Unical AIREX Series Installation And Maintenance Instructions Manual
  1. Manuals
  2. Brands
  3. Unical Manuals
  4. Boiler
  5. AIREX Series
  6. Installation and maintenance instructions manual
Unical AIREX Series Installation And Maintenance Instructions Manual

Unical AIREX Series Installation And Maintenance Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

AIREX
150 - 200 - 200 UK
INSTALLATION AND MAINTENANCE INSTRUCTIONS

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AIREX Series and is the answer not in the manual?

Questions and answers

Related Manuals for Unical AIREX Series

Summary of Contents for Unical AIREX Series

  • Page 1 AIREX 150 - 200 - 200 UK INSTALLATION AND MAINTENANCE INSTRUCTIONS...

  • Page 2: Table Of Contents

    General Information TABLE OF CONTENTS 1 GENERAL INFORMATION ....................................3 1.1 Symbols used in the manual ..................................3 1.2 Appropriate use of appliance ..................................3 1.3 Water treatment ......................................3 1.4 Information for system manager ................................... 3 1.5 Safety warnings ......................................4 1.6 Technical data plate ......................................

  • Page 3: General Information

    The appliance is intended to operate in hot air circulation heating systems. Any other use must be considered improper. UNICAL shall not be held liable for any damage resulting from improper use; in this case the user is fully responsible for the risk.

  • Page 4: Safety Warnings

    General Information 1.5 - SAFETY WARNINGS ATTENTION! The appliance must be installed, adjusted and maintained by professionally qualified personnel, in compliance with standards and provisions in force. Incorrect installation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible. DANGER! NEVER attempt performing maintenance or repairs on the boiler on your own initiative.

  • Page 5: General Warnings

    Any repairs must be performed solely by personnel authorised by as they provide important guidelines regarding installation, use Unical using original spare parts only. Failure to comply with the and maintenance safety. above can jeopardise the safety of the appliance.

  • Page 6: Technical Features And Dimensions

    Technical features and dimensions TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES The heat generator mod. AIREX is a steel boiler running with • Intermediate door complete with combustion air adjustments. natural wooden logs, total gasification, flame inverted, with • Lower door covered with refractory material and equipped the combustion chamber under negative pressure, suitable for with flame sight glass.
  • Page 7 Technical features and dimensions MODELS AIREX 150 AIREX 200 AIREX 200 UK (kW) MAXIMUM NOMINAL OUTPUT* 149,3 199,7 MAXIMUM NOMINAL INPUT (kW) 166,8 223,4 DIMENSIONS (mm) 2201 2461 (mm) (mm) 1679 1939 (mm) (mm) (mm) (mm) (mm) (mm) (mm) 1851 2111 CONNECTIONS T1 UNI 1092-1 PN16...

  • Page 8: Main Components

    REVERSED FLAME COMBUSTION Everybody knows that to make a match last it must be held with Unical has already used this principal for many years with the its head upwards. This is because it is necessary that the flame, GASOGEN boiler.
  • Page 9 Technical features and dimensions AIREX BOILER STRUCTURE The hydraulic system inside the boiler is designed in such a way that a thermostatic system always keeps the temperature of the water surrounding the wood storage high so as to eliminate the dangerous phenomenon of condensation. The boiler body is composed of two elements placed inside the other, so that between the two a cavity of water (fig.3) is formed.
  • Page 10 Technical features and dimensions REFRACTORY BURNER (4) The burner is made up of refractory stone (fig. 3, pos. 4). This stone has a rectangular central opening through which the flame passes. The embers lie directly on the stone which divides the fire wood storage from the lower combustion chamber.

  • Page 11: Installation Instructions

    Installation instructions INSTALLATION INSTRUCTIONS 3.1 - GENERAL WARNINGS ATTENTION! The appliance must be installed by a qualified technician with the technical-professional ATTENTION! requirements according to law, which This boiler is intended solely for the use for under his own responsibility, guarantees which it was expressly designed.

  • Page 12: Installation Standards

    Installation instructions 3.2 - INSTALLATION STANDARDS AIREX it is a boiler designed to run with firewood. This appliance must be installed according to that indicated by standards in force in the country where the boiler is installed.

