Unical ALKON 100 EXT, Installation And Servicing Manual

Page 1: ...E N G L I S H INSTALLATION AND SERVICING MANUAL 100 EXT 115 EXT 140 EXT ALKON ...

Page 2: ... to a dealer who offers this service Separate disposal of a domestic appliance avoids possible negative consequences for the environment and human health deriving from inappropriate waste handling and allows the recovery of the materials of which it is made in order to obtain significant energy and resource savings http www unicalag it prodotti professionale 300 light commercial alluminio 1639 alk...

Page 3: ...nection 18 3 7 Connections 19 3 8 Filling the system 20 3 9 Electrical connections 22 3 10 Commissioning 27 3 11 Measurement of combustion efficiency during installation 28 3 11 1 Calibration function activation 28 3 11 2 Probes positioning 29 3 12 Burner adjustment 29 1 General information 4 1 1 General warnings 4 1 2 Symbols used in the manual 5 1 3 Appropriate use of appliance 5 1 4 Information...

Page 4: ...the product and must be kept by the user Read the warnings contained in this instruction booklet carefully as they provide important guidelines regarding installation use and maintenance safety Keep the booklet with care for further consultation Your appliance must be installed and serviced in compliance with the standards in force according to the manufacturer instructions up to standard and by l...

Page 5: ...ope inside the packaging 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...

Page 6: ...ch 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 gas leakage ATTENTION Indications for propane gas fired appliances Make sure that the gas tank has been deaerated before installing the appliance For state of the art tank venting contact the...

Page 7: ...ircuit 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 flow rate according to...

Page 8: ...tal surfaces must be clean see system protection ACCESSORIES sect in domestic price list ATTENTION see general warnings 1 1 The heating only models are NOT suitable for the production of water for human con sumption according to Ministerial Decree D M 174 2004 Attention Any damage to the boiler caused by the formation of fouling or by cor rosive water will not be covered by the warranty VALUE MIN ...

Page 9: ...ng antifreeze products with inhibitor for heating systems specific for multidmetal Do not use car engine antifreeze products as they could damage the water gaskets P O S ANTIFREEZE FUNCTION Power supplies 30 SMG Status function antifreeze Actions Electric Gas 1 ON ON 7 C ON Burner and Pump ON until T 15 C 2 ON OFF 2 5 C OFF FAULT CODE 16 see par 4 6 ERROR CODES Ignition disabled OFF ON OFF Ignitio...

Page 10: ...EGENDA N C E S E Description 3 VG Gas valve 5 Burner 10 HL TL Safety thermostat 11 Hb SR Heating temperature sensor 1 2 12 Ht P Modulating Pump 13 Lp DK Water deficiency pressure switch 14 Boiler drain valve 18 FL FH VM Fan 19 AF AS PV Flue gas pressure switch 20 Safety valve drain system 22 rb SRR Return temperature sensor 24 Aluminium Heat Exchanger 25 Vent valve 26 Condensation drain trap 27 E ...

Page 11: ...iew from above Side view 32 Outlet flue inspection 33 Heathing Controller 34 Gas cock 35 Ignition Trasformer 37 PFmin Gas min pressure switch G Gas inlet G 1 M Heating system flow G 2 R Heating system return G 2 Scond Condensation drain DN 32 C E ERROR CODES see S E WIRING DIAGRAM ...

Page 12: ...d m c a metres of water The table provides an indication the flow the pump in function of the Dt of the primary circuit ALKON 100 EXT ALKON 115 EXT ALKON 140 EXT Power supply in kW 100 115 135 Max flow rate demanded l h Dt 15 K 5591 6422 7545 Nominal flow rate request Dt 20 K 4193 4816 5659 ...

Page 13: ...rating temperature C 85 85 85 Flue gas mass flow rate min kg h 12 58 12 58 18 2 Flue gas mass flow rate max kg h 114 39 129 20 220 8 Excess λ air 26 84 24 25 25 53 Flue losses with burner in operation min 1 65 1 65 1 65 Flue losses with burner in operation max 2 47 2 56 2 90 Minimum heating circuit pressure bar 0 5 0 5 0 5 Maximum heating circuit pressure bar 6 6 6 Max allowable pressure of the ge...

Page 14: ... output in low temperature regime Tr 30 C ƞ1 97 5 97 6 97 6 Range rated boiler YES NO YES YES YES Auxiliary electricity consumption At full load elmax kW 0 474 0 474 0 474 At part load elmin kW 0 159 0 159 0 159 In stand by mode PSB kW 0 007 0 007 0 007 Other items Heat loss in stand by Pstb kW 2 68 2 68 2 68 Emissions of nitrogen oxides ref PCI PCS NOx Mg kWh 48 43 56 50 58 52 Annual electricity ...

