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31

Instructions for the installer

4.9 - WARNINGS

HOW TO  AVOID  CORROSION  IN THE  FIRE WOOD  BOX

The use of wood with a high moisture content
(higher than about 25%)

 

and/or loadings not

proportioned to the system’s heat request
(long OFF periods with the wood storage full)
can cause considerable condensate formation
in the wood storage’s internal wall.

Check, once a week, the internal steel walls of the fire box.
They must be covered by a slight layer of opaque coloured,
dry tar, with bubbles inclined to break and fall off.
On the contrary, if the tar is bright, runny and, if removed with
the fire stoke, some liquid appears, it is necessary to use wood
with a lower moisture content and/or reduce the quantity of the
wood when loading the boiler.
If, in despite of these interventions the tar does not dry, you
must inform the local After Sales Service of  this.

The condensate inside the fire box causes the corrosion
of the steel plates.
Corrosion is not covered by the guarantee, because it is
caused  by a bad use of the boiler (wet wood, excessive
loadings, etc.).

CORROSION IN THE FLUE CIRCUIT

The flue is rich in water steam, due to combustion and the use
of wood which always retains water.
If the flue comes into contact with relatively cold surfaces (with
a minimum temperature of about 60 - 70 °C), the steam water
condensates and in combination with other combustion
products originates corrosion phenomena of the metallic parts.

Every day check if there are signs of smoke condensation (black
liquid on the floor, behind the boiler). In this case you must use
a wood with a lower moisture content; check that the
recirculation pump is working correctly, the flue temperature
at part load, and increase the working temperature. To control
the room temperature it is therefore  necessary to install a
mixing valve. 

The corrosion

 

caused by flue condensation is

not covered by the

 

guarantee, because it is caused by the

wood’s moisture content and the

 

way the boiler is used.

4.8 -

CHECKS TO BE CARRIED OUT AFTER
THE FIRST START

CHECKING SEALS

During the initial start-up check the tightness
of the circuit and the connection to the
chimney flue. If there is any noticeable leaks
fumes alert the installer and / or our Service.
If there is any noticeable aspiration of air
through the door seals, tighten the handle
with greater force.

Check the proper operation of the thermostat, Te (32) at full
power (chapter 3.12) up to stop the fan.
Check for leaks from pipe connections.
After the initial start, at boiler  off, open the lower door and
inspect the interior walls and finish of the door should be a
light color, indicative of proper adjustment of the air.
Otherwise, if the walls are blackened, it will mean a lack of
secondary air control (chapter 4.7 and 4.9).

GENERAL ADVICES

- Best performances are obtained after two/three days of
operation. Refractory material must be cooked and the tar
must encrust  the top of the wood storage.
- The flame should have a good size and fairly fill the firebox.
- The flame should not be too red (default secondary air S).
- The flame should not be too blue (excess secondary air S).
- The flame should not be too noisy (excess primary air P).
- The flame must not be too small (default primary air P).

- If the ash does not go down well (increasing the primary air
P).
- If too much ash falls (decreasing primary air P).
- If the chimney smokes (open throughout the secondary air
S).
- If it continues to smoke (give max. secondary air, and
choking even the primary S P).

AIR ADJUSTMENT FAULTS

1) If 

the primary air is excessive 

a lot of ash and small pieces

of coal will fall through the slot into the combustion chamber.
The flame is too fast, dry, a cold colour and makes a noise.
The boiler is consuming a lot of wood and the door’s refractory
insulation is white.

2) If 

the primary air is insufficient 

the flame will be slow,

indecisive, influenced by air currents and by the chimney
draught, very small, incapable of touching the lower cradle,
with low ash production and the door’s refractory insulation
will be of a dark colour.

3) If 

the secondary air is excessive 

the flame will be small, a

blueish colour and very transparent.

4) If 

the secondary air is insufficient 

the flame will be big, it

will touch the lower cradle, it will completely fill the combustion
chamber and, above all, it will be a red colour and not
transparent

Содержание AIREX 25 2S

Страница 1: ...AIREX 2S INSTALLATION AND SERVICING MANUAL 00333938 1st edition 12 11 ...

