Unical NOVAIREX Series Installation And Maintenance Instructions Manual Download

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3.15 - BOILER START-UP

Have all the hydraulic and electrical systems and the safety devices been connected in compliance with the
domestic and local laws in force

Are the expansion vessel and the safety valve (when applicable) connected correctly and cannot be shut off?

are the bulbs of fl ow probe S4 and safety thermostat locked in the relevant sheaths?

Are the control and safety devices working and confi gured correctly?

Are the refractory coverings intact?

Is the grate of the burner installed correctly?

Are the combustion air intake line and the fl ue gas evacuation line compliant with the applicable standards in force?

Are the mains voltage and frequency compatible with the burner and the electrical equipment of the boiler?

Is the system full of water and does not contain any air?

Are the drain valves closed and the system cut-off devices fully open?

Is the outside main switch ON?

Is the pump/are the pumps working correctly?

has the system been checked for water leaks?

Are the ventilation conditions and minimum distances to perform any maintenance guaranteed?

Has the operator been trained and has the documentation been supplied?

3.15.1 - PRELIMINARY CHECKS

Commissioning must be done by profession-
ally qualifi ed personnel. Unical will not be
held liable for damage to persons, animals
or objects due to failure to comply with the
above instruction.

Please tick the operations performed

The preliminary checks must be carried out by the instal-
lation fi rm.

After connecting the hydraulic and electrical system and the fuel
line to the boiler, and before starting up the boiler,

it is advisable

to check the following:

YES

Summary of Contents for NOVAIREX Series

Page 1: ...INSTALLATION AND MAINTENANCE INSTRUCTIONS NOVAIREX 35 45 55 ...

Page 2: ...or maintenance technician in compliance with current legislation The system manager is NOT authorised to service 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 ...

Page 3: ... 3 2 Installation rules 15 3 3 Installation on old systems or to be renovated 15 3 4 Packaging 16 3 5 Transport 16 3 6 Installation 17 3 7 Connecting the boiler to the system 18 3 8 Water connections 18 3 9 Connection to the flue 23 3 10 Electrical connections 26 3 11 Connections 27 3 12 Reference plumbing diagrams 28 3 13 Panel board 39 3 14 Filling the system 45 3 15 Starting the boiler 46 3 16 ...

Page 4: ...ore performing any cleaning or maintenance disconnect the appliance from the energy mains by acting on the switch of the system and or through the specific cut off devices Do not obstruct the terminals of the ventilation ducts In case of failure and or malfunctioning of the appliance switch it off and do not try to repair it or intervene on it directly Contact only personnel qualified in complianc...

Page 5: ...g The user must keep this documentation safe for future consultation Inform the user about the importance of the air vents and the flue gas exhaust system highlighting their essential features and the absolute prohibition of modifying them Inform the user concerning controlling the system s water pressure as well as operations to restore it Inform the user concerning correct temperature control co...

Page 6: ...onnected to appliance Do not modify the following parts the boiler the air water and electrical current 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...

Page 7: ... The technical data plate is adhesive and is included in the document case it must be applied by the installer on the outside of the casing The serial number of the boiler is on the riveted plaque on the front plate of the body front right top side ...

Page 8: ... combustion chamber partially covered with refractory material Burner in refractory material Horizontal smoke ducts Front door for loading wood covered with refractory material Bottom door covered with refractory material complete with combustion air adjustments and fitted with flame sight glass Rear smoke chamber with side inspection and ash removal doors Flue gas extraction with intake modulatin...

Page 9: ...80 190 81 190 78 1025 628 1380 190 81 1150 1150 628 828 mm mm mm mm mm mm mm CONNECTIONS T1 T2 T5 T6 T3 T4 T7 T8 UNI ISO 228 1 Ø mm UNI ISO 228 1 G 1 150 G G G 1 200 G G UNI ISO 228 1 H 65 65 mm G 1 200 G G 65 NOVAIREX 34 NOVAIREX 45 NOVAIREX 55 T1 Central heating flow T2 Central heating return T3 Safety thermostat probe bulb holder boiler flow probe T4 Connection for any temperature relief valve ...

