Unical MODULEX EXT Series Installation And Maintenance Instruction
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Unical MODULEX EXT Series Installation And Maintenance Instruction

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moduleX eXT
100 - 116 - 150 - 200 - 250 - 300 - 350
INsTALLATION AND MAINTENANCE INsTRUCTIONs

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Summary of Contents for Unical MODULEX EXT Series

  • Page 1 moduleX eXT 100 - 116 - 150 - 200 - 250 - 300 - 350 INsTALLATION AND MAINTENANCE INsTRUCTIONs...
  • Page 2 https://www.unicalag.it/prodotti/professionale-300/commercial-condensazione-alluminio/347/modulex-ext Provisions for proper disposal of the product After decommissioning, this appliance must not be disposed of as mixed urban waste. Separate waste collection is mandatory for this type of waste, in order to allow the recovery and reuse of the materials making up the appliance.

  • Page 3: Table Of Contents

    Attention: this manual contains instructions for the exclusive use of the professionally qualified installer and/or maintenance technician in compliance with current legislation. The user is NOT qualified to intervene on 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 1 GenerAl InformATIon..............................4 General warnings ...............................4...

  • Page 4: General Information

    Any product repairs must be performed solely by personnel product and must be kept by the user. authorised by unical, using original spare parts only. failure to comply with the above can compromise the safety of the appli- ance and void the warranty.

  • Page 5: Symbols Used In The Manual

    Any other use shall be considered as misuse. 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 6: Safety Warnings

    1.5 - sAFETY wARNINGs Attention! the appliance must not be used by children. the appliance may be used by adults and only after carefully reading the operating instructions manual for the user / person in charge. Children must be supervised so they do not play or tamper with the appliance. Attention! the appliance must be installed, adjusted and maintained by profes- sionally qualified personnel, in compliance with the standards and provisions in force.

  • Page 7: Technical Data Plate

    DAnGeR! Do not use the appliance to support any object. Specifically, do not place any liquid containers (Bottles, Glasses, Containers or Detergents) on top of the boiler. If the appliance is installed inside a box, do not insert or place other objects inside it. 1.6 - TEChNICAL DATA PLATE KeY: The CE Marking...

  • Page 8: Water Treatment

    1.7 - wATER TREATMENT ATTENTION! feed water treatment prevents problems and ANY DAMAGE TO ThE BOILER CAUsED BY maintains the functionality and efficiency of the ThE FORMATION OF sCALING OR BY COR- generator over time. ROsIvE wATER wILL NOT BE COvERED BY ThE wARRANTY.

  • Page 9: Boiler Antifreeze Protection

    1.8 - BOILER ANTIFREEZE PROTECTION It is activated by default This protection can trigger only if the electricity and gas supplies are connected. If one of the two is not available and upon reset 11 (Sm) a temperature level between 2 and 5°c is detected, the appliance will behave as described in the table below, pos 2.

  • Page 10: Technical Specifications{J}And Dimensions

    TEChNICAL FEATUREs AND DIMENsIONs NOTE! Further details in the section 2.1 - TEChNICAL FEATUREs ‘‘Technical Information’’ on the boiler page of the www.unicalag.it website 2.2 - INTERNAL vIEw wITh ThE INDICATION OF ThE MAIN COMPONENTs Burner c.e. S.e. description Silicon Aluminium heat exchanger Ufly control panel condensate level sensor...
  • Page 11 note: Pf (20) and Pfmin. (19) are opposi- te as shown in the photo. for clarity, in the drawing they are indicated side by side. Global flow Sensor Smoke pressure minimum pressure Pf min switch Automatic air vent Smoke pressure switch flue gas outlet RIGHT side (supply conditions) - LEFT side and REAR side (order rear flue gas outlet kit: MODULEX eXT 100 - 116 - 150 - 200 - 250 - 300 - 350: flow rIGhT side (supply conditions) - lefT side...

  • Page 12: Dimensions

    2.3 - DIMENsIONs RIGhT sIDE vIEw (Supply conditions for right side connections) FRONT vIEw (•) modulex eXT 100 - 200 - 300 Terminal inside casing LEFT sIDE vIEw TOP vIEw Pre-cuT lefT SIde Pre-cuT lefT SIde floW Pre-cuT lefT SIde reTurn MODULEX EXT Dimensions...

