Unical MODULEX EXT 100 Installation And Servicing Instructions Download Page 52

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Servicing schedule

Release the fixing spring from the air manifold (on right
and left side).

Remove the red silicone pipes and then the air manifold

(left / right side).

•

Wiring

Release the plastic bands fixing the harness in the upper part
of the boiler (do not to cut the plastic bands)

Remove gas valve connector

Remove fan connector

Remove gas pressostat wires

Summary of Contents for MODULEX EXT 100

Page 1: ...E N G L I S H 100 150 200 250 300 350 INSTALLATION AND SERVICING INSTRUCTIONS MODULEX EXT ...

Page 2: ...ings 14 3 2 Packaging 15 3 3 Removal from the bed and insert foot 16 3 4 Boiler location in a boiler room 16 3 6 Boiler connection 18 3 7 Gas connection 19 3 8 Connection return and flow system pipes 20 3 9 Additional safety and control devices according to the Italian Law primary circuit kit 21 3 10 Mixing header 22 3 11 Mixing header filter 22 3 12 Determination of primary boiler pump or boiler ...

Page 3: ...to be instructed on the use and operation of his heating system in particular Hand over these instructions to the end user together with any other literature regarding this appliance placed inside the envelope contained in the packaging The user has to keep these documents in a safe place in order to always have them at hand for future reference Inform the user on the importance of air vents and o...

Page 4: ...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 leakages WARNING Indications for appliances operating with propane gas Ensure yourself that before installing the appliance the gas tank has been purged For a correct purging of the tank contact the liquid gas supplier or a competent person who has bee...

Page 5: ...cuit could lead to system gathering in the boiler body causing damage UNICAL recommends contacting a specialised company for water treatment Instead if installing a Modulex boiler in a new system it is still recommended to thoroughly clean out the system with an adequate product and fit aY filter with two isolating valves onthe boiler s return pipe so that when necessary it can be cleaned This fil...

Page 6: ...x NOx 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...

Page 7: ...ifreeze or in several cases it is due to the natural formation of alkaline in the system Vice versa if the pH value is between 6 5 and 8 the aluminium surfaces of the boiler body are passivated and protected from further corrosive attacks To minimize corrosion it is essential to use a scale inhibitor however in order for this to function correctly the metallic surfaces have to be clean The best co...

Page 8: ...cleaning or servicing turn 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 intake outlet terminal ducts In the event of failure and or faulty functioning of the appliance switch off the boiler Do not attempt to make any repairs contact qualified technicians Any repairs must be carried out by Unical author...

Page 9: ... temperature flow Operation modes Ability to control power of the individual heating elements for any calibration and or assistance with access code confi dential Production of A C S by NTC of priorities for control by boiler feed pump or by three way diverter valve controller E8 included Ability to control power of the individual heating elements Control of heat demand set point temperature and l...

Page 10: ...the rear side of the boiler The rear side cover just re moved has to be re placed on the right side of the boiler Smoke and condensate evacuation connection on the R H side forniture condition L H side BACK SIDE order special BACK Flue kit MODULEX EXT 100 116 150 200 00362154 MODULEX EXT 250 300 350 00362076 C H flow connection on the R H side forniture condition L H side C H return connection on ...

Page 11: ...on D mm Condensate drain diameter mm LEFT HAND SIDE VIEW M CH flow system R CH safety system return 2 3 DIMENSIONS G Gas inlet S Outlet condensate drain 150 3 1150 764 706 770 705 50 2 64 2 64 2 150 40 200 4 1150 1032 974 770 705 50 2 64 2 64 2 150 40 250 5 1150 1032 974 770 705 50 2 64 2 64 2 200 40 300 6 1150 1300 1242 770 705 50 2 64 2 64 2 200 40 350 7 1150 1300 1242 770 705 50 2 64 2 64 2 200...

Page 12: ...rating temperature C 85 85 85 85 85 85 Flue gas mass flow rate min kg h 19 6 19 6 19 6 19 6 19 6 19 6 Flue gas mass flow rate max kg h 163 245 327 409 490 569 Excess air 25 5 25 5 25 5 25 5 25 5 25 5 Heat loss at chimney with burner on min 1 7 1 7 1 7 1 7 1 7 1 7 Heat loss at chimney with burner on max 2 2 2 2 2 2 2 2 1 9 1 7 Minimum heating circuit pressure bar 0 5 0 5 0 5 0 5 0 5 0 5 Maximum hea...

