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Unical KONf 200, Installation And Maintenance Instructions Manual

The Unical KONf 200 is a high-performance product that ensures efficient heating and hot water systems. For easy installation and maintenance, make sure to download the free "Installation And Maintenance Instructions Manual" from our website. This comprehensive manual provides detailed guidance on setup, operation, and troubleshooting to maximize your KONf 200's performance.

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Installation instructions

Technical Features

General information

Maintenance instructions

ENGLISH

2  TECHNICAL FEATURES AND DIMENSIONS ................................................................................................................10

   2.1 

Technical features ....................................................................................................................................................10

   2.2  Main components view and dimensions ..................................................................................................................10

   2.3 

Dimension ................................................................................................................................................................14

   2.4  Available flow rate / pressure diagram

 .....................................................................................................................18  

  2.5  Operation data .........................................................................................................................................................19

4  MAINTENANCE INSTRUCTIONS ...................................................................................................................................40

   4.1 

Inspection and maintenance instructions .................................................................................................................40

   4.3  Adaptation to the use of other gas  ..........................................................................................................................42

   4.4  Operation parameters programming ........................................................................................................................43  

  4.5  Wiring diagram .........................................................................................................................................................46

   4.6 

Error  codes ..............................................................................................................................................................49

3  INSTALLATION INSTRUCTIONS ....................................................................................................................................21

   3.1 

General warnings .....................................................................................................................................................21

   3.2 

Installation  standards ...............................................................................................................................................21  

  3.3  Preventive system verification and adjustment operations

 ......................................................................................21

   3.4 

Packaging ................................................................................................................................................................22  

  3.5  Positioning the boiler................................................................................................................................................23

   3.6  Flue gas exhaust pipe connection ...........................................................................................................................24

   3.7 

Connections .............................................................................................................................................................26

   3.8  Filling the system .....................................................................................................................................................28

   3.9 

Electrical  connections ..............................................................................................................................................29

   3.10  Commissioning .....................................................................................................................................................   34

   3.11  Measurement of combustion efficiency during installation

 .......................................................................................35

    

3.11.1  Calibration function activation ....................................................................................................................35

    

3.11.2  Probes  positioning .....................................................................................................................................36

   3.12  Burner adjustment

....................................................................................................................................................37

    

3.12.1 Adaptation of power to the heating system ...................................................................................................39 

    

1  GENERAL INFORMATION.................................................................................................................................................4

   1.1 

General warnings .......................................................................................................................................................4

   1.2  Symbols used in the manual ......................................................................................................................................5

   1.3  Appropriate use of appliance .....................................................................................................................................5

   1.4  Information for system manager ................................................................................................................................5

   1.5 

Safety  warnings .........................................................................................................................................................6 

   1.6  Technical data plate  ..................................................................................................................................................7

   1.7 

Water  treatment .........................................................................................................................................................8

   1.8  Boiler antifreeze protection ........................................................................................................................................9

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.   

Summary of Contents for KONf 200

Page 1: ...200 400 KONf INSTALLATION AND MAINTENANCE INSTRUCTIONS E N G L I S H ...

Page 2: ...e collection is mandatory for this type of waste in order to allow the recovery and reuse of the materials making up the appliance Please contact operators authorised for the disposal of this type of appliances Incorrect management of waste and of its disposal has potential negative effects on the environment and human health The symbol on the appliance represents the prohibition to dispose of the...

Page 3: ...g the system 28 3 9 Electrical connections 29 3 10 Commissioning 34 3 11 Measurement of combustion efficiency during installation 35 3 11 1 Calibration function activation 35 3 11 2 Probes positioning 36 3 12 Burner adjustment 37 3 12 1 Adaptation of power to the heating system 39 1 General information 4 1 1 General warnings 4 1 2 Symbols used in the manual 5 1 3 Appropriate use of appliance 5 1 4...

Page 4: ...ct and must be kept by the user Read the warnings contained in this instruction booklet carefully as they provide important guidelines regarding installation use and maintenance safety Keep the booklet with care for further consultation Installation and maintenance must be performed in compliance with the standards in force according to the instructions of the manufacturer up to standard and by pe...

Page 5: ...stats and radiators for saving energy Please note that in compliance with the standards in force the inspection and maintenance of the appliance must be carried out in compliance with the regulations and frequency indicated by the manufacturer Should the appliance be sold or transferred to a new owner or if you move and leave the appliance always make sure that the instruction manual accompanies i...

