Unical modulex 360 Installation and operating instructions

00332210-2nd edition-09/05
360 - 450
540 - 630
MODULEX
INSTALLATION, USE AND
MAINTENANCE
GB
MODULAR CONDENSING
BOILER






2
IMPORTANT
This INSTRUCTION MANUAL, which is an integral and indispensable part of the product, must be handed over to the user by the plumbers and
must be kept in a safe place for future reference.The manual must be handed over with the boiler should it be sold or transferred.
This boiler must be used for the purposes for which it has been designed. Any other use shall be considered incorrect and therefore
dangerous.
The boiler must be installed in compliance with applicable laws and standards and according to the manufacturer’s instructions given in this
manual.Incorrect installation may cause injury to persons and/or animals and damage to property.The manufacturer shall not be held liable for any
such injury and/or damage.
Damageand/or injury caused byincorrect installation or use and/or damage and/or injury due to non-observanceofthe manufacturer’sinstructions
shall relieve UNICAL from any and all contractual and extracontractual liability.
Before installing the boiler, check that the technical data corresponds to requirements for its correct use in the system.
Check that the boiler is intact and that it has not been damaged during transport and handling.Do not install equipment which is patently damaged
and/or faulty.
Do not obstruct the air suction and/or heat dissipation grates.
Only original accessories must be used for all boilers supplied with optionals or kits (including electrical ones).
Dispose of the packaging with care as all the materials can be recycled.The packaging must therefore be sent to specific waste management
sites.
Keep the packaging out of the reach of children as it may represent a choking and suffocation hazard.
In the event of failure and/or faulty functioning, switch off the boiler. Do not attempt to make repairs: contact qualified technicians.
Original parts must be used for all repairs to the boiler.
Non-observance of the above requirement may jeopardize the safety of the boilers and expose people, animals and property to danger.
To guarantee efficiency and correct functioning of the equipment it is legally binding to service the boilers once a year according to
the schedule indicated in the relative section of this manual.
In the event of long periods of inactivity of the boiler, disconnect it from the power mains and close the gas tap (Warning! In this case the boiler’s
electronic anti-freeze function will not be operative).
Should there be a risk of freezing, add anti-freeze: it is not advisable to empty the system as this may result in damage; use specific anti-freeze
products suitable for multi-metal heating systems.
N.B.
For boilers which use gaseous fuel, if you smell gas:
- do not turn on or off electrical switches and do not turn on electrical appliances;
- do not ignite flames and do not smoke;
- close the main gas tap;
- opendoors and windows;
- contact a Service Centre, qualified installer or the gas supply company.
Never use flames to detect gas leaks.
WARNING
This boiler has been built for installation in the country indicated on the technical data plate: installation in any other country may be a source
of danger for people, animals and property.
Read the warranty conditions and clauses on the warranty certificate attached to the boiler with care.

3
DATA PLATE
1 = P.I.N. code
2 = Boiler type (only for condensing boiler)
3 = (S.N°) Serial Nr.
4 = Manufacture Date
5 = Model
6 = Appliance type
7 = Elettrical supply
8 = Maximum absorbed power - Insulation
protection
9 = (Pn) Nominal Output
10 = (Pcond) Condensing Nominal Output
(only for condensing boiler)
11 = (D) Specific flow rate EN 625
12 = (Qn) Nominal heat input
13 = (Qnw) Nominal heat input for D.H.W.
system if there are different out puts
between the C.H.and D.H.W.circuits
14 = (NOx) NOx Class
15 = (PMS) Max pressure C.H. system
16 = (T max) MaxTemperature C.H.system
17 = (PMW) Max pressure D.H.W.system
18 = (T max)Temperature D.H.W.system
19 = Adjusted for gas type X
20 = Country of destination, Gas category,
Supply pressure
21 = Side for national brand
®
2H
2E
3+
3B/P
3P
G20
G20
G30/G31
G30 - 31
G31
20 - 25
20
28-30/37
30 - 50
37 - 50
mbar
mbar
mbar
mbar
mbar
IT ES IE
PT GR
TR HR
CZ SK
HU
SI
GB
CN RU RO
LV EE LT
II 2H3+
II 2H3+
II 2H3B/P
II 2H3P
II 2HS 3B/P
II 2E3P
II 2H3P
I 2H
I 2H
20 ; 28-30/37 mbar
20 ; 28-30/37 mbar
20 ; 50 mbar
18 ; 50 mbar
25 ; 30 mbar
20 ; 50 mbar
20 ; 37 mbar
20 mbar
20 mbar
/
1
2
345
678
9
12
15
17
19
20
18
16
10
13
11
14
21