Page 13: ...ture capacity Tr 30 C P1 kW 32 2 49 3 64 4 80 5 96 6 112 Performance at 30 of the rated heat output with low temperature capacity Tr 30 C ƞ1 96 7 96 7 96 7 96 7 96 7 96 7 Boiler with output range adjustment YES NO NO NO NO NO NO NO Auxiliary electricity consumption With a full load elmax kW 0 145 0 210 0 290 0 362 0 435 0 507 With a partial load elmin kW 0 040 0 040 0 040 0 040 0 040 0 040 Standby...

Page 14: ...t the chimney flue pipe has an ade quate draught does not have any constrictions and that no other appliance s flue outlets have been fitted unless the chimney is serving more than one heating appliance according to the specific standards and regulations in force The connection between the boiler and chimney flue outlet can be made only after this verification has been carried out WARNING In rooms...

Page 15: ...rminal The sealing gasket for flue socket 2 bends 1 Tee piece 1 plastic plug Ø 40 mm for condensate drain the screws necessary for fixing the smoke chamber terminal The Outer sensor Flow sensor and the D H W storage tank sensor Nipple for smokes sampling test Resistances kit for emergency operation Cable glands and for electrical supply a carton box containing 4 feet of support 3 caps for any reve...

Page 16: ...The boiler can be put on a flat and sufficiently strong base with the same dimensions as the boiler ones and at least 100 mm high see fig 2 in order to assemble the condensate drain siphon An alternative to this base may be a 100mm deep well next to the boiler as siphon housing see fig 2 After installation the boiler shall be perfectly horizontal and stable to reduce any possible vibrations or noi...

Page 17: ...17 Instructions for the installer 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 18: ...h R H side panel To move the C H Flow Return connections from the R H side std delivery position to the L H side it is necessary to change each other the two flanges screwed on the C H Flow or Return manifold ends ONLY FOR MODULEX 250 300 350 To move the smoke outlet from the R H side std delivery position to the rear position it is neces sary to request the smoke kit code No 00362076 made of a Te...

Page 19: ... it is recommended to thoroughly clean all the supply piping in order to remove any eventual residual grime which could compromise the boilers correct functioning If you smell gas a Do not turn on or off electrical switches use the telephone or any other object which can provoke sparks b Open all doors and windows in order to allow fresh air to enter and purify the room c Close all gas cocks d Con...

Page 20: ...T IS ABSOLUTELY FORBIDDEN TO FIT ON OFF VALVES ON THE GENERATOR TO THE FORE OF THE SAFTEY DEVICES WARNING Before installing the boiler we recommend that the system is flushed out with a suitable product in order to eliminate any metallic tooling or welding residues oil and grime which could reach the boiler and affect the proper running of the boiler Non observance of these instructions could caus...

Page 21: ...ay valve with manometer control 14 Thermometer it indicates the effective water temperature contained in the generator It must be graduated in degrees Celsius with a temperature scale not exceeding 120 C 17 Inspection pocket approved for inserting the control ther mometer 19 Plug G1 for the safety valves connection 3 Calibrated expansion vessel it permits the absorption of the increase in volume o...

Page 22: ...wo hydraulic circulation circuits balancing of the circuits mod Ø EXT 100 150 DN 50 EXT 200 250 DN 50 EXT 300 350 DN 50 Recomended installation Mixing HeaderModulex Ext 100 350 cod 00361976 M DN 100 G 4 R DN 100 G 4 3 11 MIXING HEADER FILTER UNICAL suggests the installation of a Y filter on the return pipe so that it can be cleaned if necessary This filter will protect the boiler from the heating ...

Page 23: ...nstallation has a mixing header NOTE The use of a mi xing header fitted bet ween the boiler circuit and the system circuit is always advisable It becomes INDISPENSABLE if the system requires flow rates superior to the maximum permitted boiler flow rates which is to say lower than 15K For a T 20 K of a MODU LEX 250 boiler the max water flow rate requested is 10514 l h From the graph of the boiler s...

Page 24: ...dditional plates to adjust the system as needed Modulex Modulex Ext 100 cod 00362087 Ext 100 cod 00362080 Ext 150 cod 00362088 Ext 150 cod 00362081 Ext 200 cod 00362089 Ext 200 cod 00362082 Ext 250 cod 00362090 Ext 250 cod 00362083 Ext 300 cod 00362091 Ext 300 cod 00362084 Ext 350 cod 00362092 Ext 350 cod 00362085 High temperature Boiler Circuit M 80 C R 65 C Heating System Circuit M 70 C R 60 C L...

