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DUA plusBTN 28 - BTFS 28
00333957 - 1st edition - 09/2011
INSTALLATION AND USERINSTRUCTION MANUAL
2
General infoWhile thanking you for buying an UNICAL product we invite you to carefully read the following forewarnings:
IMPORTANTThis INSTRUCTION MANUAL, which is an integral and indispensable part of the product, must be handed over to the user bythe plumber.Read carefully the forewarnings contained in this manual because they supply important indications concerning thesafetywhen using and maintaining the boiler. Kept the manual in a safe place for any future reference.The boiler must be installed by qualified personnel, in compliance with all applicable laws and standards, according to themanufacturer’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 heldliable for any such injury and/or damage.
After removal of the packaging, which has to be sent to specific waste management sites for recycling, check that the boiler is intact andthat it has not been damaged during transport and handling. Keep the packaging out of the reach of children as it may represent a chokingand suffocation hazard. Do not install equipment which is patently damaged and/or faulty.
Before installing the boiler, check that the technical data supplied by Unical, correspond to requirements for its correct use in the system.
Before making any service on to the boiler switch off the power supply.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 boiler and expose people, animals and property to danger.
To grant the efficiency of the appliance and for its proper operation it is necessary to do a periodical service according to theUNICAL's indications and local laws in force.
The manual must be handed over with the boiler should it be sold or transferred, in order that the new owner and/or installer can consult it.
Only original accessories must be used for all boilers supplied with optional kits (including electrical ones).
This boiler must be used for the purposes for which it has been designed. Any other use shall be considered incorrect and thereforedangerous.
Damage and/or injury caused by incorrect installation or use and/or damage and/or injury due to non-observance of the manufacturer’sinstructions shall relieve UNICAL from any and all contractual and extracontractual liability.
To guarantee efficiency and correct functioning of the equipment it is legally binding to service the boiler once a year according to theschedule 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 theboiler’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.: 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;- open doors and windows;- contact a Service Centre, qualified installer or the gas supply company.Never use flames to detect gas leaks.WARNINGThis boiler has been built for installation in the country indicated on the technical data plate, which shows, in addition to the technicalfeatures, also the gas type for which it is prepared to work. In case these indications do not correspond to your requirements, pleasecontact your nearest Unical supplier. Thanks for that.
"WATER TREATMENT IN C.H. SYSTEM FOR CIVIL USE" NOTE FOR INSTALLER AND USER1) The frequency of the cleaning of the D.H.W. heat exchanger is related to the hardness of the feeding water.2) With a water hardness higher than 14°f the use of antiscaling devices, whose choice will be made on the base of water characteristics,is suggested.3) To increase the resistance to the scaling, a D.H.W. temperature adjustment very close to that one of the actual use, is suggested.4) The adoption of a modulating room thermostat reduces the scaling danger.5) We advise you to verify the state of cleaness of the D.H.W. heat exchanger at the end of the first year and subsequently every twoyears. PED DeclarationThe appliance DUA plus BTN 28 e DUA plus BTFS 28is not under the scope of the PED Directive 97/23/CE, because it belongs to a category lower than the 1st, on the base of the comparationof their features with the limits shown on the table 4 of the directive. Furthermore the appliance is already covered by the Directives 90/396/CE (GAD - Gas Appliances Directive) and 73/23/CEE (LVD - Low Tension Directive)
3
General info
DATA PLATE DESCRIPTION
LEGEND:1 = CE Surveillance notify body2 = Boiler type3 = Boiler model4 = Number of stars (Directive 92/42/CEE)5 = (S.N°) Serial number6 = P.I.N. code7 = Approved fluing configurations8 = (N0x) N0x class
A Central Heating circuit features9 = (Pn) Nominal output10 = (Pcond) Condensing nominal output11 = (Qmax) Nominal heat input12 = (Adjusted Qn) Adjusted for nominal Heat input13 = (PMS) Max. pressure C.H. system14 = (T max) Max. C.H. temperature
B Domestic Hot Water circuit features15 = (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 EN13203-1
18 = (F factor) N°stars based on the quality of water declaredEN 13203-1
19 = (PMW) Max. pressure D.H.W. system20 = (T max) Max. temperature D.H.W system
C Electrical features21 = Electrical power supply22 = Consumption23 = Protection grade
D Countries of destination24 = Direct and indirect country of destination25 = Gas family26 = Supply pressure
E Factory setting27 = Adjusted for gas type X28 = Space for national brands
CE Marking- The CE marking documents that the boilers satisfy:- The essential requirements of the Directive regarding gas
appliances (Directive 90/396/CEE)- The essential requirements of the Directive regarding
electromagnetic compatibility (Directive 89/336/CEE)
- The essential requirements of the Efficiency Directive (Directive92/42/CEE)
- The essential requirements of the low voltage Directive (Directive73/23/CEE)
® 1
2
3
5
7 8
6
4
9
11
13
10
12
14
15
17
19
16
18
20
28
A
B
21 22
23
24 25 26
27
C D
E
4
General info
TECHNICAL CHARACTERISTICS ANDDIMENSIONS ....................................................................... pag. 5
1.1 Technical characteristics ...................................................... pag. 5
1.2 Dimensions ............................................................................. pag. 5
1.3 Hydraulic circuits ................................................................... pag. 6
1.4 Operational data ..................................................................... pag. 8
1.5 General specifications ........................................................... pag. 8
INSTRUCTIONS FORTHE INSTALLER .............................................................. pag. 9
2.1 Installations conditions .......................................................... pag. 9
2.2 Installation ............................................................................... pag. 9
2.2.1 Packaging .................................................................. pag. 9
2.2.2 Position of the boiler .................................................. pag. 10
2.2.3 Assembly the boiler ................................................... pag. 10
2.2.4 Ventilation ................................................................... pag. 11
2.2.5 Smoke evacuation systems ..................................... pag. 11
2.2.6 Smoke discharge system forced draught boilers ... pag. 14
2.2.7 Smoke discharge system forced draught boilers ... pag. 15
2.2.8 Smoke discharge with separate ducs Ø80 mm ...... pag. 16
2.2.9 On site combustion efficiency measurement .......... pag. 18
2.2.10 Gas supply line ......................................................... pag. 18
2.2.11 Hydraulic connections .............................................. pag. 18
2.2.12 Electrical connections ............................................... pag. 19
2.3 Electrical wirings .................................................................... pag. 20
2.3.1 Actual connection diagram ....................................... pag. 20
2.3.2 Jumper position ......................................................... pag. 22
2.4 Filling of the heating system .................................................. pag. 23
2.5 Burner adjustment .................................................................. pag. 23
2.6 Burner adjustment .................................................................. pag. 24
2.7 Adaptation to the use of other gas ........................................ pag. 26
2.8 Fault finding and reparation ................................................... pag. 27
INSTRUCTIONS FOR THE USER ...................... pag. 28
3.1 Panel board ............................................................................ pag. 28
3.2 Ignition and extinction ............................................................ pag. 30
3.3 Notes ....................................................................................... pag. 30
1
2
3
For your own safety, observe these safety instructions.:
PLEASE NOTE:User tip for the optimum utilisationand setting of the control(s) plus
useful information.
WARNINGfrom risk of electric shock.
WARNINGIdentifies potentially dangerous
situations.
Technical features and dimensions
5
1
- EMC Directive 89/336/EEC dated 3 May1989 amended by Directive 92/31/EECdated 28 April 1992;
- European Community’s Low VoltageDirective 73/23/EEC dated 19 February1973 amended by Directive 93/68/EECdated 22 July 1993;
The main technical features of the DUAplus B boilers are summarised below:
· 60 litre enamelled upright storage tankwith a helical steel heat exchanger;
· Monothermal, copper, high performanceheat exchanger;
· Adjustment of maximum output in heatingmode;
· Adjustment of the flame modulation as afunction of the absorbed power;
· NTC sensor for D.H.W. priority;· Safety pressure switch for low water
level;· System water inlet tap;· Storage tank exhaust tap;· Circulation pump with automatic air vent;· Filling tank pump with automatic air vent;· High limit thermostat (105°C);· Anti-freeze protection;· 7,5 litre expansion vessel;· 4 litre sanitary expansion vessel
(optional);
· Automatic differential by-pass;· Control panel with IP X4D insulation
protection;· Led indication of: D.H.W. demand, C.H.
demand, voltage presence, burner inoperation, temperature scale, faults,chimney sweeper mode;
· Manometer;· Tap water flow rate restrictor set at 12
litres/min;· Unlocking of check valves;· C.H. temperature selector (35 - 85°C);· D.H.W. temperature selector (35 - 65°C);· Main selector Winter / Summer /
Antifreeze / Only Heating;· Minimum outer temperature calibration (if
an outer sensor is connected);· Mounting frame with valves for easy
hydraulic connections (optional);· Electronic ignition with double electrode;· Casing painted with epoxypoliester
pouders;· Flue gas antispillage thermostat (natural
draught open chamber version);· Heating exhaust tap.
