Related Manuals for Automatic Heating Modulex EXT 100
Summary of Contents for Automatic Heating Modulex EXT 100
- Page 1 Modulex EXT 100 - 150 - 200 - 250 - 300 - 350 Modular Condensing Boiler Installation and Servicing Instructions...
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Page 2: Table Of Contents
Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accordance with the current laws in force. The end user MUST not make any alterations to the boiler. 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. -
Page 3: General Information
General Information GENERAL INFORMATION 1.1 - SYMBOLS USED IN THIS GUIDE When reading this guide particular care has to be given to the parts marked with the followings symbols: DANGER! WARNING! NOTE! Indicates serious danger Indicates a potentially dangerous Suggestions for the for your personal safety situation for the product and the user... -
Page 4: Safety Warnings
General Information 1.4 - SAFETY WARNINGS WARNING! The device should not be used by people with reduced physical, mental and sensory, experience and knowledge. These people must be well-informed and supervised during the work. Children must be supervised so they do not play with the appliance. WARNING! The installation, adjustment, and servicing of this appliance must be carried out by a competent person and installed in accordance with the current standards and regulations. -
Page 5: Data Plate
General Information 1.5 - DATA PLATE - The essential requirements of the Directive regarding 2004/108 EC electromagnetic compatibility (Directive CE Marking - The essential requirements of the Efficiency Directive The CE marking documents that the boilers satisfy: (Directive 92/42/EEC) - The essential requirements of the Directive regarding gas - The essential requirements of the low voltage Directive 2009-142 EC appliances (Directive... -
Page 6: General Warnings
General Information 1.6 - GENERAL WARNINGS In the event of failure and/or faulty functioning of the appliance, This instruction manual is an integral and indispensable part switch off the boiler. Do not attempt to make any repairs: of the product and must be retained by the person in charge contact qualified technicians. -
Page 7: Technical Features And Dimensions
Technical features and dimensions TECHNICAL FEATURES AND DIMENSIONS B) Automatic operation hour splitting-up system for each module to guarantee the best homogeneous use. C) D.H.W. production, by a priority sensor through the E8 heating controller, with loading pump storage tank . D) Output check of each module for any calibration and/or 2.1 - TECHNICAL FEATURES assistance by secret access code. -
Page 8: Dimensions
Technical features and dimensions RIGHT HAND SIDE VIEW 2.2 - DIMENSIONS (Delivery condition for R.H. side connection) P (770) FRONT VIEW LEFT HAND SIDE VIEW (P1) 705 UPPER VIEW PRE-CUT PART LEFT SIDE CH flow system Gas inlet CH safety system return Outlet condensate drain MODULEX Dimension... -
Page 9: Performance Data
Technical features and dimensions 2.3 - PERFORMANCE DATA BOILER TYPE MODULEX 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 97,2 146,1 195,2 244,5 294,0 342,2 Minimum Output (Tr 60 / Tm 80 °C) Pn min 11,7... -
Page 10: Rhs View Showing Main Components
Technical features and dimensions 2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS CONTROL PANEL GAS VALVE BURNER COVER AUTOMATIC GAS PIPE AIR VENT IGNITION GLOBAL FLOW IONIZATION NTC TEMPERAT. SENSOR LOCAL NTC SENSOR H.L. C.H. FLOW THERMOSTAT BURNER ALUMINIUM/ SILICON HEAT EXCHANGER C.H. -
Page 11: Instructions For The Installer
Instructions for the installer INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS WARNING! WARNING! In rooms where there is the presence of This boiler has to be destined for the use for aggressive vapours or dust the appliance which it has been expressively designed for. must operate independently from the air Any other use shall be considered improper present in the boiler’s location room! -
Page 12: Standard Codes For Installation
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 13: Packaging
Instructions for the installer 3.3 - PACKAGING 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 boiler, with the packaging, can go through a door of 890 mm, whereas, without packaging, it can go through a door of 770 mm. -
Page 14: Installation On Existing Systems
Instructions for the installer A > 400 mm B > 400 mm C = 100 mm Siphon D = 500 mm Give the boiler the minimum clearances as shown in the drawing, in order to be able to make the normal service and cleaning operations. -
Page 15: Boiler Connection
Instructions for the installer To move the hydraulic connections, C.H. flow & return, just 3.6 - BOILER CONNECTION one or both of them, from the R.H. side (std. delivery position) to the L.H. side, it is necessary to remove the pre-cut portion(s) At its delivery the boiler MODULEX has all the connections, of the side panel, in correspondence of which the i.e.: C.H. -
Page 16: Gas Connection
Instructions for the installer DANGER! 3.7 - GAS CONNECTION The gas connection must be carried out by a registered engineer who will have to respect and comply to the regulations in force and to The gas supply pipe must be connected to the boiler via the the requirements indicated by the local gas 1½”... -