Page 25: ...300 350 00361944 PREMO S MODULEX 100 116 150 00362062 MODULEX 200 150 00362063 MODULEX 300 350 00362064 PREMO C MODULEX 100 116 150 00362015 MODULEX 200 150 00362014 MODULEX 300 350 00362013 WITH MIXING HEADER BOX COVER COMPO S MODULEX 100 350 00362008 BOX COPERTURA ANELLO COMPO S MODULEX 100 350 00362008 ...

Page 26: ...drain pipe will be on the same side of the smoke chamber passing below the smoke chamber Before commissioning the boiler fill the con densate siphon with water from the dedicated filling up plug Min height of the condensate column with all fans operating at max speed requested by the EN stan dards Min height of the condensate column with all fans operating at max speed In the case it is not possib...

Page 27: ... a condensate evacuation system discharging according to the installation condition in the boiler condensate tray or in another dishpan separated from it In the construction of the flue duct it is necessary to use materials resistant to the combustion products in classW1 according to EN 1443 as stainless steel or plastic certified materials As PVDF polyvinildimethylfluorure or PPS polypropylene tr...

Page 28: ...50 300 350 Flue gas mass flow rate max kg h 163 4 245 2 326 9 408 6 490 3 572 0 Esemple MODULEX 250 Flue gas mass flow rate 408 6 Kg h Chimney height 25 m Chimney connection Ø 250 mm NOTE The diagram supplies only indicatives values Flue gas mass flow rate ...

Page 29: ...230 V 50 Hz is required The wiring to the boiler must be in accordance with the current CEI regulations WARNING We remind you that upstream of the electrical connection it will be necessary to foresee a service relay NOT SUPPLIED which when the electrical safety devices ISPESL interve ne shuts down the electrical supply to the on off fuel valve DANGER The electrical connections must be carried out...

Page 30: ...supply Gas valve ISPESL Modulating pump outside sensor flow switch In the case of intervention of the safety devices the pump ON OFF continues to work to promote the disposal of high temperature In the case of interventi on of the safety devices the modulating pump continues to work to pro mote the disposal of high temperature ...

Page 31: ...31 Instructions for the installer CONNECTING RING PRIMARY SUPPLIED WITH MODULAR PUMP THERMOSTAT ON OFF CONNECTIONS ...

Page 32: ...32 Instructions for the installer THERMOSTAT FBR 2 CONNECTION room sensor ...

Page 33: ...33 Instructions for the installer MODULATING THERMOSTAT CONNECTIONS ...

Page 34: ...34 Instructions for the installer 3 21 Functional wiring diagram Note The pictures shown on the actual wiring diagram is purely indicative ...

Page 35: ...35 Instructions for the installer ...

Page 36: ... which one is for the mains 230 V connections and the other one is for the low tension connections The main controls necessary for the C H system management and for the boiler control as well some components which are part of the boiler house must be connected to the terminal blocks Power terminal assignments Power terminal block Sensor terminal block ...

Page 37: ...37 Instructions for the installer Sensor terminal assignments Terminal assignments BCM ...

Page 38: ...NG ZONES D H W PRODUCTION 9 10 outdoor sensor 6 7 Storage tank sensor 4 Pump heating circuit 1 5 Pump heating circuit 2 6 Cylinder charging pump 5 Re circulation pump storage tank 4 5 Flow sensor heating circuit 2 9 10 outdoor sensor 4 Pump heating circuit 1 1 Flow sensor heating circuit 1 10 Ground outdoor sensor 4 Primary pump 4 Primary pump 1 Flow sensor heating circuit 1 10 Ground outdoor sens...

Page 39: ...CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES D H W PROD 1 Mixer motor heating circuit 1 OPEN 2 Mixer motor heating circuit 1CLOSE 5 Re circulation pump storage tank 7 Mixer motor heating circuit 2 OPEN 8 Mixer motor heating circuit 2 CLOSE 5 Re circulation pump storage tank 9 10 outdoor sensor 6 7 Storage tank sensor 4 Pump heating circuit 1 5 Pump heating circuit 2 6 Cylinder charging pum...

Page 40: ...40 Instructions for the installer Connection to seondary circuit Connection to section B Heating circuit 1 Connection to section C Heating circuit 2 ...

Page 41: ...r the installer For the connection to a solar installation it is necessary to change some parameters See Table Expert AREA Level SOLAR MF MF 4 FUNCTION 23 Connection to section D DHW Connection to section E solar circuit ...

