Automatic Heating Modulex EXT 440, Installation And Servicing Instructions

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CONTENTS
1 GENERAL INFORMATION ................................................................................................................................................................................... 4
1.1 Symbols used in this guide .......................................................................................................................................................................... 4
1.2 Correct use of the appliance ....................................................................................................................................................................... 4
1.3 I Information to be passed over to the person in charge of the appliance ................................................................................................ 4
1.4 Safety warnings ............................................................................................................................................................................................ 5
1.5 Data badge .................................................................................................................................................................................................... 6
1.6 General warnings ......................................................................................................................................................................................... 7
2 TECHNICAL FEATURES AND DIMENSIONS ..................................................................................................................................................... 8
2.1 Technical features ........................................................................................................................................................................................ 8
2.2 Dimensions ................................................................................................................................................................................................... 9
2.3 Performance data ....................................................................................................................................................................................... 10
2.4 RHS view showing main components ....................................................................................................................................................... 11
3 INSTRUCTIONS FOR THE INSTALLER ............................................................................................................................................................ 12
3.1 General warnings ...................................................................................................................................................................................... 12
3.2 Installation standards ................................................................................................................................................................................ 13
3.3 Packaging .................................................................................................................................................................................................. 14
3.4 Installation .................................................................................................................................................................................................. 16
3.5 Boiler location in a boiler room .................................................................................................................................................................. 17
3.6 Boiler connection ....................................................................................................................................................................................... 17
3.7
Gas connection ......................................................................................................................................................................................... 18
3.8 Connection return and flow system pipes ............................................................................................................................................... 19
3.9 Primary circuit pump or boiler pump ........................................................................................................................................................ 20
3.10 Additional safety and control devices, according to the Italian Law + primary circuit kit ..................................................................... 21
3.11 Wiring diagram for additional safety devices ........................................................................................................................................... 22
3.12 Safety pressure relief valve ..................................................................................................................................................................... 23
3.13 Mixing header filter .................................................................................................................................................................................... 23
3.14 Ballstop valves .......................................................................................................................................................................................... 23
3.15 Boiler freeze protection ............................................................................................................................................................................. 24
3.16 Mixing header and plate heat exchanger ................................................................................................................................................ 24
3.17 Condensing drain ...................................................................................................................................................................................... 25
3.18 Water treatment ......................................................................................................................................................................................... 26
3.19 Flue chimney connection .......................................................................................................................................................................... 27
3.20 Flue manifold connection .......................................................................................................................................................................... 27
3.21
Operation ................................................................................................................................................................................................... 29
3.22 Electrical connections ............................................................................................................................................................................... 31
3.23 Functional wiring diagram ......................................................................................................................................................................... 32
3.24 Wiring diagram for connection and managing ......................................................................................................................................... 34
3.25 Installation examples (functional wiring and connections description) .................................................................................................. 36
3.26 Cascade manager BCM ........................................................................................................................................................................... 40
Connections for boilers in cascade, controlled by outer compensators ............................................................................................... 43
3.27 Configuration with a modulating pump ..................................................................................................................................................... 44
3.28 Filling the system ...................................................................................................................................................................................... 45
3.29 Burner Adjustment .................................................................................................................................................................................... 46
3.30 Emergency functions ............................................................................................................................................................................... 49
3.31 Initial Lightning ........................................................................................................................................................................................... 50
4 SERVICING SCHEDULE .................................................................................................................................................................................... 51
5 CE CERTIFICATE ............................................................................................................................................................................................... 56
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.
UNICAL shall not be held liable for any injury and/or damage.