Unical PELLEXIA 80 Instructions For Installation, Use And Maintenance Manual
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Unical PELLEXIA 80 Instructions For Installation, Use And Maintenance Manual

Unical PELLEXIA 80 Instructions For Installation, Use And Maintenance Manual

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PELLEXIA 80
INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

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  • Page 1 PELLEXIA 80 INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE...
  • Page 2 Attention: this manual contains instructions for the exclusive use of the pro- fessionally qualified installer and/or maintenance technician in compliance with current legislation. The system manager is NOT authorised to service the boiler. The manufacturer will not be held liable in case of damage to persons, animals or objects resulting from failure to comply with the instructions contained in the manuals supplied with the boiler.

  • Page 3: Table Of Contents

    1 GENERAL INFORMATION ....................................5 1.1 General warnings ......................................5 1.2 Symbols used in the manual ..................................6 1.3 Appropriate use of appliance ..................................6 1.4 Information for system manager .................................. 6 1.5 Safety warnings ......................................7 1.6 Technical data plate ...................................... 8 2 TECHNICAL FEATURES AND DIMENSIONS ..............................

  • Page 5: General Information

    Any product repairs must be performed solely by personnel product and must be kept by the system manager. authorised by Unical, using original spare parts only. Failure to comply with the above can compromise the safety of the appli- Read the warnings contained in this instruction booklet carefully ance and void the warranty.

  • Page 6: Symbols Used In The Manual

    The appliance is intended to operate in hot water circulation heating systems. Any other use must be considered improper. UNICAL will not be held liable for any damage resulting from improper use. Use according to the intended purposes also includes strict compliance with the instructions in this manual.

  • Page 7: Safety Warnings

    DANGER! The boiler must be serviced or repaired by professionally qualified personnel, authorised by Unical. We recommend stipulating a maintenance contract. Insufficient or irregular maintenance can jeopardise the operating safety of the appliance and cause dam- age to persons, animals and objects for which the manufacturer cannot be held responsible.

  • Page 8: Technical Data Plate

    1.6 - TECHNICAL DATA PLATE The technical data plate is adhesive and is included in the The serial number of the boiler is on the riveted plaque on document case; it must be applied by the installer on the the front plate of the body (front right top side). outside of the casing.

  • Page 9: Technical Features And Dimensions

    TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES The heat generator mod. PELLEXIA is a steel boiler operating with wood pellets, equipped with a burner fed automatically by a feeding screw which withdraws the pellets from a tank alongside it, with combustion chamber under negative pressure, suit- able for household heating.

  • Page 10: Hydraulic Dimensions And Connections

    2.2 - HYDRAULIC DIMENSIONS AND CONNECTIONS 2030 1185 Description Pos. Descrizione FLOW Sleeve Manicotto MANDATA 2" RETURN Sleeve Manicotto RITORNO 2" Flue Gas Outlet Uscita Fumi Øe 200 Safety Exchanger connection Attacco Scambiatore di sicurezza 3/4" Temperature Relief Valve sensor sheath Guaina per sensore Valvola Scarico Termico 1/2"...

  • Page 11: Technical Data

    2.4 - TECHNICAL DATA PELLEXIA 80 MODELS EFFECTIVE NOMINAL OUTPUT* (kW) 72.2 (kW) 23.9/80.1 FURNACE MIN/MAX OUTPUT 90.18 EFFICIENCY 7.6/11.5 13/9 102.6/217.1 CO 10% (mg/Nm3) 74.6/157.9 CO 13% (mg/Nm3) (mg/Nm3) 168.3/213.6 NOx 10% (mg/Nm3) 122.4/155.4 NOx 13% (mg/Nm3) 2.7/3.8 Hc 10% (mg/Nm3) 2.0/2.8...

  • Page 12: Main Components

    9. Smoke chamber inspection door 2.6 - GENERAL The main feature of the PELLEXIA heat stove is that of burning In order to provide PELLEXIA with a long lifespan, Unical advises using certified pellets. natural fuel (pellets) obtained in an environmentally-friendly way from wood industry waste (sawdust, powders).
  • Page 13 Parameter M.U. EN plus-A1 EN plus-A2 Diameter (D) 6 (± 1) 31.5 ≤ L ≤ 40 Length (L) ≤ 10 ≤ 10 Water content (M) ≤ 0.7 ≤ 1.5 Ashes (A) ≥ 97.5 ≥ 97.5 Mechanical durability (DU) Fine particles (< 3.15 mm) <...

