Unical KONf 200 User manual

200 - 400
KONf
INSTALLATION AND MAINTENANCE INSTRUCTIONS
ENGLISH

2
http://www.unicalag.it/prodotti/professionale-300/light-commercial-alluminio/2075/konf
Provisions for proper disposal of the product
After decommissioning, this appliance must not be disposed of as mixed urban waste.
Separate waste collection is mandatory for this type of waste, in order to allow the recovery and reuse of the
materials making up the appliance.
Please contact operators authorised for the disposal of this type of appliances
Incorrect management of waste and of its disposal has potential negative e󰀨ects on the environment and human health
The symbol on the appliance, represents the prohibition to dispose of the product as mixed urban waste.

3
Installation instructions Technical Features General information
Maintenance instructions
ENGLISH
2 TECHNICAL FEATURES AND DIMENSIONS................................................................................................................10
2.1 Technical features....................................................................................................................................................10
2.2 Main components view and dimensions ..................................................................................................................10
2.3 Dimension................................................................................................................................................................14
2.4 Available ow rate / pressure diagram.....................................................................................................................18
2.5 Operation data .........................................................................................................................................................19
4 MAINTENANCE INSTRUCTIONS...................................................................................................................................40
4.1 Inspection and maintenance instructions.................................................................................................................40
4.3 Adaptation to the use of other gas ..........................................................................................................................42
4.4 Operation parameters programming........................................................................................................................43
4.5 Wiring diagram.........................................................................................................................................................46
4.6 Error codes ..............................................................................................................................................................49
3 INSTALLATION INSTRUCTIONS....................................................................................................................................21
3.1 General warnings.....................................................................................................................................................21
3.2 Installation standards...............................................................................................................................................21
3.3 Preventive system verication and adjustment operations......................................................................................21
3.4 Packaging ................................................................................................................................................................22
3.5 Positioning the boiler................................................................................................................................................23
3.6 Flue gas exhaust pipe connection ...........................................................................................................................24
3.7 Connections.............................................................................................................................................................26
3.8 Filling the system .....................................................................................................................................................28
3.9 Electrical connections ..............................................................................................................................................29
3.10 Commissioning ..................................................................................................................................................... 34
3.11 Measurement of combustion e󰀩ciency during installation.......................................................................................35
3.11.1 Calibration function activation ....................................................................................................................35
3.11.2 Probes positioning .....................................................................................................................................36
3.12 Burner adjustment....................................................................................................................................................37
3.12.1 Adaptation of power to the heating system...................................................................................................39
1 GENERAL INFORMATION.................................................................................................................................................4
1.1 General warnings.......................................................................................................................................................4
1.2 Symbols used in the manual......................................................................................................................................5
1.3 Appropriate use of appliance .....................................................................................................................................5
1.4 Information for system manager ................................................................................................................................5
1.5 Safety warnings .........................................................................................................................................................6
1.6 Technical data plate ..................................................................................................................................................7
1.7 Water treatment .........................................................................................................................................................8
1.8 Boiler antifreeze protection ........................................................................................................................................9
Attention: this manual contains instructions for the exclusive use of the professionally qualied installer and/or maintenance
technician in compliance with current legislation.
The user is NOT qualied to intervene on 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.

4
1GENERAL INFORMATION
Any repairs must be performed solely by personnel authorised
by Unical AG S.p.A., using original spare parts only. Failure to
comply with the above can compromise the safety of the appli-
ance and void the warranty.
To guarantee appliance e󰀩ciency and its correct operation,
yearly maintenance must be performed by qualied personnel.
Should you decide not to use the appliance, parts entailing
potential sources of hazard must be made safe.
Before commissioning an appliance that has not been used,
wash the domestic hot water production system, making the
water ow until it has been fully replaced.
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 dan-
gerous (*).
1.1 -GENERAL WARNINGS
The instruction booklet is an integral and essential part of the
product and must be kept by the user.
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.
Installation and maintenance must be performed in compliance
with the standards in force according to the instructions of the
manufacturer, up to standard and by personnel qualied and
certied in compliance with law.
Systems for the production of domestic hot water MUST be
constructed entirely with compliant materials.
By professionally qualied personnel we mean: personnel with
specic technical skill in the eld of heating system components
for civil use, domestic hot water production and maintenance.
Personnel must have the qualications provided for by current
legislation.
Incorrect installation or improper maintenance can cause dam-
age 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 specic cut-o󰀨 devices.
Do not obstruct the terminals of the intake/exhaust ducts.
In case of failure and/or malfunctioning of the appliance, switch
it o󰀨 and do not try to repair it or intervene on it directly. Contact
only personnel qualied in compliance with law.