Page 10: ... dB 50 50 50 MINIMUM DRAUGHT REQUIRED BY CHIMNEY Pa 20 20 20 MIN FLOW TEMPERATURE C 70 70 70 MAX FLOW TEMPERATURE C 85 85 85 MIN RETURN TEMPERATURE C 55 55 55 NOMINAL LOADING FLUE TEMPERATURE C 171 177 178 NOMINAL LOADING FLUE GAS MASS FLOW RATE kg s 0 02 0 026 0 032 EFFICIENCY 89 5 89 0 89 0 O2 4 73 5 05 6 12 CO2 13 9 13 74 13 6 2 3 TECHNICAL DATA CO 10 mg Nm3 361 469 367 CO 13 mg Nm3 263 342 267...

Page 11: ... held with its head upwards This is because in its convective motion the flame must not meet fuel other than that which has generated it As in residential heating the fuel is usually in the form of wood logs which are loaded from the top the flame has to go in the opposite direction i e downwards Natural draught is a source of negative pressure which varies greatly depending on the type of chimney...

Page 12: ...er with gas Gasification speed depends on the amount of fuel and the size of the drying area Generally it is better to use large logs if they are dry and small logs if the wood is moist The quantity of pri mary air proportional to the delivered output is regulated via the adjustment system EXCHANGE SURFACE 6 Operating on wood and without very high sulphur percentages it is important to achieve ver...

Page 13: ...igh oxygen rich bluish coloured flame This flame comes out from the oval opening and invades the combustion chamber Due to the high temperatures at play the refractory burner will turn a bright red colour COMBUSTION CHAMBER 5 Combustion is optimised by increasing the flame temperature and producing a strong turbulence in the bottom chamber For this reason the flame in addition to not touching cold...

Page 14: ... the moisture of the wood being used The heat output of the NOVAIREX boiler is calculated for wood with a 17 moisture content As an example wood which has been dried for 2 years in a sheltered area has a 25 moisture content Example moisture of the wood being used 25 output nominal output x 0 86 Correction factors for wood moisture OF HUMIDITY CALORIFIC VALUE kWh kg CORRECTION FACTOR 15 20 25 4 50 ...

Page 15: ...with the technical professional requirements according to law 37 08 which under his own responsibility guarantees compliance with the standards according to good practice rules The boiler must be connected to a central heat ing system and or domestic hot water production network compatible with its efficiency and output 3 2 INSTALLATION STANDARDS It must be installed by a professionally qualified ...

Page 16: ...ifting The document envelope inserted in the wood storage compart ment contains Hydraulic test certificate 35 kW User System manager operating instructions for the system Installation and maintenance instruction booklet Warranty Coupons for returned spare parts Adhesive plate with technical data Adhesive plate with local ventilation requirements 35 kW If the boiler is stored for long periods it sh...

Page 17: ...l draught equipment or appliances which can create a vacuum in the room in relation to the outside environment and therefore hinder the draught of the flue gas exhaust system UNI 10683 To make it easier to clean there must be a clearance space in front of the heat stove no less than the length of the stove itself You must at least make sure that the door can open 90 unobstructed NOVAIREX can be pl...

Page 18: ... CONNECTING BOILER TO SYSTEM Attention Make sure that there are no mechanical tension points while connecting the pipes to avoid the risk of leakage Heating flow and return pipes must be connected to the boiler at the respective fittings as shown on page 6 For the dimensioning of the heating circuit pipes you must take into account pressure drops caused by radiators thermostatic valves radiator st...

Page 19: ... up inside the suitable sheath located on the rear of the NOVAIREX boiler Attention The input or output can be inverted as long as the valve is installed on the cold water intake Provide a drain pipe with a funnel and a siphon leading to an appropriate drainage at the heat exchanger outlet This drainage must be controlled on sight Attention If this precaution is not taken triggering of the thermal...

Page 20: ... hardness of the mains water supply con ditions the boiler s lifespan It is always recommended to treat water with a hardness greater than 15 f Unical has designed a RECIRCULATION KIT FOR OPERATION WITH STORAGE TANK for its customers The kit is supplied as an option and is available by indicating the model of your boiler 3 8 3 ASSEMBLY INSTRUCTIONS Fan assembly Fit the fan to the smoke chamber IMP...

Page 21: ...on In case of maintenance it is possible to remove the strap by acting on the locking slots Insulation and casing assembly Detail A assemble the knob pos 4 on the top door closing handle Mount the screw and nut on the top door and screw the knob on pos 1 2 3 Detail B assemble the air header pos 2 Primary and secondary air draught adjustment is described on page 30 Detail C assemble the screw and n...

