ALKON 50 kW ALKON 70 kW 00333009/a - 3rd edition - 02/10 INSTALLATION AND SERVICING MANUAL ENGLISH
Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accordance with the current laws in force. The end user MUST not make any alterations to the boiler. Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage. CONTENTS 2 1 GENERAL INFORMATION ...........................................
General Information 1 GENERAL INFORMATION 1.1 - SYMBOLS USED IN THIS GUIDE When reading this guide particular care has to be given to the parts marked with the followings symbols: DANGER! Indicates serious danger for your personal safety and for your life WARNING! Indicates a potentially dangerous situation for the product and the environment NOTE! Suggestions for the user 1.
General Information 5- SAFETY WARNINGS WARNING! The installation, adjustment, and servicing of this appliance must be carried out by a competent person and installed in accordance with the current standards and regulations. Failure to correctly install this appliance could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any injury and/or damage.
General Information 1.
General Information 1.7 - GENERAL WARNINGS This instruction manual is an integral and indispensable part of the product and must be retained by the person in charge of the appliance. Please read carefully the instructions contained in this manual as they provide important indications regarding the safe installation, use and servicing of this appliance. Keep this manual in a safe place for future reference.
Technical features and dimensions 2 TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES The ALKON 50/70 boilers are a thermals gas fired units with an atmospheric fully pre-mixed burner. They are supplied only in heating version. These boilers have an input head power of: 50 or 70 kW, These boilers are designed for use on gas category II2H3P.
Technical features and dimensions DIMENSIONS ALKON 50/70 + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT 502 762 712 1978 1510 DIMENSIONS ALKON 50/70 in BATTERY (n.
Technical features and dimensions DIMENSIONS ALKON 50/70 in BATTERY (n.3 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT 1972 500 1500 1740 2475 3726 DIMENSIONS ALKON 50/70 in BATTERY (n.
Technical features and dimensions 2.3 - MAIN COMPONENTS ALKON 50 MODULATING FAN FLUE OUTLET PIPE (Ø80 mm) AIR INTAKE OPENING (Ø80 mm) AIR VENT VALVE IGNITION ELECTRODE IGNITION TRANSFORMER ALUMINIUM HEAT EXCHANGER/ CONDENSER OVERHEAT THERMOSTAT PIPE WITH SMOKE SAMPLING AND CONDENSATE EVACUATION CONNECTION FLOW TEMPERATURE SENSOR GAS VALVE RETURN TEMPERATURE SENSOR SPACER PIPE REPLACEABLE FOR MOUNTING OF OPTIONAL CIRCULATOR SAFETY VALVE MIN. WATER PRESSURE SWITCH N.B.
Technical features and dimensions ALKON 70 MODULATING FAN FLUE OUTLET PIPE (Ø80 mm) AIR INTAKE OPENING (Ø80 mm) AIR VENT VALVE IGNITION ELECTRODE ALUMINIUM HEAT EXCHANGER/ CONDENSER IGNITION TRANSFORMER OVERHEAT THERMOSTAT PIPE WITH SMOKE SAMPLING AND CONDENSATE EVACUATION CONNECTION FLOW TEMPERATURE SENSOR GAS VALVE RETURN TEMPERATURE SENSOR MODULANTING PUMP SAFETY VALVE MIN.
Technical features and dimensions 2.
Technical features and dimensions 2.5 - PERFORMANCE DATA For information regarding the adjustment of: INJECTORS - BURNER PRESSURES – DIAPHRAGMS – OUTPUTS – GAS CONSUMPTIONS please refer to the paragraph ADAPTMENT TO THE USE OF OTHER GASES.
Instructions for the installer 3 INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS WARNING! This boiler has to be destined for the use for which it has been expressively designed for. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at a temperature inferior to boiling point at an atmospheric pressure. WARNING! These appliances are exclusively designed to be installed inside adequate boiler rooms.
Instructions for the installer 3.2 - STANDARD CODES FOR INSTALLATION The appliance must be installed in compliance to the instructions contained in this manual. The installation must be carried out by a competent qualified engineer, whom will assume the responsibility of complying to all the local and/or national regulations published in the official publications, as well as all the applicable codes of practice.
