Automatic Heating Modulex EXT 440 Installation And Servicing Instructions Download

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Modular Condensing Boiler

Modulex EXT

440 - 550 - 660 - 770 - 900

Installation and Servicing Instructions

Summary of Contents for Modulex EXT 440

Page 1: ...Modular Condensing Boiler Modulex EXT 440 550 660 770 900 Installation and Servicing Instructions ...

Page 2: ...23 3 15 Boiler freeze protection 24 3 16 Mixing header and plate heat exchanger 24 3 17 Condensing drain 25 3 18 Water treatment 26 3 19 Flue chimney connection 27 3 20 Flue manifold connection 27 3 21 Operation 29 3 22 Electrical connections 31 3 23 Functional wiring diagram 32 3 24 Wiring diagram for connection and managing 34 3 25 Installation examples functional wiring and connections descript...

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 ...

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: ...ater circuit features 15 Qnw Nominal heat input in D H W mode if different from Qn 16 D Specific D H W flow rate according to EN 625 EN 13203 1 17 R factor N taps based on the quantity of water declared EN 13203 1 18 F factor N stars based on the quality of water declared EN 13203 1 19 PMW Max pressure D H W system 20 T max Max temperature D H W system C Electrical features 21 Electrical power sup...

Page 6: ... 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 autho...

Page 7: ...2 TECHNICAL FEATURES AND DIMENSIONS Logic of operation A Output sharing on as many modules as possible at min load down to 22 kW for the max efficiency B Automatic operation hour splitting up system for each module to guarantee the best homogeneous use C D H W production via a storage tank loading pump or a three way diverting valve controlled by a priority sensor through the E 8 heating controlle...

Page 8: ... 4 1448 1087 1039 946 80 3 100 4 100 4 300 40 395 946 235 S 1267 534 327 R M G 122 660 6 1448 1355 1307 946 80 3 100 4 100 4 300 40 770 7 1448 1623 1575 946 80 3 100 4 100 4 300 40 550 5 1448 1355 1307 946 80 3 100 4 100 4 300 40 900 8 1448 1623 1575 946 80 3 100 4 100 4 300 40 Smoke outlet Left side standard condition Right side Back side 1448 L1 287 L 62 5 24 S 2 2 DIMENSIONS FRONT VIEW RIGHT HA...

Page 9: ...Minimum Heat Input on P C I Qmin kW Nominal Output Tr 60 Tm 80 C Pn kW Minimum Output Tr 60 Tm 80 C Pn min kW Nominal Output Tr 30 Tm 50 C Pcond kW Minimum Output Tr 30 Tm 50 C Pcond min kW Efficiency at max output Tr 60 Tm 80 C Efficiency at min output Tr 60 Tm 80 C Efficiency at max output Tr 30 Tm 50 C Efficiency at min output Tr 30 Tm 50 C Efficiency Class acc to Directive 92 42 CEE Combustion...

Page 10: ... on the L H side Gas connection on the L H side BCM under the frontal panel 2 4 R H SIDE VIEW WITH MAIN COMPONENTS GAS PIPE H LIMIT THERMOSTAT IGNITION ELECTRODE CONTROLL PANEL FAN GAS VALVE BURNER COVER BURNER ALUMINIUM SILICON HEAT EXCHANGER CONDENSATE COLLECTING TRAY SMOKE MANIFOLD C H RETURN C H FLOW AUTOMATIC AIR VENT Min Depth 100 mm BOILER FRAME ...

Page 11: ... indication on the packaging and on the data badge c Check that the chimney flue pipe has an adequate 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 ...

Page 12: ...pply company The installation must be carried in accordance to the codes of practice the regulations and the requirements hereby indicated which constitute an indicative list but not a complete one as these continue to undergo evolve devolpments Moreover the boiler must be installed in accordance to all the regulations regarding the boiler room the building regulations and the prescriptions regard...

Page 13: ...have a jib crane to avoid to damage during the removal Remove the casings and make the sling with the belts A fig 3 having care to pass the belts bearing bars frame Tie the belts to thearm B during these operationsact with caution On the L H side of the boiler There is the terminal of the smoke chamber fixed A carton box containing Gasket between smoke chamber and its terminal Gasket for the base ...