4
1
2
3
TECHNICALFEATURES
ANDDIMENSIONS........................................................... pag. 6
1.1 Technical Features .................................................................. pag. 6
1.2 Dimensions.............................................................................. pag. 7
1.3 Technical Data and Main Components .................................... pag. 9
1.4 SideView................................................................................. pag. 10
INSTRUCTIONS FOR INSTALLERS ................. pag. 11
2.1 Instructions for installation...................................................... pag. 11
2.2 Installation ............................................................................... pag. 11
2.2.1 Packing ....................................................................... pag. 11
2.2.2 Boiler Location inside a Heat Power Plant ................. pag. 13
2.2.3 BoilerConnection ....................................................... pag. 13
2.2.4 Connection to Chimney .............................................. pag. 13
2.2.5 Notes on Condensate Drain ....................................... pag. 14
2.3 Types of Heating Systems ...................................................... pag. 15
2.3.1 C.H.System Air Vent.................................................. pag. 16
2.3.2 Boiler and System Filling-up & Draining .................... pag. 16
2.3.3 Max AllowableWorking Pressure............................... pag. 17
2.3.4 Safety Valve ............................................................... pag. 17
2.3.5 Gas Mains .................................................................. pag. 17
2.3.6 Hydraulic Compensator or Open Manifold ................. pag. 17
2.3.7 Filter ........................................................................... pag. 18
2.3.8 BallValves .................................................................. pag. 18
2.3.9 FeedingWaterQuality ................................................ pag. 18
2.3.10 Boiler Antifrost Protection .......................................... pag. 18
2.3.11 Min.WaterFlow Rate.................................................. pag. 19
2.4 Boiler Operation....................................................................... pag. 19
2.4.1 GeneralDescription .................................................... pag. 20
2.4.2 IgnitionSequence....................................................... pag. 21
2.4.3 SupplementaryBoard ................................................. pag. 22
2.4.4 DomesticHotWater(DHW) Mode Operation ............. pag. 23
2.5 Boiler Operation in case of technical intervention .................. pag. 23
2.6 Electric Connections ............................................................... pag. 24
2.6.1 PowerSupply .............................................................. pag. 25
2.6.1 WiringDiagram ........................................................... pag. 25
2.6.2 Electric Connection to Ignition PCB........................... pag. 26
2.6.3 Electric Connection to the Room Thermostat ............ pag. 26
2.6.4 DHWStorageTank ..................................................... pag. 27
MODULAR BOILER DRIVE (MBD)
OPERATION.......................................................................... pag. 28
3.1 General Description ................................................................. pag. 28
3.2 Operation and display instructions .......................................... pag. 28
3.2.1 “Mode”Key.............................................................. pag. 29
3.2.2 “Step”Key ............................................................... pag. 29
3.2.3 “+ / -“ Key................................................................ pag. 29
3.2.4 “Store”Key .............................................................. pag. 29
3.2.5 ServiceCode .......................................................... pag. 29
3.2.6 Programming Access Procedure ........................... pag. 30
3.2.7 “Stand-by”Key ........................................................ pag. 32

5
4
3.2.8 “Parameter”Mode ................................................... pag. 32
3.2.8.1 Installerand User programmable Operation
Parameters............................................... pag. 32
3.2.8.2 InstallerprogrammableOperation
Parameters by previously entering
the service code ...................................... pag. 33
3.2.9 “Data”Mode ............................................................ pag. 34
3.2.9.1 Installerand User programmable
parameters ............................................... pag. 34
3.2.9.2 Installerprogrammableparameters
by previously entering the
service code............................................. pag. 34
3.2.10 “Test”Mode ............................................................. pag. 35
3.2.11 “OperationTime”Mode ........................................... pag. 35
3.3 HeatingModeOperation.......................................................... pag. 36
3.3.1 Heating Mode Operation by RoomThermostat............. pag. 36
3.3.2 Heating Mode Operation by Outer Sensor.................... pag. 36
3.3.3 Heating Mode Operation by Outer Compensator .......... pag. 37
3.4 DHWMode Operation. ............................................................. pag. 37
3.4.1 DHW Mode Operation by StorageTank NTC Sensor ... pag. 37
3.4.2 DHW Mode Operation by StorageTankThermostat ..... pag. 37
3.5 Burner Pressure AdjustmentTest ........................................... pag. 38
ERRORS ................................................................. pag. 39
4.1 Blank Display ................................................................. pag. 39
4.2 The Boiler doesn’t fulfill the DHW Production Request. ......... pag. 39
4.3 Ignition Anomalies ................................................................. pag. 39
4.4 Block Errors ................................................................. pag. 39
4.5 ErrorCodes ................................................................. pag. 40
4.5.1 Error Codes by Alarm.................................................... pag. 40
4.5.2 Error Codes related to local temperatures .................... pag. 40
4.5.3 Error Codes related to gas pressure, MBD,
AM-4 and AM-5 ............................................................ pag. 41
4.5.4 Error Codes related to global temperatures .................. pag. 41
MAINTENANCE .................................................. pag. 42
5.1 Main Features .................................................. pag. 42
5.2 Siphon Cleaning .................................................. pag. 42
5

