Unical AIREX 150, Installation And Maintenance Instructions Manual

Page 1: ...AIREX INSTALLATION AND MAINTENANCE INSTRUCTIONS 150 200 200 UK ...

Page 2: ...stallation standards 12 3 3 Packaging 13 3 4 Transportation 13 3 5 Assembly 14 3 6 Connecting boiler to system 14 3 7 Connecting to safety heat exchanger drain 15 3 8 Recirculation pump 15 3 9 Assembly instructions 16 3 10 Flue connection 21 3 11 Filling the system 22 4 INDICATIVE HYDRAULIC AND ELECTRIC DIAGRAMS 23 5 INSTALLATION SUPPLY OF PANEL BOARD code 41156 32 6 STARTING THE BOILER 41 6 1 Com...

Page 3: ...he state of wear of the anode 1 4 INFORMATION FOR SYSTEM MANAGER The system manager must be instructed concerning the use and operation of his heating system in particular Give the system manager these instructions as well as the other appliance documents inserted in the envelo pe inside the packaging The system manager must keep this documentation for future consultation Inform the system manager...

Page 4: ...r cannot be held responsible Modifying parts connected to appliance Do not modify the following parts the boiler the air water and electricity lines the flue gas pipe safety valve and heating water drain pipe 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 inappropri...

Page 5: ...uction booklet accompanies it in order to be consulted by the new owner and or installer Only original accessories must be used for all appliances with optionals or kits including electric This appliance is intended solely for the use for which it was expressly designed Any other use is to be considered improper and therefore dangerous 1 8 THE CLEAN AIR ACT 1993 AND SMOKE CONTROL AREAS Under the C...

Page 6: ... 2 2 DIMENSIONS AND HYDRAULIC CONNECTIONS fig 1 1 Panel board 2 Wood storage door 3 Primary air setting 4 Secondary air setting 5 Flame sight glass 6 Combustion chamber door 7 Fan 8 Smoke pipes cleaning system control lever T1 Central Heating flow T2 Central Heating return T3 Expansion vessel connection T4 Chimney connection T5 Safety heat exchanger connections T6 Boiler drain Intermediate door co...

Page 7: ...R SIDE PRESSURE DROP MAX WORKING PRESSURE WOOD STORAGE VOLUME WOOD LOADING OPENING LENGTH OF LOGS m w c l bar l mm cm H mm I mm AIREX 150 149 3 166 8 2201 DN 65 DN 65 Rp 1 300 R 430 0 39 3 495 514x594 1475 100 151 1679 371 968 698 440 713 224 EMISSIONS 3 EFFICIENCY CLASS EN 303 5 3 3 EMISSIONS CLASS EN 303 5 3 690 CO at 10 O2 mg Nm 687 43 DUST at 10 O2 mg Nm 25 249 NOX at 10 O2 mg Nm 232 R T6 UNI ...

Page 8: ... controlled passage of combustion air contrarily to what happens with large traditional grates The air can be perfectly dosed because the grate covered with burning wood has the same crossing resistance and thus the combustion will be always optimal 1 Panel board 2 Top panel 3 Anti smoke door fitted on hinges 4 Wood storage door with refractory material gasket and handle 5 Primary and secondary ai...

Page 9: ...ystem return GASIFICATION ZONE 2 Gasification takes place in the lower part of the firewood storage It is very important that gasification is as regular as possible so as not to overload the burner with gas Gasification speed depends on the amount of wood and the dimensions of the drying zone Generally it is better to use lar ge logs if they are dry and small logs if the wood is moist The quantity...

Page 10: ...sages also has the task of collecting the ashes and possible embers The flames after having bounced off the walls of the bottom area and the refractory ones direct themselves with a whirling motion towards the front part of the combustion chamber and enter the flue ducts Combustion will be complete and clean and the dominant colour will be that of the ashes white M Hot water flow R System return V...

Page 11: ...ersonnel a Thoroughly wash all the piping of the system to remove any residue or impurities which could jeopardise proper operation of the boi ler b Check that the chimney flue has an appropriate draught without any bottlenecks and that no exhausts from other appliances are inserted unless the flue has been implemented to accommodate several utilities according to specific standards and prescripti...

Page 12: ...instructions 3 2 INSTALLATION STANDARDS AIREX it is a boiler designed to run with firewood This appliance must be installed according to that indicated by standards in force in the country where the boiler is installed ...

Page 13: ...he instruction above Description of packs 1 Boiler body 2 Package containing casing and boiler insulation 3 Package containing casing and boiler insulation 4 Package containing the panel board 5 Package containing air inlet manifold handles flame control mirror screws and nuts cleaning accessories 6 Package containing flue gas intake fan The document envelope inserted in the wood storage contains ...