Page 14: ...rn u pside down Do no t exp ose t o ra in Frag ile Do n ot ex pose t o sun ligh t Do not store at t emp eratu re l owert han 5 C 23 F s uperior tha n 50 C 122 F T max 50 C 122 F T mi n 5 C 23 F 3 Max adm itt ed bo ilers sta cked Do no t t urn u psid e do wn Do n ot exp ose to rain F ra gile Do n ot e xpo se to s unl igh t Do no t st ore at t emp eratu re l ower th an 5 C 2 3 F su pe rio r than 50 ...

Page 15: ...applicable requirement The boiler can be put on a flat and sufficiently strong base with the same dimensions as the boiler ones and at least 100mm high see fig 25 in order to assemble the conden sate drain siphon An alternative to this base may be a 100mm deep well next to the boiler as siphon housing see fig 25 After installation the boiler shall be perfectly horizontal and stable to reduce any p...

Page 16: ...ained in the system The system has been cleaned of impurities and lime scale When a Modulex boiler is installed onto an existing heating system In case the replacement of an existing boiler in an old system can be programmed it is necessary to thoroughly clean out the system with a basic solution The system must be cleaned 4 weeks before the substitution with the system firing at a temperature of ...

Page 17: ...ts indicated by the local gas supplier An incorrect installation could cause injury to persons animals or damage to property The manufacturer shall not be held liable for any injury and or damage Before installing the boiler 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 ...

Page 18: ...RBIDDENTOFITON OFF VALVES ON THE GENERATOR TO THE FORE OFTHESAFTEYDEVICES WARNING Before installing the boiler we recommend that the system is flushed out with a suitable product in compliance to the norm UNI CTI 8065 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 instruct...

Page 19: ...owing table gives an indication of the pump s flow rate in function of the Δt of the primary circuit if the installation has a mixing header For a DT 20 K of a MODULEX 900 boiler the max water flow rate requested is 36289 l h From the graph of the boiler s pressure losses it can be determined that the pump must be able to guarantee a delivery head of at least 1 8 m H2 O 0 0 4 0 2 0 6 0 8 1 1 4 1 2...

Page 20: ... pressure switch it has the function of shutting down the generator if it reaches the maximum working pressure can be calibrated from CONTROLDEVICES 11 Pressure indicator with shock absorber tube 12 and pressure gauge holder valve 13 it indicates the effective 3 10 ADDITIONAL SAFETY AND CONTROL DEVICES ACCORDING TO THE ITALIAN LAW 1 2 2a 4 6 1a 11 12 14 15 18 10 13 17 3 19 16 kit ISPELS MODULEX 44...

Page 21: ...NAL SAFETY DEVICES MODULEX 440 550 660 700 COMPO S 00361994 PREMO S 00362065 PREMO C 00362067 MODULEX 900 COMPO S 00361995 PREMO S 00362066 PREMO C 00362068 COMPO S PREMO S PREMO C 3 11 WIRING DIAGRAM FOR ADDITIONAL SAFETY DEVICES Pump management via E8 to the terminal 4 A10 from the IV connector LINE 230 V Safety devices kit RELAY L N LINE Boiler mains supply 230 V N L1 L N N L1 Terminals EXT MIN...

Page 22: ...ge pipe with a funnel and a siphon which lead to an adequate drainage The drainage has to be controllable by sight If this precaution is not made an eventual intervention of the pressure relief valve could cause injury to persons animals or damage to property The manufacturer shall not be held liable for any injury and or damage 3 14 BALLSTOP VALVES The installation of ballstop gate valves on the ...

Page 23: ...re Boiler Circuit M 70 C R 55 C Heating System Circuit M 50 C R 40 C Plate Heat exchanger COLD OUT CH FLOW to System circuit G 4 COLD IN CH RETOUR from System circuit G 4 HOT IN CH FLOW from boiler G 4 HOT OUT CH RETOUR to boiler G 4 3 15 BOILER FREEZE PROTECTION Should the flow temperature measured at global flow tempera ture NTC decrease under 7 C the system pump is set up Shoul temperature decr...

