Unical modulex 360, Installation, Use And Maintenance Manual

Page 1: ...00332210 2nd edition 09 05 360 450 540 630 MODULEX INSTALLATION USE AND MAINTENANCE GB MODULAR CONDENSING BOILER Uniservice Kft 1106 Budapest Maglódi út 16 tel 06 1 433 2612 fax 06 1 431 8349 ...

Page 2: ...must therefore be sent to specific waste management sites Keep the packaging out of the reach of children as it may represent a choking and suffocation hazard In the event of failure and or faulty functioning switch off the boiler Do not attempt to make repairs contact qualified technicians Original parts must be used for all repairs to the boiler Non observance of the above requirement may jeopar...

Page 3: ...s 14 NOx NOx Class 15 PMS Max pressure C H system 16 T max Max Temperature C H system 17 PMW Max pressure D H W system 18 T max Temperature D H W system 19 Adjusted for gas type X 20 Country of destination Gas category Supply pressure 21 Side for national brand 2H 2E 3 3B P 3P G20 G20 G30 G31 G30 31 G31 20 25 20 28 30 37 30 50 37 50 mbar mbar mbar mbar mbar IT ES IE PT GR TR HR CZ SK HU SI GB CN R...

Page 4: ... 2 3 7 Filter pag 18 2 3 8 Ball Valves pag 18 2 3 9 Feeding Water Quality pag 18 2 3 10 Boiler Antifrost Protection pag 18 2 3 11 Min Water Flow Rate pag 19 2 4 Boiler Operation pag 19 2 4 1 General Description pag 20 2 4 2 Ignition Sequence pag 21 2 4 3 Supplementary Board pag 22 2 4 4 Domestic Hot Water DHW Mode Operation pag 23 2 5 Boiler Operation in case of technical intervention pag 23 2 6 E...

Page 5: ...tion by Outer Sensor pag 36 3 3 3 Heating Mode Operation by Outer Compensator pag 37 3 4 DHW Mode Operation pag 37 3 4 1 DHW Mode Operation by Storage Tank NTC Sensor pag 37 3 4 2 DHW Mode Operation by Storage Tank Thermostat pag 37 3 5 Burner Pressure Adjustment Test pag 38 ERRORS pag 39 4 1 Blank Display pag 39 4 2 The Boiler doesn t fulfill the DHW Production Request pag 39 4 3 Ignition Anomali...

Page 6: ...t can deliver an output between a maximum of 90 kW and a minimum of 22 kW Each single boiler is equipped with NTC sensors for global temperatu re control on the flow and return ma nifolds Total premix modulating burner equipped with metallic sponge ra diation burner Premix in the pre combustion cham ber Automatic no return diaphragm for separation from combustion chamber Combustion air suction fee...

Page 7: ...dth L net mm Width with packaging mm Depth C mm Depth A mm Depth B mm Depth with packaging mm Net weight kg Gross weight kg Connections Gas mm C H system Flow M mm C H system Return R mm Chimney connection D mm Chimney width H mm Condensate drain diameter mm 360 4 1372 920 1020 1530 985 390 1200 430 496 DN50 PN 10 16 DN80 PN 10 16 DN80 PN 10 16 250 615 40 ATTENTION CHIMNEY CONNECTION INDIFFERENT P...

Page 8: ...20 425 1390 1514 1840 680 778 DN50 PN 10 16 DN100 PN 10 16 DN100 PN 10 16 300 855 40 450 5 1372 920 1020 1520 445 1120 1320 1340 510 584 DN50 PN 10 16 DN80 PN 10 16 DN80 PN 10 16 250 615 40 H 600 175 425 110 124 MODULEX Dimension No of Modules Height mm Width L net mm Width with packaging mm Width D mm Width E mm Depth F mm Depth with packaging mm Net weight kg Gross weight kg Connections Gas mm C...

Page 9: ...mum pressure in CH circuit bar Maximum pressure in CH circuit bar DHW specific flow rate l Gas Consumption Natural gas G 20 20 mbar Qn m3 h Gas Consumption Natural gas G 20 20 mbar Qmin m3 h Max available pressure at the chimney base Pa Condensate production kg h Emissions CO with 0 of O2 in the flue system ppm NOx with 0 of O2 in the flue system ppm Sound level dBA Electrical data A Voltage Frequ...

