Unical AIREX 25 2S, Installation And Servicing Manual

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

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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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Page 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 ...