Page 22: ...a suitable product Remove the protective film from the plates and apply them making sure they stick perfectly Do not remove the plates as they would then no longer stick The thermostat bulbs are identified by labels attached to their respective capillaries accordingly be careful not to tear any of these labels during any maintenance operations A Place the bulb of flow probe S4 the bulb of safety t...

Page 23: ...mply with the standards in force The flue gas chimney must be made properly to favour the normal flow of flue gas from the combustion chamber towards the outside in the case of a power outage Remember that the elimination of excess heat is managed optimally by the electronic control unit The following are the main features of the flue gas exhaust pipe according to that es tablished by standards UN...

Page 24: ...ction valve which allows you to perform efficient and periodical cleaning as well as draining any condensation formed The chimney must be strictly wind and rain proof Appropriately insulate the flue gas exhaust pipe in the section passing through the wall The flue gas exhaust pipe if completely outside should be made in double wall stainless steel to guarantee both greater resistance to atmospheri...

Page 25: ...mbustion products and to the corrosive action of condensation which could be formed Predominantly vertical with deviations no greater than 45 It is recommended to provide a solid material and or conden sation collection chamber which can be inspected through an airtight door It is recommended to abide by that established by standards UNI 9615 and 9731 for the dimensioning of the chimney cross sec ...

Page 26: ...cian may perform the electrical installation Before performing connections or any type of operation on electrical parts always dis connect electrical power and make sure that it cannot be reconnected accidentally Remember that a bipolar switch must be installed on the boiler power line with over 3 mm between contacts easy to access making maintenance quick and safe The power cable must be replaced...

Page 27: ...N BN BK GN YE BU 2a 1a 2 1 BN BN BN BU BU BK BN GN YE GN YE L1 N BU GN YE GN YE Filtro antidisturbo Inverter Morsett 7 poli colore VERDE Morsett 9 poli colore GRIGIO Mors 6 p VERDE Mors 9 p GRIGIO Negro Marrón Rojo Naranja Amarillo Verde Azul Violeta Gris Blanco Rosa Turquesa Amarillo Verde Black Brown Red Orange Yellow Green Blue Violet Grey White Pink Torquoise Yellow Green BK BN RD OG YE GN BU ...

Page 28: ...eached P1 if TA is not in de mand the pump stops Key IR heating system P2 system pump RMV mixing valve 55 C SF flue gas probe S4 flow temperature sensor of the boiler S5 return temperature sensor of the boiler VE expansion vessel VE IR RMV P2 S5 S4 A B AB S4 S5 SF Micro porta TA P2 SF Mors 6 p VERDE Mors 9 p GRIGIO J4 Morsett 7 poli colore VERDE Morsett 9 poli colore GRIGIO The fan stops when prob...

Page 29: ...s FUNCTIONAL CONFIGURATION PARAMETER 18 1 Pred 0 Storage tank absent 1 Storage tank present 2 Pred 0 Coil type storage tank 2 Combi or Puffer type storage tank 3 Pred 0 Solar absent 4 Solar present 4 Pred 0 Wood only 8 Wood auxiliary boiler 5 Pred 0 Separate or wall boiler 16 Combi overlapped boiler Parameter to be entered for settings Language selection 0 Italian 2 English 4 French 6 Spanish 19 T...

Page 30: ...mperature detected by probe S4 does not meet the value set by parameter P1 If a DHW request is active pump P2 switches off and pump P3 switches on to meet the storage tank s requirements If however there is a demand for heating pump P2 turns into system pump remains in operation and is controlled by the room thermostat The counter exchange is controlled by the temperature differ ence detected betw...

Page 31: ...0 Storage tank absent 1 Storage tank present 2 Pred 0 Coil type storage tank 2 Combi or Puffer type storage tank 3 Pred 0 Solar absent 4 Solar present 4 Pred 0 Wood only 8 Wood auxiliary boiler 5 Pred 0 Separate or wall boiler 16 Combi overlapped boiler Language selection 0 Italian 2 English 4 French 6 Spanish 19 To enable or disable the probes enter a numerical value which is the result of the su...

