Unical KON 100, Installation And Servicing Manual

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

Page 2: ... or 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 1626 ...

Page 3: ... Adaptation to use with other gas 33 4 4 PROGRAMMING OF THE OPERATION PARAMETERS 33 4 5 Wiring diagram 37 4 6 Error codes 38 4 7 Notes 40 3 INSTALLATION INSTRUCTIONS 15 3 1 General warnings 15 3 2 Installation standards 15 3 3 Preventive system verification and adjustment operations 16 3 4 Packaging 17 3 4 Positioning the boiler 19 3 6 Flue gas exhaust pipe connection 20 3 7 Connections 21 3 8 Fil...

Page 4: ...e 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 leg...

Page 5: ...velope 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 corr...

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: ... max Max domestic hot water temperature C Electrical characteristics 21 Electrical power supply 22 Consumption 23 Protection rating D Countries of destination 24 Direct and indirect countries of destination 25 Gas category 26 Supply pressure E Factory settings 27 Adjusted for gas type X 28 Space for national brands G ErP 29 Seasonal space heating energy efficiency 30 Energy efficiency in DHW produ...

Page 8: ...ntervene only if the electricity and gas supplies are connected If one of the two is not available and upon reset 11 SR a temperature between 2 5 C is detected the appliance will behave as described in tab pos 2 The heating system can be protected effectively from frost by using antifreeze products with inhibitor for heating systems specific for multidmetal Do not use car engine antifreeze product...

Page 9: ...9 E N G L I S H Technical Features 2 2 DIMENSION FRONT VIEW VIEW FROM BELOW VIEW FROM ABOVE LEFT SIDE VIEW BACK VIEW 2 TECHNICAL FEATURES AND DIMENSIONS 2 1 TECHNICAL FEATURES ...

Page 10: ...e drain system 22 rb SRR Return temperature sensor 23 TSC Excanger safety thermostat 24 Aluminium Heat Exchanger Capacitor 25 Vent valve 26 Condensation drain trap 27 E RIL Detection electrode 28 E ACC Ignition electrode 30 SMG Sensor Flow General 32 Flue combustion 35 Ignition Trasformer 38 Gas min pressure switch 40 Manual Vent valve 2 2 VIEW WITH THE INDICATION OF THE MAIN COMPONENTS ...

Page 11: ...min 58 SL Level sensor 59 Trunk with suction grille KON 100 115 mm G Gas inlet G1 M Heating system flow G1 1 4 R Heating system return G1 1 4 Rs Boiler drain Scond Condensation drain Ø 32 S Flue gas exaust Ø 100 A Air intake Ø 80 100 C E ERROR CODES see par 4 6 S E WIRING DIAGRAM KEY see par 4 5 Component not used ...

Page 12: ...m c a metres of water The table provides an indication the flow the pump in function of the Dt of the primary circuit KON 100 KON 115 Power supply kW 99 5 115 Max flow rate demanded Dt 15 K l h 5700 6600 Nominal flow rate request Dt 20 K l h 4280 4950 Power supply in condensation 50 30 kW 105 120 3 Max flow rate demanded Dt 15 K l h 6020 6897 Nominal flow rate request Dt 20 K l h 4520 5173 0 0 2 0...

Page 13: ...n 25 53 1 87 Flue losses with burner in operation max 1 72 2 29 Minimum heating circuit pressure bar 1 95 0 5 Maximum heating circuit pressure bar 0 5 6 Water content l 6 9 Gas Consumption Natural 20 mbar gas G 20 a Qn m3 h 10 57 12 08 Gas Consumption Natural gas 20 mbar G 20 a Qmin m3 h 2 11 2 11 Gas Consumption G25 supply pressure 25 mbar Qn m3 h 12 3 14 0 Gas Consumption G25 supply pressure 25 ...

Page 14: ...m heat output in low temperature regime Tr 30 C ƞ1 98 5 96 7 Range rated boiler YES NO NO NO Auxiliary electricity consumption At full load elmax kW 0 289 0 314 At part load elmin kW 0 156 0 160 In stand by mode PSB kW 0 018 0 028 Other items Heat loss in stand by Pstb kW 0 641 0 642 Emissions of nitrogen oxides ref PCI PCS NOx Mg kWh 43 39 47 42 Annual electricity consumption QHE GJ 301 349 For C...

Page 15: ...l so that the minimum distances required for installation and maintenance can be observed The boiler must be connected to a central heat ing system and or domestic hot water supply network compatible with its efficiency and output The boiler can be installed outdoors in a partially protected place or at least in a place where the boiler is not exposed to the direct action of the weather 3 1 GENERA...