Page 42: ...42 Instructions for the installer CONNECTION BATTERY 2 MODULEX managed by an external regulator E8 RING PRIMARY See manual supplied E8 ...

Page 43: ... be connected to the automation system of a boiler plant via one of its interfaces eBUS for connection to the series of E8 heating controllers or to an additional BCM Modbus application in PLC controlled boiler plants The communication protocols enable complete system management Control of heating request temperature set point and modulation level Monitoring of boiler operation and temperature sta...

Page 44: ...n the system capacity The application of a filter on the return pipe to the boiler is advisable EXAMPLE OF FILLING UP SYSTEM MANIFOLD Filling group with PRV IMPORTANT NOTE Once the system has been filled up at the right filling pressure the filling group has to be closed 3 26 BOILER FREEZE PROTECTION Should the flow temperature measured at global flow tempera ture NTC decrease under 7 C the system...

Page 45: ...pressures If necessary correct the value by turning the adjustment screw B in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrease it A MAXIMUM OUTPUT ADJUSTMENT Remove the cap of the combustion gases sampling point Connect a suitable CO2 gas analyser to the sampling point in the flue outlet terminal Operate the burner to the maximum power following th...

Page 46: ...adjusting screw In case of gas valve replacement or difficult ignition Tighten the maximum adjustment screw A in a clockwise direction until you arrive to the abutting end than slacken for 9 turns Verify the boiler ignition if the boiler goes into lockout slacken the screw A again of one turn than retry the ignition If the boiler goes into lockout again carry out the above indicated operations unt...

Page 47: ... after that the planned parameters are restored MODULEX EXT 100 150 200 250 300 350 Gas Type Supply pressure Ø Injectors Diaphragm Fan Speed CO2 levels Starting power mbar mm mm min max FL FU FU Hz min max IG Gas nat G20 20 7 31 98 9 1 9 1 80 Gas nat G25 25 9 31 98 9 1 9 1 80 Propan G31 37 7 30 91 10 8 10 8 80 ...

Page 48: ...it Thermostat when it acts it cuts the power supply to the boiler the warning lamp E lights To reset remove the cap and push the reset button Note The switches are positioned under the front panel Note The emergency function enables the boiler s burners to fire only at 50 and at 50 C in system return All the system s heating loads including the header pump must be controlled manually Condensate le...

Page 49: ...hon through the filling hole and check the correct drainage of the condensate If the appliance is used with the condensate drain siphon empty this could cause poiso ning caused by the leakage of the flue gasses there are no water leaks all the necessary ventilation conditions and minimum clea rance distances are guaranteed for subsequent servicing in case the boiler is sited in a cupboard compartm...

Page 50: ... it cannot be switched ON acciden tally Switch off the gas gate valve upstream the boiler If necessary and in function of the type of work to be carried out close any on off valves fitted on the CH flow and return pipes as well as the cold inlet valve Remove the appliance s front panel After maintenance works have been finished follow the next steps Open the CH flow and return valves as well as th...

Page 51: ...input can be caused by the obstruction of the evacuation duct or of the air intake Check first of all that this is not the reason If the actual input with the correct CO2 is within 5 of the value shown in the chapter 3 24 the boiler does not need to be cleaned The operation then can be limited to the cleaning of the siphon Act on the two closing hinges on both sides to remo ve the cover Remove the...

Page 52: ...t and left side Remove the red silicone pipes and then the air manifold left right side Wiring Release the plastic bands fixing the harness in the upper part of the boiler do not to cut the plastic bands Remove gas valve connector Remove fan connector Remove gas pressostat wires ...

Page 53: ...or open wrengh and remove the fixing plates Screws on thermal elements Remove the screws A fixing the burner covers with a 13 mm socket wrengh Remove the screws gas collector left and right side Remove the four screws with a 10 mm socket wrengh then the gas flange ...

Page 54: ...lightly 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 Insert the small pins in the D holes in order to support the burner assembly ...

Page 55: ...e evacuation pipe and the chimney Third phase Reassembly When reassembly proceed in the reverse order taking care to tight the fixing screws of the mixer fan group to the body with a tightening torque of 13 Nm WARNING AT EACH MAINTENANCE OPERATION IT IS COMPULSORY TO REPLACE THE SEALING GASKETS ON EACH BURNER Spare parts code 00251482 KIT OF BURNER GASKETS MODULEX 5 pz 95262823 KIT BURNER MODULEX ...

Page 56: ...ves the right to bring those changes that it will hold necessary to it own products or profits without jeopardizing its essential characteristics 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 00333467 3 rd edition 10 15 www unical eu ...

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