Unical XC-K 1140, Installation And Maintenance Instructions Manual

Page 1: ...INSTALLATION AND MAINTENANCE INSTRUCTIONS 44879 03 12 rev 0 XC K ...

Page 2: ... 12 Connecting gas 20 3 13 Packaging 21 3 14 Assembling casing 22 3 15 Electrical connections 24 3 16 MODULATING MASTER panel board code 37892 26 3 17 Programming heating controllers with single boiler 26 3 18 Hydraulic and electric system connection with panel board code 37892 30 3 19 Programming heating controllers with boilers in cascade 32 3 20 MODULATING CASCADE panel board code 37900 36 3 21...

Page 3: ...s occasion also check the state of wear of the anode 1 4 INFORMATION FOR SYSTEM MANAGER The user must be instructed concerning the use and operation of his heating system in particular Deliver these instructions to the user as well as other documents concerning the appliance inserted in the bag contained in the packaging The user must keep this documentation so that it is available for further con...

Page 4: ...arts 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 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 deaeration of th...

Page 5: ...n 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 bottom side Condensing boiler Serial No Year of construction Q Boiler water content Max Water pressure l OUTPUTS P I No Useful diesel output Useful gas output kW 80 C 60 C 46033 CASTELDARIO MN Via Roma tel 0376 5700...

Page 6: ...not try to repair it or intervene on it directly Contact only personnel qualified in compliance with law Any repairs must be performed solely by personnel authorised by Unical using original spare parts only Failure to comply with the above can jeopardise the safety of the appliance To guarantee appliance efficiency and its correct operation yearly maintenance must be performed by qualified person...

Page 7: ...are designed to operate with ON OFF dual stage or modulating burner as long as the minimum heat output that can be reached is no lower than the value indicated on the technical data plate The boilers are provided with two attachments for conduits with an inside diameter of 15 mm suitable to house 3 bulbs each The shell has holes at the sides for the cable glands of the power pumps burner cables an...

Page 8: ...40 Pressure drop water side kPa 1 5 9 8 Pressure drop flue side daPa Maximum operating pressure boiler bar 6 Weight kg 365 Minimum dimensions for boiler room access Pressure drops corresponding to a thermal drop of 15K fig 3 fig 2 T7 Øi mm 182 T8 Øe mm 40 Nominal output 50 30 C kW 124 T3 ISO 7 1 XC K Model 124 DIMENSIONS A mm 650 B mm 1100 1032 C mm 190 D mm 205 E mm F mm 37 G mm 329 730 I mm 135 ...

Page 9: ...ater side kPa 3 8 2 5 3 2 2 2 9 18 6 25 4 32 3 34 3 39 2 Pressure drop flue side daPa Maximum operating pressure boiler bar 6 6 6 6 6 Weight kg 525 660 800 1007 1137 XC K 200 570 fig 4 200 290 400 480 570 T7 Øi mm 202 252 252 302 302 45 60 60 65 65 S mm 1 Panel board 2 Flame sight glass T1 C H flow T2 Low temperature C H return T3 High temperature C H return T4 Expansion vessel connection T5 Boile...

Page 10: ...83 CONNECTIONS T1 T2 UNI 2276 PN6 T4 UNI 2276 PN6 T5 ISO 7 1 T6 Ø mm DN 125 DN 125 DN 150 DN 150 DN 200 DN 200 DN 125 DN 125 DN 150 DN 150 DN 200 DN 200 DN 65 DN 65 DN 80 DN 80 DN 100 DN 100 Rp 1 Rp 1 Rp 1 Rp 1 Rp 1 Rp 1 270 270 320 320 320 320 700 900 1140 1420 1820 2160 XC K Model Nominal input kW 654 2 841 1 1065 4 1327 1 1700 9 2018 7 Boiler capacity l 625 664 1107 1157 1936 1904 Pressure drop...