6
GENERAL DESCRIPTION
1
1.1 - TECHNICAL /
FEATURES
- MODULEX is a compact, gas fired,
Low NOx, condensing boiler, made
up by one sectional boiler body (so
called
heat module ), set to operate
separately or in cascade.
This heat module consists of two or
more thermal elements (from 4 to 7),
which cannot be separated from
each other, being under the same
protectingcasing.These thermal ele-
ments are connected to a single
smoke exhaust manifold and are
controlled by a single microproces-
sor which manages completely the
temperatures from the point of view,
both operational and safety.
- If, for instance, one of the thermal
elements whose the boiler is com-
posed, goes out of order, the other
thermal elements continue to sup-
ply their output. It is nearly impossi-
ble the boiler go completely out of
order.
- MODULEX has been examined ac-
cording the following European di-
rectives:
- (GAD) Gas Appliances Directive
No. 90/396 CEE
- (BED) Boiler Efficiency Directive
No. 92/42 CEE
by CERTIGAZ, under the No.
1312BP4012, fortype B23 operation,
i.e. the boiler can be connected to a
traditional natural draught chimney,
andfor operation in category I2H (G20
–20mbar).
It also conforms to the following Eu-
ropean directives:
- EMC (Electro Magnetic Compatibi-
lity) Directive No.89/336 CEE
- LVD (LowVoltage Directive)
No. 73/23 CEE
- Machines Directive
No. 89/392 CEE
- The boiler body, made by sections
of cast aluminium/magnesium/sili-
cium alloy, is conceived to recover
the sensible and the latent heat of
the combustion gases, thus al-
lowing to reach an efficiency of
109% on the N.C.V.
- Each thermal element, composed of
a combustion chamber with burner,
modulating fan with control pressu-
re switch, gas valve, ignition devi-
ce, flame control, NTC sensor for lo-
cal temperature control and safety
thermostat, can deliver an output
between a maximum of 90 kW and a
minimum of 22 kW.
- Each single boiler is equipped with
NTC sensors for global temperatu-
re control on the flow and return ma-
nifolds.
- Total premix modulating burner
equipped with metallic sponge ra-
diation burner.
Premix in the pre-combustion cham-
ber. Automatic no return diaphragm
for separation from combustion
chamber.
- Combustion air suction/feeding sy-
stem from the boiler house
- Possible cascade installation of 2 or
more MODULEX
- Heating Operation: setting of instan-
taneous output by a main micropro-
cessor, with a comparison parame-
ters pre-setting between the reque-
sted temperature (or calculated by
the outer compensator) and the glo-
bal flow temperature.
- Logic of operation:
A) Output sharing on as many mo-
dules as possible at min. load (down
to 22 kW) for the max.efficiency.
B) Automatic operation hour split-
ting-up system for each module to
guarantee the best homogeneous
use.
C) DHW production by a priority sen-
sor which, thanks to the dedicated
electronic board, drives a special
loading pump or a 3-way diverting
valve for the preparation of a stora-
ge tank with the possibility of pre-
setting the D.H.W. circuit output, up
tomaximum360kW.
D) Output check of each module for
any calibration and/or assistance by
secret access code.
- Control panel with alphanumeric di-
splay, programming keys, reset and
hydrometer.
- Displays:globalflow/returntempera-
ture,DHW temperature,external tem-
perature.
- Adjustments: flow temperature, fan
speed,max/min. output percentage.
- Access to all testing/programming
parametersofeach module:operation
test, operation time, boiler anti-frost
protection from 7°C, pump’s anti-
blocking system.
- Integral easily removable panel set
(painted steel panels).
- Condensate collecting tank equip-
ped with drain siphon and stain-
less steel smoke chamber.
- Built-in air vent.
- Weights and dimensions are limi-
ted (see table at par. 1.2).
4
5
6
7
360
450
540
630
60
75 l/h
90 l/h
105 l/h
l/h