Page 24: ...allation its minimum height when all the fans are in oper ation must be at least 25 mm 1 in Is forbidden discharge the condensate through the rain gutters given the risk of ice and degradation of the materials normally used The connection discharge should be visible due to the level of condensate acidity pH 3 to 5 as a material piping must be used only suitable plastics The outlet of the condensat...

Page 25: ... water is alkaline or it is caused by an alkaline treatment for example phosphate or glycol used as an antifreeze 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 in...

Page 26: ...to the national and local rules in force For the dimensioning follow the instruction in pr EN 13384 In order to prevent during the operation the formation of ice the temperatureof the internal wall of the combustion product evacuation system in all its length has not to be below 0 C For condensation operating conditions of the appliance at the external design temperature it will be necessary to fo...

Page 27: ...296 370 444 519 593 668 741 889 1037 3 4 3 9 4 4 5 0 5 6 7 8 9 11 17 22 28 34 39 44 50 56 67 78 89 100 111 167 222 277 333 389 445 555 667 778 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 0 009 0 010 0 015 0 020 0 030 0 035 0 040 0 050 0 060 0 070 0 080 0 090 0 100 0 150 0 200 0 250 0 300 0 350 0 400 0 500 0 600 5 0 700 9 0 10 8 12 0 14 4 22 25 29 32 36 54 72 90 108 126 144 180 216 252 288 324 ...

Page 28: ...nsate collecting manifold and then are evacuated through the chimney Condensate collecting tray smoke manifold Control Panel Burner Siphon Fan Ionization electrode Combustion Chamber H L Thermostat Thermic element Gas valve The MODULEX EXT is made of inter linked modules each module is made of Combustion Chamber Burner Fan Gas valve Local NTC Negative Temperature Coefficient sensor checks the flow...

Page 29: ...es clearly efficiencies much higher than those obtained in traditional groups of small boilers installed in cascade When the input shared on each thermal element is less than 12 kW one thermal element after the other is automatically excluded and the remaining input is shared on thermal elements having the smallest number of operation hours by the automatic operation time calculating system Modula...

Page 30: ...ction 230V The electric connections of the boiler are shown in the section named WIRING DIAGRAMS A mains supply of 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...

Page 31: ...N L1 L 1 M2 BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE BLUE 1 2 3 Y2 4 5 6 7 Y3 1 2 3 Jp1 1 2 3 Y4 4 DL1 DL2 DL3 1 2 3 Y1 4 5 6 A1 SW1 0 10 V Modbus B Modbus A PLC BMS BCM eBUS eBUS 24 V PR IG GREY PINK WHITE WHITE BLACK BROWN BROWN BLACK RED II I O 1 1a 1b SE8 BCM BROWN WHITE BLACK BROWN BLUE BLUE TL TL1 ARANCIO NERO MARRONE PWM BLU TACHO BLU N MARRONE L1 RIL REG ALIM 2...

Page 32: ...L8 SR2 SR7 RIL REG ALIM 230V ORANGE BLACK BROWN PWM BLUE TACHO BLUE N BROWN L1 BLUE BROWN BLUE BROWN BLUE BROWN RED WHITE WHITE LIGHT BLUE LIGHT BLUE E RIL 2 E RIL8 PINK GREY PINK GREY BLUE BROWN WHITE 2 8 Modules TR ACC 2 TR ACC 8 E ACC 2 E ACC 8 VG2 VG8 BLUE BROWN BLUE BROWN BLUE BROWN RED SL ORANGE ORANGE BROWN WHITE 24 V eBUS eBUS RED BROWN BLACK 0 1 2 3 4 5 6 7 8 9 BROWN BLUE BROWN LIGHT BLUE...

Page 33: ...8 A9 A10 A11 IV 4 M 2 1 3 n 1 2 3 4 IX L H BUS 50 Hz 230 V 1 2 3 III IMP 0 10V F17 F15 3 1 FBR 1 2 VIII PT1000 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 N L 1 L 1 1 2 1 Power supply PINK GREY From BCM BLUE BROWN BLACK Terminal II II A1 A2 A3 A4 A5 A6 N L1 L1 M T1 T2 6 7 8 9 10 1 2 3 4 5 N L 1 L 1 1 2 1 II N L1 L2 Neutral conduc...

