Unical Modulex 360 Installation and operating instructions

00332210-2nd edition-09/05

360 - 450

540 - 630

MODULEX

INSTALLATION, USE AND

MAINTENANCE

MODULAR CONDENSING

BOILER











IMPORTANT

This INSTRUCTION MANUAL, which is an integral and indispensable part of the product, must be handed over to the user by the plumbers and

must be kept in a safe place for future reference.The manual must be handed over with the boiler should it be sold or transferred.

This boiler must be used for the purposes for which it has been designed. Any other use shall be considered incorrect and therefore

dangerous.

The boiler must be installed in compliance with applicable laws and standards and according to the manufacturer’s instructions given in this

manual.Incorrect installation may cause injury to persons and/or animals and damage to property.The manufacturer shall not be held liable for any

such injury and/or damage.

Damageand/or injury caused byincorrect installation or use and/or damage and/or injury due to non-observanceofthe manufacturer’sinstructions

shall relieve UNICAL from any and all contractual and extracontractual liability.

Before installing the boiler, check that the technical data corresponds to requirements for its correct use in the system.

Check that the boiler is intact and that it has not been damaged during transport and handling.Do not install equipment which is patently damaged

and/or faulty.

Do not obstruct the air suction and/or heat dissipation grates.

Only original accessories must be used for all boilers supplied with optionals or kits (including electrical ones).

Dispose of the packaging with care as all the materials can be recycled.The packaging 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 jeopardize the safety of the boilers and expose people, animals and property to danger.

To guarantee efficiency and correct functioning of the equipment it is legally binding to service the boilers once a year according to

the schedule indicated in the relative section of this manual.

In the event of long periods of inactivity of the boiler, disconnect it from the power mains and close the gas tap (Warning! In this case the boiler’s

electronic anti-freeze function will not be operative).

Should there be a risk of freezing, add anti-freeze: it is not advisable to empty the system as this may result in damage; use specific anti-freeze

products suitable for multi-metal heating systems.

N.B.

For boilers which use gaseous fuel, if you smell gas:

- do not turn on or off electrical switches and do not turn on electrical appliances;

- do not ignite flames and do not smoke;

- close the main gas tap;

- opendoors and windows;

- contact a Service Centre, qualified installer or the gas supply company.

Never use flames to detect gas leaks.

WARNING

This boiler has been built for installation in the country indicated on the technical data plate: installation in any other country may be a source

of danger for people, animals and property.

Read the warranty conditions and clauses on the warranty certificate attached to the boiler with care.

DATA PLATE

1 = P.I.N. code

2 = Boiler type (only for condensing boiler)

3 = (S.N°) Serial Nr.

4 = Manufacture Date

5 = Model

6 = Appliance type

7 = Elettrical supply

8 = Maximum absorbed power - Insulation

protection

9 = (Pn) Nominal Output

10 = (Pcond) Condensing Nominal Output

(only for condensing boiler)

11 = (D) Specific flow rate EN 625

12 = (Qn) Nominal heat input

13 = (Qnw) Nominal heat input for D.H.W.

system if there are different out puts

between the C.H.and D.H.W.circuits

14 = (NOx) NOx Class

15 = (PMS) Max pressure C.H. system

16 = (T max) MaxTemperature 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

