Unical PK 150 X 2S, Installation And Servicing Instructions

Page 1: ...PK 150 X 2S PK 230 X 2S PK 300 X 2S PK 348 X 2S 00334158 1st edition 05 2012 INSTALLATION ANDSERVICING INSTRUCTIONS ...

Page 2: ...ng header and plate heat exchanger 26 3 15 Water treatment 27 3 16 Casing assembly 28 3 17 Filling the system 28 3 18 Electrical connections 29 3 19 Functional low wiring diagram 31 3 20 Types of installation 32 3 21 Electrical panel 34 3 22 Wiring connection for electrical panel 35 3 23 Wiring connection panel within multiinox Master Slave 35 3 24 Table positioning selector and cards 37 3 25 Inst...

Page 3: ...cs of the water We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently every two years in this occasion check the state of wear of the anode 1 4 INFORMATION TO BE HANDED OVER TO THE USER The user has to be instructed on the use and operation of his heating system in particular Hand over these instructions to the end...

Page 4: ...er supply pipes and electrical current to the flue pipe safety relief valve and its drainage pipe to the constructive components which influence the appliance s safe operation WARNING When tightening or loosening the screw pipe connections use only adequate fork spanners The improper use and or the use of inadequate equipment can cause damages for example water or gas leakages WARNING Indications ...

Page 5: ...er circuit features 15 Qnw Nominal heat input in D H W mode if different from Qn 16 D Specific D H W flow rate according to EN 625 EN 13203 1 17 R factor N taps based on the quantity of water declared EN 13203 1 18 F factor N stars based on the quality of water declared EN 13203 1 19 PMW Max pressure D H W system 20 T max Max temperature D H W system C Electrical features 21 Electrical power suppl...

Page 6: ...ailure and or faulty functioning of the applian ce switch off the boiler Do not attempt to make any repairs contact qualified technicians Any repairs must be carried out by Unical authorized service engineers and using only original spare parts Non obser vance of the above requirement may jeopardize the safety of the appliance To guarantee the efficiency and correct functioning of the ap pliance i...

Page 7: ...aning severity of heat transfer surfaces Double return for medium and low temperature in the lower back Smoke chamber with stainless steel condensate drain connection and condensate level sensor Opening the door to the left with the possibility of change of rotation Control panel and electronic HSCP Master Heating System Control Panel external to the mantle with tempe rature control unit eBus plac...

Page 8: ...nd then sent to the chimney During burner operation within the boi ler s output range the combustion chamber is always under positive pressure For this pressure value refer to the table on page 8 to the column Heating losses flue side 2 4 5 M Rmt Ve Rbt 1 3 6 7 1 Furnace 2 Flue pipes with flue deflectors 3 Door complete with flame control light 4 Smoke chamber 5 Body insultation Control panel not ...

Page 9: ... 55 0 60 35 40 45 50 Flue side losses mm c a Max boiler working pressure bar 5 5 5 5 Weight without burner kg 310 447 540 661 PKX 2S Model DIMENSIONS A mm 700 830 880 960 Minimum dimensions for boiler room access requirements Hydraulic resistance for delta T 15K Minimum pressure gas train entrance natural gas G20 T9 Øi mm 163 163 163 163 Heat output 80 60 C kW 136 5 209 2 273 6 317 7 T10 Øe mm 40 ...

Page 10: ... 100 30 Combustion efficiency at nominal load Combustion efficiency at reduced load Flue losses with burner On Flue losses with burner Off Flue gas temperature tf ta min C Flue gas temperature tf ta max C Flue gas mass flow rate min kg h Flue gas mass flow rate max kg h Air excess CO2 min CO2 max N0x value according to EN 297 A3 mg kWh N0x class Heat loss at chimney with burner on min Perdite al c...

Page 11: ...ienical point of view b Check that the boiler has been preset for operating with the gas type available This is verifiable via the indication on the packaging and on the data badge c Check that the chimney flue pipe has an adequate draught does not have any constrictions and that no other applian ce s flue outlets have been fitted unless the chimney is serving more than one heating appliance accor...

Page 12: ...ese appliances are exclusively designed to be installed inside adequate boiler rooms Before installing the boiler the following points have to be carried out by a competent engineer a The whole system should be thoroughly flushed in order to remove any residual dirt or grime which could compromise the good operation of the boiler even from a hygienical point of view b Check that the boiler has bee...

Page 13: ... the following contents Hydraulic test certificate Service logbook Instruction manual for the person in charge of the appliance Instruction manual for the installer and servicing personnel Warranty certificate Adhesive sticker indicating local venting regulations ISOLATION AND CASING N B For the model PK150X 2S mantle and isolation are contained in 1 package marked 38353 casing insulation PK150X 2...

