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Modular Condensing Boiler
Modulex EXT440 - 550 - 660 - 770 - 900
Installation and Servicing Instructions
3
CONTENTS
1 GENERAL INFORMATION ................................................................................................................................................................................... 41.1 Symbols used in this guide .......................................................................................................................................................................... 41.2 Correct use of the appliance ....................................................................................................................................................................... 41.3 IInformation to be passed over to the person in charge of the appliance ................................................................................................ 41.4 Safety warnings ............................................................................................................................................................................................ 51.5 Data badge .................................................................................................................................................................................................... 61.6 General warnings ......................................................................................................................................................................................... 7
2 TECHNICAL FEATURES AND DIMENSIONS ..................................................................................................................................................... 82.1 Technical features ........................................................................................................................................................................................ 82.2 Dimensions ................................................................................................................................................................................................... 92.3 Performance data ....................................................................................................................................................................................... 102.4 RHS view showing main components ....................................................................................................................................................... 11
3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 123.1 General warnings ...................................................................................................................................................................................... 123.2 Installation standards ................................................................................................................................................................................ 133.3 Packaging .................................................................................................................................................................................................. 143.4 Installation .................................................................................................................................................................................................. 163.5 Boiler location in a boiler room .................................................................................................................................................................. 173.6 Boiler connection ....................................................................................................................................................................................... 173.7 Gas connection ......................................................................................................................................................................................... 183.8 Connection return and flow system pipes ............................................................................................................................................... 193.9 Primary circuit pump or boiler pump ........................................................................................................................................................ 203.10 Additional safety and control devices, according to the Italian Law + primary circuit kit ..................................................................... 213.11 Wiring diagram for additional safety devices ........................................................................................................................................... 22
3.12 Safety pressure relief valve ..................................................................................................................................................................... 233.13 Mixing header filter .................................................................................................................................................................................... 233.14 Ballstop valves .......................................................................................................................................................................................... 233.15 Boiler freeze protection ............................................................................................................................................................................. 243.16 Mixing header and plate heat exchanger ................................................................................................................................................ 243.17 Condensing drain ...................................................................................................................................................................................... 253.18 Water treatment ......................................................................................................................................................................................... 263.19 Flue chimney connection .......................................................................................................................................................................... 273.20 Flue manifold connection .......................................................................................................................................................................... 273.21 Operation ................................................................................................................................................................................................... 293.22 Electrical connections ............................................................................................................................................................................... 313.23 Functional wiring diagram ......................................................................................................................................................................... 323.24 Wiring diagram for connection and managing ......................................................................................................................................... 343.25 Installation examples (functional wiring and connections description) .................................................................................................. 363.26 Cascade manager BCM ........................................................................................................................................................................... 40
Connections for boilers in cascade, controlled by outer compensators ............................................................................................... 433.27 Configuration with a modulating pump ..................................................................................................................................................... 443.28 Filling the system ...................................................................................................................................................................................... 453.29 Burner Adjustment .................................................................................................................................................................................... 463.30 Emergency functions ............................................................................................................................................................................... 493.31 Initial Lightning ........................................................................................................................................................................................... 50
4 SERVICING SCHEDULE .................................................................................................................................................................................... 51
5 CE CERTIFICATE ............................................................................................................................................................................................... 56
Warning: this manual contains instructions to be used exclusively by theinstaller and/or a competent person in accordance with the current laws inforce.The end user MUST not make any alterations to the boiler.Failure to follow the instructions indicated in this manual, which is suppliedwith the boiler, could cause injury to persons, animals or damage to property.UNICAL shall not be held liable for any injury and/or damage.
4
General information
1.1 - SYMBOLS USED IN THIS GUIDEWhen 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 MODULEX appliance has been designed utilizing today’s heating technology and in compliance with thecurrent safety regulations.However, following an improper use, dangers could arise for the safety and lifeof the user or of other people, or damage could be caused to the appliance or other objects.The applianceis designed to be used in pumped hot water central heating systems. Any other use of this appliance will beconsidered improper. UNICAL declines any responsibility for any damages or injuries caused by an improperuse; in this case the risk is completely at the user’s responsibility.In order to use the appliance accordingto 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
1 GENERAL INFORMATION
NOTE!Suggestions for theuser
WARNING!Indicates a potentially dangeroussituation for the product and theenvironment
DANGER!Indicates serious dangerfor your personal safetyand 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 safeplace 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 absolutelyforbidden 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 correctpressure.
• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensurethe greatest possible fuel economy.
• Remind the user that it is obligatory to carry out a comprehensive service annually and a combustion analysisevery 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 theappliance installed, ensure yourself that the manual always follows the appliance so that it can be consultedby the new owner and/or installer.
Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause injuryto persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/or damage.
5
General information
WARNING!The device should not be used by people with reduced physical, mental and sensory, experience andknowledge. These people must be well-informed and supervised during the work. Children must besupervised so they do not play with the appliance.
WARNING!The installation, adjustment, and servicing of this appliance must be carried out by a competent person andinstalled in accordance with the current standards and regulations. Failure to correctly install this appliancecould cause injury to persons, animals or damage to property. The manufacturer shall not be held liable forany injury and/or damage.
DANGER!Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICALrecommends drawing up a service contract. Bad or irregular servicing could compromise the safe operationof the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall notbe held liable.
Modifications to parts connected to the applianceDo 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 gasleakages).
WARNING!Indications for appliances operating with propane gasEnsure 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 legallyauthorized.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 gasIf 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 substancesDo not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the roomwhere the appliance has been installed.
1.4 - SAFETY WARNINGS
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 temperaturelower than -15°C and higher than 40°C.
The boiler has to be protected against environmental variations with:
- The insulation of the hydraulic pipelines and the condensate evacuation- The adoption of specific antifreeze products in the C.H. installation.
6
General information
® 1
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A
B
21 22
23
24 25 26
27
C D
E
CE MarkingThe CE marking documents that the boilers satisfy:- The essential requirements of the Directive regarding gas
appliances (Directive 2009-142 EC)
LEGEND:1 = Year of CE certification issue2 = Boiler type3 = Boiler model4 = Number of stars (Directive 92/42/CEE)5 = (S.N°) Serial number6 = P.I.N. code7 = Approved fluing configurations8 = (N0x) N0x class
A = Central Heating circuit features9 = (Pn) Nominal output10 = (Pcond) Condensing nominal output11 = (Qmax) Nominal heat input12 = (Adjusted Qn) Adjusted for nominal Heat input13 = (PMS) Max. pressure C.H. system14 = (T max) Max. C.H. temperature
B = Domestic Hot Water circuit features15 = (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 EN13203-1
18 = (F factor) N°stars based on the quality of water declaredEN 13203-1
19 = (PMW) Max. pressure D.H.W. system20 = (T max) Max. temperature D.H.W system
C = Electrical features21 = Electrical power supply22 = Consumption23 = Protection grade
D = Countries of destination24 = Direct and indirect country of destination25 = Gas family26 = Supply pressure
E = Factory setting27 = Adjusted for gas type X28 = Space for national brands
- The essential requirements of the Directive regardingelectromagnetic compatibility (Directive 2004/108 EC)
- The essential requirements of the Efficiency Directive(Directive 92/42/EEC)
- The essential requirements of the low voltage Directive(Directive 2006/95EC).
1.5 - DATA PLATE
7
General information1.6 - GENERAL WARNINGS
This instruction manual is an integral and indispensable partof the product and must be retained by the person in charge
of the appliance.
Please read carefully the instructions contained in this manualas they provide important indications regarding the safeinstallation, use and servicing of this appliance.
Keep this manual in a safe place for future reference.
The installation and servicing must be carried out inaccordance with the regulations in force according to themanufacturer’s instructions and by legally competentauthorized persons.
By a competent person, we imply a person who has aspecific technical qualification in the field of componentsfor central heating systems for domestic use, domestichot water production and servicing. The person must havethe qualifications foreseen by the current laws in force.
Bad or irregular servicing could compromise the safeoperation of the appliance, and could cause injury to persons,animals or damage to property. The manufacturer shall notbe held liable for any such injury and/or damage.
Before carrying out any cleaning or servicing turn off theelectrical supply to the boiler by means of the ON/OFF switchand/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 authorizedtechnicians and using only original spare parts. Non-observance of the above requirement may jeopardize thesafety of the appliance.
To guarantee the efficiency and correct functioning of theappliance it is indispensable to have the boiler servicedannually by a qualified person.
If the boiler remains unused for long periods, ensure that anydangerous parts are rendered innocuous.
If the appliance is sold or transferred to another owner or ifthe present user moves home and leaves the applianceinstalled, ensure yourself that the manual always follows theappliance so that it can be consulted by the new owner and/or installer.
Only original accessories must be used for all appliancessupplied with optionals or kits (including electrical ones).
This appliance must be used only for the purposes for whichit has been expressively designed. Any other use shall beconsidered incorrect and therefore dangerous (*).
8
Technical features and dimensions
45678
440550660770900
2.1 - TECHNICAL FEATURES
• MODULEX is a compact, gas fired, Low NOx, condensingboiler, made up by one sectional boiler body,This boiler body consists of two or more modules (from 4 to8), which cannot be separated from each other, being un-der the same protecting casing, and are set to operate se-parately or in cascade. These modules are connected to asingle smoke exhaust manifold and are controlled by asingle microprocessor (BMM), which manages completelythe temperatures from the point of view, both operationaland safety. This version is suitable for only central heatingCAUTION: These devices are not suitable for theproduction of water for human consumption
• Efficiency at full load with temperature 30/50°C = 101,1%.At part load (30% of the nominal) with 30°C return tempe-rature = 107,2%.
• Efficiency Class:• Each module, is composed of a combustion chamber, me-
tallic fiber pre-mix burner, modulating fan, gas valve, igni-tion electrode, flame detection, NTC sensor for manage-ment control (BMM), local temperature control and afetythermostat.
• Each single boiler is equipped with NTC sensors for globaltemperature control on the flow and return manifolds.
• Integral, non allergic, synthetic wool insulation.• Total premix burner, modulating burner with a radiant “me-
tal sponge” (NIT). Premix antechamber combustion. Auto-matic backflow valve, preventing gas in the place of instal-lation.
• Fully pre-mixed, radiating, modulating, metallic spongeburner, Automatic no return diaphragm for separation fromcombustion chamber.
• Nominal input, per module: max. 108 kW, min. 22 kW.• Noise level at maximum output: lower than 50 dBA.• Modules configuration possibilities:• Possible cascade installation of 2 or more Modulex• Heating Operation: setting of instantaneous output by a
main microprocessor, with a comparison parameters pre-setting between the requested temperature (or calcula-ted by the outer compensator) and the global flow tem-perature.