  • Page 15: Installation Instructions

    INSTRUCTIONS FOR INSTALLATION 3.1- GENERAL WARNINGS b) Check that the chimney/flue has an appropri- ate draught, without any bottlenecks, and that no exhausts from other appliances are in- ATTENTION! serted, unless the flue has been implemented This boiler is intended solely for the use for to accommodate several utilities according to which it was expressly designed.

  • Page 16: Packaging

    Unical will not be held liable for damage to persons, animals or objects due to failure to comply with the instruction above. After having removed all packaging, make sure that the supply is complete and undamaged.

  • Page 17: Installation

    3.5 - INSTALLATION PELLEXIA is a heat generator which withdraws the combustion To make it easier to clean, there must be a clearance space air required for the combustion process directly from the environ- in front of the heat stove no less than the length of the stove ment in which it is installed.

  • Page 18: Hydraulic Connections

    3.6 - HYDRAULIC CONNECTIONS The fittings of the boiler must not take the weight of the connecting pipes of the sys- tem; suitable supporting devices should be ATTENTION! installed to do this. Before connecting the boiler to the heating system, thoroughly clean the piping with an appropriate product compliant with UNI-CTI The dimensions of the supply and return pipes for each boiler 8065, in order to eliminate metallic residue...
  • Page 19 3.6.2 - RECIRCULATION PUMP For correct generator operation, a recirculation pump must be installed in the boiler. The recirculation pump, supplied in an optional kit, must be connected as indicated in the figure. If it is not installed, besides limiting the boiler's lifespan, it will invalidate the warranty.

  • Page 20: Assembly Instructions

    3.7 - ASSEMBLY INSTRUCTIONS IMPORTANT! Before beginning the casing work, perform the hydraulic testing of the boiler and of the plant connected to it. When installing the boiler, consider the size of the pellet tank on the left side (refer to the dimensions on page 10) and leave sufficient space for loading pellets in this tank.
  • Page 21 Electric and probe connections The screw motor must be connected with the cable which is Unlatch the upper cover of the boiler, lifting it upwards. supplied already wired to the panel board. Open the panel board by undoing the five screws with a screw- To perform this connection, remove the upper protective casing of the feeding screw motor.

  • Page 22: Connection To The Flue

    3.8 - CONNECTION TO THE FLUE To connect the flue gas exhaust pipe, local and national stand- A weatherproof terminal must be used to avoid altering ards must be observed. the slight state of overpressure found in the flue (do not fit a horizontal section at the end of the pipe);...
  • Page 23 3.8.1 - EXHAUST THROUGH EXTERNAL WALL One of the installation solutions which can be adopted is that weatherproof terminal Terminale antintemperie of positioning the PELLEXIA near a perimeter wall of the home so that flue gas is discharged directly outside. Here are some guidelines from the standard UNI 7129 for this particular type of configuration: Always provide an inspection valve which allows you to...

  • Page 24: Electrical Connections

    Have professionally qualified personnel check that the electric Approvals system is adequate for the maximum power absorbed by the The UNICAL panel board for PELLEXIA boilers received the EC appliance, indicated on the data plate. Make sure in particular approval according to the standard EN 60335-1.

  • Page 25: Filling The System

    This could damage the gaskets manifolds; and cause noise during operation. make sure that all the connections are water- Unical will not be held liable for damage to tight; persons, animals or objects due to failure to after commissioning the boiler and bringing the comply with the instruction above.