5
DANGER!
Danger of burns!
DANGER!
Serious danger
to safety and health
ATTENTION!
Possible dangerous
situation for the product
and the environment
OBLIGATION!
Wear protective
gloves
NOTE!
Tips for the user
NOTE!
For further details refer to the
Technical Information:
at the address indicated
on page 2.
1.2 - SYMBOLS USED IN THE MANUAL
When reading this manual, pay special attention to the parts marked by the symbols shown:
1.4 -INFORMATION FOR THE SYSTEM MANAGER
The user must be instructed on use and operation of the 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 reference.
• Inform the user about the importance of the air vents and the ue gas exhaust system, highlighting their essential
features and the absolute prohibition of modifying them.
• Inform the user on how to control the system's water pressure as well as operations to restore it.
• Inform the user on correct temperature control, control units/thermostats and radiators for saving energy.
• Please note that, in compliance with the standards in force, the inspection and maintenance of the appliance must
be carried out in compliance with the regulations and frequency indicated by the manufacturer.
• 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 manual accompanies it so that the new owner and/or installer can refer to it.
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.
1.3 - APPROPRIATE USE OF APPLIANCE
The boiler has been constructed according to the current level of engineering and acknowledged technical
safety rules.
Nonetheless, improper use could result in hazards for the safety and life of the user or other persons, i.e.
damage to the appliance or other property.
The appliance is designed to work in heating systems, with hot water circulation, for the production of
domestic hot water.
Any other use shall be considered as misuse.
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.

6
1.5 - SAFETY WARNINGS
ATTENTION!
The boiler must not be used by people with 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 have access to the boiler.
ATTENTION!
The appliance must be installed, adjusted and maintained by professionally qualied 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!
NEVER attempt performing maintenance or repairs on the boiler on your own initiative.
Any work must be done by professionally qualied personnel. We recommend stipulating a maintenance
contract.
Insu󰀩cient 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.
Changes to the parts connected to the boiler (once the boiler installation is complete)
Do not modify the following parts:
- the boiler
- the gas, air, water and electricity supply lines
- the ue 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 ttings, use only appropriate xed spanners.
Incompliant use and/or inappropriate tools can cause damage (e.g. water or gas leakage).
ATTENTION!
Indications for propane gas-red appliances
Make sure that the gas tank has been deaerated before installing the appliance.
For state-of-the-art tank venting, contact the LPG supplier or person qualied in compliance with the law requirement.
If the tank has not been professionally deaerated, ignition problems could arise.
In that case, contact the supplier of the LPG tank.
Smell of gas
Should a smell of gas be perceived, follow these safety guidelines:
- do not turn electric switches on or o󰀨
- do not smoke
- do not use the telephone
- close the gas shut-o󰀨 valve
- air out the area where the gas leakage has occurred
- inform the gas supplier or a company specialised in installation and maintenance of heating systems.
Explosive and easily ammable substances
Do not use or store explosive or easily ammable materials (e.g. petrol, paints, paper) in the room where the boiler
is installed.

7
General information
ENGLISH
/
The technical data plate is placed inside the
boiler, the COPY of the data plate is placed
inside the front door.
1.6 -TECHNICAL DATA PLATE
The CE marking
certies the compliance of the equipment with the essential
safety requirements dened in the directives and applicable
European regulations and that its functioning satisfy applicable
technical standards.
The CE marking is a󰀩xed to each piece of equipment with an
appropriate label.
The CE declaration of conformity issued in accordance with
international standards by the manufacturer, is placed in docu-
mentation envelope supplied with the product.
KEY:
1 = CE monitoring body
2 = Type of boiler
3 = Boiler model
4 = Number of stars (directive 92/42 EEC)
5 = (S.N°) Serial Number
6 = P.I.N.ProductIdenticationNumber
7 = Typesofapproveduegasexhaustcongurations
8 = (NOx)NOxClass
A = Heatingcircuitcharacteristics
9 = (Pn) Effective nominal output
10 = (Pcond) Effective output in condensation
11 = (Qn)Maximumheatoutput
12 = (AdjustedQn)Adjustedforratedheatoutput
13 = (PMS)Max.heatingoperatingpressure
14 = (Tmax)Max.heatingtemperature
B = Domestichotwatercircuitcharacteristics
15= (Qnw)Ratedheatoutputindomestichotwaterfunction(ifdifferentto
Qn)
16= (D)SpecicD.H.W.owrateaccordingtoEN625-EN13203-1
17= (Rfactor)No.oftapsaccordingtothedeclaredamountofwater(EN
13203-1)
18 = (Ffactor)No.ofstarsaccordingtothedeclaredqualityofthewater
(EN13203-1)
19 = (PMW)Max.domestichotwateroperatingpressure
20 = (Tmax)Max.domestichotwatertemperature
C = Eletricalcharacteristics
21= Electricalpowersupply
22 = Consumption
23 = Protection rating
D = Countries of destination
24 = Direct and indirect countries of destination
25 = Gas category
26 = Supply pressure
E = Factory settings
27 = Adjusted for gas type X
28 = Space for national brands
G = ErP
29 = Seasonalspaceheatingenergyefciency
30 =EnergyefciencyinDHWproductionmode