2 TECHNICAL FEATURESAND DIMENSIONS
• 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 eachmodule to guarantee the best homogeneous use.C) D.H.W. production, via a storage tank loading pump or athree way diverting valve, controlled by a priority sensorthrough the E 8 heating controller.D) Output check of each module for any calibration and/orassistance 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 boilerplant’s automation system: : (in case of remote control ofthe complete boiler house):
• Input for “Constant setpoint”: 82°C, maximum output 50%.• Alarm reset input.• Alarm 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)• Instrument panels secreted (POP-UP)
SENSORS supplied with the boiler:• 00262208 outdoor temperature sensor• 00262209 flow temperature sensor for mixed zone• 00262210 boiler temperature sensor• 00262211 D.H.W. storage temperature sensor
Optional accessories:• 00262603 Sensor (Solar) PT1000• 00262829 Acid condensate inhibitor 1500 kW• 00361044 Cleaning kit bodies• 00361332 Kit thermoregulation E8• 00361358 Remote control kit BM8• 00361359 Kit custody thermoregulation• 00361545 Kit expansion module E8
• Primary circuits: COMPO S - PREMO S - PREMO C -COMPO S RING BOX COVER. - Safety devices - , see cap.3.10
• 00361997 Mixing header• 0036..... gas terminal Support kit• 0036....... Boiler support Kit 10 cm
9
Technical features and dimensions
MODULEXDimensionNo. of ModulesHeight mmWidth ‘’L’’ mmWidth ‘’L1’’ mmDepth mm
ConnectionsGas mm (inch)C.H. system Flow M mm (inch)C.H. system Return R mm (inch)Chimney connection mmCondensate drain diameter mm
440
4144810871039946
80 (3)100 (4)100 (4)
30040
395
946235 S
1267
534
327
R
M
G
122
660
6144813551307946
80 (3)100 (4)100 (4)
30040
770
7144816231575946
80 (3)100 (4)100 (4)
30040
550
5144813551307946
80 (3)100 (4)100 (4)
30040
900
8144816231575946
80 (3)100 (4)100 (4)
30040
Smoke outlet:Left side (standard condition)Right sideBack side
1448
L1287
L
62,5
24
S
2.2 - DIMENSIONSFRONT VIEW RIGHT HAND SIDE VIEW
LEFT HAND SIDE VIEW UPPER VIEW
= =
10
Technical features and dimensions
2.3 - PERFORMANCE DATA
900
86422
849,05 20,57873,9323,5998,2793,5
101,15107,22
497,898,50,20,1
2,5845,81386
24,25-
645
365090,5
6122
91,362,33
106,252,71
67,071,71100
146,7
<95<30<49
230/504
1252X5D
20
770
75622
742,62 20,57773,3823,5998,2393,5
102,3107,22
497,898,50,20,1
2,5846,71213
24,25-
645
319330,5
6108
79,942,33
92,972,71
58,681,71100
128,4
<95<30<49
230/504
1096X5D
20
660
64822
636,5320,57
662,9023,5998,2393,5
102,3107,22
497,898,50,20,1
2,5146,71040
24,25-
645
273710,5
694
68,522,33
79,692,71
50,301,71100110
<95<30<49
230/504
940X5D
20
550
54022
530,44 20,57552,4223,5998,2393,5
102,3107,22
497,798,50,20,1
2,5346,7866
24,25-
645
228090,5
680
57,102,33
66,412,71
41,921,7110091,7
<95<30<49
230/504
783X5D
20
440
43222
424,35 20,57446,9323,5998,2393,5
102,3107,22
497,798,50,20,1
2,5846,7693
24,25-
645
182470,5
667
45,682,33
53,132,71
33,531,7110073,4
<95<30<49
230/504
626X5D
20
(*) Room Temperature = 20°C(**) See paragraph ‘’INJECTORS – PRES
SURES’’(***) The protection IP X5D is obtained with
cap down.
The Technical data plate is placed under thecasingand is positioned near to the BCM.
BOILER TYPE MODULEXAppliance category II
2H3P
Nominal Heat Input on P.C.I. Qn kWMinimum Heat Input on P.C.I. Qmin kWNominal Output (Tr 60 / Tm 80 °C) Pn kWMinimum Output (Tr 60 / Tm 80 °C) Pn min kWNominal Output (Tr 30 / Tm 50 °C) Pcond kWMinimum Output (Tr 30 / Tm 50 °C) Pcond min kWEfficiency 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 CEECombustion 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) °CFlue gas mass flow rate (max) kg/hExcess of air λ %(**) CO
2 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/hMinimum pressure in CH circuit barMaximum pressure in CH circuit barWater content lGas Consumption Natural gas G 20 (20 mbar) Qn m3/hGas Consumption Natural gas G 20 (20 mbar) Qmin m3/hGas Consumption G25 (supply pressure 25 mbar) Qn m3/hGas Consumption G25 (supply pressure 25 mbar) Qmin m3/hGas Consumption G31 (supply pressure 37/50 mbar) Qn kg/hGas Consumption G31 (supply pressure 37/50 mbar) Qmin kg/hMax. available pressure at the chimney base PaCondensate production max kg/hEmissionsCO with 0% of O2 in the flue system ppmNOx with 0% of O2 in the flue system ppmSound level dBAElectrical DataVoltage / Frequency V/HzFuse on main supply A (F)Max power absorbed W(***) Insulation degree IPStandby Consumption W
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Technical features and dimensions
Smoke outlet on the L.H. side, on R.H. side, on the BACK sideC.H. flow connection on the L.H. sideC.H. return connection on the L.H. sideGas connection on the L.H. sideBCM: under the frontal panel
2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS
GAS PIPE
H. LIMITTHERMOSTAT
IGNITION ELECTRODE
CONTROLL PANEL
FAN
GAS VALVE
BURNER COVER
BURNER
ALUMINIUM/SILICON HEAT EXCHANGER
CONDENSATE COLLECTING TRAY-SMOKEMANIFOLD
C.H.RETURN
C.H. FLOW
AUTOMATIC AIR VENT
Min. Depth 100 mm
BOILER FRAME
12
Instructions for the installer
3 INSTRUCTIONS FORTHE INSTALLER
3.1 - GENERAL WARNINGS
WARNING!This boiler has to be destined for the use forwhich it has been expressively designed for.Any other use shall be considered improperand therefore dangerous.This boiler is designed to heat water at atemperature inferior to boiling point at anatmospheric pressure.
WARNING!These appliances are exclusively designedto be installed inside adequate boiler rooms.Therefore these appliances must not beinstalled and operated externally.
Before installing the boiler the following pointshave to be carried out by a competent engineer:a) The whole system should be thoroughlyflushed in order to remove any residual dirt orgrime which could compromise the correctboiler operation.b) Check that the boiler has been preset foroperating with the gas type available.This is verifiable via the indication on thepackaging and on the data badge;c) Check that the chimney/flue pipe has anadequate draught,does not have anyconstrictions, and that no other appliance’sflue outlets have been fitted, unless the chimneyis serving more than one heating appliance,according to the specific standards andregulations in force.The connection between the boiler andchimney/flue outlet can be made only after thisverification has been carried out.
WARNING!In rooms where there is the presence ofaggressive vapours or dust the appliancemust operate independently from the airpresent in the boiler’s location room!
WARNING!The appliance must be installed by a qualifiedengineer, who complies to the technical-professional requirements according to thenational applicable law and who, under hisown responsibility, guarantees thecompliance with the standards according tothe latest regulations.
WARNING! Install the appliance respecting the minimum clearances for operation and servicing.
The boiler must be connected to a heatingsystem which is compatible to its performancesand output.
13
Instructions for the installer3.2 - STANDARD CODES FOR
INSTALLATION
The appliance must be installed in compliance to theinstructions contained in this manual.
The installation must be carried out by a competent qualifiedengineer, whom will assume the responsibility of complyingto all the local and/or national regulations published in theofficial publications, as well as all the applicable codes ofpractice.
Before installing the appliance please contact the gas supplycompany.
The installation must be carried in accordance to the codesof practice, the regulations and the requirements herebyindicated which constitute an indicative list, but not a completeone, as these continue to undergo evolve devolpments.
Moreover, the boiler must be installed in accordance to all theregulations regarding the boiler room, the building regulationsand the prescriptions regarding central heating plants in forcein the country where the boiler is installed.
The appliance must be installed, commissioned and servicedaccording to the regulations in force. This is also valid for thehydraulic system, the flue outlet system and the boiler locationroom.
14
Instructions for the installer
15151515151515151515
440550660770900
12631531153117991799
kg551 kg kg806 kg kg
11201120112011201120
3.3 - PACKING
The boiler MODULEX is delivered assembledand protected by a plastic bag inside a strongcardboard box and fixed on pallet. This allowsthe boiler to be handled also by forklift. The boi-ler, with the packaging, can go through a door of800 mm, whereas, without packaging, it can gothrough a door of 700 mm.
Remove both straps and finally the cardboardbox from above, making sure the product isintact. The packing elements (cardboard box,straps, plastic bags, etc…) shall not be left tochildren’s hand since they may be dange-rous.
For the removal of the boiler from the pallet it is necessaryto have a jib crane, to avoid to damage, during the removal.- Remove the casings and make the sling with the belts
‘’A‘’ fig. 3, having care to pass the belts bearing barsframe
- Tie the belts to thearm ‘’ B ‘’; during these operationsactwith caution.
On the L.H. side of the boiler:- There is the terminal of the smoke chamber, fixed.
- A carton box containing:• Gasket between smoke chamber and its terminal,• Gasket for the base of flue socket, gasket Ø 300• Two curves + a Te piece + a plastic plug, for the
condensate evacuation system• The fixing screws• The sensors (3x).• Nipple for smokes sampling test• Kit resistance• Metal plate and passage cable for power output
- A carton box containing:• The flanges
Inside the casing, on the back side:- Two pipes for the condensate evacuation system of 1 m
each.
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
C
B A
15
Instructions for the installer
WARNING!Handling with forklift or hoist bands,
1
M ax. adm itte d b oiler s st acked
Do not tur n up side down Do n ot ex pose to r ain Fr agile Do no t exp ose to su nligh t Do not sto re at tem per atur e:lower than - 5 ° C / 23 °Fsup erior th an 50 °C / 122 °F
T max50°C/ 122°F
T mi n-5°C /23°F
2
M ax. adm itted bo ile rs s tacked
Do no t turn u pside down Do no t exp ose t o ra in Frag ile Do n ot ex pose t o sun ligh t Do not store at t emp eratu re :l ower t han - 5 ° C / 23 °Fs uper ior tha n 50 °C / 122 °F
T max50°C/122°F
T mi n-5°C /23°F
3
Max . adm itt ed bo ilers sta cked
Do no t t urn u psid e do wn Do n ot exp ose to rain F ra gile Do n ot e xpo se to s unl igh t Do no t st ore at t emp eratu re:l ower th an - 5 ° C / 2 3 °Fsu pe rio r than 50 °C / 1 22 °F
T max50°C /122°F
T mi n-5°C /23°F
4
WARNING!Waypoints bands for lifting. Brackets must bemounted on bearing stringers.