Page 6: ...te Do not modify the following parts the boiler the gas air water and electricity supply lines the flue gas pipe the safety valve and the exhaust pipe the construction parts which affect the operating safety of the appliance Attention To tighten or loosen the screwed fittings use only appropriate fixed spanners Incompliant use and or inappropriate tools can cause damage e g water or gas leakage AT...

Page 7: ...Class A Heating circuit characteristics 9 Pn Effective nominal output 10 Pcond Effective output in condensation 11 Qn Maximum heat output 12 Adjusted Qn Adjusted for rated heat output 13 PMS Max heating operating pressure 14 T max Max heating temperature B Domestic hot water circuit characteristics 15 Qnw Rated heat output in domestic hot water function if different to Qn 16 D Specific D H W flow ...

Page 8: ...AX PH 6 5 8 Hardness fr 9 15 NOTE Further details in the section Technical Information on the boiler page of the www unicalag it website 1 7 WATER TREATMENT Feed water treatment prevents problems and maintains the functionality and efficiency of the generator over time The ideal water pH in heating systems must be within To minimise corrosion it is crucial to use a cor rosion inhibitor in order fo...

Page 9: ...you must use the additional heater kit optional for antifreeze siphon cap Declared TA room temperature using the resistance kit 15 C 1 8 BOILER ANTIFREEZE PROTECTION It is activated by default This protection can intervene 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 wi...

Page 10: ...citor 25 Vent valve 26 Condensation drain trap 27 E RIL Detection electrode 28 E ACC Ignition electrode 29 Return shut off 3 Way valve 30 SMG Sensor Flow General 31 Condensation drain trap 32 Outlet flue inspection 35 Ignition transformer KEY N C E S E Description 3 VG Gas valve 5 Burner 10 HL TL Safety thermostat 11 Hb SR Heating temperature sensor 12 Ht P Modulating Pump 13 Lp DK Water deficienc...

Page 11: ...ondensate sensor level 44 PFmin Flue pressure switch min FL Flow pressure switch DN mm G Gas inle 50 60 3 M Heating system flow 80 88 9 R Heating system return 80 88 9 Scond Condensation drain 32 S Smoke outlet Ø 100 C E ERROR CODES see par 4 6 S E WIRING DIAGRAM KEY see par 4 5 N U Component not used NOTE Insert the flows switch approved cod 00368501 as shown in figure ...

Page 12: ...shut off 3 Way valve 30 SMG Sensor Flow General 31 Condensation drain trap 32 Outlet flue inspection 35 Ignition transformer KEY N C E S E Description 3 VG Gas valve 5 Burner 10 HL TL Safety thermostat 11 Hb SR Heating temperature sensor 12 Ht P Modulating Pump 13 Lp DK Water deficiency pressure switch 14 Boiler drain valve 18 FL FH VM Modulating Fan 20 Safety valve 22 rb SRR Return temperature se...

Page 13: ...ondensate sensor level 44 PFmin Flue pressure switch min FL Flow pressure switch DN mm G Gas inle 50 60 3 M Heating system flow 80 88 9 R Heating system return 80 88 9 Scond Condensation drain 32 S Smoke outlet Ø 100 C E ERROR CODES see par 4 6 S E WIRING DIAGRAM KEY see par 4 5 N U Component not used NOTE Insert the flows switch approved cod 00368501 as shown in figure ...

Page 14: ...14 2 3 DIMENSIONS FRONT VIEW 950 1214 INT 1 INT 2 KONf 200 ...

Page 15: ...15 Technical Features E N G L I S H TOP VIEW SIDE VIEW DX 606 134 166 134 132 119 179 381 449 118 277 ...

Page 16: ...16 KONf 400 1860 1214 INT 1 INT 2 INT 1 INT 2 FRONT VIEW ...

Page 17: ...17 Technical Features E N G L I S H 606 134 166 134 132 119 179 118 277 449 381 TOP VIEW SIDE VIEW DX ...

Page 18: ... rate demanded l h Dt 15 K l h 12040 24080 Nominal flow rate request Dt 20 K l h 9030 18060 n 1 Pump at Qnom n 1 Pump at Qmin n 2 Pump at Qnom n 1 Pump at Qmin 2 4 DIAGRAM OF FLOW RATE PRESSURE AVAILABLE FOR INSTALLATION Avaible Head m H 2 O Δt rate between Flow and Return it must NOT be less than 15 K NOTE The use of a mixing header fitted betwe en the boiler circuit and the system circuit is alw...