Page 10: ...n 5 to 8 Automatic air vent on the flow mani fold Boiler draining filling tap on return manifold Minimum gas pressure switch on gas manifold Condensate collecting tray Plastic pipe 1m and fittings for con densate evacuation Ø40 Smoke chamber terminal with flue soc ket Ø 250 mm for models 360 and 450 Ø 300 mm for models 540 and 630 Integral painted steel casing Modulation and control PCB MBD with P...

Page 11: ... prepare the sling with the bands A fig 3 by taking care of let the bands pass internally of flow return and gas manifolds Bind the bends to the jib during this step be particularly careful Inside the packing on the rear part of the boiler for Mo dulex 360 450 on the front part of the boiler for Mo dulex 540 630 you can find the smoke chamber con taining a plastic bag containing 3 gaskets 1 rectan...

Page 12: ...12 fig 4 1 2 3 4 PALLET REMOVAL BOILER UNLOADING AND PACKAGE REMOVAL A B ...

Page 13: ... be a 100 mm deep well next to the boiler as siphon housing see fig 2 After instal lation the boiler shall be perfectly horizontal and stable to redu ce any possible vibrations or noises 2 2 3 BOILER CONNECTION The boiler Modulex leaves the factory pre disposed for the hydraulic and gas con nection on the back side of the boiler The smoke outlet is placed on the back side 2 2 4 CONNECTION TO THE C...

Page 14: ... EN standards Min height of the condensate column with all fans operating at max speed In the case it is not possible to create a 100 mm basement install the boiler on the floor and foresee a min 100 mm well to lodge the siphon see fig 2 2 2 6 WATER TREATMENT If the installation needs a water treat ment the following conditions are to be respected the pH for boilers with aluminium alloy body must ...

Page 15: ...has to be adjusted at 5 K above the temperature of the radiator group working at the highest temperature 11 12 13 1 2 4 3 5 7 6 S TO RE MODE R E SET ST EP 16 17 18 Return Flow Filter Boiler pump See fig 16 Mixing bottle Heating Circuit See fig 16 D H W Circuit The following system figures are to illus trate some but not all types of heating systems Filter Boiler pump Return Flow 11 1213 Mixing bot...

Page 16: ...torage tank with loading pump installed on the secondary circuit in parallel with the heating circuit Note The Pr pump heating pump shall be off while the storage tank pump is running In this case the second digit of parameter A shall be set to 2 three way valve For the connection of a boiler pump on the primary circuit or of a storage tank loading pump or a three way valve convenient information ...

Page 17: ...For the correct operation of the boiler the use of an hydraulic compensator is advisable because it guarantees separation and gathering of circuit dirt best air venting hydraulic de coupling of the two hydraulic circulation circuits nection on the return manifold and elec trical in series connection on the min gas pressure switch terminals gas valves have their own filter UNICAL suggests one furth...

Page 18: ...ks The use of an inhibitor is advisa ble to treat feeding waters and to protect heating systems against calcareous scales corrosion and microbiologic growth In case of freezing as well the use of an anti frost together with the inhibitor is advisable Qualified companies can provide boiler de scaling tem A closed expansion vessel proper ly dimensioned and equipped with its safety valve shall be fit...

Page 19: ...t by heating or DHW systems the boiler starts up and water will be heated by an aluminium boil er body Then the boiler pump sends wa ter to the mixing bottle and from here to the radiators according to the heating system choosen The combustion air is supplied by fans and taken in from the boiler room The combustion air is then pushed into the pre combustion chamber through a dia phragm Beyond the ...

Page 20: ...r each thermal element 1 Thermal element 90 kW 100 4 Thermal elem 90 kW x 4 360 kW 400 400 360kW 200 X X 200x360 400 180 kW output shared on 4 thermal elements Output shared on 4 thermal elements total output 180 360 0 5 50 Such principle provides clearly efficien cies much higher than those obtained in traditional groups of small boilers installed in cascade When the output shared on each thermal...

Page 21: ...of the combustion chamber for 10 sec in the meanwhile the air pres sure switch actuated by the fan switch es from C NO open position to C NC closed position allowing the ignition spark to be obtained and the gas valve to be opened after 5 to 8 sec allowing the AIR GAS mixture If within the safety time there is no burner lighting the burn er is put definitely in lockout position the relevant red pu...