  • Page 13: Operating Data

    2.4 - OPERATING DATA AND GENERAL FEATUREs For the adjustment data: NOZZLES - PRESSURE - COLLECTORS - FLOW RATES refer to the paragraph ADAPTATION TO oTher TYPeS of GAS. moduleX eXT 100 eXT 116 eXT 150 eXT 200 eXT 250 eXT 300 eXT 350 Boiler category 2h3P modulation ratio...

  • Page 14: Technical Data According To Erp Directive

    2.4.1 - TEChNICAL DATA ACCORDING TO ErP DIRECTIvE MODULEX eXT 100 eXT 116 eXT 150 eXT 200 eXT 250 eXT300 eXT 350 Element symbol Unit Effective nominal output Prated Seasonal energy efficiency of central ƞ heating Season efficiency class for heating For boilers for central heating and mixed boilers:...

  • Page 15: Determination Of The Primary Circuit Pump Or Boiler Pump

    2.4.2 - DETERMINATION OF ThE PRIMARY CIRCUIT PUMP OR BOILER PUMP The boiler pump must have head that is able to ensure the The pump is not an integral part of the boiler. pump's flow rates according to the circuit's ∆t. It is recommended to select a pump with a flow rate and head of approximately 2/3 of its characteristic curve.

  • Page 16: Instructions For The Installer

    INsTRUCTIONs FOR INsTALLATION 3.1 - GENERAL wARNINGs ATTENTION! In rooms with the presence of aggressive ATTENTION! vapours or dust, the appliance must operate This boiler is intended solely for the use it independently from the air inside the instal- was expressly designed for. Any other use lation room! is considered improper and therefore dan- gerous.

  • Page 17: Package And Weights

    3.4 - PACKAGING The boiler is supplied assembled in a sturdy cardboard box. - one box containing: Gasket between pan and terminal. After removing the two straps, remove the card- collar gasket board from the top and ensure the integrity of the Two elbows + a Tee + a plastic contents.

  • Page 18: Positioning In Boiler Room

    3.5 -POsITIONING IN ThE BOILER ROOM Special attention must be paid to the standards and local laws with regard to boiler rooms, especially the minimum distances comply with the minimum clearance distances in order to execute normal maintenance and that must be kept free around the boiler. cleaning operations.

  • Page 19: Flue Gas Exhaust Pipe Connection

    3.6 - FLUE GAs EXhAUsT PIPE CONNECTION To connect the flue gas exhaust pipe, local and national stand- The boiler is type approved for the exhaust configurations listed ards must be observed below: B23P ATTENTION ATTENTION for this type of connection, the room follows the for the C63 configuration, you must order same installation rules for boilers with natural the optional air intake kit, which contains the...

  • Page 20: Connection Reversibility

    3.7 - CONNECTION REvERsIBILITY GAs Reversibility The boiler leaves the factory ready for hydraulic, gas and flue gas outlet connections (flow and return) on the RIGHT side of the boiler. To move the gas connection to the opposite side, invert the blind flange FLUE GAs Reversibility with the flanged nozzle.

  • Page 21: Connection

    3.8 - CONNECTION G 2’’ FLOw G 2½’’ RETURN G 2½’’ Danger! The gas must be connected only by a qual- ified installer who must respect and apply the requirements set forth by relevant laws in force and by the local prescriptions of the supply company.
  • Page 22 Condensation drain The boiler, during the combustion process, produces conden- sation that, through pipe “A”, flows into the trap. into a suit- The condensation that forms inside the boiler flows able drain via pipe “B”. Danger! The outlet of the condensate drainage pipe is towards the con- Before commissioning the appliance: nection side of the flue gas box manifold, removing the pre-cut - check that the siphon is assembled correctly...

  • Page 23: Filling And Emptying The System

    3.9 - FILLING AND EMPTYING ThE sYsTEM When all system connections have been com- pleted, the circuit can be filled. To fill the system, you must provide a filling valve on the system's return. EXAMPLE OF ThE sYsTEM's LOADING UNIT loAdInG unIT To fill the system, you must provide a filling valve...