3B/P

G20

G30/G31

G30 - 31

G31

20 - 25

28-30/37

30 - 50

37 - 50

mbar

IT ES IE

PT GR

TR HR

CZ SK

CN RU RO

LV EE LT

II 2H3+

II 2H3B/P

II 2H3P

II 2HS 3B/P

II 2E3P

II 2H3P

I 2H

20 ; 28-30/37 mbar

20 ; 50 mbar

18 ; 50 mbar

25 ; 30 mbar

20 ; 50 mbar

20 ; 37 mbar

20 mbar

345

678

TECHNICALFEATURES

ANDDIMENSIONS........................................................... pag. 6

1.1 Technical Features .................................................................. pag. 6

1.2 Dimensions.............................................................................. pag. 7

1.3 Technical Data and Main Components .................................... pag. 9

1.4 SideView................................................................................. pag. 10

INSTRUCTIONS FOR INSTALLERS ................. pag. 11

2.1 Instructions for installation...................................................... pag. 11

2.2 Installation ............................................................................... pag. 11

2.2.1 Packing ....................................................................... pag. 11

2.2.2 Boiler Location inside a Heat Power Plant ................. pag. 13

2.2.3 BoilerConnection ....................................................... pag. 13

2.2.4 Connection to Chimney .............................................. pag. 13

2.2.5 Notes on Condensate Drain ....................................... pag. 14

2.3 Types of Heating Systems ...................................................... pag. 15

2.3.1 C.H.System Air Vent.................................................. pag. 16

2.3.2 Boiler and System Filling-up & Draining .................... pag. 16

2.3.3 Max AllowableWorking Pressure............................... pag. 17

2.3.4 Safety Valve ............................................................... pag. 17

2.3.5 Gas Mains .................................................................. pag. 17

2.3.6 Hydraulic Compensator or Open Manifold ................. pag. 17

2.3.7 Filter ........................................................................... pag. 18

2.3.8 BallValves .................................................................. pag. 18

2.3.9 FeedingWaterQuality ................................................ pag. 18

2.3.10 Boiler Antifrost Protection .......................................... pag. 18

2.3.11 Min.WaterFlow Rate.................................................. pag. 19

2.4 Boiler Operation....................................................................... pag. 19

2.4.1 GeneralDescription .................................................... pag. 20

2.4.2 IgnitionSequence....................................................... pag. 21

2.4.3 SupplementaryBoard ................................................. pag. 22

2.4.4 DomesticHotWater(DHW) Mode Operation ............. pag. 23

2.5 Boiler Operation in case of technical intervention .................. pag. 23

2.6 Electric Connections ............................................................... pag. 24

2.6.1 PowerSupply .............................................................. pag. 25

2.6.1 WiringDiagram ........................................................... pag. 25

2.6.2 Electric Connection to Ignition PCB........................... pag. 26

2.6.3 Electric Connection to the Room Thermostat ............ pag. 26

2.6.4 DHWStorageTank ..................................................... pag. 27

MODULAR BOILER DRIVE (MBD)

OPERATION.......................................................................... pag. 28

3.1 General Description ................................................................. pag. 28

3.2 Operation and display instructions .......................................... pag. 28

3.2.1 “Mode”Key.............................................................. pag. 29

3.2.2 “Step”Key ............................................................... pag. 29

3.2.3 “+ / -“ Key................................................................ pag. 29

3.2.4 “Store”Key .............................................................. pag. 29

3.2.5 ServiceCode .......................................................... pag. 29

3.2.6 Programming Access Procedure ........................... pag. 30

3.2.7 “Stand-by”Key ........................................................ pag. 32

3.2.8 “Parameter”Mode ................................................... pag. 32

3.2.8.1 Installerand User programmable Operation

Parameters............................................... pag. 32

3.2.8.2 InstallerprogrammableOperation

Parameters by previously entering

the service code ...................................... pag. 33

3.2.9 “Data”Mode ............................................................ pag. 34

3.2.9.1 Installerand User programmable

parameters ............................................... pag. 34

3.2.9.2 Installerprogrammableparameters

by previously entering the

service code............................................. pag. 34

3.2.10 “Test”Mode ............................................................. pag. 35

3.2.11 “OperationTime”Mode ........................................... pag. 35

3.3 HeatingModeOperation.......................................................... pag. 36

3.3.1 Heating Mode Operation by RoomThermostat............. pag. 36

3.3.2 Heating Mode Operation by Outer Sensor.................... pag. 36

3.3.3 Heating Mode Operation by Outer Compensator .......... pag. 37

3.4 DHWMode Operation. ............................................................. pag. 37

3.4.1 DHW Mode Operation by StorageTank NTC Sensor ... pag. 37

3.4.2 DHW Mode Operation by StorageTankThermostat ..... pag. 37

3.5 Burner Pressure AdjustmentTest ........................................... 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 Anomalies ................................................................. pag. 39

4.4 Block Errors ................................................................. pag. 39

4.5 ErrorCodes ................................................................. pag. 40

4.5.1 Error Codes by Alarm.................................................... pag. 40

4.5.2 Error Codes related to local temperatures .................... pag. 40

4.5.3 Error Codes related to gas pressure, MBD,

AM-4 and AM-5 ............................................................ pag. 41

4.5.4 Error Codes related to global temperatures .................. pag. 41

MAINTENANCE .................................................. pag. 42

5.1 Main Features .................................................. pag. 42

5.2 Siphon Cleaning .................................................. pag. 42

GENERAL DESCRIPTION

1.1 - TECHNICAL /

FEATURES

- MODULEX is a compact, gas fired,

Low NOx, condensing boiler, made

up by one sectional boiler body (so

called

heat module

), set to operate

separately or in cascade.

This heat module consists of two or

more thermal elements (from 4 to 7),

which cannot be separated from

each other, being under the same

protectingcasing.These thermal ele-

ments are connected to a single

smoke exhaust manifold and are

controlled by a single microproces-

sor which manages completely the

temperatures from the point of view,

both operational and safety.

- If, for instance, one of the thermal

elements whose the boiler is com-

posed, goes out of order, the other

thermal elements continue to sup-

ply their output. It is nearly impossi-

ble the boiler go completely out of

order.