Page 11: ...80 60 C Nominal heat output 50 30 C Nominal heat input Heat efficiency at nominal load 80 60 C Heat efficiency at nominal load 50 30 C Heat efficiency at 30 load Combustion efficiency 80 60 C Combustion efficiency 50 30 C Heat loss at shell 80 60 C Heat loss at shell 50 30 C Heat loss at chimney with burner on 80 60 C Heat loss at chimney with burner on 50 30 C Heat loss at chimney with burner off...

Page 12: ...r b Check that boiler is set up to operate with the available type of fuel This can be seen written on the package and on the technical feature plate c 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 prescri...

Page 13: ...icable technical standards XC K is a steel boiler which can be combined with air blown burners operating on gas of category II2H3 Contact the gas supplying company before installing the appliance Directives concerning boiler rooms building regulations and combustion heating provisions in the country of installation must also be respected The appliance must be installed commissioned and undergo mai...

Page 14: ... hooks or shifting it on rollers underneath the sturdy base longerons 3 5 BURNER The burners operating with the XC K boilers must have the EC certification and comply with Gas appliance directive 90 396 EEC EMC Directive Electromagnetic Compatibility 89 336 EEC They must also be approved according to the specifications UNI EN 676 air blown burners for gaseous fuel Efficiency Directive 92 42 EEC 3 ...

Page 15: ...eep it from blackening If the cooling tube is not connected to the sight glass it could break ATTENTION the flame sight glass can be very hot therefore pay the utmost attention fig 13 3 5 2 INSTALLING THE BURNER The burner must be mounted to the door of the boiler guaranteeing perfect sealing of the combustion products The burner is supplied with a piece of ceramic fiber cord which must be placed ...

Page 16: ... B Crosswise rotation loosening the hinges fixed on the front plate of the boiler and moving them sideways C Axial rotation screwing different tightening nuts fig 14 3 7 2 XC K 1140 XC K 1420 BOILERS For all these models the door is hinged and fixed according to the layout in fig 15 In these cases the two hinges on the left are normally used as rotation hinges from right to left while the two on t...

Page 17: ...following adjustments can be made on the door of these boiler models A Vertical adjustment by acting on the nut of the upper hinge pin which the door turns on B Crosswise rotation loosening the hinges fixed on the front plate of the boiler and moving them sideways C Axial rotation screwing different tightening nuts fig 16 3 7 4 IMPORTANT NOTE Before opening the door of the furnace take the followi...

Page 18: ... for the evacuation of combustion products which must be filled after assembly and must remain at least 25 mm high with the boiler running see fig 17 Do not discharge condensation through gutter drainpipes due to the risk of turning into ice and the deterioration of the materials usually used to make the drainpipes consult local hygiene regulations The drain fitting must be visible Due to the acid...

Page 19: ...is precaution is not taken triggering of the safety valve can cause damage to persons animals and objects for which the manufacturer cannot be held responsible Connection of expansion vessel XC K boilers are suitable for operating with forced water circulation both with the expansion vessel opened or closed An expansion vessel is always necessary to compensate the increase in water volume due to h...

Page 20: ...on system and therefore before connecting it to the gas meter check its sealing carefully If any part of the system is out of sight the sealing test must be done before the pipes are covered Before connecting the appliances the system must be tested with air or inert gas at a pressure of at least 100 mbar The following operations and checks must also be performed while commissioning the system Ope...

Page 21: ...lastic 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 contains System manager operating instructions Installation and maintenance instruction booklet Warranty Local ventilation requirements label N B For models...

Page 22: ...r having greased the relevant part with the specific solvent The plates are included in the document envelope Assembly sequence Ref fig 18 21 A Mount the insulation jackets pos 1 and 2 of the boiler body and secure the 2 edges with the elastic straps pos 3 supplied in the accessory box hooking them to the external fabric part of the insulation B Mount the rear insulation pos 4 C Open the boiler do...