8
ATTENTION (*) see general warnings 1.1:
The heating only models are NOT suitable
for the production of water for human con-
sumption according to Ministerial Decree
D.M. 174/2004.
ATTENTION!
ANY DAMAGE TO THE BOILER CAUSED BY
THE FORMATION OF FOULING OR BY COR-
ROSIVE WATER WILL NOT BE COVERED BY
THE WARRANTY.
VALUE MIN MAX
PH 6.5 8
Hardness [°fr] 9 15
NOTE!
Further details in the section
‘‘Technical Information’’ on the boiler
page of the www.unicalag.it website
1.7 - WATER TREATMENT
Feed water treatment prevents problems and
maintains the functionality and e󰀩ciency of the
generator over time.
The ideal water pH in heating systems must be
within:
To minimise corrosion, it is crucial to use a cor-
rosion inhibitor; in order for it to work properly,
the metal surfaces must be clean.
(see system protection ACCESSORIES sect. in
domestic price list)

9
Technical Features
ENGLISH
P
O
S
ANTIFREEZE FUNCTION
Power supplies 30 - SMG (*)
Status
antifreeze function
Actions
Electric Gas
1ON ON < 7 °C ON - Burner and Pump ON until T > 15°C
ON ON < 2 ÷ 5 °C ON FAULT SIGNAL CODE 16
(with Electrical power supply ON)
(see par. 4.6 - ERROR CODES).
Ignition inhibited.
2ON OFF OFF (with Electrical power supply ON)
OFF ON OFF (see par. 4.6 - ERROR CODES).
OFF OFF OFF Ignition inhibited.
(*) Sensor 30 par. 2.2
For outdoor installations, in partially protected places, you must use the additional heater
kit (optional) for antifreeze siphon cap.
Declared TA room temperature, using the resistance kit = -15°C.
1.8 - BOILER ANTIFREEZE
PROTECTION
It is activated by default
This protection can intervene only if the electricity
and gas supplies are connected.
If one of the two is not available and upon reset
11 (SM) a temperature level between 2 and
5°C is detected, the appliance will behave as
described in the table below, pos 2.
The heating system can be protected e󰀨ectively
from frost by using antifreeze products with
inhibitor for heating systems (specific for
multidmetal)
Do not use car engine antifreeze products as
they could damage the water gaskets.

10
2.2 - INTERNAL VIEW WITH THE INDICATION OF THE MAIN COMPONENTS
2TECHNICAL FEATURES AND DIMENSIONS
2.1 - TECHNICAL FEATURES
NOTE! Further details in the section ‘‘Technical Information’’ on the boiler page of the www.unicalag.it website
KONf 200
23 TSC Fluegascollectorsafetythermostat
24 AluminiumHeatExchanger/Capacitor
25 Vent valve
26 Condensation drain trap
27 E. RIL. Detection electrode
28 E. ACC. Ignition electrode
29 Returnshut-off(3Way)valve
30 SMG Sensor FlowGeneral
31 Condensation drain trap
32 Outletueinspection
35 Ignition transformer
KEY
N° C.E. S.E. Description
3 VG Gas valve
5Burner
10 HL TL Safetythermostat
11 Hb SR Heating temperature sensor
12 Ht P Modulating Pump
13 Lp DK Waterdeciencypressureswitch
14 Boiler drain valve
18 FL FH VM Modulating Fan
20 Safety valve
22 rb SRR Returntemperaturesensor

11
Technical Features
ENGLISH
37 Flowshut-off(3Way)valve
38 Gaspressureswitch
40 Manual Vent valve
41 SmokeThermostat
42 PFmax Fluepressureswitchmax
43 SL Condensate sensor level
44 PFmin Fluepressureswitchmin
FL* Flowpressureswitch(*)
DN mm
GGas inle 50 60,3
MHeatingsystemow 80 88,9
RHeating system return 80 88,9
Scond Condensation drain 32
S Smoke outlet Ø 100
C.E. = ERRORCODESseepar.4.6
S.E. WIRINGDIAGRAM
KEY see par. 4.5
(N.U) Component not used
NOTE:
Insert the ows switch approved, cod.
00368501, as shown in gure.

