Unical MODULEX EXT 150 User guide

ENGLISH
100 - 150 - 200 - 250 - 300 - 350
INSTALLATION AND SERVICING INSTRUCTIONS
MODULEX EXT

2
Warning: this manual contains instructions to be used exclusively by the in-
staller and/or a competent person in accordance with the current laws in force.
The end user MUST not make any alterations to the boiler.
Failure to follow the instructions indicated in this manual, which is supplied
with the boiler, could cause injury to persons, animals or damage to property.
UNICAL shall not be held liable for any injury and/or damage.
CONTENTS
1 GENERAL INFORMATION .................................................................................................................................................................................3
1.1 Symbols used in this guide...........................................................................................................................................................................3
1.2 Correct use of the appliance.........................................................................................................................................................................3
1.3 Information to be passed over to the person in charge of the appliance......................................................................................................3
1.4 Safety warnings............................................................................................................................................................................................4
1.5 Standard code for installations......................................................................................................................................................................5
1.6 Installation.....................................................................................................................................................................................................5
1.7 Data badge...................................................................................................................................................................................................5
1.8 Water treatment............................................................................................................................................................................................7
1.9 General warnings..........................................................................................................................................................................................8
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................9
2.1 Technical features.........................................................................................................................................................................................9
2.2 RHS view showing main components.........................................................................................................................................................10
2.3 Dimensions.................................................................................................................................................................................................11
2.4 Performance data .......................................................................................................................................................................................12
2.4.1 Performance DATA ErP......................................................................................................................................................................13
3 INSTRUCTIONS FORTHE INSTALLER...........................................................................................................................................................14
3.1 General warnings.......................................................................................................................................................................................14
3.2 Packaging..................................................................................................................................................................................................15
3.3 Removal from the bed and insert foot........................................................................................................................................................16
3.4 Boiler location in a boiler room..................................................................................................................................................................16
3.6 Boiler connection.......................................................................................................................................................................................18
3.7 Gas connection..........................................................................................................................................................................................19
3.8 Connection return and flow system pipes..................................................................................................................................................20
3.9 Additional safety and control devices, according to the Italian Law + primary circuit kit ...........................................................................21
3.10 Mixing header............................................................................................................................................................................................22
3.11 Mixing header filter....................................................................................................................................................................................22
3.12 Determination of primary boiler pump or boiler system pump...................................................................................................................23
3.13 Ballstop valves...........................................................................................................................................................................................23
3.14 Plate heat exchanger.................................................................................................................................................................................24
3.15 Primary circuit............................................................................................................................................................................................24
3.16 Condensing drain ......................................................................................................................................................................................26
3.17 Flue chimney connection...........................................................................................................................................................................27
3.18 Flue mainfold connection.......................................................................................................................................................................... 27
3.19 Electrical connection .................................................................................................................................................................................29
3.20 Wiring diagram ..........................................................................................................................................................................................30
CONNECTING RING PRIMARY (SUPPLIED WITH MODULAR PUMP)................................................................................................. 31
THERMOSTAT ON / OFF CONNECTIONS .............................................................................................................................................31
THERMOSTAT FBR 2 CONNECTION (room sensor) ..............................................................................................................................32
MODULATING THERMOSTAT CONNECTIONS ......................................................................................................................................33
3.21 FUNCTIONAL WIRING DIAGRAM ...........................................................................................................................................................34
3.22 WIRING DIAGRAM FOR CONNECTIONS AND MANAGING ................................................................................................................35
3.23 Installation examples (functional wiring and connections description) ......................................................................................................38
3.24 Cascade manager BCM ............................................................................................................................................................................43
3.25 Filling the system.......................................................................................................................................................................................44
3.26 Boiler Freeze protection.............................................................................................................................................................................44
3.27 Burner Adjustment.....................................................................................................................................................................................45
3.28 Emergency functions .............................................................................................................................................................................. 48
3.29 Lighting and shutting down procedures.....................................................................................................................................................49
4 SERVICING SCHEDULE ..................................................................................................................................................................................50