  • Page 26: Hydraulic Base Diagrams

    3.11 - HYDRAULIC BASE DIAGRAMS The following diagrams are for reference only and therefore are not binding. Unical declines any responsibility for errors or omissions. 3.11.1 - SYSTEM WITH PELLEXIA BOILER FOR HEATING In this diagram, the boiler is connected only to the heating cir- triggered by the ambient chronothermostat (input 15-16 on the cuit and requires the "P3 heating system pump”...
  • Page 27 LIST OF PARAMETERS DEFAULT SETTINGS Parameter Boiler operating temperature (°C) Minimum boiler temperature (°C) Maximum boiler temperature for alarm (°C) Start temperature for filling storage tank (°C). End temperature for filling storage tank (°C). Maximum temperature for storage tank (solar protection) (°C). Thermostat control temperature tolerance band for heating (°C) Temperature tolerance band for filling storage tank (°C) Maximum temperature tolerance band for boiler body (°C)
  • Page 28 3.11.2 - PELLEXIA BOILER SYSTEM FOR HEATING AND FOR THE PRODUCTION OF DOMESTIC HOT WATER, WITH SINGLE-COIL TYPE STORAGE TANK In this diagram, the boiler is connected to both the heating sys- cause it controls the temperature and the priority of either heat- tem and to a domestic hot water storage tank;...
  • Page 29 LIST OF PARAMETERS DEFAULT SETTINGS Parameter Boiler operating temperature (°C) Minimum boiler temperature (°C) Maximum boiler temperature for alarm (°C) Start temperature for filling storage tank (°C). End temperature for filling storage tank (°C). Maximum temperature for storage tank (solar protection) (°C). Thermostat control temperature tolerance band for heating (°C) Temperature tolerance band for filling storage tank (°C) Maximum temperature tolerance band for boiler body (°C)
  • Page 30 3.11.3 - PELLEXIA BOILER SYSTEM FOR HEATING AND FOR THE PRODUCTION OF DOMESTIC HOT WATER, WITH DOUBLE-COIL TYPE STORAGE TANK + SOLAR SYSTEM In this diagram, the boiler is connected to both the heating sys- mum threshold, the control unit prioritises domestic hot water. tem and to a domestic hot water storage tank;...
  • Page 31 LIST OF PARAMETERS DEFAULT Parameter SETTINGS Boiler operating temperature (°C) Minimum boiler temperature (°C) Maximum boiler temperature for alarm (°C) Start temperature for filling storage tank (°C). End temperature for filling storage tank (°C). Maximum temperature for storage tank (solar protection) (°C). Thermostat control temperature tolerance band for heating (°C) Temperature tolerance band for filling storage tank (°C) Maximum temperature tolerance band for boiler body (°C)
  • Page 32 3.11.4 - PELLEXIA BOILER SYSTEM FOR HEATING AND FOR THE PRODUCTION OF DOMESTIC HOT WATER, WITH PUFFER This diagram shows a stratification heat storage tank for the probe detects a temperature above that of the S2 probe plus a production of domestic hot water. heat differential (normally 6°C).
  • Page 33 LIST OF PARAMETERS DEFAULT Parameter SETTINGS Boiler operating temperature (°C) Minimum boiler temperature (°C) Maximum boiler temperature for alarm (°C) Start temperature for filling storage tank (°C). End temperature for filling storage tank (°C). Maximum temperature for storage tank (solar protection) (°C). Thermostat control temperature tolerance band for heating (°C) Temperature tolerance band for filling storage tank (°C) Maximum temperature tolerance band for boiler body (°C)
  • Page 34 3.11.5 - PELLEXIA BOILER SYSTEM FOR HEATING AND FOR THE PRODUCTION OF DOMESTIC HOT WATER, WITH PUFFER + SOLAR SYSTEM probe detects a temperature above that of the S2 probe plus a This diagram shows a stratification heat storage tank for the production of domestic hot water.
  • Page 35 LIST OF PARAMETERS DEFAULT Parameter SETTINGS Boiler operating temperature (°C) Minimum boiler temperature (°C) Maximum boiler temperature for alarm (°C) Start temperature for filling storage tank (°C). End temperature for filling storage tank (°C). Maximum temperature for storage tank (solar protection) (°C). Thermostat control temperature tolerance band for heating (°C) Temperature tolerance band for filling storage tank (°C) Maximum temperature tolerance band for boiler body (°C)