- MODULEX has been examined ac-

cording the following European di-

rectives:

- (GAD) Gas Appliances Directive

No. 90/396 CEE

- (BED) Boiler Efficiency Directive

No. 92/42 CEE

by CERTIGAZ, under the No.

1312BP4012, fortype B23 operation,

i.e. the boiler can be connected to a

traditional natural draught chimney,

andfor operation in category I2H (G20

–20mbar).

It also conforms to the following Eu-

ropean directives:

- EMC (Electro Magnetic Compatibi-

lity) Directive No.89/336 CEE

- LVD (LowVoltage Directive)

No. 73/23 CEE

- Machines Directive

No. 89/392 CEE

- The boiler body, made by sections

of cast aluminium/magnesium/sili-

cium alloy, is conceived to recover

the sensible and the latent heat of

the combustion gases, thus al-

lowing to reach an efficiency of

109% on the N.C.V.

- Each thermal element, composed of

a combustion chamber with burner,

modulating fan with control pressu-

re switch, gas valve, ignition devi-

ce, flame control, NTC sensor for lo-

cal temperature control and safety

thermostat, 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/feeding sy-

stem from the boiler house

- Possible cascade installation of 2 or

more MODULEX

- Heating Operation: setting of instan-

taneous output by a main micropro-

cessor, with a comparison parame-

ters pre-setting between the reque-

sted temperature (or calculated by

the outer compensator) and the glo-

bal flow temperature.

- Logic of operation:

A) Output sharing on as many mo-

dules as possible at min. load (down

to 22 kW) for the max.efficiency.

B) Automatic operation hour split-

ting-up system for each module to

guarantee the best homogeneous

use.

C) DHW production by a priority sen-

sor which, thanks to the dedicated

electronic board, drives a special

loading pump or a 3-way diverting

valve for the preparation of a stora-

ge tank with the possibility of pre-

setting the D.H.W. circuit output, up

tomaximum360kW.

D) Output check of each module for

any calibration and/or assistance by

secret access code.

- Control panel with alphanumeric di-

splay, programming keys, reset and

hydrometer.

- Displays:globalflow/returntempera-

ture,DHW temperature,external tem-

perature.

- Adjustments: flow temperature, fan

speed,max/min. output percentage.

- Access to all testing/programming

parametersofeach module:operation

test, operation time, boiler anti-frost

protection from 7°C, pump’s anti-

blocking system.

- Integral easily removable panel set

(painted steel panels).

- Condensate collecting tank equip-

ped with drain siphon and stain-

less steel smoke chamber.

- Built-in air vent.

- Weights and dimensions are limi-

ted (see table at par. 1.2).

360

450

540

630

75 l/h

90 l/h

105 l/h

l/h

1.2 - DIMENSION

fig. 1-a

REAR VIEW

UPPER VIEW

L.H. SIDE VIEW FRONT VIEW

MODULEX 360

1243

576

STOR

RES

STE

920

206

171

1372

666

232

474

974 398

474 446

Øi D

110

124

MODULEX

Dimension

No. of Modules

Height mm

Width ''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

1372

920

1020

1530

985

390

1200

430

496

DN50 PN 10/16

DN80 PN 10/16

250

615

ATTENTION

CHIMNEY

CONNECTION

INDIFFERENT

POSITION FROM THE

ONE SHOWN ARE

NOT ALLOWED.

fig. 1-b

MODULEX 450 - 540 - 630

1243

576

ORE

MOD

STEP

920

(D) 1520

(E) 425

474

124

232 666

206

171

974 398

1372

350

Øi D

ATTENTION

CHIMNEY

CONNECTION

INDIFFERENT

POSITION FROM THE

ONE SHOWN ARE

NOT ALLOWED.

540

1372

920

1020

1520

425

1256

1380

1700

620

700

DN50 PN 10/16

DN100 PN 10/16

300

720

630

1372

920

1020

1520

425

1390

1514

1840

680

778

DN50 PN 10/16

DN100 PN 10/16

300

855

450

1372

920

1020

1520

445

1120

1320

1340

510

584

DN50 PN 10/16

DN80 PN 10/16

250

615

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.H. system Flow M mm

C.H. system Return R mm

Chimney connection ''D'' mm

Chimney width ''H'' mm

Condensate drain diameter mm

REAR VIEW

UPPER VIEW

R.H. SIDE VIEW FRONT VIEW

1.3 - TECHNICAL DATA

The Technical data plate is placed under the front jacket next to the control

panel.

BOILER TYPE MODULEX

Nominal Heat Input on P.C.I

Minimum Heat Input on P.C.I .