BOILER UNLOADING AND PACKAGE REMOVAL
16
Instructions for the installer
Special attention shall be paid to local regulations and lawsabout boiler houses and particularly to the obligation ofkeeping minimum clearances and empty space around theboiler. The installation shall be in compliance with all latestregulations and laws about boiler houses, installations ofheating and hot-water systems, ventilation, chimneys capableof evacuating the flue gases of condensing boilers and anyother applicable requirement.
The boiler can be put on a flat and sufficiently strong basewith the same dimensions as the boiler ones and at least100mm high (see fig. 25), in order to assemble the conden-sate drain siphon. An alternative to this base may be a 100mmdeep well next to the boiler as siphon housing (see fig. 25).After installation the boiler shall be perfectly horizontal andstable, to reduce any possible vibrations or noises.
A
C
B
D
A > 400 mmB > 400 mmC = 100 mmD = 500 mm
Sifone
Give the boiler the minimum clearances as shownin the drawing, in order to be able to make thenormal service and cleaning operations.
3.4 - BOILER LOCATION INSIDE A BOILER HOUSE
17
Instructions for the installer
Diaphragm Gaskets
A
C
F
F
G
F
RM
3.6 - BOILER CONNECTION
The boiler Modulex leaves the factory predisposed for thehydraulic / gas connection and smoke outlet on the Left sideof the boiler.
For the smoke chamber fixing, use the screws and gasketsincluded into the carton box, and a 10 mm key.
The smoke collector is a standard on the left side, you canalso exit on the right side and rear side.
3.5 - INSTALLATION
F
F
G
F
R M
A
B
When the appliance is installed on existing systems, ensureyourself that:
- The flue outlet pipe is suitable for condensing boilers, forthe temperature of the products of combustion, calculatedand manufactured according to the regulations in force. Itmust be installed as much as possible in a straight line,tested for soundness, insulated and must not have anyocclusions or restrictions.
- The flue outlet pipe has a connection for the discharge ofcondensate.
- The boiler room has a suitable outlet for the discharge ofcondensate produce by the boiler.
- The electrical system has been fitted in compliance to thespecific norms and the work has been carried out by acompetent person.
- The circulation pump’s output, the head and flow directionare suitable.
- The gas feeding supply pipe and the eventual tank areconstructed according to the regulations in force.
- The expansion vessels assure the total absorption of thedilatation 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 existingheating system:In case the replacement of an existing boiler in an old systemcan be programmed, it is necessary to thoroughly cleanout the system with a basic solution. The system must becleaned 4 weeks before the substitution, with the systemfiring 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 ha-ving first performed what said in the previous pa-ragraph, Do not wash now the system, as resi-dual products, present in the circuit, could leadto system gathering in the boiler body, causingdamage. UNICAL recommends contacting a spe-cialised company for water treatment.
Instead, if installing a Modulex boiler in a new system, it isstill recommended to thoroughly clean out the system with anadequate product and fit a Y filter with two isolating valvesonthe boiler’s return pipe, so that, when necessary, it can becleaned. This filter will protect the boiler from the dirt comingfrom the heating system.
When sizing pumps, it is necessary to take into considerationthe pressure losses which occurin the primary circuit.
The sealing gasket with diaphragm Ø18 (A) are fitted only in theflow connection seat of the first and last aluminium section ofthe boiler.The sealing gasket with diaphragm Ø 27 (B) are fitted in theother fow connection seats of the remaining aluminium sections.
In all the return connection seats of the aluminium sections,only sealing gasket (C), without, is fitted.
18
Instructions for the installer
3.7 - GAS CONNECTION
The gas supply pipe must be connected to the boiler via therespective pipe connection R 3” as indicated on page 9.
The gas supply pipe must have a section which is identical orgreater then the one used on the boiler and must assure acorrect gas pressure.
It is however important to comply with the specific norms andrequirements in force, foreseeing on-off valves, gas filter,anti-vibrating joint etc.
Before commissioning an internal gas distribution systemand therefore before connecting it to the gas meter, thecomplete installation must be tested for gas soundness.
If any part of the system is concealed from view the gassoundness test must be carried out before covering the pipes.
DANGER!The gas connection must be carried out by aregistered engineer who will have to respectand comply to the regulations in force and tothe requirements indicated by the local gassupplier. An incorrect installation couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any injury and/or damage.
Before installing the boiler it is recommendedto thoroughly clean all the supply piping in orderto remove any eventual residual grime whichcould compromise the boilers correctfunctioning.
If you smell gas:a. Do not turn on or off electrical switches, use
the telephone or any other object which canprovoke sparks;
b. Open all doors and windows in order toallow fresh air to enter and purify the room;c. Close all gas cocksd. Contact a service engineer, qualifiedinstaller or the gas supply company.
As a safety measure against gas leaks, Unicalrecommends installing a surveillance andprotective system made up of a gas leakagedetector combined with an on-off selenoid valveon the gas supply line.
1 2 3 4 5 66
INSIDEBOILER ROOM
OUTSIDEBOILERROOM
1. On-off gas supply valve2. Double membrane regulator3. Gas filter4. Anti-vibrating joint5. Selenoid valve6. On-off cock
EXAMPLE OF A GAS SUPPLY SYSTEM
19
Instructions for the installer
3.8 - FLOW AND RETURN PIPE CONNEC-TIONS
The CH flow and return circuits have to be connected to theboiler via the respective connections 4” M and R as indicatedon page 9.
When determining the size of the CH circuit pipes it isessential to bear in mind the pressure losses induced by anyof the system’s components and by the configuration of thesame system.
The route of the piping has to be conceived taking all thenecessary precautions in order to avoid air locks and tofacilitate the continuous purging of the system.
WARNING!IT IS ABSOLUTELY FORBIDDEN TO FIT ON-OFFVALVES ON THE GENERATOR TO THE FOREOF THE SAFTEY DEVICES
WARNING!Before installing the boiler we recommendthat the system is flushed out with a suitableproduct in compliance to the norm UNI-CTI8065, in order to eliminate any metallictooling or welding residues, oil and grimewhich could reach the boiler and affect theproper running of the boiler.
Non-observance of these instructions couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any such injury and/or damage.
Ensure yourself that the system’s piping is notused as the earth clamps for the electrical ortelephonic system. They are absolutelyunsuitable for this use. In a short time this couldcause serious damage to the piping, boilerand radiators.
20
Instructions for the installer
Boiler Model
Max water flow rateDemanded in l/h ( t=15 K)Δ
Max water flow rateDemanded in l/h ( t=20 K)Δ
440 550 660 770 900
18243 22804 27365 31926 36487
24326 30404 36487 42570 48647
3.9 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP
The size of the pumps must be determinedby installers or technical engineersaccording to boiler data and system design.
The water side resistance curve of the boileris shown in the following diagram.The pump is not an integral part of the boiler.
It is recommended to choose a pump withthe rate and delivery head at about 2/3 of itscharacteristic heating curve.
The boiler pump must have a delivery head which can ensurethe water flow rate as shown in the diagram “Water pressurelosses”.
The following table gives an indication of the pump’s flow ratein function of the Δt of the primary circuit if the installation hasa mixing header.
For a DT 20 K, of a MODULEX 900 boiler, the max. water flow rate requested is 36289 l/h.From the graph of the boiler’s pressure losses, it can be determined that the pump must be ableto guarantee a delivery head of at least 1,8 m/H2O.
0
0,40,20,60,8
1
1,41,21,61,8
2
2,42,22,62,8
3
3,43,2
3,63,8
4
4,44,24,64,8
5
5,45,2
5,65,8
6
0 2000 4000 6000 8000 10000 12000 14000 16000 20000 22000 24000 28000 30000 32000 34000 36000 38000 40000 42000 44000 46000 48000 50000 52000 5400018000
900 EXT
770 EXT660 EXT440 EXT 550 EXT
WATER FLOW (l/h)
Pres
sure
Los
ses
(m/H
)2O
NOTE: The use of a mixing header fitted between the boiler circuit and the system circuit isalways advisable. It becomes INDISPENSABLE if the system requires flow rates superior to themaximum permitted boiler flow rates, which is to say lower than 15K.
21
Instructions for the installer
CERTIFICATION OF THE ADDITIONAL SAFETY DEVICES:
DISPOSITIVI DI SICUREZZA1. On-off gas valve: a device which has the function of cut-
ting off the gas supply when the water temperature rea-ches the max. predetermined value. The sensible elementhas to be installed as nearest as possible to the genera-tor (flow pipe) at a distance which has to be < 500 mm andmust not be able to be cut-off. Not supplied by Unical.
2 Pressure relief valve: it has the function of discharging inthe atmosphere the fluid contained in the generator whenthis has, for whatever motive, reached the maximumworking pressure. Not supplied by Unical.
2a Visible drain funnel. Not supplied by Unical.
PROTECTIVE DEVICES10 Overheat thermostat: it has the function of shutting down
the generator if the safety thermostat fitted in the boilermalfunctions. It must be calibrated to a value of < 100°C,which MUST not be changed.
15 Minimum pressure switch: it has the function of shuttingdown the generator In case of low pressure (can be cali-brated from 0.5 to 1.7 bar). It must be able to be resetmanually.
16 Additional plug G1'’:18 Safety pressure switch: it has the function of shutting
down the generator if it reaches the maximum workingpressure (can be calibrated from..
CONTROL DEVICES11. Pressure indicator with shock absorber tube (12) andpressure gauge holder valve (13): it indicates the effective
3.10 - ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW
12
2a4
6
1a
11121415
18
10
1317
3
1916
kit ISPELS
MODULEX 440 - 550 - 660 - 770: 00361998
MODULEX 900: 00361999
pressure existing in the generator. It must be graduated in“bar” and must have the maximum operating pressure inscale and be equipped with a 3-way valve with the connectionfor the manometer.
14 Thermometer: it indicates the effective water temperatu-re contained in the generator. It must be graduated in de-grees Celsius with a temperature scale not exceeding120°C.
17 Inspection pocket: approved for inserting the control ther-mometer
19 Plug ¼’’: for the safety valves connection
3 Calibrated expansion vessel: it permits the absorption ofthe increase in volume of the system’s water following anincrease in temperature; The pressure must not exceedthe safety valve set pressure. Not supplied by Unical.
8 Y filter
7 Modulating pump (Not supplied in kit ISPELS)
5 Mixing bottle (Not supplied in kit ISPELS)
4 Automatic air vent. Not supplied by Unical
6 Drain cock. Not supplied by Unical.
22
Instructions for the installer
In case of safety devices intervention, thepump ON / OFF continues to work in order todecrease the high temperature..
In case of safety devices intervention, theModulating pump continues to work at theminimum in order to decrease the hightemperature
PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETYDEVICESMODULEX 440 - 550 - 660 - 700:(COMPO S. 00361994) (PREMO S. 00362065) (PREMO C. 00362067)
MODULEX 900(COMPO S. 00361995) (PREMO S. 00362066) (PREMO C. 00362068)
COMPO S.
