Unical PELLEXIA 80, Instructions For Installation, Use And Maintenance Manual

Page 1: ...PELLEXIA 80 INSTRUCTIONS ON INSTALLATION USE AND MAINTENANCE ...

Page 2: ...or maintenance technician in compliance with current legislation The system manager is NOT authorised to service the boiler The manufacturer will not be held liable in case of damage to persons animals or objects resulting from failure to comply with the instructions contained in the manuals supplied with the boiler ...

Page 3: ...S 15 3 1 General warnings 15 3 2 Installation standards 15 3 3 Installation on old or retrofittable systems 15 3 4 Packaging 16 3 5 Installation 17 3 6 Hydraulic connections 18 3 7 Assembly instructions 20 3 8 Connection to the flue 22 3 9 Electrical connections 24 3 10 Filling the system 25 3 11 Hydraulic base diagrams 26 3 12 Panel board 36 3 13 Panel board electrical connections 41 3 14 Boiler ...

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Page 5: ...nsible Before performing any cleaning or maintenance disconnect the appliance from the energy mains by acting on the switch of the system and or through the specific cut off devices Do not obstruct the terminals of the ventilation ducts In case of failure and or malfunctioning of the appliance switch it off and do not try to repair it or intervene on it directly Contact only personnel qualified in...

Page 6: ...e 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 temperat...

Page 7: ...ing parts connected to appliance Do not modify the following parts the boiler the air water and electrical current lines the flue gas pipe the safety valve and the exhaust pipe the construction parts which 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...

Page 8: ...plate is adhesive and is included in the document case it must be applied by the installer on the outside of the casing The serial number of the boiler is on the riveted plaque on the front plate of the body front right top side destination Country ...

Page 9: ...NTS Steel boiler body with combustion chamber partially covered with refractory material Air blown pellet burner with automatic feeding Three smoke circuits with the third equipped with turbolators Front doors with refractory coating and flame warning light on the burner Rear smoke chamber with inspection door and ash removal door Smoke extraction fan Safety heat exchanger Boiler body insulated wi...

Page 10: ...tacco Scambiatore di sicurezza Guaina per sensore Valvola Scarico Termico Guaina per sonde Attacco Vaso Espansione Attacco Valvola Sicurezza DN 2 2 Øe 200 3 4 1 2 1 2 3 4 1 2 2 3 DIMENSIONS OF PELLET CONTAINER 1000 1000 1004 1004 1430 772 Description FLOW Sleeve RETURN Sleeve Flue Gas Outlet Safety Exchanger connection Probe sheath Expansion Vessel Connection Safety Valve Connection Temperature Re...

Page 11: ... 217 1 CO 13 mg Nm3 74 6 157 9 NOx 10 mg Nm3 168 3 213 6 NOx 13 mg Nm3 122 4 155 4 Hc 10 mg Nm3 2 7 3 8 Hc 13 mg Nm3 2 0 2 8 Dust 10 nominal output mg Nm3 14 0 Dust 13 nominal output mg Nm3 10 1 FUEL CHARACTERISTICS See par 2 6 THERMAL STORAGE VOLUME Recommended l 1600 MAX SUPPLY WATER TEMPERATURE SAFETY HEAT EXCHANGER C 15 SUPPLY WATER PRESSURE SAFETY HEAT EXCHANGER bar 2 BOILER OPERATION WITH FA...

Page 12: ...low moisture content lower than 10 its high density 600 kg m3 as well as its regularity and compactness providing to this type of fuel a high Net Calorific Value In order to provide PELLEXIA with a long lifespan Unical advises using certified pellets The pellets used to feed the boiler must have high quality fea tures such as for example those determined by the standard EN 14961 2 The following ar...

Page 13: ... cause PELLEXIA malfunctioning and shall terminate the warranty Storage and handling of pellets are important operations to be performed with care The fuel must be stored in a dry place which is not cold Pellets must be moved in such a way to avoid excessive crush ing into fine powders Compliance with these two simple rules provides better com Parameter Diameter D Length L Water content M Ashes A ...

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Page 15: ... the technical professional requirements according to law 37 08 which under his own responsibility guarantees compliance with the standards according to good practice rules The boiler must be connected to a central heat ing system and or domestic hot water production network compatible with its efficiency and output 3 2 INSTALLATION STANDARDS It must be installed by a professionally qualified tech...

