Related Manuals for Unical SuperModulex 440
Summary of Contents for Unical SuperModulex 440
- Page 1 SuperModulex 440 - 550 - 660 - 770 - 900 MODULAR CONDENSING BOILER INSTALLATION AND SERVICING INSTRUCTIONS 00331587/a - 2 edition - 02/10...
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Page 3: Table Of Contents
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 GENERAL INFORMATION .................................... -
Page 4: General Information
Any other use of this appliance will be considered improper.UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this case the risk is completely at the user’s responsibility.In order to use the appliance according to the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide. -
Page 5: Safety Warnings
Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL recommends drawing up a service contract. Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not be held liable. -
Page 6: Data Badge
General information 1.5 - DATA PLATE - The essential requirements of the Directive regarding electromagnetic compatibility (Directive 89/336/CEE) CE Marking - The essential requirements of the Efficiency Directive The CE marking documents that the boilers satisfy: (Directive 92/42/CEE) - The essential requirements of the Directive regarding gas - The essential requirements of the low voltage Directive appliances (Directive 90/396/CEE) (Directive 73/23/CEE) -
Page 7: General Warnings
Please read carefully the instructions contained in this manual Any repairs must be carried out by Unical authorized as they provide important indications regarding the safe technicians and using only original spare parts. Non- installation, use and servicing of this appliance. -
Page 8: Technical Features And Dimensions
Technical features and dimensions TECHNICAL FEATURES AND DIMENSIONS • Logic of operation: A) Output sharing on as many modules as possible at min. load (down to 22 kW) for the max. efficiency.. 2.1 - TECHNICAL FEATURES B) Automatic operation hour splitting-up system for each module to guarantee the best homogeneous use. -
Page 9: Dimensions
Technical features and dimensions 2.2 - DIMENSIONS FRONT VIEW RIGHT HAND SIDE VIEW 1378 LEFT HAND SIDE VIEW UPPER VIEW Øi 250 SuperModulex Dimension No. of Modules Height 1372 Width 1378 Depth Connections mm (inch) 50 (2) C.H. system Flow M mm (inch) 80 (3) C.H. - Page 10 Technical features and dimensions FRONT VIEW RIGHT HAND SIDE VIEW LEFT HAND SIDE VIEW UPPER VIEW Øi D SuperModulex Dimension No. of Modules Height 1372 1372 1372 Width ''L'' 1390 1122 1256 Depth 1520 1520 1520 Connections mm (inch) 50 (2) 50 (2) 50 (2) C.H.
- Page 11 Technical features and dimensions FRONT VIEW RIGHT HAND SIDE VIEW 1574 LEFT HAND SIDE VIEW UPPER VIEW 472,5 488,5 Øi D SuperModulex Dimension No. of Modules Height 1434 Width 1674 Depth 1546 Connections mm (inch) 80 (3) C.H. system Flow M mm (inch) 100 (4) C.H.
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Page 12: Performance Data
Technical features and dimensions 2.3 - PERFORMANCE DATA BOILER TYPE SUPERMODULEX Appliance category 2H3P Nominal Heat Input on P.C.I. Qn Minimum Heat Input on P.C.I. Qmin Nominal Output (Tr 60 / Tm 80 °C) Pn 424,27 530,33 636,40 742,47 848,53 Minimum Output (Tr 60 / Tm 80 °C) Pn min 20,33 20,33... -
Page 13: Rhs View Showing Main Components
Technical features and dimensions 2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS AIR INTAKE CONNECTION CONTROLL PANEL GAS VALVE GAS PIPE BURNER AUTOMATIC COVER AIR VENT BURNER C.H. FLOW ALUMINIUM/ SILICON HEAT EXCHANGER C.H. RETURN CONDENSATE COLLECTING TRAY- SMOKE MANIFOLD CONDENSATE BOILER FRAME DRAIN... -
Page 14: Instructions For The Installer
Instructions for the installer INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS WARNING! WARNING! This boiler has to be destined for the use for In rooms where there is the presence of which it has been expressively designed for. aggressive vapours or dust the appliance Any other use shall be considered improper must operate independently from the air and therefore dangerous. -
Page 15: Installation Standards
Instructions for the installer 3.2 - STANDARD CODES FOR INSTALLATION The appliance must be installed in compliance to the Moreover, the boiler must be installed in accordance to all the instructions contained in this manual. regulations regarding the boiler room, the building regulations and the prescriptions regarding central heating plants in force The installation must be carried out by a competent qualified in the country where the boiler is installed. -
Page 16: Packaging
Instructions for the installer - PACKING The boiler MODULEX is delivered assembled and protected by a plastic bag inside a strong cardboard box and fixed on pallet. This allows the boiler to be handled also by forklift. The boi- ler, with the packaging, can go through a door of 800 mm, whereas, without packaging, it can go through a door of 700 mm. - Page 17 Instructions for the installer BOILER UNLOADING AND PACKAGE REMOVAL PALLET REMOVAL...
