PK 150 X 2S PK 230 X 2S PK 300 X 2S PK 348 X 2S INSTALLATION AND SERVICING INSTRUCTIONS 00334158 - 1st edition - 05/2012
General Information Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accordance with the current laws in force. The end user MUST not make any alterations to the boiler. Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage. CONTENTS 2 1 GENERAL INFORMATIONI ......................
General Information 1 GENERAL INFORMATION 1.1 - SYMBOLS USED IN THIS GUIDE When reading this guide particular care has to be given to the parts marked with the followings symbols: DANGER! Indicates serious danger for your personal safety and for your life WARNING! Indicates a potentially dangerous situation for the product and the environment NOTE! Suggestions for the user 1.
General Information 1.4 - SAFETY WARNINGS WARNING! The device should not be used by people with reduced physical, mental and sensory, experience and knowledge. These people must be well-informed and supervised during the work. Children must be supervised so they do not play with the appliance. WARNING! The installation, adjustment, and servicing of this appliance must be carried out by a competent person and installed in accordance with the current standards and regulations.
General Information - The essential requirements of the Directive regarding gas appliances (Directive 2009-142 EC) - The essential requirements of the Directive regarding electromagnetic compatibility (Directive 2004/108 EC) - The essential requirements of the Efficiency Directive (Directive 92/42/EEC) - The essential requirements of the low voltage Directive (Directive 2006/95EC). 1.
General Information WARNING If the boiler operates with a forced draught gas burner, the appliance, not appertaining to any category contemplated in the annexe II of the legislative decree n°93 dated 25/02/2000 (implementation of the PED Directive 97/23/EC), and moreover also being contemplated in the Gas Appliances Directive 90/396/EEC), to which the art. 1, comma 3 paragraph "f.5" refers to, results as being excluded from the scope of the same decree. 1.
Technical features and dimensions 2 TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES The PK series ... X is made up of gas heating units and very low condensing temperature according to dir. 92/42, made ??entirely of stainless steel, high water content, complete with modulating burner premix. Efficiency class: (4) stars Power supplye 150 to 348 kW Performance in condensation, more than 107% to 100% and 109% load at 30% load, thanks to the special pipes patented progressive.
Technical features and dimensions 2.2 - MAIN COMPONENTS AND FUNCTIONING The PKX boilers are built with a blind furnace, in which the burner's central flame travels towards the bottom and then is distributed in the flue pipes; at the terminal part of the pipes the combustion gas is collected in the flue chamber and then sent to the chimney. During burner operation, within the boiler's output range, the combustion chamber is always under positive pressure.
Technical features and dimensions 2.3 - DIMENSIONS 2 1 1 Control box 2 Flame control sight glass T1 T2 T3 T4 T5 PKX 2S Heat output (50°-30°C) Heat output (80°-60°C) Furnace Output Model kW kW kW 150 150 136,5 230 230 209,2 300 300 348 348 Boiler Volume C.H flow Average temperature system return Low temperature system return Expansion vessel connection Boiler drainage Water side losses (**) Flue side losses l m c.a.
Technical features and dimensions 2.
Instructions for the installer 3 INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS AThis boiler has to be destined for the use for which it has been expressively designed for. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at a temperature inferior to boiling point at an atmospheric pressure. WARNING! These appliances are exclusively designed to be installed inside adequate boiler rooms.
Instructions for the installer 3 INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS AThis boiler has to be destined for the use for which it has been expressively designed for. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at a temperature inferior to boiling point at an atmospheric pressure. WARNING! These appliances are exclusively designed to be installed inside adequate boiler rooms.
Instructions for the installer 3.3 - PACKAGING The PKX boilers are delivered fully complete with door and smoke chamber already fitted, whilst the casing with the insulation mattress is contained in separate cardboard packaging(s). The control panel and accessories are inside the combustion chamber.