Instructions for the installer 3.3 - PACKAGING The ALKON 50/70 boiler is supplied fully assembled in a strong cardboard box. After having unpacked the boiler check that it is intact and undamaged. Keep the packaging material (cardboard box, plastic bags, polyester protection etc.) out of the reach of children as they can be dangerous. UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations.
Instructions for the installer - The boiler room has a suitable outlet for the discharge of condensate produce by the boiler. - The electrical system has been fitted in compliance to the specific norms and the work has been carried out by a competent person. 3.5 - INSTALLATION ON EXISTING HEATING SYSTEMS When the appliance is installed on existing systems, ensure yourself that: - The circulation pump’s output, the head and flow direction are suitable.
Instructions for the installer 3.7 - FLOW AND RETURN PIPE CONNECTIONS The CH flow and return circuits have to be connected to the boiler via the respective connections 1” or 1’’¼ as indicated on page 16. When determining the size of the CH circuit pipes it is essential to bear in mind the pressure losses induced by any of the system’s components and by the configuration of the same system.
Instructions for the installer 3.8 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP The boiler pump must have a delivery head which can ensure the water flow rate as shown in the diagram “Water pressure losses”. The size of the pumps must be determined by installers or technical engineers according to boiler data and system design.
Instructions for the installer 3.9 - SUPPLEMENTAL SAFETY, PROTECTIVE AND CONTROL DEVICES PRESCRIBED BY THE GOVERNMENT DECREE 01-12-1975 AND RELATIVE APPLICABLE TECHNICAL SPECIFICATIONS (CONTAINED IN THE “RACCOLTA R EDITION 1982”) CERTIFICATION OF THE SUPPLEMENTAL SAFETY DEVICES: CONTROL DEVICES Several notified bodies prescribe supplemental safety devices.
Instructions for the installer 3.10 - PRESSURE RELIEF VALVE DRAIN PIPE A pressure relief valve must be fitted on the flow pipe, within 0,5 m from the boiler. It must be dimensioned for the capacity of the boiler and must comply to the regulations in force, WARNING! Please remember that it is forbidden to interpose, between the boiler and the pressure relief valve, any type of cutting-off device.
Instructions for the installer 3.12 - MIXING HEADER FILTER UNICAL suggests the installation of a Y filter on the return pipe so that it can be cleaned if necessary. This filter will protect the boiler from the heating system dirt. 3.13 - MIXING HEADER (cod.
Instructions for the installer 3.14 - CONDENSATE DRAIN Condensate inlet coming from the heat exchanger During the combustion process the boiler produces condensate which, through the “A” pipe, flows into the siphon. The condensate which forms inside the boiler has to be routed into an adequate drain by means of the pipe “B”. DANGER! Before commissioning the appliance fill the siphon and check the correct drainage of the condensate.
Instructions for the installer 3.15 - WATER TREATMENT The chemical/physical features of the heating system’s water are fundamental for the boiler’s correct operation and safety. An appropriate treatment of the supply water will prevent the above stated problems and will maintain the correct operation and efficiency of the generator in time.
Instructions for the installer 3.16 - FLUE OUTLET INSTALLATION The flue system must be installed in accordance with the local and national Standards. . We recommend using only original UNICAL flue outlet systems. Damages caused by installation errors and for non-observance of the instructions given by the manufacturer will invalidate all the supplier’s contractual or extra contractual responsibilities. C53 Boiler with separate air inlet and products outlet.
Instructions for the installer FLUE OUTLETS Ø 80 mm Type B23 Preliminary operations: Fit the smoke evacuation pipe Ø 80 mm, supplied in the carton, as shown in the picture. x= m - L ma L min = 1 30 m 00310012 TSC0130C KIT5770C The total allowed linear maximum length of the smoke evacuation and air intake pipes, of Ø 80 mm, is 30 m, including one wide radius curve and one evacuation terminal.
Instructions for the installer HORIZONTAL FLUE OUTLET WITH CONCENTRIC DUCTS Ø 80/125 mm - Type C 13 Preliminary operations: - Insert the supplied pipe Ø 80 in the adapter for coaxial pipes Ø80/125 (code 00361255) - Fit the assembly pipe/adapter on the boiler as shown in figure. The minimum allowed length of the horizontal coaxial pipes is 1 meter. The maximum allowed length of the horizontal coaxial pipes is 5 meters.