Page 16: ... as the appliance the packaging contains A DOCUMENTATION ENVELOPE User operating instructions booklet Instruction booklet for the installer and maintenance engineer 2 Spare parts form Certificate of conformity Gas conversion label Air inlet filter Condensate evacuation siphon Aluminum pipe Ø 100 mm for smoke evacuation Boiler support bracket Boiler drain tap Silicon gasket KON 100 KON 115 P depth ...

Page 17: ...rs 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 on a support kit otional For ...

Page 18: ...18 SUPPORT FRAME optional Installation of generators as cascade For installation instructions electrical connections safety devices refer to MT instruction available on the website ...

Page 19: ...figu rations listed below ATTENTION For the type of connection B23P the room follows the same installation rules for boilers with natural draught Please note These values relate to exhausts made by means of rigid pipes and smooth original UNICAL CAUTION LT total length is a reference value for the dimensioning of the ducts of A intake and S Exhaust Subtracting the values of LT reported at values o...

Page 20: ...stallation Type C63 Air suction Ø80 and drain Ø100 Installation Type B23p Air suction from top grid and drain Ø100 For this configura tion use item A optional Air intake is carried out through the grid shown ...

Page 21: ...s and objects for which the manufacturer cannot be held responsible 3 7 CONNECTION Danger The gas connection must be carried out only by a qualified installer who must respect and apply that foreseen by relevant laws in force in the local prescriptions of the supply company Incorrect in stallation can cause damage to persons animals and objects for which the manufacturer cannot be held responsible...

Page 22: ... gaskets and cause noise during operation Unical will not be held liable for damage to persons animals or objects due to failure to comply with the above instruction Condensation drain The boiler during the combustion process produces conden sation that through pipe A flows into the trap The condensation that forms inside the boiler flows into a suitable drain via pipe B Danger Before commissionin...

Page 23: ... Before performing connections or any type of operation on electrical parts always disconnect elec trical power and make sure that it cannot be reconnected accidentally 3 9 ELECTRICAL CONNECTIONS HSCP Heating Slave Controller Programmer connection 1 2 3 4 ROOM STAT IN OUT BUS Y1 A12 HSCP 2 3 24 BUS 1 4 Connect the HSCP Heating Slave Controller Program merwire between terminals BUS and OUT Warning ...

Page 24: ...ard as required the regulations in force The power cable must be replaced by technical personnel authorised using original spare parts only Failure to comply with the above can jeop ardise the safety of the appliance The power cable must be replaced by technical personnel authorised using original spare parts only Failure to comply with the above can jeop ardise the safety of the appliance Electri...

Page 25: ...ndicated in chapter 3 7 are any system shut off gate 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 ...

Page 26: ...DISABLING After calibration press the PLUS and MINUS at the same time the symbol off Flue gas probe To determine the combustion efficiency one must make the following measurements measurement of the combustion air temperature measurement of the flue gas temperature and content of CO2 taken in the relevant hole 2 Take the measurements with the generator in steady state conditions see par 3 11 1 3 1...

Page 27: ...USTING THE BURNER 2 Minimum output adjustment Operate the boiler in calibration mode at MINIMUM OUTPUT see 3 11 1 Once the 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 Remove the cap and insert the CO2 analysis probe in ...

Page 28: ...bserving 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 KON 100 Type of Gas Supply Press Ø Nozzles Collector diaphragm Fan speed CO2 levels Start up power mbar mm Ø mm min max FL FU FH FU min max ...

Page 29: ...stance Centres only The user is NOT authorised to activate the function described below It is possible to adjust the maximum thermal capacity in heating mode by decreasing the burner pressure value 3 12 1 ADAPTATION OF THE POWER TO THE HEATING SYSTEM Power Supply KW Act on parameter FH par 4 2 SE parameters list to achieve the value corresponding to the desired output ...

Page 30: ...liance from the electrical mains and make sure that it cannot be reconnected accidentally Close the gas shut off valve upstream the boiler If needed and depending on the intervention to be carried out close any shut off valves on the flow and return line of the heating system as well as the cold water inlet valve Once all maintenance operations are complete resume boiler operation Open the heating...

Page 31: ...an the trap with water Heat exchanger body 9 1 Measure the Thermal Capacity using a me ter and compare the value with that contained in table 3 12 The data measured indicates if the exchanger needs cleaning 2 Check that the space between the rungs of the exchanger are not clogged It is recommended to use the products purposely created by Unical see sys tem protectionACCESSORIES sect in the domesti...