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Page 18: Boiler Location In A Boiler Room
Instructions for the installer 3.4 - BOILER LOCATION INSIDE A BOILER HOUSE Special attention shall be paid to local regulations and laws smoke chamber terminal, with the flue socket, is left to the about boiler houses and particularly to the obligation of R.H. -
Page 19: Installation On Existing Systems
UNICAL - The electrical system has been fitted in compliance to the recommends contacting a specialised company for water tre- specific norms and the work has been carried out by a atment. -
Page 20: Gas Connection
As a safety measure against gas leaks, Unical If any part of the system is concealed from view the gas recommends installing a surveillance and soundness test must be carried out before covering the pipes. -
Page 21: Connection Return And Flow System Pipes
Instructions for the installer 3.8 - FLOW AND RETURN PIPE CONNEC- TIONS The CH flow and return circuits have to be connected to the 3’’- 4” boiler via the respective connections M and R as indicated on page 9-11. When determining the size of the CH circuit pipes it is essential to bear in mind the pressure losses induced by any of the system’s components and by the configuration of the same system. -
Page 22: Primary Circuit Pump Or Boiler Pump
Instructions for the installer 3.9 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP The size of the pumps must be determined The boiler pump must have a delivery head which can ensure by installers or technical engineers the water flow rate as shown in the diagram “Water pressure according to boiler data and system design. -
Page 23: Additional Safety And Control Devices According To The Italian Law
11 Mixing bottle pressure. It must be able to be reset manually. 12 Automatic air vent. Not supplied by Unical 13 Drain cock. Not supplied by Unical. PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETY... -
Page 24: Wiring Diagram For Additional Safety Devices
Instructions for the installer 3.11 - WIRING DIAGRAM FOR ADDITIONAL SAFETY DEVICES ON-OFF PUMP MODULATING PUMP Pump management via E8 Terminals EXT-MIN to the terminal 4 (A10) interface WILO from the IV connector Boiler mains modulating pump Boiler mains supply supply 230 V 230 V... -
Page 25: Mixing Header Filter
Instructions for the installer 3.13 - MIXING HEADER FILTER UNICAL suggests the installation of a Y filter on the return pipe so that it can be cleaned if necessary. This filter will protect the boiler from the heating system dirt. -
Page 26: Boiler Freeze Protection
Heating Boiler System Circuit Circuit 1/2’’ CH RETURN CH RETURN See the Unical catalogue and the price list to identify the most convenient mixing header and 1/2’’ primary circuit. TABLE FOR THE RECOMMENDED DIMENSION OF THE HYDRAULIC COMPENSATOR 30.000 1.000 1.650... -
Page 27: Condensing Drain
Instructions for the installer 3.17 - CONDENSATE DRAIN Avoid the condensate stagnation inside the combustion The outlet of the condensate drain pipe will be on the same side of the smoke chamber, passing below the smoke cham- products evacuation system, (for this reason the evacuation ber. -
Page 28: Water Treatment
Instructions for the installer 3.18 - WATER TREATMENT We recommend that the heating system’s water pH value The chemical-physical characteristics of the filling water and is systematically controlled (minimum twice a year). In order reinstatement water in heating systems are of fundamental to do this, it is not necessary to run a chemical analysis in importance for guaranteeing correct and safe boiler operation. -
Page 29: Flue Chimney Connection
Instructions for the installer EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FOR WATER TREATMENT 1. Ball valve 2. Inspection pocket 3. Filling-up group 4. Disconnector 5. Scale reducing device 6. Litre counter (recommended) 7. “Y” filter... - Page 30 Instructions for the installer Chimney dimension Flue Gas Temperature 40°C DIN 4705 Pressure avaible 40 Pa CO levels kg/h kg/s 2520 0,700 1037 1400 1400 2160 0,600 1200 1200 1800 0,500 1000 d400 1000 1440 0,400 1260 0,350 1080 0,300 d315 0,250 0,200...
