Installation Manual - Unical Lattner Condensing Hot Water Boilers

ALKON 9000332917 - 1 st edition - 06/08INSTALLATIONAND SERVICINGMANUAL

General Information5 - SAFETY WARNINGSWARNING!The installation, adjustment, and servicing of this appliance must be carried out by a competent person andinstalled in accordance with the current standards and regulations. Failure to correctly install this appliancecould cause injury to persons, animals or damage to property. The manufacturer shall not be held liable forany injury and/or damage.DANGER!Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICALrecommends drawing up a service contract. Bad or irregular servicing could compromise the safe operationof the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall notbe held liable.Modifications to parts connected to the applianceDo not carry out any modifications to the following parts:- the boiler- to the gas, air, water supply pipes and electrical current- to the flue pipe, safety relief valve and its drainage pipe- to the constructive components which influence the appliance’s safe operationWARNING!When tightening or loosening the screw pipe connections, use only adequate fork spanners.The improper use and/or the use of inadequate equipment can cause damages (for example water or gasleakages).WARNING!Indications for appliances operating with propane gasEnsure yourself that before installing the appliance the gas tank has been purged.For a correct purging of the tank contact the liquid gas supplier or a competent person who has been legallyauthorized.If the tank has not been correctly purged problems could occur during ignition.If this occurs contact the liquid gas tank’s supplier.Smell of gasIf you smell gas follow these safety indications:- Do not turn on or off electrical switches- Do no smoke- Do not use the telephone- Close the main gas tap- Open all windows and doors where the gas leakage has occurred- Inform the gas society or a company specialized in installing and servicing heating systemsExplosive and easily inflammable substancesDo not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the roomwhere the appliance has been installed.4

1.6 DATA BADGECE Marking- The CE marking documents that the boilers satisfy:- The essential requirements of the Directive regarding gas appliances (Directive90/396/CEE)General Information- The essential requirements of the Directive regarding electromagnetic compatibility(Directive 89/336/CEE)- The essential requirements of the Efficiency Directive (Directive 92/42/CEE)- The essential requirements of the low voltage Directive (Directive 73/23/CEE)®123546A7 891110121314B151716181920CD21 2224 25 2623E2728LEGEND:1 = Year of CE certification issue2 = 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 classA = 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. temperatureB = 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 13203-117 = (R factor) N° taps based on the quantity of water declared EN13203-118 = (F factor) N°stars based on the quality of water declaredEN 13203-119 = (PMW) Max. pressure D.H.W. system20 = (T max) Max. temperature D.H.W systemC = Electrical features21 = Electrical power supply22 = Consumption23 = Protection gradeD = Countries of destination24 = Direct and indirect country of destination25 = Gas family26 = Supply pressureE = Factory setting27 = Adjusted for gas type X28 = Space for national brands5

General Information1.7 - GENERAL WARNINGSThis instruction manual is an integral and indispensablepart of the product and must be retained by the person incharge of the appliance.Please read carefully the instructions contained in this manualas they provide important indications regarding the safeinstallation, use and servicing of this appliance.Keep this manual in a safe place for future reference.The installation and servicing must be carried out inaccordance with the regulations in force according to themanufacturer’s instructions and by legally competentauthorized persons.By a competent person, we imply a person who has a specifictechnical qualification in the field of components for centralheating systems for domestic use, domestic hot waterproduction and servicing. The person must have thequalifications foreseen by the current laws in force.Bad or irregular servicing could compromise the safeoperation of the appliance, and could cause injury to persons,animals or damage to property. The manufacturer shall notbe held liable for any such injury and/or damage.Before carrying out any cleaning or servicing turn off theelectrical supply to the boiler by means of the ON/OFF switchand/or by means of the appropriate shutdown devices.In the event of failure and/or faulty functioning of the appliance,switch off the boiler. Do not attempt to make any repairs:contact qualified technicians.Any repairs must be carried out by Unical authorizedtechnicians and using only original spare parts. Nonobservanceof the above requirement may jeopardize thesafety of the appliance.To guarantee the efficiency and correct functioning of theappliance it is indispensable to have the boiler servicedannually by a qualified person.If the boiler remains unused for long periods, ensure that anydangerous parts are rendered innocuous.If the appliance is sold or transferred to another owner or ifthe present user moves home and leaves the applianceinstalled, ensure yourself that the manual always follows theappliance so that it can be consulted by the new owner and/or installer.Only original accessories must be used for all appliancessupplied with optionals or kits (including electrical ones).This appliance must be used only for the purposes for whichit has been expressively designed. Any other use shall beconsidered incorrect and therefore dangerousDo not obstruct the intake/outlet terminal ducts.6

2TECHNICAL FEATURESAND DIMENSIONSTechnical features and dimensions2.1 - TECHNICAL FEATURESThe ALKON 90 boiler is a low water content thermal element(about 10 lt), with a built-in premix gas burner, for heating only.It is mainly used as element for the modular boilers in cascade(max 4 boilers).PECULIAR CHARACTERISTICS:1) modular structure to tall integration.2) mainly for outdoor installation: IPX5D.3) prearranged for quick installation ‘’ Plug and Play ‘’ alsoin cascade of up to 4 modules.4) modulating pump driven by the electronic PCB, for themaximum efficiency in condensation5) optional regulator for the management of the single andcascade modules and the thermal loads (remotecontrollable)6) modulation ratio of the single module7) control for every single module, with display anddiagnosticOptional regulator for the management of the single or cascademodules and of the remotable thermal loads These boilershave a normal input of 90 kW and they have been approvedin order to operate with natural gas or LPG in all the Europeancountries, according to the UNICAL instructions.The ALKON boiler is supplied complete with all the safetyand control devices in accordance with all the currentregulations and its technical and functional features complywith the regulations prescribed by the law No. 1083 dated 06/12/1971 concerning safety and use of combustible gas andwith the requirements prescribed in the law No. 10 dated 09/01/1991 and any subsequent amendments – Gas Directive90/396 CEE – Efficiency Directive 92/42 CEE –Electromagnetic Compatibility Directive 89/336 CEE – LowVoltage Directive 73/23 CEE.The boilers of the ALKON range are rated in the class 4 starcategory for efficiency, according to the Directive 92/42 CEEand D.P.R. 660; moreover they are rated in Class 5 for theirN0x emissions in accordance to the Standards EN 297 andEN 483.DESCRIPTION OF COMPONENTS AND FEATURES1 Aluminium heat exchanger/condenser;2 premixed combustion group working at constant airgasratio3 Safety limit thermostat;4 Flow temperature sensor;5 Return temperature sensor;6 Automatic air vent;7 Control panel with electrical protection IP X5D;8 Condensate drain siphon;9 Electronic ignition;10 Flame modulation in function of the absorbed power;11 Pump overrun function;12 modulating pump13 eBUS connection14 E8 regulator (optional)15 BCM (optional)16 ON/OFF switch17 temperature adjustment in heating mode between 30and 85°C;What to order for 1x ALKON 90:• 1 - boiler ALKON 90 MASTER 41010081(NG)– 41010082 (LPG)What to order for (2 up to 4) ALKON 90:• 1/2/3 - boilers ALKON 90 SLAVE41010046 (NG) – 41010048 (LPG)1 – outdoor cover kit for 2 boilers 00361522outdoor cover kit for 3 boilers 00361523outdoor cover kit for 4 boilers 00361524OPTIONAL KITS in general:• Additional safety kit + manifolds 00361528• Additional protection and control kit 00361316• External frame for safety devices kit xxxxxxxxxExpansion vessel supporting kit 00361529• E8 regulator kit 00361332• Box for E8 regulator kit 00361359• BM8 remote control kit 00361358• BCM panel kit 00361602• Condensate neutralizing kit NH500 00361551• E8 zone expanding kit 00361545Installation of 1x ALKON 90• Hydraulic header connection kit (DN 65) 00361484• Hydraulic header kit up to 180 kW 00361499• Y filter kit (DN65) 00361488Installation of 2x ALKON 90 in cascade• Hydraulic header connection kit (DN 65) 00361484• Hydraulic header kit up to 180 kW 00361499• Y filter kit (DN65) 00361488Installation of 3x or 4x ALKON 90 in cascade• Hydraulic header connection kit (DN 100) 00361487• Hydraulic header kit up to 450 kW 00361500• Y filter kit DN100 00361489Smoke kit for indoor installation:• Smoke thermostat kit for cascade installation 00361451• Expansion smoke thermostat kit for base cascade00361339• Expansion smoke thermostat kit for 3 boilers in cascade00361340• Expansion smoke thermostat kit for 4 boilers in cascade003613417

Technical features and dimensions2.2 - DIMENSIONSFRONT VIEW119LEFT SIDE VIEW1300M DN 80G DN 50448315285149SCR DN 80129251287,5430607VIEW FROM ABOVE93513R CH safety system return DN 80M CH flow system DN 80G Gas Inlet DN 50Sc Outlet condensate drain siphon Ø 328