PREMO S.
PREMO C.
3.11 - WIRING DIAGRAM FOR ADDITIONALSAFETY DEVICES
Pump management via E8 to the terminal 4 (A10) from the IV connector
LINE 230 V
Safety deviceskit
RELAY
L
N
LINE
Boiler mainssupply230 V
NL1
L
N
NL1
Terminals EXT-MINinterface WILO
modulating pump
LINE 230 V
Safety deviceskit
RELAY
LINE
Boiler mainssupply230 V
ON-OFF PUMP
MODULATING PUMP
23
Instructions for the installer
Note:Modulex 660 - 770 - 900 need 2 securityvalve.
17
SAFETY VALVEVISIBLEDRAINFUNNEL
3.12- PRESSURE RELIEF VALVE DRAINPIPE
A pressure relief valve must be fitted on the flowpipe, within 0,5 m from the boiler. It must bedimensioned for the capacity of the boiler andmust comply to the regulations in force,
WARNING!Please remember that it is forbidden tointerpose, between the boiler and thepressure relief valve, any type of cutting-offdevice. Moreover it is recommended to usecutting-off valves which do not exceed themaximum allowable operating pressure.
WARNING!In correspondence to the heating pressurerelief valve foresee the installation of adischarge pipe with a funnel and a siphonwhich lead to an adequate drainage. Thedrainage has to be controllable by sight.If this precaution is not made, an eventualintervention of the pressure relief valve couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any injury and/or damage.
3.14 - BALLSTOP VALVES
The installation of ballstop gate valves, on the C.H. flow andreturn connection, is recommended.Doing so, in case of normal or extraordinary service, the boi-ler can be drained without emptying the whole C.H. sistem.
WARNING!IT IS NOT ALLOWED TO ISOLATE THE SAFETYDEVICES, as the safety valve and the expan-sion vessel, FROM THE BOILER.
3.13 - MIXING HEADER FILTER
UNICAL suggests the installation of a Y filteron the return pipe so that it can be cleaned ifnecessary.This filter will protect the boiler from the heatingsystem dirt.
Secondarycircuit
24
Instructions for the installer
3.16 - MIXING HEADER AND PLATE HEAT EXCHANGERn order to ensure correct boiler operation it is necessary touse 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
he plate heat exchanger, conveniently dimensioned, has theadvantage to keep hydraulically the two circuits (primary andsecondary),protecting the boiler heat exchanger water / smo-ke. allows subsequently, by adding or removing additionalplates to adjust the system as needed.
M
MR
R
Boiler Circuit
Heating SystemCircuit
Mixing HeaderModulex Ext 440 - 900cod. 00361997M = DN 100 - (G 4’’)R = DN 100 - (G 4’’)
Modulex ModulexExt 440 code 00362093* Ext 440 code 00362098Ext 550 code 00362094* Ext 550 code 00362099Ext 660 code 00362095 Ext 660 code 00362100Ext 770 code 00362096 Ext 770 code 00362101Ext 900 code 00362097 Ext 900 code 00362102
80°C (ht)
65°C (ht)
70°C (ht)
60°C (ht)
70°C (bt)50°C (bt)
40°C (bt)55°C (bt)
High temperature:Boiler CircuitM = 80 °C - R = 65 °CHeating System CircuitM = 70 °C - R = 60 °C
Low Temperature:Boiler CircuitM = 70 °C - R = 55 °CHeating System CircuitM = 50 °C - R = 40 °C
Plate Heat exchanger:
COLD OUT CH FLOW to System circuit (G 4’’)COLD IN CH RETOUR from System circuit (G 4’’)HOT IN CH FLOW from boiler (G 4’’)HOT OUT CH RETOUR to boiler (G 4’’)
3.15 - BOILER FREEZE PROTECTIONShould the flow temperature (measured at global flow tempera-ture NTC) decrease under 7°C, the system pump is set up. Shoultemperature 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 pro-tection of the system, a second freeze protection thermostat isnecessary to switch on the heating system pump.To protect the C.H. system from freezing when boiler is not inoperation 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 thealuminum.
WARNINGAFTER A LONG INOPERATION PERIOD OF THEBOILER, IN CASE THE BOILER TEMPERATUREIS BELOW 3°C, ABSOLUTELY DO NOT TRY TOSTART THE BOILER.
THIS CAN BE ALLOWED ONLY IF YOU ARE SURE THAT ANANTIFREEZE SOLUTION HAS BEEN ADDED, IN THE PROPERPERCENTAGE, TO THE C.H. WATER.
See the Unical catalogue and the price list toidentify the most convenient mixing header andprimary circuit.
* = G2
25
Instructions for the installer
3.17 - CONDENSATE DRAIN
Discharge of condensate must be:- Built in order to prevent the escape of gas products of thecombustion in the location or sewer (siphon).- Dimensioned and constructed as to allow the proper flowof liquid discharges by preventing leaks (3% slope).- Installed in order to prevent freezing of the liquid contents,in function of the operating conditions.- Easily inspected
The condensate, before being evacuated to the sewer, has tobe neutralized, neutralisation which can be obtained by mixingthe drain water coming from washing maschines, dishwashing maschines, etc., which normally have a basic pH.
Avoid the condensate stagnation inside the combustionproducts evacuation system, (for this reason the evacuationduct must have an inclination toward the drain of at least 30mm/m (3/8 in. / ft) except the liquid column, inside thecondensate siphon, which needs to be filled with water afterinstallation: its minimum height, when all the fans are in oper-ation, must be at least 25 mm (1 in.).
Is forbidden discharge the condensate through the raingutters, given the risk of ice and degradation of thematerials normally used.The connection discharge should be visible.due to the level of condensate acidity (pH 3 to 5) as amaterial piping must be used only suitable plastics.
The outlet of the condensate drain pipe will be on the sameside of the smoke chamber, passing below the smoke cham-ber.
The recommended material must be PE (polyethylene) orPPI (polypropylene).
Before commissioning the boiler fill the con-densate siphon with water, from the dedica-ted filling-up plug.
PAVIMENTO DELLA C.T.
150
150
La generatrice superiore del tubo di scarico non dovrà trovarsi ad un livello superiore al fondo della bacinella.
* Min. height of the condensate column, with all fansoperating at max. speed, requested by the EN stan-dards.
** Min. height of the condensate column, with all fans opera-ting at max. speed. In the case it is not possible to create a100 mm basement, install the boiler on the floor and fore-see a min. 100 mm well to lodge the siphon.
26
Instructions for the installer3.18 - WATER TREATMENT
The chemical-physical characteristics of the filling water andreinstatement water in heating systems are of fundamentalimportance for guaranteeing correct and safe boiler operation.
Before filling the CH circuit with water, it is necessary to analysethe water and decide for a proper treatment.
The purpose of this treatment is finalized to eliminate orsubstantially reduce the following problems:
- lime scale deposit- corrosions- deposits- biological growths (moulds, bacteria, algae, fungi, etc)
The chemical treatment of the network water enables theprevention of these problems and guarantees safe boileroperation and economical advantages, in terms ofmaintenance and global thermal efficiency.
The chemical analysis of the water enables us to obtain a lotof 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 indicatealkalinity.
The ideal pH value for water in heating systems fitted withaluminium boilers is between 6,5 and 8, with a hardness of15°F.
In heating systems where the water has a value outside thisrange, this considerably accelerates the destruction of theprotective oxidized layer which naturally develops inside thealuminium bodies: if the pH is below 6, acidity is present, if it isabove 8, the water is alkaline or it is caused by an alkalinetreatment (for example phosphate or glycol used as anantifreeze) or in several cases it is due to the natural formationof alkaline in the system.
Vice versa, if the pH value is between 6,5 and 8, the aluminiumsurfaces of the boiler body are passivated and protected fromfurther corrosive attacks.To minimize corrosion it is essential to use a scale inhibitor,however in order for this to function correctly, the metallicsurfaces have to be clean.
The best corrosion inhibitors on sale also contain aprotective system for aluminium which acts by stabilizingthe water’s pH value, preventing unforeseen variations.
We recommend that the heating system’s water pH valueis systematically controlled (minimum twice a year). In orderto do this, it is not necessary to run a chemical analysis ina 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 willbe necessary to fit the devices indicated in the figure below
THE CONNECTION MUST BE FITTED ON THEPRIMARY CIRCUIT’S RETURN PIPEDOWNSTREAM OF THE CIRCULATING PUMP
All the necessary precautions must be taken in order to avoidthe formation and localization of oxygen in the system’s water.For this reason, the plastic pipes used in underfloor heatingsystems must be impermeable to oxygen.
If any antifreeze solutions are used ensure yourself that theyare compatible with aluminium and with any other componentsand materials fitted on the system.
WARNING!ANY DAMAGE CAUSED BY THE BOILER, DUETO THE FORMATION OF LIME SCALE OR DUETO CORROSIVE WATER WILL INVALIDATE THEAPPLIANCE WARRANTY.
27
Instructions for the installer
45678
440550660770900
300300300300300
For fixing the flue manifold use the 6 x nutsCH 10 and washers supplied in the plastic bag.
Smoke plug outlet have to be positionned on therectilinear lenght into the 1st meter of the boilerIn order to fit the combustion gases sampletest nipple, drill a hole Ø 21 mm in the smokeoutlet and fit the test nipple following theindicated sequence.
holeØ21 mm
3.20 - FLUE MANIFOLD CONNECTION
3.19 - CONNECTION TO THE CHIMNEY
In a condensing boiler the smokes are evacuated at a verylow temperature (Max about 84°C). Then it is necessary thatthe chimney is perfectly impermeble to the condensate of thecombustion products and is made of materials corrosion resi-stant.The different spigot joints must be well sealed and equippedwith suitable gaskets, in order to prevent the outlet of conden-sate and the inlet of air.Concerning the cross section and the height of the chimney, itis necessary to make reference to the national and local rulesin force.For the dimensioning follow the instruction in pr EN 13384.In order to prevent, during the operation, the formation of ice,the temperatureof the internal wall of the combustion productevacuation system, in all its length, has not to be below 0°C.For condensation operating conditions of the appliance at theexternal design temperature, it will be necessary to foresee acondensate evacuation system, discharging, according to theinstallation condition, in the boiler condensate tray or inanother dishpan separated from it.
In the construction of the flue duct it is necessary to usematerials resistant to the combustion products, in classW1, according to EN 1443, as stainless steel or plastic cer-tified materials.
As PVDF (polyvinildimethylfluorure) or PPS (polypropylenetransparent simple) certified for this use. Other materials antthicknesses are also autorized provided they can guarantee,at least, equivalent characteristics.
Any contractual or extra-contractual respon-sibility of the supplier, for damages caused bymistakes in the installation and in the use, and,in any case, due to the non respect of the in-structions given by the suplier, is excluded.