Qmin

Nominal Output (Tr 60 / Tm 80 °C)

Minimum Output (Tr 60 / Tm 80 °C)

Pn min

Nominal Output (Tr 30 / Tm 50 °C)

Pcond

Minimum Output (Tr 30 / Tm 50 °C)

Pcond min

Efficiency at max. output (Tr 60 / Tm 80°C) %

Efficiency at min. output (Tr 60 / Tm 80°C) %

Efficiency at max. output (Tr 30 / Tm 50°C) %

Efficiency at min. output (Tr 30 /Tm 50°C) %

Efficiency at 30 % at part load (Tm 50°C) %

Efficiency at 30 % at part load (Tr 30°C) %

Efficiency Class acc. to Directive 92/42 CEE

Efficiency Class acc. to Directive 92/42 CEE (100%) %

Efficiency Class acc. to Directive 92/42 CEE (30%) %

Combustion efficiency at nominal load %

Combustion efficiency at part load %

Stand-by losses (Q min.) %

Stand-by losses (Q nom.) %

Flue gas temperature (min) °C

Flue gas temperature (max) °C

Flue gas mass flow rate (min) kg/h

Flue gas mass flow rate (max) kg/h

Excess of air λ%

CO2 (min) %

CO2 (max) %

NOX(value according EN 297/A3 + EN 483) mg/kWh

NOXclass

Flue losses with burner in operation (min.) %

Flue losses with burner in operation (max) %

Flue losses with burner off %

Min. water flow rate in CH circuit (∆T 20°C) l/h

Minimum 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 O2in the flue system ppm

NOxwith 0% of O2in the flue system ppm

Sound level dBA

Electrical data A

Voltage / Frequency V/Hz

Fuse on main supply A (F)

Max / Min absorbed power W

Insulation degree IP

Standby Consumption W

360

353,9

21,3

377,60

23,80

98,30

96,82

104,89

108,18

102,0

109,2

98,10

96,65

97,52

97,86

1,0

n.r

36,6

583,0

24,25

8,9

9,2

2,48

2,14

0,2

16237

0,5

38,06

2,33

100

22,7÷60

<35

<50

230 / 50

540/41

450

442,5

21,3

472,0

23,80

98,33

96,82

104,89

108,18

102,0

109,2

98,29

96,94

97,52

97,86

1,0

n.r

36,6

728,7

24,25

8,9

9,2

2,48

2,14

0,2

20296

0,5

47,58

2,33

100

28,3÷75

<35

<50

230 / 50

675/41

540

531,8

21,3

566,4

23,80

98,48

96,82

104,89

108,18

102,0

109,2

98,45

97,18

97,52

97,86

1,0

n.r

36,6

874,4

24,25

8,9

9,2

2,48

2,14

0,2

24355

0,5

103

57,10

2,33

100

34÷90

<35

<50

230 / 50

810/41

630

621,3

21,3

660,8

23,80

98,62

96,82

104,89

108,18

102,0

109,2

98,59

97,38

97,52

97,86

1,0

n.r

36,6

1020,2

24,25

8,9

9,2

2,48

2,14

0,2

28414

0,5

118

66,61

2,33

100

39,7÷105

<35

<50

230 / 50

945/41

fig. 2

1.4 - SIDE VIEW WITH MAIN COMPONENTS

2.1 - COMPOSITION OF THE

SUPPLY

- Boilerbody made ofsectionsof alumi-

nium/magnesium/siliciumalloy (5to 8)

- Premix stainless-steel burner (4 to 7)

- Premixing chamber (8 to 14) with bu-

ilt-in non return valve

- Modulating fan (4 to 7) with air pres-

sure switch control

-Gas valve (2 for each module – from 8

to 14) with separated flame control

device SATRONIC (from 4 to 7)

- NTCsensorsforlocal temperaturecon-

trolon eachboilersection (5to8)

- NTC sensor for global flow manifold

temperature

- NTC sensor for global return mani-

fold temperature

- High Limit thermostat on each boiler

section (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

- Smokechamberterminal,withflue 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 PC interface

- AM-4 PCB for DHW production and

outdoortemperature sensor

- Supplementary PCB type AM-5 (1 x

mod. 360; 2 x mod. 450 and mod. 540;

3 x mod. 630)

- Electronic card for interface

- Outdoor sensor (into the smoke cham-

ber)

150

FAN

GAS VALVE

GAS PIPE

BURNER

ALUMINIUM/

SILICON HEAT

EXCHANGER

CONDENSATE

DRAIN

SIPHON

CONDENSATE

COLLECTING

TRAY-

SMOKE

MANIFOLD

FILLING-UP

ELBOW

C.H. RETURN

C.H. FLOW

Min. Depth 100 mm

BOILER FRAME

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