Page 22: ...AM 5 fitted such operation is carried out at the manufac turer s workshop and will also be done on site in case of the replacement of a faulty one X1 CVI supply ignition PCB X2 CVI supply ignition PCB X3 230 V electrical supply from mains X7 to MDB by flat cable Fig 11 SUPPLEMENTARY BOARD DIPSWITCH 2 DIPSWITCH 1 AM 5 X3 X1 X2 X7 Fig 10 2 1 O F F 2 1 O F F 2 1 O F F 2 1 O F F 2 1 O F F 2 1 O F F N ...

Page 23: ...e ously X1 diverting valve or storage tank loading pump X2 outer compensator D H W tank NTC X7 to the MBD by flat cable Fig 11 AM 4 0 10 V DHW Tank NTC X1 X2 DIPSWITCH 2 DIPSWITCH 1 X7 Flue Temp IN THE MODULEX BOILERS WITH AN OUTPUT HIGHER THAN 360 KW In order to guarantee the best D H W production the dip switches present configuration allows a maximum avai lability up to 360 kW For example If we...

Page 24: ...o not expose the boiler to sunlight rain etc keep the boiler away from untrained people The boiler supplying cable shall not be replaced by the user In case of any damage to the cable stop the boiler and contact qualified personnel for its replacement For the technical characteristics see the boiler data plate The boiler electrical supply 230 V 50 Hz single phase is to be done direct ly on the thr...

Page 25: ...SFORMATOR RED BLUE BLUE TANGENTIAL FAN K IT BROWN ALIMENTAZIONE 230 V 50 Hz RED BROWN BROWN BLUE BROW N BROWN BLUE YEL GREEN RED BLACK BROWN 00331506 CONDOTTO CAVI 230 V CONDOTTO CAVI 24 V HIGH LIMIT THE RMOSTAT G ENERAL LAMP HIGH LIMIT GENERAL THERMOSTATE ...

Page 26: ...turban ces it is necessary to separate the external sensor wiring between sensor and terminal strip from the 230 or 400 V harness a plastic conduit for 230 or 400 V harness and one for 24 V wiring Depending on the outdoor temperature detected by the sensor the boiler will mod ulate and adjust the flow temperature ac cording to the programmed heating curve see fig 19 ON OFF room thermostat in combi...

Page 27: ... 16 18 only when there is a heat demand by the DHW NTC sensor or by a DHW thermostat in this case the display will show 4 XX see 3 2 5 WARNING There is a 230 V tension between terminals 11 13 only when there is a heat demand by the DHW NTC sensor or by a DHW thermostat in this case the display will show 4 XX see 3 2 5 na nc c 16 17 18 B DHW tank Boiler AB A Heating system Line 3 contact relay Neut...

Page 28: ...iler does not use a 3 way valve but rather a If no other keys are pressed within 15 minutes from the last pressing except when the TEST mode is used the panel board will go into standby mode dis playing the global flow temperature Standby mode gives information as shown in par 3 2 6 concerning the MODULEX instantaneous operation phase storage tank loading pump such a pump is set up for 1 min every...

Page 29: ... pressing mode key it is possible to choose by pressing step key the parameter and 3 2 3 KEY 3 2 4 STORE KEY Once the values requested have been entered it is necessary to store them in order to make them operative To this purpose press store Once the values requested have been entered it is necessary to store them in order to make them operative To this purpose press store In the par 3 2 6 is sho...

Page 30: ...oiler All about the burner 1 is applicable to all other burners 2 to 7 Stand by mode Display The parameter number is not displayed NOTE Once the mode has been selected by the key the installer can enter the different parameters by pressing the key After some minutes from last pressing one of the 5 keys the boiler shall switch to mode If on the contrary the installer wishes to switch to the followi...

Page 31: ...E S E T it selects parameters data all single test all single it chooses the mode It displays when in DATA mode It stores when in PARA mode it increases or decreases the displayed value Reset the boiler The User has not access to these parameters Only the installer or service technician can get access by previously entering the service code see paragraph 3 2 8 2 see 3 2 10 paragraph see 3 2 10 par...

Page 32: ...loading temperature of the heat exchanger of DHW tank For the steps 1 2 and 5 the thermal 3 2 8 PARA MODE When in stand by press the mode key and is displayed Para Description Possible Adjustment Factory Adjustment meters adjustemnt range 1 Requested DHW Temperature in the storage tank 40 65 C 60 40 65 C 2 C H and D H W production ON or OFF options 00 DHW production and Heating 01 00 01 02 11 12 a...