Страница 2: ... 3 4 Transportation 13 3 5 Installation 14 3 6 Boiler system connection 14 3 7 Connection to the heat exchanger s drainage 15 3 8 Recycling pump 15 3 9 Installation instructions 16 3 10 Flue outlet connection 20 3 11 Electrical connections 21 3 12 Standard control panel 22 3 13 Water and electrical connection diagrams 24 3 14 Filling the system 26 4 BOILER START UP 27 4 1 Initial lighting 27 4 2 F...

Страница 3: ...eck the state of wear of the anode 1 4 INFORMATIONTO BE HANDED OVERTOTHE USER OR PERSON IN CHARGE OFTHE APPLIANCE The user or the person in charge has to instructed on the use and operation of his heating system in particular Hand over these instructions to the end user or person in charge of the appliance together with any other litera ture regarding this appliance placed inside the envelope cont...

Страница 4: ...e appliance must be carried out by qualified service engineers UNICAL recommends drawing up a service contract Bad or irregular servicing could compromise the safe operation of the appliance and could cause injury to persons animals or damage to property for which UNICAL shall not be held liable Modifications to parts connected to the appliance Do not carry out any modifications to the following p...

Страница 5: ...ing 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 authorized ...

Страница 6: ...door for loading wood covered with refractory Lower door complete of air combustion adjustments coated with refractory material and equipped with light flame control Smokebox rear side doors and inspection cleaning ashes Smoke exhaust with fan inlet n 2 fan for the model AIREX 65 2S and AIREX 80 2S Smoke ventilation fan in the suction Patented thermostatic valve system Safety heat exchanger Boiler...

Страница 7: ...A B C D E F G 560 700 655 700 655 900 1225 1355 190 160 190 160 245 1030 1355 190 160 245 245 1140 1140 mm mm mm mm mm mm mm AIREX 65 2S 65 78 2 755 955 1405 190 160 245 1180 AIREX 80 2S 80 96 755 1255 1405 190 160 245 1180 Power achieved with good quality wood containing 15 moisture Pressure drop corresponds to the capacity on a temperature difference of 15K T3 T4 T5 T6 T7 T8 UNI ISO 7 1 Ø mm UNI...

Страница 8: ...s This is because it is necessary that the flame in its convective motion does not meet another fuel in addition to the one which it has generated it As in residential heating the fuel is in form of wood logs which are loaded from the top the flame has to go in the opposite way i e downwards Natural draught is a very variable source of depression according to the type of chimney on the weather con...

Страница 9: ...utput is regulated via the adjustment system EXCHANGE SURFACE 6 As the boiler operates on wood and because the sulphur concentrations are not very high it is important to obtain very low smoke temperatures in order to increase the water efficiency To obtain this Unical has opted for an exchange surface with dry smoke passes fig 4 which have already been extensively tested in oil fired boilers work...

Страница 10: ...sible embers The flames after having bounced off the walls of the bottom area and the refractory ones direct themselves with a whirling motion towards the front part of the combustion chamber and enter the flue ducts The combustion will be complete and clean and the dominant colour will be that of the ashes white THERMOSTATIC VALVE 9 As well known wood normally has a high moisture content when com...

Страница 11: ...ore installing the boiler the following points have to be carried out by a professionally qualified person a The whole system should be thoroughly flushed in order to remove any residual dirt or grime which could compromise correct boiler operation b 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 ...

Страница 12: ...uctions for the installer 3 2 INSTALLATION CODES OF PRACTICE The AIREX 2S is a boiler foreseen for operation with firewood The appliance must be installed in compliance with all applicable laws and regulations ...

Страница 13: ...recommendations Packages description 1 Boiler body 2 Package containing the shell and boiler insulation 3 Package containing the instrument panel 4 Package containing the fume extraction fan 5 Package containing manifold air inlet inspection covers smoking chamber handles mirror flame detector various screws cleaning accessories This package is shipped inside the wood storage In the documents plac...

Страница 14: ...stable so as to reduce possible vibrations and noise An adequate clearing must be left behind the boiler for servicing INSTALLATION IN BOILER ROOM Note The minimum clearances indicated in figure 9 are compulsory only for boilers with an output higher than 35 kW 3 6 BOILER SYSTEM CONNECTION Warning Make sure the connection of the pipelines is free of mechanical stresses in order to avoid pressure l...