1.1 - TECHNICALFEATURES
DUA plus is a wall hung gas boiler withbuilt-in atmospheric gas burner for heatingand D.H.W. production; it is available in thefollowing versions:
DUA plus BTN 28 with natural draughtopen chamber
DUA plus BTFS 28 with forced draughtroom sealedcombustionchamber
All versions have electronic ignition.
DUA plus B boilers are supplied with allcontrol and safety features according to thelatest laws in force, and comply with thefundamental requirements of the followingEEC directives:The BEA boilers comply with thefundamentalrequirements of the following EECdirectives:- Directive Gas 90/396/EEC dated 29 June
1990;- Yield Directive 92/42 EEC dated 21 May
1992;
fig. 1
182
167
600
870
475
®
plusDUA
RF
MG
140
42
175
69 189 65 71,5 57 148,5
C
1.2 - DIMENSIONS
TECHNICAL FEATURES ET DIMENSIONS
view from above
view from below
Technical features and dimensions
6
fig. 2
fig. 3
DUA plus BTN 28
DUA plus BTFS 28
MR G C F
1312
98
76
5
4
3
2
1
10
11
14
20
26
191817
16
21
22
23
2425
272829
R G M C F
5
4
3
2
1
67
9
10
16
15
14
13
12
11
191817
20
21
2322
24
29
252627
28
30
3132
33
34
8
15
30
1.3 - HYDRAULIC CIRCUITS 1 Filling system cock2 Boiler draining valve3 By-pass4 No-return valve5 Pump6 Air vent7 Modulating gas valve8 Low water pressure switch9 Ignition electrode10 Burner injectors11 Ignition electrode12 Ionisation electrode13 Main heat exchanger14 Smoke safety thermostat15 Draught diverter16 Safety thermostat17 Manual air vent18 Boiler expansion tank valve inflation19 Expansion vessel20 Flow temperature sensor21 Expansion vessel l. 4 (optional)22 Heat exchanger draining valve23 Tank24 Tank draining valve25 Magnesium anode26 Tank temperature sensor27 Domestic Hot Water flow restrictor28 Filter29 C.H. safety valve30 Boiler safety valve
M C.H. flow 3/4"C D.H.W. outlet 1/2"G Gas inlet 3/4"F D.C.W. inlet 1/2"R C.H. return 3/4"
1 Filling system cock2 Boiler draining valve3 By-pass4 No-return valve5 Pump6 Air vent7 Modulating gas valve8 Low water pressure switch9 Ignition electrode10 Burner injectors11 Ignition electrode12 Ionisation electrode13 Main heat exchanger14 Smoke pressure nipple15 Extraction fan16 Air intake and smoke evacuation duct17 Microswitch of the smoke pressure18 Safety pressureswitch of smoke circuit19 Smoke pressure nipple20 Safety thermostat21 Manual air vent22 Boiler expansion tank valve inflation23 Expansion vessel24 Flow temperature sensor25 Heat exchanger draining valve26 Expansion vessel l. 4 (optional)27 Tank28 Tank draining valve29 Magnesium anode30 Tank temperature sensor31 Domestic Hot Water flow restrictor32 Filter33 C.H. safety valve34 Boiler safety valve
M C.H. flow 3/4"C D.H.W. outlet 1/2"G Gas inlet 3/4"F D.C.W. inlet 1/2"R C.H. return 3/4"
Technical features and dimensions
7
DUA plus BTN 28II2H3+
8,9
0,5
3
3,25
85
35
7,5
139,9
0,5
6
60
16
12
8,98
9,98
11,43
13,33
15,99
187
35 - 65
230/50
4
89
X4D
82
l/min
bar
bar
l
°C
°C
l
l
bar
bar
l
l/min.
l/min.
l/min.
l/min.
l/min.
l/min.
l/min.
l
°C
V-Hz
A (F)
W
IP
kg
kW
kW
%
%
%
%
n.
%
%
%
°C
g/s
%
%
mg/kwh
%
%
DUA plus BTN 2827,9
12,5
89,95
89,89
89,68
87,34
2
92,87
88,88
2,62 - 2,92
64,6 - 83,4
22,05 - 24,3
126,46
2,3 - 4,6
186
2
11,12 - 7,13
0,449
DUA plus BTFS 2828,8
12,9
92,94
92,92
92,04
90,38
3
94,96
90,74
2,04 - 2,02
60,4 - 69,6
19,51 - 20,55
89,4
2,6 - 5,9
-
-
130
3
11,03 - 6,61
0,489
DUA plus BTFS 28II2H3+
8,8
0,5
3
3,25
85
35
7,5
139,3
0,5
6
60
16
12
9,1
10,2
11,7
13,6
16,4
187
35 - 65
230/50
4
148,5
X4D
89
1.4 - OPERATIONAL DATAFor some data (NOZZLES - BURNER GAS PRESSURE - DIAPHRAGMS - INPUTS - GAS CONSUMPTIONS)refer to paragraph ADAPTATION TO THE USE OF OTHER GAS on page 26.
1.5 - GENERAL SPECIFICATIONS
(*) Warning: The utilisation of this type of boilers in the "floor heating systems" needs the use of specific equipments (e.g.:UNICAL Thermic Module) to avoid all risks of smoke condensation within the boiler.
Nominal output
Minimum output
Actual water efficiency at 100 % of nominal load
Minimum water efficiency required at 100 % of nominal load
Actual water efficiency at 30 % of nominal load
Minimum water efficiency required at 30 % of nominal load
Star number (according to Efficiency Directive 92/42/CE)
Combustion efficiency at 100 % of nominal load
Combustion efficiency at minimum load
Heat losses through the casing (min. / max.)
Maximum net smoke température (Ts- Ta)
Massive smoke flow rate (min. / max.)
Air exces (lambda)
CO2
NOx (ponderal value according to EN 297/A3+EN 483)
NOx class (ponderal value according to EN 297/A3 + EN 483)
Chimney heat losses with burner in operation (min./max.)
Chimney heat losses with burner shut-off
Boiler category
Minimum water low rate in heating circuit (ΔT 20°C)
Minimum pressure in heating circuit
Maximum pressure in heating circuit
Water content of the primary circuit
Maximum operation temperature in heating mode
Minimum operation temperature in heating mode (*)
Expansion vessel total content
Maximum water content of the heating circuit (max. temp. 90°C)
Minimum pressure in the D.H.W. circuit
Maximum pressure in the D.H.W. circuit
Tank capacity
Specific D.H.W. flow rate ( t 30°C according to EN 625)
Flow rate of the D.H.W. flow restrictor
Contiunuous D.H.W. production with t 45 K
Contiunuous D.H.W. production with t 40 K
Contiunuous D.H.W. production with t 35 K
Contiunuous D.H.W. production with t 30 K
Contiunuous D.H.W. production with t 25 KDHW available at a temp. of 45°C in the first 10 mins of draw-off with storagetank water at 60°C and cold water at 10°C (*)
D.H.W. temperature adjustable between
Electrical power supply Tension/Frequency
Supply fuse
Maximum absorbed output
Insulation degree
Net weight (dry)
Installation info
8
fig. 4
650960
665
2 INSTRUCTIONS FORTHE INSTALLER
2.1 - INSTALLATIONCONDITIONS
DUA plus is a gas boiler which must beinstalled in accordance with the latestregulations or rules in force.For the boiler category, which changesaccording to the destination country,see page 3.
NOTE:Observe the corresponding technical rulesand the building supervisory and statutoryregulations of the country of final usewhen installing and operating the system.Always ensure that an appropriatelyspecialised company is entrusted withinstallation, gas supply and flue gasconnection, commissioning and powersupply, as well as all servicing and repairworks.Work on gas conduits and fittings must onlybe carried out by a registered serviceprovider.
The system must be cleaned and servicedonce a year. This includes an inspection ofthe entire system to see if it is in fullworking order.Defects and faults must be eliminatedimmediately.Please note that we can accept no liabilitywhatsoever for loss or injury resulting fromunauthorised adjustment or manipulation ofthe system’s control or regulating devices.
2.2 - INSTALLATION
2.2.1 - PACKING
Dua plus B is packed and delivered in astrong cardboard box. Once the boiler hasbeen unpacked check that it is intact. Thepackaging material can be recycled and itmust be disposed of accordingly.Keep the packaging out of the reach of chi-ldren as it represents a choking and suffo-cation hazard.UNICAL waives all liability for injury topersons and animals or damage to pro-perty resulting from non-observance ofthe above.
The packaging contains:- the copper pipe kit for hydraulic connec-
tion of the boiler to the heating and watersystem and to the gas mains;
- a bag with:a) installation, use and maintenance hand-
book,b) template for fixing the boiler to the wall,c) 4 screws with dowels to fix the boiler to
the wall,d) for models TFS, a diaphragm for flue gas
exhaust.