Page 14: ...duced by the boiler The electrical system has been fitted in compliance to the specific standards and the work has been carried out by a competent person The circulation pump s output the head and flow direc tion are suitable The gas feed supply pipe and eventual tank are con structed according to the regulations in force The expansion vessels assure the total absorption of the expansion of the fl...

Page 15: ...ons in force 3 6 BOILER LOCATION The boiler must be installed in accordance with the relevant requirements of the Gas Safety Regulations current I E E Regulations local water authority by e laws and it should also comply with any relevant requirements of the local gas sup plier local authority and the relevant Standard Codes of Prac tice and building regulations The boiler house must be ventilated...

Page 16: ...3 389 445 555 667 778 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 0 009 0 010 0 015 0 020 0 030 0 035 0 040 0 050 0 060 0 070 0 080 0 090 0 100 0 150 0 200 0 250 0 300 0 350 0 400 0 500 0 600 5 0 700 9 0 10 8 12 0 14 4 22 25 29 32 36 54 72 90 108 126 144 180 216 252 288 324 360 540 720 900 1080 1260 1440 1800 2160 2520 6 7 8 9 10 12 14 16 18 20 30 40 50 60 70 80 90 100 120 140 160 180 200 300 ...

Page 17: ...ning at maximum output If the boiler is not installed on a plinth then it can be fitted directly onto the boiler floor and than a deep well of at least 100 mm will be required to house the siphon 3 8 CONDENSARE DRAIN Any neutralization devices can be connected to the conden sate after the trap For the calculation of the neutralization of the charge must be assessed the state of wear of the neutral...

Page 18: ...The door is therefore installed with two rotating hinges on the left hand side the door is shut via 4 screws position C The door mounting can be reversed so that it hinges from left to right Door adjustment A Axial door adjustment further adjustment to the position of the door in relation to the chamber can be achieved throu gh adjustment o the screws WARNING Before opening the furnace door it is ...

Page 19: ... fitted on the gas supply line The gas supply pipe must have a section which is adequate to the burner s output It is however important to comply with the specific standards and requirements in force Before commissioning an internal gas distribution system and therefore before connecting it to the gas meter the complete installation must be tested for gas soundness If any part of the system is con...

Page 20: ...g system we recommend that the system is flushed out with a suitable product in order to eliminate any metallic tooling or welding residues oil and grime which could reach the boiler and affect the proper running of the boiler Do not use any solvents for flushing out the system as they could damage the system and or its components Non observance of these instructions could cause injury to persons ...

Page 21: ...MP OR BOILER SYSTEM PUMP The boiler pump must have a delivery head which can ensure the water flow rate as shown in the graph Water pressure losses The following table gives an indication of the pump s flow rate in function of the t of the primary circuit The size of the pumps must be determined by installers or technical engineers accor ding to boiler data and system design The water side resista...

Page 22: ...di carico mmh2O PK230X 2S Perdita di carico lato acqua 0 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 32000 34000 36000 38000 40000 42000 44000 46000 48000 Q portata acqua l h perdita di carico mmh2O PK300X 2S Q water flow rate l h Pressure losses mmH2O WATER SIDE PRESSURE LOSSES Q water flow rate l h Pressure losses mm...

Page 23: ...00 15000 20000 25000 30000 35000 40000 45000 50000 55000 Q portata acqua l h perdita di carico mmh2O PK348X 2S Q water flow rate l h Pressure losses mmH2O WATER SIDE PRESSURE LOSSES 3 13 FROST PROTECTION If the flow temperature measured at global flow NTC falls below 7 C the system pump circulates water around the water circuit and all the heat modules will operate at minimum output Note The anti ...

Page 24: ...lycol used as an antifreeze or in several cases it is due to the natural formation of alkaline in the system Vice versa if the pH value is between 6 5 and 8 the aluminium surfaces of the boiler body are passivated and protected from further corrosive attacks To minimize corrosion it is essential to use a scale inhibitor however in order for this to function correctly the metallic surfaces have to ...

Page 25: ...blanket 3 and secure in to place using the elasticated straps 2 provided ensu ring that the metal clips grip in to the external surface of the boiler shell s insulation Make a convenient cut in the upper part of the insula tion blanket to get easy access to the bulb holders C Fit the self tapping screws onto the internal profiles of the 2 side panels 4 and 5 D Fit the left side panel 4 fixing it o...

Page 26: ...l panel to the right hand side panel 5 F Fit the right hand side panel 5 to the lower panel and fix it to the upper squadretta on the right hand side of the boiler body inserting the lower bend inside the bottom L profi les G Insert the thermometer and thermostat bulbs in the sensor pockets as shown in Fig 8 boiler sensor termometer sensor HL thermostat sensor and connect the mains the burner the ...