Page 23: ...and insert the electric inlet cables and the outlet probe capillaries through the slots at the base Fit the panel board to the upper panel pos 9 Fit the upper panel pos 9 complete with panel board to the two sides of the casing G Insert into the conduits the bulbs of the instruments as indicated in fig 21 and depending on the panel board installed on the boiler the probes as illustrated in the ele...

Page 24: ...e electric inlet cables and the outlet probe capillaries through the slots at the base Fit the panel board to the upper panel pos 13 Fit the upper panel pos 13 complete with panel board to the two sides of the casing H Insert into the conduits the bulbs of the instruments as indicated in fig 21 and depending on the panel board installed on the boiler the probes as illustrated in the electric hydra...

Page 25: ...h wet and or moist parts of the body and or in bare 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 electrical connections are illustrated in chapters 3 16 3 17 3 18 3 19 and 3 21 for modulating burners and ch...

Page 26: ...ne system pump switch 21 Pz2 mixed zone system pump switch 33Working thermostat 35Safety thermostat The heating controller probes boiler storage tank external flow are included in the supply the ambient probes 1 and 2 are optional the mixer valve and relative control motor are not included in the supply Should ambient probes be mounted optional the room temperature will only be determined with the...

Page 27: ... 110 C MAX T HS2 85 C 01 08 BOILER BUS ID 10 C 80 C MIN T HS2 10 C 0 11 VOLTAGE CURVE 11 0 00 10 00V CURVE 11 U2 0V 0 00 10 00V CURVE 11 U2 10V 00 120 C CURVE 11 T1 0 C 00 120 C CURVE 11 T2 100 C 0 00 10 00V CURVE 11 UA 0V 10 C 85 C T WARM UP 10 DISPLAY ONLY BOILER DETECTED 00 1000kW OUTPUT LEVEL see note 00 01 OFF ON NEW CONFIGURATION 00 100 MINIMUM MODULATION CASCADE 00 00 08 DHW LEVELS 00 K CON...

Page 28: ...fault Individual values Value range Description DOMESTIC HOT WATER PRODUCTION 00 01 OFF ON CHARGE PUMP 01 ON 00 01 02 03 PARALLEL PUMP RUNNING 01 00K 50K T DHW 20K 5K 30K DHW HYSTERESIS 5 degrees 00 min 30 min DHW FOLLOWUP 00 min 00 01 OFF ON THERMOSTAT INPUT 00 OFF 00 01 OFF ON THERMOSTAT FUNCTIONING 00 OFF Exit level using RETURN 00 01 OFF ON LOAD THROUGH 00 OFF Default Individual values Value r...

Page 29: ...01 02 00 03 MF 1 4 T NOM 30 C 5 25 MF 1 4 HYSTERESIS 5 C 5 25 F 15 FUNCTION 0 Exit level using RETURN C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 PARAMETERS PROGRAMMABLE BY TECHNICIAN FOR HEATING CONTROLLER Lago Basic 0201 RV 1 1 2 3 1 1 Switch selector to burner 1 2 Press OK 2 3 Turn the knob 3 until mm appears on the display modulating burner 4 Press OK 2 2 1 Switch the selector 1 to the sym...

Page 30: ...e domestic hot water production Key M flow Rat HIGH temperature return Rbt LOW temperature return Vmix2 zone mixer valve motorised Pz1 HIGH TEMPERATURE zone heating system pump Pz2 LOW TEMPERATURE zone heating system pump VE expansion vessel IR AT HIGH TEMPERATURE heating system distribution IR BT LOW TEMPERATURE heating system distribution Ps DHW recirculation pump Pb DHW production charge pump S...

Page 31: ...e pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached The panel is set up to manage the modulating burners With this system configuration the heat controller is capable of regulating direct zone system the control unit commands the system pump The room temperature is controlled by the programming curves set ...

