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Summary of Contents for Unical MODULEX EXT 150
- Page 1 MODULEX EXT 100 - 150 - 200 - 250 - 300 - 350 INSTALLATION AND SERVICING INSTRUCTIONS...
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Page 2: 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 1 GENERAL INFORMATION ....................................3 1.1 Symbols used in this guide ................................... -
Page 3: 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 4: Safety Warnings
Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL re- commends 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 5: Standard Code For Installations
- The boiler room has a suitable outlet for the discharge of lead to system gathering in the boiler body, causing damage. condensate produce by the boiler. UNICAL recommends contacting a specialised company for water treatment. - The electrical system has been fitted in compliance to the specific norms and the work has been carried out by a Instead, if installing a Modulex boiler in a new system, it is competent person. - Page 6 General Information 1.6 - TECHNICAL DATA pLATE KEY: 1 = CE monitoring body CE marking The CE marking certifies that the boilers meet: 2 = Type of boiler 3 = Boiler model The essential requirements of the gas appliance directive 4 = Number of stars (directive 92/42 EEC) (directive 2009/142/EEC) 5 = (S.N°) Serial Number The essential requirements of the electromagnetic compat-...
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Page 7: Water Treatment
General Information 1.8 - WATER TREATMENT To minimize corrosion it is essential to use a scale inhibitor, however in order for this to function correctly, the metallic The chemical-physical characteristics of the filling water and surfaces have to be clean. reinstatement water in heating systems are of fundamental importance for guaranteeing correct and safe boiler operation. -
Page 8: General Warnings
Do not attempt to make any repairs: contact qualified technicians. Any repairs must be carried out by Unical authorized technicians and using only original spare parts. Non-observance of the above requirement may jeopardize the safety of the appliance. -
Page 9: Technical Features And Dimensions
Technical features and dimensions TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES • Monitoring of operating status and temperature. • MODULEX is a compact, gas fired, Low NO , condensing • Reporting of alarms. boiler. • Setting parameters. • made up by one sectional boiler body, suitable for a single • Relay control for the activation of a fixed speed pump boiler working or directly as cascade • Analog output 0 to 10V to control a modulating pump. -
Page 10: Rhs View Showing Main Components
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. -
Page 11: Dimensions
Technical features and dimensions 2.3 - DIMENSIONS RIGHT HAND SIDE VIEW FRONT VIEW (Delivery condition for R.H. side connection) (•) Modulex EXT 100 - 200 - 300 Flue terminal into the casing LEFT HAND SIDE VIEW UppER VIEW CH flow system Gas inlet CH safety system return Outlet condensate drain MODULEX Dimension... -
Page 12: Performance Data
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 EXT 100 EXT 150 EXT 200 EXT 250 EXT 300 EXT 350 Boiler category 2H3P 2H3P 2H3P 2H3P 2H3P 1:16,7 Modulation ratio 1:8,3 1:12,5 1:20,8 1:25 1:29 Rated heat output on P.C.I. Qn Minimum heat output on P.C.I. Qmin 97,2 341,7 Rated useful power (Tr 60 / Tm 80 °C) Pn... -
Page 13: Performance Data Erp
Instructions for the installer 2.4.1 - PERFORMANCE DATA Erp DIRECTIVE EXT 100 EXT 150 EXT 200 EXT 250 EXT300 EXT 350 MODULEX Element Symbol Unit Effective nominal output Pnominale Seasonal energy efficiency to heat ƞ the room Season efficiency class to discharge For boilers to heat the room and mixed boilers: useful heat output Useful heat output with 97,2 341,7... -
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 ag- which it has been expressively designed for. gressive vapours or dust the appliance must Any other use shall be considered improper operate independently from the air present in... -
Page 15: Packaging
Instructions for the installer Resistances kit for emergency operation 3.2 - PACKAGING Cable glands and for electrical supply The boiler MODULEX is delivered assembled - a carton box containing: and protected by a plastic bag inside a strong 4 feet of support cardboard box and fixed on pallet. -
Page 16: Removal From The Bed And Insert Foot
Instructions for the installer 3.3 - REMOVAL FROM THE BOILER BED AND INSERT FOOT Insert the 4 feet (contents into the box) Attach the feet to the chassis by 4 screws’’A’’previously Remove the casing of the boiler removed. Lift the boiler with a hoist or forklift bands Place the boiler on concrete slab and mount the casing. - Page 17 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.