Page 32: ...pump P2 is in operation until the temperature detected by probe S4 meets the value set by pa rameter P1 After that its function is controlled by the coun ter exchange between probe S4 and probe S2 The temperature differential which controls operation of pump P2 based on the temperatures detected by probe S4 and by probe S2 is represented by the value set in parameter P9 ad justable Pump P2 is on i...

Page 33: ...0 Storage tank absent 1 Storage tank present 2 Pred 0 Coil type storage tank 2 Combi or Puffer type storage tank 3 Pred 0 Solar absent 4 Solar present 4 Pred 0 Wood only 8 Wood auxiliary boiler 5 Pred 0 Separate or wall boiler 16 Combi overlapped boiler Language selection 0 Italian 2 English 4 French 6 Spanish 19 To enable or disable the probes enter a numerical value which is the result of the su...

Page 34: ...e the temperature set in the operating thermostat of the back up boiler has been reached in this case pump Pg does not stop In the event of wood fired boiler over temperature during back up boiler operation when the temperature in S4 reaches the value of parameter P1 pump P2 starts and some of the energy in the boiler is discharged into the puffer If the temperature in S4 should further increase u...

Page 35: ...0 Storage tank absent 1 Storage tank present 2 Pred 0 Coil type storage tank 2 Combi or Puffer type storage tank 3 Pred 0 Solar absent 4 Solar present 4 Pred 0 Wood only 8 Wood auxiliary boiler 5 Pred 0 Separate or wall boiler 16 Combi overlapped boiler Language selection 0 Italian 2 English 4 French 6 Spanish 19 To enable or disable the probes enter a numerical value which is the result of the su...

Page 36: ...ood fired boiler over temperature during back up boiler operation when the temperature in S4 reaches the value of parameter P1 pump P2 starts and some of the energy in the boiler is discharged into the puffer If the temperature in S4 should further increase until reaching the temperature value set in parameter P2 both the burner of the back up boiler and pump P4 switch off the system pump P3 switc...

Page 37: ...0 Storage tank absent 1 Storage tank present 2 Pred 0 Coil type storage tank 2 Combi or Puffer type storage tank 3 Pred 0 Solar absent 4 Solar present 4 Pred 0 Wood only 8 Wood auxiliary boiler 5 Pred 0 Separate or wall boiler 16 Combi overlapped boiler Language selection 0 Italian 2 English 4 French 6 Spanish 19 To enable or disable the probes enter a numerical value which is the result of the su...

Page 38: ...1 and S2 reduces to P10 3 C To enable the solar system you must access parameter 17 as sign value 1 to the probe present The final value to be entered in parameter 17 is given by the sum of the weights of the selected probes If for instance all the probes are enabled the number value to be assigned to the parameter is 31 The same operation must be repeated for parameter 18 Enable function 3 and as...

Page 39: ... side boiler functions adjustment MENU key functions value increase key functions value decrease key key to change priority domestic hot water heating boiler maximum temperature sound alarm acknowledge Functions of indicator lights solar panel pump start indicator light load pump start indicator light storage tank heating pump start indicator light free indicator light fan start indicator light au...

Page 40: ...orage tank with a coil It stops heating in favour of DHW production and vice versa The storage tank water production cycle or storage tank load ing will automatically activate when the storage tank minimum temperature is reached and it will de activate when the storage tank has reached the desired temperature When room heating is managed by the chronothermostat or room thermostat control with clos...

Page 41: ...vailable heat with regards to the heating system Puffer High Point 7 Fan Speed 8 Residual Time is the residual time activated during boiler ignition phase Display procedure The screens can be scrolled by using the direction arrows and present on the panel Boiler temperature adjustment procedure Boiler temperature may be adjusted by pressing key for about 3 seconds in this way the list of parameter...

Page 42: ...tank TANK in TANK or HEATING STORAGE TANK CONTROL PUFFER both with option to have one coil and relevant supporting SOLAR PANEL SYSTEM BACK UP BOILER CONTROL Before commissioning the boiler you must choose the op erating mode and follow the instructions for configuration of the board according to the type of system to be managed see diagrams below BOARD SUPPLY The circuit board has the following in...

Page 43: ...on of the boiler temperature is performed on an 8 C scale in four 2 C steps starting from the boiler working temperature defined by parameter no 0 see the list of parameters electro plumbing diagram page 23 Furthermore it is possible to set higher or lower modula tion according to parameter no 14 Modulation Step to adjust the fan stopping points as the temperature rises Massima Temp Fumi 180 C Vel...