7
1.2 - DIMENSION
fig. 1-a
REAR VIEW
UPPER VIEW
L.H. SIDE VIEW FRONT VIEW
MODULEX 360
®
1243
576
STOR
E
MO
DE
RES
ET
STE
P
920
S
BA
C
206
171
1372
666
232
474
974 398
R
M
G
474 446
Øi D
110
124
H
MODULEX
Dimension
No. of Modules
Height mm
Width ''L'' net mm
Width with packaging mm
Depth ''C'' mm
Depth ''A'' mm
Depth ''B'' mm
Depth with packaging mm
Net weight kg
Gross weight kg
Connections
Gas mm
C.H. system Flow M mm
C.H. system Return R mm
Chimney connection ''D'' mm
Chimney width ''H'' mm
Condensate drain diameter mm
360
4
1372
920
1020
1530
985
390
1200
430
496
DN50 PN 10/16
DN80 PN 10/16
DN80 PN 10/16
250
615
40
ATTENTION
CHIMNEY
CONNECTION
INDIFFERENT
POSITION FROM THE
ONE SHOWN ARE
NOT ALLOWED.

8
fig. 1-b
MODULEX 450 - 540 - 630
®
1243
576
ST
ORE
MOD
E
R
ES
ET
STEP
920
(D) 1520
(E) 425
F
474
124
232 666
G
=
206
171
974 398
R
M
G
1372
==
350
S
Øi D
ATTENTION
CHIMNEY
CONNECTION
INDIFFERENT
POSITION FROM THE
ONE SHOWN ARE
NOT ALLOWED.
540
6
1372
920
1020
1520
425
1256
1380
1700
620
700
DN50 PN 10/16
DN100 PN 10/16
DN100 PN 10/16
300
720
40
630
7
1372
920
1020
1520
425
1390
1514
1840
680
778
DN50 PN 10/16
DN100 PN 10/16
DN100 PN 10/16
300
855
40
450
5
1372
920
1020
1520
445
1120
1320
1340
510
584
DN50 PN 10/16
DN80 PN 10/16
DN80 PN 10/16
250
615
40
H
600
175 425
110
124
MODULEX
Dimension
No. of Modules
Height mm
Width ''L'' net mm
Width with packaging mm
Width ''D'' mm
Width ''E'' mm
Depth ''F'' mm
Depth with packaging mm
Net weight kg
Gross weight kg
Connections
Gas mm
C.H. system Flow M mm
C.H. system Return R mm
Chimney connection ''D'' mm
Chimney width ''H'' mm
Condensate drain diameter mm
REAR VIEW
UPPER VIEW
R.H. SIDE VIEW FRONT VIEW