Page 27: ...r shell of the control panel H Fit the top panel 8 and fix it onto the side panels 4 5 I Fix the retaining strips 9 onto the lower left hand side rear panel 4 and to the upper panel 8 10 8 4 8 4 5 L Fit the right hand side rear panel 10 onto the left hand side rear panel 4 and to the upper rear panel 8 10 9 Fix the platelets pos 6 support the two sides of the con duit and the plate pos 7 closing t...

Page 28: ...ront panel 13 and fix it on to the side panels 4 and 5 13 4 5 14 15 P Remove the protective paper film from the data plates and fit them on to the side panel The data plates are in the plastic bag containing the docu ments Warning In the event that the panel is mounted on the left side you must turn the temperature control unit eBus To turn the temperature control unit eBus on the control panel yo...

Page 29: ...r 4 un screw the 2 nuts 5 and remove the bracket 6 4 S Turn the Unit 180 5 6 5 T to reposition the unit 3 through the bracket 6 and ti ghten the 2 nuts 5 3 5 6 5 U plug the connector 4 on the unit 4 V replace the cover 2 access to the terminal unit and se cure with the two screws 1 1 2 ...

Page 30: ...ned recommendations After completing all the system s service connections the circuits may be filled To fill the system it is necessary to fit a filling cock on the system s return The boiler is equipped with its own drain tap whose position is indicated in the figure on page 17 This tap must NEVER be used for draining of the whole system as this could lead to system dirt gathering in the boiler c...

Page 31: ...p and permit the boiler to cool down Gain access to the Y1 terminal board Room thermostat connect the thermostat s cables to the terminals 1 and 2 DANGER Switch off and disconnect the electricity sup ply before carrying out any operations on the electrical parts Room Thermostat Room thermostat connection 3 18 ELECTRICAL CONNECTIONS General warnings The elctrical safety of the appliance is assured ...

Page 32: ... connection EBUS UNIT 1 2 3 4 5 6 7 8 9 10 11 OUTDOOR SENSOR 0 1 2 3 4 5 6 7 8 9 BUS Single boiler DANGER Switch off and disconnect the electricity sup ply before carrying out any operations on the electrical parts Gain access to the Y2 terminal board on the BCM Cascade controller Outdoor sensor connection insert the cables between the pins 6 and 7 on the terminal board Boilers installed in a casc...

Page 33: ...information of the 0 10 Volt signal also refer to the pump manual FIX RATE PUMP Modulating Pump 1 2 3 Y2 4 5 6 7 Y3 1 2 3 Jp1 1 2 3 Y4 4 DL1 DL2 DL3 1 2 3 Y1 4 5 6 A1 SW1 ALLARM SIGNAL BCM eBUS eBUS 24 V MAIN SUPPLY 230 V 50 Hz N L1 N 0 10 V terminals Wilo modulating pump interface 0 10 V L1 SUPPLY MODULATION PUMP APM MODULATING PUMP Pump Connection FIXED RATE PUMP Single Boiler 1 2 L1 N MARRONE M...

Page 34: ...NGE ORANGE BROWN BROWN WHITE WHITE SR BROWN BLUE PG 1 3 mod 150 SL TL BLUE BLUE BROWN WHITE 1 nc c 3 PF IG TR ACC 1 2 L1 N BROWN BLUE 1 2 3 4 5 6 7 8 9 10 11 M1 3 19 FUNCTIONAL FLOW WIRING DIAGRAM E ACC Ignition electrode E RIV Ionization electrode IG Main switch PF Flue switch PG Gas switch SR CH sensor SRR CH return sensor SL Condensate level sensor TL Limit thermostat TR ACC Ignition transforme...

Page 35: ... the installer 3 20 TYPES OF INSTALLATION Single boiler Control panel fitted with an eBus heating controller Boiler Cascade Slave Panel BCM cascade manager kit 00361602 Control panel fitted with an eBus heating controller ...

Page 36: ... 3 Y4 4 DL1 DL2 DL3 1 2 3 Y1 4 5 6 A1 SW1 BCM SMG eBUS eBUS 24 V 0 1 2 3 4 5 6 7 8 9 BOILER 1 eBUS BOILER 2 BOILER 3 BCM 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 eBUS eBUS eBUS eBUS eBUS eBUS eBUS eBUS eBUS 24V Board selector setting 0 1 2 3 4 5 6 7 8 9 pos BCM 0 Boiler 1 with eBus UNIT 0 Boiler 2 Slave 1 Boiler 3 Slave 2 Boiler 4 Slave 3 Boiler 5 Slave 4 Boiler 6 Slave 5 Boiler...

Page 37: ...ing system with 1 direct high temperature heating zone CH SYSTEM HIGH TEMPEARTURE EXPANSION VASSEL BOILER PKX BOILER SENSOR NB In case of a single system return low or medium temperature the connection must ALWAYS be carried out on the inlet and the lower back of the boiler stub low temperatu re system return ...