Instructions for the installer 3.4 - HANDLING AND LIFTING The boiler can be moved by lifting, via the holes or upper hooks. If necessary, due to the dimensions of the boiler, it is possible to remove the front door to facilitate the introduction in the boiler house. A A 3.
Instructions for the installer 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 supplier, local authority and the relevant Standard Codes of Practice and building regulations.
Instructions for the installer Chimney dimension DIN 4705 Flue gas mass rate Flue Gas Temperature Pressure avaible 40°C 40 Pa Co2 level kg/h kg/s 6% 8% 10% 2520 0,700 778 1037 1400 2160 0,600 667 889 1200 1800 0,500 555 1440 0,400 445 741 668 593 1000 900 800 1260 0,350 389 519 700 1080 0,300 333 444 600 900 0,250 277 370 500 720 0,200 222 296 400 540 0,150 167 222 300 5 10 15 20 25 30 1200 da 400 1000 900 800 700 600 da 315 500 400 da 250 300
Instructions for the installer 3.
Instructions for the installer 3.9 - FIRE DOOR: ADJUSTMENT,OPENING & CLOSING IMPORTANT - The door must be opened only when the boiler is cold to avoid causing damages to the fibre lining due to thermal stress. - The door's fibre lining can crack after a brief period of boiler operation; this however does not reduce it's insulating capacity or it's life span. - The door's fibre lining is easily replaceable and is covered by a 2 years guarantee. For these models the door is assembled according to fig. 6.
Instructions for the installer 3.10 - GAS CONENCTION DANGER! The gas connection must be carried out only by a qualified registered engineer who will have to respect and comply to the regulations in force and to the requirements indicated by the local gas supplier. An incorrect installation could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any injury and/or damage. The gas supply pipe must have a section which is adequate to the burner's output.
Instructions for the installer 3.11 - SYSTEM CONNECTION WARNING! Before connecting the boiler to the heating 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.
Instructions for the installer 3.12 - DETERMINATION OF PRIMARY CIRCUIT PUMP OR BOILER SYSTEM PUMP The size of the pumps must be determined by installers or technical engineers according to boiler data and system design. The water side resistance curve of the boiler is shown in the following graph. The boiler pump must have a delivery head which can ensure the water flow rate as shown in the graph "Water pressure losses".
Instructions for the installer Perdita di carico lato acqua PK230X 2S WATER SIDE PRESSURE LOSSES 4 Pressure (mmH2O) perdita dilosses carico (mmh2O) 3,5 3 2,5 2 1,5 1 0,5 0 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 32000 34000 36000 38000 Q : portata acqua (l/h) Q: water flow rate (l/h) carico lato acqua WATERPerdita SIDEdiPRESSURE LOSSES PK300X 2S 6 5,5 Pressure (mmH2O) perdita di losses carico (mmh2O) 5 4,5 4 3,5 3 2,5
Instructions for the installer carico lato acqua WATERPerdita SIDEdiPRESSURE LOSSES PK348X 2S 6 5,5 Pressure (mmH2O) perdita dilosses carico (mmh2O) 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 Q : portata acqua (l/h) Q: water flow rate (l/h) 3.
Instructions for the installer 3.15 - WATER TREATMENT The chemical-physical characteristics of the filling water and reinstatement water in heating systems are of fundamental importance for guaranteeing correct and safe boiler operation. Before filling the CH circuit with water, it is necessary to analyse the water and decide for a proper treatment.
Instructions for the installer 3.16 - CASING ASSEMBLY (con pannello comandi montato a destra) C. Fit the self-tapping screws onto the internal profiles of the 2 side panels (4 and 5 ). A. Fit the insulation blanket (1) onto the boiler shell and secure in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. B.
Instructions for the installer E. After removal of the two side screws from the control panel rotate its cover towards the front 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 profiles. and insert the cables and the capillaries of thermometer and thermostats through the slots on its base. G. Insert the thermometer and thermostat bulbs in the sensor pockets as shown in Fig.