Installation info
9
fig. 5
2.2.3 - ASSEMBLING THE BOILER
Before connecting the boiler to the D.H.W.and heating system pipes, carefully cleanthe pipes to remove all traces of metalresulting from processing and weldingoperations as well as any oil and greasewhich could damage the boiler orjeopardize its operation.
Unical refuses all liability for injury to personsand animals or damage to property resultingfrom non-observance of the above.To installthe boiler:- Fix with tape the paper template to the
wall- make two Ø 12 holes in the wall and
insert the hooks;
- position the junction points for theconnection of the gas supply pipe, coldwater supply pipe, D.H.W. outlet, CH flowand return in the positions shown by thetemplate.
- fit the boiler onto the support hooks;- connect the boiler to the gas pipe,
domestic cold and hot water pipes, CHflow and return pipes.
- connect to electrical supply.
NOTE:NOTE:NOTE:NOTE:NOTE:----- Do not use solvents which couldDo not use solvents which couldDo not use solvents which couldDo not use solvents which couldDo not use solvents which could
damage the components.damage the components.damage the components.damage the components.damage the components.
M = C.H. flow 3/4"C = D.H.W. outlet 1/2"G = Gas inlet 3/4"F = D.C.W. inlet 1/2"R = C.H. return 3/4"S = Draining safety valve
MOUNTING TEMPLATE
2.2.2 - POSITIONING OF THE BOILER
Every boiler is supplied with a dedicated"Metallic mounting jig" to allow the correctpositioning of the gas, water and C.H.system connections when the hydraulicsystem is being laid out and before the boileris installed.This mounting jig must be fixed to the wallchosen for the installation of the boiler usingtwo screws with expanding dowels.The lower part of the mounting jig allows thecorrect marking on the wall of the pointswhere the fittings for the gas, C.H. flow andreturn, D.H.W. and D.C.W. have to arrive.
Determine the position of the boiler takingcare:- of leaving a minimum clearance of 50
mm on both sides of the boiler to allowaccessibility for service.
- of a good resistance of the screwssupporting the boiler on the wall.
- of avoiding to position the boiler abovean equipment whose use could beprejudicial for the boiler (stove withemission of greasy vapours, washingmachines, etc...).
IMPORTANT:350 mm free space must be left betweenthe top of the boiler and the ceiling toallow replacement of the magnesiumanode. This condition is met when thereis a space of 436 mm between the axis ofthe holes in the boiler bracket and theceiling.
The mounting jig allows the completion of allthe connections and the making of thesoundness test of the full installation withoutthe boiler in place.If the boiler is not put in place immediately,protect the different connections in order toavoid that the mortar and the paintcannot compromise the soundness of thesubsequent connections.
Because the temperature of the wall, onwhich the boiler is fitted, does not rise morethan 60 K when the boiler is in operation,there are no special requirements to complywith.
Installation info
10
2.2.4 - VENTILATION
The boiler must be installed in a suitable roomaccording to the rules in force and particu-larly:
NATURAL DRAUGHT OPEN FLUE BOI-LERS(TYPE B11bs and VMC INSTALLATIONS)The boilers DUA PLUS TN, are open flueboilers and are foreseen for chimneyconnection: the air for combustion is takendirectly from the room in which the boiler isinstalled.The room can have both a direct ventilation(i.e. with ventilation openings facing out-wards) or an indirect ventilation (i.e. with ven-tilation openings facing an adjacent room)provided that the following requirements arecomplied with:Direct ventilation:- The room has to have a ventilation open-
ing of, at least,6 cm² /kW of installed input (see inputtable on par. 2.7) and, in no case, lowerthan 100 cm² and made directly onto anexternal wall.
- The opening has to be as close as possi-ble to the floor.
- It should not be possible to close it and itshould be protected with a grate not re-ducing its usefull ventilation section.
- A correct ventilation can be optained alsothrough the addition of more openings,provided the addition of the different sec-tions is not less than that really needed.
- In case it is not possible to make a venti-lation opening close to the floor, it will benecessary to increase its usefull sectionof at least 50%.
- If an open fire is present in the same roomit needs an indipendent air supply, other-wise the installation of a type B applianceis not permitted.
- If in the room there are other deviceswhich need air for their operation (e.g. awall exhauster) the section of the venti-lation opening has to be the properly si-zed.
Indirect ventilationIn case it is not possible to make a roomventilation opening on an external wall, it ispossible to have an indirect ventilation,sucting the air from an adjacent room,making anopening in the lowest part of a door.This solution is possible only if:- The adjacent room is not a bed room- The adjacent room is not a common part
of the building and is not a room with firedanger (e.g. a fuel deposit, a garage, etc..)
FORCED DRAUGHT ROOM SEALED BOI-LER(TYPE C12 - C32 - C42 - C52 - C62 - C82)The DUA PLUS TFS are forced draught,room seal-ed boilers; so they do not needparticular ventilation openings for thecombustion air, in the room in which theyare installed.
FORCED DRAUGHT, OPEN FLUEBOILER(TYPE B22)If the DUA PLUS TFS are installed in a roomac-cording to the chimney configuration ontype B22, the same ventilation requirementsestablished in paragraphs Directventilation and Indirect ventilation apply.
2.2.5 - FLUE GAS DISCHARGESYSTEM
NATURAL DRAUGHT OPEN FLUE BOI-LERS
Connection to the chimney
A good chimney is very important for thecorrect functioning of the boiler; it musttherefore conform with the followingrequirements:- it must be made from waterproof material
and be resistant at the temperature ofthe flue gas and relative condensate;
- it must have sufficient mechanicalstrength and low thermal conductivity;
- it must be perfectly sealed to preventcool-ing due to parasite air inlets;
- it must be as vertical as possible and theend section must have a chimney capwhich guarantees efficient and constantevacuation of the combustion products;
- the chimney must have a diameter notsmaller than that of the boiler’s draughtdiverter; for chimneys with a square or
rectangular section, the internal sectionmust be 10% larger than the section ofthe connection duct to the draughtdiverter.
- starting from the draught diverter, the ductmust have a vertical section with a lengthmore than twice the diameter, before get-ting into the chimney.
Direct emission into the atmosphere
Natural draught boilers can dischargecombustion products directly into the atmo-sphere using a duct, which goes throughthe outside walls of the building, connectedto a flue exhaust terminal.The exhaust duct must also comply with thefollowing requirements:- the sub-horizontal part inside the building
must be as short as possible (no morethan 1 m);
- for boilers with vertical discharge, suchas boilers Dua plus B, there must be nomore than 2 direction changes;
- it must receive the discharge from asingle boiler;
- the part going through the wall must beprotected by a sheath duct; the part ofthe sheath duct facing the inside of thebuild-ing must be sealed and the partfacing outwards must be open;
- the final section, on which the draughtterminal will be fixed, must protrude fromthe wall of the building for a length of atleast twice the diameter of the duct;
- the draught terminal must overlap theconnection to the boiler by at least 1.5 m(see fig. 8).
Installation info
11
fig. 6
fig. 7
600
167
88
0
Ø 140
182
475
2 Ø min.
Slopemin. 3%
Ø
1,5
m m
in.
2 Ø 1 m max.
1,5
m m
in.
2 Ø
Ø
Slopemin. 3%
1 m max.
2 Ø min.
> 3
Ø>
3 Ø
®plu sDUA ®
plusDUA
®
plusDUA
WARNING:The boiler is fitted with an automatic safetyreset device as protection against spillageof combustion products inside the building.In case of the device operation, the boilerwill remain in lock-out position indicating theanomaly on the display.After 15 minutes the boiler will be resetautomatically.
It is absolutely forbidden toby-pass the smokethermostat.If the boiler cuts off regularly,
it is necessary to ask a technician for a checkof the flue gas exhaust duct. This duct maybe obstructed or may be unsuitable for thedischarge of flue gas into the atmosphere.
UNICAL refuses all liability fordamage caused as a result ofincorrect installation, use, modi-
fication of the boilers or for non-observanceof the instructions provided by the manu-facturer or applicable installation regulations
DIMENSIONS FOR CONNECTING FLUE GAS DUCT
Installation info
12
fig. 8
The DUA plus B is a forced draught, roomseled boiler; so it does not need particularventilation openings for the combustion air,in the room in whichit is installed.
POSITIONING OF TERMINALS FOR TYPE ‘’C’’ BOILERS
Posit ion of the terminalPosit ion of the terminalPosit ion of the terminalPosit ion of the terminalPosit ion of the terminal Min. DistancesMin. DistancesMin. DistancesMin. DistancesMin. Distances mm
- Under a window A 600
- Under a ventilation opening B 600
- Under a gutter C 300
- Under a balcony (1) D 300
- From an adjacent window E 400
- From an adjacent ventilation opening F 600
- From vertical or horizontal air pipes or drains (2) G 600
- From an external corner of the building H 300
- From an internal corner of the building I 1000
- From the ground or from another floor L 1800
- Between two vertical terminals M 1500
- Between two horizontal terminals N 1000
NOTES(1) Terminals below a practicable balcony shall be arranged in such a way as to assure that the total run of smokes, from their outletfrom terminal up to outlet from balcony external perimeter, including the height of protection baluster, if any, is not less than 2 m.(2) Distances of not less than 500 mm shall be adopted in placing the terminals, due to the proximity to materials subject to the actionof products of combustion such as plastic gutters or waterspouts, wooden jetties, etc.) unless adequate screening measures aretaken for the said materials.