3
General Information
1.1 -SYMBOLS USED IN THIS GUIDE
When reading this guide particular care has to be given to the parts marked with the followings symbols:
1.2 -CORRECT USE OFTHE APPLIANCE
The ALKON appliance has been designed utilizing today’s heating technology and in compliance with the
current safety regulations.However, following an improper use, dangers could arise for the safety and life
of the user or of other people, or damage could be caused to the appliance or other objects.The appliance
is designed to be used in pumped hot water central heating systems.Any other use of this appliance will be
considered improper. UNICALdeclines any responsibility for any damages or injuries caused by an improper
use; in this case the risk is completely at the user’s responsibility. In order to use the appliance according
to the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide.
1.3 - INFORMATION TO BE HANDED OVER TO THE USER
1GENERAL INFORMATION
NOTE!
Suggestions for the
user
WARNING!
Indicates a potentially dangerous
situation for the product and the en-
vironment
DANGER!
Indicates serious danger
for your personal safety
and for your life
The user has to be instructed on the use and operation of his heating system, in particular:
•Hand over these instructions to the end user, together with any other literature regarding this appliance,
placedinside the envelope containedin the packaging. The user has to keep these documents in a safe
place in order to always have them at hand for future reference.
• Informtheuserontheimportanceofairventsandoftheueoutletsystem,stressingthefactthatisabsolutely
forbidden to make any alterations to the boiler.
•Inform the user how to check the system’s water pressure as well as informing him how to restore the correct
pressure.
•Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure
the greatest possible fuel economy.
•Remind the user that it is obligatory to carry out a comprehensive service annually and a combustion analysis
every two years (in compliance with the national law).
•If the appliance is sold or transferred to another owner or if the present user moves home and leaves the
appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted
by the new owner and/or installer.
Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause injury
to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury
and/or damage.

4
General Information
WARNING!
The device should not be used by people with reduced physical, mental and sensory, experience and
knowledge. These people must be well-informed and supervised during the work. Children must be
supervised so they do not play with the appliance.
WARNING!
The installation, adjustment, and servicing of this appliance must be carried out by a competent person
and installed in accordance with the current standards and regulations. Failure to correctly install this
appliance could cause injury to persons, animals or damage to property. The manufacturer shall not be
held liable for any injury and/or damage.
DANGER!
Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL re-
commends drawing up a service contract. Bad or irregular servicing could compromise the safe operation of the
appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not be held
liable.
Modications to parts connected to the appliance
Donotcarryoutanymodicationstothefollowingparts:
- the boiler
- to the gas, air, water supply pipes and electrical current
- totheuepipe,safetyreliefvalveanditsdrainagepipe
- totheconstructivecomponentswhichinuencetheappliance’ssafeoperation
WARNING!
When tightening or loosening the screw pipe connections, use only adequate fork spanners.
Theimproper useand/orthe useof inadequate equipmentcan causedamages (for examplewater orgas leakages).
WARNING!
Indications for appliances operating with propane gas
Ensure yourself that before installing the appliance the gas tank has been purged.
Foracorrectpurgingof thetankcontact theliquid gassupplieror acompetent personwhohas beenlegallyauthorized.
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 gas
If 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 systems
Explosive and easily inammable substances
Donotuseorleaveexplosiveoreasilyinammablematerial(asforexample:petrol,paint,paper)intheroomwhere
the appliance has been installed.
1.4 -SAFETY WARNINGS
WARNINGS
The boiler has to be installed in such way to avoid,
under the foreseen operation conditions, the congelation of the water and
to prevent that the control devices are exposed to a temperature
lower than -15°C and higher than 40°C.
The boiler has to be protected against environmental variations with:
- The insulation of the hydraulic pipelines and the condensate evacuation
- TheadoptionofspecicantifreezeproductsintheC.H.installation.

