Unical ALLBIOMIX User manual

ALLBIOMIX
INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

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Attention: this manual contains instructions for the exclusive use of the
professionally qualified installer and/or maintenance technician in compliance
with current legislation.
The system manager is NOT authorised to service the boiler.
The manufacturer will not be held liable in case of damage to persons, animals
or objects resulting from failure to comply with the instructions contained in
the manuals supplied with the boiler.

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1 GENERAL INFORMATION ................................................................................................................................................................................ 5
1.1 General warnings ......................................................................................................................................................................................... 5
1.2 Symbols used in the manual ........................................................................................................................................................................ 6
1.3 Appropriate use of appliance ....................................................................................................................................................................... 6
1.4 Information for system manager .................................................................................................................................................................. 6
1.5 Safety warnings ........................................................................................................................................................................................... 7
1.6 Technical data plate ...................................................................................................................................................................................... 8
General informationTechnical featuresInstallation instructionsMaintenance instructions
4 INSPECTION AND MAINTENANCE ................................................................................................................................................................45
Inspection and maintenance instructions........................................................................................................................................................... 45
Maintenance of the body ................................................................................................................................................................................... 46
Cleaning and routine maintenance .................................................................................................................................................................... 46
3 INSTALLATION INSTRUCTIONS .................................................................................................................................................................... 19
3.1 General warnings .................................................................................................................................................................................... 19
3.2 Installation standards................................................................................................................................................................................ 19
3.3 Installation on old or retrofittable systems ............................................................................................................................................... 19
3.4 Packaging ................................................................................................................................................................................................ 20
3.5 Removal of the packaging and supporting pallet ..................................................................................................................................... 20
3.6 Installation ............................................................................................................................................................................................... 21
3.7 Hydraulic connections .............................................................................................................................................................................. 21
3.8 Pellet tank assembly sequence ............................................................................................................................................................... 23
3.9 Connection to the flue............................................................................................................................................................................... 25
3.10 Electrical connections .............................................................................................................................................................................. 28
3.11 Filling the system...................................................................................................................................................................................... 29
3.12 Hydraulic base diagrams ......................................................................................................................................................................... 30
3.13 Panel board .............................................................................................................................................................................................. 34
3.14 Connections ............................................................................................................................................................................................. 39
3.15 Boiler start-up ........................................................................................................................................................................................... 40
3.16 Troubleshooting ........................................................................................................................................................................................ 42
3.17 Alarms and checks ................................................................................................................................................................................... 42
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................9
2.1 Technical features......................................................................................................................................................................................... 9
2.2 Hydraulic dimensions and connections ...................................................................................................................................................... 10
2.3 Installing the boiler and pellet tank ............................................................................................................................................................. 11
2.4 Technical data............................................................................................................................................................................................. 14
2.5 Main components ....................................................................................................................................................................................... 16
2.6 Features of the pellet .................................................................................................................................................................................. 17
2.6 Features of the wood .................................................................................................................................................................................. 18

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General information
1GENERAL INFORMATION
1.1 - GENERAL WARNINGS
The instruction booklet is an integral and essential part of the
product and must be kept by the system manager.
Read the warnings contained in this instruction booklet carefully
as they provide important guidelines regarding installation, use
and maintenance safety.
Keep the booklet with care for further consultation.
Your appliance must be installed and serviced in compliance
with the standards in force according to the manufacturer
instructions, up to standard and by legally qualified and
certified personnel.
Systems for the production of domestic hot water MUST be
constructed entirely with materials that comply with M.D.
174/2004 (taps, pipes, fittings, etc.).
By professionally qualified personnel we mean: personnel
with specific technical skill in the field of heating system
components for civil use, domestic hot water production
and maintenance. Personnel must have the qualifications
provided for by current legislation.
Incorrect installation or improper maintenance can cause damage
to persons, animals or objects for which the manufacturer is not
responsible.
Before performing any cleaning or maintenance, disconnect the
appliance from the energy mains by acting on the switch of the
system and/or through the specific cut-off devices.
Do not obstruct the terminals of the ventilation ducts.
In case of failure and/or malfunctioning of the appliance, switch
it off and do not try to repair it or intervene on it directly. Contact
only personnel qualified in compliance with law.
Any product repairs must be performed solely by personnel
authorised by Unical, using original spare parts only. Failure
to comply with the above can compromise the safety of the
appliance and void the warranty.
To guarantee appliance efficiency and its correct operation,
yearly maintenance must be performed by qualified personnel.
Should you decide not to use the appliance, parts entailing
potential sources of hazard must be made safe.
Should the appliance be sold or transferred to a new owner or
if you move and leave the appliance, always make sure that the
instruction booklet accompanies it in order to be consulted by
the new owner and/or installer.
Only original accessories must be used for all appliances with
optionals or kits (including electric).
This appliance is intended solely for the use for which it was
expressly designed.
Any other use is to be considered improper and therefore
dangerous.