Page 15: ...em to remove any residues or impurities which could jeopardise proper operation of the boiler even from a hygienic point of view b Check that boiler is set up to oper ate with the available type of fuel This can be seen written on the package and on the technical feature plate c Check that the chimney flue has an appropri ate draught without any bottlenecks and that no exhausts from other applianc...

Page 16: ...tion above The packaging elements cardboard box straps plastic bags etc must be kept out of the reach of children as they are potential sources of danger As well as the appliance the packaging contains A DOCUMENTATION ENVELOPE User operating instructions booklet Instruction booklet for the installer and maintenance engineer Certificate of conformity Gas conversion label Air inlet filter Kit multif...

Page 17: ...mbustion of condensing boilers and everything else applicable When choosing the place of the installation of the appliance follow the safety instructions below Place the boiler in a partially protected place and protect from frost Avoid installation in rooms with a corrosive or very dusty atmosphere The appliance must only be installed on a vertical and solid wall which can support its weight or o...

Page 18: ...18 SUPPORT FRAME 2 optional 2 ...

Page 19: ...B23P TOTAL LENGTH LS SINGLE Ø120 FROM m TO m 1 20 Connection to a combustion products evacuation pipe outside the room the combustion air is taken directly from the room where the appliance is installed C63x C63 Boiler intended for connection to a combustion air intake and combustion products evacuation system approved and sold separately ATTENTION The flue must comply with standards in force NOTE...

Page 20: ...cts for which the manufacturer cannot be held responsible If you smell gas a Do not operate electric switches the telephone or any other object that may cause sparks b Immediately open doors and windows to create air current to purify the room c Shut the gas cocks Condensation drain The boiler during the combustion process produces conden sation that through pipe A flows into the trap The condensa...

Page 21: ...ake sure that drain valve 29 it is closed The system must be equipped with its own drain valve with a size suitable to the capacity of the system Pressure in the mains supply must be between 0 5 and 6 bar In case of higher pressure a pressure reducer it must be installed Attention Do not mix the heating water with incorrect concentrations of antifreeze or anti corrosion substances This could damag...

Page 22: ...50 LEGENDA N Descrizione 37 BMM 2 Burner modul manager body 1 40 BMM 1 Burner modul manager body 2 41 M1 Power supply terminal 230 V 42 M2 Power Fans Terminal 45 BCM Burner Control Manager Cascade controller 46 F1 Power Fuse 6 3 A 47 F2 Power Fuse 6 3 A 48 INT C1 Switch Inhibit Body 1 49 INT C2 Switch Inhibit Body 2 50 PPD2 Connection pressure switch 2 51 PPD1 Connection pressure switch 1 52 Power...

Page 23: ...th a power cable boiler installation requires electric al connection to the mains power supply This connection must be made up to standard as required the regulations in force 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 Electric power supply connection ATTENTION Size of power supply cable...

Page 24: ...M Y2 6 7 INAIL safety connections FL Flow switch connection Remove the jumper and connect the cables as indicated between Y2 11 and terminal board M2 Remove the jumper and connect the cables as indicated between Y2 10 and terminal board M2 Safety Connection ...

Page 25: ...cated Y2 4 5 External 230 V 50 Hz power supply NOTE The boiler is set up for direct flow and storage tank management If Stemp ACC is connected automatically DHW is activated which will have priority management with regard to direct flow through the pumps shown below Should additional services be requested storage If the storage tank temperature sensor is connected DHW service is automatically acti...

Page 26: ...26 Control panel remotely NOTE For more information See Technical Info from site indicated at pag 2 ...

Page 27: ...e valves open does the gas to be used correspond to the boiler calibration gas otherwise perform the boiler conversion in order to use the gas available see section 4 3 this operation must be carried out by technical staff qualified in compliance with the standards in force is the gas supply valve open has the system been checked for gas leaks is the outside main switch ON is the system safety val...

Page 28: ...T OF THE COMBUSTION EFFICIENCY DURING INSTALLATION Generator Menu ATTENTION Function reserved for After Sale Service Centres only ATTENTION These functions are explained in chapter 2 9 Burner menu of the Ufly P TOUCH CONTROL instal lation and maintenance manual ...

Page 29: ...e burner is on check that the CO2 MINIMUM value corresponds to that indicated in the table NOZZLES PRES SURE Correct it if needed by turning with a screwdriver the screw R CLOCKWISE to increase it ANTICLOCKWISE to de crease it S ADJUSTMENT SCREW MAXIMUM OUTPUT R ADJUSTMENT SCREW MINIMUM OUTPUT Remove the cap and insert the CO2 analysis probe in the flue gas sample point of the intake exhaust termi...

Page 30: ...off the main switch For proper operation the CO2 values must be calibrated with particular attention observing the values indicated in the table close the flue gas inspection sample points of the intake and exhaust terminal check that there are no gas leaks If they are not obstructed check if the burner and or the exchanger aluminium sections are well cleaned ALKON 100 EXT Type of Gas Supply Press...