Page 19: ...ner in operation max 2 0 1 74 Minimum heating circuit pressure bar kPa 0 5 50 0 5 50 Maximum heating circuit pressure bar kPa 6 600 6 600 Water content l 22 44 Gas Consumption Natural 20 mbar gas G 20 a Qn m3 h 21 04 42 1 Gas Consumption Natural gas 20 mbar G 20 a Qmin m3 h 2 11 2 11 Gas Consumption G25 supply pressure 25 mbar Qn m3 h 24 5 49 Gas Consumption G25 supply pressure 25 mbar Qmin m3 h 2...

Page 20: ...perature capacity Tr 30 C ƞ1 98 1 97 3 Boiler with output range adjustment YES NO NO NO Auxiliary electricity consumption With a full load elmax kW 0 580 1 160 With a partial load elmin kW 0 156 0 156 Standby mode PSB kW 0 025 0 032 Other elements Heat loss in stand by Pstb kW 0 962 0 9238 Emissions of nitrogen oxides ref PCI PCS NOx Mg kWh 46 41 46 41 Annual electricity consumption QHE GJ 606 122...

Page 21: ...ny residues or impurities which could jeopardise proper operation of the boiler even from a hygienic point of view b Check that boiler is set up to oper ate with the available type of fuel This can be seen written on the package and on the technical feature plate c Check that the chimney flue has an appropri ate draught without any bottlenecks and that no exhausts from other appliances are insert ...

Page 22: ...let 6 screws for KONf 200 8 screws for KONf 400 Only transport the boiler using appropriate transport equipment Follow the transport instructions on the packa ging OBLIGATION wear protective gloves KONf 400 P depth mm L width mm H height mm Net Weight kg Gross Weight kg 675 1890 1500 632 688 As well as the appliance the packaging contains ENVELOPE DOCUMENTATION Instruction for regulator HSCP Instr...

Page 23: ...ns not smaller than the ones of the boiler After installation the boiler will result perfectly horizontal and very stable in order to reduce vibrations and noise Installation When choosing the installation place the following items have to be considered To grant an easy access to the boiler components in order to facilitate the ordinary and extraordinary service operations The floor should not be ...

Page 24: ...inals exten sions you get the value if 0 OK POSSIBLE configuration if 0 NO WRONG configuration Values in the MT018 available on the website ATTENTION For the type of connection B23P the room fol lows the same installation rules for boilers with natural draught Please note These values relate to exhausts made by means of rigid pipes and smooth original UNICAL C63x C63 Boiler intended for connection...

Page 25: ...100 Only for indoor installation Installation Type B23p Air inlet from upper grid and smoke outlet Ø100 Detail A Optional Combustion air inlet is carried out through the indicated grid hole a through the air intake holes of the case For this configuration DO NOT use the case cover provided with the boiler A ...

Page 26: ...26 KON 200 Smoke accessories Ø 200 Siphon 00363843 Smoke outlet expansion Kit 00366433 Single exhaust manifold 00366437 Smoke extension kit 00366435 480 10 6 5 10 6 5 450 ...

Page 27: ...27 Installation instructions E N G L I S H KON 400 480 10 6 6 6 5 5 10 6 6 6 450 ...

Page 28: ...must be carried out only by a qualified installer who must respect and apply that foreseen by relevant laws in force in the local prescriptions of the supply company Incorrect in stallation can cause damage to persons animals and objects for which the manufacturer cannot be held responsible If you smell gas a Do not operate electric switches the telephone or any other object that may cause sparks ...

Page 29: ...he siphon Condensation drain The boiler during the combustion process produces conden sation that through pipe A flows into the trap The condensation that forms inside the boiler flows into a suitable drain via pipe B Danger Before commissioning the appliance check that the trap is assembled properly H 180 mm fill the trap and check that the condensation is drained properly If the appliance is use...

Page 30: ...k pro perly sized Pressure in the mains supply must be between 0 5 and 6 bar In case of higher pressure a pressure reducer it must be installed Attention Do not mix the heating water with incorrect concentrations of antifreeze or anti corrosion substances This could damage the gaskets and cause noise during operation Unical will not be held liable for damage to persons animals or objects due to fa...

Page 31: ...31 Installation instructions E N G L I S H 2 1 3 9 ELECTRICAL CONNECTIONS ...

Page 32: ...37 BMM Burner management board 39 230 V Power Supply Terminals 41 Supplementary terminal 24V BCM 42 eBus connessione 43 BCM Boiler controller 46 INTC Switch Inhibit Body 1 2 3 4 48 PD1 PD2 Connection FL flow switch 1 2 3 4 50 Power supply PCB 6 3A F ...