5
General Information
When the appliance is installed on existing systems, ensure
yourself that:
- Theueoutletpipeissuitableforcondensingboilers,for
the temperature of the products of combustion, calculated
and manufactured according to the regulations in force. It
must be installed as much as possible in a straight line,
tested for soundness, insulated and must not have any
occlusions or restrictions.
- Theueoutletpipehasaconnectionforthedischargeof
condensate.
- The boiler room has a suitable outlet for the discharge of
condensate produce by the boiler.
- Theelectricalsystemhasbeenttedincompliancetothe
 specicnormsandtheworkhasbeencarriedoutbya
competent person.
- Thecirculationpump’soutput,theheadandowdirection
are suitable.
- The gas feeding supply pipe and the eventual tank are
constructed according to the regulations in force.
- The expansion vessels assure the total absorption of the
 dilatationoftheuidcontainedinthesystem.
- The system has been cleaned of impurities and lime scale.
When a Modulex boiler is installed onto an existing
heating system:
Incase thereplacement ofan existingboiler inan oldsystem can
be programmed, it is necessary to thoroughly
clean out the system with a basic solution.
The system must be cleaned 4 weeks before
the substitution, with the system ring at a
temperature of 35°C to 40°C.
WARNING!
If it is noticed that a new Modulex has replaced,
in an old system the existing boiler without having first perfor-
med what said in the previous paragraph, Do not wash now
the system, as residual products, present in the circuit, could
lead to system gathering in the boiler body, causing damage.
UNICAL recommends contacting a specialised company for
water treatment.
Instead, if installing a Modulex boiler in a new system, it is
still recommended to thoroughly clean out the system with an
adequateproductand fit aY filter withtwo isolating valves onthe
boiler’s return pipe, so that, when necessary, it can be cleaned.
This filter will protect the boiler from the dirt coming from the
heating system.
When sizing pumps, it is necessary to take into consideration
the pressure losses which occurin the primary circuit.
1.6 - INSTALLATION ON EXISTING HEATING SYSTEMS
1.5 - STANDARD CODES FOR
INSTALLATION
Theappliance mustbe installedincompliance tothe instructions
contained in this manual.
Theinstallationmust becarriedoutbya competentqualied
engineer, whom will assume the responsibility of complying to
allthelocaland/ornationalregulationspublishedintheofcial
publications, as well as all the applicable codes of practice.
Before installing the appliance please contact the gas supply
company.
The installation must be carried in accordance to the codes of
practice, the regulations and the requirements hereby indicated
which constitute an indicative list, but not a complete one, as
these continue to undergo evolve devolpments.
Moreover, the boiler must be installed in accordance to all the
regulations regarding the boiler room, the building regulations
and the prescriptions regarding central heating plants in force
in the country where the boiler is installed.
The appliance must be installed, commissioned and serviced
according to the regulations in force. This is also valid for the
hydraulicsystem,theueoutletsystemandtheboilerlocation
room.
Failure to comply with these rules will
nullify the warranty

6
General Information
1.6 -TECHNICAL DATA PLATE
CE marking
TheCEmarkingcertiesthattheboilersmeet:
- The essential requirements of the gas appliance directive
(directive 2009/142/EEC)
- The essential requirements of the electromagnetic compat-
ibility directive (2004/108/EEC)
- Theessentialrequirementsoftheefciencydirective(92/42/
EEC)
- Theessentialrequirementsoftheefciencydirective(direc-
tive 2006/95/EEC)
The Technical data plate is placed
under the casing over the forehead
stirrup.
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
19= (PMW)Max.domestichotwateroperatingpressure
20= (Tmax)Max.domestichotwatertemperature
C = Electrical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

