Unical Alkon Cargo 35 Installation Manual Download | Manualshive

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Instructions for the installer

3.9 - FLUE OUTLET INSTALLATION

The flue system must be installed in accordance with the local
and national Standards (refer to Standard UNI-CIG 7129, point
4 and UNI-CIG point 5)

We recommend using only original UNICAL
flue outlet systems.
Damages caused by installation errors and for
non-observance of the instructions given by
the same manufacturer will invalidate all the
supplier’s contractual or extra contractual re-
sponsibilities.

If the boiler has to be replaced ALWAYS replace the flue
outlet system.

The boiler has been approved for the following flue configura-
tions:

Type C13

Boiler designed for connection to horizontal inlet and outlet
terminals, which admit fresh air to the burner and discharge
the products of combustion to the outside through concentric
or twin ducts.
The minimum distance between the inlet air duct and the flue
outlet duct must be of 250 mm and both terminals must be
positioned within a 500 mm square section.

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Type C33

Boiler designed for connection to vertical inlet and outlet ter-
minals, which admit fresh air to the burner and discharge the
products of combustion to the outside through concentric or
twin ducts.
The minimum distance between the air inlet duct and the flue
gas outlet duct must be of 250 mm and moreover both termi-
nals must be positioned within a 500 mm square area.

Type C43

Boiler designed for connection to collective flue systems inclu-
ding two ducts, one for the air inlet and the other for the di-
scharge of products of combustion through concentric or twin
ducts.

Type C53

Boiler with separate air inlet and products outlet. These ducts
can discharge into areas with different pressure.

The two terminals must not be fitted on to two opposite
walls.

Type C83

Boiler designed for connection to a terminal for the intake of
combustion air and to an individual or collective chimney for
the discharge of the products of combustion.

The chimney must comply to the current regulations.

Type B23

Boiler designed to be connected to an open flue which will
terminate vertically through the roof. The combustion air is
withdrawn directly from the room where the boiler is installed.

WARNING: for this type of connection the room must comply
with the same installation regulations valid for open chimney
boilers.

The chimney must comply to the current regulations.

Type C63

Boiler designed for connection to a combustion air inlet and
flue products discharge system approved and sold separately.

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Summary of Contents for Alkon Cargo 35

Page 1: ...ALKON CARGO 35 INSTALLATION AND SERVICING MANUAL 00332603 2nd edition 04 2008 ...

Page 2: ... 24 Connection to mains supply 230V 24 Access to the terminal block and external connections 24 3 11 Wiring diagrams 26 27 3 12 Filling the system 28 3 13 Initial lighting 29 3 14 Burner pressure adjustment 30 3 15 Gas conversions 32 3 16 Programming the operating parameters 33 3 17 Description of the heating controller s operating menus and operating levels 35 3 18 Commissioning procedure 36 4 MA...

Page 3: ...the one you really require We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently on the basis of the lime scale found this period can be extended to two years 1 4 INFORMATION TO BE HANDED OVER TO THE USER 1 GENERAL INFORMATION The user has to be instructed on the use and operation of his heating system in particula...

Page 4: ...nstructive components which influence the appliance s safe operation WARNING When tightening or loosening the screw pipe connections use only adequate fork spanners The improper use and or the use of inadequate equipment can cause damages for example water or gas leaka ges WARNING Indications for appliances operating with propane gas Ensure yourself that before installing the appliance the gas tan...

Page 5: ...ective 73 23 CEE LEGEND 1 P I N Product identification number 2 Boiler type only if condensing boiler 3 S N Serial number 4 Year 5 Boiler model 6 Approved fluing configurations 7 Number of stars Directive 92 42 CEE 8 Pn Nominal output 9 Pcond Condensing nominal output only if condensing boiler 10 D Specific D H W flow rate according to EN 625 11 Qn Nominal heat input 12 Qnw Nominal heat input in D...