  • Page 24: Electrical Connections

    3.10 - ELECTRICAL CONNECTIONs Danger! Before performing connections or any type of operation on electrical parts, always disconnect the electrical power and make sure that it cannot be reconnected accidentally. 18:28 giov 30 10/10 °C °C °C effettiva richiesta sanitaria modulazione generator status...
  • Page 25 Electrical connection to the main power sup- Danger! ply. Only a qualified technician may perform the This connection must be made up to standard, as electrical installation. required by regulations in force. remember that a bipolar switch must be installed on the boiler power line with over 3 mm between contacts, easy to access, making maintenance quick and safe.
  • Page 26 NOTE: The boiler is set up for direct flow and storage tank Should additional services be requested (storage tanks, mixed management. areas, solar, etc), you must purchase shC multifunction kits for If stemp. ACC is connected automatically, dhW is full control through the Ufly P heating control. activated, which will have priority management with regard to direct flow through the pumps shown be- low.
  • Page 27 connections for: Y2 Bcm Y4 - Bcm modbus Bcm remote boiler control Alarm signal 3 - 4 Alarm / signal contact (no potential-free contact) A (1) data connection (**) B (2) data connection P. coll. 1 - 2 manifold pump (primary loop) P.
  • Page 29 Connection diagram example: Power supply, InAIl, modulating pump, external sensor, flow switch Menu 230 V - 50 Hz 0-10V Ext. Min mod. Y4- BCM Y3- BCM Y2-HSCP/UFLY Y1- BMM1 Y2- BCM INAIL SAFE 1.3 (T.S.) 1.1 (P. max.) 1.2 (P. min.) description InAIl - Safety bodies main electrical panel (not supplied)
  • Page 30 Connection diagram example: 2 modulex in pack managed by cascade manager primary loop Menu 230 V - 50 Hz 0-10V Ext. Min mod. (*) Note: Y4- BCM Y3- BCM Y2-HSCP/UFLY Y1- BMM1 for the cascade connection, position the selector on the Bcm in the indicated position.
  • Page 31 with direct zone and dhW production. secondary loop Stemp. P. Car. 12 11 10 9 8 7 6 5 4 3 2 1 Note: In case of installation with single boiler, the above connections must be made on the return terminal board (Bcm board) inside the boiler.
  • Page 32 Wilo Stratos modulating pump setting (ext. input enabling 0 - 10 V)

  • Page 33: Commissioning

    3.11 - COMMIssIONING commissioning must be done by professionally Before commissioning the boiler, check the following: qualified personnel. Unical will not be held liable for damage to persons, animals or objects, due to failure to comply with the aforesaid instructions.

  • Page 34: Measurement Of Combustion Efficiency During Installation

    3.12 - MEAsUREMENT OF ThE COMBUsTION EFFICIENCY DURING INsTALLATION Generator Menu 3.12.1 - CALIBRATION FUNCTION (ChIMNEY swEEP) ATTENTION! ATTENTION! These functions are explained in Function reserved for After sale chapter 2.9 (Burner menu) of the service Centres only. Ufly P. TOUCH CONTROL instal- lation and maintenance manual.

  • Page 35: Burner Pressure Adjustment

    3.13 - ADJUSTING THE BURNER The following instructions are intended exclusively All boilers leave the factory already calibrated and for authorised service personnel. tested, however, if required, recalibrate the gas valves (module 1, module 2, etc.) remove the cap and insert the co2 analysis sensor in the flue gas sample point of the intake/exhaust terminal, see chap.
  • Page 36 Follow this procedure to also adjust the other modules. If the capacity read is too low, make sure the power feed and drain system (feed and drain pipes) are not clogged. If they are not clogged, make sure the burner and/or heat ex- changer is not dirty.

  • Page 37: Control Panel / Emergency Operation And Safety Devices

    3.14 - EMERGENCY OPERATION AND sAFETY DEvICEs 18:28 giov 30 °C °C °C effettiva richiesta sanitaria 10/10 generatore modulazione status INFO MENU The Bcm prevents system shutdown if the man- noTe: agement of the Ufly system or main boiler system The devices are positioned under the casing, next is out of service to the control unit.