Page 33: ...W request increase of parameter 1 in order to fulfil the request regardless the heating set temperature parameter 3 5 to 25 K C Maximum fan speed in C H mode operation x 100 factory set 58 10 to 60 rpm D Maximum fan speed in DHW mode operation x 100 factory set 58 10 to 60 rpm E Minimum fan speed x 100 factory set 22 10 to 60 rpm F Starting speed in percentage of the maximum speed shown on the 10 ...

Page 34: ...temperature NTC5 C to bur 4 3 Thermal element 1 fan speed adjustment 4 rpm xxxx 4 Thermal element 1 actual fan speed 4 rpm xxxx Data 1 Local flow temperature NTC5 C relevant 2 Local flow temperature NTC6 C to bur 5 3 Thermal element 1 fan speed adjustment 5 rpm xxxx 4 Thermal element 1 actual fan speed 5 rpm xxxx Data 1 Local flow temperature NTC6 C relevant 2 Local flow temperature NTC7 C to bur ...

Page 35: ...and the figures after comma by 10 xxx x From 100 0 to 999 9 hours Multiply the figures before comma by 1000 and the figures after comma by 100 Eg The figure 33 45 means the thermal element operation time is 33x1000 33 000 45x10 450 33 450 h equal to about 4 year continuous operation Step Option Signification ALL OFF All thermal elements are OFF HHH All thermal elements start at high output LLL All...

Page 36: ...The boiler will switch off if the flow temperature exceeds by 5K the pre set flow temperature value i e Pa rameter 3 The boiler will start again as soon as the flow temperature has gone under the pre set value Param eter 3 minus the heating system hys teresis Parameter 8 Parameter 3 Maximum global flow temperature setting at the minimum outer temperature Parameter 4 Minimum global flow temperature...

Page 37: ...th 0 10 V outlet signal is employed this signal can be combined with the boiler By the AM 4 PCB the outer compensator can be combined with the boiler The con nection can be carried out on the termi nal strip of fig 16 terminals 1 2 The parameters applied are shown on the right The boiler will switch off if the flow Parameter G the setting is carried out at a 0 V signal equivalent to the mini mum g...

Page 38: ... see fig 20 you can get after removing by an ALLEN wrench the screw cap on the gas valve By turning it clockwise the CO2 percentage increases while it de creases anticlockwise Follow the same procedure to adjust the other burners If the CO2 percentage is too low check if the air and smoke ducts are not ob structed If they are not obstructed check if the burner and or the exchanger alu minium secti...

Page 39: ... 4 3 DIAGNOSTICS CVI ELECTRONIC CARD In case of failure the LED A will be con tinuously lighted Every 10 seconds the light will be interrupted by a blinking code reporting the failure reason The se quence here reported will be repeated up to the reset Sequence 4 4 BURNER LOCKOUTS A burner lockout is detected by the num bers of the thermal element the error re fers to followed by a blinking spot Th...

Page 40: ...C 8 in short circuit no L1 3 Open Connector on the Local Temperature NTC 1 no L2 3 Open Connector on the Local Temperature NTC 2 no L3 3 Open Connector on the Local Temperature NTC 3 no L4 3 Open Connector on the Local Temperature NTC 4 no L5 3 Open Connector on the Local Temperature NTC 5 no L6 3 Open Connector on the Local Temperature NTC 6 no L7 3 Open Connector on the Local Temperature NTC 7 n...

Page 41: ...o L6 1 The difference between the Global Return Temperature and the Local Flow Temp of thermal elements 6 is too high no L7 1 The difference between the Global Return Temperature and the Local Flow Temp of thermal elements 7 is too high no L8 1 The difference between the Global Return Temperature and the Local Flow Temp of thermal elements 8 is too high no Possible Causes and Solutions As for the ...

Page 42: ...e different for example for the cable removal and for the opening that will be done on the opposite side left side Only for Modulex 450 540 630 remo ve the electric connections of the mo dules marked by the label 1 6 or 7 limit thermostat ignition and detection electrode hearting and immersion sen sor 5 1 MAIN FEATURES If the boiler is correctly adjusted it about doesn t need maintenance it only n...

Page 43: ... the baffle Q setting into the condensation collector use the provi ded for sliding tracks Before starting the boiler ascertain that the condensate siphon is filled with water Before opening the gas feeding che ck that the gas connection previously disconnected is now correctly sealed To do this open the gas cock and che ck the soundness of the coupling using a soap solution As soon as a burner is...

Page 44: ...es if owed to errors of tran script 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 Uniservice Kft 1106 Budapest Maglódi út 16 tel 06 1 433 2612 fax 06 1 431 8349 ...