Technical features and dimensionsDIMENSIONS ALKON 90 master + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT2313995500130217121500DIMENSIONS ALKON in 90 BATTERY (n.2 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT279514765001302171215009

Technical features and dimensionsDIMENSIONS ALKON 90 in BATTERY (n.3 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT3415195838982440500130215001785500130217851500DIMENSIONS ALKON 90 in BATTERY (n.4 boilers) + KIT SAFETY DEVICES + HYDRAULIC HEADER +Y FILTER KIT10

Technical features and dimensions2.3 - MAIN COMPONENTSFLUEOUTLETPIPE Ø100AIR INTAKEOPENINGAIRVENTVALVEIGNITIONELECTRODEMODULATINGFANGAS VALVEMANUALAIR VENTOVERHEATTHERMOSTATFLAMEDETECTIONELECTRODEALUMINIUM HEATEXCHANGER/CONDENSERCONDENSATESENSOR NIVEAUMIN. GASPRESSURESWITCHCONDENSATEDRAINFLOWTEMPERATURESENSORMIN. WATERPRESSURESWITCH3 WAY VALVE(FLOW)RETURNTEMPERATURESENSORFLOW MANIFOLDDN 80GAS MANIFOLDDN 50MODULANTINGPUMPRETURNMANIFOLDDN 802 WAY VALVE(flow stop)RETURNBOILERDRAINCOCK11

Technical features and dimensions2.4 - BOILER WATER CIRCUIT DIAGRAM98171011718125 61341714321RMG15161 Non return valve2 Return gate valve3 Modulanting pump4 Flow gate valve (the way to the siphonis open in order to drain theboiler)5 CH flow temperature sensor6 CH return temperature sensor7 Overheat thermostat8 Manual air vent9 Air vent valve10 Heat exchanger11 Fan12 Premix13 Condensate niveau sensor14 Gas valve15 Gas cock16 Gas pressostat17 Condensate drain siphon18 Flue outlet19 Pressure switch against lack ofwaterMGRC.H flowGas supplyC.H. return12

2.5 - PERFORMANCE DATA ACCORDINGTO STANDARD UNI 10348Minimum heat imputNominal heat imputNominal heat outoutMinimum heat outputEfficiency at full load (100%)Required efficiency at full load (100%)Efficiency at 30% part loadRequired efficiency at part load (30%)Nominal heat output in condensing modeMinimum heat ouput in condensing modeEfficiency at nominal load (100%) in condensing modeRequired efficiency (100%) in condensing modeEfficiency at 30% part load in condensing modeRequired efficiency at part load (30%) in condensing modeNumber of stars (according to CEE 92/42 and D.P.R. n° 660)Combustion efficiency at nominal load (100%)Combustion efficiency at part load (30%)Stand-by losses (min-max)(*) Flue gas temperature tf-ta (max)Flue gas mass flow rate (min-max)Air excess λCondensate production maxCO 2(min - max)CO at 0% of O (min - max)2N0x (value according to EN 297/A3 and EN 483N0x classFlue losses with burner in operation (min-max)Flue losses with burner off(*) Room Temperature = 20°C2.6 - GENERAL FEATURESAppliance’s family gas categoryMin. water flow rate in CH circuit (Δt 20 °C)Min. pressure in CH circuitMax. pressure in CH circuitMin. dynamic gas pressure (natural gas)Water content in primary circuitMax operating temp. in CH modeMin operating temp. in CH modeTotal volume CH expansion vesselTotal pre-loading expansion vesselMax water content CH circuit (calculated for a max temp. of 82°C)Min flow rate DHW circuitMin. DHW inlet pressureMax DHW inlet pressureDHW specific flow rate ( t 30 °C)DHW flow restrictorDHW production in continuous operation with t 45 KDHW production in continuous operation with t 40 KDHW production in continuous operation with t 35 KDHW production in continuous operation with t 30 K (*)DHW production in continuous operation with t 25 K (*)DHW adjustable temperatureElectrical supply /power consumptionFuse ratingMaximum absorbed power (with optional modulating pump)Electrical protectionNet weightTechnical features and dimensionsFor information regarding the adjustment of: INJECTORS - BURNER PRESSURES – DIAPHRAGMS– OUTPUTS – GAS CONSUMPTIONS please refer to the paragraph ADAPTMENT TO THE USE OFOTHER GASES.ALKON 90kW 22kW 90kW 87,5kW 21,1% 97,26% 96,88% 105,2% 94,83kW 93,6kW 24,0% 104,0% 92,97% 108,64% 98,97n. 4% 98,15% 98,31% 2,29 - 0,90°C 38,5g/s 8,7 - 39,1% 19,4kg/h 14,54% 8,8 - 9,6mg/kWh 21,5 - 104,4mg/kWh 35,625% 1,69 - 1,85kW 0,235l/minbarbarmbarl°C°Clbarllbarbarl/min.l/min.l/min.l/min.l/min.l/min.l/min.°CV-HzA (F)WIPkgALKON 90II 2H3P15,140,5814108530--------------230/504303X5D13513

Instructions for the installer3INSTRUCTIONS FORTHE INSTALLER3.1 - GENERAL WARNINGSWARNING!This boiler has to be destined for the use forwhich it has been expressively designed for.Any other use shall be considered improperand therefore dangerous.This boiler is designed to heat water at atemperature inferior to boiling point at anatmospheric pressure.WARNING!These appliances are exclusively designedto be installed inside adequate boiler rooms.Therefore these appliances must not beinstalled and operated externally. An outdoorinstallation could cause malfunctioning andcould be dangerous. For externalinstallations, it is recommended to useappliances which are specifically designedand predisposed for this purpose.Before installing the boiler the following pointshave to be carried out by a competent engineer:a) The whole system should be thoroughlyflushed in order to remove any residual dirt orgrime which could compromise the correctboiler operation.b) Check that the boiler has been preset foroperating with the gas type available.This is verifiable via the indication on thepackaging and on the data badge;c) Check that the chimney/flue pipe has anadequate draught,does not have anyconstrictions, and that no other appliance’sflue outlets have been fitted, unless the chimneyis serving more than one heating appliance,according to the specific standards andregulations in force.The connection between the boiler andchimney/flue outlet can be made onlyafter thisverification has been carried out.WARNING!In rooms where there is the presence ofaggressive vapours or dust the appliancemust operate independently from the airpresent in the boiler’s location room!WARNING!The appliance must be installed by a qualifiedengineer, who complies to the technicalprofessionalrequirements according to thelaw 46/90 and whom, under his ownresponsibility, guarantees the compliance ofthe standards according to the latestregulations.WARNING!The appliance must be installed only on aclosed, vertical flat wall, made of noncombustible material.The appliance must be positioned so that atleast the minimum operational and servicingclearances are provided.The boiler must be connected to a heatingsystem which is compatible to its performanceand output.14

Instructions for the installer3.2 - STANDARD CODES FORINSTALLATIONThe appliance must be installed in compliance to theinstructions contained in this manual.The installation must be carried out by a competent qualifiedengineer, whom will assume the responsibility of complyingto all the local and/or national regulations published in theofficial publications, as well as all the applicable codes ofpractice.Before installing the appliance please contact the gas supplycompany.The installation must be carried in accordance to the codesof practice, the regulations and the requirements herebyindicated which constitute an indicative list, but not a completeone, as these continue to undergo evolve devolpments.National installation regulations:Gas plants for domestic use fed by network distributionStandard UNI-CIG 7129Gas plants for domestic use not fed by network distributionStandard UNI-CIG 7131Law dated 5.03.90 n°46Law dated 9.01.91 n°10Other applicable statutory requirements:Law 1083/71 (ref. Standard UNI for the design, installationand maintenance).Law 46/90 and D.P.R. 447/91Law 10/91 and D.P.R. 412/93 and subsequent amendmentsD.M 1.12.1975Moreover, the boiler must be installed in accordance to all theregulations regarding the boiler room, the building regulationsand the prescriptions regarding central heating plants in forcein the country the boiler is installed.The appliance must be installed, commissioned and servicedaccording to the regulations in force. This is also valid for thehydraulic system, the flue outlet system and the boiler locationroom.3.3 - PACKAGINGThe ALKON 90 boiler is supplied fully assembled in a strongcardboard box.After having unpacked the boiler check that it isintact and undamaged.Keep the packaging material (cardboard box,plastic bags, polyester protection etc.) out ofthe reach of children as they can bedangerous.UNICAL refuses all liability for injury to persons,animals or damage to property deriving fromnot having respected the above mentionedrecommendations.143In the packaging, in addition to the boiler, you can also findthe following contents:- Service logbook- Instruction manual for the person in charge of theappliance- Instruction manual for the installer and servicing personnel- Warranty- Nr. 2 spare parts request couponsEnvelope with adjustable feet, lock and key(placed on the pallet, inside the boiler).54,5A67ARemove the ‘’A’’ to remove the boiler from pallet.15

