ENGLISH MODULEX EXT 100 - 150 - 200 - 250 - 300 - 350 INSTALLATION AND SERVICING INSTRUCTIONS
Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accordance with the current laws in force. The end user MUST not make any alterations to the boiler. Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage. CONTENTS 1 GENERAL INFORMATION...............................................
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 1.4 - SAFETY WARNINGS WARNING! The device should not be used by people with reduced physical, mental and sensory, experience and knowledge. These people must be well-informed and supervised during the work. Children must be supervised so they do not play with the appliance. WARNING! The installation, adjustment, and servicing of this appliance must be carried out by a competent person and installed in accordance with the current standards and regulations.
General Information 1.5 - STANDARD CODES FOR INSTALLATION The appliance must be installed in compliance to the instructions contained in this manual. The installation must be carried out by a competent qualified engineer, whom will assume the responsibility of complying to all the local and/or national regulations published in the official publications, as well as all the applicable codes of practice. Before installing the appliance please contact the gas supply company.
General Information 1.6 - Technical data plate CE marking The CE marking certifies that the boilers meet: - The essential requirements of the gas appliance directive (directive 2009/142/EEC) - The essential requirements of the electromagnetic compatibility directive (2004/108/EEC) - The essential requirements of the efficiency directive (92/42/ EEC) - The essential requirements of the efficiency directive (directive 2006/95/EEC) The Technical data plate is placed under the casing over the forehead stirrup.
General Information 1.8 - WATER TREATMENT The chemical-physical characteristics of the filling water and reinstatement water in heating systems are of fundamental importance for guaranteeing correct and safe boiler operation. Before filling the CH circuit with water, it is necessary to analyse the water and decide for a proper treatment.
General Information 1.9 - 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 • MODULEX is a compact, gas fired, Low NOx, condensing boiler. • made up by one sectional boiler body, suitable for a single boiler working or directly as cascade • Place even outside (IP X5D) • Low water content • Fast response to load variations • Flue terminal positionable on 3 sides • Manifold unified delivery and return (everseble in simple way p.
Technical features and dimensions 2.2 - R.H. SIDE VIEW, WITH MAIN COMPONENTS - Smoke and condensate evacuation connection on the R.H. side (forniture condition), L.H. side, BACK SIDE order special BACK Flue kit MODULEX EXT 100 - 116 - 150 - 200 : 00362154 MODULEX EXT 250 - 300 - 350 : 00362076 - C.H. flow connection on the R.H. side (forniture condition), L.H. side - C.H. return connection on the R.H. side (forniture condition), L.H. side - Gas connection on the R.H. side (forniture condition), L.H.
Technical features and dimensions 2.3 - DIMENSIONS RIGHT HAND SIDE VIEW (Delivery condition for R.H. side connection) FRONT VIEW (•) Modulex EXT 100 - 200 - 300 into the casing Flue terminal LEFT HAND SIDE VIEW UPPER VIEW M R CH flow system CH safety system return MODULEX Dimension No. of Modules Height mm Width ‘’L’’ mm Width ‘’L1’’ mm Depth ‘’P’’ mm Depth ‘’P1’’ mm Connections Gas mm (inch) C.H. system Flow M mm (inch) C.H.
Technical features and dimensions 2.4 - PERFORMANCE DATA For the adjustment data: NOZZLES - PRESSURE - DIAGRAMS - FLOW RATES refer to the paragraph ADAPTATION TO OTHER TYPES OF GAS. MODULEX Boiler category Modulation ratio Rated heat output on P.C.I. Qn Minimum heat output on P.C.I.
Instructions for the installer 2.4.
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.
Instructions for the installer 3.2 - PACKAGING The boiler MODULEX is delivered assembled and protected by a plastic bag inside a strong cardboard box and fixed on pallet. This allows the boiler to be handled also by forklift. Remove both straps and finally the cardboard box from above, making sure the product is intact. The packing elements (cardboard box, straps, plastic bags, etc…) shall not be left to children’s hand since they may be dangerous.
Instructions for the installer 3.3 - REMOVAL FROM THE BOILER BED AND INSERT FOOT 1 3 2 4 - Remove the casing of the boiler Lift the boiler with a hoist or forklift bands Remove the 4 screws’’A’’ - Insert the 4 feet (contents into the box) Attach the feet to the chassis by 4 screws’’A’’previously removed. Place the boiler on concrete slab and mount the casing. 3.
Instructions for the installer Give the boiler the minimum clearances as shown in the drawing, in order to be able to make the normal service and cleaning operations.
Instructions for the installer 3.6 - BOILER CONNECTION At its delivery the boiler MODULEX has all the connections, i.e.: C.H. flow & return, gas, and smoke outlet on its R.H. side. To move the gas connection, from the R.H. side (std. delivery position) to the L.H. side, it is necessary to change each other the two flanges screwed on the gas manifold ends. Gas reversibility To move the smoke outlet from the R.H. side (std. delivery position) to the L.H. side it is necessary to change each other L.