The forced draught, room seled boilers, nor-mally should evacuate the smokes on theroof of the building.
When, in some country, it is allowed to eva-cuate on the front of the building, the fol-lowing distances of the terminals, have tobe complied with:
TERMINALS POSITION
Installation info
13
2.2.5 - SMOKE DISCARGE AND AIRSUCTION DUCTS CONFIGURATIONTYPES C12, C32, C42, C52, C82
The DUA plus boiler has been approved forthe following air suction and smokeevacuation tipes:
C12Boiler designed for connection to horizontalexhaust and suction terminals directly intothe atmosphere using coaxial or dual ducts.The distance between the air intake ductand the flue gas outlet duct must be at least250 mm and both end sections mustbe located within a 500 mm square.
C32Boiler designed for connection to verticaldischarge and suction outlets directly intothe atmosphere using coaxial or dual ducts.The distance between the air intake ductand the flue gas outlet duct must be at least250 mm and both end sections must belocated within a 500 mm square.
C42Boiler designed for connection to collectivechimneys including two ducts,one for the suction of combustionair and the other for the exhaustof the combustion products,through coaxial or dual ducts.The chimney must comply with relevantapplicable law provisions.
C52Boiler with separate combustion airsuction and combustion productexhaust ducts.These ducts can discharge into areaswith different pressure.The dual ducts must not be locatedon two opposite walls.
C82Boiler designed for connection to an airsupply terminal and fitted to an individualor shared chimney.The chimney must comply with relevantapplicable law provisions.
typeC12
typeC32
typeC52
type C82
typeC42
Installation info
14
fig. 10
fig. 9
Ø 1
00
95
88
0
182
600 475
minimo 500
®
plusDUA
167
DIMENSIONS FOR CONNECTION OF THE COAXIAL DUCTS
Type C12
The maximum autorised length for thehorizontal coaxial pipes is 3 meters; for eachsupplementary bend the maximum length willbe reduced by 1 meter; furthermore the pipeshal have a downward inclination of 1% onthe outlet direction in order to avoid the rainenter the pipe.
For installations with horizontal coaxial pipewith length between 1 m, it is necessary toplace, inside the fan outlet, the diaphragmsupplied with the boiler (see fig. 9).
Type C32
The maximum allowed length of the coaxialvertical pipes is 5 meters, included the roofterminal; for each supplementary bend themaximum allowed length will be reduced by1 meter.
For installations with coaxial ducts having alength between 1.5 m, it is necessary toplace, inside the fan outlet, the diaphragmsupplied with the boiler (see fig. 9).
2.2.7 - SMOKE DISCHARGE SYSTEMFORCED DRAUGHT BOILERS
C12: between 0.5 and 1 m with
diaphragm Ø 40 L max = 3 m
Neoprene
Diaphragm
C12
: b
etw
een
1.2
an
d 2
.5 m
wit
h d
iap
hra
gm
Ø 4
0 L
max
= 3
Diaphragm
gasket
Installation info
15
fig. 11
fig. 12
600 475
88
0
120
167
Ø 80
182
®
plusDUA
2.2.8 - SMOKE EVACUATIONTHROUGH TWO SEPARATEDUCTS Ø 80(Type B accessories)
NB: The maximum allowed pressuredrop, according to the installationtype, must be equal to the valueindicated in the installationexamples given on page 17.
For installations with smokeevacuation through separateducts, whose pressure drop valueis between 15 Pa and 30 Pa, it isnecessary to fit a diaphragm,supplied with the boiler, inside thesmoke outlet (see fig. 11).
Diaphragm
Neoprenegasket
Diaphragm
From ΔΔΔΔΔP=40 Pa
DIMENSIONS FOR CONNECTION THE AIR INTAKE AND THE FLUE GAS DISCHARGE WITH DUAL DUCTS
Installation info
16
fig. 13
> 50
0_
Hmin. = 165 mm
CONFIGURATIONS FOR SEPARATEPIPES (SUCTION AND OUTLET) Ø 80
Example N.1
Primary air suction from perimeter wall andflue gas discharge on roof.
Maximum allowable pressure loss:65 Pa
Example N.1
Installation info
17
fig. 14
135
45
Hmin. = 165 mm
250
min
.
Example N.2
Primary air intake from an outer wall andsmoke evacuation through the same wall.
Maximum allowed pressure drop: 72Pa
CALCULATION OF PRESSURE LOSSFOR DISCHARGE & SUCTIONDUCTS
Bear in mind the following parameterswhen calculating pressure losses:- for each metre of duct with Ø 80 (both
suction and discharge) the pressure lossis 2 Pa;
- for each 90° Ø 80 (R=D) bend with longradius, the pressure loss is 4 Pa;
- for the Ø 80 L = 0.5 m horizontal air inletterminal, the pressure loss is 3 Pa;
- Ø 80 L = 0.6 m horizontal discharge endsection, the pressure loss is 5 Pa;
NB: These values refer to discharges through original UNICAL non- flexible and smooth ducts.
In both of the following examplesthe hypotized compositions of theintake and evacuation ducts arepossible because the total pressureloss is lower than 72 Pa, which isthe maximum allowed pressure loss.
Example of check using wide radiusbends:
- 15 m duct Ø 80 x 2 = 30 Pa- 2x90° Ø80 long radius bends 2x4= 8 Pa- horizontal Ø 80 air inlet terminal = 3 Pa- horizontal Ø 80 terminal = 5 Pa
Total pressure loss = 46 Pa
Example N.2
Installation info
18
fig. 17
1 2
fig. 15
1 2
TSC0210C
ADA0160C
Analyserprobes
Analyserprobes
Smokes
Air
2.2.9 - ON SITE COMBUSTIONEFFICIENCY MEASUREMENT
Coaxial ducts(Type A accessories)To determine combustion efficiency thefollowing measurements must be made:
- the combustion air temperature measuredin hole 2 (see fig. 15).- the flue gas temperature and CO2 %measured in hole 1 (see fig. 15).Make these measurements with theboiler running in a steady statecondition.
(Type B accessories)Separate ductsTo determine combustion efficiency thefollowing measurements must be made:
- the combustion air temperature measuredin hole 2 (see fig. 15).- the flue gas temperature and CO2 %measured in hole 1 (see fig. 15).Make these measurements with theboiler running in a steady statecondition.
Analyserprobes
2.2.10 - GAS SUPPLY LINE
The gas supply line must have a diameterequal or larger than the one used in the boiler.Comply with the applicable local installationrequirements which shall be considered ashaving been incorporated in full in thismanual.Before opening the internal gas supplysystem; i.e. before connecting the gasmeter, all seals must be checked.If any part of the system is concealed theseals must be checked before the pipesare covered.
The seal test must be conducted using airor nitrogen at a pressure of at least 100mbar.The commissioning of the boiler alsoincludes the following operations andchecks:- Opening of the gas gate valve and ventingof the air contained in the piping and boiler,proceding appliance by appliance.- Check, with the gate valve of all theappliance
DIAGRAM FLOW RATE/MANOMETRIC HEAD AVAILABLE FOR C.H. SYSTEM
= By-Pass CLOSED= By-Pass OPEN..............
Flow rate l/h (Q)
Ava
ilab
le M
ano
met
ric
Hea
d m
c.e
.
2.2.11 - HYDRAULIC CONNECTIONS
Before installing the boiler we recommendthat the system be cleaned to remove anyimpurities which could originate fromcomponents and which could risk damagingthe circulating pump and heat exchanger.
HEATINGThe heating flow and return must beconnected to the relevant ¾” connectionsof the boiler M and R (see fig. 5).When determining the size of the heatingcircuit pipes it is essential to bear in mindthe pressure losses induced by radiators,any thermostatic valves, radiator cut-offvalves and the configuration of the system.In the boiler, between the flow and returnpipes,an automatic bypass device is fitted(a differential valve with a flow rate ofabout 150 l/h) which guarantees alwaysminimum flow rate through the heatexchanger, also in the case, for instance,that all the thermostatic valves fitted on theradiators, are closed.
Off, that there are no gas leaks.During the 2nd quarter of a hour from thebeginning of the test no pressure reductionis to be detected on the gas pressuregauge. If gas leaks have to be found, useonly water soap solution or any otherspecific gas leak detector which can beavailable on the market. Never look for gasleaks using a nacked flame.
Installation info
19
D.H.W. PRODUCTION
Cold water temperature = 15 °CQuantity drawn at 14 litres/min
fig. 19
Dra
win
g t
emp
erat
ure
°C
Quantity drawn in litres
By-Pass CLOSED
By-Pass OPEN fig. 18
It is possible to adjust the by-pass byacting onto the adjusting screw (see fig.18).