12
KONf 400
23 TSC Fluegascollectorsafetythermostat
24 AluminiumHeatExchanger/Capacitor
25 Vent valve
26 Condensation drain trap
27 E. RIL. Detection electrode
28 E. ACC. Ignition electrode
29 Returnshut-off(3Way)valve
30 SMG Sensor FlowGeneral
31 Condensation drain trap
32 Outletueinspection
35 Ignition transformer
KEY
N° C.E. S.E. Description
3 VG Gas valve
5Burner
10 HL TL Safetythermostat
11 Hb SR Heating temperature sensor
12 Ht P Modulating Pump
13 Lp DK Waterdeciencypressureswitch
14 Boiler drain valve
18 FL FH VM Modulating Fan
20 Safety valve
22 rb SRR Returntemperaturesensor

13
Technical Features
ENGLISH
37 Flowshut-off(3Way)valve
38 Gaspressureswitch
40 Manual Vent valve
41 SmokeThermostat
42 PFmax Fluepressureswitchmax
43 SL Condensate sensor level
44 PFmin Fluepressureswitchmin
FL* Flowpressureswitch(*)
DN mm
GGas inle 50 60,3
MHeatingsystemow 80 88,9
RHeating system return 80 88,9
Scond Condensation drain 32
S Smoke outlet Ø 100
C.E. = ERRORCODESseepar.4.6
S.E. WIRINGDIAGRAM
KEY see par. 4.5
(N.U) Component not used
NOTE:
Insert the ows switch approved, cod.
00368501, as shown in gure.

14
2.3 - DIMENSIONS
FRONT VIEW
950
1214
INT.1INT. 2
KONf 200

15
Technical Features
ENGLISH
TOP VIEW
SIDE VIEW DX
606
134 166 134
132
119179
381 449
118
277

16
KONf 400
1860
1214
INT.1INT. 2INT.1INT. 2
FRONT VIEW

17
Technical Features
ENGLISH
606
134 166 134
132
119179
118
277
449
381
TOP VIEW
SIDE VIEW DX

18
Q: Flow rate (l/h)
Q: Flow rate (l/h)
Avaible Head (m/H2O)
The table provides an indication the flow the pump in function of the Dt of the primary circuit.
KONf 200 KONf 400
Power supply in kW kW 199 398
Max ow rate demanded l/h (Dt 15 K) l/h 11400 22818
Nominal ow rate request (Dt 20 K) l/h 8860 17110
Power supply in condensation (50/30) kW 210 420
Max ow rate demanded l/h (Dt 15 K) l/h 12040 24080
Nominal ow rate request (Dt 20 K) l/h 9030 18060
n. 1 Pump at Qnom n. 1 Pump at Qmin
n. 2 Pump at Qnom n. 1 Pump at Qmin
2.4 - DIAGRAM OF FLOW RATE/PRESSURE AVAILABLE FOR INSTALLATION
Avaible Head (m/H2O)
Δt rate between Flow and Return it must NOT
be less than 15 ° K.
NOTE: The use of a mixing header tted betwe-
en the boiler circuit and the system circuit is
always advisable. It becomes INDISPENSABLE
if the system requires ow rates superior to the
maximum permitted boiler ow rates, which is to
say lower than 15K.