9
1.3 - TECHNICAL DATA
The Technical data plate is placed under the front jacket next to the control
panel.
BOILER TYPE MODULEX
Nominal Heat Input on P.C.I
Qn kW
Minimum Heat Input on P.C.I . Qmin kW
Nominal Output (Tr 60 / Tm 80 °C) Pn kW
Minimum Output (Tr 60 / Tm 80 °C) Pn min kW
Nominal Output (Tr 30 / Tm 50 °C) Pcond kW
Minimum Output (Tr 30 / Tm 50 °C) Pcond min kW
Efficiency at max. output (Tr 60 / Tm 80°C) %
Efficiency at min. output (Tr 60 / Tm 80°C) %
Efficiency at max. output (Tr 30 / Tm 50°C) %
Efficiency at min. output (Tr 30 /Tm 50°C) %
Efficiency at 30 % at part load (Tm 50°C) %
Efficiency at 30 % at part load (Tr 30°C) %
Efficiency Class acc. to Directive 92/42 CEE
Efficiency Class acc. to Directive 92/42 CEE (100%) %
Efficiency Class acc. to Directive 92/42 CEE (30%) %
Combustion efficiency at nominal load %
Combustion efficiency at part load %
Stand-by losses (Q min.) %
Stand-by losses (Q nom.) %
Flue gas temperature (min) °C
Flue gas temperature (max) °C
Flue gas mass flow rate (min) kg/h
Flue gas mass flow rate (max) kg/h
Excess of air λ%
CO2 (min) %
CO2 (max) %
NOX(value according EN 297/A3 + EN 483) mg/kWh
NOXclass
Flue losses with burner in operation (min.) %
Flue losses with burner in operation (max) %
Flue losses with burner off %
Min. water flow rate in CH circuit (∆T 20°C) l/h
Minimum pressure in CH circuit bar
Maximum pressure in CH circuit bar
DHW specific flow rate l
Gas Consumption Natural gas G 20 (20 mbar) Qn m3/h
Gas Consumption Natural gas G 20 (20 mbar) Qmin m3/h
Max. available pressure at the chimney base Pa
Condensate production kg/h
Emissions
CO with 0% of O2in the flue system ppm
NOxwith 0% of O2in the flue system ppm
Sound level dBA
Electrical data A
Voltage / Frequency V/Hz
Fuse on main supply A (F)
Max / Min absorbed power W
Insulation degree IP
Standby Consumption W
360
360
22
353,9
21,3
377,60
23,80
98,30
96,82
104,89
108,18
102,0
109,2
4
98,10
96,65
97,52
97,86
1,0
n.r
42
50
36,6
583,0
24,25
8,9
9,2
62
5
2,48
2,14
0,2
16237
0,5
6
73
38,06
-
2,33
-
100
22,7÷60
<35
<35
<50
230 / 50
4
540/41
40
10
450
450
22
442,5
21,3
472,0
23,80
98,33
96,82
104,89
108,18
102,0
109,2
4
98,29
96,94
97,52
97,86
1,0
n.r
42
50
36,6
728,7
24,25
8,9
9,2
62
5
2,48
2,14
0,2
20296
0,5
6
88
47,58
-
2,33
-
100
28,3÷75
<35
<35
<50
230 / 50
4
675/41
40
10
540
540
22
531,8
21,3
566,4
23,80
98,48
96,82
104,89
108,18
102,0
109,2
4
98,45
97,18
97,52
97,86
1,0
n.r
42
50
36,6
874,4
24,25
8,9
9,2
62
5
2,48
2,14
0,2
24355
0,5
6
103
57,10
-
2,33
-
100
34÷90
<35
<35
<50
230 / 50
4
810/41
40
10
630
630
22
621,3
21,3
660,8
23,80
98,62
96,82
104,89
108,18
102,0
109,2
4
98,59
97,38
97,52
97,86
1,0
n.r
42
50
36,6
1020,2
24,25
8,9
9,2
62
5
2,48
2,14
0,2
28414
0,5
6
118
66,61
-
2,33
-
100
39,7÷105
<35
<35
<50
230 / 50
4
945/41
40
10

10
fig. 2
1.4 - SIDE VIEW WITH MAIN COMPONENTS
2.1 - COMPOSITION OF THE
SUPPLY
- Boilerbody made ofsectionsof alumi-
nium/magnesium/siliciumalloy (5to 8)
- Premix stainless-steel burner (4 to 7)
- Premixing chamber (8 to 14) with bu-
ilt-in non return valve
- Modulating fan (4 to 7) with air pres-
sure switch control
-Gas valve (2 for each module – from 8
to 14) with separated flame control
device SATRONIC (from 4 to 7)
- NTCsensorsforlocal temperaturecon-
trolon eachboilersection (5to8)
- NTC sensor for global flow manifold
temperature
- NTC sensor for global return mani-
fold temperature
- High Limit thermostat on each boiler
section (5 to 8)
- Automatic air vent on the flow mani-
fold
- Boiler draining/filling tap on return
manifold
- Minimum gas pressure switch on gas
manifold
- Condensate collecting tray
- Plastic pipe (1m) and fittings for con-
densate evacuation Ø40
- Smokechamberterminal,withflue soc-
ket:
Ø 250 mm for models 360 and 450
Ø 300 mm for models 540 and 630
- Integral painted steel casing
- Modulation and control PCB (MBD)
with PC interface
- AM-4 PCB for DHW production and
outdoortemperature sensor
- Supplementary PCB type AM-5 (1 x
mod. 360; 2 x mod. 450 and mod. 540;
3 x mod. 630)
- Electronic card for interface
- Outdoor sensor (into the smoke cham-
ber)
150
FAN
GAS VALVE
GAS PIPE
BURNER
ALUMINIUM/
SILICON HEAT
EXCHANGER
CONDENSATE
DRAIN
SIPHON
CONDENSATE
COLLECTING
TRAY-
SMOKE
MANIFOLD
FILLING-UP
ELBOW
C.H. RETURN
C.H. FLOW
Min. Depth 100 mm
BOILER FRAME