Page 6: ...servicing switch off the electrical supply to the boiler by means of the ON OFF switch and or by means of the appropriate shutdown devices Do not obstruct the inlet outlet terminals In the event of failure and or faulty functioning of the applian ce switch off the boiler Do not attempt to make any repairs contact qualified technicians Any repairs must be carried out solely by Unical authorized tec...

Page 7: ...E and D P R 660 moreover they are classified in class 5 for their N0x emission levels according to the Standard EN 297 and 483 DESCRIPTION OF COMPONENTS AND FEATURES Primary silicon aluminium heat exchanger 150 litre enamelled vertical storage tank with an helicoidal heat exchanger Control and management microprocessor E8 heating controller for adjusting the heat loads and data communication to th...

Page 8: ...tem flow mixed zone control 2 optional R1 System return mixed zone control 1 R2 System return direct zone control R3 System return mixed zone control 2 optional G Gas inlet C DHW outlet F Cold water inlet Ri Recycle VSS DHW safety valve 7 bar VSR CH safety valve 3 bar S Condensate drain outlet R1 R2 G R3 M1 M2 M3 C VSS Ri VSS F ...

Page 9: ...fan 3 way valve motor Manifold flow Mixed zone control circulation pump Direct zone control circulation pump Filling system cock Central heating circuit safety valve Manifold return System discharge valve Storage cylinder discharge valve Storage cylinder DHW expansion vessels Mixing header discharge valve Mixing header Gas valve Modulating pump Diverter valve motor Condensate drain siphon Automati...

Page 10: ...iverter valve 22 Return manifold 23 Storage cylinder 24 Storage cylinder sensor 25 DHW safety valve 26 System discharge valve 27 Storage cylinder discharge valve 28 Filling cock 29 DHW expansion vessels 30 Central heating circuit safety valve 31 CH expansion vessel 2 4 BOILER WATER CIRCUIT G M M M1 M2 M3 R1 R2 R3 C F 30 10 29 19 28 18 16 14 13 12 11 9 8 20 26 24 23 22 21 6 4 3 31 2 1 2 M1 System f...

Page 11: ...g h mg kWh mg kWh Appliance s family gas category Min water flow rate in CH circuit t 20 C Min pressure in CH circuit Max pressure in CH circuit Water content in primary circuit Max operating temp in CH mode Min operating temp in CH mode Total volume CH expansion vessel Expansion vessel charge pressure Max water content CH circuit calculated for a max temp of 90 C Min flow rate DHW circuit Min DHW...

Page 12: ...This is verifiable via the indication on the packaging and on the data badge c Check that the chimney flue pipe has an adequate draught does not have any con strictions and that no other appliance s flue outlets have been fitted unless the chim ney is serving more than one heating ap pliance according to the specific standards and regulations in force The connection between the boiler and chimney ...

Page 13: ...ulations published in the official publications as well as all the applicable co des of practice The installation must be carried in accordance to the codes of practice the regulations and the requirements hereby indica ted which constitute an indicative list but not a complete one as these continue to undergo developments National installation regulations Gas plants for domestic use fed by networ...

Page 14: ... the room where the appliance has been installed The appliance must be installed exclusively on a vertical and solid wall capable of adequately supporting the weight of the boiler Leave a clearance of at least 100 mm on each side of the boiler to facilitate subsequent servicing VIEW ON WALL C Hot water outlet F Cold water inlet G Gas supply M1 System flow zone 1 MIXED M2 System flow zone 2 DIRECT ...

Page 15: ...g and subsequently proceed to vent device by device Check with the gas cock turned off that there are no gas leaks During the 2nd quarter of the hour from the start of the test no pressure drop should be detected by the pres sure gauge Any gas leaks must be found by using only water soap solutions or an equivalent product and elimi nated Never look for gas leaks using a naked flame DANGER The gas ...

Page 16: ...osses induced by the radiators any eventual thermostatic radiator valves lockshield valves and by the heating system s layout The routing of the piping has to be laid down taking all the necessary precautions in order to avoid air locks and to facilitate the continuous purging of the system Ensure yourself that the system s piping is not used as earth clamps for the electrical or telephonic system...