Instructions for the installer3.4 - LOCATION OF BOILER INSIDE ABOILER ROOMMounting of the adjustable feetThe boiler must be installed in accordance with the directionsindicated in the most recent Standards and legislationsregarding boiler rooms, installation of heating and hot watersystems, boiler ventilation, chimney’s capable of dischargingthe products of combustion of condensing boilers and anyother applicable requirement.The boiler will be placed on a flat and sufficiently strong basement,,with dimensions not smaller than the ones of the boiler.After installation the boiler will result perfectly horizontal andvery stable ( in order to reduce vibrations and noise).InstallationWhen choosing the installation place, the following itemshave to be considered:- To grant an easy access to the boiler components in orderto facilitate the ordinary and extraordinary service operations.- The floor should not be of flammable material.- If the floor is flammable an insulation material, with thecapacity to withstand to the fire for at least 120 min shouldbe placed between the boiler and the floor and will protrudede boiler basement of 0.5 m all around.Before positioning the boiler, screw down theadjustable feet supplied with the boiler.Mounting of the lockerThe casing front panel is hinged on the R.H.side. The hinges ‘’A’’ are factory fitted on theR.H. side of the frame. For the introduction ofthe cocker remove the precut disk ‘’B’’ witha screwdriver and fit the cocker as shown inthe figure.In case the casing front panel needs to be hinged on theL.H. side, deplace the hinges ‘’A’’ from R.H. to L.H. side; thenremove the precut disk ‘’C’’ from the front panel and fit thelocker as shown in the figure.INTERNALSIDE OFTHECASINGBEXTERNALSIDE OFTHECASINGCBAA16

3.5 - INSTALLATION ON EXISTINGHEATING SYSTEMSWhen the appliance is installed on existing systems, ensureyourself that:- The flue outlet pipe is suitable for condensing boilers, forthe temperature of the products of combustion, calculatedand manufactured according to the regulations in force. Itmust be installed as much as possible in a straight line,tested for soundness, insulated and must not have anyocclusions or restrictions.- The flue outlet pipe has a connection for the discharge ofcondensate.Instructions for the installer- The boiler room has a suitable outlet for the discharge ofcondensate produce by the boiler.- The electrical system has been fitted in compliance to thespecific norms and the work has been carried out by acompetent person.- The circulation pump’s output, the head and flow directionare suitable.- The gas feeding supply pipe and the eventual tank areconstructed according to the regulations in force.- The expansion vessels assure the total absorption of thedilatation of the fluid contained in the system.- The system has been cleaned of impurities and lime scale.3.6 - GAS CONNECTIONThe gas supply pipe must be connected to the boiler via therespective pipe connection ¾” as indicated on page 13.The gas supply pipe must have a section which is identical orgreater then the one used on the boiler and must assure acorrect gas pressure.It is however important to comply with the specific norms andrequirements in force, foreseeing on-off valves, gas filter,anti-vibrating joint etc.Before commissioning an internal gas distribution systemand therefore before connecting it to the gas meter, thecomplete installation must be tested for gas soundness.If any part of the system is concealed from view the gassoundness test must be carried out before covering the pipes.DANGER!The gas connection must be carried out by aregistered engineer who will have to respectand comply to the regulations in force and tothe requirements indicated by the local gassupplier. An incorrect installation couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any injury and/or damage.Before installing the boiler it is recommendedto thoroughly clean all the supply piping in orderto remove any eventual residual grime whichcould compromise the boilers correctfunctioning.If you smell gas:a. Do not turn on or off electrical switches, usethe telephone or any other object which canprovoke sparks;b. Open all doors and windows in order toallow fresh air to enter and purify the room;c. Close all gas cocksd. Contact a service engineer, qualifiedinstaller or the gas supply company.As a safety measure against gas leaks, Unicalrecommends installing a surveillance andprotective system made up of a gas leakagedetector combined with an on-off selenoidvalve on the gas supply line.1. On-off gas supply valve2. Double membrane regulator3. Gas filter4. Anti-vibrating joint5. Selenoid valve6. On-off cockEXAMPLE OF A GAS SUPPLY SYSTEMINSIDEBOILERROOMOUTSIDEBOILERROOM1 2 3 4 65 617

Instructions for the installer3.7 - FLOW AND RETURN PIPE CONNEC-TIONSThe CH flow and return circuits have to be connected to theboiler via the respective connections 3" M and R (DN 80) asindicated on page 8.When determining the size of the CH circuit pipes it isessential to bear in mind the pressure losses induced by anyof the system’s components and by the configuration of thesame system.The route of the piping has to be conceived taking all thenecessary precautions in order to avoid air locks and tofacilitate the continuous purging of the system.Non-observance of these instructions could cause injuryto persons, animals or damage to property. Themanufacturer shall not be held liable for any such injuryand/or damage.Ensure yourself that the system’s piping is notused as the earth clamps for the electrical ortelephonic system. They are absolutelyunsuitable for this use. In a short time this couldcause serious damage to the piping, boilerand radiators.WARNING!Before installing the boiler we recommendthat the system is flushed out with a suitableproduct in compliance to the norm UNI-CTI8065, in order to eliminate any metallictooling or welding residues, oil and grimewhich could reach the boiler and affect theproper running of the boiler.WARNING!IT IS ABSOLUTELY FORBIDDEN TO FIT ON-OFFVALVES ON THE GENERATOR TO THE FOREOF THE SAFTEY DEVICESWATER SIDE PRESSURE LOSSESPrevalenza Disponibile7,8 80 100 200 300 400 500 600 700 800 900 1000 1100 120013001400 15001600 1700180019002000 21002200 23002400 25002600 2700280029003000 31003200 33003400 35003600 37003800 39004000 4100Pressure losses p (mmH2O)7,67,47,276,86,66,46,25,8 65,65,45,254,84,64,44,23,8 43,63,43,232,82,62,42,21,8 21,61,41,210,80,60,40,20Q: water flow rate (l/h)PWM 99%PWM 30%EXAMPLE:For a ÄT 15K the max. water flow rate demanded is 2849 l/h.From the graph of the boiler’s pressure losses it can be determined that the pump must be able to guaranteea head of at least 3,1 mH20.18

Instructions for the installer3.10 - SUPPLEMENTAL SAFETY, PROTECTIVE AND CONTROL DEVICES PRESCRIBED BYTHE GOVERNMENT DECREE 01-12-1975 AND RELATIVE APPLICABLE TECHNICALSPECIFICATIONS (CONTAINED IN THE “RACCOLTA R EDITION 1982”)CERTIFICATION OF THE SUPPLEMENTAL SAFETY DEVICES:Several notified bodies prescribe supplemental safetydevices.For the safety valves and on-off gas valves it is necessary toobtain the ISPESL (Institution for preventive measures andsafety at work) calibration certificate which confirms that theyare free from lead or bossing.The expansion vessels with a capacity superior to 24 litresmust have be supplied with an approval booklet released byISPESL and a manufacturers conformity declaration.All the accessories must have an ISPESL approval certificate.SAFETY DEVICES1. On-off gas valve: a device which has the function of cuttingoff the gas supply when the water temperature reaches themax. predetermined value. The sensible element has to beinstalled as nearest as possible to the generator (flow pipe)at a distance which has to be < 500 mm and must not be ableto be cut-off.4. Safety pressure switch: it has the function of shuttingdown the generator if it reaches the maximum workingpressure. It must be able to be reset manually.CONTROL DEVICES5. Pressure indicator with shock absorber tube andpressure gauge holder valve: it indicates the effectivepressure existing in the generator. It must be graduated in“bar” and must have the maximum operating pressure inscale and be equipped with a 3-way valve with the connectionfor the manometer.6. Thermometer: it indicates the effective water temperaturecontained in the generator. It must be graduated in degreesCelsius with a temperature scale not exceeding 120°C.7. Inspection pocket: approved for inserting the controlthermometer8. Calibrated expansion vessel: it permits the absorptionof the increase in volume of the system’s water following anincrease in temperature; the boiling point (ISPESL) must notbe superior to the pressure relief valve’s calibrated pressure.2. Pressure relief valve: it has the function of dischargingin the atmosphere the fluid contained in the generator whenthis has, for whatever motive, reached the maximum workingpressure.PROTECTIVE DEVICES3. Overheat thermostat: it has the function of shutting downthe generator if the safety thermostat fitted in the boilermalfunctions. It must be calibrated to a value of < 100°C,which MUST not be changed.19

Instructions for the installer3.11 - PRESSURE RELIEF VALVE DRAINPIPEA pressure relief valve must be fitted on the flowpipe, within 0,5 m from the boiler. It must bedimensioned for the capacity of the boiler andmust comply to the regulations in force,WARNING!Please remember that it is forbidden tointerpose, between the boiler and thepressure relief valve, any type of cutting-offdevice. Moreover it is recommended to usecutting-off valves which do not exceed themaximum allowable operating pressure.WARNING!In correspondence to the heating pressurerelief valve foresee the installation of adischarge pipe with a funnel and a siphonwhich lead to an adequate drainage. Thedrainage has to be controllable by sight.If this precaution is not made, an eventualintervention of the pressure relief valve couldcause injury to persons, animals or damageto property. The manufacturer shall not beheld liable for any injury and/or damage.3.12 - WORKING PRESSUREThe boiler’s maximum allowable working pressure is set at3 bar; whilst the minimum pressure is pre-charged to 0,5bar.WARNING!The boiler does not have any specific protectivedevice against water loss, as this function iscarried out promptly by the overheatthermostat.However, on the boiler’s electronic board, thepossibility of connection to a minimumpressure switch is foreseen..20