Page 34: ...ensor Buf stor tank middle sensor FBR heat circ 1 room sensor Buf stor tank top sensor FBR heat circ 1 set value 1 2 V SPF F12 F11 VF Terminal V V VF SPF Pin 1 Flow sensor heating circuit 1 sensor multifunction 1 Pin 2 Service water low sensor sensor multifunction 2 1 2 VIII PT1000 F14 F13 Terminal VIII F13 F14 Pin 1 Sensor HS2 Solar 2 Multifunction relay 3 Pin 2 Sensor Solar 1 Sensor multifunctio...

Page 35: ...ION 9 10 outdoor sensor 4 Pump heating circuit 1 AF 1 Flow sensor heating circuit 1 VF 10 I 10 Ground outdoor sensor 4 Collector pump 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 4 Collector pump 1 Flow sensor heating circuit 1 VF 10 I 10 Ground outdoor sen...

Page 36: ...SE n 5 Re circulation pump storage tank 4 Collector pump INSTALLATION OF A BOILERWITH CONNECTIONTOTWO MIXED ZONES D H W PRODUCTION F Ric C VF VF SPF 1 2 n 4 VF VF VF AF 3 Heating Circuit 1 Heating Circuit 2 Mixing Header Primary system pump Outside Sensor Safety devices kit Filter 9 10 outdoor sensor 4 5 Flow sensor heating circuit 2 6 7 Storage tank sensor 4 Pump heating circuit 1 5 Pump heating ...

Page 37: ...heating circuit 2 6 Cylinder charging pump SPF AF n 5 Re circulation pump storage tank VF V 2 Hot water tank low Multifunction relay sensor 2 2 PT1000 sensor solar 1 Multifunction relay sensor 4 PT1000 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 4 Collector pump 7 Mixer motor heating circuit 2 OPEN 8 Mix...

Page 38: ...ulation pump storage tank ATTENTION In this type of installation it is necessary to adjust in the E8 controller the parameter BUS ID HS The external regulator E8 MASTER has to be set to the boiler regulators E8 SLAVES have to be set to 01 to 08 1 Flow sensor heating circuit 1 VF 10 I 10 Ground outdoor sensor 9 10 outdoor sensor 4 5 Flow sensor heating circuit 2 optional 6 7 Storage tank sensor 4 P...

Page 39: ...ol of heating request temperature set point and modulation level Monitoring of boiler operation and temperature status Alarm control Functional parameters setting Management of the header pump Relay command for running a pump at fixed rate 0 10 analogical output for control of a modulating pump Special functions Emergency it avoids system shutdown caused by an interruption in communication with th...

Page 40: ... eBUS remoto BCM eBUS eBUS 24 V eBUS remoto BCM modulex 1 Y2 3 4 BCM modulex 2 Y2 3 4 1 2 3 Y2 4 5 6 7 Y3 1 2 3 Jp1 1 2 3 Y4 4 DL1 DL2 DL3 1 2 3 Y1 4 5 6 A1 SW1 eBUS remoto BCM eBUS eBUS 24 V eBUS remoto BCM modulex 3 Y2 3 4 Cascade Manager Cascade Manager Dalla 1a caldaia portare il collegamento eBUS lato HOST BCM su eBUS 2a e 3a etc dopo aver posizonato il selettore di questa su 0 Removed wiring...

Page 41: ... 1 2 3 Y1 4 5 6 A1 SW1 eBUS remoto BCM eBUS eBUS 24 V eBUS remoto BCM modulex 2 Y2 3 4 Connection for boilers in a cascade arrangement connected to an external BCM optional and managed by PLC BMS E8 disconnected The applications in a cascade arrangement managed with an additional BCM require the correct boiler address setting within the cascade formation via the BCM s internal SWI selector 0 7 all...

Page 42: ...W1 eBUS remoto BCM eBUS eBUS 24 V eBUS remoto BCM modulex 2 Y2 1 2 Connection for boilers in a cascade arrangement managed by an external PLC E8 disconnected The applications in a cascade arrangement managed with Modbus require the correct boiler address setting within the cascade formation via the BCM s internal SWI selector 1 7 all different and in sequence exactly as requested by the single bur...