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Page 18: Boiler Connection
Instructions for the installer To move the gas connection, from the 3.6 - BOILER CONNECTION R.H. side (std. delivery position) to the L.H. side, it is necessary to At its delivery the boiler MODULEX has all the connections, change each other the two flanges i.e.: C.H. flow & return, gas, and smoke outlet on its R.H. side. screwed on the gas manifold ends. -
Page 19: Gas Connection
As a safety measure against gas leaks, Unical recommends installing a surveillance and protec- If any part of the system is concealed from view the gas sound- tive system made up of a gas leakage detector ness test must be carried out before covering the pipes. -
Page 20: Connection Return And Flow System Pipes
Instructions for the installer 3.8 - FLOW AND RETURN PIPE CON- NECTIONS Non-observance of these instructions could cause injury The CH flow and return circuits have to be connected to the to persons, animals or damage to property. boiler via the respective connections 2½“ M and R as indicated The manufacturer shall not be held liable for on page 11. -
Page 21: Additional Safety And Control Devices, According To The Italian Law + Primary Circuit Kit
CONTROL DEVICES pressure. Not supplied by Unical. 13 (Pressure Indicator - not provided by Unical) with (12) Visible drain funnel. Not supplied by Unical. and shock tube (11) tap-port gauge: Indicates the actual pressure existing in the generator must be calibrated in “bar”, having the full scale of the maximum pressure rela-... -
Page 22: Mixing Header
3.11 - MIXING HEADER FILTER n order to ensure correct boiler operation it is necessary to use UNICAL suggests the installation of a Y filter a mixing header which guarantees: on the return pipe so that it can be cleaned if necessary. -
Page 23: Determination Of Primary Boiler Pump Or Boiler System Pump
Instructions for the installer 3.12 - DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP The size of the pumps must be determined by The boiler pump must have a delivery head which can ensure the installers or technical engineers according to water flow rate as shown in the diagram “Water pressure losses”. -
Page 24: Plate Heat Exchanger
Instructions for the installer 3.14 - PLATE HEAT EXCHANGER 3.15 - PRIMARY CIRCUIT WITH PLATE HEAT EXCHANGER The plate heat exchanger, conveniently dimensioned, has the SPINOX COMPO S. advantage to keep hydraulically the two circuits (primary and secondary),protecting the boiler heat exchanger water / smoke. MODULEX 100-150-200: 00361949 MODULEX 250-300-350:... - Page 25 Instructions for the installer WITH MIXING HEADER COMPO S. PREMO S. MODULEX 100-116-150: 00361944 MODULEX 100-116-150: 00362062 MODULEX 200-150: 00361945 MODULEX 200-150: 00362063 MODULEX 300-350: 00361944 MODULEX 300-350: 00362064 PREMO C. BOX COVER COMPO S MODULEX 100-350: 00362008 MODULEX 100-116-150: 00362015 BOX COPERTURA ANELLO COMPO S MODULEX 200-150: 00362014 MODULEX 100-350: 00362008 MODULEX 300-350: 00362013...
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Page 26: Condensing Drain
Instructions for the installer 3.16 - CONDENSATE DRAIN Avoid the condensate stagnation inside the combustion products be neutralized, neutralisation which can be obtained by mixing evacuation system, (for this reason the evacuation duct must the drain water coming from washing maschines, dish washing have an inclination toward the drain of at least 30 mm/m (3/8 in. -
Page 27: Flue Chimney Connection
Instructions for the installer 3.17 - CONNECTION TO THE CHIMNEY In a condensing boiler the smokes are evacuated at a very low temperature (Max about 84°C). Then it is necessary that the As PVDF (polyvinildimethylfluorure) or PPS (polypropylene chimney is perfectly impermeble to the condensate of the com- transparent simple) certified for this use. - Page 28 Instructions for the installer Esemple: Flue gas mass flow rate MODULEX 250 Modulex Flue gas mass Flue gas mass flow rate 408,6 Kg/h flow rate (max) Chimney height 25 m kg/h Chimney connection Ø 250 mm 163,4 245,2 326,9 NOTE: 408,6 The diagram supplies only indicatives values 490,3 572,0...
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Page 29: Electrical Connection
Do not touch the appliance with any wet part of your body and/or barefooted; UNICAL refuses responsibility for any damages arising from Do not pull the supply cables failure to earth the boiler correctly. Do not permit children or inexpert people to use the It is necessary that a qualified technician verifies that the elec- appliance. -
Page 30: Wiring Diagram
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. -
Page 31: Connecting Ring Primary (Supplied With Modular Pump)
Instructions for the installer CONNECTING RING PRIMARY (SUPPLIED WITH MODULAR PUMP) THERMOSTAT ON / OFF CONNECTIONS... -
Page 32: Thermostat Fbr 2 Connection (Room Sensor)
Instructions for the installer THERMOSTAT FBR 2 CONNECTION (room sensor) -
Page 33: Modulating Thermostat Connections
Instructions for the installer MODULATING THERMOSTAT CONNECTIONS... -
Page 34: Functional Wiring Diagram
Instructions for the installer 3.21 - FUNCTIONAL WIRING DIAGRAM Note: The pictures shown on the actual wiring diagram, is purely indicative. - Page 35 Instructions for the installer...