  • Page 38: Programming Operating Parameters

    3.15 - PROGRAMMING ThE OPERATING PARAMETERs ATTENTION! ATTENTION! These functions are explained Function reserved for After sale in chapter 2.8 (DEvICEs menu) service Centres only. of the Ufly P. TOUCH CONTROL installation and maintenance manual. Bmm parameters code Symbol description unit min.
  • Page 39 Bcm Parameters code Symbol description unit min. max. Imp. fab. enabled Services Gen: Temp. Max Differential °K 50.0 Burner hysteresis °K 20.0 ch#1: minimum Set-point °c 20.0 40.0 ch#1: maximum Set-point °c 45.0 85.0 Input 0/10V Programmable Input #1 Pump: Post-circulation min.

  • Page 40: Release And Reset Error Codes

    3.16 - ERROR CODEs fault that causes the boiler to stop: fault that does noT cause the boiler to stop: - The error code is displayed, the boiler has stopped - The error code is displayed, the boiler has a heat- running.
  • Page 41 NO AIR UPON IGNITION check that the fan head is at least 60 Pa. stop UNEXPECTED AIR FLOw Blocked min pressure switch (closed) sPEED OUT OF CONTROL check fan operation (18) and the connections Alteration of the fan speed; the speed is not reached.

  • Page 42: Inspection And Maintenance

    4.1 - INsPECTION AND MAINTENANCE INsTRUCTIONs To assure long-term functioning of your appliance and to avoid once all maintenance operations are complete altering its approved status, only original UNICAL spare parts resume boiler operation must be used. • Open the heating flow and return pipes, as well as the cold water inlet valve (if closed previously).
  • Page 43 we recommend having qualified technical personnel carry out the provisions of current regulation concerning periodic maintenance checks. Since the dust is vacuumed inside, the fl ue gas side resistance, through the boiler, increases which, eventually, will lead to a reduction of the thermal load (and, consequently, of the power). Before cleaning, check the thermal load and co percentage (see 3.13).
  • Page 44 - remove the gas valve connector - release the fan chamber fastening spring (right/left side). - remove the fan connector - remove the red silicon pipes and then the fan chamber • wiring - remove the gas pressure switch connection - release the wire ties at the top of the boiler (do noT cuT)
  • Page 45 • Element screws - remove the gas pipe fastening screws (right and - remove screws “A” for each element left sides) (with 13 mm socket wrench) - remove the four screws with a 10 mm socket wrench, then - remove the screws “B” (with 13 mm socket wrench / 13 the gas fl ange mm hex spanner) and remove the fastening plates...
  • Page 46 - Insert the dowels in the holes ”D” to support the burner block. - Slightly lift the rear burner block and remove the 2 pins using a 4 mm hex spanner, until you reach the holes “C” - lift the burner block (front part)
  • Page 47 second phase – Cleaning Third phase – Re-assembly • Remove the gaskets and the burners. • After cleaning the body and/or burners, put the burners back • Dry clean the burners by blowing compressed air from the in their seats “flame side”...

  • Page 48: Wiring Diagram

    4.2 - PRACTICAL CONNECTION wIRING DIAGRAM ALIM. VENT. ALIM. VENT. EXT 100 ÷ 350 EXT 440 ÷ 900 N° MOD. FILTER POSITION BETWEEN MOD. 2-3/4-5 intermediate / 2-3/4-5 1° Mod. 2-3/4-5/6-7 last module VM (A) VM (A) VM (A) VM (A) VM (A) VM (A) FILTER...
  • Page 49 ALIM. VENT. COLOURs Blue BroWn BlAcK Green VM (A) VM (A) GreY SKY Blue orAnGe PInK YelloW INAIL YelloW Green FILTER FILTER WhITe VIoleT VIOLA 12 11 10 9 8 7 6 5 4 3 2 1 +24V 3 4 5 6 7 10 11 12 13 14 1 2 3 4 5 6 3 4 5 6 7...
  • 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:

Modulex ext 100Modulex ext 116Modulex ext 150Modulex ext 200Modulex ext 250Modulex ext 300 ... Show all

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