Page 43: ...s preset to 3 for minimum speed 10 Volt for maximum speed These values can be changed according to the type of pump fitted For further information on the 0 10Volt signal please also refer to the pump s manual MODULATING PUMP ON OFF PUMP MODULATING PUMP 1 2 3 Y2 4 5 6 7 Y3 1 2 3 Jp1 1 2 3 Y4 4 DL1 DL2 DL3 1 2 3 Y1 4 5 6 A1 SW1 PUMP BCM eBUS eBUS 24 V N L1 N L1 P N L POWER TERMINALS E8 ALARM Mains s...

Page 44: ... the system a filling tap has to be foreseen on the system return pipe The filling up can also be made through the draining tap on the boiler return manifold Never use such a tap to drain the system since the system dirt could gather in the boiler and compromise its operation The system itself shall be equipped with its own draining tap whose size depends on the system capacity The application of ...

Page 45: ...ion CASCA DE MAN 100 Check that the C02 values are within the values indicated in the table Burner pressures If necessary correct the value by turning the adjustment screw A in a CLOCKWISE direction to decrease the va lue and in an ANTICLOCKWISE direction in order to incre ase it 3 1 2 4 WARNING Remove the cap 2 fix red cap 3 to the gas outlet Insert the CO2 analysis probe 4 on hole of the cap Mea...

Page 46: ...BASIC ADJUSTMENTS Check the C02 values at the minimum and maximum outlet If necessary make the required adjustments To ensure correct operation the C02 values have to be adjusted with extreme care respecting the values indicated in the table Close the sampling test point in the flue outlet terminal Do not force the end switches of the adjusting screw In case of gas valve replacement or difficult i...

Page 47: ... after that the planned parameters are restored SW NO XXXX CASCATA MANU BOILER 01 00 CHANGE PER CENT VALUE TO 10 BOILER 01 10 VARY THE VALUE FROM 10 TO 100 PER CENT BOILER 01 100 RELAY TEST Turn anticlok wise O displayed pen the operating flap DISPLAY GENERAL After 2 sec is displayed level DATA TIME SERVICE Press to open the level Before open the operating flap turn clock wise Shaft encoder to sym...

Page 48: ...mostat 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 level sen...

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 poisoning caused by the leakage of the flue gasses there are no water leaks all the necessary ventilation conditions and minimum cle arance distances are guaranteed for subsequent servi cing in case the boiler is sited in a cupboard compartm...

Page 50: ...it cannot be switched ON acci dentally 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 the...

Page 51: ...ce will increase which finally will result in a reduced heat input and consequently a reduced output efore cleaning the boiler body sections check the boiler input and the CO2 percentage see 3 24 Note Areduction of the 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 ...

Page 52: ...ciare la molla di fissaggio camera ventilatori lato destro sinistro Remove the red silicone pipe and then the fans room Remove the screws A fixing the burner covers with a 13 mm socket or open wrengh A Screws on thermal elements ...

Page 53: ...s with 5 mm hex key to reach the holes C left and right C move up the burners block Front Remove gas fittings from the gas manifold with flat key 36 mm Remove the screws gas collector left and right side Remove the four screws with a 36 mm socket wrengh then the gas flange ...

Page 54: ...ber Compressed air 3rd phase Reassembly Reassemble all the components previously removed by following the reverse order sure to tighten the screws of the mixer fans to the body with torque of 13 Nm CAUTION FOR EACH OPERATION OF MAINTENANCE MUST BE REPLACED THE GASCKETS FOR EACH BURNER Spare code 95251632 GASKETS KIT for BURNER MODULEX EXT 348 900 5 pz 95262961 BURNER KIT MODULEX EXT 348 900 Before...

Page 55: ...ting Pty Ltd ABN 90 446 545 923 51 Assembly Tullamarine Vic 3043 Australia PO Box 356 Tullamarine Vic 3043 Australia 61 3 9330 3300 61 3 9310 5655 sales automaticheating com au Telephone Facsimile Email www automaticheating com au ...

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Automatic Heating Modulex EXT 440, Installation And Servicing Instructions

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