Instructions for the installer 3.7 - GAS CONNECTION The gas supply pipe must be connected to the boiler via the respective pipe connection R 1½ as indicated on page 8. The gas supply pipe must have a section which is identical or greater then the one used on the boiler and must assure a correct gas pressure. It is however important to comply with the specific norms and requirements in force, foreseeing on-off valves, gas filter, antivibrating joint etc.
Instructions for the installer 3.8 - FLOW AND RETURN PIPE CONNECTIONS The CH flow and return circuits have to be connected to the boiler via the respective connections 2½“ M and R as indicated on page 11. When determining the size of the CH circuit pipes it is essential to bear in mind the pressure losses induced by any of the system’s components and by the configuration of the same system.
Instructions for the installer 3.9 - ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW CERTIFICATION OF THE ADDITIONAL SAFETY DEVICES: Dispositivi di sicurezza 1 On-off gas valve: a device which has the function of cutting off the gas supply when the water temperature reaches the max. predetermined value. The sensible element has to be installed as nearest as possible to the generator (flow pipe) at a distance which has to be < 500 mm and must not be able to be cut-off.
Instructions for the installer Recomended installation 3.10 - MIXING HEADER 3.11 - MIXING HEADER FILTER n order to ensure correct boiler operation it is necessary to use a mixing header which guarantees: - the separation and collection of circuit dirt optimal air venting hydraulic de-coupling of the two hydraulic circulation circuits balancing of the circuits Boiler Circuit Heating System Circuit Mixing HeaderModulex Ext 100 - 350 cod.
Instructions for the installer 3.12 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP The boiler pump must have a delivery head which can ensure the water flow rate as shown in the diagram “Water pressure losses”. The size of the pumps must be determined by installers or technical engineers according to boiler data and system design. The following table gives an indication of the pump’s flow rate in function of the Ät of the primary circuit if the installation has a mixing header.
Instructions for the installer 3.14 - PLATE HEAT EXCHANGER 3.15 - PRIMARY CIRCUIT The plate heat exchanger, conveniently dimensioned, has the advantage to keep hydraulically the two circuits (primary and secondary),protecting the boiler heat exchanger water / smoke. allows subsequently, by adding or removing additional plates to adjust the system as needed. WITH PLATE HEAT EXCHANGER SPINOX COMPO S.
Instructions for the installer WITH MIXING HEADER COMPO S. MODULEX 100-116-150: 00361944 MODULEX 200-150: 00361945 MODULEX 300-350: 00361944 PREMO S. MODULEX 100-116-150: 00362062 MODULEX 200-150: 00362063 MODULEX 300-350: 00362064 BOX COVER COMPO S MODULEX 100-350: 00362008 BOX COPERTURA ANELLO COMPO S MODULEX 100-350: 00362008 PREMO C.
Instructions for the installer 3.16 - CONDENSATE DRAIN Avoid the condensate stagnation inside the combustion products evacuation system, (for this reason the evacuation duct must have an inclination toward the drain of at least 30 mm/m (3/8 in. / ft) except the liquid column, inside the condensate siphon, which needs to be filled with water after installation: its minimum height, when all the fans are in operation, must be at least 25 mm (1 in.).
Instructions for the installer 3.17 - CONNECTION TO THE CHIMNEY In a condensing boiler the smokes are evacuated at a very low (Max about 84°C). Then it is necessary that the temperature chimney is perfectly impermeble to the condensate of the combustion products and is made of materials corrosion resi-stant. The different spigot joints must be well sealed and equipped with suitable gaskets, in order to prevent the outlet of condensate and the inlet of air.
Instructions for the installer Flue gas mass flow rate Modulex 100 150 200 250 300 350 28 Flue gas mass flow rate (max) kg/h 163,4 245,2 326,9 408,6 490,3 572,0 Esemple: MODULEX 250 Flue gas mass flow rate Chimney height Chimney connection Ø = = = 408,6 Kg/h 25 m 250 mm NOTE: The diagram supplies only indicatives values
Instructions for the installer 3.19 - ELECTRICAL CONNECTIONS Regulations in force power, indicated on the data plate, verifying in particular that the section of the system’s cables is suitable to the appliance’s maximum absorbed power. The gas and water feeding pipes and the CH system pipes cannot be used as ground plates. For the appliance’s general electrical supply the use of adaptors, multiple sockets and/or extension cords is strictly forbidden.
Instructions for the installer 3.20 - WIRING DIAGRAM: main supply, Gas valve, ISPESL, ON-OFF pump, outside sensor, flow switch In the case of intervention of the safety devices, the pump ON / OFF continues to work to promote the disposal of high temperature. main supply, Gas valve, ISPESL, Modulating pump, outside sensor, flow switch In the case of intervention of the safety devices, the modulating pump continues to work to promote the disposal of high temperature.
Instructions for the installer CONNECTING RING PRIMARY (SUPPLIED WITH MODULAR PUMP) THERMOSTAT ON / OFF CONNECTIONS 31
Instructions for the installer THERMOSTAT FBR 2 CONNECTION (room sensor) 32
Instructions for the installer MODULATING THERMOSTAT CONNECTIONS 33
Instructions for the installer 3.21 - Functional wiring diagram 34 Note: The pictures shown on the actual wiring diagram, is purely indicative.