Instructions for the installer VERTICAL FLUE OUTLET WITH COAXIAL DUCTS Ø80/125 mm - TYPE C 33 Preliminary operations: - Insert the supplied pipe Ø 80 in the adapter for coaxial pipes Ø80/125 (code 00361255) - Fit the assembly pipe/adapter on the boiler as shown in figure. L min = 1 m - L max = 7 m The minimum allowed length of the horizontal coaxial pipes is 1 meter. The maximum allowed length of the horizontal coaxial pipes is 7 meters.
Instructions for the installer Smoke evacuation by two separate ducts Ø 80 mm - Type C53 Preliminary operations: - Fit the supplied pipe of Ø 80 mm, as shown in the picture. The maximum allowed pressure drop, independently from the type of installation, doesn’t have to overcome the value of 60 Pa. cuati oke eva m s 1 n less tha tion) e. + not smoke evacua k ta in ir 2 m (1 a ke.
Instructions for the installer 3.17 - ELECTRICAL CONNECTIONS Regulations in force Mains electrical supply connection 230V The elctrical safety of the appliance is assured only when it is correctly earthed, according to the electrical rules in force. The gas, D.H.W. and the CH system pipes cannot be used as ground plates.
Instructions for the installer Room thermostat and/or E8 heating controller connection DANGER! Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts. E8 heating controller Room thermostat For the connection of the E8 heating controller, to remove the “bridge wire” existing between the terminals 1 and 2. - Gain access to the Y1 terminal board - A Room Thermostat will be connected to the terminals 1 and 2 after removal of the existing bridge wire.
Instructions for the installer Connection of the additional safety devices for ALKON in battery DANGER! Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts. - For the connection remove the existing jumper.
Instructions for the installer 3.18 - ACTUAL WIRING DIAGRAM for ALKON 50 E. ACC VM RED 2 3 BROWN 1 LIGHT-BLUE BROWN (PWM) BLUE (TACHO) ORANGE + 1 BROWN LIGHT-BLUE BROWN LIGHT-BLUE BLACK BLACK (-) 2 BROWN (L1) LIGHT-BLUE (N) 4 5 BROWN LIGHT-BLUE ALIM. RIL./REG. 230V YELL/GREEN VG BROW N BLUE NERO BLU MA RRONE ARANCIO N L1 BROWN YELL/GREEN LIGHT-BLUE 230 V - 50 Hz BLU E BROWN Fs1 LIGHT-BLUE LIGHT-BLUE WHITE WHITE GREEN GREEN E. RIV.
Instructions for the installer ACTUAL WIRING DIAGRAM for ALKON 70 VM E. ACC ROSSO 2 3 BROWN 1 LIGHT-BLUE 1 BROWN (L1) LIGHT-BLUE (N) BROWN (PWM) BLUE (TACHO) 2 ORANGE + 4 BROWN LIGHT-BLUE BROWN LIGHT-BLUE BLACK BLACK (-) 5 BROWN LIGHT-BLUE ALIM. RIL./REG. 230V GIA/VER VG BROWN BLUE BROWN BROWN YELL/GREEN N L1 BLUE BROWN LIGHT-BLUE 230 V - 50 Hz LIGHT-BLUE PM BLACK BLUE BROWN ORANGE Fs1 LIGHT-BLUE WHITE WHITE GREEN GREEN YELL-GREEN LIGHT-BLUE E. RIV.
Instructions for the installer Boiler pump at constant flow rate (optional cod. 00361321 ALKON 50) P* VM ALIM. 230V BROWN (L1) 2 3 LIGHT-BLUE (N) 1 LIGHT-BLUE BROWN LIGHT-BLUE BROWN YELL-GREEN YELL-GREEN P LIGHT-BLUE P = Boiler pump at constant flow rate, controlled via an ON/OFF Room thermostat BROWN P * = Boiler pump at constant flow rate, controlled via the heating controller E8. Modulating pump (optional cod. 00361320 ALKON 50) PM ALIM.