Page 17: ...80 240 300 360 420 480 540 600 0 TEMPERA TURE C TIME secs DOMESTIC HOTW ATER PRODUCTION Cold water inlet 9 C draft off at 15 l min Note The pressure in the system must be between 1 and 3 bar if the pressure is higher fit a reducing pressure valve WARNING The hardness of the mains water supply conditions the frequency with which the DHW heat exchanger is cleaned In hard water areas the opportunity ...

Page 18: ...ent the end user utilizing the condensate produced a siphon must be fitted supplied with the boiler there must be no bottlenecks it must be installed so as to avoid freezing of the liquid when the boiler is operating and prevent the eventual pres surization of the sewage system consent the correct downflow of the appliance s liquid di scharges it must be made with one of the following materials wh...

Page 19: ...e the products of combustion to the outside through concentric or twin ducts The minimum distance between the air inlet duct and the flue gas outlet duct must be of 250 mm and moreover both termi nals must be positioned within a 500 mm square area Type C43 Boiler designed for connection to collective flue systems inclu ding two ducts one for the air inlet and the other for the di scharge of produc...

Page 20: ...ype C13 The minimum allowable length of the horizontal concentric pi pes is of 0 75 metres The maximum allowable length of the horizontal concentric pipes is of 3 5 metres For each elbow added the maximum length permitted has to be reduced by 1 metre FLUE OUTLETS WITH CONCENTRIC DUCTS Ø 60 100 mm Important the outlet inlet flue has to have a minimum inclination of 3 towards the top in the outlet d...

Page 21: ...as to have a minimum inclination of 3 towards the top in the outlet direction so as to enable the collection of any condensate formed in the boiler Type C33 The maximum allowable length of the vertical concentric pi pes is of 8 5 metres including the terminal Ø 80 125 For each elbow added the maximum length permitted has to be reduced by 1 metre FLUE OUTLETS WITH CONCENTRIC DUCTS Ø 80 125 mm Impor...

Page 22: ...SC0130C or TSC0150C 120 Ø 80 303 5 12 5 FLUE OUTLET WITH SEPARATE DUCTS Ø 80 mm The maximum pressure loss permitted independently from the type of installation must not exceed the value of 100 Pa It is not permitted to position the two termi nals on opposite walls ...

Page 23: ...oss is of 1 5 Pa in the combustion product outlet For the Ø 80 L 1 horizontal combustion air inlet terminal the pressure loss is of 3 5 Pa For the Ø 80 L 1 horizontal combustion products outlet terminal the pressure loss is of 5 5 Pa For the vertical flue outlet duct Ø 80 L 1 the pressure loss is of 8 Pa Note These values refer to flue systems made with original UNICAL non flexible and smooth pipe...

Page 24: ...and or extension cords is strictly forbid den The use of any power supplied equipment implies the obser vance of several fundamental rules such as Do not touch the appliance with any wet part of your body and or barefooted Do not pull the supply cables Do not expose the boiler to sunlight rain etc unless it is explicitly foreseen Do not permit children or inexpert people to use the ap pliance Conn...

Page 25: ...esent on the electrical panel carrying out the following operations Remove the grommet 1 Unscrew the ring nut 2 Remove the plastic tap 3 Insert the cable 4 Wire the electrical connections onto the terminal strip Replace the grommet 1 in its housing Tightly close the ring nut 2 to block the cable Remove 1 2 3 4 ...

Page 26: ...or SRR CH return temperature sensor SZ1 Temperature sensor zone 1 SZ2 Temperature sensor zone 2 optional TA Room thermostat TA Z1 Room thermostat zone 1 TA Z2 Room thermostat zone 2 optional TL Overheat safety thermostat TRASF ACC Ignition transformer VG Gas valve VM Modulating fan 2 1 VM ORANGE BLACK BROWN PWM BLUE TACHO 4 5 LIGHT BLUE N 1 3 BROWN L1 2 RIL REG ALIM 230V SRR SR TL BLACK WHITE GREE...