Instructions for the installer3.11 - MIXING HEADER FILTERUNICAL suggests the installation of a Y filteron the return pipe so that it can be cleaned ifnecessary.This filter will protect the boiler from the heatingsystem dirt.3.12 - MIXING HEADERIn order to ensure correct boiler operation it is necessary touse a mixing header which guarantees:- the separation and collection of circuit dirt- optimal air venting- hydraulic de-coupling of the two hydraulic circulationcircuits- balancing of the circuits21

Instructions for the installer3.13 - CONDENSATE DRAINDuring the combustion process the boiler producescondensate which, through the “A” pipe, flows into the siphon.The condensate which forms inside the boiler has to be routedinto an adequate drain by means of the pipe “B”.DANGER!Before commissioning the appliance fill thesiphon through the filling pipe “C” and checkthe correct drainage of the condensate.If the appliance is used with the condensatedrain siphon empty there could be danger ofintoxication resulting from the escape of gasfumes.CFillingpipeThe connection between the appliance and the sewagesystem must be carried out in compliance with the specificnorms, and in particular:- prevent the end user utilizing the condensate produced- it must be fitted with a siphon (supplied with the boiler)- it must be fitted without any bottlenecks;- it must be installed so as to avoid freezing of the liquidwhen the boiler is operating and prevent the eventualpressurization of the sewage system;- consent the correct downflow of the appliances liquiddischarges;- it must be made with one of the following materials whichare resistant to condensate:- Grès, according to the Standards DIN 1230-1 and 6,EN 295-1 or 2 or 3- Glass (boron silicate)- Polyvinyl chloride (PVC) , according to DIN V 19534-1 and 2, and DIN 19538- Polyethylene (PE) DH type, according to DIN 19535-1 and 2 and DIN 19537-1 and 2- Polypropylene (PP) and copolymer styrene (ABS)according to DIN V 19561- Polyesterific resin (GF-UP), according to DIN 19565-1- Stainless steelABBoilercondensateinletCondensateoutlet,pipe toconnect to thesewagesystwm22

Instructions for the installer3.14 - WATER TREATMENTThe chemical/physical features of the heating system’s waterare fundamental for the boiler’s correct operation and safety.Infact the Standards indicated here below foresee a preventivetreatment before placing water inside the CH circuit.Reference standards:UNI CTI 8065/1989 “Water treatment in thermal heatingsystems for civil use”UNI CTI 8364/1984 “ Heating systems – Control andmaintenance”The scope of this treatment is finalized for eliminating orsubstantially reducing the following problems:- lime scale deposit- corrosion sludge- deposits- microbiological growths (moulds, bacteria etc.)An appropriate treatment of the supply water will preventthe above stated problems and will maintain the correctoperation and efficiency of the generator in time.For this purpose it will be necessary to fix the followingchemical-physical characteristics of the water:PH include between 6,5 and 8Hardness 15° FRTherefore, before filling the heating system it will be necessaryto fit the devices indicated in the figure.THE INSTALLATION MUST BE FORESEEN ONTHE RETURN PIPE OF THE PRIMARY CIRCUITDOWNSTREAM OF THE CIRCULATING PUMP.All necessary precautions must be taken for preventing theformation and localization of oxygen in the system’s water.For this reason, ensure yourself that the plastic piping usedin underfloor heating systems is impermeable to oxygen.If any anti-freeze solutions are used ensure that they arecompatible with aluminium and any other boilercomponents and materials.WARNING!Any damage caused to the boiler due to theformation of lime scale or by corrosive waterwill not be covered by the warranty.EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FOR WATER TREATMENT1 2 3 4 5 2 67 11 BALL VALVE2 INSPECTION POCKET3 FILLING MANIFOLD4 DISCONNECTOR5 SCALE REDUCING DEVICE6 LITER COUNTER (Recommended)7 Y filter23

Instructions for the installer3.15 - FLUE INSTALLATIONThe flue system must be installed in accordance with thelocal and national Standards (refer to UNI 13384-1-2)The flue outlet must be made only with material resistantto products of combustion, pertaining to class W1according to UNI EN 1443, and as a rule made in stainlesssteel or plastic material.We recommend using only original UNICAL flueoutlet systems.Damages caused by installation errors and fornon-observance of the instructions given bythe same manufacturer will invalidate all thesupplier’s contractual or extra contractualresponsibilities.FLUE OUTLETS Ø 100 mm Type B23The maximum total horizontal run permittedby the Ø 100mm outlet and intake pipe is 30 minclusive of 1 wide radius bend and 1 flue outletterminal.L min = 1 m - L max = 30 m0026251400361494The boiler has been approved for the following flueconfigurations:00361495Type B23Boiler designed to be connected to an open flue which willterminate vertically through the roof. The combustion air isintaken directly from the room where the boiler is installed.WARNING: for this type of connection the room must complywith the same installation regulations valid for open chimneyboilers.The chimney must comply to the current regulations.Preliminaryoperations:Min. 300 mm0036149300361495- Fit the flue outlet pipeØ 100mm, suppliedin the packaging, asindicated in thefigure.24

Instructions for the installer3.16 - ELECTRICAL CONNECTIONSRegulations in forceThe gas and water feeding pipes and the CH system pipescannot be used as ground plates.Ensure that the above safety electrical requirements subsist;in case of doubt, ask for a professionally qualified technicianto check the appliance’s electrical system.UNICAL refuses responsibility for any damages arising fromfailure to earth the boiler correctly.It is necessary that a qualified technician verifies that theelectrical system is adequate to the appliance’s maximumabsorbed power, indicated on the data plate, verifying inparticular that the section of the system’s cables is suitableto the appliance’s maximum absorbed power.For the appliance’s general electrical supply the use ofadaptors, multiple sockets and/or extension cords is strictlyforbidden.The use of any power supplied equipment implies theobservance of several fundamental rules, such as:- Do not touch the appliance with any wet part of your bodyand/or barefooted;- Do not pull the supply cables- Do not expose the boiler to sunlight, rain, etc., unless it isexplicitly foreseen;- Do not permit children or inexpert people to use theappliance.Mains electrical supply connection 230VThe boiler is provided complete with a mains supply cable1,5 m long and with a cross section area of 3x0,75 mm2.The electric connections of the boiler are shown in the sectionnamed “WIRING DIAGRAMS” (paragraph 3.17 page 26)A mains supply of 230 V – 50 Hz is required. The wiring to theboiler must be in accordance with the current CEI regulations.WARNING!We remind you that upstream of the electricalconnection, it will be necessary to foresee aservice relay (NOT SUPPLIED) which, whenthe electrical safety devices (ISPESL)intervene, shuts down the electrical supplyto the on-off fuel valve fitted on the gas supplycircuit, but not to the boiler so as toguarantee the running of the pump and permitthe boiler to cool down.DANGER!The electrical connections must be carriedout only by a qualified engineer.Before carrying out the connections or anyother operation on the electrical parts,always switch off and disconnect theelectricity supply and ensure yourself that itcannot be accidentally turned on.It is necessary to fit a double pole switch on the electricalsupply line, having a 3 mm contact separation in both poles,in an easy accessible position in order to make quick andsafe the servicing operations.25

Instructions for the installerRoom thermostat and/or E8 heating controller connectionDANGER!Switch off and disconnect the electricitysupply before carrying out any operations onthe electrical parts.TermostatoAmbienteCentralinaTermoregolazione- Gain access to the Y1 terminal board- For the Room thermostat connection 1 and 2and connect them to the thermostat’s cables.- For the Heating Controller connection use theconnecting terminals 3 and 4.Connection of the additional safety devicesDANGER!Switch off and disconnect the electricitysupply before carrying out any operations onthe electrical parts.For the connection remove the existing jumper.LIGHTB LUELIGHTBLUELIGHTBLUEPrearrangement for theconnection of theadditional safety devicesCC2 NCThermostatPressostat26

Connection of the additional safety devices for ALKON 90 in batteryDANGER!Switch off and disconnect the electricitysupply before carrying out any operations onthe electrical parts.Instructions for the installerFor the connection remove the existing jumper.LIGHTBLUELIGHTBLUEPrearrangement for theconnection of theadditional safety devicesLIGHTBLUEBoiler 1 Boiler 2 Boiler 3 Boiler 4C2 NCThermostatCPressostatSupplieRelais27