Instructions for the installer 3.19 - WIRING DIAGRAM AND MANAGEMENT WITH E8 REGULATOR (Optional) The main controls, necessary for the C.H. system management and for the boiler control, as well some components which are part of the boiler house, must be connected to the terminal blocks. On the back side of the E8 regulator there are two terminal blocks, of which one is for the mains (230 V) connections and the other one is for the low tension connections. Primay circuit pump D.H.W.
Instructions for the installer Sensor terminal assignments VII VII 1 Pin 1: eBUS (FA) or 0-10V output Pin 2: (Ground) I 3 2 1 F3 F2 F1 Terminal I VF VF F5 F6 6 I 5 8 F9 F8 7 SPF SPF KF AF AF 10 9 AF KF / SPF VF 4 FBR Connection to BCM 2 FA eBUS 0-10 V Terminal VII V VF 2 V1 F12 F11 SPF VF Terminal V Buffer storage tank low sensor Buf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor) Buf. stor. tank top sensor / FBR heat. circ.
Instructions for the installer 3.
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO DIRECT HEATING ZONES + D.H.W. PRODUCTION VF (4-5) Flow sensor heating circuit 2 SPF (6-7) Storage tank sensor AF (9-10) outdoor sensor (4) Pump heating circuit 1 (5) Pump heating circuit 2 (6) Cylinder charging pump (5) Re-circulation pump storage tank n VF I (1) Flow sensor heating circuit 1 (10) Ground outdoor sensor 10 C Heating Circuit 1 Ric.
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PRODUC.
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W.
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W.
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION C Heating Circuit 1 Expansion vessel (optional) Ric.
Instructions for the installer 3.
Instructions for the installer INSTALLATION OF TWO ALKON 50/70 IN BATTERY DN 65 8 DN 65 5 6 4 1 9 3 2 DN 50 DN 50 DN 50 2 DN 50 11 1 2 3 4 5 6 8 9 - 00361363 00361314 00361313 00361316 00361499 00361414 00361361 00361320 00361321 = = = = = = = = = Supporting frame for two boilers Manifold kit for Alkon 50/70 Pipe kit for additional safety devices Safety devices kit Mixing bottle kit Pipes kit for connection of mixing bottle Smoke outlet for two boilers Modulating pump (only for Alkon 50)
Instructions for the installer INSTALLATION OF THREE ALKON 50/70 IN BATTERY 8 DN 65 DN 65 1a DN 65 5 8a 6 4 1 9 3 DN 50 2 DN 50 2 DN 50 DN 50 2 DN 50 11 1 1a 2 3 4 5 6 8 8a Supporting frame for two boilers Added supporting frame for one boiler Manifold kit for Alkon 50/70 Note: Pipe kit for additional safety devices The insulation of the battery flow and return maSafety devices kit nifolds is suggested.
Instructions for the installer INSTALLATION OF FOUR ALKON 50/70 IN BATTERY 8 DN 100 1a DN 100 DN 100 1a 8a 5 6 4 8a 9 3 DN 50 1 2 DN 50 2 DN 50 DN 50 2 DN 50 2 DN 50 11 Supporting frame for two boilers Added supporting frame for one boiler Manifold kit for Alkon 50/70 Pipe kit for additional safety devices Note: Safety devices kit The insulation of the battery flow and return maMixing bottle kit nifolds is suggested.
Instructions for the installer 3.22 - FILLING THE SYSTEM Warning! Do not mix the CH system’s water with antifreeze or anti-corrosion solutions using wrong concentrations! It could cause damage to the washers and could provoke noise during normal boiler operation. UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations. Once all the connections are made, it is possible to fill the circuit.
Instructions for the installer 3.23 - INITIAL LIGHTING PRELIMIARY CHECKS The first ignition must be carried out by a qualified technician. Failure to do so could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage. DANGER! Before firing the appliance fill up the siphon through the filling hole and check the correct drainage of the condensate.
Instructions for the installer 3.24 - BURNER ADJUSTMENT WARNING! All the instructions indicated below are for the exclusive use of qualified UNICAL service technicians or installers. All the boilers are supplied already calibrated and tested. If it is necessary to change the calibration due to gas conversion or adaptation to the mains supply system, the gas valve must be re-calibrated. A) - Max output adjustment Connect a suitable C02 gas analyser to the sampling point in the flue inlet/outlet terminal.