Page 16: ...ded for this purpose using appropriate lifting systems below the cas ing cover The packaging elements cardboard boxes straps plastic bags etc must be kept out of the reach of children as they are potential sources of danger Unical will not be held liable for damage to persons animals or objects due to failure to comply with the instruction above The document envelope inserted in the furnace contai...

Page 17: ...pment or appliances which can create a vacuum in the room in relation to the outside environment and therefore hinder the draught of the flue gas exhaust system UNI 10683 To make it easier to clean there must be a clearance space in front of the heat stove no less than the length of the stove itself You must at least make sure that the door can open 90 unobstructed PELLEXIA can be placed directly ...

Page 18: ...ring of the thermal discharge valve can cause damage to persons animals and objects for which the manufacturer cannot be held responsible SCARICO 2 ALIMENTAZIONE 1 3 6 HYDRAULIC CONNECTIONS ATTENTION Before connecting the boiler to the heating system thoroughly clean the piping with an appropriate product compliant with UNI CTI 8065 in order to eliminate metallic residue from processing and weldin...

Page 19: ...t is not installed besides limiting the boiler s lifespan it will invalidate the warranty ATTENTION The hardness of the mains water supply conditions the boiler s lifespan Depending on the hardness of the mains water supply the possibility of installing appropriate domestic water soften ers has to be taken into consideration in compliance with DM n 443 of 21 12 90 It is always recommended to treat...

Page 20: ...sufficient space for loading pellets in this tank As an indication there should be a clearance of no less than 1000 mm between the boiler and any wall on the left side for standing next to the tank and to fill it easily Assemble the expansion vessel 3 2 1 Assembly of internal components A Check the correct position of the grate pos 1 B Position the refractory stones pos 2 in the upper part of the ...

Page 21: ...ut the return probe in the relative pit at the bottom of the boiler Insert the flue gas temperature thermocouple in the relative sheath of the flue gas outlet nozzle Connect the power supply of the screw and the pellet level sen sor passing the cables from the connection point on the burner through the hole at the front of the pellet container making sure the cables do not touch the front door of ...

Page 22: ...ed smoke pipes The flue must comply with the standards in force The flue gas chimney must be made properly to favour the normal flow of flue gas from the combustion chamber towards the outside in the case of a power outage Remember that the elimination of excess heat is managed optimally by the electronic control unit The following are the main features of the flue gas exhaust pipe according to th...

Page 23: ...as can also be discharged using a traditional pre existing flue as long it is made to standard see UNI 10683 We will briefly list some of the main features highlighted by the standard which characterise a good chimney Adequate insulation especially in the outside section exposed to the atmosphere Constant internal cross section there must be no cross section constrictions Made with material resist...

Page 24: ...unskilled persons to use the appli ance 230V electric power supply connection The electrical connections are described in sections 3 14 and 3 15 Boiler installation requires connection to a 230 V 50 Hz electric mains This connection must be set up according to standard as in tended by current IEC regulations Danger Only a qualified technician may perform the electrical installation Before performi...

Page 25: ...ion above After making all the hydraulic connections fill the boiler and check the soundness of all the connections This operation must be performed carefully re specting the following phases open the bleeder valves of the radiators radiant batteries and or distribution manifolds open the system filling tap gradually making sure that the automatic air release valves in stalled on the system work p...

Page 26: ...ial it serves the purpose of balancing the flow and return tem perature of the boiler and adds cold water when necessary to prevent the risk of condensation The P3 heating system pump is enabled in Winter mode It is triggered by the ambient chronothermostat input 15 16 on the control unit and when the boiler temperature exceeds the mini mum value which is normally 60 C Sensor legend S4 flow temper...

Page 27: ...14 Time for cleaning burner seconds 15 Time for post rotation of feeding screw 2 seconds 21 Time for pre igniting the burner seconds 16 Time for preloading fuel seconds 17 Pre combustion combustion time minutes 18 Time for running the feeding screw motor ON seconds 19 Time for pausing the feeding screw motor OFF seconds 20 Time for final cleaning of burners seconds 22 Fan speed with burner running...