Instructions for the installer3.17 - FUNCTIONAL FLOW WIRING DIAGRAMDK = Minimum water pressure switchE. ACC = Ignition electrodeE. RIV = Detection electrodePG = Gas pressostatPM = Modulating pumpSR = CH sensorSRR = CH return sensorSL = Condensate level sensorTE = Flue-gas spillage thermostat (optional)TL = Limit thermostatVG = Gas valveVM = Modulating fan detection/adjustmentVMVGE. ACCREDYELL/GREENRIL./REG.5 4 2ALIM.230V1 2 3LIGHT BLUEBROWNBLACK (-)BROWN (PWM)BLUE (TACHO)ORANGE +BROWN (L1)LIGHTBLUE (N)LIGHTBLUEBROWNTAE8BROWNLIGHTBLUELIGHTBLUEBROWNYELL/GREENN L1230 V - 50 HzE. RIV.YELL/GREENBROWNLIGHT BLUEBROWNLIGHTBLUEBROWNLIGHTBLUELIGHTBLUELIGHTBLUELIGHTBLUEWHITEPINK (+)GREY (Modulation)BLACKPMWHITEBROWNSRR SRTLTEPrearrangement for theconnection of theadditional safety devicesBROWNDK321WHITEBLUEBLUEPGSL28

Instructions for the installer3.18 - WIRING DIAGRAM AND MANAGEMENT WITH E8 REGULATOR (Optional)On the back side of the E8 regulator there are two terminalblocks, of which one is for the mains (230 V) connections andthe other one is for the low tension connections.The main controls, necessary for the C.H. system managementand for the boiler control, as well some componentswhich are part of the boiler house, must be connected to theterminal blocks.AlimentazionePompa PrimarioPompa Ricircolo BollitorePowerterminalblockN L1 L1 1 2 11 2 3 4 5 6 7 8 9 10II A1 A2 A3 A4 A5 A61 2VI A71 2 3 4 5A8 A9 IV A10 A11M1 2 3M450 Hz 230 VN L1 L1’T1 T2T3 T4nBUSLHFBR3 1IMP0-10 VPT1000SPFVFAF KF / SPF VFFBRFAeBUS0-10 VSensorterminalblock4IX3 21F17 F153 2III1F14 F132 VIII 1F12 F112 V 1F9 F8 F6 F5 F3 F2 F1I10 9 8 7 6 5 4 3 2 1VII2 1Power terminal assignmentsGRIGIOROSADalla caldaiaTerminal IIIIN L1 L1’T1 T2M1 2 3 4 5 6 7 8 9 10II A1 A2 A3 A4 A5 A6N L1 L1 1 2 1N: Neutral conductor, mainsL1: Power supply, unitL2: Power supply to relay: heating circuit pump HK 1: heating circuit pump HK 2: Storage tank charging pump::Mixer open, heating circuit 2Mixer closed, heating circuit 2Terminal VI VI1 2VI A7T3 T4nTerminal IV IVM1 2 341 2 3 4 5A8 A9 IV A10 A11: Mixer open, heating circuit 1: Mixer closed, heating circuit 1Multifunction relayRecycle pump / Multifunction relay123429

IInstructions for the installerSensor terminal assignmentsFATerminal VIIeBUS0-10 V12VIIConnection to BCMVIIPin 1: eBUS (FA) or 0-10V outputPin 2: (Ground)Terminal IIFBRAF KF / SPF VFF9 F8 F6 F5 F3 F2 F19 8 7 6 5 4 3 2 110VFVFSPFSPFKFAFAFBuffer storage tank low sensorBuf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor)Buf. stor. tank top sensor / FBR heat. circ. 1 (set value)Pin 4: Flow sensor, heating circuit 2 (ground)Pin 5: Flow sensor, heating circuit 2Pin 6: Storage tank sensorPin 7: Storage tank and boiler sensor (ground)Pin 8: Boiler sensorPin 9: Outdoor sensorPin 10: Outdoor sensor (ground)Terminal V VSPFVFF12 F112 V 1VFSPFPin 1: Flow sensor heating circuit 1 / sensor multifunction 1Pin 2: Service water low sensor / sensor multifunction 2Terminal VIIIPT1000F14 F132 VIII 1F13F14Pin 1: Sensor HS2 / Solar 2 / Multifunction relay 3Pin 2: Sensor Solar 1 / Sensor multifunction relay 4FBR3 1Terminal III IIIIMP 0-10 V1F17 F15III23F15F17Pin 1: FBR heating circuit 2 (room sensor) / 0-10V IN / LightPin 2: FBR heating circuit 2 (ground)Pin 3: FBR heating circuit 2 (set value) / Pulse counter forMorsetto IX IXBUSL HIX4 3 2 1For connection to remote control devicesHL-+CAN Bus Pin 1 = H (Data)CAN Bus Pin 2 = L (Data)CAN Bus Pin 3 = - (ground, Gnd)CAN Bus Pin 4 = + (12V supply)30

Instructions for the installer3.19 - INSTALLATION EXAMPLES (functional wiring and connections description)INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONEAF (9-10) outdoor sensorVF(1) Flow sensor heating circuit 1(4) Collector pumpI10(10) Ground outdoor sensorHeating Circuit 1Expansionvessel(optional)OutsideSensorAFVFMRVFVF1Safety devices kit< 1 mFilterMixing HeaderNOTE!THE CONFIGURATIONS, SHOWN IN THIS MANUAL, ARE DOABLE BY USING THE E8 REGULATOR, SUPPLIED ASAN OPTION.BEFORE USING OTHER MODELS OF REGULATORS, MAKE SURE THEY ARE COMPATIBLE31

Instructions for the installerINSTALLATION OF A BOILER WITH CONNECTION TO TWO DIRECT HEATING ZONES + D.H.W. PRODUCTIONVF(4-5) Flow sensor heating circuit 2SPF(6-7) Storage tank sensorAF (9-10) outdoor sensor(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pumpn(5) Re-circulation pump storage tankIVF(1) Flow sensor heating circuit 110(10) Ground outdoor sensorCRic.FHeating Circuit 1 Heating Circuit 24nSPFExpansionvessel(optional)OutsideSensorAFVFVFMVFVFVFR1 2Safety devices kit< 1 mFilterMixing Header32

Instructions for the installerINSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD.VF VF(1) Flow sensor heating circuit 1(4-5) Flow sensor heating circuit 2SPF(6-7) Storage tank sensorI10(10) Ground outdoor sensorAF (9-10) outdoor sensor(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pumpn(5) Re-circulation pump storage tankCRic.FHeating Circuit 1 Heating Circuit 24nSPFExpansionvessel(optional)SondaEsternaAFVFVFMRVF1VFVF2Safety devices kit< 1 mFilterMixing Header33

Instructions for the installerINSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTIONVF(4-5) Flow sensor heating circuit 2SPF(6-7) Storage tank sensorAF (9-10) outdoor sensorIVF10(1) Flow sensor heating circuit 1(10) Ground outdoor sensor(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump(7) Mixer motor heating circuit 2 OPEN(8) Mixer motor heating circuit 2 CLOSE(1) Mixer motor heating circuit 1 OPEN(2) Mixer motor heating circuit 1CLOSEn(5) Re-circulation pump storage tankV(2) Hot water tank low / Multifunction relay sensor 2PT1000(2) PT1000 sensor solar 1 / Multifunction relay sensor 4CRic.FHeating Circuit 1Heating Circuit 24nSPFExpansionvessel(optional)OutsideSensorAFVFVFMVFVFVFR1 2Safety devices kit< 1 mFilterMixing Header34

Instructions for the installerINSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION BY SOLAR PANELSVF(4-5) Flow sensor heating circuit 2SPF(6-7) Storage tank sensorAF (9-10) outdoor sensorIVF10(1) Flow sensor heating circuit 1(10) Ground outdoor sensor(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump(7) Mixer motor heating circuit 2 OPEN(8) Mixer motor heating circuit 2 CLOSE(1) Mixer motor heating circuit 1 OPEN(2) Mixer motor heating circuit 1CLOSEn(5) Re-circulation pump storage tank(4) Collector pumpV (2) Hot water tank low / Multifunction relay sensor 2PT1000(2) PT1000 sensor solar 1 / Multifunction relay sensor 4Circuito diriscaldamento 1Circuito diriscaldamento 2CFPT1000F142+SPFVasoespansionedi caldaia(non fornito)SondaEsternaAF4MVFVFVFVF5A11RVF1 2F122+ISPESL< 1 mFiltroSeparatoreidraulicoFor the connection to a solar installation it isnecessary to change some parameters. SeeTable:Expert AREA ⇒ Level SOLAR / MF ⇒ MF 4FUNCTION = ‘’23’’35