Page 33: ...aced by technical personnel authorised using original spare parts only Failure to comply with the above can jeop ardise the safety of the appliance Y2 9 and terminal board M2 after removing the jumper Optional WH R TA ON OFF 24V BK G Y4 1 2 3 4 1 2 3 1 2 3 4 5 6 Y3 Y2 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 Jp2 9 8 10 11 12 13 14 2 1 3 4 5 6 7 ON OFF room thermostat connection Electric powe...

Page 34: ... connect the cables as indicated between Y2 10 and terminal board M2 10 FL 11 INAIL WH R BK G Y4 1 2 3 4 1 2 3 1 2 3 4 5 6 Y3 Y2 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 Jp2 9 8 10 11 12 13 14 2 1 3 4 5 6 7 24V 10 FL 11 INAIL WH R 24V BK G FL Y4 1 2 3 4 1 2 3 1 2 3 4 5 6 Y3 Y2 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 Jp2 9 8 10 11 12 13 14 2 1 3 4 5 6 7 WH R 24V BK G Y4 1 2 3 4 1 2 3 1...

Page 35: ...Pump heating circuit P Car DHW Storage tank loading pump Stemp ACC Storage Tank Temperature Sensor P Mod Modulating Heating Pump Connect the cables as indicated Y4 Connect the cables as indicated Y3 1 2 3 Connect the temperature sensor cables as indicated Y2 4 8 Connect the modulation control cables as indicated Y2 4 5 External 230 V 50 Hz power supply NOTE The boiler is set up for direct flow and...

Page 36: ...he gas to be used correspond to the boiler calibration gas otherwise perform the boiler conversion in order to use the gas available see section 4 3 this operation must be carried out by technical staff qualified in compliance with the standards in force is the gas supply valve open has the system been checked for gas leaks is the outside main switch ON is the system safety valve efficient and is ...

Page 37: ...ng knob C select symbol 2 Calibration function SELECTION Set to using knob C and confirm by pressing A input the access code 3 MAXIMUM MINIMUM OUTPUT Set knob C to Confirm by pressing A it displays Set knob C to Confirm by pressing A Using knob C adjust the power to calibrate Press A to confirm MINIMUM OUTPUT MAXIMUM OUTPUT Calibrate each heating element by selecting the burners 4 DISABLING Upon c...

Page 38: ...e combustion efficiency one must make the following measurements measurement of the combustion air temperature measurement of the flue gas temperature and content of CO2 taken in the relevant hole 2 Take the measurements with the generator in steady state conditions see par 3 11 1 3 11 2 Positioning the probes ...

Page 39: ...STING THE BURNER 2 Minimum output adjustment Operate the boiler in calibration mode at MINIMUM OUTPUT see 3 11 1 Once the burner is on check that the CO2 MINIMUM value corresponds to that indicated in the table NOZZLES PRES SURE Correct it if needed by turning with a screwdriver the screw R CLOCKWISE to increase it ANTICLOCKWISE to de crease it S ADJUSTMENT SCREW MAXIMUM OUTPUT R ADJUSTMENT SCREW ...

Page 40: ... a closed combustion chamber NOZZLES PRESSURE FLOW RATES TABLE 3 Conclusion of the basic calibrations once the CO2 values at minimum and maximum output have been checked and any adjustments have been made sections 1 2 disable the timed calibration function by switching off the main switch For proper operation the CO2 values must be calibrated with particular attention observing the values indicate...

Page 41: ...stance Centres only The user is NOT authorised to activate the function described below It is possible to adjust the maximum thermal capacity in heating mode by decreasing the burner pressure value 3 12 1 ADAPTATION OF THE POWER TO THE HEATING SYSTEM Power Supply KW Act on parameter FH par 4 2 SE parameters list to achieve the value corresponding to the desired output ...

Page 42: ...ecessary restore the heating pressure until reaching a pressure of 0 8 1 0 bar Open the gas shut off valve Switch the boiler on Make sure the appliance is gas tight and watertight Failure to perform Inspections and Maintenance can entail material and personal damage INSPECTION AND MAINTENANCE Danger of burns during maintenance operations OBLIGATION wear gloves protective TABLE OF RESISTANCE VALUES...

Page 43: ...ting Heat the TL until it intervenes at 102 C and check that it intervenes at 102 DK safety pressure switch against water deficiency 13 Does the pressure switch block the boiler if the water pressure is below 0 4 bar Without request close the shut off valves of the heating circuit open the drain valve to make the water pressure de crease Before pressurising again check the pressure of the expansio...

Page 44: ...ank has been deaer ated before installing the appliance For state of the art deaeration of the tank contact the LPG supplier or a person qualified in compliance with law If the tank has not been professionally deaer ated ignition problems could arise In that case contact the supplier of the LPG tank 4 3 ADAPTATION TO THE USE OF OTHER GAS Gas Conversion The boilers are produced for the type of gas ...