28
Instructions for the installer
SuperModulex
440550660770900
Flue gas massflow rate (max)
kg/h693866104012131386
Flue gas mass flow rate Example:SUPERMODULEX 660Flue gas mass flow rate = 1040 Km/hChimney height = 25 mChimney connection Ø = 315 mm
NOTE:the diagram provides indicativevalue
CO levels2 2
d125a
d400a
d315a
d250a
d200a
d160a
d110a
d75a
6
78
910
12
14
161820
30
40
50
60
70
8090
100
120
140
160180200
300
400
500
600
700
800900
1000
1200
1400
4,4
5,96,6
7,48
9
10
12
22
30
37
44
52
596674
89
104
119133148
222
296
370
444
519
593668741
889
1037
3,4
3,94,4
5,05,6
7
8
9
11
17
22
28
34
39
445056
67
78
89100111
167
222
277
333
389
445
555
667
778
0,001
0,0020,003
0,0040,005
0,006
0,007
0,0080,0090,010
0,015
0,020
0,030
0,035
0,040
0,050
0,060
0,070
0,0800,0900,100
0,150
0,200
0,250
0,300
0,350
0,400
0,500
0,600
50,700
9,0
10,812,0
14,4
22
25
293236
54
72
90
108
126
144
180
216
252
288324360
540
720
900
1080
1260
1440
1800
2160
2520
6
78
910
12
14
161820
30
40
50
60
70
8090
100
120
140
160180200
300
400
500
600
700
800900
1000
1200
1400
8%6%
Chimney dimensionDIN 4705
kg/skg/h 10%10 15 20 25 30
5 10 15 20 25 30
Pressure avaibleFlue Gas Temperature
40 Pa40°C
606
Nom
inal
Hea
t inp
ut (
kW)
Nom
inal
Hea
t inp
ut (
kW)
with
CO
leve
l at 1
0%
2
29
Instructions for the installer
In case of more heat request by heating or DHW systems, theboiler starts up and water will be heated by the aluminiumboiler bodyThen the boiler pump will send the water to the mixing bottleand from here to the radiators, according to the heatingsystem chosen.The combustion air is supplied by fans which take it from theboiler room. The combustion air is then pushed into the pre-mixing chamber through a diaphragm.Beyond the diaphragm, the air mixes with gas and suchmixture, passing through the non-return valve, is sent to theburner.Then, on leaving the burner surface, the air/gas mixture igniteselectrically and the resulting combustion gases, after beingtransported (and cooled) through finned sections, enter thecondensate collecting manifold and then are evacuatedthrough the chimney.
Condensatecollectingtray smokemanifold
Control Panel
Burner
Siphon
Fan
IonizationelectrodeCombustion
ChamberH.L. Thermostat
Thermicelement
Gas valve
The MODULEX EXT is made of inter-linked modules; eachmodule is made of:- Combustion Chamber- Burner- Fan- Gas valve- Local NTC ((Negative Temperature Coefficient) sensor
(checks the flow temperature of each aluminium section)- BMM (Burner Modular Manager)- High Limit thermostat- Ignition electrode- Ionization electrode- Air pressure switch
A module is able to supply a maximum power of 110 kW. So,for instance, a boiler model 440 is constituted by 4 modules.Each module has its temperature sensor NTC - NegativeTemperatures Coefficient - that locally checks the temperatureof every single module.The flow temperature at the boiler outlet and the returntemperature at the boiler inlet are controlled by global NTCtemperature sensors.
3.20 - BOILER OPERATION
30
Instructions for the installer
When there is a heat request from the E8 controller or from aBCM (Boiler Cascade Manager), the E8 or BCM calculatesthe necessary output according to the difference between theset temperature (or the temperature calculated by the outercompensator) and the global flow temperature. The numberof thermal elements (each thermal element represents a ma-ximum input of 110 kW) x 100% determines the maximuminput expressed in %.When the input has been determined, the boiler pump (notsupplied by Unical) is set up and the fan of one thermal ele-ment is set in motion at starting speed. The gas valve opensand ignition is to occur within 5 sec. When the ionisation elec-trode detects the flame, the thermal element starts operating.Subsequently other thermal elements are likely to start in thesame way. One of the operation principles for this boiler isletting as many burners as possible operate simultaneouslyat minimum load to reach the maximum efficiency.
For example, if a 4 thermal element boiler is requested tooperate at its max input, this shall be 400% i.e. :
110 kW x 4 thermal elements = 440 kW = 400%.If it is requested to operate at 200% input, thanks to the inputsharing system on the highest number of thermal elements,each thermal element will operate at 50% output i.e. :
200% : 4 moduli = 50 %corrispondente a 100 kW totaliossia 25 kW per ciascun modulo.
Such principle provides clearly efficiencies much higher thanthose obtained in traditional groups of small boilers installedin cascade.When the input shared on each thermal element is less than12 kW, one thermal element after the other is automaticallyexcluded and the remaining input is shared on thermalelements having the smallest number of operation hours (bythe automatic operation-time calculating system).Modulation, i.e. input reduction, is based on the differencebetween the set temperature (or the temperature calculatedby the outer compensator) and the global flow temperature.When no ignition occurs, the ignition device repeats two moretimes the ignition sequence and then puts to lock out positionthe thermal element concerned.
4 thermal elements of 50 kW each working at 50% of the output give = 100 kW = (200%),
i.e. 25 kW / thermal element
0
5
1015
20
2530
3540
kW
4550
5560
10
100
104
% (p.c.i.)
20 5030 4022
109,6109
P (kW)60 70 80 90 100 108
50 % = 54 kW
1 thermalelemets
100 % = 108 kW
54
1 thermalelemets
400% : 200 kW = 200% : X
X = (432x200) : 400 = 216 kW input shared on 4thermal elements
Input shared on 4 thermal elements : total input= 216:432 = 0,5 = 50%
Efficiency of a thermal element working at full capacity108 kW = 103,2 % (in condensation)
Efficiency of a thermal element working at reducedcapacity 54 kW = 106,7 % (in condesation)
Efficiency of a thermal element working at minimumcapacity 22 kW = 108,8 % (in condesation)
All the thermal elements work in parallel at the same ou-tput, equalizing, thus, the C.H. system efficiency to the oneof the thermal element.
1 Thermal element (module) = 108 kW = 100%
4 Thermal elem. = 108 kW x 4 = 432 kW = 400%
31
Instructions for the installer
A
3.22 - ELECTRICAL CONNECTIONS
Regulations in force
The gas and water feeding pipes and the CH system pipescannot be used as ground plates.
Ensure that the above safety electrical requirements subsist;in case of doubt, ask for a professionally qualified technicianto check the appliance’s electrical system.
UNICAL refuses responsibility for any damages arising fromfailure to earth the boiler correctly.
It is necessary that a qualified technician verifies that theelectrical system is adequate to the appliance’s maximumabsorbed power, indicated on the data plate, verifying inparticular that the section of the system’s cables is suitableto the appliance’s maximum absorbed power.
For the appliance’s general electrical supply the use ofadaptors, multiple sockets and/or extension cords is strictlyforbidden.
The use of any power supplied equipment implies theobservance 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 permit children or inexpert people to use the
appliance.
Mains electrical supply connection 230VThe electric connections of the boiler are shown in the sectionnamed “WIRING DIAGRAMS”
A mains supply of 230 V – 50 Hz is required. The wiring to theboiler must be in accordance with the current CEI regulations.
WARNING!We remind you that upstream of the electricalconnection, it will be necessary to foresee aservice relay (NOT SUPPLIED) which, whenthe electrical safety devices (ISPESL)intervene, shuts down the electrical supplyto the on-off fuel valve fitted on the gas supplycircuit, but not to the boiler so as toguarantee the running of the pump and permitthe boiler to cool down.
DANGER!The electrical connections must be carriedout only by a qualified engineer.Before carrying out the connections or anyother operation on the electrical parts,always switch off and disconnect theelectricity supply and ensure yourself that itcannot be accidentally turned on.
It is necessary to fit a double pole switch on the electricalsupply line, having a 3 mm contact separation in both poles,in an easy accessible position in order to make quick andsafe the servicing operations.
The boiler electrical supply (230 V – 50 Hz – single phase) isto be done directly on the three pole plug supplied with theboiler.
WARNING!230 V cables shall be separated from 24 Vones, using the two plastic conduits suppliedwithin the boiler casing L.H. side panel.
32
Instructions for the installer3.23 - FUNCTIONAL WIRING DIAGRAM
Note: The pictures shown on theactual wiring diagram, is purelyindicative.
Smoke pressure switch
Ignition electrodeIonization electrodeMain switchGlobal Flow Temperature Sensor E8Warning lampe for the General Limit Thermostat
Minimum Gas pressure swich
E.ACC 1..8E.RIL 1..8IGKFLTGLPFPG
PV 1..8SLSMGSRSR 1..8SRRTL
Fan pressure swichCondensate level sensor
Flow NTC Temperature sensorLocal Flow NTC Temperature sensorGlobal Return NTC Temperature sensorHigh limit thermostat
Sonda Mandata Globale BCM
TL 1..8TLGVG 1....8TRA. ACC 1..8VM 1..8
Local High limit thermostatGlobal High limit thermostatGas ValveIgnition TransformerModulating Fan
RED
SMG
230 V - 50Hz
1 2 3 4 5 6 7 8 9 10
IIA1A2A3A4A5A6
NL1L1’
M
T1T2
12A7
T3T4
VI12345A8A9A10A11 IV
4
M2 13
n
1 2 3 4IX
LHBUS
1 2 3III
IMP0-10 V
F17F15
31 FBR
1 2VIII
PT1000
F14F131 2V
SPF
F12F11
VFAFKF / SPFVF
F9F8F6F5F3F2F1
FBR
eBUSFA
0-10 V
1 2 IVII
678910 12345
121 NL1L1
M2
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
123Y24567
Y3
123
Jp1123
Y44
DL1 DL2 DL3
1 2 3Y14 5 6
A1
SW1
0-10
V
Mod
bus
- BM
odbu
s - A
PLC /BMS
BCM
eBU
S -
eBU
S +
+ 24
V
PR IG
GREY
PINK
WHITE
WHITE
BLACK
BROWN
BR
OW
N
BLA
CK
RE
D( - )
( - )
( + )
II
I
O1
1a
1b
SE8/BCM
BROWN
WHITE
BLA
CK
BR
OW
N
BLU
E
BLU
E
TLTL1
ARANCIO +
NERO (-)
MARRONE (PWM)
BLU (TACHO)
BLU (N)
MARRONE (L1)
RIL
./RE
G.
ALI
M.