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Page 31: Operation
Then, on leaving the Max. output of a module is 108 kW. So, a SuperModulex 440 burner surface, the air/gas mixture ignites electrically and the (Nom. - Page 32 %. When the input has been determined, the boiler pump (not supplied by Unical) is set up and the fan of one thermal ele- ment is set in motion at starting speed. The gas valve opens and ignition is to occur within 5 sec. When the ionisation elec- trode detects the flame, the thermal element starts operating.
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Page 33: Electrical Connections
CEI regulations. to check the appliance’s electrical system. UNICAL refuses responsibility for any damages arising from failure to earth the boiler correctly. WARNING! -
Page 34: Functional Wiring Diagram
Instructions for the installer 3.22 - FUNCTIONAL WIRING DIAGRAM eBUS CONTROL remote MODULATION external PUMP Cascade manager) Set point Ext sens EMERGENCY SET POINT open 82°C Choose set point value as indicated in the table * (IF NECESSARY) and Ω insert resistence between Y2 (6-7). - Page 35 Instructions for the installer E.ACC 1..8 Ignition electrode 1-2 / 2-3 / 3-4 E.RIL 1..8 Ionization electrode 1-2 / 2-3 / 3-4 / 4-5 Main switch 1-2 / 2-3 / 3-4 / 4-5 / 5-6 Inserit BCM Board 1-2 / 2-3 / 3-4 / 4-5 / 5-6 / 6-7 1-2 / 2-3 / 3-4 / 4-5 / 5-6 / 6-7 / 7-8 Global Flow Temperature Sensor E8 LTLG...
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Page 36: Wiring Diagram For Connection And Managing
Instructions for the installer 3.23 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGING On the back side of the E8 regulator there are two terminal The main controls, necessary for the C.H. system manage- blocks, of which one is for the mains (230 V) connections and ment and for the boiler control, as well some components the other one is for the low tension connections. - Page 37 Instructions for the installer Sensor terminal assignments Terminal VII Connection to BCM Pin 1: eBUS (FA) or 0-10V output Pin 2: (Ground) Terminal I Buffer storage tank low sensor Buf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor) Buf.
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Page 38: Installation Examples (Functional Wiring And Connections Description)
Instructions for the installer 3.24 - INSTALLATION EXAMPLES (functional wiring and connections description) INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE Heating Circuit 1 (9-10) outdoor sensor (1) Flow sensor heating circuit 1 (10) Ground outdoor sensor (4) Pump heating circuit 1 (4) Collector pump Outside... - Page 39 Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD. (4-5) Flow sensor heating circuit 2 (1) Flow sensor heating circuit 1 (10) Ground outdoor sensor (6-7) Storage tank sensor (9-10) outdoor sensor F Ric.
- Page 40 Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION BY SOLAR PANELS (4-5) Flow sensor heating circuit 2 (1) Flow sensor heating circuit 1 (6-7) Storage tank sensor (10) Ground outdoor sensor (9-10) outdoor sensor (4) Pump heating circuit 1 (5) Pump heating circuit 2...
- Page 41 Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION F Ric. Heating Circuit 1 Heating Circuit 2 Remote Boiler Sensor Master Outside Sensor Safety devices kit Slave 1 Filter Primary system pump Safety devices kit Slave 2 Mixing Header...
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Page 42: Cascade Manager Bcm
Instructions for the installer 3.26 - CASCADE MANAGER (BCM) Application: Special functions Emergency: it avoids system shutdown caused by an The BCM completes the range of functions offered by the Modulex boilers: interruption in communication with the boiler plant’s - ON/OFF alarm control automation system: - Input for “Constant setpoint”... -
Page 43: Connections For Boilers In Cascade, Controlled By Outer Compensators
Instructions for the installer Connection for boilers in a cascade arrangement managed by a E8 heating controller with PLC supervision. MASTER CanBUS SLAVE 1 - Cascade Manager (Pos 1) Scheda PLC/BMS Modbus - System Supervisor Switch ‘’C’’ (see pag. 47) in Position II (for each boilers) SLAVE 2... -
Page 44: Verifica Regolazione Della Pressione Al Bruciatore
Instructions for the installer Connection for boilers in a cascade arrangement connected to an external BCM optional and managed by PLC/BMS (E8 disconnected). PLC/BMS board BCM board Modbus eBUS Modbus - Cascade Manager - System Manager - System Supervisor - System Monitor (Pos 0) (Pos 1÷7) Switch ‘’C’’... - Page 45 Instructions for the installer Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected) Scheda PLC/BMS Modbus SLAVE 1 - System Supervisor (Pos 1) - Cascade Manager Switch ‘’C’’ (see pag. 47) in Position 0 (for each boilers) I = Comunication by MODBUS SLAVE 2...