  • Page 13: Packaging

    Unical will not be held liable for damage to persons, animals or objects due to failure to comply with the instruction above. fig. 8 Description of packs: 1.

  • Page 14: Assembly

    Installation instructions 3.5 - ASSEMBLY The AIREX boiler does not differ from a normal solid fuel fired boi- ler; therefore there are no particular installation codes of practice other than the safety provisions foreseen by standards in force. The installation room must be properly ventilated by openings with a total surface of at least 0.5 m².

  • Page 15: Connecting To Safety Heat Exchanger Drain

    Installation instructions 3.7 - CONNECTING TO SAFETY HEAT EXCHANGE DRAIN Solid fuel fired boilers must be installed with the safety devices foreseen by relevant laws in force. For this purpose, AIREX boilers are fitted with a safety heat exchanger. The installer must fit a heat discharge valve on this safety heat exchanger, with the control bulb inserted in the bulb holder placed on the rear wall of the AIREX boiler.

  • Page 16: Assembly Instructions

    Installation instructions 3.9 - ASSEMBLY INSTRUCTIONS Fan assembly Fit the fan to the smoke chamber. IMPORTANT! Before installing the fan, check the perfect tightness of the bypass cover which links the wood storage directly with the smoke chamber. To do this, with the wood loading door open, act manually on the control rod of the bypass simulating closing of the door and make sure there is no gap.
  • Page 17 Installation instructions Fitting body insulation - Fit the front insulation of the body making a suitable cut near the upper flow connection and upper expansion vessel connection. Fit the insulation with straps is described in fig. 14. - Fit the rear insulation of the body making a suitable cut near the lower return pipe connection.
  • Page 18 Installation instructions Assembling turbulator control lever mechanism and microswitch - Fit the extension of the turbulator cleaning lever mechanism (pos. 1). - Fit the microswitch (pos. 2) to the bracket making sure it makes correct contact with the plate at the upper wood loading door opening;...
  • Page 19 Installation instructions fig. 16 fig. 17...
  • Page 20 UNICAL, to help its customers, has therefore developed a hydraulic kit for recirculation that enhances the function of the circulating water in the boiler.

  • Page 21: Flue Connection

    Installation instructions 3.10 - FLUE CONNECTION Use only exhaust pipes suitable for the type To connect the flue gas exhaust pipe, local and national standards of fuel used. must be respected (see Standards UNI-CIG 7129 point 4 and The supplier will have no contractual or 7131 point 5).

  • Page 22: Filling The System

    The pressure gauge fitted on the system allows Unical will not be held liable for damage to you to read circuit pressure. persons, animals or objects due to failure to comply with the instruction above.