Page 32: ...ON After performing the conversion for the op eration of the boiler with a type of gas e g propane gas other than that specifically requested when ordering the appliance will only work with this new type of gas ATTENTION Indications for propane gas fired appliances Make sure that the gas tank has been deaer ated before installing the appliance For state of the art deaeration of the tank contact th...

Page 33: ...E key simulta neously to enter in the service mode SE and change value A Operation READING PARAMETER Press the YELLOW key to view default setting B Operazion CHANGE PARAMETER Press key PLUS MINUS to modify C Operazion SET MODIFY PARAMETER Press the YELLOW key BURNER MODULATION LEVEL IN IGNITION Continue with the modification of parameters by pressing the MINUS Repeat the operations A B C to change...

Page 34: ...parameters by pressing the MINUS Repeat the operations A B C to change value VALUE FROM TO DEFAULT 20 100 99 DHW ENABLE THE TEMPERATURE SENSOR 7 Continue with the modification of parameters by pressing the MINUS Repeat the operations A B C to change value VALUE FROM TO DEFAULT 0 1 0 MODULATING PUMP MINIMUM MOD LEVEL 6 Continue with the modification of parameters by pressing the MINUS Repeat the op...

Page 35: ...ation of parameters by pressing the MINUS Repeat the operations A B C to change value VALUE FROM TO DEFAULT 35 C 45 C 40 C SETTING OF THE MAXIMUM HEATING TEMP 9 Continue with the modification of parameters by pressing the MINUS Repeat the operations A B C to change value VALUE FROM TO DEFAULT 65 C 85 C 80 C SETTING OF THE MAXIMUM DHW TEMPERATURE only if combined with an external storage tank 11 Co...

Page 36: ...m minx1000 Fb Fan PWM modulation at maximum fan speed Pu Fan tacho Pulse Revolution Sb Fanmodulation level at burner standby Fu Massima velocità ventilatore METANO GPL FH Maximum relative fun speed GPL FL Minimum relative fun speed GPL dt Storage tank regulation gain tH Storage tank hysteresys 0 automatic 1 30 C Hp Temperature control proportional gain Hl Temperature control integrative gain Hd Te...

Page 37: ...ermostat VG Gas Valve VM A VM R Modulating fan A supply Modulating fan R regulation TA On off TA connection terminals 4 5 WIRING DIAGRAM 1 2 3 4 ROOM STAT IN OUT BUS Y1 A12 A10 X1 A5 A1 A2 A3 A4 A13 A6 A7 A8 A9 GND1 GND2 GND3 GND4 A11 A1 BK BL TACHO OR BR PWM ST2 WH BR PK GR MODULATION VM R DK CPM A9 APM YG BR BL VM A YG BL BR A8 230V 50 Hz YG BL BR YG BL BR IG 1 2 3 4 ROOM STAT IN OUT BUS TA BK E...

Page 38: ...ation Press the reset key on the panel Ht 06 HIGH TEMPERATURE Over high temperature detected by the heating sensor SR 95 C Check the operation the pump and possibly clean the heat exchanger 24 LP 08 Lack of water Fill up the water circuit IF 10 Internal fault Replace the control board Fd 11 FLAME PARASITE Flame detected in ignition Check the wiring electrode Acc Ril and remove any oxidation press ...

Page 39: ...erence Press the reset button if the fault does not clear replace the board LL 32 Mains voltage 190 Vac Check that the mains voltage is 190Vac if the mains voltage is correct replace the control board Sr REQUEST FOR MAINTENANCE After 10 000 switching On or 2 000 hours of operation of the burner boiler needs servicing The blink code Sr does not preventthe normal operation of the boiler Service the ...

Page 40: ...side the siphon If there are any deposits flush them out with clean water reassemble the siphon in reverse order Danger Before commissioning the appliance fill the siphon via the filling hole and check the cor rect drainage of the condensate 4 7 NOTE If the appliance is used with the condensate drain siphon empty this could lead to danger of intoxication following the escape of flue gasses ...

Page 41: ...nspection or mainte nance is made on the burner When refitting the mixer tighten the nuts pro gressively and in crossed way by using a dy namometric wrench adjusted at 10 Nm 1 kgm Remove the gas flange A from the mixer fan remove the 8 screws B burner plate and proce ed to clean the burner and heat exchanger body Gasket Burner ...

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Page 44: ...6 info unical ag com export unical ag com www unical eu AG S p A Unical declines every responsibility for the possible inaccuracies if owed to errors 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 ...