Page 27: ...T1000 F14 F13 1 2 V SPF F12 F11 VF AF KF SPF VF F9 F8 F6 F5 F3 F2 F1 FBR eBUS FA 0 10 V 1 2 I VII 6 7 8 9 10 1 2 3 4 5 1 2 1 N L1 L1 BROWN LIGHT BLUE L1 N Mains supply 230 V 50 Hz LIGHT BLUE BLUE MODULAZ BROWN BROWN YELLOW GREEN PM RED GREEN WHITE MDV 2 3 6 2 3 6 RED BROWN WHITE GREEN WHITE GREEN BROWN BROWN BLUE RED BLUE YELLOW GREEN YELLOW GREEN BLUE BLUE BLUE YELLOW GREEN SE TA Zone 1 TA Zone 2...

Page 28: ...s lower use the filling cock on the boiler to adjust the pres sure This operation must be carried out when the sy stem is cold Use the pressure gauge fitted on the boiler to read the system s pressure value NOTE If the boiler has not been fired for a long period the pump could be jammed Before firing the boi ler it is important to carry out the following un jamming operation place a cloth undernea...

Page 29: ... subsequent servicing in case the boiler is sited in a cupboard compartment or in a narrow space Lighting and shutting down procedures For lighting and shutting down the boiler refer to the USER S INSTRUCTIONS GUIDE Information to be passed on to the user The user must be instructed on the use and operation of his boiler and in particular detail Hand over to the end user the booklet USER S INSTRUC...

Page 30: ...y pressing the DECREASE key again the boiler will operate at the minimum output led 1 blinking MAXIMUM OUTPUT ADJUSTMENT SCREW 1 The chimney sweeper mode remains active for 15 minutes To disenable the chimney sweeper mode befo re this time has elapsed press the INCREA SE and DECREASE keys simultaneously led 1 Off Check that the C02 values are within the values indicated in the table Burner pressur...

Page 31: ...case of gas valve replacement or diffi cult ignition Screw down the maximum adjustment screw A in a clockwise direction until it comes to its terminal point than unscrew it for 3 turns Check boiler ignition if the boiler goes into lockout loosen the screw A again of one turn than attempt to fire the boiler once again If the boiler goes into lockout again carry out the above indicated operations un...

Page 32: ...o operate only with the new gas type WARNING Indications for appliances operating with propane gas Ensure yourself that before installing the appliance the gas tank has been vented For a correct venting of the tank contact the liquid gas supplier and or legally qualified personnel If the gas tank has not been correctly vented it could cause ignition problems If this occurs contact the liquid gas s...

Page 33: ... V I O L A G I A L L O B L U A Z Z U R R O V I O L A G I A L L O B L U BURNER MODULATION LEVEL IN IGNITION Continue to change the parameters by pressing the key decrease The successive parameter which can be changed is BURNER MODULATION LEVEL IN IGNITION IG Press down the YELLOW and LIGHT BLUE key simultaneously to enter in the service menu SE which will appear on the display and change the pre se...

Page 34: ...R O V I O L A G I A L L O B L U Repeat the operations A B C for setting the desired value from 20 to 60 C Standard setting 30 C MAXIMUM HEATING TEMPERATURE SETTING Continue to change the parameters by pressing the key decrease The successive parameter which can be changed is MAXIMUM HEATING TEMPERATURE SETTING HH A Z Z U R R O V I O L A G I A L L O B L U Repeat the operations A B C for setting the...

Page 35: ...he domestic hot water adjustment is controlled by the electronic board fitted on the boiler Heat circuit I II All display values and settings that relate to the associated consumer circuit also for example as decentral hot water Solar MF All indicator and set values that relate to solar energy recovery and settings for the multifunction relay Operation is divided into different main menu areas Gen...

Page 36: ...tion press the programming key for entering the access code 0 0 0 0 NUM CODICE 0 0 0 0 0 0 0 0 0 0 0 0 Assistenza Data Ora Ferie Visualizzazione Utente Progrramma Tempo Tecnico Installaz Acqua calda Circuito riscaldamento I Circuito riscaldamento II Pannelli solari 4 3 2 1 1 2 1 2 1 2 Service 3 18 COMMISSIONING PROCEDURE 1 CHECKING THE SETTINGS Fit controller make electrical connections and fire b...