  • Page 23: Indicative Hydraulic And Electric Diagrams

    INDICATIVE HYDRAULIC AND ELECTRIC DIAGRAMS The following diagrams are for reference only and therefore are not binding. Unical declines any responsibility for errors or omissions. Systems with AIREX boiler. Production of water for central heating system with temperature control by means of manual mixer valve (or electric managed by supplementary heating controller).
  • Page 24 Installation instructions SONDA FLUE GAS FUMI PROBE WOOD BOILER CALDAIA A LEGNA fig. 22 KEY: recirculation pump (if not installed, the warranty is null and void) manual zone mixer valve (or electric, managed by supplementary heating controller) heating system pump open expansion vessel heating system distribution (loading) thermal discharge valve probe...
  • Page 25 Installation instructions LIST OF PANEL BOARD PARAMETERS code 44913 x diagram fig. 22 DEFAULT SETTABLE Parameter VALUES VALUES 80 °C 65÷85 °C Boiler working temperature 60 °C 55÷60 °C Minimum boiler temperature for pumps Pi and Pb 88 °C Temperature at which acoustic alarm starts (not blocking) Temperature for starting loading buffer or DHW storage tank 45 °C 45÷50 °C...
  • Page 26 Installation instructions System with OH boiler and DOMESTIC HOT WATER single or double coil STORAGE TANK with SOLAR PANELS. Production of water for central heating system with temperature control by means of manual mixer valve (or electric managed by supplementary heating controller). if the temperature detected by probe S4 is greater than that The panel board of the AIREX boiler automatically manages detected by probe S3 plus the PARAMETER 6 (storage tank...
  • Page 27 Installation instructions S1 S2 S3 S4 S5 VENTILATORE POWER SUPPLY ALIMENTAZIONE 230V ~ 50Hz SONDA FLUE GAS FUMI PROBE DOMESTIC HOT CALDAIA A LEGNA WOOD BOILER PRODUTTORE ACQUA WATER PRODUCER CALDA SANITARIA fig. 25...
  • Page 28 Installation instructions LIST OF PANEL BOARD PARAMETERS code 44913 x diagram fig. 24 DEFAULT SETTABLE Parameter VALUES VALUES 80 °C 65÷85 °C Boiler working temperature 60 °C 55÷60 °C Minimum boiler temperature for pumps Pi and Pb 88 °C Temperature at which acoustic alarm starts (not blocking) Temperature for starting loading buffer or DHW storage tank 45 °C 45÷50 °C...
  • Page 29 Installation instructions System with AIREX boiler and DOMESTIC HOT WATER immersion and coil STORAGE TANK with SOLAR PANELS. Production of water for central heating system with temperature control by means of manual mixer valve (or electric managed by supplementary heating controller). With this type of configuration, operation of the system pump is When a “COMBI”...
  • Page 30 Installation instructions S1 S2 S3 S4 S5 VENTILATORE ALIMENTAZIONE POWER SUPPLY 230V ~ 50Hz SONDA FLUE GAS FUMI PROBE WOOD BOILER CALDAIA A LEGNA SCAMBIATORE AD STORAGE TANK fig. 27 ACCUMULO HEAT EXCHANGER (TANK in TANK) (TANK in TANK)
  • Page 31 Installation instructions LIST OF PANEL BOARD PARAMETERS code 44913 x diagram fig. 26 DEFAULT SETTABLE Parameter VALUES VALUES 80 °C 65÷85 °C Boiler working temperature 60 °C 55÷60 °C Minimum boiler temperature for pumps Pi and Pb 88 °C Temperature at which acoustic alarm starts (not blocking) Temperature for starting loading buffer or DHW storage tank 45 °C 45÷50 °C...

  • Page 32: Installation / Supply Of Panel Board (Code 41156)

    Installation instructions INSTALLATION / SUPPLY OF PANEL BOARD (code 44913) GENERAL FEATURES AND STANDARD SUPPLY: Microprocessor circuit board with alphanumerical four line LCD display, keyboard and 6 indicator lights indicating activation of servomechanisms. EPROM non-volatile memory (in case of a power outage, all settings remain valid). Memorised data remains in the memory for about 10 years without power.
  • Page 33 Installation instructions USER INTERFACE: The front display of the board provides direct reading of the temperature and operating status of the boiler; you may use the keyboard to scroll the screens to check the operating conditions according to the following writings: 1 “Solar Panels”...
  • Page 34 Installation instructions The following are the functions of the individual indicator lights: solar panel pump indicator light boiler / storage tank loading pump indicator light heating pump indicator light boiler recirculation pump indicator light free indicator light auxiliary boiler indicator light (gas / diesel oil). FUNCTIONS OF CONTROL SWITCHES / KEYS: Pressing the switch powers the panel and all the operations connected to it.
  • Page 35 Installation instructions 5.1 - ELECTRICAL CONNECTIONS on the boiler power line with over 3 mm between contacts, easy to access, making maintenance quick and safe. General warnings The power cable must be replaced by authorised technical per- sonnel. Failure to comply with the above can The electrical safety of the appliance is guaranteed only when jeopardise the safety of the appliance.
  • Page 36 Installation instructions LOADS CONNECTION AND PANEL BOARD POWER SUPPLY 9 10 11 12 13 14 15 16 Alimentazione 230 Vac POWER SUPPLY 230 Vac WIRING INTERFACE INTERFACCIA CABLAGGIO IN 230Vac BRUCIATORE Ventilatore Non usato Pompa Pompa Pompa Pompa BURNER Fixed or Not used Boiler C.H.
  • Page 37 Installation instructions TECHNICAL PROGRAMMING MODE (ONLY QUALIFIED PERSONNEL): Programming procedure: PHASE 1 To enter programming of functional parameters, keep the key pressed for about 8 seconds until the writing “PROGRAMMING MODE” appears. PHASE 2 As soon as you have entered the program, on the subsequent screen it will be possible to see the first parame- (Parameter 0) with the value programmed in the memory.
  • Page 38 Installation instructions MODULATION OF COMBUSTION OUTPUT: The circuit board simultaneously performs two combustion output modulations: 1 Modulation of flue gas temperature. 2 Modulation of boiler temperature. The modulation of the flue gas temperature limits the temperature of the flue gas leaving the flue. The limitation is defined by parameter n°...
  • Page 39 Installation instructions ALARM DIAGRAM AND TROUBLESHOOTING: Probe alarm signal: In case of failure or disconnection of one or more temperature probes, the control unit signals that they are missing indicating the number of the missing probe by a short beep of the buzzer. To eliminate the problem, check the connection of the probe and/or replace it.

