

CO2 levels

(%)

min

(rpm)

Starting

power

(%)

Fan speed

max

(rpm)

min

max

Gas type

Nat. gas (G20) Nat. gas (G25) Propan (G31)

Supply

pressure

(mbar)

Supply

pressure

(mbar)

Diaphragm

Instructions for the installer

Per caldaia 01 ... 02 etc. si intende il numero dell’elemento termico che si desidera analizzare.

SERVICE MODE FUNCTION

RELAY TEST

Turn

anticlok-wise

displayed

pen the operating flap,

DISPLAY

GENERAL

fter 2 sec is displayed level

DATA/TIME

SERVICE

SW NO XXXX

CASCATA MANU

Press

to open

the level

Before open the oper ating flap

turn clock-wise Shaft encoder,

to symbol

BOILER 01 - 00% BOILER 02 - 00%

CHANGE PER CENT 0 % = MIN TO 100% = MAX

BOILER 01 - 100%

BOILER 03 - 00%

BOILER 04 - 00%

BOILER 05 - 00%

BOILER 06 - 00% BOILER 07 - 00%

BOILER 08 - 00%

Turn

anticlok-wise

Turn

clok-wise

Press

to open

the level

Turn

clok-wise

Press

to open

the level

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

Instructions for the installer

It avoids system shutdown in case the main boiler plant’s system management is out of use.

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.

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.

3.29 - EMERGENCY FUNCTIONS

Yellow LED = Blinking (communication between BMM and BCM) OK

Green LED = ON (Pump enabled)

Red LED = ON (Failure code detected)

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;

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.

- 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

user of the appliance must retain this

literature for any future reference.

- Inform The user of the importance of the air vents and of the flue outlet system, stressing the fact that absolutely no 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.

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.

SERVICING SCHEDULE

Relation between the temperature (°C) and the nom. resistance (Ohm) of the heating sensor SR and the return heating sensor 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

T ABLE OF THE RESISTANCE VALUES IN FUNCTION OF THE HEA TING SENSOR (SR) AND RETURN HEATING SENSOR TEMPERA TURE (SRR)

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

At 90°C, the nominal resistance is 920 Ohm

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

(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.

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.

• Remove the “B” fixing screws on the two sides of the bur- ner manifold.

• Remove the 2 screws “C” from the front frame using a spanner of 13 mm

Servicing schedule

• Remove the safety clip “D” of the supporting rod “E”.

• Rotate the burner assembly on its rotation axis (two

persons required).

• Bring up the supporting rod “E” and fix it with the safety clip “D”.

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.

• 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.

• Remove the burner by lifting it only on the long sides, right or left, as shown in fig. “O”, to avoid its deformation.

• 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

BURNER KIT FOR SUPERMODULEX Code No. 95262515

Warning: proceed with caution, by using gloves and a cutter.

Servicing schedule

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.

DICHIARAZIONE DI CONFORMITA’ /

DECLARATION OF CONFORMITY

AG s.p.a

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

Sono inoltre marcate /

All these boiler ranges have the following

PIN n° 1312BM3615 Modulex ...u PIN n° 1312BR4912 Modulex ...p PIN n° 1312BR4795 Modulex 100 PIN n° 1312BP4012 Modulex 360 PIN n° 1312BS4959 Supermodulex

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*

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

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

Castel d’ Ario, 13 Maggio / May 2009

Unical AG s.p.a.

La Unical AG s.p.a. DECLINA ogni responsabilita’ per sinistri a persone, animali o cose derivanti da manomissioni dell’apparecchio da parte di terzi non autorizzati, ovvero da un’errata installazione, od una manutenzione o riparazione carente o irregolare. / Unical declines any responsibility for injuries to persons, animals or to property deriving from wrong handling

of the boiler by unauthorized third parties, or by bad installation or servicing.

pr EN 15420

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.

92/42/EEC

Direttiva Rendimenti / Boiler Efficiency Directive

90/396/EEC

Direttiva Gas / Gas Appliances Directive

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.

EN 15417

2006/95/EC

2004/108/EC

Direttiva Bassa Tensione / Low Voltage Directive

Direttiva Compatibilità Elettromagnetica / Electromagnetic Compatibility Directive

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.

EN 656

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

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

as gas fired condensing boiler manufacturers

DICHIARA / DECLARE

Gli apparecchi sopra menzionati hanno ottenuto i requisiti di rendimento energetico corrispondente a 4 “Stelle”, secondo la Direttiva Rendimenti 92/42/EEC, dall’Ente Omologante CERTIGAZ / The a.m. appliances, with output up to

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

Direttore Tecnico / Technical Manager

Dino Lanza

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

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

(*) questi modelli non sono coperti dalla direttiva / These models are not covered by the European directive 92/42/EEC

AG S.P.A.

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

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

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

Unical SuperModulex 440, SuperModulex 550, SuperModulex 660, SuperModulex 900, SuperModulex 770 Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual