Unical ELL 1100, Installation, Use And Servicing Instruction

Page 1: ...26739 01 13 rev 4 ELLPREX INSTALLATION USE AND SERVICING INSTRUCTION to be kept by the user ...

Page 2: ... boiler house the safety devices the chimney the fuel supply lines the electrical installations and all the other local requirements and safety instructions Approvals The UNICAL boilers ELLPREX range have been tested and CE certified for the gas operation by TECHNIGAS BELGIUM who has recognised to these boilers the conformity certificate according to the following directives Gas Appliances Directi...

Page 3: ...ater systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 6644 Ventilation for gas appliances of rated input exceeding 60 kW HEALTH SAFETY DOCUMENT No 635 The Electricity atWork Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performan...

Page 4: ... 2 7 3 Burner installation page 15 2 8 Connection of the sight glass to the burner via a cooling line page 16 2 9 Casing assembly page 16 STANDARD PANEL BOARD page 24 3 1 Panel board type 21057 functions description page 24 3 2 Electrical wiring diagram for single phase burner pump page 24 3 3 Introduction of the electronic panel board type 30688 page 25 3 4 Panel board type 30688 functions descri...

Page 5: ... by a textile in mineral fiber For models from ELL 4500 to ELL 7000 the outer shell is insulated with a felt lamellar matress thick 50 mm protected by an alumi fig 1 1 2 WORKING PRINCIPLE The ELLPREX boilers are provided with a blind furnace in which the burner makes a central flame the combustion gases come back to the front door and then they enter the upper or peripheral tube bundle according t...

Page 6: ...nt l 190 251 264 298 398 462 565 Water side pressure loss m w c 0 09 0 15 0 19 0 33 0 12 0 21 0 16 0 28 0 09 0 17 0 14 0 25 0 21 0 38 9 15 15 28 13 25 17 34 16 29 24 43 32 55 Smoke side pressure loss mm w c Maximum working pressure bar 6 6 6 6 6 6 6 Weight kg 435 510 588 629 796 919 1049 ELLPREX Model ELL 170 ELL 240 ELL 290 ELL 340 ELL 420 ELL 510 ELL 630 A mm 820 820 860 860 890 890 890 B mm 885...

Page 7: ...2 1122 1122 B mm 1605 1800 1995 1432 1432 1432 C mm 190 190 190 D mm 195 195 195 E mm F mm 190 190 190 G mm 765 765 765 H mm 480 480 480 1989 2184 2379 L mm 125 125 125 1540 1540 1540 M mm 298 298 298 N mm 435 630 825 O mm 440 440 440 P mm 1020 1020 1020 Q mm 1504 1699 1894 R mm Nominal Output kW 580 760 660 870 750 970 T1 T2 UNI2278PN16 T3 UNI2278PN16 T5 Øi mm T6 Ø mm DN 125 DN 125 DN 125 DN 65 D...

Page 8: ... 950 H mm 595 595 640 640 690 690 2346 2686 2781 3151 3225 3545 L mm 180 180 75 75 75 75 1540 1540 1650 1650 1810 1810 M mm 461 461 561 561 661 662 N mm 330 670 510 880 670 990 O mm 500 500 550 550 700 700 P mm 1250 1250 1360 1360 1520 1520 Q mm 1846 2186 2176 2546 2590 2910 R mm DETAIL FOR DOOR DRILLING ELL 1100 1320 DETAIL FOR DOOR DRILLING ELL 2200 2650 DETAIL FOR DOOR DRILLING ELL 1570 1850 No...

Page 9: ...60 G mm 1315 1535 1535 H mm 772 915 915 3835 3879 4279 L mm 115 144 144 1990 2271 2271 M mm 325 377 777 N mm 1100 1060 1060 O mm 1330 1280 1420 P mm 1620 1870 1870 Q mm 3200 3164 3564 R mm Nominal Output kW 2300 3000 2700 3500 3040 4000 Nominal Input kW 2492 3280 2930 3825 3297 4371 Water content l 2667 4142 4455 Water side pressure loss m w c 0 36 0 62 0 54 0 84 0 54 0 85 1 Panel board 2 Burner f...

Page 10: ...3420 4500 3800 5000 4180 5500 4560 6000 4940 6500 5320 7000 3638 3 4838 7 4064 2 5421 8 4446 8 5914 4877 6506 2 5255 3 6989 2 5689 8 7590 5 6012 6012 7058 7058 7909 7909 0 70 0 85 0 80 1 05 0 95 1 15 1 00 1 35 1 05 1 50 1 10 1 75 51 88 65 110 60 100 68 120 61 105 69 120 6 6 6 6 6 6 8310 8310 9300 9300 12600 12600 DN 125 DN 125 DN 125 DN 125 DN 125 DN 125 DN 250 DN 250 DN 250 DN 250 DN 250 DN 250 R...

Page 11: ...tion is highly recommended To allow the cleaning of the smoke pipes in front of the boiler a clearance equal to the length of the boiler has to be available With the boiler door opened at 90 the distance between the front of the door and the adjacent wall must be equal at least at the length of the burner The boiler must stand on a non combustible floor i e concrete or brick of dimensions Q x R se...

Page 12: ... the entity of the reinstatement water to avoid inconvenients due to untreated water For that reason it is suggested to fit in the feeding line to the boiler a water meter for small capacities 2 5 2 C H FLOW AND RETURN CONNECTIONS The dimensions of flow and return connections are shown for each boiler model in the table DIMENSIONS Before connecting the boiler to the C H system this one has to be t...

Page 13: ...ble A Adjustment in vertical way it is possible only by introducing some washers of convenient thickness under the hinge on which the door rotates fig 17 B Adjustment in transversal way it is possible by unscrewing and side moving the hinges fixed to the front tube plate C Adjustment in axial way it is possible by screwing more or less the fixing screws 2 6 2 BOILERS ELL 760 ELL 970 For all these ...

Page 14: ... L H side are normally used as rotating hinges from Right to Left whilst the two ones on the R H side are used as closing hinges Exactly the contrary will happen when the door is hinged on the R H side and the door needs to be opened from Left to Right To get the reversion of the opening it is sufficient to move the bushing support of the door On the door of these models of boiler the following ad...

Page 15: ...760 970 270 270 ELLPREX 290 630 220 250 ELLPREX 170 240 180 250 2 7 1 CONFORMITY OFTHE BURNER All the burners equipping the ELLPREX boilers must be CE certificated and must conform to the following directives and standards Gas Appliances Directive 90 396 CEE EMC Directive 89 336 CEE EN 267 Automizing oil burners of monobloc type Testing EN 676 Automatic forced draught burners for gaseous fuels ELL...

Page 16: ...PREX 1850 30001 casing upper part ELLPREX 1850 30002 casing front part ELLPREX 2200 30003 casing rear part ELLPREX 2200 30004 casing upper part ELLPREX 2200 30002 casing front part ELLPREX 2650 30081 casing rear part ELLPREX 2650 30082 casing upper part ELLPREX 2650 30083 casing central part ELLPREX 2650 30111 casing front part ELLPREX 3000 30112 casing rear part ELLPREX 3000 30113 casing central ...

Page 17: ...tion B Locate the side panels 3 and 4 with the lower bend inside the bottom L profiles and the upper bend in the seats of front and rear tube plates To determine which is the left and right panel ensure that the cable clamp plates are positioned facing toward the front edge C Open the combustion chamber door and fit the front insulation 5 inserting the hinges in the pre cuts Insert the side ends o...

Page 18: ...ght panel ensure that the cable clamp plates are positioned facing toward the front edge Fit the four flathead screws 8 on the inner bend of the rear side panels 3b 4b C Open the combustion chamber door and fit the front insulation 6 inserting the hinges in the pre cuts Insert the side ends of the insulation under the bend of the two side panels 3a 4a D Fit the rear insulation 7 fix the rear lower...

Page 19: ...end to the upper L profile To determine which is the left and right panel ensure that the cable clamp plates 5 are positioned facing toward the front edge C Open the combustion chamber door and fit the front insulation 6 inserting the hinges in the pre cuts Insert the side ends of the insulation under the bend of the two side panels 3a 4a D Fit the rear upper panel 7 Fit the plastic cable clamps 8...

Page 20: ...he side panels 3a 3b 3c and 4a 4b 4c with the lower bend inside the bottom L profiles and hooking the upper bend to the upper L profile To determine which one of the front side panels is the left or the right ensure that the cable clamp plates 5 are positioned facing toward the front edge C Fit the rear upper panel 6 Fit the plastic cable clamps 7 to the upper rear panel 6 D After removal of the t...

Page 21: ...iles and hook them to the screws fitted to the upper square tube To determine which one of the front side panels is the left or the right ensure that the cable clamp plates 5 are positioned facing toward the front edge D Fit the panel board to the left or right front side panel After removal of the two side screws from the panel board rotate its cover towards the front and insert the cables and th...

Page 22: ... thermostat 3 minimum thermostat 4 We recommend that the introduction of the sensors is made up to bottom of the bulb holder s To get a better contact introduce also the arcuated spring 6 and secure the capillaries with the special clip 5 1 Thermometer bulb 2 Working thermostat bulb 3 High limit thermostat bulb 4 Minimum thermostat bulb 5 Bulb retaining clip 6 Contact spring ...

Page 23: ...l of the two side screws from the panel board rotate its cover towards the front and insert the cables and the capillaries of thermometer and thermostats through the slots on its base Insert the capillaries of the thermostats in the pipe foreseen for their passage that is found under the casing see detail A Pay particular attention when unrolling the capillaries and insert the bulbs in the two bul...

Page 24: ...ween the switching points of the two double pole is 6 C not adjustable Theminimumthermostat accessiblethrough the opening of the panel board cover switches OFF the C H pump during the reacing of the steady state and up to the obtention of 50 C within the boiler On the electrical supply line to the boiler a switch with fuses is to be forseen 3 STANDARD PANEL BOARD fig 30 3 2 ELECTRICAL WIRING DIAGR...

Page 25: ...ter and flow are included in the supply the room sensors for the C H systems No 1 and No 2 are optionals The mixing valve and the relevant motor are not supplied by Unical When the room sensor is not fitted it is optional the room temperature is determined and controled only by the heating curve of the outer compensator program The electronic panel board type 30688 is supplied as standard with the...

Page 26: ... G V 6 6 7 7 8 8 9 9 10 10 2nd stage Tm Minimum thermostat Ts High limit thermostat Vm2 Mixing valve for 2nd zone A Burner lockout warning lamp eventual B Hourmeter eventual 3 5 ELECTRICAL WIRING DIAGRAM FOR SINGLE PHASE BURNER AND PUMPS Ipi2 Pump switch for C H system No 2 Ipb D H W tank pump switch Pb D H W tank loading pump Pi1 C H pump for direct zone Pi2 C H pump for mixed zone Te Working the...

Page 27: ...0 08 RELAY FUNC 1 00 30 C 90 C RELAY TEMP 1 30 C 2K 10K HYST RELAY 1 5K 00 03 RELAY FUNC 2 00 00 01 OFF ON SCREED 00 OFF See explanation SCREED PROGR RETURN Default IV Value range Designation HOTWATER 00 01 OFF ON CP LOCK 01 ON 00 01 02 03 PARALLEL 00 00 C 50 C HS T DHW 20 C 5K 30K HYST DHW 5K 00 min 30 min DHW FOLLOWUP 00 min 00 01 OFF ON THERM INPUT 00 OFF 00 01 OFF ON CHARGETHROUGH 00 OFF Exit ...

Page 28: ... 00 24 00 OUT TEMP DEL 1 0K 50K SLOPE OFFSET 5K 00 01 OFF ON B HEAT SINK 01 ON Exit level using RETURN Default IV Value range Designation HEATING CIRCUIT 1 00 04 HC FUNCTION 00 00 03 PUMP MODE 00 5 25 MIXER OPEN not for HW circuit 16 5 25 MIXER CLOSE not for HW circuit 12 20 C 110 C MAX FLOW T 80 C 10 C 110 C MIN FLOW T 10 C 15 C 5 C FROST PROT 0 C 0 00 24 00 OUT TEMP DEL 1 0K 50K SLOPE OFFSET 5K ...