Страница 15: ... visible Warning In absence of this precautionary measure the eventual intervention of the heat discharge valve could cause damages to people animals or property The manufacturer shall not be held liable for any such injury and or damage MAINS DRAIN 3 8 RECIRCULATION PUMP For correct boiler operation it is necessary to install a recirculation pump in the boiler The recirculation pump supplied as a...

Страница 16: ...ight on the lower door fig 11 fig 12 fig 13 IMPORTANT When installing the fan should check the tightness of the seal on the smoke chamber otherwise it would cause the deformation of the wall resulting in severe damage to the impeller and or fan motor This shortcoming is all the more rapid the more frequent the opening of the door loading wood Fit the insulation of the boiler by performing a suitab...

Страница 17: ... on the round the instrument panel to the cover mantle pos 3 4 5 e 6 Fix to the top panel the rear profile support cable ties pos 7 Open the instrument panel by acting with a screwdriver on the two side screws Lift the cover posteriorly by rotating it forward Insert all the capillaries of the thermostats unroll carefully the connecting cable of the fan output The microswitch cable opening door inp...

Страница 18: ...el Pay attention that the wires do not come in contact with the smoke chamber During operation this reaches high temperatures TERMOSTATO DI ESERCIZIO Te TERMOMETRO MOLLA DI CONTATTO TERMOSTATO DI MINIMA Tsc MOLLA DI FISSAGGIO TERMOSTATO DI MASSIMA Tmax TERMOSTATO DI SICUREZZA Ts MOLLA DI FISSAGGIO 3 2 1 The solid fuel thermal generators are installed with the security provided by the laws in force...

Страница 19: ...mp to prevent a return to low temperature which could compromise the life of the boiler The UNICAL to help its customers has therefore developed a hydraulic kit for recirculation that enhances the function of the circulating water in the boiler This kit is supplied as an option and is available by quoting the order code on the model of your boiler fig 18 ...

Страница 20: ...d joints to avoid that flue condensate leave the walls dirty due to permeation The entrance to the chimney should be at an angle of 45 At the base of the chimney a flue inspection opening has to be made It is advisable to insulate the boiler pipe connection to the chimney in order to reduce the heat losses and noise 1 Boiler 2 Flue outlet connection 3 Ashes collecting chamber 4 Chimney 5 External ...

Страница 21: ... or inexpert people to use the appliance Connection to mains electrical supply 230V I collegamenti elettrici generali sono illustrati a pag 23 e negli schemi pratici di collegamento a pag 24 e 25 A mains supply of 230 V 50 Hz is required The wiring to the boiler must be in accordance with the current CEI regulations DANGER The electrical connections must be carried out only by a qualified engineer...

Страница 22: ...time the temporized relay stops the fan This can be due to the boiler not firing or due to an insufficient load of the firewood To avoid this inconvenience it is possible to increase the temporized relay s intervention time this operation has to be done only by trained personnel or more firewood has to be loaded If the boiler fires in a regular manner when the boiler reaches 65 C the C H pump is a...

Страница 23: ...utral F1 General fuse max 4A IG Mains switch with warning light Ipi C H pump switch Iv Fan switch LL Power ON lamp Pi C H system pump Pr Recirculation pump Rt Temporized relay R1 Relay Te Working thermostat 75 C 85 C TKS By pass shaft microswitch Tmax Limit thermostat 90 C Ts Safety overheat thermostat 100 C Tsc Minimum thermostat for wood fired boiler 65 C V Fan s 34 reference to front view facia...

Страница 24: ...ening switch TA Thermostat fig 22 The Standard panel AIREX boiler operates automatically the shut off of the fan and the recirculation pump if the boiler temperature After 30 minutes from the closing of the door top loading for the ignition of the boiler does not reaches 65 C temperature minimum The panel and the cycle can be reset only after opening the upper door to a new power or by the off and...

Страница 25: ...fter opening the upper door to a new power or by the off and the power of the main switch pos 11 The same logic of the instrument panel production stop the fan and the recirculation pump at the end of loading the wood The pump system will operate only after passing the minimum temperature in the boiler of 65 C Upon reaching the lower threshold of 65 C down the pump system will shut down The charge...