D.H.W. (Domestic Hot Water)Inlet and Outlet and of D.H.W. must beconnected to the relevant ½” connectionsof the boiler C and F (see fig. 5).
The pressure in the water mains must bebetween 1 and 3 bar (in case of higherpressure it is necessary to fit a PRV(Pressure Reducing Valve).
We recommend that the discharge of thesafety valve mounted in the boiler beconveyed into the sewer.If this precaution is not taken, activation ofthe safety valve may result in flooding ofthe room where the boiler is installed.UNICAL shall not be held responsible fordamage caused by non-observance of thistechnical precaution.
The hardness of the supply water affectsthe frequency of the cleaning of the heatexchanger; the opportunity to install a watersoftning device depends on thecharacteristics of the water it self.
NOTE:With a water whose hardness is higherthan 20°f the use of a softner is stronglyrecommended
60
55
50
45
40
35
0 50 100 150 200 250 300
65
2.2.12 - ELECTICAL CONNECTIONS
The electrical connections of DUA plus 30μtank are shown in the clause ‘’WIRINGDIAGRAMS’’ (par. 2.3 - pag. 20).The boiler must be connected tothe mains supply at 230 V - 50 Hz. Thisconnection is to be perfectly done, asforeseen by the IEC and local rules andmust be earthed.
This fundamental requirement for safetypurposes must be checked; in case ofdoubt, ask for a professionally qualifiedtechnician to check the electrical system.UNICAL disclaims all liability for damage orcaused by failure to earth the system.Gas, domestic water and centralheating pipes are not suitable forearthing purposes.
The boiler is supplied with 1.5 m long3x0,75mm² cord. PhasePhasePhasePhasePhase and Neutral Neutral Neutral Neutral Neutral mustcompulsory be connected to PhasePhasePhasePhasePhase andNeutralNeutralNeutralNeutralNeutral of the supply socket.A double pole switch with a distancebetween the contacts higher than 3 mm,must be installed upstream the boiler toenable all maintenance operations to becarried out safely.
Installation info
20
fig. 20
A6
65
43
21
7
76
54
32
1
A2
BLUEBROWN S
S
E. R
IV.
TEFLON WHITE
RO
DA
9 BROWN
V
BLUEYEL/GREEN
32
1
SR
GREEN
BROWN
WHITE
BLUE
87
65
43
21
A3
43
21
A1
54
32
1
A4
WHITE
WHITE WHITEWHITE
WHITE
BLUE
BLUEBLUE
BROWNGREEN
VE
RS
ION
E
TN
VE
RS
ION
E
TF
S
54
32
1
DK T
FT
LP
VTL
MD
A8
65
43
21
BROWNBLUEYEL/GREEN
BROWN
BLUEYEL/GREEN
PS
PR
BROWN
E. A
CC
. 1
TEF
LON
RE
D
TE
FLO
N R
ED
V2
V1
E. A
CC
. 2
BLUE
BROWN
BLUE
YEL/GREEN
DIS
PLA
Y P
CB
BR
OW
N
SE
TA 1
BL
AC
K
BLU
EY
EL/
GR
EE
N
L1 NL1 N
AL
IME
NTA
TIO
N2
30 V
- 5
0 H
z
IG
54
32
1
GN
D1
GN
D2
GN
D4
RO
D
N
Y2
GN
D5
L1EXTSENSOR
Y1
A8
76
54
32
14
32
17
65
48
32
1
21
21
A6
A9
A3
A1
A2
A4
TA 2
EV
Z
2.3 - ELECTRICAL WIRING
2.3.1 - ACTUAL CONNECTION DIAGRAM
KEYA1…A8 = Utility connectorsROD = Ionization electrode connection
on the main boardY1 = Room thermostat and outer
sensor connectorsY2 = Voltage connectorDK = Pressure switch for low water
levelE. RIV. = Ionization electrodeE.ACC1 = Ignition electrodeE.ACC2 = Ignition electrodeMD = Modulating coilPR = Heating pumpPS = Sanitary pumpPV = Fan pressure switch (only fan
assisted version)SE = Outer sensor (optional)SS = D.H.W. temperature sensorSR = C.H. temperature sensorTA = Room thermostat (optional)TF = Flue gas antispillage thermostat
(natural draught version)TL = Limit thermostatV = Fan (only fan assisted version)VG = Gas valveJP1 = Jumper for on/off or modulating
chronothermostat selection (seepage 22)
JP2 = Jumper for boiler versionselection (natural draught or fanassisted)
Installation info
21
fig. 21
AZZURRO
AZZURRO (N)
GIA/VERDE GIA/VERDE
CAVO PVC 3x0,75 Ø MARRONE
MARRONE (L)
A
B
C
D
Y2GND 1
E
F
BC
DEF
®
plusDUA
MAX
MAX
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
-20 °C 10 °C
0 °C-10 °C
MIN - MAX
GENERAL INFORMATION ON THEELECTRICAL CONNECTIONS
Access to the supply terminal block
- WARNING! Disconnect power supply- Remove the front casing.- Widen the two plastic flaps (A); pull front-
wards the panel board and rotate itdownwards.
- To get access directly to the connectionzone, unscrew the two screws (B) andremove the cover (C); if this isn't enough,unscrew the five screws (D) to getaccess completely inside the panel board(act carefully).
Replacement of the supply cable
When replacing the supply cord, the UNICALoriginal one, Part. code 00610308, must beused.- Get access to the supply terminal block
Y2 (see previous paragraph).- Insert the new power supply cord through
the extractable cable gland E- Pul out the terminal block Y2 and make the
connections respecting the position and thecolours. The female faston of the earthingwire must be introduced on the tab GND 1.
L1= phase = brown - terminal Y2 - 1N =neutral = bleu - terminal Y2 - 2 = earth = yellow/green - tab GND1
Room thermostat connection(ROOM STAT)
- Get access to the terminal block Y1
- Remove the link between terminals 4 - 5.- Insert the room thermostat cable TA
through the extractable gland, suppliedwith the boiler, and connect it to theterminals 4 and 5.
- WARNING! If an ON/OFF room stat isused, the jumper JP1 of the modulatingPCB must be positioned between pins 2and 3 (see fig. 23).
External sensor connectionEXT SENS)
- Get access to the terminal block Y1- Insert the external sensor cable through
the extractable cable gland, supplied withthe boiler, and connect it to the terminals 2and 3 of the block Y1; if the cable is ofshielded type, then connect the shield tothe terminal 1 of the block Y1.
For the connection of the ROOM STAT andthe EXT SENSOR, replace the plastic plugs Fof the panel board with the cable glandssupplied with the boiler.
ACCESS TO THE MODULATING PCB
Front view
Panel board side view
Installation info
22
2.3.2 - POSITIONING OF THE JUMPERS
fig. 23
JUMPERS ON THE DISPLAY PCB
JP4 : GAS TYPE SELECTIONNaturl gas: Jumper on NAT (standard supply position)Liquefied Petroleum Gas: move jumper to LPG position
The standard supply position correspond to the gas type shown on allthe labels within the boiler
JP3 : EXTRNAL TEMPERATURE COMPENSATION FOR OUTER SENSOR
Boiler with outer temperature sensor: jumper onJ
Boiler without outer temperature sensor: jumper on OFF
JP2 : SELECTION OF PUMP OPERATION MODEIf pump has to work continuously: jumper on 1If pump has to stop after an overrun of 5 min since the stop of the heatingdemande: jumper on pos. 2 (standard supply position)
JP1 : CHRONOSTAT FUNCTION (do not change posion of the jumper)This function is not yet available.Jumper on (Standard supply position: for a good working keep the jumper inthis position).
T°C 0 1 2 3 4 5 6 7 8 90 32755 31137 29607 28161 26795 25502 24278 23121 22025 20987
10 20003 19072 18189 17351 16557 15803 15088 14410 13765 1315320 12571 12019 11493 10994 10519 10067 9636 9227 8837 846630 8112 7775 7454 7147 6855 6577 6311 6057 5815 558440 5363 5152 4951 4758 4574 4398 4230 4069 3915 376850 3627 3491 3362 3238 3119 3006 2897 2792 2692 259660 2504 2415 2330 2249 2171 2096 2023 1954 1888 182470 1762 1703 1646 1592 1539 1488 1440 1393 1348 130480 1263 1222 1183 1146 1110 1075 1042 1010 979 94990 920 892 865 839 814 790 766 744 722 701
Relation between the temperature (°C) and the resistance (Ohm) of the heatin temp. sensor SR and the D.H.W. temp. sensorSR. Example: At 25 °C the nominal resistance is 10067 Ohm - At 90 °C the resistance is 920 Ohm.