Page 14: ...dequate clearance space must be left behind the boiler to allow the fan to be opened and serviced POSITIONING IN BOILER ROOM N B The minimum clearances indicated to the side are required to allow the AIREX boiler correct maintenance fig 9 3 6 CONNECTING BOILER TO SYSTEM Attention Make sure that there are no mechanical stresses while connecting the pipes to avoid the risk of leakage Heating flow an...

Page 15: ... sight Attention If this precaution is not taken triggering of the thermal discharge valve can cause damage to persons animals and objects for which the manufacturer cannot be held responsible 3 8 RECIRCULATION PUMP For correct boiler operation a recirculation pump must be installed The recirculation pump supplied in an optional kit must be connected is indicated in fig 19 If it is not installed b...

Page 16: ...osing cover of smoke chamber with the relative seal Wood must be loaded in as little time as possible to keep the impeller of the fan from overheating and thus malfunctioning This problem occurs more quickly the more the wood loading door is opened Assembling the handles Mount the screw and nut on the top door and screw the knob pos 1 2 3 Fit the knob pos 4 on the top door closing handle Mount the...

Page 17: ...e strap an excessive crushing of mineral wool would cause a non homogeneous insulation In case of maintenance it is possible to remove the strap by acting on the locking slots Fitting body insulation Fit the front insulation of the body making a suitable cut near the upper flow connection and upper expansion vessel connection Fit the insulation with straps is described in fig 14 Fit the rear insul...

Page 18: ...b holder small conduit fastening it with the fixing clip Place the bulb of the flow probe S4 in the rear left bulb holder large conduit fastening the cable with the fixing clip Insert the bulb of the return probe S5 in the bulb holder on the boiler return pipe between the boiler and the recirculation pump Fit the bulb holder lg 100 supplied in the accessory bag on the specific attachment on the fl...

Page 19: ...Installation instructions 19 8 11 1 4 2 7 3 10 17 6 5 18 12 fig 16 fig 17 13 14 15 16 ...

Page 20: ...ecific bulb holder It is recommended to convey the discharge Remember that for solid fuel boilers due to the thermal inertia of the fuel the installation of the thermal discharge valve is mandatory SCARICO 1 2 ALIMENTAZIONE fig 19 Recirculation kit For the correct operation of the AIREX range of boi lers it is necessary to foresee a recirculation pump to prevent a low temperature return which coul...

Page 21: ... have perfectly sealed joints to avoid that flue condensate smudge the walls due to permeation The entrance to the chimney should be at a 45 angle At the base of the chimney a flue inspection opening has to be made It is recommended to insulate the pipe connecting to the chimney to reduce heat loss and noise 1 Boiler 2 Flue outlet connection 3 Ash collection chamber 4 Chimney 5 External flue linin...

Page 22: ...at all the connections are watertight after commissioning the boiler and bringing the system to the operating temperature stop the pumps and repeat the air bleed operations let the system cool down and if necessary bring the water pressure back to 1 bar this is valid only for installations equip ped with a closed expansion vessel consult local regulations if this is allowed for installations equip...

Page 23: ... been loaded to reach the set temperature PARAMETER 1 or that the time set in PARAMETER 9 is too short To overcome this stalemate press the fan start key to start a new combustion phase If the boiler temperature detected by probe S4 rises to satisfy PARAMETER 1 within the useful time set in PARAMETER 9 the system pump will switch on and the boiler will run normally Having reached the temperature s...

Page 24: ... TKS TA FLUE GAS PROBE recirculation pump if not installed the warranty is null and void manual zone mixer valve or electric managed by supplementary heating controller heating system pump open expansion vessel heating system distribution loading thermal discharge valve probe flow temperature probe return temperature probe door opening microswitch room thermostat or chronothermostat flue gas tempe...

Page 25: ...f present 16 16 Total probes parameter 24 FUNCTIONAL SETTING PARAMETER 11 If Solar absent 0 If Solar present 1 0 If Recirculation present 0 If Recirculation absent 2 0 If buffer Storage tank absent 0 If buffer Storage tank present 4 0 If Coil type storage tank 0 If Combi type storage tank 8 0 If Wood only 0 If Wood auxiliary boiler 16 0 Total functional parameter 0 Language Select 0 Italian 2 Engl...

Page 26: ...of the boiler detected by probe S4 must be greater than the mi nimum temperature PARAMETER 1 and loading is performed if the temperature detected by probe S4 is greater than that detected by probe S3 plus the PARAMETER 6 storage tank loading thermal delta To manage solar panels enable probes S2 and S1 probe setting parameter aswellastheSOLAR function with the FUNCTIONAL SETTING PARAMETER The recir...