19
Technical Features
ENGLISH
KONf 200 KONf 400
Appliance category II2H3P II2H3P
Modulation Ratio 1 : 10,0 1 : 20,0
Nominal Heat Input on P.C.I. Qn kW 199 398
Minimum Heat Input on P.C.I. Qmin kW 20 20
Nominal Output (Tr 60 / Tm 80 °C) Pn kW 195 391
Minimum Output (Tr 60 / Tm 80 °C) Pn min kW 19,1 19,21
Nominal Output (Tr 30 / Tm 50 °C) Pcond kW 206 413
Minimum Output (Tr 30 / Tm 50 °C) Pcond min kW 21,2 21,2
E󰀩ciency at max. output (Tr 60 / Tm 80°C) % 97,9 98,8
E󰀩ciency at min. output (Tr 60 / Tm 80°C) % 95,6 95,6
E󰀩ciency at max. output (Tr 30 / Tm 50°C)) % 104 104
E󰀩ciency at min. output (Tr 30 / Tm 50°C) % 106 106
Rendimento al 30% del carico (Tr 30°C) % 108,9 108
Combustion e󰀩ciency with nominal load % 98,02 98,26
Combustion e󰀩ciency with minimum load % 98,2 98,2
Heat loss at casing with burner in operation (Qmin) % 2,6 2,56
Heat loss at casing with burner in operation (Qn) % 0,14 0,05
Flue gas temperature tf-ta (min)(*) °C 34,0 34,5
Flue gas temperature tf-ta (max)(*) °C 40 35,6
Maximum allowable temperature °C 100 100
Maximum operating temperature °C 85 85
Flue gas mass ow rate (min) kg/h 34,31 34,31
Flue gas mass ow rate (max) kg/h 319,57 639,14
Excess λ air % 23 23
Flue losses with burner in operation (min) % 1,8 1,8
Flue losses with burner in operation (max) % 2,0 1,74
Minimum heating circuit pressure bar (kPa) 0,5 (50) 0,5 (50)
Maximum heating circuit pressure bar (kPa) 6 (600) 6 (600)
Water content l 22 44
Gas Consumption Natural (20 mbar) gas G 20 a Qn m3/h 21,04 42,1
Gas Consumption Natural gas (20 mbar) G 20 a Qmin m3/h 2,11 2,11
Gas Consumption G25 (supply pressure 25 mbar) Qn m3/h 24,5 49
Gas Consumption G25 (supply pressure 25 mbar) Qmin m3/h 2,46 2,46
Gas Consumption G31 (supply pressure 37/50 mbar) Qn kg/h 15,5 31,0
Gas Consumption G31 (supply pressure 37/50 mbar) Qmin kg/h 1,55 1,55
Max. available pressure at the chimney base Pa 150 150
Max Condensation production kg/h 12,8 26,0
Emissions
CO at Minimum Heat Input with 0% of O2 mg/kWh 153 156
NOx at Nominal Heat Input with 0% of O2 mg/kWh 68 70
NOx Class 6 6
Electrical Data
Voltage/Frequency electric power supply V/Hz 230/50 230/50
Fuse on main supply A (R) 6.3 A T - 250V 6.3 A T - 250V
Insulation degree IP X5D X5D
Room Temperature = 20°C
(*) Temperatures detected with the unit in operation (Tr 60 / Tm 80°C)
CO2 (min/max) See table INJECTORS PRESSURES
Seasonal space heating energy
2009/125 CEE (<=400Kw) ηs - see ErP table
Stand-by heat loss ∆T 30°C - Pstb - see ErP table
Consumption in stand-by - Psb - see ErP table
2.5 - OPERATING DATA ACCORDING TO UNI 10348 and GENERAL FEATURES
For the adjustment data: NOZZLES - PRESSURE - DIAGRAMS - FLOW RATES - CONSUMPTION refer to the paragraph ADAP-
TATION TO OTHER TYPES OF GAS.

20
KONf 200 KONf 400
Element Symbol Unit
E󰀨ective nominal output Pnominale kW 195 388
Seasonal energy e󰀩ciency to heat
the room ƞs% 93 92
Season e󰀩ciency class to
discharge A A
For boilers to heat the room
and mixed boilers: useful heat output
Useful heat output with
high temperature capacity
(Tr 60 °C / Tm 80 °C)
P4kW 195 391
Rated heat output e󰀩ciency
with high temperature capacity
(Tr 60 °C / Tm 80 °C)
ƞ4% 88,2 88,5
Useful power at 30% of the rated heat
output with low temperature
capacity (Tr 30 °C)
P1kW 65,0 129,0
Performance at 30% of the rated heat
output with low temperature
capacity (Tr 30 °C)
ƞ1% 98,1 97,3
Boiler with output range adjustment: YES / NO NO NO
Auxiliary electricity consumption
With a full load elmax kW 0,580 1,160
With a partial load elmin kW 0,156 0,156
Standby mode PSB kW 0,025 0,032
Other elements
Heat loss in stand-by Pstb kW 0,962 0,9238
Emissions of nitrogen oxides ref. PCI (PCS) NOx Mg/kWh 46 (41) 46 (41)
Annual electricity consumption QHE GJ 606 1220
For CH & DHW production boilers
Declarerd load prole - -
Energy e󰀩ciency in DHW production mode ƞwh % - -
Daily electricity consumption Qelec kWh - -
Daily fuel consumptionl Qfuel kWh
Inside sound power level Lwa dB (A)
Annual electricity consumption AEC kWh - -
Annual fuel consumption AFC GJ
Seasonal e󰀩ciency class
in DHW production mode - -
2.5.1 - TECHNICAL DATA ACCORDING ErP DIRECTIVE