230V
RED
RED
BLACK
WHITE
BLACK
WHITE
BROWN
WHITE
LIG
HT
BLU
E
LIG
HT
BLU
E
LIG
HT
BLU
E
LIG
HT
BLU
E
GIA/VER
1° Module
E.RIL.1
SR1
SRR
SR
WHITE
PG
PF
BIANCO
MARRONE
(3) (1)
1 (nc)
(c 3 )
01
2 3 45
6
789
0 1 23
456
78
9
BLACK
BLACK
ABVT N
L1
J61
J31
BLUEBLUEBLUEBROWNBROWN
J41 BROWN
BROWN
BLACKBLACK
RED
ORANGE
J31
BROWN
BLACKBLUE
J21
BROWN
BROWNBLUE
BLUE IG(IG1)
(IG2)
5L 4L
1N2N
C 2
1RED
1b 1aTLGLTLGF10A
F6.3A
BRO
WN
BLU
E
N L1
KF
On board
1° moduleof
CONTROL E8
CONNECTIONWIRE NEUTRAL (N)
MAIN SUPPLY
SIG
NA
LA
LAR
M
PUM
P B
OIL
ER C
IRCU
IT
RES
ETIN
SER
TB
CM
eBUSremote
(Cascademanager)
CONTROLMODULATION
PUMP EMERGENCY
(*)
SET POINTChoose set point value as indicated
in the table * (IF NECESSARY) andinsert resistence between Y2 (6-7).
(3) (1)
BR
OW
N
WH
ITE
PV1
Ext sensopen
100 K4722
Short circuit
Ω K K
10 K
ΩΩΩ
Set point82°C7160493827
°C°C°C°C°C
(*)
33
Instructions for the installer
0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 23 3 3 3 3 3 34 4 4 4 4 4 4
5 5 5 5 5 5 5
6 6 6 6 6 6 67 7 7 7 7 7 78 8 8 8 8 8 89 9 9 9 9 9 9
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)
01
2 3 45
6789
Module 8(Pos 7)
Setting of modules selectors
FILTER
BL
UE
BL
AC
K
BL
UE
BR
OW
N
L1 N1 2 3
VM (A)12345
ST 2
3° - 8° MODULES
3° - 8° MODULES
TR.ACC.1E.ACC.1
VG1
TL2...TL8
SR2...SR7
RIL
./RE
G.
ALI
M.
230V
ORANGE +
BLACK (-)
BROWN (PWM)
BLUE (TACHO)
BLUE(N)
BROWN (L1)
BLUE
BROWN
BLUE
BROWN
BLU
E
BR
OW
N
RE
D
WHITE
WHITE
LIG
HT
BLU
E
LIG
HT
BLU
E
E.RIL.2...E.RIL8
PIN
K
GR
EY
PIN
K
GR
EY
BLU
E
BR
OW
N
WHITE
2° - 8° Modules
TR.ACC.2...TR.ACC.8
E.ACC.2...E.ACC.8
VG2...VG8
BLUE
BROWN
BLUE
BROWN
BLU
E
BR
OW
N
RE
D
SL
OR
AN
GE
OR
AN
GE
BROWNWHITE
+ 24
V
eBU
S +
eBU
S -
RE
D
BR
OW
N
BLA
CK
( )
01
2 3 45
6
789
BROWN
BLUE
BROWN
LIGHT BLUE
BL
UE
BR
OW
NY
EL
-GR
EE
N
L1 N1 2 3
VM (A)12345
ST 2
BL
AC
K
BLU
E
YEL-GREEN
1° MODULE
BLACK
BLUE
FILTER
BL
UE
BR
OW
N
YE
L-G
RE
EN
L1 N1 2 3
VM (A)12345
ST 2
END MODULE
BLACK
BLUE
YE
L-G
RE
EN
YEL-GREEN
ConnectionWith BCM
On board
2° moduleof
(3) (1)
BR
OW
N
WH
ITE
PV1
34
Instructions for the installer
3.24 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGINGOn the back side of the E8 regulator there are two terminalblocks, of which one is for the mains (230 V) connections andthe other one is for the low tension connections.
The main controls, necessary for the C.H. system manage-ment and for the boiler control, as well some componentswhich are part of the boiler house, must be connected to theterminal blocks.
Power terminal assignments
Powerterminalblock
Sensorterminalblock
12345678910
II A1 A2 A3 A4 A5 A6
N L1 L1’
M
T1 T2
1 2A7
T3 T4
VI1 2 3 4 5A8 A9 A10 A11IV
4
M21 3
n
1234IX
L HBUS
50 Hz 230 V
123 III
IMP 0-10 V
F17 F15
3 1FBR
12 VIII
PT1000
F14 F1312 V
SPF
F12 F11
VF AF KF / SPF VF
F9 F8 F6 F5 F3 F2 F1
FBR
eBUSFA
0-10 V
12IVII
6 7 8 9 101 2 3 4 5
N L1 L1 1 2 1
Power supply
PIN
K
GR
EY
From BCM
BLU
E
BR
OW
N
BLA
CK
Terminal IIII
A1
A2
A3
A4
A5
A6
NL1
L1’
M
T1T2
67
89
101
23
45
NL1
L11
21
II
N: L1: L2: : : : : :
Neutral conductor, mainsPower supply, unitPower supply to relayheating circuit pump HK 1heating circuit pump HK 2Storage tank charging pump
Mixer open, heating circuit 2Mixer closed, heating circuit 2
12
A7
T3T4
VI
Terminal VI VI
12
34
5A
8A9
A10
A11IV
4
M2
13
n
Terminal IV IV
: :
Mixer open, heating circuit 1Mixer closed, heating circuit 1
Multifunction relayMultifunction relayRecycle pump /
21
43
35
Instructions for the installerSensor terminal assignments
Connection to BCM
For connection to remote control devices
Terminal VII VII
eBUSFA 0-10
V 12
VII Pin 1:
Pin 2: eBUS (FA) or 0-10V output(Ground)
Terminal I I
12
34
56
78
910A
FKF
/ SP
FVF
F9F8
F6F5
F3F2
F1
FBR
I
Pin 4: Pin 5: Pin 6: Pin 7: Pin 8: Pin 9: Pin 10:
Flow sensor, heating circuit 2 (ground)Flow sensor, heating circuit 2Storage tank sensorStorage tank and boiler sensor (ground)Boiler sensorOutdoor sensorOutdoor sensor (ground)
VFVF
SPFSPFKFAFAF
Buffer storage tank low sensorBuf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor)Buf. stor. tank top sensor / FBR heat. circ. 1 (set value)
12
V
SPF
F12
F11
VF
Terminal V V
VFSPF
Pin 1: Flow sensor heating circuit 1 / sensor multifunction 1Pin 2: Service water low sensor / sensor multifunction 2
12
VIII
PT10
00
F14
F13
Terminal VIIIF13F14
Pin 1: Sensor HS2 / Solar 2 / Multifunction relay 3 Pin 2: Sensor Solar 1 / Sensor multifunction relay 4
Terminal III III
12
3III
IMP
0-10 V
F17
F15
31
FBR
Pin 1: Pin 2:
FBR heating circuit 2 (room sensor) / 0-10V IN / LightFBR heating circuit 2 (ground)
F15
F17 Pin 3: FBR heating circuit 2 (set value) / Pulse counter for
12
34
IX
LH
BUS
Morsetto IX IX
H CAN Bus Pin 1 = H (Data)CAN Bus Pin 2 = L (Data)CAN Bus Pin 3 = - (ground, Gnd)CAN Bus Pin 4 = + (12V supply)
L-+
36
Instructions for the installer
VF
1
VFVF
AF
1 2 3
Y44BCM
1-2
*
Safety devices kit
Mixing Header
Filter
Primarysystem pump
Heating Circuit 1
OutsideSensor
SPF
AF
n
VF
not necessary to active 2° circuit**
*
*
3.25 - 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
(4) Pump heating circuit 1
AF (1) Flow sensor heating circuit 1VF
10I (10) Ground outdoor sensor
(4) Collector pump
(9-10) outdoor sensor
(6-7) Storage tank sensor
(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump
(5) Re-circulation pump storage tank
(4-5) Flow sensor heating circuit 2
(4) Collector pump
(1) Flow sensor heating circuit 1VF
10I (10) Ground outdoor sensor
F Ric. C
VFVF
SPF
12
n
4
VFVF
VF
AF
3
***
Filter
Heating Circuit 1Heating Circuit 2
OutsideSensor
Mixing Header
Safety devices kit
Primarysystem pump
This sensor can also remain unused
This sensor can also remain unused
37
Instructions for the installer
F Ric. C
VFVF
SPF
12
n
4
VFVF
VF
AF
3
*
Filter
Heating Circuit 1Heating Circuit 2
OutsideSensor
Mixing Header
Safety devices kit
Primarysystem pump
*
n
*
INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD.
(9-10) outdoor sensor
(6-7) Storage tank sensor
(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump
SPF
AF
VF(4-5) Flow sensor heating circuit 2(1) Flow sensor heating circuit 1VF
10I (10) Ground outdoor sensor
(7) Mixer motor heating circuit 2 OPEN(8) Mixer motor heating circuit 2 CLOSE
n(5) Re-circulation pump storage tank
(4) Collector pump
INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION
F Ric. C
VFVF
SPF
12
n
4
VFVF
VF
AF
3
*
Heating Circuit 1Heating Circuit 2
Mixing Header
Primarysystem pump
OutsideSensor
Safety devices kit
Filter
(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
SPF
AF
(1) Mixer motor heating circuit 1 OPEN(2) Mixer motor heating circuit 1CLOSE
(5) Re-circulation pump storage tank
VF
(4) Collector pump
(1) Flow sensor heating circuit 1VF
10I (10) Ground outdoor sensor
This sensor can also remain unused
necessary for mixing valve control
38
Instructions for the installer
*
Filter
VFVF
12
VFVF
VF
AF
SPF
C F
A115
4
PT1000
2+F14
F122+
3
*
Heating Circuit 1Heating Circuit 2
OutsideSensor
Mixing Header
Safety devices kit
Primarysystem 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
AF
n(5) Re-circulation pump storage tank
VF
V (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 isnecessary to change some parameters. SeeTable:Expert AREA ⇒ Level SOLAR / MF ⇒ MF 4FUNCTION = ‘’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 1VF
10I (10) Ground outdoor sensor
necessary for mixing valve control
39
Instructions for the installer
F Ric. C
VFVF
SPF
12
n
4
VFVF
VF
AF
Filtro
3
3
KF
* Slave 1
Slave 2
Heating Circuit 1
OutsideSensor
Filter
Heating Circuit 2
Remote E8Master
Mixing Header
Primarysystem pump
Safety devices kit
BoilerSensor
Primarysystem pump
Safety devices kit
INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION
Connections on to the MASTER controllerThe connections of the secondary circuit have to be done onto the MASTER controller.
n (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.
(1) Flow sensor heating circuit 1VF
10I (10) Ground outdoor sensor
(9-10) outdoor sensor
(4-5) Flow sensor heating circuit 2 (optional)
(6-7) Storage tank sensor
(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump
SPF
AF
VF
(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
necessary for mixing valve control*
(7-8) Cascade global sensorKF
40
Instructions for the installer
3.26 - CASCADE MANAGER (BCM)
Application:The BCM completes the range of functions offered by theModulex 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 installingModulex boilers in the most advanced BuildingAutomation Systems.