TABLE OF THE RESISTANCE VALUES ACCORDING TO THE TEMPERATURE OF THE HEATING SENSOR (SR) ANDD.H.W. TEMPERATURE SENSOR (SS)
NAT
GPL
OFF
JP4
JP3J
JP2
JP1
1
2
1
2
POSITIONING OF THE JUMPER
Installation info
23
fig. 23
boilersafetyvalve
Fillingcock
tankdrainingvalve
Adjustableby-pass
RF
GCM
manometer
boilerdrainingvalve
2.4 - FILLING THE SYSTEM
After completing all the connections of thesystem the heating circuit can be filled.This filling operation must be performedwith care as follows:- open the air vents of the radiators and
check that the automatic air vent in theboiler is works properly;
- gradually open the water tap and checkoperation of any automatic air ventsinstalled in the system;
- close the air vents on the radiators assoon as water comes out;
- use the pressure gauge on the boiler tocheck that the pressure has reached thevalue of 0.8/1bar;
- close the water inlet tap and then releasethe air again through the radiator airvents;
- after switching on the boiler and after thesystem has reached the correcttemperature, stop the pump and repeatthe air relief operations;
- let the system cool down and then adjustthe water pressure to 0.8/1 bar.
This must be performed when the systemis cold. Use the temperature and pressuregauge on the boiler to read the pressurevalue of the circuit.
WARNINGThe minimum water pressure switch doesnot give electrical impulse to the burner toignite when the pressure is lower than 0.4bar. The pressure of the water in the C.H.system must not be lower than 0.8/1bar; ifthis value is lower use the water filling tapon the boiler to adjust the pressure.This must be performed when the systemis cold. Use the temperature and pressuregauge on the boiler to read the pressurevalue of the circuit.NB: NB: NB: NB: NB: AfAfAfAfAfter a given period of inactivityter a given period of inactivityter a given period of inactivityter a given period of inactivityter a given period of inactivityand without electrical supply theand without electrical supply theand without electrical supply theand without electrical supply theand without electrical supply thepump could be blocked.pump could be blocked.pump could be blocked.pump could be blocked.pump could be blocked.Before switching on the boiler it isBefore switching on the boiler it isBefore switching on the boiler it isBefore switching on the boiler it isBefore switching on the boiler it isimportant to restart the pump asimportant to restart the pump asimportant to restart the pump asimportant to restart the pump asimportant to restart the pump asf o l l o w s :f o l l o w s :f o l l o w s :f o l l o w s :f o l l o w s :
- loosen the protection screw in thecentre of the pump motor,
- insert a screwdriver in the hole and thenmanually rotate the pump shaftclockwise.
Once the pump has been restarted tightenthe protection screw and check that thereare no water leaks.
WARNINGOnce the protection screw hasOnce the protection screw hasOnce the protection screw hasOnce the protection screw hasOnce the protection screw hasbeen removed a litt le water maybeen removed a litt le water maybeen removed a litt le water maybeen removed a litt le water maybeen removed a litt le water mayleak out. Before replacingleak out. Before replacingleak out. Before replacingleak out. Before replacingleak out. Before replacingthe casing of the boiler dry any wetthe casing of the boiler dry any wetthe casing of the boiler dry any wetthe casing of the boiler dry any wetthe casing of the boiler dry any wets u r f a c e s .s u r f a c e s .s u r f a c e s .s u r f a c e s .s u r f a c e s .
- there are no gas leaks;- the external mains switch is on;- the boiler’s safety valve is not locked;- there are no water leaks.
SWITCHING ON AND OFFTo switch on and off the boiler follow theindications in the “Users’ Instructions”.
- the supply voltage of the boiler is 230 V-50 Hz;
- the system is correctly filled with water(pressure at the gauge 0.8/1 bar);
- any gate valves of the system are open;- the mains gas corresponds to that with
which the boiler has been adjusted;otherwise convert the boiler to use thegas available on site (see:“MODIFICATION FOR OTHER GASES “):this operation must be performedby qualified technicians;
- the gas supply taps are open;
2.5 - STARTING THEBOILER
PRELIMINARY CHECKSBefore starting the boiler check that:- the boiler installation has been made in
accordance with all the applicableregulations concerning water and gasinstallation, smoke evacuation andelectrical installation
- the flue gas exhaust duct and itsterminal are installed correctly: whenthe boiler is switched on theremust be no leakage of anycombustion products from anyseals;
24
Adjustment info
fig. 25
2.6 - ADJUSTING THEBURNER
All the instructions below are for theexclusive use of qualified technicians.All the boilers leave the factory adjustedand tested.If it is necessary to change the adjustmentdue to changes in the gas or adaptation tothe supply network conditions, it will be alsonecessary to re-adjust the gas valve.Attention: during this re-adjustment donot draw any Domestic Hot Water.For this reason it’s necessary to know theboiler operation in service mode.In order to activate this function, push andkeep hold the service push button, on thecontrol panel, for 3 seconds: the servicemode green led will be continuously .lighted( continuous) and the boiler willoperate at the maximum capacity. Thenpush once again the same button: theservice mode green led will start blinking( blinking). The service mode functionremains active for 15 minutes.For cleaning this function before this fixedperiod, push the reset button: the servicemode led will switched off ( off)..To correctly adjust the gas valve, follow thesteps below:
A) Maximum output adjustment- check the value of the supply pressure
(see table NOZZLES - PRESSURES);- Remove the cover (A) protecting the
pressure regulator on the top of themodulating coil.
- Connect a manometer at the outlet gasvalve pressure nipple.
- Activate the service mode function tothe maximum capacity (service mode ledcontinuous lighted).
- When the burner is ON, check that the“MAXIMUM” pressure valuecorrespondsto that indicated on the table “NOZZLES- PRESSURES”:
- Adjust, eventually, the value rotating the“C” nut (fig. 25) by clockwise rotation thegas pressure increases, by anticlockwiserotation the gas pressure decreases.
B) Minimum output adjustment- Operate the boiler in service mode at
minimum output (service mode ledblinking).
- When the burner is ON, check that the“MINIMUM” pressure value corresponds
to that shown on the table “NOZZLESPRESSURES”:
- Adjust, eventually, the value by keepinglocked the ‘’C’’ nut with a 10 mm openwrench and rotating the “B” screw (fig.25) by clockwise rotation the gaspressure increases, by anticlockwiserotation the gas pressure decreases.
C) Ending of basic adjustments- check the min. and max. pressure values
of the gas valve by acting the servicemode
- if necessary make any fine adjustments
- Clear the service mode function bypushing the reset button or switching off.
- Remove the plastic pipe from pressuretest nipple and close the inner screw;
fig. 24
MP
Carry out theadjustment Min.output blocking theposition of theretaining nut “C”with a 10 mm.spanner to avoiduncalibration anduse a scewdriveron the “B screw
A
- Use soap solution tocheck for gasleaks.
Adjustment Max.output “C”retaining nut with10 mm. wrench
SERVICE MODE ATMAX CAPACITY
MIN - MAX MIN - MAX
SERVICE MODE ATMIN CAPACITY
SERVICE MODEDISABLED(BEFORE 15 MINUTES)
MIN - MAX
MP = pressure test nipple
PRESSURE TEST NIPPLE
MODULATING COILGAS VALVE
Outletpressuretestnipple
Inletpressuretest nipple
B = Minimum pressure adjust. screw
(red)
C = Maximum pressure adjust. nut
(wrench 10 mm)
25
Adjustment info
fig. 27
fig. 26
1612 1713 1814 1915 20 21 2522 2623 2724 28
BTFS 28PROPAN
BUTAN
NAT. GAS
5
10
15
20
25
30
35
40
0
Power supply (kW)
Bur
ner p
ress
ure
(mba
r)
CAP
CH - POWER
1612 1713 1814 1915 20 21 2522 2623 2724 28
BTN 28PROPAN
BUTAN
NAT. GAS
5
10
15
20
25
30
35
40
0
Power supply (kW)
Bur
ner p
ress
ure
(mba
r)
2.7 - ADAPTING THERMALPOWER TO THE HEA-TING SYSTEM
With the heating system cold.Connect the pressure gauge to the burner
as shown in fig. 24, switch on the boiler inheating mode and proceed as follows.
- Wait about two minutes to allow the pres-sure to reach the operating value.
- Read the pressure measured and checkthat the thermal power generated by theboiler suits the installation requirements.
- If necessary – but this is not compul-sory – you can regulate the potentiome-ter CH POWER on the modulation boardto adjust the thermal power to the heatingsystem. Turn the potentiometer clockwise(seen from the front) to increase thepressure or anticlockwise to decreaseit.
NoteSince the boiler is the modulating type, itautomatically adapts the thermal powerto the features of the heating system. Byoperating potentiometer CH POWER youeffectively limit the maximum power of theboiler and hence its pickup capacity.
Using the pressure/thermal power graph(fig. 26)
Assuming that the heating system has atotal absorption of 18 kW, using the graphin figure you can determine the maximumpressure at which the burner can be set.
Example 1If the boiler runs on methane gas, adjustthe potentiometer CH POWER to set thepressure to 7,3 mbar for version TN andto 7,1 mbar for version TFS.