Page 44: ...ctional settings parameter SEE ATTACHED DIAGRAMS Please note If you have any trouble installing and there fore enabling or disabling a probe you can use a wire to bridge the two connectors of the terminal block on the board to disable the missing or defective probe alarm 3 13 7 FUNCTIONAL SETTINGS OF THE BOILER AND ACCESSORIES Parameter 11 This parameter allows you to configure the printed circuit...

Page 45: ...uction above After making all the hydraulic connections fill the boiler and check the soundness of all the connections This operation must be performed carefully re specting the following phases open the bleeder valves of the radiators radiant batteries and or distribution manifolds open the system filling tap gradually making sure that the automatic air release valves in stalled on the system wor...

Page 46: ...ent of the boiler Is the system full of water and does not contain any air Are the drain valves closed and the system cut off devices fully open Is the outside main switch ON Is the pump are the pumps working correctly has the system been checked for water leaks Are the ventilation conditions and minimum distances to perform any maintenance guaranteed Has the operator been trained and has the docu...

Page 47: ...anner of loading do not prevent regular feeding of the fuel The wood logs must be placed lengthwise and horizontally No log should be tilted or placed sideways Once you have checked flame inversion it is possible to proceed with further loading bear in mind that the primary and secondary air adjustment indications in the table are approximate FURTHER LOADING Before loading wood once again consume ...

Page 48: ...ompletely open P Slightly closed in order to keep gasification low but sufficiently open to evacuate the ash that might close the combustion head GENERAL ADVICE Better performance will be achieved after two or three days of running In fact the refractory material must be fired and the tar must encrust the upper walls of the wood storage compartment The flame should have a good size and fairly fill...

Page 49: ...ollowing these rules 1 Use very dry wood 2 Load a small amount of wood in the boiler 2 or 3 times a day as needed Important It is very wrong to load the boiler completely providing it with long self sufficiency for example 24 hours This way the boiler with fan stopped would produce much acid condensation corrod ing the wood storage compartment 3 17 WARNINGS HOW TO AVOID CORROSION IN THE WOOD STORA...

Page 50: ...re reloading Problem The boiler does not reach the requested temperature The flame is small and there is too much air Inspecting the wood storage the formation of log bridg es is found Remedy Check the length of the logs see par 3 15 2 Check the arrangement of the logs see par 3 15 2 Cut the logs in half see par 3 15 2 Use smaller blogs round or square about 5 7 cm diameter Mix medium large sized ...

Page 51: ...ill appear at the bottom of the display The fan will run at full speed to extract the flue gas through the bypass After the door has closed the system continues working automatically following the panel board logic Just close the door to silence the alarm Remember that keeping the door open for long periods during reloading could deform the flue gas extraction impeller Faulty probe temperature mea...

Page 52: ...inted circuit board Advice for the user if it is necessary to set a working tem perature of more than 80 C it is advisable to proportionally increase parameter 2 max temperature for thermal inertia in the boiler PROBE AUDIBLE ALARM The boiler has an intermittent alarm system that signals one or more faults with the probes due to these being disconnected or out of range in any case a message is dis...

Page 53: ...l Unical spare parts must be used Before proceeding with maintenance always perform the following operations Isolate the appliance from the electric mains by means of an isolated device with a contact opening of at least 3 mm e g safety devices or power switches and make sure that it cannot be re connected accidentally Close the supply gas shut off valve to the back up boiler upstream of the boile...

Page 54: ...lame dies down before loading wood Every week Remove carefully all the residues of combustion accumulated in the firewood storage compartment Use the supplied brush to clean the triangular ducts in the furnace Remove the ashes contained in the smoke chamber from the side doors using a scraper Make sure that the slots in the grate are not obstructed if they are clear them up using the poker If the ...

Page 55: ......

Page 56: ...more it reserves the right to modify its products as deemed necessary or useful without affecting their essential features 46033 casteldario mantova Italy tel 39 0376 57001 telefax 39 0376 660556 info unical ag com export unical ag com www unical eu AG S p A 00335395 a 2 nd edition 08 15 www unical eu ...

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Unical NOVAIREX Series, Installation And Maintenance Instructions Manual

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