Features:The BCM can be connected to the automation system ofa 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 systemmanagement:- 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 functionsEmergency: it avoids system shutdown caused by aninterruption in communication with the boiler plant’sautomation 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 generatorsmanaged by a E8 heating controller, automatically selectsthe “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 theemergency function previously described.
41
Instructions for the installer
SLAVE 1
SLAVE 2
E8
CanBUS
- Cascade Manager
MASTER
1 for each cascade of boiler
IIA
1A2
A3
NL1
L1’
12
34
IX
LH
BUS
12
3III
IMP
0-10 V
F17
F15
31
FBR
12
VIII
PT10
00
F14
F13
2V
SPF
F12
F11
61
23
45
12
NL1
L1
1 2 3 4IX
LHBUS
E8Cascade Manager
IIA1
A2
A3
NL1
L1’
12
34
IX
LH
BUS
12
3III
IMP
0-10 V
F17
F15
31
FBR
12
VIII
PT10
00
F14
F13
2V
SPF
F12
F11
61
23
45
12
NL1
L1
E8Cascade Manager1
23
Y2 45
67
Y3
12
3
Jp11
23Y4
4DL1
DL2
DL3
12
3Y14
56
A1
SW1
eBUS remoto
BC
M
eBUS -
eBUS +
+ 24 V
eBUS remoto
12
3Y2 4
56
7
Y3
12
3
Jp11
23
Y44D
L1D
L2D
L3
12
3Y14
56
A1
SW1
eBUS remoto
BC
M
eBUS -
eBUS +
+ 24 V
eBUS remoto
BCM (modulex 1)Y2 (3-4)
BCM (modulex 2)Y2 (3-4)
12
3Y2 4
56
7
Y3
12
3
Jp11
23Y4
4DL1DL2
DL3
12
3Y14
56
A1
SW1
eBUS remoto
BC
M
eBUS -
eBUS +
+ 24 V
eBUS remoto
BCM (modulex 3)Y2 (3-4)
Cascade Manager
Cascade Manager Dalla 1a caldaia portare il collegamento eBUSlato HOST BCM su eBUS 2a e 3a etc. dopo averposizonato il selettore di questa su 0.
Removedwiring
Removedwiring
Connection for boilers in a cascade arrangement managed by a external E8
WARNING!In this connection the “BUS-ID HS„parameter must be set on the E8 heatingcontroller
The external E8 heating controller (MASTER) must be setto: - - - -,The E8 heating controllers fitted on each boiler (SLAVE)must be set from: 01 to 08.
I = BCM in seriesII = Forniture Position
Switch ‘’C’’ (see pag. 47)in Position II
In this configuration,switch ‚‘‘C‘‘ must bepositionned on II.
42
Instructions for the installer
- Cascade Manager- System Monitor
eBUS Modbus
- System Manager- System Supervisor
Modbus
01
2 3 45
6
789
BCM(Pos 1÷7)
SLAVE 1
01
2 3 45
6
789
BCM(Pos 0)
SLAVE 2
01
2 3 45
6789
BCM(Pos 1)
BCM board PLC/BMS board
eBUS Modbus
- System Manager- System Supervisor
Scheda PLC/BMS
Modbus
- Cascade Manager- System Monitor
- System Manager- System Supervisor
Scheda BCM
12
3Y2 4
56
7
Y3
12
3
Jp11
23Y4
4DL1
DL2
DL3
12
3Y14
56
A1
SW1
eBUS remoto
BC
M
eBUS -
eBUS +
+ 24 V
eBUS remoto
BCM (modulex 2)Y2 (3-4)
Connection for boilers in a cascade arrangement connected to an external BCM optional and managed byPLC/BMS (E8 disconnected).
The applications in a cascade arrangementmanaged with an additional BCM require thecorrect boiler address setting (within thecascade formation) via the BCM’s internalSWI selector: 0....7, all different and insequence, (exactly as requested by the singleburner modules).
Switch ‘’C’’ (see pag. 47)in Position 0
(for each boilers)
In this configuration,switch ‚‘‘C‘‘ must bepositionned on 0.
- E8 not wired to the BUS -
I = BCM in seriesII = Forniture Position
43
Instructions for the installer
- System Supervisor- Cascade Manager
Board PLC/BMS
ModbusSLAVE 1
01
2 3 45
6
789
BCM(Pos 0)
SLAVE 2
01 2 3 4
56
789
BCM(Pos 1)
1 for each cascade of boiler
01
2 3 45
6
789
BCM(Pos 1÷7)
System Supervisor
Scheda PLC/BMS
Modbus
Cascade Manager
12
3Y2 4
56
7
Y3
12
3
Jp11
23Y4
4DL1
DL2
DL3
12
3Y14
56
A1
SW1
eBUS remoto
BC
M
eBUS -
eBUS +
+ 24 V
eBUS remoto
BCM (modulex 2)Y2 (1-2)
Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected)
The applications in a cascade arrangementmanaged with Modbus require the correctboiler address setting (within the cascadeformation) via the BCM’s internal SWIselector: 1....7, all different and in sequence,(exactly as requested by the single burnermodules).
In this configuration,switch ‚‘‘C‘‘ must bepositionned on 0.
Switch ‘’C’’ (see pag. 47)in Position 0
(for each boilers)
I = BCM in seriesII = Forniture Position
44
Instructions for the installer
he BCM board elaborates the data concerning the thermalhead (Ät between primary flow and return and suppliedheat output). When the supplied heat output diminishes,the number of the pump’s revolutions decreases andsubsequently the hourly rate, maintaining the thermal headpractically constant. Thus obtaining a higher efficiency incondensing mode and reducing energy costs.
3.27 - CONFIGURATION WITH A:
The 0÷10 Volt modulation signal is preset to:-3 for minimum speed-10 Volt for maximum speedThese values can be changed accordingto the type of pump fitted. For furtherinformation on the 0÷10 Volt signal, pleasealso refer to the pump’s manual.
MODULATING PUMP
ON-OFF PUMP
MODULATING PUMP
123Y24567
Y3
123
Jp1123
Y44
DL1 DL2 DL3
1 2 3Y14 5 6
A1
SW1
PUMP
BCM
eBU
S -
eBU
S +
+ 24
V
N L1 NL1
P
N
L
POWER TERMINALS E8A
LARM
Mains supply 230 V - 50 Hz
RELAY
Mains supply 230 V - 50 Hz
123Y24567
Y3
123
Jp1123
Y44
DL1 DL2 DL3
1 2 3Y14 5 6
A1
SW1
BCM
eBU
S
-
eBU
S +
+ 2
4 V
NL1
N
TERMINALS 0-10 VINTERFACE
WILO MODULATING PUMP
(-) (0 -
10 V
)
L1
SupplyModulating
Pump
APM
ALA
RM
Mains supply 230 V -50 Hz
45
Instructions for the installer
3.28 - FILLING THE SYSTEM
Warning!Do not mix the CH system’s water with anti-freeze or anti-corrosion solutions using wrongconcentrations! It could cause damage to thewashers and could provoke noise duringnormal boiler operation.UNICAL refuses all liability for injury to persons,animals or damage to property deriving fromnot having respected the above mentionedrecommendations.
For filling-up the system a filling tap has to be foreseen onthe system return pipe.
The filling-up can also be made through the draining tap onthe boiler return manifold.
Never use such a tap to drain the system, since the system dirtcould gather in the boiler and compromise its operation. Thesystem itself shall be equipped with its own draining tap, whosesize depends on the system capacity. The application of afilter on the return pipe to the boiler is advisable.
EXAMPLE OF FILLING-UP SYSTEM MANIFOLD
Filling group with PRV
IMPORTANT NOTEOnce the system has been filled upat the right filling pressure, the fillinggroup has to be closed.
46
Instructions for the installer
B) MINIMUM OUTPUT ADJUSTMENT
- Operate on a burner at minimum power, following the pro-cedure described on page 46 ‘’sweep Function (CASCA-DE MAN 10%)
- Check that the C02 values are within the values indicatedin the table “Burner pressures”
- If necessary correct the value by turning the adjust-ment screw “B” in a CLOCKWISE direction to increasethe value and in an ANTICLOCKWISE direction in or-der to decrease it.
A) REGOLAZIONE ALLA POTENZA MASSIMA
- Remove the cap of the combustion gases sampling point- Connect a suitable C0
2 gas analyser to the sampling point
in the flue outlet terminal.- Operate on a burner at maximum power, following the pro-
cedure described on page 46 ‘’sweep Function (CASCA-DE MAN 100%)
- Check that the C02 values are within the values indicated
in the table “Burner pressures”- If necessary correct the value by turning the adjustment
screw “A” in a CLOCKWISE direction to decrease the va-lue and in an ANTICLOCKWISE direction in order to incre-ase it.
3
12
4
WARNING!Remove the cap 2, fix red cap 3 to the gasoutlet. Insert the CO2 analysis probe 4 onhole of the cap.Measurement. remove the cap and close theoutlet exhaust smoke cap 2.
MAXIMUM OUTPUTADJUSTMENT SCREW MINIMUM OUTPUT
ADJUSTMENTSCREW
3.29 - BURNER ADJUSTMENT
WARNING!All the instructions indicated below are for theexclusive use of qualified UNICAL servicetechnicians or installers.
All the boilers are supplied already calibratedand tested. If it is necessary to change thecalibration due to gas conversion or adaptationto the mains supply system, the gas valve mustbe re-calibrated. (Using service mode function)
47
Instructions for the installer
CO2 levels (%)Gas type Supplypressure
(mbar)min
(rpm)
Startingpower
IG(%)
20
25
37
ØInjectors
(mm)
9
9
9
Gas nat. (G20)
Gas nat. (G25)
Propan (G31)
Fan speed
max(rpm)
1760
1760
1760
6300
6300
6300
50
50
50
min
9,1
9,1
10,2
max
9,3
8,6
10,4
MODULEX440 - 550660 - 770 - 900
Diaphragm
-
-
-
Follow this procedure also for the other bur-ners
If the CO2 percentage is too low, check if the air and smoke
ducts are not obstructed. If they are not obstructed, check if theburner and/or the exchanger (aluminium sections) are wellcleaned.
Check the C02 levels often, especially at low flow rateINJECTORS – PRESSURES
C) COMPLETION OF THE BASICADJUSTMENTS
- Check the C02 values at the minimum and maximum outlet- If necessary make the required adjustments
To ensure correct operation the C02 valueshave to be adjusted with extreme carerespecting the values indicated in the table.
- Close the sampling test point in the flue outlet terminal
Do not force the end switches of theadjusting screw.
In case of gas valve replacement or difficultignition:
Tighten the maximum adjustment screw “A”in a clockwise direction until you arrive tothe abutting end, than slacken for 9 turns.Verify the boiler ignition; if the boiler goesinto lockout slacken the screw “A” again ofone turn, than retry the ignition. If the boilergoes into lockout again, carry out the aboveindicated operations until the boiler islighted.At this point carry out the burner adjustmentas previously indicated.