  • Page 40: Starting The Boiler

    Commissioning must be done by professionally qualified personnel. Information for system manager Unical will not be held liable for damage to persons, animals or objects due to failure to comply with the instruction above. The system manager must be instructed concerning the use and operation of his heating system, in particular: •...

  • Page 41: Firewood

    Installation instructions 6.2 - FIREWOOD Wood is formed mainly by cellulose and lignite. Resinous trees are, normally, second-rate quality fuels. It also contains other substances, such as resin Wood is therefore an extremely heterogeneous fuel, due to (fir - pine), tannin (oak - chestnut) and, obviously, a different essences (beech, oak, fruit, resinous), different moisture large quantity of water.

  • Page 42: Starting

    Installation instructions 6.6 - STARTING It is necessary to use wood logs with the length stated in the previous paragraph. IGNITION Place the new wood logs as described above. Make sure that the controls referred to in point 6.5 have been performed. Close the bottom door and power the control board.

  • Page 43: Combustion Air Adjustment

    Installation instructions 6.7 - COMBUSTION AIR Example n. 2 Very inflammable wood logs CONTROL S - Completely open. P - Slightly closed in order to keep gasification reduced, but PRIMARY AND SECONDARY AIR sufficiently open to evacuate the ash that can close the ADJUSTMENT combustion head.

  • Page 44: Warnings

    Installation instructions 6.9 - WARNINGS HOW TO AVOID CORROSION IN THE WOOD STORAGE COMPARTMENT The use of wood with a high moisture content (higher than condensates and, combining with other combustion products, about 25%) and/or loads not proportioned to the originates corrosion of the metallic parts.

  • Page 45: Eliminating Faults

    - Make sure voltage reaches the power connector on the any other interventions and contact an main board. authorised UNICAL After-Sales Service. - Use a tester to check electric continuity in the fuse. Problem: - The fan does not start.

  • Page 46: Inspections And Maintenance

    Unical spare parts must be used. its long life. Maintenance of the appliance is mandatory in compliance with Laws in force.
  • Page 47 Inspections and maintenance Boiler body maintenance - If the boiler continues to operate badly, even after having cleaned it as described above, the cause can be attributed to bad distribution of the secondary air. Danger! Before performing any maintenance, make In this case: sure the boiler and its components have 1) Check the adjustment of the air setting, according to the...
  • Page 48 Inspections and maintenance Remount the upper rear casing cover. Switch the boiler back on. Cleaning primary and secondary air distributor Open the front intermediate door and clean the inner space carefully from tarry residues, dust and wood flakes which have entered through the primary and secondary air holes.
  • Page 49 Inspections and maintenance Components to check during yearly inspection Component Solution of problem Replace if necessary Cast iron fire bars and steel grates Primary and secondary air inlets Clean if necessary Bypass disc sealing Replace bypass disc if necessary Integrity of the wood storage refractory insulation bottom Repair with refractory kit if necessary Integrity of refractory catalysts Replace if necessary...
  • Page 50 Inspections and maintenance...
  • Page 51 Inspections and maintenance...
  • Page 52 - export@unical-ag.com - www.unical.eu Unical shall not be held liable for any inaccuracies due to transcription or printing errors. Furthermore, it reserves the right to modify its products as deemed necessary or useful, without aff ecting their essential features.

This manual is also suitable for:

Airex 150Airex 200Airex 200 uk

Table of Contents