Page 17: 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 WARNING! boiler via the respective connections 2" M and R as indicated IT IS ABSOLUTELY FORBIDDEN TO FIT ON-OFF on page 8. -
Page 18: Determination Of Primary Boiler Pump Or Boiler System 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 19: Additional Safety And Control Devices According To The Italian Law
Instructions for the installer 3.10 - ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW CERTIFICATION OF THE ADDITIONAL SAFETY DEVICES: “bar” and must have the maximum operating pressure in scale and be equipped with a 3-way valve with the connection DISPOSITIVI DI SICUREZZA for the manometer. -
Page 20: Wiring Diagram For Additional Safety Devices
Instructions for the installer PRIMARY OR BOILER CIRCUIT KIT, WITH ADDITIONAL SAFETY DEVICES 3.11 - WIRING DIAGRAM FOR ADDITIONAL SAFETY DEVICES MODULEX 100-150: (COMPO S. 00361944) (PREMO S. 00362062) (PREMO C. 00362015) ON-OFF PUMP Pump management via E8 MODULEX 200-250 to the terminal 4 (A10) (COMPO S. -
Page 21: Pressure Relief Valve Drain Pipe
Instructions for the installer 3.12- PRESSURE RELIEF VALVE DRAIN PIPE A pressure relief valve must be fitted on the flow pipe, within 0,5 m from the boiler. It must be dimensioned for the capacity of the boiler and must comply to the regulations in force, SAFETY VALVE WARNING! VISIBLE... -
Page 22: Boiler Freeze Protection
Instructions for the installer materials present in the system, and mainly with the .15 - BOILER FREEZE PROTECTION aluminum. Should the flow temperature (measured at global flow tempera- ture NTC) decrease under 7°C, the system pump is set up. Shoul WARNING temperature decrease to under 3°C, all modules will start at min. -
Page 23: Condensate 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 24: Water Treatment
Instructions for the installer 3.18 - 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 25: Impiego Come Generatore Di Tipo Stagno
Instructions for the installer 3.19 - CONNECTION TO THE CHIMNEY In a condensing boiler the smokes are evacuated at a very As PVDF (polyvinildimethylfluorure) or PPS (polypropylene low temperature (Max about 84°C). Then it is necessary that transparent simple) certified for this use. Other materials ant the chimney is perfectly impermeble to the condensate of the thicknesses are also autorized provided they can guarantee, combustion products and is made of materials corrosion resi-... - Page 26 Instructions for the installer Chimney dimension Flue Gas Temperature 40°C DIN 4705 Pressure avaible 40 Pa Portata fumi Tenore di CO kg/h kg/s 2520 0,700 1037 1400 1400 2160 0,600 1200 1200 d 400 1800 0,500 1000 1000 1440 0,400 1260 0,350 1080...
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Page 27: Operation
Instructions for the installer 3.21 - BOILER OPERATION The water’s temperature leaving the boiler (Flow) and the temperature of the water returning in the boiler (Return) are checked by global temperature sensors NTCs. The MODULEX is made of modules interconnected each other; If there is an heat demand from the heating system or from every module is composed of: the D.H.W production the boiler will be put in operation. - Page 28 Instructions for the installer When there is a heat request from the E8 controller or from a sharing system on the highest number of thermal elements, BCM (Boiler Cascade Manager), the E8 or BCM calculates each thermal element will operate at 50% output i.e. : the necessary output according to the difference between the set temperature (or the temperature calculated by the outer 200% : 4 thermal elements = 50%...
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Page 29: Electrical Connections
Instructions for the installer 3.22 - ELECTRICAL CONNECTIONS Mains electrical supply connection 230V The electric connections of the boiler are shown in the section Regulations in force named “WIRING DIAGRAMS” The gas and water feeding pipes and the CH system pipes A mains supply of 230 V –... -
Page 30: Functional Wiring Diagram
Instructions for the installer eBUS remote 3.23 - SCHEMA DI COLLEGAMENTO PRATICO (Cascade manager) Ext sens Set point open 82°C CONTROL Ω MODULATION 100 K °C PUMP Ω °C PLC / EMERGENCY Ω SET POINT °C ROSA Choose set point value as indicated Ω... - Page 31 Instructions for the installer E.ACC 1..7 Ignition electrode E.RIL 1..7 Ionization electrode Main switch Inserit BCM Board Global Flow T emperature Sensor E8 LTLG Warning lampe for the General Limit Thermostat Minimum Gas pressure swich (not supplied) 2-3 / 4-5 Reset push button 2-3 / 4-5 PV 1..7...
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Page 32: Wiring Diagram For Connection And Managing
Instructions for the installer 3.24 - 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 33 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 34: Installation Examples (Functional Wiring And Connections Description)
Instructions for the installer 3.25 - 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 This sensor can also remain unused (4) Primary pump... - Page 35 Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD. This sensor can also remain unused (1) Flow sensor heating circuit 1 (4-5) Flow sensor heating circuit 2 (10) Ground outdoor sensor Ric.