Page 28: ...orage tank be cause it controls the temperature and the priority of either heat ing or hot water When the temperature of the storage tank falls below the mini mum threshold the control unit prioritises domestic hot water The storage tank pump is enabled when the boiler temperature the S4 probe is above the minimum boiler temperature nor mally 60 C the storage tank pump is also enabled when the S4 ...

Page 29: ...ing burner seconds 15 Time for post rotation of feeding screw 2 seconds 21 Time for pre igniting the burner seconds 16 Time for preloading fuel seconds 17 Pre combustion combustion time minutes 18 Time for running the feeding screw motor ON seconds 19 Time for pausing the feeding screw motor OFF seconds 20 Time for final cleaning of burners seconds 22 Fan speed with burner running 23 Fan speed dur...

Page 30: ...ither heat ing or hot water When the temperature of the storage tank falls below the mini mum threshold the control unit prioritises domestic hot water The P2storage tank pump is enabled when the boiler tempera ture the S4 probe is above the minimum boiler temperature normally 60 C the storage tank pump is also enabled when the S4 boiler flow probe detects a temperature above that of the S3 probe ...

Page 31: ...3 Modulation of fuel and air in relation to boiler temperature 6 14 Time for cleaning burner seconds 40 15 Time for post rotation of feeding screw 2 seconds 5 21 Time for pre igniting the burner seconds 60 16 Time for preloading fuel seconds 55 17 Pre combustion combustion time minutes 5 18 Time for running the feeding screw motor ON seconds 14 19 Time for pausing the feeding screw motor OFF secon...

Page 32: ... temperature normally 60 C The storage tank pump is enabled when the S4 boiler flow probe detects a temperature above that of the S2 probe plus a heat differential normally 6 C Running the heating system In this configuration the P3 heating system pump is connected directly to the storage tank and depends therefore not on the boiler temperature but on the temperature of the storage tank The S3 pro...

Page 33: ...3 Modulation of fuel and air in relation to boiler temperature 6 14 Time for cleaning burner seconds 40 15 Time for post rotation of feeding screw 2 seconds 5 21 Time for pre igniting the burner seconds 60 16 Time for preloading fuel seconds 55 17 Pre combustion combustion time minutes 5 18 Time for running the feeding screw motor ON seconds 14 19 Time for pausing the feeding screw motor OFF secon...

Page 34: ...ature normally 60 C The P2storage tank pump is enabled when the S4 boiler flow probe detects a temperature above that of the S2 probe plus a heat differential normally 6 C Running the heating system In this configuration the P3 heating system pump is connected directly to the storage tank and depends therefore not on the boiler temperature but on the temperature of the storage tank The S3 probe co...

Page 35: ...h 4 French 6 Spanish 30 Maximum operating time of burner hours 10 Number of burner start up attempts 11 Duration of burner flame ignition cycle minutes 12 Time for detecting stability of burner flame seconds 13 Modulation of fuel and air in relation to boiler temperature 14 Time for cleaning burner seconds 15 Time for post rotation of feeding screw 2 seconds 21 Time for pre igniting the burner sec...

Page 36: ...circulation 8 Warning light Fuel feeding screw 9 Key to access the settings and parameters configuration menu restricted to the author ised technician 10 Key for selecting the season Summer Winter 11 Set up key Off Automatic Burner Reset manually resettable alarms 12 Priority selection key Production of domestic hot water Heating 13 Silence alarm key 14 Keys for scrolling through the pages on the ...

Page 37: ...nless steel tip for flue gas Fan with incorporated speed control inverter Terminal block on the side of the boiler for the electrical con nections of the pumps Manually resettable mechanical safety thermostat in the control board The second page displays the readings of the solar panel probe and of the probes at the top and bottom of the storage tank The third page displays burner flame intensity ...

Page 38: ...nvolves an attempt to ignite using the pre loaded fuel Phase 4 referred to as PreC on the screen is the phase im mediately after ignition and involves the preparation of a good bed of embers the speed of the fan varies according to the speed of combustion without the addition of new fuel Phase 5 indicated on the screen as COMB is when the fuel is added and involves start and stop cycles The system...