Page 32: ...CTED BY ACCESS CODE FOR HEATING CONTROLLER type E8 5064 00 01 OFF ON TEMPERATURE MASTER 30 C 110 C MAX T HS1 MAX T HEADER 10 C 80 C MIN T HS1 MIN T HEADER 01 ON 85 C 10 C 0 01 BUS CONNECTION 01 00 01 OFF ON BUS SUPPLY 01 ON 2K 20K HYSTERESIS 00 30 min HYSTERESIS TIME 00 01 02 MINIMUM LIMIT 5 00 min 00 30 C 110 C MAX T HS2 85 C 01 08 BOILER BUS ID 10 C 80 C MIN T HS2 10 C 0 11 VOLTAGE CURVE 11 0 00...

Page 33: ... 1 in the second leave dashes Set value of first stage of second boiler at 1 in the second leave dashes If there are more than 2 boilers in cascade enable the first stages of the boilers in cascade See E8 5064 heating controller instruction book Default Individual values Value range Description DOMESTIC HOT WATER PRODUCTION CHARGE PUMP PARALLEL PUMP RUNNING T DHW DHW HYSTERESIS 5 degrees DHW FOLLO...

Page 34: ...SED MAX FLOW TEMPERATURE MIN FLOW TEMPERATURE FROST PROTECTION TEMP OUTSIDE TEMP DELAY HEATING SLOPE DISTANCE B HEAT SINK Exit level using RETURN Default Individual values Value range Description SOLAR M F MF 1 4 FUNCTION MF 1 4 T NOM MF 1 4 HYSTERESIS F 15 FUNCTION Exit level using RETURN 20 C 110 C 80 C 10 C 110 C 30 C 15 C 5 C 0 C 0 00 24 00 0 00 00K 50K 5 C 00 01 OFF ON 01 00 04 0 00 03 0 5 25...

Page 35: ... 2 Press OK 2 3 Turn the knob 3 until mm appears on the display 4 Press OK 2 2 1 Switch the selector 1 to the symbol of the mixer valve 2 Press OK 2 3 Turn the knob 3 until the number 15 appears on the display burner servomotor time 4 Press OK 2 3 1 Switch the selector 1 to BUS ID 2 Press OK 2 3 Turn the knob 3 until the number 1 appears on the display boiler ID 4 Press OK 2 Turn the knob 1 back t...

Page 36: ... working temperature of the boiler n 2 is regulated by the heating controller to achieve this the thermostat must be placed at maximum full scale pos 32 Modulation of the burner will be managed by heat control The electric power line of the boiler s control board must have a switch with protective fuses For use of the panel board see the system manager instruction booklet As far as the practical c...

Page 37: ... 2 Press OK 2 3 Turn the knob 3 until mm appears on the display 4 Press OK 2 2 1 Switch the selector 1 to the symbol of the mixer valve 2 Press OK 2 3 Turn the knob 3 until the number 15 appears on the display burner servomotor time 4 Press OK 2 3 1 Switch the selector 1 to BUS ID 2 Press OK 2 3 Turn the knob 3 until the number 2 appears on the display boiler ID 4 Press OK 2 Turn the knob 1 back t...

Page 38: ...tion fig 28 Ps DHW recirculation pump P1 circulation pump Pb DHW production charge pump SPF storage tank probe KF E8 5064 heat control boiler probe KF 1 Lago Basic 0201 RV 1 heat control boiler probe VF flow probe AF external probe P1 C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 31 42 11 41 12 13 32 Ps PRODUTTORE ACQUA CALDA SANITARIA Pb Pz1 P1 IR BT Pz2 Vmix2 IR AT SPF VF SONDA ESTERNA AF 14 1...

Page 39: ...he storage tank charge pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached The panel is set up to manage the modulating burners With this system configuration the heat controller is capable of regulating direct zone system the control unit commands the For practical connections both electrical and of the pro...