Instructions for the installer 35
Instructions for the installer 3.22 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGING On the back side of the E8 regulator there are two terminal blocks, of which one is for the mains (230 V) connections and the other one is for the low tension connections. Power terminal block Sensor terminal block Power terminal assignments 36 The main controls, necessary for the C.H.
Instructions for the installer Sensor terminal assignments Terminal assignments BCM 37
Instructions for the installer 3.23 - INSTALLATION EXAMPLES (functional wiring and connections description) INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE (9-10) outdoor sensor (1) Flow sensor heating circuit 1 (10) Ground outdoor sensor (4) Pump heating circuit 1 (4) Primary pump INSTALLATION OF A BOILER WITH CONNECTION TO TWO DIRECT HEATING ZONES + D.H.W.
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD.
Instructions for the installer Connection to seondary circuit Connection to section B (Heating circuit 1) Connection to section C (Heating circuit 2) 40
Instructions for the installer Connection to section D ( DHW ) Connection to section E (solar circuit) For the connection to a solar installation it is necessary to change some parameters.
Instructions for the installer CONNECTION BATTERY 2 MODULEX managed by an external regulator E8 (RING PRIMARY) * See manual supplied E8 42
Instructions for the installer ALTERNATE CONNECTION IN BATTERY 2 MODULEX operated by BCM (RING PRIMARY) 3.24 - CASCADE MANAGER (BCM) Application: The BCM completes the range of functions offered by the Modulex boilers: - ON/OFF alarm control - Control of a modulating primary pump with the aim of significantly increasing efficiency at low heating loads.
Instructions for the installer 3.25- 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. The filling-up can also be made through the draining tap on the boiler return manifold.
Instructions for the installer 3.27 - 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.
Instructions for the installer Follow this procedure also for the other burners If the CO2 percentage is too low, check if the air and smoke ducts are not obstructed. If they are not obstructed, check if the burner and/or the exchanger (aluminium sections) are well cleaned.
Instructions for the installer INJECTORS – PRESSURES MODULEX EXT: 100 - 150 - 200 - 250 - 300 - 350 Gas Type Supply pressure Ø Injectors Diaphragm [mbar] (mm) [mm] Fan Speed CO2 levels Starting power [%] [%] min max FL [% FU] FU [Hz] min max IG Gas nat. (G20) 20 7 - 31 98 9,1 9,1 80 Gas nat.
Instructions for the installer 3.28 - EMERGENCY FUNCTIONS The BCM It avoids system shutdown in case the main boiler plant’s system E8 5064 management is out of use. L A YELLOW LED = Blinking RED LED = ON (Failure code detected) Emergency is active or the control is managed by PLC or BMS I= Series connection (the cascade is managed by the BCM) II = Parallel connection (condition of forniture).
Instructions for the installer 3.29 INITIAL LIGHTING PRELIMIARY CHECKS The first ignition must be carried out by a qualified technician. Failure to do so could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage. Before lighting the boiler check that: - the boiler installation has been carried out in accordance with the specific Standards.
Servicing schedule 4 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary, and that only original spare parts are used. The law in force states that the boiler must be serviced annually. If the boiler is not checked and serviced when necessary it could cause material and personal damages.
Servicing schedule We recommend that periodical service is made by qualified technical personnel according to the frequency stated by national rules in force. As much as the dust present in the air will be sucked inside the combustion chamber, the smoke side resistance will increase, which, finally, will result in a reduced heat input (and consequently a reduced output). efore cleaning the boiler body sections, check the boiler input and the CO2 percentage (see 3.24).
Servicing schedule - Remove gas valve connector - Release the fixing spring from the air manifold (on right and left side). - Remove fan connector - Remove the red silicone pipes and then the air manifold (left / right side).
Servicing schedule • Screws on thermal elements - Remove the screws “A”, fixing the burner covers, with a 13 mm socket wrengh, - Remove the screws gas collector (left and right side).
Servicing schedule - Insert the small pins in the “D” holes in order to support the burner assembly - Slightly lift the rear burner assembly and remove the 2 pins with an open wrengh of 4 mm, up to reach the holes ‘’C’’ - 54 Lift the burner assembly (front part)
Servicing schedule Second phase - Cleaning • Remove the gaskets and the burners. • Perform cleaning of the burners only by blowing, with compressed air, acting from the “side flame” • Verify visually the state of the spot weldings of the L profiles and the burner mesh. Third phase – Reassembly • After the cleaning of the boiler body and/or the burners, re position the burners in their seats. • Position the new gaskets in graphite The burner gaskets must be replaced at every cleaning operation.
00333467 - 3rd edition 10/15 www.unical.eu AG S.p.A. 46033 casteldario - mantova - italia - tel. +39 0376 57001 - fax +39 0376 660556 info@unical-ag.com - export@unical-ag.com - www.unical.eu 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.