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Page 36: Connections For Boilers In Cascade, Controlled By Outer Compensators
Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION BY SOLAR PANELS necessary for mixing valve control (4-5) Flow sensor heating circuit 2 (optional) (1) Flow sensor heating circuit 1 (6-7) Storage tank sensor (10) Ground outdoor sensor (9-10) outdoor sensor (4) Pump heating circuit 1... - Page 37 Instructions for the installer INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION Ric. Heating Circuit 1 Heating Circuit 2 Outside Boiler Sensor Sensor Remote Master Safety devices kit Filter Primary system pump Slave 2 Safety devices kit Mixing Header Filter Primary...
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Page 38: Cascade Manager Bcm
Instructions for the installer 3.26 - CASCADE MANAGER (BCM) Application: Special functions The BCM completes the range of functions offered by the Emergency: it avoids system shutdown caused by an Modulex boilers: interruption in communication with the boiler plant’s - ON/OFF alarm control automation system: - Control of a modulating primary pump with the aim of - Input for “Constant setpoint”... - Page 39 Instructions for the installer Connection for boilers in a cascade arrangement managed by a external E8 SLAVE 1 MASTER CanBUS 1 for each cascade of boiler - Cascade Manager Switch ‘’C’’ (see pag. 47) in Position II SLAVE 2 BCM in series Forniture Position In this configuration, switch ‚‘‘C‘‘...
- Page 40 Instructions for the installer Connection for boilers in a cascade arrangement connected to an external BCM optional and managed by PLC/BMS (E8 disconnected). BCM board PLC/BMS board Modbus eBUS Modbus (Pos 0) - Cascade Manager - System Manager - System Supervisor - System Monitor (Pos 1÷7) Switch ‘’C’’...
- Page 41 Instructions for the installer Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected) PLC/BMS Board Modbus (Pos 0) 1 each cascade of Boiler - System Supervisor - Cascade Manager Switch ‘’C’’ (see pag. 47) (Pos 1÷7) in Position 0 (for each boilers) BCM in series...
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Page 42: Configuration With A Modulating Pump
Instructions for the installer 3.27 - CONFIGURATION WITH MODULATING PUMP TERMINALS 0-10 V Mains supply INTERFACE 230 V -50 Hz Modulating pump WILO MODULATING PUMP The BCM board elaborates the data concerning the thermal head (Ät between primary flow and return and supplied heat output). -
Page 43: Filling The System
Instructions for the installer 3.28- FILLING THE SYSTEM Warning! system itself shall be equipped with its own draining tap, whose Do not mix the CH system’s water with anti- size depends on the system capacity. The application of a freeze or anti-corrosion solutions using wrong concentrations! It could cause damage to the filter on the return pipe to the boiler is advisable. -
Page 44: Burner Adjustment
Instructions for the installer 3.29 - BURNER ADJUSTMENT WARNING! All the instructions indicated below are for the exclusive 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 45 Instructions for the installer COMPLETION OF THE BASIC ADJUSTMENTS Follow this procedure also for the other bur- ners Check the C0 values at the minimum and maximum outlet - If necessary make the required adjustments If the CO percentage is too low, check if the air and smoke ducts are not obstructed.
- Page 46 Instructions for the installer SWEEPER MODE Before open the operating flap turn clock-wise Shaft encoder, to symbol pen the operating flap, Turn Turn anticlok-wise displayed anticlok-wise After 2 sec DATA/TIME SERVICE GENERAL DISPLAY is displayed level Press to open the level Displayed RELAY TEST Turn...
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Page 47: Emergency Functions
Instructions for the installer 3.30 - EMERGENCY FUNCTIONS The BCM It avoids system shutdown in case the main boiler plant’s system E8 5064 management is out of use. YELLOW LED = Blinking Change-over Series/Parallel (communication between BMM and BCM) OK Emergency is active or the control is managed by PLC or BMS GREEN LED = ON (Active Pump) -
Page 48: Lighting And Shutting Down Procedures
Instructions for the installer 3.31 INITIAL LIGHTING PRELIMIARY CHECKS The first ignition must be carried out by a there are no water leaks; qualified technician. Failure to do so could cause injury to persons, animals or damage all the necessary ventilation conditions and minimum cle- to property. -
Page 49: Servicing Schedule
Servicing schedule SERVICING SCHEDULE To ensure the continued safe and efficient INSTRUCTIONS FOR SERVICING operation of the boiler it is highly recommended that it is checked at regular To ensure a long life to all your boiler intervals and serviced when necessary, and components and in order not to alter the that only original spare parts are used. - Page 50 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 consequently a reduced output).
- Page 51 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 52 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 53 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 54 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.
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Page 55: Ce Certificate
DISTRIBUTED BY 51 Assembly Tullamarine Vic 3043 Australia PO Box 356 Tullamarine Vic 3043 Australia Telephone +61 3 9330 3300 Facsimile +61 3 9310 5655 Email sales@automaticheating.com.au www.automaticheating.com.au...
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