Instructions for the installerINSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTIONRemoteE8MasterHeating Circuit 1Heating Circuit 2CRic. F4nSPFExpansionvessel(optional)Expansionvessel(optional)OutsideSensorAFVFVFMMVFVFVFRR1 2Sonda dicaldaiaKFSafety devices kit< 1 mFilterMixing HeaderConnection of several ALKON 90The electrical connection of several ALKON 90 in cascademust be done between the terminals 3-4 of Y1 (ALKON 90 / 1)and 3-4 of Y1 (ALKON 90 / 2of the PCBsY11 2 3 4Y11 2 3 4ALKON 90/1 ALKON 90/2ALKON 90/3Attention!Respect the polarity: BUS - / BUS -BUS + / BUS +Connections on to the MASTER controllerThe connections of the secondary circuit have to be done onto the MASTER controller.VF(4-5) Flow sensor heating circuit 2SPF(6-7) Storage tank sensorAF (9-10) outdoor sensor(4) Pump heating circuit 1(5) Pump heating circuit 2(6) Cylinder charging pump(7) Mixer motor heating circuit 2 OPEN(8) Mixer motor heating circuit 2 CLOSE(1) Mixer motor heating circuit 1 OPEN(2) Mixer motor heating circuit 1CLOSEThe E8 regulator (OPTIONAL) will recognise automaticallythe number of boilers connected and their output .n(5) Re-circulation pump storage tank(4) Collector pumpFor the connection of several ALKON 90 (Max8 boilers) it is necessary to change someparameters of prearrangement (see tableRegulator E8 on page 6:TIPE CR1 from ‘’2’’ to ‘’6’’CR1 BUS prearranged ‘’03’’IVF10(1) Flow sensor heating circuit 1(10) Ground outdoor sensor36

3.20 - EXAMPLES OF CONNECTION WITH OPTIONAL KITSINSTALLATION OF A SINGLE ALKON 90Instructions for the installer475862311 - 41010081 = Alkon 90 Master (NG)with side panels and flanges41010082 = Alkon 90 Master (LPG)with side panels and flanges2 - 00361529 = External frame for safety devices kit3 - 00361528 = Additional safety kit and manifold4 - 00361316 = Additional protection and control kit5 - 00361499 = Hydraulic header kit up to 90-180 kWDN656 - 00361488 = Y filter kit DN 657 - 00361484 = Hydraulic header connection kit DN 658 - 00361522 = Outdoor cover kit for 2 boilersSMOKE ACCESSORIES00361493 = Vertical flue terminal Ø 10000361494 = Horizontal flue terminal Ø 10000361495 = Extension Ø 100 L = 100000262514 = Elbow 90° Ø 10000262476 = Elbow 45° Ø 100Note:The insulation of the battery flow and return manifoldsis suggested.ACCESSORI DI REGOLAZIONE00361332 = Centralina di Termoregolazione E8REGULATION 00361359 ACCESSORIES= Kit custodia WAG per montaggio00361332 = a E8 parete regulator kit00361359 00361358 = Kit Box comando for E8 regulator remoto BM8 kit00361358 = BM8 remote control kit00361602 = BCM panel kit37

Instructions for the installerINSTALLATION OF TWO ALKON 90 IN BATTERY9687435211 - 41010081 = Alkon 90 Master (NG)with side panels and flanges41010082 = Alkon 90 Master (LPG)with side panels and flanges2 - 41010046 = Alkon 90 (NG)41010047 = Alkon 90 (LPG)3 - 00361528 = External frame for safety devices kit4 - 00361529 = Additional safety kit and manifold5 - 00361316 = Additional protection and control kit6 - 00361523 = Outdoor cover kit for 3 modules7 - 00361484 = Hydraulic header connection kit DN 658 - 00361488 = Y filter kit DN 659 - 00361499 = Hydraulic header kit up to 90-180 kWDN 65Note:The insulation of the battery flow and return manifoldsis suggested.REGULATION ACCESSORIES00361332 = E8 regulator kit00361359 = Box for E8 regulator kit00361358 = BM8 remote control kit00361602 = BCM panel kitSMOKE ACCESSORIES00361493 = Vertical flue terminal Ø 10000361494 = Horizontal flue terminal Ø 10000361495 = Extension Ø 100 L = 100000262514 = Elbow 90° Ø 10000262476 = Elbow 45° Ø 10038

Instructions for the installerINSTALLATION OF THREE ALKON 90 IN BATTERY96843572211 - 41010081 = Alkon 90 Master (NG)with side panels and flanges41010082 = Alkon 90 Master (LPG)with side panels and flanges2 - 41010046 = Alkon 90 (NG)41010047 = Alkon 90 (LPG)3 - 00361528 = External frame for safety devices kit4 - 00361529 = Additional safety kit and manifold5 - 00361316 = Additional protection and control kit6 - 00361524 = Outdoor cover kit for 4 modules7 - 00361487 = Hydraulic header connection kit DN 1008 - 00361489 = Y filter kit Y DN1009 - 00361500 = Hydraulic header kit up to 180-450 kWDn100Note:The insulation of the battery flow and return manifoldsis suggested.REGULATION ACCESSORIES00361332 = E8 regulator kit00361359 = Box for E8 regulator kit00361358 = BM8 remote control kit00361602 = BCM panel kitSMOKE ACCESSORIES00361493 = Vertical flue terminal Ø 10000361494 = Horizontal flue terminal Ø 10000361495 = Extension Ø 100 L = 100000262514 = Elbow 90° Ø 10000262476 = Elbow 45° Ø 10039

Instructions for the installerINSTALLATION OF FOUR ALKON 90 IN BATTERY968423572211 - 41010081 = Alkon 90 Master (NG)with side panels and flanges41010082 = Alkon 90 Master (LPG)with side panels and flanges2 - 41010046 = Alkon 90 (NG)41010047 = Alkon 90 (LPG)3 - 00361528 = External frame for safety devices kit4 - 00361529 = Additional safety kit and manifold5 - 00361316 = Additional protection and control kit6 - 00361525 = Outdoor cover kit for 4 modules + 17 - 00361487 = Hydraulic header connection DN 1008 - 00361489 = Kit filter kit Y DN1009 - 00361500 = Hydraulic header kit up to 180-450 kWDn100Note:The insulation of the battery flow and return manifoldsis suggested.REGULATION ACCESSORIES00361332 = E8 regulator kit00361359 = Box for E8 regulator kit00361358 = BM8 remote control kit00361602 = BCM panel kitSMOKE ACCESSORIES00361493 = Vertical flue terminal Ø 10000361494 = Horizontal flue terminal Ø 10000361495 = Extension Ø 100 L = 100000262514 = Elbow 90° Ø 10000262476 = Elbow 45° Ø 10040

Instructions for the installer3.21 - FILLING THE SYSTEMWarning!Do not mix the CH system’s water with antifreezeor anti-corrosion solutions using wrongconcentrations! It could cause damage to thewashers and could provoke noise duringnormal boiler operation.UNICAL refuses all liability for injury to persons,animals or damage to property deriving fromnot having respected the above mentionedrecommendations.The boiler is equipped with its own drain cock, whose positionis shown in the figure of page 11. This cock never has tobe used for the drain of the system, because all the dirtinessof the installation could accumulate in the boiler, compromisingits operation.. For that reason the installation must beequipped with own drain cock, correctly sized according tothe installation water content.Once all the connections are made, it is possible to fill thecircuit.For the filling of the system it is necessary to fit a fillingvalve on the C.H. return.EXAMPLE OF FILLING-UP SYSTEM MANIFOLDFilling manifold41

Instructions for the installer3.22 - INITIAL LIGHTINGPRELIMIARY CHECKSThe first ignition must be carried out by aqualified technician. Failure to do so couldcause injury to persons, animals or damageto property. UNICAL shall not be held liablefor any injury and/or damage.Before lighting the boiler check that:- the boiler installation has been carried out in accordancewith the specific Standards and regulations in force forthe gas part and for the electrical part;- the air supply and the discharge of the products ofcombustion are carried out in the correct way inaccordance to the specific Standards and regulations inforce;- the gas supply system is correctly dimensioned for theboiler’s output and is fitted with all the safety and controldevices prescribed by the regulations in force;- the electrical supply must be 230 V - 50 Hz;- the system has been filled with water (pressureregistered on the gauge 0,8/1 bar with pump not running);- any on-off valves of the system are open;- the mains supply gas corresponds to the one which theboiler has been calibrated for: otherwise convert the boilerto use the available gas (refer to section: “GASCONVERSION”); this operation must be carried out by aqualified technician in compliance to the regulations inforce;- the gas supply cock is open;- there are no gas leaks;- the external mains supply switch is on;- the system’s safety valve on the boiler is not blocked andthat it is connected to the sewage system;- the condensate drain siphon has been filled with water;DANGER!Before firing the appliance fill up the siphonthrough the filling hole and check the correctdrainage of the condensate.If the appliance is used with the condensatedrain siphon empty this could lead to dangerof- there are no water leaks;- all the necessary ventilation conditions and minimumclearance distances are guaranteed for subsequentservicing.LIGHTING AND SHUTTING DOWN PROCEDURESFor lighting and shutting down the boiler refer to the“INSTRUCTIONS GUIDE FOR THE PERSON IN CHARGE OFTHE APPLIANCE”Information to be passed on to the person incharge of the applianceThe person in charge of the appliance must be instructedon the use and operation of the boiler and in particular detail:- Hand the booklet: “INSTRUCTIONS GUIDE FOR THEPERSON IN CHARGE OF THE APPLIANCE”, as well asall the other literature relative to the appliance, andplaced in the envelope contained in the packaging, tothe person in charge of the appliance. The person incharge of the appliance must retain this literature forany future reference.- Inform the person in charge of the appliance of theimportance of the air vents and of the flue outlet system,stressing the fact that absolutely no modification can bemade.- Inform the person in charge of the appliance regardingthe control of the system water pressure and how torestore it to the correct value.- Explain and demonstrate to the person in charge of theappliance the correct function and adjustment of thetemperature, thermostats and radiators for theeconomic use of the system.- Remind the person in charge of the appliance that acomprehensive service and the measurement of thecombustion efficiency should be carried out regularly(as requested by the national law).- If the appliance is sold or transferred to another owneror if the present user moves home and leaves theappliance installed, ensure yourself that the manualalways follows the appliance so that it can be consultedby the new owner and/or installer.42