Page 27: ...ANITARIA S3 S1 S2 Ps VE1 CS VENTILATORE M TKS ALIMENTAZIONE 230V 50Hz L1 N J1 J2 J3 J4 J5 J6 J7 J10 J11 J2 N N N N N N N N N N F F F F F F F F F F 1 2 3 5 7 9 11 13 15 4 6 8 10 12 14 16 J4 TA POWER SUPPLY FAN WOOD BOILER DOMESTIC HOT WATER PRODUCER FLUE GAS PROBE J11 J10 J7 J6 J5 J4 J3 J2 J1 J4 J2 S1 S2 S3 S4 S5 J1 ...

Page 28: ...16 Total probes parameter 31 FUNCTIONAL SETTING PARAMETER 11 If Solar absent 0 If Solar present 1 1 If Recirculation present 0 If Recirculation absent 2 0 If buffer Storage tank absent 0 If buffer Storage tank present 4 4 If Coil type storage tank 0 If Combi type storage tank 8 8 If Wood only 0 If Wood auxiliary boiler 16 0 Total functional parameter 13 Language Select 0 Italian 2 English 4 Romani...

Page 29: ...minimum storage tank temperature measured by probe S3 Therefore if the combi storage tank is at a higher temperature than the minimum set temperature PARAMETER 3 the system pump will be activated on demand by the room thermostat even if the boiler is cold As for operation of the boiler recirculation pump and of the solar panel loading pump it is the same as described on page 26 This type of system...

Page 30: ...MULO TANK in TANK S3 S2 VENTILATORE M ALIMENTAZIONE 230V 50Hz L1 N J1 J2 J3 J4 J5 J6 J7 J10 J11 J2 N N N N N N N N N N F F F F F F F F F F 1 2 3 5 7 9 11 13 15 4 6 8 10 12 14 16 J4 TKS TA POWER SUPPLY FAN WOOD BOILER FLUE GAS PROBE STORAGE TANK HEAT EXCHANGER TANK in TANK J11 J10 J7 J6 J5 J4 J3 J2 J1 J4 J2 S1 S2 S3 S4 S5 J1 ...

Page 31: ... 8 Probe 5 if absent 0 if present 16 16 Total probes parameter 31 FUNCTIONAL SETTING PARAMETER 11 If Solar absent 0 If Solar present 1 1 If Recirculation present 0 If Recirculation absent 2 0 If buffer Storage tank absent 0 If buffer Storage tank present 4 4 If Coil type storage tank 0 If Combi type storage tank 8 8 If Wood only 0 If Wood auxiliary boiler 16 0 Total functional parameter 13 Languag...

Page 32: ...TEM 3 HEATING PRODUCTION OF DOMESTIC HOT WATER with combined tank TANK in TANK or HEATING STORAGE TANK PUFFER both with the possibility of having a coil and its control of SOLAR PANEL SYSTEM as support Before commissioning the boiler you must choose the operating mode and follow the instructions for configuration of the board according to the type of system to be managed See diagrams on page 23 BO...

Page 33: ...oiler Ret is the boiler return temperature 6 Flue gas Temp is the combustion flue gas outlet temperature Display procedure The screens can be scrolled by using the direction arrows and present on the panel Boiler temperature adjustment procedure The temperature of the boiler can be adjusted by pressing the key for about 1 2 seconds a beep confirms the operation and the displayed views the set valu...

Page 34: ...oduction cycle or storage tank loading will be activated automatically when the minimum temperature of the boiler or torage tank has been reached It will be deactivated when the boiler or storage tank has reached the desired temperature When room heating is managed by the chronothermostat or room thermostat control with closed contact and suf ficient boiler temperature the board activates the heat...

Page 35: ...e feet Do not pull the electric cables Do not leave the appliance exposed to atmospheric agents rain sun etc unless expressly designed Do not allow children or unskilled persons to use the appliance 230V electric power supply connection The electric connections are illustrated in the section INDICATIVE HYDRAULIC AND ELECTRIC DIAGRAMS chap 4 page 23 Boiler installation requires connection to a 230 ...

Page 36: ...12 14 J3 N Sonda 1 Pannelli Solari 1 Sonda 3 Boiler P Alto 4 Sonda 5 Ritorno Caldaia 16 Ingresso Contatto Porta Sonda 2 Scambiat Solare o Puffer P Basso 2 Sonda 4 Mandata Caldaia 8 Ingresso Crono Termostato Sonda Fumi PT 1000 F1 F Comando INVERTER ventilatore Alimentazione 230Vac INVERTER MOTORE WIRING INTERFACE 230 Vac POWER SUPPLY BURNER or auxiliary boiler Fixed or modulating speed fan Not used...