48
Instructions for the installerSWEEPER MODE
C
BCM
For the adjustment of each individual module it isnecessary to put the switch ‘’ C ‘’, in position I, asshown in the figure. In this way all the modulesare switched OFF and the first module is ignited.To pass to the following modules (after the previousone has been switched OFF) repeat the step 0 - 1of the switch ‘’ C’ as shown in figure.
The function is active for a time of 15 min,after that the planned parameters arerestored.
SW NO XXXX
CASCATA MANU
BOILER 01 - 00%
CHANGE PER CENTVALUE TO 10 %.
BOILER 01 - 10%
VARY THE VALUE
FROM 10 % TO 100%.PER CENT
BOILER 01 - 100%
RELAY TEST
Turnanticlok-wise
Odisplayed
pen the operating flap,
DISPLAY GENERALAfter 2 sec is displayedlevel
DATA/TIME SERVICEPress
to open the level
Before open the operating flapturn clock-wise Shaft encoder,
to symbol
Turnanticlok-wise
Turnclok-wise
Pressto open the level
Turnclok-wise
Pressto open the level
All modules of theboiler running andworking at MINIMUMpower
All modules of theboiler running andworking at MAXIMUMpower
49
Instructions for the installer
C B
BCM
DEFGHI AL1 2
The BCM It avoids system shutdown in case the mainboiler plant’s system E8 5064 management is out ofuse.
A YELLOW LED = Blinking(communication between BMM and BCM) OK
GREEN LED = ON (Active Pump)
RED LED = ON (Failure code detected)
C 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
F Warning lamp of the thermostatic lockoutfrom TLG
I TLG General Limit Thermostat: when it acts, itcuts the power supply to the boiler, thewarning lamp E lights. To reset, remove thecap and push the reset button.
Note: The switches are positioned underthe front panel.
Note: The emergency function enablesthe boiler’s burners to fire only at 50%and at 50°C in system return. All thesystem’s heating loads, including theheader pump, must be controlledmanually.
Condensate level sensor position
D Idrometer (optional)
E Control Panel E8
G Fuse: 1 = 6.3 A 2 = 10 A
H Main Switch
3.30 - EMERGENCY FUNCTIONS
L Change-over Series/Parallel
0 = Emergency is active or the control ismanaged by PLC or BMS
I = Series connection (the cascade ismanaged by the BCM,
II = Parallel connection condition of forniture
50
Instructions for the installer
3.31 INITIAL LIGHTING
PRELIMIARY CHECKS
The first ignition must be carried out by aqualified technician. Failure to do so couldcause injury to persons, animals or damageto property. UNICAL shall not be held liablefor any injury and/or damage.
Before lighting the boiler check that:
- the boiler installation has been carried out in accordancewith the specific Standards.
- the combustion air inlet and the discharge of the productsof combustion occur in the correct way in accordance tothe specific Standards in force;
- the gas supply system is correctly dimensioned for the boi-ler’s output;
- the boiler’s electrical supply is 230 V - 50 Hz;
- the system has been filled with water (pressure registeredon 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 theboiler has been calibrated for: otherwise convert the boilerto use the available gas (refer to section: “GAS CONVER-SION”); this operation must be carried out by a qualifiedtechnician 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 isconnected to the sewage system;
- the condensate drain siphon has been filled with waterand that it is connected to the sewage system;
DANGER!Before firing the appliance fill up the siphonthrough the filling hole and check the correctdrainage of the condensate.If the appliance is used with the condensatedrain siphon empty this could causepoisoning caused by the leakage of the fluegasses.
- there are no water leaks;
- all the necessary ventilation conditions and minimum cle-arance distances are guaranteed for subsequent servi-cing 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 useand operation of his boiler and in particular detail:
- Hand over to the end user the booklet: “USER’S INSTRUC-TIONS GUIDE”, as well as all the other literature relative tothe appliance and placed in the envelope contained in thepackaging. The user of the appliance must retain thisliterature for any future reference.
- Inform The user of the importance of the air vents and ofthe flue outlet system, stressing the fact that absolutely noalteration can be made.
- Inform the user regarding the control of the system’s waterpressure and how to restore it to the correct value.
- Explain and demonstrate to The user the correct functionand adjustment of the temperature, thermostats and radia-tors for the economic use of the system.
- Remind the user that in order to comply to the regulationsin force the boiler has to be inspected and serviced regu-larly as indicated by the manufacturer.
- If the appliance is sold or transferred to another owner or ifthe present user moves home and leaves the applianceinstalled, ensure yourself that the manual always followsthe appliance so that it can be consulted by the new ownerand/or installer.
51
Servicing schedule
To ensure the continued safe and efficientoperation of the boiler it is highlyrecommended that it is checked at regularintervals and serviced when necessary, andthat only original spare parts are used.The law in force states that the boiler mustbe serviced annually.
If the boiler is not checked and serviced whennecessary it could cause material andpersonal damages.
For this reason UNICAL recommends that a servicing con-tract should be made with a heating installer.
The regular inspection is useful to determine the actual stateof an appliance and to compare it with an optimum state. Thisis achieved through measurement, control and observation.
The service is necessary to eliminate eventual deviations ofthe actual state from the optimum state. This is normally donethrough the cleaning, the parameters setting and the even-tual replacement of single components subject to mechanicalwear.
The frequency of servicing will be determined by the serviceengineer and will depend on appliance’s state of condition.
4
INSTRUCTIONS FOR SERVICING
To ensure a long life to all your boilercomponents and in order not to alter theconditions of the approved product onlyoriginal UNICAL spare parts must be used.
After having carried out all the necessary maintenance, alwaysfollow 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 powerswitches) and make sure it cannot be switched ON acci-dentally.
• 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 returnpipes, as well as the cold inlet valve.
- Remove the appliance’s front panel.
After maintenance works have been finished, follow the nextsteps:- 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..
SERVICINGSCHEDULE
Relation between the temperature (°C) and the nom.resistance (Ohm) of the heating sensor SR and the returnheating sensor SRR.
T°C 0 1 2 3 4 5 6 7 8 90 32755 31137 29607 28161 26795 25502 24278 23121 22025 20987
10 20003 19072 18189 17351 16557 15803 15088 14410 13765 1315320 12571 12019 11493 10994 10519 10067 9636 9227 8837 846630 8112 7775 7454 7147 6855 6577 6311 6057 5815 558440 5363 5152 4951 4758 4574 4398 4230 4069 3915 376850 3627 3491 3362 3238 3119 3006 2897 2792 2692 259660 2504 2415 2330 2249 2171 2096 2023 1954 1888 182470 1762 1703 1646 1592 1539 1488 1440 1393 1348 130480 1263 1222 1183 1146 1110 1075 1042 1010 979 94990 920 892 865 839 814 790 766 744 722 701
TABLE OF THE RESISTANCE VALUES IN FUNCTION OF THE HEATING SENSOR (SR) AND RETURN HEATING SENSORTEMPERATURE (SRR)
Example: At 25°C, the nominal resistance is 10067 OhmAt 90°C, the nominal resistance is 920 Ohm
52
Servicing schedule
- Act on the two closing hinges (on both sides) to remo-ve the cover
- Remove the screws panel left, right and back side.
- Rotate the screw shown to lift the cover cap
- Rimuovere le 2 viti di fissaggio coperchio
We recommend that periodical service is madeby qualified technical personnel according tothe frequency stated by national rules in force.
As much as the dust present in the air will be sucked insidethe combustion chamber, the smoke side resistance willincrease, which, finally, will result in a reduced heat input(and consequently a reduced output).
efore cleaning the boiler body sections, check the boiler inputand the CO2 percentage (see 3.24).
Note! A reduction of the input can be causedby the obstruction of the evacuation duct orof the air intake. Check, first of all, that thisis not the reason.
If the actual input (with the correct CO2) is within 5% of thevalue shown in the chapter 3.24, the boiler does not need tobe cleaned.The operation then, can be limited to the cleaningof the siphon.
- all panels of the casing.
1st Phase - Disassembly• Switch off power and gas supply and ascertain the gas
cock is well closed.• Remove
53
Servicing schedule
- Sganciare la molla di fissaggio camera ventilatori(lato destro/sinistro).
- Remove the red silicone pipe and then the fans room
- Remove the screws “A”, fixing the burner covers,(with a 13 mm socket or open wrengh)
A
• Screws on thermal elements
54
Servicing schedule
- move up the rear burner block and remove the 2 pins with5 mm hex key to reach the holes ‘’C’’ (left and right).
C
- move up the burners block (Front)
- Remove gas fittings from the gas manifold with flat key36 mm.
- Remove the screws gas collector (left and right side).
- Remove the four screws with a 36 mm socket wrengh,then the gas flange
55
Servicing schedule
2nd phase – Cleaning• Remove from their seat the sealing gaskets and the bur-
ners.• Make a dry-cleaning by blowing compressed air on the “
flame” side of the burner• Visually check the condition of the welds of the metal spon-
ge burner.
The burner sealing gaskets, must be repla-ced at each cleaning of the burner.
• Wash, with a water jet, the combustion chamber: pay atten-tion to not to wet the electrical wiring. During this operationascertain that the condensate evacuation pipe is alwaysfree, so that the water cannot come out from the tray.
• Blow with compressed air in the combustion chamber, inbetween the sections, so that all dirty parts are removedfrom the aluminum protrusions.
• Once the cast aluminum sections have been washed, makesure the condensate evacuation siphon is free: if neces-sary clean it.
• Inspect the flue duct and the smoke chamber.
Compressed air
3rd phase – Reassembly
Reassemble all the components previouslyremoved by following the reverse order sureto tighten the screws of the mixer / fans to thebody, with torque of 13 Nm
CAUTIONFOR EACH OPERATION OF MAINTENANCE‘MUST BE REPLACED THE GASCKETS FOREACH BURNER.
Spare code:
95251632 - GASKETS KIT for BURNER MODULEX EXT 348-900 (5 pz.)
95262961 - BURNER KIT MODULEX EXT 348-900
• Before starting the boiler ascertain that the condensate si-phon is filled with water.
• Before opening the gas cock on the burner manifold makesure the coupling is well tight. To do this, open the gas cockand check the soundness of the coupling using a soap so-lution.
• As soon as a burner is put into operation check immedia-tely the soundness between the gas valve and the relevantpremixing chamber.
• Make the combustion analysis and check the combustionparameters.
• Make sure that all the gas pressure test nipples, previouslyopen, are closed and tight.
• After cleaning the body and / or burners reposition theburners in their seats
• Replace the NEW burner sealing gaskets
DISTRIBUTED BY
Autom
atic Heating P
tyLtd
AB
N 90 446 545 923
51 Assembly Tullamarine Vic 3043 AustraliaPO Box 356 Tullamarine Vic 3043 Australia
+61 3 9330 3300 +61 3 9310 5655sales@automaticheating.com.au
Telephone FacsimileEmailwww.automaticheating.com.au
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