Page 40: ...e system pump switch 21 Pz2 mixed zone system pump switch 33Working thermostat 35Safety thermostat The heating controller probes boiler storage tank external flow are included in the supply the ambient probes 1 and 2 are optional the mixer valve and relative control motor are not included in the supply Should ambient probes be mounted optional the room tem perature will only be determined with the...

Page 41: ...MODULATION CASCADE DHW LEVELS CONTROL VARIANCE DISPLAY NOMINAL OUTPUT INDEX DISPLAY SWITCH VALUE DISPLAY REMAINING min BLOCK TIME DISPLAY MAXIMUM BOILER TEMPERATURE BOILER DYNAMICS UPWARD BOILER DYNAMICS DOWNWARD RESET TIME MODULATION MAX MODULATION MIN MIN MODULATION HS MODULATION DHW BOILER SEQUENCE 1 BOILER SEQUENCE 2 0000 9999 0000 9999 0000 00 01 015 01 00 01 016 02 00 01 disins ins 01 ON 00 ...

Page 42: ...HYSTERESIS 5 degrees DHW FOLLOWUP THERMOSTAT INPUT THERMOSTAT FUNCTIONING Exit level using RETURN LOAD THROUGH Default Individual values Value range Description HEATING CIRCUIT 1 HEATING CIRCUIT FUNCTION PUMP MODE MIXER OPEN MIXER CLOSED MAX FLOW TEMPERATURE MIN FLOW TEMPERATURE FROST PROTECTION TEMP OUTSIDE TEMP DELAY HEATING SLOPE DISTANCE B HEAT SINK Exit level using RETURN SEQUENCE MODE 00 min...

Page 43: ...1 PARAMETERS PROGRAMMABLE BY TECHNICIAN FOR HEATING CONTROLLER Lago Basic 0201 RV 1 1 2 3 1 1 Switch selector to burner 1 2 Press OK 2 3 Turn the knob 3 until 2 appears on the display dual stage burner 4 Press OK 2 2 1 Switch the selector 1 to the symbol of the mixer valve 2 Press OK 2 3 Turn the knob 3 until the number 15 appears on the display 4 Press OK 2 3 1 Switch the selector 1 to BUS ID 2 P...

Page 44: ... zone 1 low temperature zone controlled by a motorised mixer valve domestic hot water production Key Vmix2 zone mixer valve motorised Pz1 HIGH TEMPERATURE zone heating system pump Pz2 LOW TEMPERATURE zone heating system pump VE expansion vessel IR AT HIGH TEMPERATURE heating system distribution IR BT LOW TEMPERATURE heating system distribution Ps DHW recirculation pump Pb DHW production charge pum...

Page 45: ... pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached The panel is set up to manage the modulating burners With this system configuration the heat controller is capable of regulating direct zone system the control unit commands the system pump The room temperature is controlled by the programming curves set i...

Page 46: ...X T HS1 MAX T HEADER MIN T HS1 MIN T HEADER BUS CONNECTION BUS SUPPLY HYSTERESIS HYSTERESIS TIME MINIMUM LIMIT MAX T HS2 BOILER BUS ID MIN T HS2 VOLTAGE CURVE CURVE 11 U2 CURVE 11 U2 CURVE 11 T1 CURVE 11 T2 CURVE 11 UA T WARM UP DISPLAY ONLY BOILER DETECTED OUTPUT LEVEL see note NEW CONFIGURATION MINIMUM MODULATION CASCADE DHW LEVELS CONTROL VARIANCE DISPLAY NOMINAL OUTPUT INDEX DISPLAY SWITCH VAL...

Page 47: ...able the first and second stages of the boilers in cascade See E8 5064 heating controller instruction book Default Individual values Value range Description DOMESTIC HOT WATER PRODUCTION CHARGE PUMP PARALLEL PUMP RUNNING T DHW DHW HYSTERESIS 5 degrees DHW FOLLOWUP THERMOSTAT INPUT THERMOSTAT FUNCTIONING Exit level using RETURN LOAD THROUGH Default Individual values Value range Description HEATING ...