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1.2 - SYMBOLS USED IN THE MANUAL
Pay special attention when reading this manual to the parts marked by the symbols:
NOTE!
Tips
for the user
ATTENTION!
Possible dangerous
situation for the product
and the environment
DANGER!
Serious danger for
personal safety and life
1.3 - APPROPRIATE USE OF THE APPLIANCE
The ALBIOMIX appliance has been built according to the current level of engineering and acknowledged
technical safety rules.
Nonetheless, if improperly used, dangers could arise for the safety and life of the user and other persons
or damage to the equipment or other objects.
The appliance is intended to operate in hot water circulation heating systems.
Any other use must be considered improper.
UNICAL will not be held liable for any damage resulting from improper use.
Use according to the intended purposes also includes strict compliance with the instructions in this manual.
The user must be instructed concerning the use and operation of his heating system, in particular:
• Deliver these instructions to the user, as well as other documents concerning the appliance inserted in the envelope
inside the packaging. The user must keep this documentation safe for future consultation.
• Inform the user about the importance of the air vents and the flue gas exhaust system, highlighting their essential
features and the absolute prohibition of modifying them.
• Inform the user concerning controlling the system's water pressure as well as operations to restore it.
• Inform the user concerning correct temperature control, control units/thermostats and radiators for saving energy.
• Remember that the system must receive regular maintenance at least once a year and combustion analysis must
be performed every two years (as per national law).
• Should the appliance be sold or transferred to a new owner or if you move and leave the appliance, always make
sure that the instruction booklet accompanies it in order to be consulted by the new owner and/or installer.
The manufacturer will not be held liable in the event of damage to persons, animals or objects resulting from
failure to comply with the instructions contained in this manual.
1.4 - INFORMATION FOR SYSTEM MANAGER

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General information
1.5 - SAFETY WARNINGS
ATTENTION!
The appliance must be installed, adjusted and maintained by professionally qualified personnel, in com-
pliance with the standards and provisions in force. Incorrect installation can cause damage to persons,
animals and objects for which the manufacturer cannot be held responsible.
DANGER!
The boiler must be serviced or repaired by professionally qualified personnel, authorised by Unical. We
recommend stipulating a maintenance contract.
Insufficient or irregular maintenance can jeopardise the operating safety of the appliance and cause damage
to persons, animals and objects for which the manufacturer cannot be held responsible.
Modifying parts connected to appliance
Do not modify the following parts:
- the boiler
- the air, water and electrical current lines
- the flue gas pipe, the safety valve and the exhaust pipe
- the construction parts which affect the operating safety of the appliance
Attention!
To tighten or loosen the screwed fittings, use only appropriate fixed spanners.
Incompliant use and/or inappropriate tools can cause damage (e.g. water or gas leakage).
Explosive and easily flammable substances
Do not use or store explosive or easily flammable materials (e.g. petrol, paints, paper) in the room where the ap-
pliance is installed.
ATTENTION!
The appliance must not be used by people with reduced physical, sensory and mental abilities, without
experience and knowledge.These people must be previously trained and supervised during the manoeuvre
operations. Children must be supervised so that they do not play with the appliance.

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1.6 - TECHNICAL DATA PLATE
The technical data plate is adhesive and is included in the
document case; it must be applied by the installer on the
outside of the casing.

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Technical features
2TECHNICAL FEATURES
AND DIMENSIONS
2.1 - TECHNICAL FEATURES
Wood gas and reverse flame "2 in 1" multi-fuel generator,
with thermal power of 34.8 - 45.5 and 80 kW for solid biomass
fuel like wood and briquettes, equipped also with a special
pellet burner with flue extraction fan.
Inclusive of a tank able to take 230 kg of fuel, which can be
installed on the three sides and which automatically feeds the
burner; and a safety exchanger.
Exceptional yield and low emissions, guaranteeing quick
depreciation thanks also to the government incentives for high
energy class boilers (EN 303-5 of 2012).
Combustion chamber made of special AISI 430 thermal
stainless steel, highly stable and resistant to extreme
temperatures and acid corrosion.
Large loading compartment with functional bypass system
for logs, ensuring long loading intervals.
Grate made of thick (15 mm) AISI 304 thermal stainless
steel guaranteeing absolute durability.
Primary air ducts at the sides, 6 mm thick.
Vertical pipes with movable turbolators powered by rods and
rocker arms, with time-driven programming to increase the
efficiency and yield of the generator (practical removal of the
ashes from the front).
BIOTRONIC control panel for controlling:
- automatic switching of the fuel
- work modes
- safety devices (audible and visual alarms)
- data collected by the system
Burner located behind the boiler, made of self-cleaning AISI
304 stainless steel
Two separate screws for loading and conveying
Quick start-up
Armoured photocell for detecting the presence and intensity
of the flame
Modulations at the control board
Wood combustion
1st reduction of fan speed linked to the temperature of the
water in the boiler
2nd reduction of fan speed in relation to the flue gas temperature
of the boiler (safety modulation)
Pellet combustion
1st modulation linked to the temperature of the water in the
boiler, reducing the amount of air by slowing down the fan.
Reduction of the amount of fuel supplied by the screw,
increasing the pause time between two consecutive loading
processes.
The two modulations are connected.
2nd reduction of fan speed linked to the flue gas temperature of
the boiler (safety modulation)
3rd adjustment of fan speed linked to the light emissions of
the brazier detected by the optical sensor (the speed
is increased when a decrease in the intensity of light is
detected)

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2.2 - HYDRAULIC DIMENSIONS AND CONNECTIONS