Page 31: ...eating pressure until reaching a pressure of 0 8 1 0 bar Open the gas shut off valve Switch the boiler on Make sure the appliance is gas tight and watertight Failure to perform Inspections and Maintenance can entail material and personal damage TABLE OF RESISTANCE VALUES ACCORDING TO THE TEMPERATURE TO THE HEATING PROBE 11 sr and to the DOMESTIC HOT WATER probe 1 ss and any heating return probe 22...

Page 32: ... safety pressure switch against water deficiency 13 Does the pressure switch block the boiler if the water pressure is below 0 4 bar Without request close the shut off valves of the heating circuit open the drain valve to make the water pressure de crease Before pressurising again check the pressure of the expansion vessel Condensation drain trap 27 Has the trap got deposits on the bottom Clean th...

Page 33: ...ke sure that the gas tank has been deaer ated before installing the appliance For state of the art deaeration of the tank contact the LPG supplier or a person qualified in compliance with law If the tank has not been professionally deaer ated ignition problems could arise In that case contact the supplier of the LPG tank 4 3 ADAPTATION TO THE USE OF OTHER GAS Gas Conversion The boilers are produce...

Page 34: ...peed 0 100 22 2590 Burner maximum capacity kW 1 1000 70 483 rP Water Δ temperature protection C 0 50 30 622 FS Water minimum flow rate protection 0 1 0 34 HY Burner OFF hysteresis C 5 20 5 336 HS Temperature control slope limit C MIN 1 30 10 353 HP Temperature control proportional gain 0 50 25 354 HI Temperature control integrative gain 0 50 12 478 Hd Temperature control derivative gain 0 50 0 486...

Page 35: ...stment 0 15 0 656 drT DHW Temp Requested Differential K 20 20 4 657 drH DHW Requested Temp Hysteresis K 1 20 8 310 DpT DHW Pump Postcirc sec 5 600 60 660 dbT DHW Temp Maximum Boiler C 50 0 85 0 75 0 48 ChSet CH 1 Set point C 20 0 85 0 85 0 64 ChPO1 CH 1 Parallel Supply 0 1 0 346 FL Minimum Modulation 0 100 0 25 0 600 mB Burners Min Inserted 1 8 1 616 BSt Gen Insertion Time sec 30 900 120 613 BRt G...

Page 36: ... 2 3 A11 BMM1 R 24V BR eBUS BK eBUS 1 2 3 4 A4 1 2 3 Y1 BCM min2 Menu A1 1 2 3 4 A2 1 2 3 1 2 3 4 5 6 7 8 A3 A4 1 2 3 4 5 6 A5 1 A10 2 1 3 A11 2 1 3 ROD Y1 X G 1 2 3 4 SE GND OUT IN ROOM STAT BUS A13 1 2 3 A8 A6 1 2 3 4 5 6 GND5 GND4 GND3 GND2 GND1 A7 2 1 F1 4AF A9 1 2 3 4 5 6 7 FSI 0 1 2 3 4 5 6 7 8 9 C V JP1 BMM1 min1 COM NO eBUS eBUS 2 4 eBUS eBUS COM NO eBUS 1 3 2 R BK BR ...

Page 37: ...ting Fan C P M G Modulation Pump Control general System eBUS outer cascade manager PLC BMS supervisor PLC ALARM SIGNAL Collector Pump Control V 24 R BK USC ALLARM SIGNAL COMAND COM INGR ANALOG Modbus B Modbus A 0 10V GND 0 10V INGR Stemp ACC BR eBUS INAIL 24V eBUS eBUS 0 1 2 3 4 5 6 7 8 9 Y4 1 2 3 4 1 2 3 M3 R FL C P M P CH COMAND P Coll COMAND P Car DHW 1 2 3 4 5 6 Y3 Y2 12 11 10 9 8 7 6 5 4 3 2 ...

Page 38: ...ions 14 RETUR HEATING SENSOR Auxiliary SRR sensor interrupted Check the wiring if needed replace the auxiliary sensor 22 15 WATER CIRCULATION INSUFFICIENT Primary circuit water circulation insuffi cient t 40 C Check pump operation and speed remove any heating system ob structions 16 EXCHANGER FREEZING 24 Exchanger freezing is detected If the heat ing sensor detects a temperature below 2 C burner i...

Page 39: ...e function of antifreeze and then it may be only a warning 18 Maximum protection Dt flow and return Status stop Control of the circulation verify installation 19 OVERHEATING OF CH FLOW Overheating of the outlet It is activated when the flow temperature is 95 It is reset automatically when the temperature is 80 Effect Stop burner pump on Control of the circulation 37 Faulty parameter memory Flame a...

Page 40: ...ght 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 ORIGINAL INSTRUCTION 00335799EN a 2 nd ed 02 22 www unical eu ...