Instructions for the installer - If necessary correct the value by turning the adjustment screw “B” in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrease it. C) COMPLETION OF THE BASIC ADJUSTMENTS Check the C02 values at the minimum and maximum outlet If necessary make the required adjustments To ensure correct operation the C02 values have to be adjusted with extreme care respecting the values indicated in the table.
Instructions for the installer 3.25 - VARIATION OF OUTPUT RANGE It is possible to adjust the maximum input by reducing the fan speed. Modify the parameter FH from the boiler panel board: Factory parameter (access code) For example: ALKON 50 with parameter FH set on 72 (G 20) the correspondent maximum input will be of 34,8 kW. For example: ALKON 70 with parameter FH set on 76 (G 20) the correspondent maximum input will be of 50 kW.
Instructions for the installer 3.27 - PROGRAMMING OF THE OPERATING PARAMETERS WARNING! THESE OPERATIONS ARE ACCESSIBLE TO TRAINED INSTALLERS AND SERVICE ENGINEERS ONLY FOR CHANGING THE PARAMETER SETTINGS Press the YELLOW key and the LIGHT BLUE key simultaneously to enter in the service mode SE and change the values of the pre-set operating parameters. (Operation C) After setting the desired value pressing the YELLOW key stores this new value in the memory.
Instructions for the installer MODULATING PUMP MODULATING CAPACITY Continue to change the parameters by pressing the – key (decrease). The successive parameter which can be changed is: MODULATING PUMP MODULATING CAPACITY (Pr). V I O L A A Z Z U R R O G I A L L O B L U Repeat the operations A-B-C for setting the desired value from 20 to 99%. Standard setting: 99% SETTING OF THE MAXIMUM HEATING TEMPERATURE Continue to change to the parameters by pressing the – key (decrease).
Servicing schedule 4 INSPECTION AND SERVICING SCHEDULE To ensure the continued safe and efficient operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary, and that only original spare parts are used. Regular attention will prolong the life of the boiler. INSTRUCTIONS FOR INSPECTION AND SERVICING If the boiler is not checked and serviced regularly it could cause material and personal damages.
Servicing schedule CLEANING THE CONDENSATE DRAIN SIPHON In order to check and clean the siphon carry out the following steps: - disconnect the transparent pipe (1) check that no deposits have accumulated inside the siphon (2). - unscrew the plastic nuts (3) and (4) and to remove the siphon; - Verify if there are any deposits flush them out with clean water; - reassemble the siphon in reverse order.
Fault finding 5 FAULT FINDING 5.1 - ERROR CODES which could occur during boiler operation or commissioning of the boiler. When the fault signalling led (1) is on, press the LIGHT BLUE key (2) to check the error code on the display (3).
Fault finding Code: Description: Modulating fan failure Code: Corrective action: Check the fan’s wiring Code: Code: Corrective action: Disconnect the gas valve’s wire from the control board; if the error code disappears replace the control board, otherwise replace the gas valve.
Fault finding 5.3 - DISPLAY OF ERROR CODES ON HEATING CONTROLLER E8 In case of fault, on the display of the regulator a blinking triangle with its error code will appear Here below you will find the E8 error codes, the relevant meaning and corrective actions. 24 18 6 12 For the error codes related to the heating system, make reference to the paragraph “Fault finding” of the “User Instruction manual” supplied with the E8.5064 heating controller.
Fault finding Code: E 24 Description: Modulating fan failure Code: Description: E 30 Alteration of the operating parameters caused by EMC disturbances Corrective action: Corrective action: Check the fan’s wiring Restore the factory parameters Code: E 26 Description: Modulating fan failure Code: Description: Corrective action: E 11 Flame detected before the starting of the ignition cycle Check the fan’s wiring Code: Description: E8 Lack of water (only for pump with SensorLogic) Correc
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AG S.P.A. 46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - fax 0376/660556 www.unical.ag - info@unical-ag.com The Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also reserves the right to bring those changes that it will hold necessary to it own products or profits, without jeopardizing its essential characteristics.