Instructions for the installer3.23 - BURNER ADJUSTMENTWARNING!All the instructions indicated below are for theexclusive use of qualified UNICAL servicetechnicians or installers.All the boilers are supplied already calibratedand tested. If it is necessary to change thecalibration due to gas conversion or adaptationto the mains supply system, the gas valve mustbe re-calibrated.Warning: during this operation do not requestany DHW draw-off .A) Max output adjustment- Connect a suitable C0 2gas analyser to the samplingpointin the flue inlet/outlet terminal.MAXIMUM OUTPUTADJUSTMENT SCREWB) Min output adjustment- By pressing the key “- decrease” again the boiler willoperate at the minimum output (led 1 blinking).VIOLAAZZURRO- Pressing simultaneously the keys + (increase) and –(decrease) for at least 3 seconds the boiler will operatein the CH mode at the maximum output (led 1GIALLOBLUVIO1AZZU-To disenable the CHIMNEY SWEEPER MODEpress the keys + (increase) and – (decrease)simultaneously (led 1 off).LRAROGIB1ALLOLUVIOAZZULRAROilluminated).- Check that the C0 2values are within the valuesindicated in the table “Burner pressures”- If necessary correct the value by turning the adjustmentscrew “A” in a CLOCKWISE direction to decrease thevalue and in an ANTICLOCKWISE direction in order toincrease it.GIALLO- Check that the C0 2values are within the values indicatedin the table “Burner pressures”BLU43

Instructions for the installer- If necessary correct the value by turning the adjustmentscrew “B” in a CLOCKWISE direction to increase the valueand in an ANTICLOCKWISE direction in order to decreaseit.C) COMPLETION OF THE BASIC ADJUSTMENTS- Check the C0 2values at the minimum and maximumoutlet- If necessary make the required adjustmentsTo ensure correct operation the C0 2valueshave to be adjusted with extreme carerespecting the values indicated in the table.- Close the sampling test point in the flue inlet/outletterminal with the appropriate cap C.In case of replacement of the gas valve or ignition difficulty:MINIMUM OUTPUTADJUSTMENTSCREWTighten the maximum adjustment screw “A”in a clockwise direction until you arrive tothe abutting end, than slacken for 3 turns.Verify the boiler ignition; if the boiler goesinto lockout slacken the screw “A” again ofone turn, than retry the ignition. If the boilergoes into lockout again, carry out the aboveindicated operations until the boiler islighted.At this point carry out the burner adjustmentas previously indicated.INJECTORS – PRESSURESALKON 90Check the C0 2levels often, especially at low flow rateTipo diGasGas nat. (G20)Propano (G31)Supplypressure(mbar)2037CollectorDiaphragm(Ø and n°holes )--C0 2levels(%)min8,810,5C0 2levels(%)max9,110,9Fan speed(rpm)min17001700max64005900Ø Mixerinjectors(Ø mm)9,07,0Mingasconsumption2,35 m³/h1,712 kg/hMaxgasconsumption9,7 m³/h6,99 kg/hStartingoutput %453544

3.24 - PROGRAMMING OF THE OPERATING PARAMETERSInstructions for the installerWARNING! THESE OPERATIONS ARE ACCESSIBLE TO TRAINED INSTALLERS AND SERVICE ENGINEERSONLY FOR CHANGING THE PARAMETER SETTINGSPress the YELLOW key and the LIGHT BLUE key simultaneouslyto enter in the service mode SE and change the valuesof the pre-set operating parameters.(Operation C)After setting the desired value pressing the YELLOW key storesthis new value in the memory.VIOLAGIALLOAZZURROAZZURROVIOLAGIALLOBLUBLUeBUS IDENTIFICATION CODEBy pressing the YELLOW key you have access to the firstadjustable parameter eBUS IDENTIFICATION CODE (SC).Standard setting 0BURNER MODULATION LEVEL IN IGNITIONContinue to change the parameters by pressing the – key(decrease).The successive parameter which can be changed is: BURNERMODULATION LEVEL IN IGNITION (IG)VIOLAGIALLOAZZURRO(Operation A)By pressing the YELLOW key again the standard parametersetting is displayed.BLUVIOLAGIALLORepeat the operations A-B-C for setting the desired valuefrom 0 to 99%.AZZURROBLUVIOLAGIALLO(Operation B)By pressing the keys + (increase) or – (decrease) a numberof times the parameter can be changed.AZZURROBLUStandard Natural Gas setting 45%Standard LPG setting 35%PUMP OVERRUNContinue to change to the parameters by pressing the – key(decrease).The successive parameter which can be changed is: PUMPOVERRUN (Po).VIOLAGIALLOAZZURROBLUVIOLAGIALLOAZZURROBLUWARNING!DO NOT CHANGE THE PARAMETERRepeat the operations A-B-C for setting the desired valuefrom 1 to 10 minutes.Standard setting: 5 minutes45

Instructions for the installerMODULATING PUMP MODULATING CAPACITYContinue to change the parameters by pressing the – key(decrease).The successive parameter which can be changed is:MODULATING PUMP MODULATING CAPACITY (Pr).ISETTING OF THE MAXIMUM HEATING TEMPERATU-REContinue to change to the parameters by pressing the – key(decrease).The successive parameter which can be changed is: SETTINGOF THE MAXIMUM HEATING TEMPERATURE (HHVIOLAGIALLOAZZURROAZZURROVIOLAGIALLOBLUBLURepeat the operations A-B-C for setting the desired valuefrom 20 to 99%.Standard setting: 99%Repeat the operations A-B-C for setting the desired valuefrom 65 to 85°CStandard setting: 80°CMODULATING PUMP MINIMUM MODULATION LEVELContinue to change to the parameters by pressing the – key(decrease).The successive parameter which can be changed is:MODULATING PUMP MINIMUM MODULATION LEVEL (PL).SETTING OF THE MINIMUM DHW TEMPERATURE (onlyif combined with an external storage tank)Continue to change to the parameters by pressing the – key(decrease).The successive parameter which can be changed is: SETTINGOF THE MINIMUM DHW TEMPERATURE (dL).VIOLAGIALLORepeat the operations A-B-C for setting the desired valuefrom 0 to 99%.Standard setting: 16%SETTING OF THE MINIMUM HEATING TEMPERATUREContinue to change to the parameters by pressing the – key(decrease).The successive parameter which can be changed is: SETTINGOF THE MINIMUM HEATING TEMPERATURE (HL).AZZURROBLUVIOLAGIALLORepeat the operations A-B-C for setting the desired valuefrom 35 to 45°CStandard setting: 40°CSETTING OF THE MAXIMUM DHW TEMPERATURE(only if combined with an external storage tank)Continue to change to the parameters by pressing the – key(decrease).The successive parameter which can be changed is: SETTINGOF THE MAXIMUM DHW TEMPERATURE (dH).AZZURROBLUVIOLAGIALLOAZZURRORepeat the operations A-B-C for setting the desired valuefrom 20 to 60°CStandard setting: 35°CBLUVIOLAGIALLORepeat the operations A-B-C for setting the desired valuefrom 50 to 65°CStandard setting: 60°C.AZZURROBLU46