  • Page 36: Panel Board

    3.12 - PANEL BOARD 3.12.1 - FRONT OF PANEL BOARD FUEL RECIRCULATION PUMP SOLAR PANELS INTEGRATION HEATING SYSTEM PUMP 8. - Warning light: Fuel feeding screw 1. - Main switch 9. - Key to access the settings and parameters configuration menu (restricted to the author- 2.
  • Page 37 3.12.2 - MAIN TECHNICAL EQUIPMENT The main features of the control unit are as follows: Probes: A microprocessor with EEPROM memory (all the settings and 4 x PTC probes with silicone insulated cable and 6 mm stain- work modes are saved in the event of a power cut). less steel tip;...
  • Page 38 3.12.4 - SELECTING THE WORK MODE (With key nr. 11) There is a two-way electronic selector switch for setting either mediately after ignition and involves the preparation of a good of two boiler work modes: bed of embers; the speed of the fan varies according to the speed - 1.
  • Page 39 3.12.5 - COMBUSTION POWER MODULATION The circuit board simultaneously performs three combustion output modulations: 1. Modulation of flue gas temperature Data available to the Technician 2. Modulation of boiler temperature 3. Modulation of burner combustion (using a photosensor). Points The modulation of the flue gas temperature limits the temper- Maximum Temp.

  • Page 40: Programming Procedure

    3.12.6 - TECHNICAL PROGRAMMING MODE (ONLY QUALIFIED PERSONNEL): Programming procedure: PHASE 1In order to configure the functional parameters, press PHASE 4 Select a parameter and press the arrow key . The and hold the button for about 6 seconds, until parameter will start flashing and you can edit it.

  • Page 41: Panel Board Electrical Connections

    3.13 - PANEL BOARD ELECTRICAL CONNECTIONS...

  • Page 42: Boiler Start-Up

    The preliminary checks must be carried out by the company Commissioning must be done by profession- who installs the system. ally qualifi ed personnel. Unical will not be held liable for damage to persons, animals After connecting the hydraulic and electrical system and the fuel...
  • Page 43 3.14.2 - START-UP IGNITION The boiler starts up automatically without the need for manual remove the grate and clean it with a steel brush. intervention. It starts up whenever the storage tank requires domestic hot Vacuum residual ashes which could be deposited below the water or the input contact of the room thermostat requires heat- grate, make sure that the side air intake holes are free and ing.

  • Page 44: Troubleshooting

    3.15 - TROUBLESHOOTING Problem: The panel board does not switch on. Remedy: Make sure the panel board is powered. Check integrity of the fuse on the board Problem: The fan does not start. Remedy: Make sure no alarm appears on the display. Check the power connection of the fan.

  • Page 45: Alarms Of The Electronic Control Board

    3.16 - ALARMS OF THE ELECTRONIC CONTROL BOARD Refer to the third page on the screen and check the status of alarms in the third line. Problem encountered Solution The boiler triggers alarm 1 Check that the bottom door is shut and check the relative con- "bottom door of burner open"...

  • Page 46: Audible Alarms

    3.17 - AUDIBLE ALARMS MAXIMUM TEMPERATURE PROBE AUDIBLE ALARM AUDIBLE ALARM The boiler has an intermittent alarm system that signals one or more faults with the probes due to these being disconnected or The boiler triggers an audible alarm when it is overheated. out of range;...

  • Page 47: Inspection And Maintenance

    To assure long-term functioning of your appliance and to avoid All maintenance must be carried out by quali- altering its approved status, only original Unical spare parts fied personnel. must be used. Yearly maintenance of the appliance is manda- tory in compliance with Laws in force.

  • Page 48: Maintenance Of The Body

    EXCHANGER BODY MAINTENANCE CLEANING AND ROUTINE MAINTENANCE Danger! Every day Before performing any maintenance on the - Fill the pellet tank boiler, make sure the boiler and its compo- nents have cooled down. Every 3 days - Remove ashes in the pan. Warnings To perform this operation, act as follows: - turn off the power at the main switch upstream of the boiler;...

  • Page 49: Maintenance Operations

    MAINTENANCE OPERATIONS Every year Feeding screw reducer Check preloading of the expansion vessel Condition of pellet feeding hose Fan: general overhaul and inspection of the state of the impeller, cleaning and lubricating the bearings, checking the direction of rotation and that the impeller spins freely Check the hermetic seal of the doors Make sure that the sealing gaskets are intact Check the operation of the safety devices...
  • Page 52 46033 casteldario - mantova - Italy - tel. +39 0376 57001 - telefax +39 0376 660556 S.p.A. info@unical-ag.com - export@unical-ag.com - www.unical.eu Unical will not be held responsible for possible inaccuracies due to transcription or printing errors. It reserves the right to modify its products as deemed necessary or useful, without jeopardising their essential features.

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