Страница 26: ...again through the radiator s air vents check all the connections for soundness after having fired the boiler for the first time and the system has reached the correct temperature arrest the pump and repeat the air bleeding operations let the system cool down and if necessary re establish the water pressure to 1 bar this is valid only for installations equipped with a closed expansion vessel consul...

Страница 27: ... and that it is connected to the sewage system there are no water leaks all the necessary ventilation conditions and minimum clearance distances are guaranteed for subsequent servicing LIGHTING AND SHUTTING DOWN PROCEDURES For lighting and shutting down the boiler refer to the USER INSTRUCTIONS MANUAL Information to be passed on to the user The user must be instructed on the use and operation of t...

Страница 28: ...iler s output and therefore to reduce its autonomy Moreover they fall with greater facility in the lower chamber reducing the risk of the formation of bridges The so called bridge is an empty space in the firebox where unburnt wood logs remain In this case the bed of embers is not fed with continuity and the refractory burner s slot is uncovered In these conditions preferential air passages are cr...

Страница 29: ...er or similar Approach the top door and turn on the fan Wait a few minutes that the fire takes and produce the coals 5 10 minutes After few minutes If looking through the light of lower door it will see that the flame inversions is beginning add more bigger wood Close the top door Important during the operation the by pass must be always perfectly closed The wood must be of the following length a ...

Страница 30: ...ulations see fig 28 At first start you need to adjust the primary and secondary air bearing in mind that the primary air determines the power of the boiler and therefore the amount of wood that is burned and the secondary air completes the combustion It is necessary for proper regulation of air according to the wood used and its actual moisture observe the flame through the inspection glass placed...

Страница 31: ...t up check the tightness of the circuit and the connection to the chimney flue If there is any noticeable leaks fumes alert the installer and or our Service If there is any noticeable aspiration of air through the door seals tighten the handle with greater force Check the proper operation of the thermostat Te 32 at full power chapter 3 12 up to stop the fan Check for leaks from pipe connections Af...

Страница 32: ...l If this problem is repeated inform the local After Sales Service PRECAUTIONS TO BE TAKEN DURING BOILER OPERATION After every air adjustment wait 5 to 10 minutes before making a new adjustment Once the best adjustment has been established at the end of the day check that the surfaces of the combustion chamber and the door insulation are of a white colour In the ash deposited in the cradle there m...

Страница 33: ... not remain unused for long periods see paragraph 6 9 Use thicker wood logs Use up all the wood before loading a new batch Problem The boiler does not reach the requested temperature The flame is small and there is too much air When the fire box is checked a formation of log bridges is found Remedy Check the length of the wood logs see paragraph 6 6 Check how the wood logs are loaded in the fire b...

Страница 34: ...e indicated INSTRUCTIONS FOR INSPECTION AND SERVICING To ensure a long life to all your boiler components and in order not to alter the conditions of the approved product only original UNICAL spare parts must be used Before servicing always carry out the following steps Disconnect the mains electricity supply Separate the appliance from the electrical supply by means of a separating device with an...

Страница 35: ...case of maintenance works on structures sited near to the chimney or flue outlet system and their accessories switch OFF the boiler and when the work is finished check that they are functioning correctly Do not clean the boiler or its parts with easily inflammable products gasoline alcohol etc Do not leave inflammable products in the room where the boiler is installed Do not clean the boiler room ...

Страница 36: ...he formation of condensate or tar tears clean very carefully in order not to bend or deform the blades This could make the fan noisy during operation and could reduce the fan s performances Cleaning the primary and secondary air distributor Remove the central wall fig 30 where the air adjustments are placed and clean the inner space carefully from tarry residues dust and wood flakes which have ent...

Страница 37: ...rity of doors seals Correct operation of the loading door microswitch Cleaning the fan blades Fan noise Cleaning the flue circuit on the rear side of boiler If necessary replace If necessary replace If necessary replace If necessary clean them If necessary adjust it If necessary repair it using the refractory kit see spare parts list If necessary re position it If necessary repair and or replace t...

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Страница 40: ... of transcript or press Also reserves the right to bring those changes that it will hold necessary to it own products or profits without jeopardizing its essential characteristics AG S P A 46033 casteldario mantova italia tel 0376 57001 r a fax 0376 660556 www unical ag info unical ag com ...

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