Page 48: ...SED MAX FLOW TEMPERATURE MIN FLOW TEMPERATURE FROST PROTECTION TEMP OUTSIDE TEMP DELAY HEATING SLOPE DISTANCE B HEAT SINK Exit level using RETURN Default Individual values Value range Description SOLAR M F MF 1 4 FUNCTION MF 1 4 T NOM MF 1 4 HYSTERESIS F 15 FUNCTION Exit level using RETURN 20 C 110 C 80 C 10 C 110 C 30 C 15 C 5 C 0 C 0 00 24 00 0 00 00K 50K 5 C 00 01 OFF ON 01 00 04 0 00 03 0 5 25...

Page 49: ... 2 Press OK 2 3 Turn the knob 3 until mm appears on the display 4 Press OK 2 2 1 Switch the selector 1 to the symbol of the mixer valve 2 Press OK 2 3 Turn the knob 3 until the number 15 appears on the display burner servomotor time 4 Press OK 2 3 1 Switch the selector 1 to BUS ID 2 Press OK 2 3 Turn the knob 3 until the number 1 appears on the display boiler ID 4 Press OK 2 Turn the knob 1 back t...

Page 50: ... working temperature of the boiler n 2 is regulated by the heating controller to achieve this the thermostat must be placed at maximum full scale pos 32 Modulation of the burner will be managed by heat control The electric power line of the boiler s control board must have a switch with protective fuses For use of the panel board see the system manager instruction booklet As far as the practical c...

Page 51: ...r 1 2 Press OK 2 3 Turn the knob 3 until 2 appears on the display dual stage burner 4 Press OK 2 2 1 Switch the selector 1 to the symbol of the mixer valve 2 Press OK 2 3 Turn the knob 3 until the number 15 appears on the display 4 Press OK 2 3 1 Switch the selector 1 to BUS ID 2 Press OK 2 3 Turn the knob 3 until the number 2 appears on the display boiler ID 4 Press OK 2 Turn the knob 1 back to R...

Page 52: ...system consisting in 2 boilers in cascade serving 1 high temperature zone 1 low temperature zone controlled by a motorised mixer valve domestic hot water production Boiler n 1 is fitted with a panel board code 37892 boiler n 2 is fitted with a panel board code 37900 Key M flow Rat HIGH temperature return NOT USED Rbt LOW temperature return Vmix2 zone mixer valve motorised Pz1 HIGH TEMPERATURE zone...

Page 53: ...he storage tank charge pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached The panel is set up to manage the modulating burners With this system configuration the heat controller is capable of regulating direct zone system the control unit commands the system pump The room temperature is controlled by the pr...

Page 54: ...ERATING 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 OPERATING INSTRUCTIONS as well as the other appliance documents inserted in the envelope inside the packaging The system manager must keep this documentation for future consultation Inform the syste...

Page 55: ...tenance is required to eliminate any differences between the actual status and the nominal status This is normally done by cleaning setting and replacing individual components 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 instructions To assure long term functionin...

Page 56: ...ow signs of deterioration if so they must be replaced using only original spare parts Maintenance of burner Burner maintenance must be carried out by personnel authorised by its manufacturer or else the warranty shall be terminated Checking ignition electrode Burner maintenance must be carried out by personnel authorised by its manufacturer or else the warranty shall be terminated COMPONENT Safety...

Page 57: ...Inspections and maintenance 57 ...

Page 58: ...58 Inspections and maintenance ...

Page 59: ...Inspections and maintenance 59 ...

Page 60: ...6 www unical eu info unical ag com Unical will not be held responsible for possible inaccuracies if due to transcription or printing errors It also reserves the right to modify its products as deemed necessary or useful without jeopardising their essential features AG S P A ...