Example 2If the boiler runs on butane gas, adjustthe potentiometer CH POWER to set thepressure to 12,5 mbar for version TN andto TFS.
Example 3If the boiler runs on propane gas, adjustthe potentiometer CH POWER to set thepressure to 15,3 mbar for version TN andto 15,5 mbar for version TFS.
GAS PRESSURE BURNER DIAGRAM CORRESPONDING TOTHE SYSTEMS OUTPUT
26
Adjustment info
fig. 28
DUA plus BTN 28
Metano (G20)
Propano(G31)
Butano (G30)
12,5 - 27,9
12,5 - 27,9
12,5 - 27,9
14,5 - 31
14,5 - 31
14,5 - 31
20
37
29
15
15
15
1,30
0,76
0,76
NO
NO
NO
2,3
7,8
5,8
9,7
34,3
27,3
1,53 m³/h
1,13 kg/h
1,14 kg/h
3,28 m³/h
2,41 kg/h
2,44 kg/h
DUA plus BTFS 28
Metano (G20)
Propano(G31)
Butano (G30)
12,9 - 28,8
12,9 - 28,8
12,9 - 28,8
14,5 - 31
14,5 - 31
14,5 - 31
20
37
29
15
15
15
1,30
0,76
0,76
NO
NO
NO
1,9
7,7
6
10,6
35,3
27,6
1,53 m³/h
1,13 kg/h
1,14 kg/h
3,28 m³/h
2,41 kg/h
2,44 kg/h
1
2.8 - MODIFICATION FOROTHER GASES
The boilers are manufactured for the typeof gas specifically required upon order.Any subsequent conversion must beperformed by qualified technicians who willuse the kits supplied by Unical and performthe conversion and required adjustmentsfor correct preparation of the boiler for use.
To convert the boiler from one type of gasto another proceed as follows:
for conversion from natural gas toLPG- remove the main burner;- disassemble the 15 injectors "11111"of the
main burner and replace them with thosewith a diameter corresponding to thenew type of gas (see table “INJECTORS -PRESSURES”);
- reassemble the main burner;- position the jumper on the modulation PCB
in the panel board as shown in fig. 23- remove plug ‘’A’’ (fig. 25) on the gas
valve and fully tighten max pressureadjustment nut ‘’C"
- check the pressure value upstream thegas valve (see table “INJECTORS -PRESSURES”) and adjust the min.pressure of the burner as shown insection " ADJUSTING THE BURNER”, byscrewing the nut "B" to increase orunloosing the nut "B" to decrease theburner pressure.
- check that the burner is functioningproperly;
- check that there are no gas leaks.- tighten and seal the plug “A” (fig. 25) of
the modulating coil;
- when the conversion is completed, fill inthe label, supplied with the kit, with theinformation required and stick it onto theboiler alongside the data plate.
for conversion from LPG to naturalgas- remove the main burner;- disassemble the 15 injectors of the main
burner and replace them with those witha diameter corresponding to the newtype of gas (see “INJECTORS -PRESSURES”);
- reassemble the main burner;- get access to the modulating PCB inside
the panel board and position the jumpershown in thefig. 28;
- remove plug ‘’A’’ (fig. 25) from the gasvalve modulating coil and adjust themaximum and minimum output sdescribed in paragraph 2.6;
NAT
GPL
JP4
- check that the burner is functioningproperly;
- check that there are no gas leaks.- tighten the screw “A” of the plug of the
gas governor (fig. 25);- when the conversion is completed, fill in
label, supplied with the kit, with theinformation required and stick it onto theboiler alongside the data plate.
NOZZLES - DIAPHRAGMS - PRESSURES - GAS FLOW RATESThe pressures at the burner indicated in the following table must be checked after the boiler has been operating for 3minutes.
Type ofgas
Supplypressure(mbar)
No. ofNozzles
ØDiaphragme
(mm)
ØNozzles
(mm)min.
(mbar)max
(mbar)
Burner pressure
max.min.
Gasconsumption
Outputmin. - max
(kW)
Inputmin. - max
(kW)
Type ofgas
Supplypressure(mbar)
No. ofNozzles
ØDiaphragme
(mm)
ØNozzles
(mm)min.
(mbar)max
(mbar)
Burner pressure
max.min.
Gasconsumption
Outputmin. - max
(kW)
Inputmin. - max
(kW)
POSITIONING OF THE JUMPER
27
Service info
2.9 – FAULT FINDING CHART AND POSSIBLE SOLUTIONSIn case of fault lamp lighting depress the Reset push button and, while kipping itdepressed, look at the error code given by the flashing leds.Note: The error code is given by the combination of two, three, four of five leds,flashing on the temperature scale.
SIGNIFICATION OF THE ERROR CODEFault on the outer temperaturesensor (if connected)
POSSIBLE SOLUTIONThe control of the flow temperature bythe outer sensor is non active. Callthe After Sale Service
BOILER STATUSThis fault does not cause the lockingof the boiler.
SIGNIFICATION OF THE ERROR CODEFaulty flame control PCB
POSSIBLE SOLUTIONReplace the ignition and/or modulating
PCB
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEFault on the gas valve modulationsystem (coil interrupted)
POSSIBLE SOLUTIONReplace the gas valve modulationcoil, after checking of the harness,the supply tension and the gaspressure.
BOILER STATUSChaudière fonctionnant à la puissancemini.
SIGNIFICATION OF THE ERROR CODEThe air pressure switch is faulty or inshort circuit (only for TFS version)
POSSIBLE SOLUTIONInspect the air pressure switchoperation
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEToo high boiler temperature
POSSIBLE SOLUTIONMake sure the pump is properlyoperating and the heat exchanger isclean inside
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERRORCODEFault on the smoke evacuationsystem; after 15 min there is anautomatic reset.
POSSIBLE SOLUTIONFor TN version: check thechimney draughtFor TFS version: ascertain thegood operation of the fan and itsair pressure switch.Depress the Reset button.
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEThe water pressure within theinstallation is below 0.5 bar
POSSIBLE SOLUTIONReinstate the water pressure throughthe filling valve (accessible also tothe user) and look for possible waterleaks. If the problem is not solvedcall the After Sale Service.
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEProbable freezing of the primary heatexchanger; temperature below 2°Cdetected by the SR or SS sensors.
POSSIBLE SOLUTIONCut the power supply, close the gasvalve and call the After Sale Service.
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEFault on the DHW temperature sensor(SS)
POSSIBLE SOLUTIONAscertain that the SS sensor has theright resistance values shown on thetable of the resistance values and itharness is correct (see table on page14)
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEFault on the CH temperat. sensor (SR)
POSSIBLE SOLUTIONAscertain that the SR sensor has theright resistance values shown on thetable of the resistance values and itsharness is correct (see table on page16).
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEAlteration of factory parameters
POSSIBLE SOLUTIONNone. Replace the modulating PCB
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEFault on the modulation system of thegas valve.
POSSIBLE SOLUTIONCheck first the modulating coil or itsharness are not earthed or in shortcircuit: if this is the case replacethem. If no result, replace themodulating PCB.
BOILER STATUSThe boiler is in lockout position
SIGNIFICATION OF THE ERROR CODEMain PCB (modulation) is damaged.
POSSIBLE SOLUTIONCut and reinstate the power supply tothe boiler: if no result, replace themain PCB.
BOILER STATUSThe boiler is in lockout position
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
SIGNIFICATION OF THE ERROR CODEIntervention of the safety thermostat
POSSIBLE SOLUTIONMake sure the water is circulatingthrough the heat exchanger and thesafety thermostat TL and its harnessare not interrupted. Check as well theCH temperature sensor (SR).
BOILER STATUSThe boiler is in lockout position
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
28
Service info
3
C
A
P fig. 29
M
N
B DLIHG
O
E
F
®
plusDUA
MAX
MAX
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
-20 °C 10 °C
0 °C-10 °C
MIN - MAX
A = Mode selector: Heating only- Heating + D.H.W.- Antifrost - D.H.W. only
B = Heating temperature adjusting knobC = D.H.W.temperature adjusting knobD = ThermometerE = Signal lamp of heating temperature scale
F = Signal lamp of D.H.W. temperature scaleG = Power ON signal lamp (antifrost)H = Burner in operation signal lampI = Fault indication lampeL = Burner lockout warning lampM = Manual reset button
3.1 - PANEL BOARD
N = Special functions button (for service purposes)O = Special functions signal lampe
(for service purposes)P = Outer temperature selector (opérational only
if outer temperature sensor is fitted).
USER'S INSTRUCTIONS
By acting on the selector the operation modeis choosen :
CENTRAL HEATING ONLYWith the mode selector in this position theboiler works for Central Heating only.
CH & DHWWith the mode selector in this position theboiler works for Central Heating andDomestic Hot Water production
MODE SELECTOR:CH ONLY - CH & DHW -ANTIFROST - DHW ONLY
D.H.W. TEMPERATUREADJUSTING KNOB
With this knob it is possible to set themaximum desired temperature in the boiler.The setting range of this temperature isbetween a minimum of 35°C and a maximumof 65°C.