Page 37: ...1 2 1 2 Relay TEST By turning the rotary knob in a clockwise direction you can select the SENSOR TEST 4 3 2 1 1 2 1 2 Sensor TEST Start the SENSOR TEST by pressing the programming key Start the SENSOR TEST by pressing the programming key By turning the rotary knob in a clockwise direction you can select the F1 from F1 to F15 refer to table 4 3 2 1 1 2 1 2 Sensor TEST F1 F1 Buffer storage temperatu...

Page 38: ...zzazione Utente Progrramma Tempo Tecnico Installaz Acqua calda Circuito riscaldamento I Circuito riscaldamento II Pannelli solari 4 3 2 1 1 2 1 2 1 2 User Assistenza Data Ora Ferie Visualizzazione Utente Progrramma Tempo Tecnico Installaz Acqua calda Circuito riscaldamento I Circuito riscaldamento II Pannelli solari 4 3 2 1 1 2 1 2 1 2 Hot water Heating circuit I II Designation Value range Default...

Page 39: ...azione Utente Progrramma Tempo Tecnico Installaz Acqua calda Circuito riscaldamento I Circuito riscaldamento II Pannelli solari 4 3 2 1 1 2 1 2 1 2 Expert Open the heating controller s panel cover and turn the ro tary knob in a clockwise direction until the EXPERT area menu appears on the display Assistenza Data Ora Ferie Visualizzazione Utente Progrramma Tempo Tecnico Installaz Acqua calda Circui...

Page 40: ...MO SU using the rotary knob CIRCL TIME Program for circulation pump HOTW PROG Program for hot water charging pump HTG PROG 1 1st heating program for first controller heating circuit HTG PROG 2 2nd heating program for first controller heating circuit HTG PROG 1 1st heating program for second controller heating circuit HTG PROG 2 2nd heating program for second controller heating circuit Enabled only...

Page 41: ...he frequency of servicing will be determined by the service engineer and will depend on the appliance s state of condi tion To ensure reliable and efficient boiler operation please refer to the table on page 42 where the recommended maintenance operations are indicated 4 INSPECTION AND SERVICING SCHEDULE Instructions for inspection and servicing To ensure a long life to all your boiler com ponents...

Page 42: ...ck the seals of the hot water circuit storage tank for soundness Recommended servicing operations Check annually Examine all water seal components for soundness Clean the combustion circuit heat exchanger body Clean the fan Check the gas flow rate and eventual gas adjustment Check the flue outlet system Check the hydraulic system Check efficiency of fan s operation Test for gas soundness Clean the...

Page 43: ...gnition phase Corrective action Press the reset button on the control panel Code Description Modulating fan failure Corrective action Check the fan s wiring Code Description Modulating fan failure Corrective action Check the fan s wiring Code Description Main heat exchanger frozen Corrective action Carefully de frost the exchanger Code Description Water temperature too high detected by the CH sens...

Page 44: ... gas valve Code Description Internal failure Corrective action Replace the control board Ensure that the appliance is serviced and subsequently reset the counter to zero by selecting the text Cr from the parame ter menu and entering the relative unblocking code The boiler is equipped with an integrated system which after 10 000 ignitions or 2 000 hours of burner operation signals that the boiler h...

Page 45: ...g Description Main heat exchanger frozen Corrective action Carefully de frost the exchanger Description Intervention of the overheat safety thermostat TL Corrective action Press the reset key on the control panel Description Heating sensor failure SR Corrective action Check the sensor s efficiency and or wiring Description Alteration of the factory parameters caused by electromagnetic disturbances...

Page 46: ...NOTE ...

Page 47: ...NOTE ...

Page 48: ... 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 AG S P A 46033 casteldario mantova italia tel 0376 57001 r a fax 0376 660556 www unical ag info unical ag com ...

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