Page 45: ...knob C and press A to access the technical program of each device requested password 0000 4 SELECTION Use knob C to select the parameter Press A selec 5 EDIT Turn knob C to edit the value Press A save 2 Device management SELECTION The screen displays the status and active system sections not active 1 active HCM Check the BCM cascade SHC optional multifunction module BMM burner management board Sel...

Page 46: ...0 100 346 FL Minimum relative fan speed 0 100 2590 Burner maximum capacity kW 1 1000 483 rP Water Δ temperature protection C 0 50 622 FS Water minimum flow rate protection 0 1 34 HY Burner OFF hysteresis C 5 20 336 HS Temperature control slope limit C MIN 1 30 353 HP Temperature control proportional gain 0 50 354 HI Temperature control integrative gain 0 50 478 Hd Temperature control derivative ga...

Page 47: ...x C 45 0 85 0 786 ES Outdoor Temperature sensor 0 2 322 Po Pump Postcirculation min 1 10 341 PL Pump Minimum command Volt 0 0 10 0 313 Pr Pump Maximum Command Volt 0 0 10 0 346 FL Minimum Modulation 0 0 100 0 800 mB Burners Min Inserted 1 8 336 HS Temperature Gradient C min 1 30 353 HP CH PID Proportional C 0 50 354 HI CH PID Integrative 0 50 478 Hd CH PID Derivatives 0 50 816 MI Modbus address 1 ...

Page 48: ...1 D YG BR BL VG 0 1 2 3 4 5 6 7 8 9 Y1 SHC KIT BR BK R 24V eBUS eBUS G PK G PK BR BL BR BL A2 A1 A1 A4 A3 A3 A8 A9 1 2 3 4 5 6 7 VM A 1 APM 1 E RIL 1 WH BR BR BL BL YG YG BL BL BL T BL BL T T WH BK BR OR BR OR WH WH BK C V A1 A2 A3 A4 A13 A8 A7 A9 A6 Y1 A14 A10 A11 GND5 GND1 GND2 GND3 GND4 ROD F 1 S A5 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 1 2 3 2 1 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 ...

Page 49: ...1 2 3 1 2 3 4 5 6 7 8 9 1 2 3 2 1 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 1 2 3 4 1 2 2 1 PK MODULATING GR BK BL TACHO BR PWM O ST2 1 2 3 4 5 4 3 2 1 Min Max C NC C NO BL BL BL TSC 2 BL BL T 2 F T 2 L P 2 V S 2 L WH BK BR OR BR OR WH WH BK S 2 R CPM 2 VM R 2 6 A6 V1 V2 MODULE 2 NO COM M 2 L 1 2 N 5 4 3 2 1 YG BR BL R E ACC 2 YG BR BR BL P 2 D YG BR BL VG eBUS eBUS 2 1 3 A13 P2 ...

Page 50: ...ing Controller Touch BCM services FL Flow switch INAIL Connection TA Room thermostat S temp ACC Storage Tank Temperature Sensor INGR ANALOG Analogical input GND 0 10V ING Analogical input 0 10 V 0 10V C P M Modulating Pump Control ALLARM SIGNAL Alarm Output Comm P COLL Boiler collector pump control Comm P CH Heating pump control P car DHW Storage tank loading pump control COM Common Optional or on...

Page 51: ...trode connection probable contacts oxidation 12 HEATING SENSOR 11 Heating sensor fault Check the efficiency of the sensor see table Res Temp Par 4 or its connections 14 RETUR HEATING SENSOR Auxiliary SRR sensor interrupted Check the wiring if needed replace the auxiliary sensor 22 15 WATER CIRCULATION INSUFFICIENT Primary circuit water circulation insuffi cient t 40 C Check pump operation and spee...

Page 52: ... and then it may be only a warning 18 Maximum protection Dt flow and return Status stop Control of the circulation verify installation 19 OVERHEATING OF CH FLOW Overheating of the outlet It is activated when the flow temperature is 95 It is reset automatically when the temperature is 80 Effect Stop burner pump on Control of the circulation 37 Faulty parameter memory Flame arrest Contact Customer S...

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Page 54: ...54 ...

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Page 56: ... reserves the right to modify its products as deemed necessary or useful without affecting their essential features 46033 casteldario mantova italia tel 39 0376 57001 fax 39 0376 660556 info unical ag com export unical ag com www unical eu AG S p A www unical eu IORIGINAL INSTRUCTION 00338089EN 1 st ed 08 18 ...

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