By rotating COUNTER-CLOCKWISE thisknob a minimum temperature of 35°C isreached.
By rotating completely CLOCKWISE thisknob a maximum temperature of 65°C isreached.
D.H.W. onlyWith the mode selector in this position theboiler works for D.H.W. only.
HEATING TEMPÉRATUREADJUSTING KNOB
With this knob it is possible to set themaximum desired temperature in the heatingcircuit.The setting range of this temperature isbetween a minimum of 35°C and a maximumof 85°C.
By rotating COUNTER-CLOCKWISE thisknob a minimum temperature of 35°C isreached.
By rotating completely CLOCKWISE thisknob a maximum temperature of 85°C isreached.
MAX
MAX
ANTIFROSTWith the mode selector in this position theboiler is not in operation: the antifrostprotection on the heating circuit only isoperational.The antifrost protection system isoperational only if the boiler is feededwith gas and electrical supply.
29
Service info
MANOMETERIt shows the water pressure inside theheating circuit, whose value, in coldcondition,should not be lower than 0,8/1 bar.
Note that if the pressure decreases below0,4/0,6 bar the boiler goes into lockout, notallowing the ignition of the burner.In this case reinstate the minimum requiredfilling pressure (0,8/1 bar) following theinstructions given on figure 23.
POWER ON SIGNAL LAMP
The function of this GREEN lamp is to showthat the power to the boiler is ON; to get theboiler ON, position the "A" switch on "I"position.
BURNER IN OPERATIONSIGNAL LAMPThe function of this GREEN lamp is to showthe proper operation of the burner
FAULT INDICATION LAMPEThe function of this RED lamp is to show anoperation fault.By depressing on the RESET button (N) it ispossible to see the error code given by thecombination od the flashing leds. Seeparagrapf 2.9 "FAULT FINDING ANDREPARATIONS".
BURNER LOCKOUT WARNING LAMPLa fonction de ce témoin (ROUGE) est designaler l’intervention du dispositif de miseen sécurité du brûleur.
MANUAL RESET BUTTON
This button allows the re-establishment ofthe boiler operation after a lockout of theburner control and to know the error codegiven by the combination of the flashing leds(burner lockout warning lamp). (témoin dedéfaut allumé).
SPECIAL FUNCTIONS BUTTON(FOR SERVICE PURPOSES)This button allows the activation of theSERVICE mode. (see paragraphe 2.6"Burner adjustment). To reset this modebefore the expiring time depress on themanual reset button.WARNING! OPERATIONS RESERVEDONLY TO SERVICE TECHNICIANS.
SPECIAL FUNCTIONS LAMP(FOR SERVICE PURPOSES)The function of this GREEN LAMP is toindicate the activation of the SERVICE mode:Continuous ON led = Max output for 15 min.Flashing led = Minimum output for 15 min.
OUTER TEMPERATURESELECTOR (OPERATIONALONLY IF OUTER SENSOR IS FITTEDSi the kit outer sensor is fitted, it is possible,through this button, to set an outertemperature value between -20°C(completely counterclockwise) and 10°C(completely clockwise).If the outer temperature is equal or lowerthan the one selected by the selector "Q"the boiler temperature will be the one adjustedon the "C" button.If the outer temperature is higher than theone selected by the selector "Q"the boilertemperature will decrease linearly,independently from the one adjusted on the"C" button.WARNING! OPERATIONS RESERVEDONLY TO SERVICE TECHNICIANS.
MODULATING ROOMTHERMOSTATWarning: The mounting of a modulatingroom thermostat imply the modification ofthe functions of the heating temperatureadjuster (C) and D.H.W. temperatureadjuster (D).Refer to the specific instructions suppliedwith the modulating thermostat.
F
G
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
Through the thermometer scale of the panelboard it is possible to verify:on the L.H. side scale the flow températureof the heating circuit, (F green led ON); onthe following example the temperature willbe 80°C.
on the R.H. side scale the outlettempérature of the D.H.W. (G green led ON);on the following example the temperaturewill be 55°C.
On both cases, when two leds are ON thetemperature value will correspond to thehalf of temperature difference betwee thetwo ON leds.
80° 60°
65°
70° 55°
60° 50°
50° 45°
40° 40°
30° 35°
20°
Manometer
THERMOMETER
75°C 57,5°C
30
Service info
3.3 - IMPORTANTSUGGESTIONSAND NOTES
According to the national laws the service ofthe heating appliances is compulsory.
This service consistes, as a minimum, of anannual systematic visit, during which theserviceman will control the safety equipmentand will make the cleaning of the combustioncircuit of the boiler.
This annual visit must be conducted withinthe frame of a service contract, whosedifferent variants can include all or part ofthe interventions concerning thedeplacement, the manpower and the spareparts.
Only persons professionally qualified canperform interventions on the gas valveadjustment.
Check regularly the filling pressure of theheating system through the manometer, and,if necessary, reinstate the minimumpressure value (0.8/1 bar in cold condition).
When the boiler stays without been used fora long period, before putting the boiler inoperation make sure the pump is not jamed.To make it free, if necessary, remove theplug on the motor axis, put a screwdriver inthe slot foreseen on the motor shaft end andtry to rotate it manually, clockwise.
Once this dejamming operation has beenconcluded, replace the protecting plug andmake sure there are no water leaks.
This operation has to be made,preferably, by the Unical Service Centercharged for maintenance of the boiler.
The hardness of the domestic waterconditions the frequency of the cleaning ofthe coil heat exchanger.The convenience of water treatment mustbe examined on the base of the watercharacteristics.
N.B. If the water hardness is higher than20°f (french), the adoption of a water softeris strongly recommended.
FROST PROTECTION
If the boiler is connected to the mains andthe main switch "A" is in the antifrost position,the heating pump is put into operation, for afew seconds, every day, in order to impedethe pump jamming.
The boiler is equipped with an automaticantifrost protection system: this system isoperational when the temperature detectedby the flow temperature sensor falls below7°C by switching on the heating pump.
Below 5°C, the burner and the pump areswitced on, untill the temperature of 15°C, isreached with a 15 min. maximum time limit.
After that, burner and pump are swiched off.This cycle will be repeated, if necessary.
3.2 - IGNITION ANDEXTINCTION
BOILER IGNITION
Position the main switch"A" on "I" position .
SUMMER mode (D.H.W.production only)Select the SUMMER operation mode actingon the selector "B".Turn the temperature adjusting knob "D" onthe desired value.By CLOCKWISE rotation the maximumtemperature is achieved.
WINTER mode (Heating and D.H.W. production)Select the WINTER operation mode actingon the selector "B".Turn both, the heating temperature adjustingknob "C" and the D.H.W. temperatureadjusting "D" on the desired values.
By CLOCKWISE rotation the maximumtemperature is achieved.
HEATING mode (Heating only is activated)Select the HEATING only operation modeacting on the selector "B".Turn the temperature adjusting knob "C" onthe desired value.By CLOCKWISE rotation the maximumtemperature is achieved.
The boiler gives always the priority to theD.H.W. mode (see SUMMER operation).Once the D.H.W. demande is satisfied, if theroom thermostat asks for heat, the boilergoes to HEATING mode.During the heating operation mode the boilerswitches ON and OFF controled by theroom thermostat and by the electronic P.C.B.of the panel board.The electronic control built-in the panelboard, depending on the detectedtemperature difference between the oneadjusted on the knob and the one mesured,
puts the burner into operation plus or minusfrequently in order to satisfy very quicklythe heat demande by the room thermostat.
ANTIFROST modeSelect, by acting on the selector "B" the
position (Antifrost)
NB: The signal lamp "H" is ON..
COMPLETE EXTINCTION OF THEBOILERCut the elctrical power supply to the boileracting on the main switch "A" (position O).
If, for any reason (lack of gas or electricity),the antifrost protection system does notwork and the temperature detected by theflow temperature sensor falls below 2°C, theoperation of the burner is automaticallyinhibited until the detected temperature risesabove 5°C.
This system protects the boiler and the even-tual DHW tank from freezing, but it does notprotect the C.H. and sanitary circuits.Moreover special anti-freeze products sui-table for the multimetal installations can ef-fectively protect the heating system from thefreeze.Do not use the anti-freeze products forcar's engines because they can damagethe water sealing gaskets.
NoteThe anti-freeze protection device systemwill start running only if both the electricaland gas supply of the boiler are leftconnected.
Information for the userThe user can gain access only to theparts of the boiler which can be reachedwithout the need of tools.It is therefore forbidden to disassemblethe outer casing of the boiler and tam-per with the internal parts.
31
Service info
AG S.P.A.46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - fax 0376/660556
www.unical.ag - [email protected]
The Unical decl ines every responsibi l i ty for the possible inaccuracies i f owed to errors of transcript or press. Alsoreserves the right to bring those changes that it will hold necessary to it own products or profits, without jeopardizing itsessent ial character ist ics.