Instructions for the installer Guide the burner plug through the side cable clamp plate(6) and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates to the casing side panels. H. Fit the top panel (8) and fix it onto the side panels (4 & 5). 8 4 5 Refit the upper shell of the control panel. I. Fix the retaining strips (9) onto the lower left hand side rear panel (4) and to the upper panel (8).
Instructions for the installer M. Fit the lower right hand side rear panel (11) onto the right hand side rear panel (5), to the left hand side rear panel (10) and to the upper rear panel (8). Unite the two rear panels with the retaining strips profile (12). O. Position the top panels (14 and 15) and press them against the side panels. 15 14 N. Fit the lower front panel (13)and fix it on to the side panels (4 and 5). P.
Instructions for the installer R) after removing the cover disconnect the connector "4", unscrew the 2 nuts "5" and remove the bracket "6", 6 5 U) plug the connector "4" on the unit, 4 5 4 V) replace the cover "2" access to the terminal unit, and secure with the two screws "1".
Instructions for the installer 3.17 - SYSTEM FILLING AND DRAINING Warning! Do not mix the CH system's water with antifreeze or anti-corrosion solutions using wrong concentrations! It could cause damage to the washers and could provoke noise during normal boiler operation. UNICAL refuses all liability for injury to persons, animals or damage to property deriving from not having respected the above mentioned recommendations. To fill the system it is necessary to fit a filling cock on the system's return.
Instructions for the installer 3.18 - ELECTRICAL CONNECTIONS It is necessary to fit a double pole switch on the electrical supply line, having a 3 mm contact separation in both poles, in an easy accessible position in order to make quick and safe the servicing operations. General warnings The elctrical safety of the appliance is assured only when it is correctly earthed, according to the electrical rules in force. The gas, D.H.W. and the CH system pipes cannot be used as ground plates.
Instructions for the installer Outdoor sensor connection Single boiler DANGER! Switch off and disconnect the electricity supply before carrying out any operations on the electrical parts. - Gain access to the rear of the eBus and remove the terminals numbered from 5 to 11. - Outdoor sensor connection: insert the cables between the pins 9 and 10 on the e-Bus terminal board.
Instructions for the installer Pump Connection Single Boiler - For the fixed flow rate pump connection, place the cables between pin 1.2 and terminal M1. FIXED RATE PUMP P MARRONE 1 BLU 2 MARRONE BLU GIA/VER GIA/VER L1 N M1 Boiler battery Modulating Pump The BCM (optional kit) board, elaborates the data concerning the thermal drop (Δt between primary flow and return) and provided power.
Instructions for the installer 3.19 - FUNCTIONAL FLOW WIRING DIAGRAM Ignition electrode Ionization electrode Main switch Flue switch Gas switch CH sensor CH return sensor Condensate level sensor Limit thermostat Ignition transformer Gas valve Modulating fan detection/adjustment E. ACC VM RED YEL/GREEN VG 2 3 4 2 3 BROWN 1 TR. ACC. BROWN 2 5 6 7 8 9 10 11 BLACK 1 4 BLUE BLACK (-) 5 BLUE ALIM. RIL./REG.
Instructions for the installer 3.
Instructions for the installer Electrical connections for boilers installed in a cascade formation The cable for the connection between the boiler and the BCM must have the following characteristics: PVC HT CABLE 3x0,5 EBUS UNIT eBUS + eBUS - 1 2 3 4 (*) 5 6 7 8 9 10 11 BOILER 1 NERO 2 3 7 8 90 1 4 56 (*) remove the bridge between contacts IN and OUT Y1 terminal eBUS + eBUS eBUS eBUS + BCM 90 1 5 4 3 2 78 1 4 1 Y2 Jp1 3 2 1 Y4 Y3 DL1 DL2 eBUS eBUS + DL3 eBUS + 4 A1 90 1
Instructions for the installer 3.21 - INSTALLATION EXAMPLES (Functional diagram) Boiler connection to the heating system, with 1 direct high temperature heating zone CH SYSTEM HIGH TEMPEARTURE EXPANSION VASSEL BOILER SENSOR BOILER PKX 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").