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Page 36: Wiring Diagram For Connections And Managing
Instructions for the installer 3.22 - 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 management blocks, of which one is for the mains (230 V) connections and and for the boiler control, as well some components which are the other one is for the low tension connections. - Page 37 Instructions for the installer Sensor terminal assignments Terminal assignments BCM...
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Page 38: Installation Examples (Functional Wiring And Connections Description)
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. - Page 39 Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING zONES + D.H.W. PROD. (1) Flow sensor heating circuit 1 (4-5) Flow sensor heating circuit 2 (10) Ground outdoor sensor (6-7) Storage tank sensor (9-10) outdoor sensor (4) Pump heating circuit 1 (5) Pump heating circuit 2 (6) Cylinder charging pump (7) Mixer motor heating circuit 2 OPEN...
- Page 40 Instructions for the installer Connection to seondary circuit Connection to section B (Heating circuit 1) Connection to section C (Heating circuit 2)
- Page 41 Instructions for the installer Connection to section D ( DHW ) Connection to section E (solar circuit) See Table: For the connection to a solar installation it is Expert AREA ⇒ Level SOLAR / MF ⇒ MF 4 FUNCTION = ‘’23’’ necessary to change some parameters.
- Page 42 Instructions for the installer CONNECTION BATTERY 2 MODULEX managed by an external regulator E8 (RING PRIMARY) See manual supplied E8...
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Page 43: Cascade Manager Bcm
Instructions for the installer ALTERNATE CONNECTION IN BATTERY 2 MODULEX operated by BCM (RING PRIMARY) 3.24 - CASCADE MANAGER (BCM) - Modbus: application in PLC controlled boiler plants The communication protocols enable complete system management: Application: - Control of heating request: temperature set point and modulation level The BCM completes the range of functions offered by the Modulex - Monitoring of boiler operation and temperature status boilers: - Alarm control... -
Page 44: Filling The System
Never use such a tap to drain the system, since the system dirt boiler operation. could gather in the boiler and compromise its operation. The UNICAL refuses all liability for injury to persons, system itself shall be equipped with its own draining tap, whose animals or damage to property deriving from not size depends on the system capacity. -
Page 45: Burner Adjustment
Instructions for the installer 3.27 - BURNER ADJUSTMENT WARNING! All the instructions indicated below are for the ex- clusive 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. - Page 46 Instructions for the installer Follow this procedure also for the other burners WARNING To calibrate the VG (Gas Valve) when boiler is placed in the boiler room, If the CO percentage is too low, check if the air and smoke ducts follow the procedures described in are not obstructed.
- Page 47 Instructions for the installer INJECTORS – PRESSURES MODULEX EXT: 100 - 150 - 200 - 250 - 300 - 350 Gas Type Ø Supply Diaphragm Fan Speed levels Starting pressure Injectors power [mbar] (mm) [mm] FL [% FU] FU [Hz] Gas nat. (G20) Gas nat. (G25) Propan (G31) 10,8...
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Page 48: Emergency Functions
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. Change-over Series/Parallel Emergency is active or the control is YELLOW LED = Blinking managed by PLC or BMS (communication between BMM and BCM) OK Series connection (the cascade is... -
Page 49: Lighting And Shutting Down Procedures
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: there are no water leaks;... -
Page 50: Servicing Schedule
UNICAL The law in force states that the boiler must spare parts must be used. - Page 51 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 conse- quently a reduced output).
- Page 52 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). • Wiring - Remove gas pressostat wires - Release the plastic bands fixing the harness in the upper part of the boiler (do not to cut the plastic bands)
- Page 53 Servicing schedule • Screws on thermal elements - Remove the screws “A”, fixing the burner covers, - Remove the screws gas collector (left and right side). with a 13 mm socket wrengh, - Remove the screws “B” (with a 13 mm socket or open - Remove the four screws with a 10 mm socket wrengh, wrengh) and remove the fixing plates then the gas flange...
- Page 54 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’’ Lift the burner assembly (front part)
- Page 55 Servicing schedule Second phase - Cleaning Third phase – Reassembly • Remove the gaskets and the burners. • After the cleaning of the boiler body and/or the burners, re • Perform cleaning of the burners only by blowing, with com- position the burners in their seats.
- Page 56 46033 casteldario - mantova - italia - tel. +39 0376 57001 - fax +39 0376 660556 S.p.A. 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.
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