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Page 46: Configuration With A Modulating Pump
Instructions for the installer 3.26 - CONFIGURATION WITH A: MODULATING PUMP MODULATING PUMP he BCM board elaborates the data concerning the thermal head (Ät between primary flow and return and supplied TERMINALS 0-10 V Mains supply INTERFACE 230 V -50 Hz heat output). -
Page 47: Filling The System
UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations. - Page 48 WARNING! to the mains supply system, the gas valve must All the instructions indicated below are for the be re-calibrated. exclusive use of qualified UNICAL service technicians or installers. B) REGOLAZIONE ALLA POTENZA MINIMA A) Max output adjustment Force the desired burner working at minimum output...
- Page 49 Instructions for the installer In case of gas valve replacement or difficult ignition: Tighten the maximum adjustment screw “A” in a clockwise direction until you arrive to the abutting end, than slacken for 3 turns. Verify the boiler ignition; if the boiler goes into lockout slacken the screw “A”...
- Page 50 Instructions for the installer SERVICE MODE FUNCTION Before open the operating flap turn clock-wise Shaft encoder, to symbol pen the operating flap, Turn Turn displayed anticlok-wise anticlok-wise After 2 sec DATA/TIME SERVICE GENERAL DISPLAY is displayed level Press to open the level RELAY TEST Turn...
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Page 51: Emergency Functions
Instructions for the installer 3.29 - EMERGENCY FUNCTIONS It avoids system shutdown in case the main boiler plant’s system management is out of use. A) In position I the plant will operate when requested at “CONSTANT SETPOINT”: 70°C – Max heat output 50% B) Enables burner reset in case of lock-out TLG General Limit Thermostat: when it acts, it cuts the... -
Page 52: Lighting And Shutting Down Procedures
Failure to do so could cause injury to persons, animals or damage all the necessary ventilation conditions and minimum cle- to property. UNICAL shall not be held liable arance distances are guaranteed for subsequent servi- for any injury and/or damage. -
Page 53: Servicing Schedule
3 mm in the switch contacts (e.g.: safety devices or power switches) and make sure it cannot be switched ON acci- dentally. For this reason UNICAL recommends that a servicing con- • Switch off the gas gate valve upstream the boiler. - Page 54 Servicing schedule We recommend that periodical service is made • Remove the screws “A”, fixing the burner covers, with a 13 by qualified technical personnel according to mm socket wrengh. the frequency stated by national rules in force. As much as the dust present in the air will be sucked inside the combustion chamber, the smoke side resistance will increase, which, finally, will result in a reduced heat input (and consequently a reduced output).Before cleaning the boiler...
- Page 55 Servicing schedule • Remove the safety clip “D” of the supporting rod “E”. • Rotate the burner assembly on its rotation axis (two persons required). • Bring up the supporting rod “E” and fix it with the safety clip “D”.
- Page 56 Servicing schedule Dismantle burner procedure Warning: proceed with caution, by using gloves and a cutter. Verify the condition of the silicone gaskets; if they are glued to the aluminum body, before removing them, sprinkle on them a silicone product and leave it to act for at least 5 minutes;...
- Page 57 Servicing schedule phase – Cleaning • Remove from their seat the sealing gaskets and the bur- ners and blow them with compressed air from the convex side to the dished side. The burner sealing gaskets, must be repla- ced at each cleaning of the burner. •...
- Page 58 (dove log Pn è il logaritmo in base 10 della potenza ulile nominale del singolo generatore, espressa in kW), come richiesto dal comma 1a dell’art. 9. La Unical AG s.p.a. DECLINA ogni responsabilita’ per sinistri a persone, animali o cose derivanti da manomissioni dell’apparecchio da parte di terzi non autorizzati, ovvero da un’errata installazione, od una manutenzione o riparazione...
- Page 60 - 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...
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