Page 38: ...omestic hot water production NB In case of a single system return low or medium temperature the connection must ALWAYS be carried out on the inlet and the lower back of the boiler stub low temperature system return VE VE BOILER PKX 1 Master BOILER PKX 2 Slave CH SYSTEM HIGH TEMPERATURE BOILER SENSOR BOILER SENSOR Connection for eventual mixing header for perfect balance of the heating ...

Page 39: ... the boiler and in particular detail Hand over to the person in charge of the appliance the booklet INSTRUCTIONS GUIDE FOR THE PERSON IN CHARGE OF THE APPLIANCE as well as all the other literature relative to the appliance and placed in the en velope contained in the packaging The person in charge of the appliance must retain this literature for any future reference Inform the person in charge of ...

Page 40: ...e the value and in an ANTICLOCKWISE direction in order to decrea se it MAXIMUM OUTPUT ADJU STMENT SCREW A Max output adjustment Remove the sampling point cap and insert a suitable C02 gas analyser in the flue outlet terminal Via the e bus controller activate the Test mode and run the boiler at maximum output Check that the C02 values are within the values indica ted in the table Burner pressures I...

Page 41: ... pressures If necessary correct the value by turning the adjustment screw A in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrea se it Flue sam pling point Levels CO2 min Levels CO2 max Fan speed Consump min Gas nat G20 min max Diafraghm collettore Ø e n fori PKX 150 Starting Power FL FH 20 3 7 m h 14 8 m h 9 1 96 31 9 0 9 1 60 In case of gas valve re...

Page 42: ...urning the adjustment screw B in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrea se it Gas nat G20 min max PKX 230 20 5 28 m h 22 83 m h 9 2 82 24 15 9 2 60 Gas nat G20 PKX 300 20 7 4 m h 29 61 m h 9 1 87 24 15 9 1 50 Gas nat G20 PKX 348 20 7 4 m h 34 26 m h 9 1 99 24 15 9 1 50 Levels CO2 min Levels CO2 max Fan speed Consump min Diafraghm collettore...

Page 43: ...o appears on the display Press key A 2 zero appears on the display Press key A 3 zero appears on the display Press key A 4 zero appears on the display For activating the CHIMNEYSWEEPER MODE proceed as follows on the display Turn the knob C on Press key A store Turn the C until Manual control appears on the display 1 2 3 Select the activation command of the function Select the modulation level sett...

Page 44: ... password Rotate knob C to ZERO Press key A 1st zero appears on the display To display modify the operating parameters proceed as fol lows Press key A 2nd zero appears on the display Press key A 3rd zero appears on the display Press key A 4th zero appears on the display Rotate knob C up Press key A save At this point you can modify the parameters Rotate knob C to select the involved parameter Pres...

Page 45: ...0 99 8 346 Minimum Modulation 32 29 24 28 9 488 Fan PWM Max 10 10 20 20 10 527 Fan Set Rev 2 2 3 3 11 161 Burner power 150 230 300 350 12 483 Max differential Temp 0 0 0 0 13 622 Minimum flow sensor 0 0 0 0 14 34 Burner hysteresis 50 50 50 50 15 336 Temperature Gradient 10 10 10 10 16 353 Proportional adjustment 20 20 20 20 17 354 Integrative adjustment 12 12 12 12 18 478 Derivative Adjustment 10 ...

Page 46: ...ctions To assure long term functioning of your ap pliance and to avoid altering its approved sta tus only original Unical spare parts must be used Before proceeding with maintenance always perform the fol lowing operations Disconnect the electric mains switch Isolate the appliance from the electric mains by means of an isolated device with a contact opening of at least 3 mm e g safety devices or p...

Page 47: ...l spare parts Check the status of the smoke chamber ins pection cover gasket Replace it if worn using only original spare parts Components to check during yearly inspection COMPONENT Ts safety thermostat System expansion vessel Door gaskets Smoke chamber gaskets Ignition electrode Detection electrode Burner VERIFY Does the thermostat place the boiler in safety when overheating Does the vessel cont...

Page 48: ...orrect operation of the condensation draining system Code Meaning Sanitary sensor failure only if the boiler is cou pled with an outer storage tank Solution Make sure the sensor and or wiring is efficient Code Meaning Mains voltage 190 Vac Solution Check the mains voltage if 190 Vac if the mains voltage is correct replace the control board Code Meaning Insufficient gas pressure Solution Check the ...

Page 49: ... Modulating fan failure Solution Check the fan wiring 26 Code Meaning Modulating fan failure Solution Check the fan wiring 24 Code Meaning Flame detected before starting the ignition cycle Solution Disconnect the detection electrode cable from the control board if the error code disappears re place the cable otherwise replace the control board Code Meaning Flame detected once the burner has been t...

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