Servicing schedule4SERVICINGSCHEDULETo ensure the continued safe and efficientoperation of the boiler it is highlyrecommended that it is checked at regularintervals and serviced when necessary, andthat only original spare parts are used.The law in force states that the boiler mustbe serviced annually.If the boiler is not checked and serviced whennecessary it could cause material andpersonal damages.For this reason UNICAL recommends that a servicing contractshould be made with a heating installer.The boiler must have regular maintenance and cleaning inorder to ensure reliable and efficient operation. Regularattention will prolong the life of the boiler.The frequency of servicing will be determined by the serviceengineer and will depend on appliance’s state of condition.INSTRUCTIONS FOR SERVICINGTo ensure a long life to all your boilercomponents and in order not to alter theconditions of the approved product onlyoriginal UNICAL spare parts must be used.Before servicing always carry out the following steps:- Disconnect the mains electricity supply.- Separate the appliance from the electrical supply bymeans of a separating device with an opening contact ofat least 3 mm (for example safety devices or powerswitches) and ensure yourself that it cannot beaccidentally reinserted.- Close the on-off valve fitted upstream of the boiler.- If necessary, and in function of the type of work to be carriedout, close any on-off valves fitted on the CH flow and returnpipes, as well as the cold inlet valve.- Remove the appliance’s front panel.After having carried out all the necessary maintenance alwaysfollow these steps:- Open the CH flow and return valves as well as the coldinlet valve (if previously closed),- Purge and, if necessary, proceed with restoring the heatingsystem’s pressure until a pressure of 0,8/1 bar is reached.- Open the on-off gas valve.- Reconnect the appliance to the electrical supply andswitch on the mains electrical supply.- Test for gas soundness, on the gas side and on the waterside.- Replace the appliance’s front panel.IMPORTANT:After having serviced the appliance, rememberto reset the counter to zero by selectingthe text “Cr” from the parameter menu andentering the relative unblocking code.TABLE OF THE RESISTANCE VALUES IN FUNCTION OF THE HEATING SENSOR (SR) AND RETURN HEATING SENSORTEMPERATURE (SRR)T°C 0 1 2 3 4 5 6 7 8 90 32755 31137 29607 28161 26795 25502 24278 23121 22025 2098710 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 701Relation between the temperature (°C) and the nom.resistance (Ohm) of the heating sensor SR and the returnheating sensor SRR.Example:At 25°C, the nominal resistance is 10067 OhmAt 90°C, the nominal resistance is 920 Ohm47

Servicing scheduleCLEANING THE CONDENSATE DRAINSIPHONIn order to check and clean the siphon carry out the followingsteps:- disconnect the transparent pipe (A) check that no depositshave accumulated inside the siphon. If there are any depositsflush them out with clean water;- reassemble the siphon in reverse order.Danger!Before commissioning the appliance fill thesiphon via the filling hole and check thecorrect drainage of the condensate.If the appliance is used with the condensatedrain siphon empty this could lead to dangerof intoxication following the escape of fluegasses.Condensatecoming fromthe boilerCondensatedrain.Pipe to beconnectedto the sewageAGuarnizione di tenuta fra distributore e corposcambiatoreDANGER!It is absolutely necessary to replace thegasket at any time the inspection or maintenanceis made on the burner.When refitting the mixer tighten the nutsprogressively and in crossed way, by using adynamometric wrench adjusted at 10 Nm (1kgm).MixerGasketbetweenmixer andboiler body.BurnerBody48

Servicing scheduleService operations suggestedCheck Check everyonce a year two yearsControl of the water soundness componentsInspect for the gas circuit soundnessCheck the good operation of water and gas safety devicesClean the combustion circuitClean the burner and check the ignitionClean the fanControl the operation of the fanCheck the gas flow rate and ad just if necessaryInspect the smoke evacuation ductCheck the idraulic connectionMake the combustion analysisClean the condensate siphon and check its good draining49

Fault finding5 FAULT FINDING5.1 - ERROR CODESThe boiler is fitted with an integrated diagnostic readout which,in case of malfunction, consents the immediate individuationof the type of fault directly on the control panel displayIn the following fault finding table our purpose is to give sometechnical information regarding the solutions to any problemswhich could occur during boiler operation or commissioningof the boiler.When the fault signalling led (1) is on, press the LIGHT BLUEkey (2) to check the error code on the display (3).VIOLAGIALLO1AZZUROBLU23Code:Description: DHW sensor failure (only if the boileris combined with an external storage tank)Code:Description: Failure of the heating return sensor(SRR)Corrective action: Check the sensor’s efficiencyand/or its wiringCorrective action: Check the efficiency of thesensor and/or wiringCode:Description: Mains voltage < 190 VacCode:Description: Over high temperature detected bythe heating sensor (SR) (>95°C)Corrective action: Check that the mains voltageis 35°C.Code:Description: No flame detected during the ignitionphase.Corrective action: Check the installationCorrective action: Press the reset key on thecontrol panel50

Fault findingCode:Description: Modulating fan failureCode:Description: Alteration of the operatingparameters caused by EMC disturbancesCorrective action: Check the fan’s wiringCorrective action: Restore the factory parametersCode:Description: Modulating fan failureCode:Description: Flame signal detected before theignition cycleCorrective action: Check the fan’s wiringCode:Description: Lack of water (only for pumpequipped with SensorLogic)Corrective action: Disconnect the detectionelectrode’s wire from the control board; if the errorcode disappears replace the cable, otherwisereplace the control board.Corrective action: Fill-up the water circuitCode:Description: Flame detected after burner OFFCode:Description: Main heat exchanger frozenCorrective action: Carefully de-frost the exchangerCorrective action: Disconnect the gas valve’s wirefrom the control board; if the error codedisappears replace the control board, otherwisereplace the gas valve.Code:Description: Intervention of the high limitthermostat (TL)Code:Description: Internal failureCorrective action: Press the reset key on thecontrol panelCorrective action: Replace the control boardCode:Description: Heating sensor failureCorrective action: Check the sensor’s efficiencyand/or wiring51

Fault finding5.2 - DISPLAY OF ERROR CODES ON HEATING CONTROLLER E8Cod:Mining:24E30Alteration of the operating parameterscaused by EMC disturbances18126E32Mains supply voltage < 190 VacIn case of fault, on the display of the regulator a blinking trianglewith its error code will appearHere below you will find the E8 error codes, the relevantmeaning and corrective actions.Cod:E01E02E04E05E06E08Mining:Intervention of the high limit thermostat (TL)Insufficient gas pressureNo flame detected during the ignition phaseLost of the flame signal during the operationToo high water temperature detected by theheating sensor (SR) (> 95°C)Lack of waterE69E70E71E72E75E76E78E80E81E8: F5 – Flow temperature sensor heatingcircuit 2E8: F11 – Flow temperature sensor heatingcircuit 1E8: F1 – Lower storage temperature sensor(Buffer)E8: F3 – Higher storage temperaturesensor (Buffer)E8: F9 – Outer temperature sensor (AF)E8: F6 – DHW storage temperature sensor(SPF)E8: F8 – Boiler temperature sensor (KF)E8: F2 – Room temperature sensor heatingcircuit 1E8: EEPROM fault. The invalid value hasbeen replaced by the standard valueE10E11E12Internal faultFlame detected before the starting of theignition cycleFault at the heating flow sensor (SR)E83E90E8: F15 – Room temperature sensorheating circuit 2E8: BUS addresses 0 and 1. The BUScodes 0 and 1 cannot be used at the sametime.E13Fault at the DHW sensorE91E8: BUS code occupied. The set BUS codeis already used by another applianceE14Fault at the heating return sensor (SRR)E99E8: Internal failureE15E16E20E24Temperature difference between heating flowtemp. sensor (SR) and heating return temp.sensor (SRR) is > 35KBoiler water is frozenFlame detected after burner extinctionModulating fan speed failure: it doesn‘t reachthe correct speed within 30 s from starting ofburnerignition cycleE135E8: F12 – Lower DHW storage temperaturesensor MF2E136 E8: F13 – Boiler 2, Manifold 2 MF 3E137 E8: F14 – Manifold 1, Multifunction 4.E200E8: Intervention os safety devices (fansrotating at maximum speed) /communication error module 152

DECLARATION OF CONFORMITYLaAG s.p.awith headquarters in Casteldario (MN) - Via Roma, 123 - Italyas gas fired condensing boiler manufacturers of the range:DECLARESThat the range of models:ALKON 90do not belong to any of the categories specified in clause 9 of the European Directive 97/23/CE (regarding pressureequipment) and that all the a.m. model are fully equipped with all the safety and control instruments foreseen by thelatest relevant regulations, and comply, with regards to the technical and operating characteristics, to therequirements stated in the following Standards and Directives:UNI EN 677Gas fired central heating - Specific requirements for condensing boilerswith a nominal heat input not exceeding 70 kW.UNI EN 483UNI EN 625(Dove applicabile)Gas fired central heating boilers - Type C boilers of nominal heat inputnot exceeding 70 kWGas fired central heating boilers - Type B boilers of nominal heat inputexceeding 70 kW but not exceeding 300 kWDir. 90/396/CEEDir. 92/42/CEEDir. 73/23/CEEDir. 89/336/CEEGas appliances Directive “GAD”Boiler efficiency DirectiveLow voltage Directive “LVD”Electromagnetic compatibility Directive “EMC”The a.m. appliances have got the efficiency class of 4 stars according to the Efficiency Directive 92/42/CEE by thenotified body CERTIGAZ.The a.m. appliances have a water efficiency, at full capacity, higher o equal to 93 + 2log Pn, (where Pn, in kW, is theNominal Output of each single boiler, as requested by the paragraph 1a of ’art. 9.All these boilers aremarkedPIN n° 1312BR4926Unical declines any responsibility for injuries to persons, animals or to property deriving from wrong handlingof the boiler by unauthorized third parties, or by bad installation or servicing.Unical AG s.p.a.Castel d’ Ario, 10 October 2007TechnicalManagerDino Lanza

AG S.P.A.46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - fax 0376/660556www.unical.ag - info@unical-ag.comThe Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also reservesthe right to bring those changes that it will hold necessary to it own products or profits, without jeopardizing its essentialcharacteristics.