Page 29: ...sensor code no required after input there is a restart of the controller RETURN end of INSTALLATION Start INSTALLATION Set value Save value and next value Start INSTALLATION Set value Save value and next value Acc to version GERMAN GERMAN 20 20 CONTRAST 0 Sensor weekday DISPLAY SEL Exit level using RETURN Default IV Value range Designation HOTWATER 00 01 OFF ON 1X DHW 00 OFF 10 C 70 C DHW TEMP 1 6...

Page 30: ...1 02 OPTIMIZAT 00 0 00 3 00 h M OPT TIME 2 00 h 0 00 3 00 h ECONO OPTI 0 00 h 0000 9999 PC ENABLE 0000 Default IV Value range Designation HEATING CIRCUIT 2 MODE 5 C 40 C T ROOM DES 1 20 C 5 C 40 C T ROOM DES 2 20 C Exit level using RETURN 5 C 40 C T ROOM DES 3 20 C 5 C 40 C ECONO TEMP 10 C 5 C 40 C REDUCEDTEMP 15 C 5 C 40 C T LIMIT DAY 19 C 5 C 40 C T LIMIT N 10 C 0 00 3 00 HEAT SLOPE 0 8 00 01 OF...

Page 31: ... Mo Tu We TH Fr 06 00 to 22 00 Sa Su 07 00 to 23 00 Value range Designation HEAT CIRCUIT 2 HEAT PROGRAM 1 FACTORY SETTING Mo Tu We TH Fr 06 00 to 08 00 16 00 to 22 00 Sa Su 07 00 to 23 00 HEAT PROGRAM 2 FACTORY SETTING Mo Tu We TH Fr 05 00 to 21 00 Sa Su 06 00 to 22 00 Value range Designation HOTWATER FACTORY SETTING Mo Tu We TH Fr 05 00 to 21 00 Sa Su 06 00 to 22 00 Value range Designation CIRCUL...

Page 32: ...e hydraulic schemas shown in the figs 35 36 are principle schemas in case of different system circuits contact please our after sale service dept which will supply you with all the necessary informations 3 7 ELECTRICAL AND HYDRAULIC CONNECTIONS OF C H fig 35 In a C H installation equipped with a D H W storage tank the hydraulic schema shown in fig 36 can be used Note Also in this case the remarks ...

Page 33: ...sponsibility of a specialized and well trained burner technician authorised by the burner manufacturer In that occasion a commissioning report has to be filled out POSITION OF THE CORE INSIDE THE TURBULATOR ONLY FOR MODELS ELL 170 870 ELL 170 ELL 240 ELL 290 ELL 340 ELL 420 ELL 510 ELL 630 ELL 760 ELL 870 A A A A A A A A A 50 260 200 320 390 560 700 590 810 Note In case of boiler use at minimum ou...

Page 34: ...IRSTCOMMISSIONING At the commissioning stage of the boiler a qualified technician has to perform the following checks Internal and external sound test of burner and fuel feeding pipe Adjustment of the fuel throughput according to the nominal input of the boiler it is convenient to remember that the nominal input can be adjusted between the minimum and the maximum shown in the table of pages6 to10 ...

Page 35: ... 0 position 5 1 GENERAL RULES Before effecting any operation of cleaning or maintenance disconnect the boiler from the electrical supply acting on the main switch onto the panel board In case of failure or bad operation of the boiler switch it off abstaining your self from any attempt of reparation or direct intervention Exclusively address to professionally qualified personnel The possible repara...

Page 36: ...ety and control devices imposed by local requirements that cannot be attributed to the constructive geometry and or to the materials used and to the constructive technique and therefore they are not covered by guarantee On the occasion of the ordinary maintenance it is useful to perform a small discharge from the boiler to verify if sludges escape In affirmative case it will be necessary to prolon...

Page 37: ...37 Notes ...

Page 38: ...38 Notes ...

Page 39: ...39 Notes ...

Page 40: ...m Unical AG declines any liability for the inaccuriaces that may appear due to errors in trascription or printing It also reserves the right to introduce those modifications to its products that it considers necesssary or useful without compromising the essential characteristics of the said products AG S P A ...