Page 37: ...rameters repeat the sequence scrolling with the direction arrows and PHASE 6 After having set or changed the parameters you must hold the key pressed for 8 seconds to transfer the data to the non volatile memory Correct connection of probes N B to correctly view the temperature measured by the probe if the cable passes near electric cables or has an ex tension of over 3 metres a shielded cable mus...

Page 38: ...performed on an 8 C scale in four 2 C steps starting from the boiler working temperature defined by parameter n 0 see the list of electro hydraulic diagram parameters page 23 Furthermore it is possible to adjust a higher or lower modulation according to the parameter n 13 Modulation Step which allows to adjust the fan stopping points as the temperature rises For example if the parameter n 0 Boiler...

Page 39: ...s through the bypass After the door has closed the system continues working automatically following the panel board logic Just close the door to silence the alarm Remember that keeping the door open for long periods during reloading could deform the flue gas intake impeller Probe temperature measurement fault Should one or more probes supply faulty temperature measurements try to replace it them a...

Page 40: ...inage there is no water leakage ventilationconditionsand minimum distancesare guaranteed to perform maintenance Switching boiler on and off To switch the boiler on and off see the SYSTEM MANAGER OPERATING INSTRUCTIONS Information for system manager The system manager must be instructed concerning the use and operation of his heating system in particular Give the system manager the SYSTEM MANAGER O...

Page 41: ...ntial air passages are created with a very small flame due to an excess of air The AIREX boiler must be fed with natural wood logs at the length indicated in paragraph 6 6 The logs must normally be round Ø approximately 10 cm 6 5 INITIAL LIGHTING CHECKS GENERAL CONTROLS At the first ignition check that the C H system has been properly filled and properly purged that the safety heat exchanger is co...

Page 42: ...cm 1 cm 4 cm for AIREX 200 200 UK The firewood must be of 20 cm diameter maximum These measures must be strictly observed As for good combustion it is essential that there is a uniform descent of the wood it is necessary to ensure that the length of the wood logs introduced their shape and the manner of loading does not prevent the regular descent of the fuel The wood logs must be placed longitudi...

Page 43: ...operation of the panel board with the boiler at full capacity until the fan is forced to stop when the set tempe rature has been reached Check for leaks from pipe connections After the initial start with the boiler off open the lower door and inspect the internal walls and insulation of the door they should be of a light colour indicative of a proper air adjustment Example n 2 Very inflammable woo...

Page 44: ...re content check that the recirculation pump is working correctly and the flue gas tempe rature at partial load and increase the working temperature In order to control the room temperature it is therefore necessary to install a mixer valve The corrosion caused by the flue gas condensation is not covered by the warranty as it is caused by the wood s moisture content and the way the boiler is used ...

Page 45: ... door slowly Use larger logs Consume the previous load of wood before reloading Problem The boiler does not reach the requested temperature The flame is small and there is too much air Inspecting the wood storage the formation of log bridges is found Remedy Check the length of the logs see page 43 44 Check the arrangement of the logs see page 43 44 Cut the logs in half see page 43 44 Use smaller b...

Page 46: ...ialist based on the status of the appliance ascertained through inspection Inspection and maintenance jobs must be performed in the order shown on page 47 Inspection and maintenance instructions To assure long term functioning of your appliance and to avoid altering its approved status only original Unical spare parts must be used Before proceeding with maintenance always perform the following ope...

Page 47: ...ven in the paragraph Combustion air adjustment 2 Check that the two adduction holes for the secondary air placed in the grate seat are not obstructed if they are pass a soft brush in this pipe Check that the fire bars and steel grate are positioned correctly and that the side insulation wool is in place Monthly Check that the bypass is working as indicated in paragraph 6 5 and that when the loadin...

Page 48: ...dary air distributor Open the front intermediate door and clean the inner space carefully from tarry residues dust and wood flakes which have entered through the primary and secondary air holes Carefully clean the secondary air passages in the main stone with a soft brush During summer we recommend keeping the boiler doors closed fig 36 ...

Page 49: ...d bottom door insulation Integrity of door sealing gaskets Correct operation of microswitch Cleaning of fan blades Fan noise Cleaning of flue gas circuit rear side Replace if necessary Clean if necessary Replace bypass disc if necessary Repair with refractory kit if necessary Replace if necessary Repair and or replace doors if necessary Replace gaskets if necessary Adjust if necessary Clean if nec...

Page 50: ...50 Inspections and maintenance ...

Page 51: ...Inspections and maintenance 51 ...

Page 52: ...Furthermore it reserves the right to modify its products as deemed necessary or useful without affecting their essential features 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 44984 rev 01 08 17 www unical eu ...