BOILER SENSOR BOILER PKX 1 (Master) VE BOILER SENSOR BOILER PKX 2 (Slave) VE 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").
Instructions for the installer 3.26 - INITIAL LIGHTING PRELIMINARY CHECKS The first ignition must be carried out by a qualified technician. Failure to do so could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage.
Instructions for the installer 3.23 - BURNER PRESSURE ADJUSTMENT PK150X 2S WARNING! All the instructions indicated below are for the exclusive use of qualified UNICAL service technicians or installers. All the boilers are supplied already calibrated and tested. However, if it is necessary to change the calibration, the gas valve must be re-calibrated. Warning: during this operation do not request any DHW draw-off .
Instructions for the installer In case of gas valve replacement or difficult ignition: Tighten the maximum adjustment screw "A" in a clockwise direction until you arrive to the abutting end, than slacken for 7 turns. Verify boiler ignition; if the boiler goes into lockout slacken the screw "A" again of one turn, than retry to light the boiler. If the boiler goes into lockout again, carry out the above indicated operations until the boiler fires.
Instructions for the installer B) Min output adjustment MINIMUM OUTPUT ADJUSTMENT SCREW + Via the e-bus controller Change the "Test" mode and run the boiler at minimum output (refer to procedure illustrated on page 43). - Check that the C02 values are within the values indicated in the table "Burner pressures" - If necessary correct the value by turning the adjustment screw "B" in a CLOCKWISE direction to increase the value and in an ANTICLOCKWISE direction in order to decrease it.
Instructions for HSCP calibration/adjustment 3.25 - ACTIVATION CHIMNEYSWEEPER MODE A B Turn the knob C on Press key A (store) Turn the C display.
Instructions for HSCP calibration/adjustment 3.
Instructions for HSCP calibration/adjustment DEFAULT SETTINGS Position Identification Parameter description PKX 150 PKX 230 PKX 300 PKX 348 1 31 CH: Minimum Setpoint 20 20 20 20 2 39 CH: Maximum Setpoint 85 85 85 85 3 322 Pump: Overrun 5 5 5 5 4 309 System Config. (single master) 3 3 3 3 System Config. (master in battery) 2 2 2 2 System Config.
Inspections and maintenance 4 INSPECTIONS AND MAINTENANCE Inspections and maintenance performed professionally and according to a regular schedule as well as the use of original spare parts are of the utmost importance for fault-free operation of the boiler and to guarantee its long life. Yearly maintenance of the appliance is mandatory in compliance with Laws in force. Failure to perform Inspections and Maintenance can entail material and personal damage.
Inspections and maintenance Checking status of gaskets and insulation fibres Boiler body maintenance Danger! Before performing any maintenance, make sure the boiler and its components have cooled off. The insulation fibre of the door can show cracks after a short time of operation; this however does not reduce its insulation capacity nor jeopardise its lifespan. Disconnect the boiler from the electric mains and shut the gas supply to the appliance.
Error codes 5 ERROR CODES 5.1 - ERROR CODES DISPLAY Failure notification Reset key Error description Error code Error codes of EBUS control unit are indicated below together with its meaning and corrective actions.
Error codes Code: Meaning: 6 Excessive water temperature detected by the heating sensor (SR) (> 95°C) Code: 1 Meaning: Safety thermostat intervention (TL) Solution: Press the unblock key on the panel Solution: Check water circulation in installation Code: Code: Meaning: 5 Loss of the flame signal during operation 12 Meaning: Heating system failure (SR) Solution: Make sure the sensor and/or wiring is efficient Solution: Press the unblock key on the panel Code: Meaning: 4 No flame detec
AG S.P.A. 46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - telefax 0376/660556 www.unical.ag - 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.