Page 39: ...med on an 8 C scale in four 2 C steps starting from the boiler working tem perature defined by parameter n 0 Furthermore it is possible to set higher or lower modulation according to parameter n 14 Modulation Step to adjust the fan stopping points as the temperature rises For example if parameter no 0 Boiler working temperature is set at 80 C and parameter no 14 Modulation step is set at 2 points ...

Page 40: ...ess the key for about 6 seconds to exit programming mode and return to the user display Example of how to set the Probes Parameter If the boiler is used and connected for heating only as shown in the diagrams in section 3 11 1 the two probes S4 and S5 are required You therefore need to add 8 16 24 The number to be entered is 24 Please note If you have any trouble installing and therefore enabling ...

Page 41: ... A Fusible 3 15 A N F RD GY WH PK GN YE BU GN YE BN WH WH GN GN BN BN BN BN GN YE GN YE Filter PT1000 N F N F N F N F PUMP 3 Heating system PUMP 2 Boiler or storage PUMP 1 Solar panels PUMP 4 Boiler recirc 16 pin connettor high voltage wiring Low voltage wiring BN BN B Detail Fan Power supply 230 V 50 Hz MOTOR INVERTER Main switch Probe 0 Solar Boiler P High 4 Probe 2 Solar Exchanger or Puffer P L...

Page 42: ...rained and has the documentation been supplied 3 14 1 PRELIMINARY CHECKS Commissioning must be done by profession ally qualified personnel Unical will not be held liable for damage to persons animals or objects due to failure to comply with the above instruction Please tick the operations performed The preliminary checks must be carried out by the company who installs the system After connecting t...

Page 43: ...esence of dense smoke inside the combustion chamber immediately SWITCH OFF the boiler and replace the pellets as they are too moist if you insist the combustion chamber risks an explosion If during routine cleaning you find spongy but very hard residue inside the burner which tends to stick to the grate replace the pellets as they come from poor quality sawdust Running the burner with the combusti...

Page 44: ...oading of the pellets after which an alarm is triggered Remedy Check the nature of the triggered alarm Check the condition of the igniters Replace the igniters Other alarms that can occur during use of the boiler and the measures to be taken Triggering of the pellet clogging sensor Check for clogging of pellets or check whether the sensor is dirty Triggering of the water safety thermostat Check th...

Page 45: ... The alarm resets itself automatically when the temperature of the storage tank and or solar panels falls below the maximum temperature again Fault due to triggering of the automatically resettable fire safety thermostat on the manifold of the burner To reset this alarm press key 11 on the panel board refer to section 3 12 Before resetting this alarm you must check that there is no fuel or non com...

Page 46: ...rinted circuit board Advice for the user if it is necessary to set a working tem perature of more than 80 C it is advisable to proportionally increase parameter 2 max temperature for thermal inertia in the boiler PROBE AUDIBLE ALARM The boiler has an intermittent alarm system that signals one or more faults with the probes due to these being disconnected or out of range in any case a message is di...

Page 47: ...ents subject to wear Maintenance intervals and their extent are determined by a specialist based on the status of the appliance ascertained through inspection Inspection and maintenance jobs must be performed in the order shown on page 51 Inspection and maintenance instructions To assure long term functioning of your appliance and to avoid altering its approved status only original Unical spare pa...

Page 48: ... any rags make sure you collect all these Keeps the screws and nuts lubricated CLEANING AND ROUTINE MAINTENANCE Every day Fill the pellet tank Every 3 days Remove ashes in the pan To perform this operation act as follows turn off the power at the main switch upstream of the boiler unplug the burner and pressure switch open the doors of the boiler by undoing the nuts with the spanner provided use a...

Page 49: ...ns freely Check the hermetic seal of the doors Make sure that the sealing gaskets are intact Check the operation of the safety devices Clean the smoke ducts Make sure that the refractory stones are intact Check wear cleanliness and repositioning of the burner grate X X X X X X X X X X X Every year Lubricate grease the hinges and door opening levers X MAINTENANCE OPERATIONS X Thorough cleaning of t...

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Page 52: ...s It reserves the right to modify its products as deemed necessary or useful without jeopardising their essential features 46033 casteldario mantova Italy tel 39 0376 57001 telefax 39 0376 660556 info unical ag com export unical ag com www unical eu AG S p A 00335402 a 2 nd edition 09 15 www unical eu ...