7
General Information
1.8 - WATERTREATMENT
The chemical-physical characteristics of the filling water and
reinstatement water in heating systems are of fundamental
importance for guaranteeing correct and safe boiler operation.
Before filling the CH circuit with water, it is necessary to analyse
the water and decide for a proper treatment.
The purpose of this treatment is finalized to eliminate or sub-
stantially reduce the following problems:
- lime scale deposit
- corrosions
- deposits
- biological growths (moulds, bacteria, algae, fungi, etc)
The chemical treatment of the network water enables the
prevention of these problems and guarantees safe boiler
operation and economical advantages, in terms of mainte-
nance and global thermal efficiency.
The chemical analysis of the water enables us to obtain a lot
of information on the system’s condition and state of “health”.
It is essential to avoid any problems with the boiler.
The pH is a measure of the acidity or alkalinity of a solution.
The pH scale has a range of 0-14, where 7 is neutral.
Values inferior to 7 indicate acidity, values above 7 indicate
alkalinity.
The ideal pH value for water in heating systems fitted with
aluminium boilers is between 6,5 and 8, with a hardness
of 15°F.
Inheating systems wherethe waterhas a value outside thisran-
ge,thisconsiderablyacceleratesthe destruction ofthe protective
oxidized layer which naturally develops inside the aluminium
bodies: if the pH is below 6, acidity is present, if it is above 8,
the water is alkaline or it is caused by an alkaline treatment (for
example phosphateor glycolused asan antifreeze)orin several
cases it is due to the natural formation of alkaline in the system.
Vice versa, if the pH value is between 6,5 and 8, the aluminium
surfaces of the boiler body are passivated and protected from
further corrosive attacks.
To minimize corrosion it is essential to use a scale inhibitor,
however in order for this to function correctly, the metallic
surfaces have to be clean.
The best corrosion inhibitors on sale also contain a pro-
tective system for aluminium which acts by stabilizing the
water’s pH value, preventing unforeseen variations.
We recommend that the heating system’s water pH value is
systematically controlled (minimum twice a year). In order
to do this,it is not necessary to run a chemical analysis in a
laboratory, but it is sufficient to use a simple analytical‘kit’
contained in portable cases, easily found on sale.
Therefore, prior to filling the heating system with water it will be
necessary to fit the devices indicated in the figure below.
THE CONNECTION MUST BE FITTED ON THE
PRIMARY CIRCUIT’S RETURN PIPE DOWN-
STREAM OFTHE CIRCULATING PUMP
All the necessary precautions must be taken in order to avoid
the formation and localization of oxygen in the system’s water.
For this reason, the plastic pipes used in underfloor heating
systems must be impermeable to oxygen.
Ifany antifreezesolutions areused ensureyourselfthattheyare
compatible with aluminium and with any other components and
materials fitted on the system.
WARNING!
ANY DAMAGE CAUSED BY THE BOILER,
DUE TO THE FORMATION OF LIME SCALE
OR DUETO CORROSIVEWATERWILL INVA-
LIDATETHE APPLIANCE WARRANTY.
1. Ball valve
2. Inspection pocket
3. Filling-up group
4. Disconnector
5. Scale reducing device
6. Litrecounter
(recommended)
7. “Y” filter
EXAMPLE OF SCALE REDUCING DEVICE CONNECTION FORWATERTREATMENT

8
General Information
1.9 -GENERAL WARNINGS
This instruction manual is an integral and indispensable part
of the product and must be retained by the person in charge of
the appliance.
Pleaseread carefullytheinstructionscontainedin thismanual as
theyprovide importantindications regardingthe 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 in ac-
cordance with the regulations in force according to the
manufacturer’s instructions and by legally competent
authorized persons.
By a competent person, we imply a person who has a spe-
cic technical qualication in the eld of components for
central heating systems for domestic use, domestic hot
water production and servicing. The person must have the
qualications foreseen by the current laws in force.
Bad or irregular servicing could compromise the safe operation
of the appliance, and could cause injury to persons, animals or
damage to property. The manufacturer shall not be held liable
for any such injury and/or damage.
Beforecarrying outanycleaning orservicing turnofftheelectrical
supply to the boiler by means of the ON/OFF switch and/or by
means of the appropriate shutdown devices.
Do not obstruct the intake/outlet terminal ducts.
In the event of failure and/or faulty functioning of the appliance,
switchoff theboiler. Do notattempt to makeanyrepairs: contact
qualiedtechnicians.
Anyrepairs mustbe carried outby Unicalauthorized technicians
andusing onlyoriginalspare parts.Non-observanceof theabove
requirement may jeopardize the safety of the appliance.
Toguaranteetheefciencyandcorrectfunctioningoftheap-
pliance it is indispensable to have the boiler serviced annually
byaqualiedperson.
If the boiler remains unused for long periods, ensure that any
dangerous parts are rendered innocuous.
If the appliance is sold or transferred to another owner or if the
present user moves home and leaves the appliance installed,
ensure yourself that the manual always follows the appliance
so that it can be consulted by the new owner and/or installer.
Only original accessories must be used for all appliances sup-
plied with optionals or kits (including electrical ones).
This appliance must be used only for the purposes for which it
has been expressively designed. Any other use shall be consi-
dered incorrect and therefore dangerous (*).

9
Technical features and dimensions
TECHNICAL FEATURES
AND DIMENSIONS
2.1 -TECHNICAL FEATURES
• MODULEX is a compact, gas fired, Low NOx, condensing
boiler.
• made up by one sectional boiler body, suitable for a single
boiler working or directly as cascade
• Placeevenoutside(IPX5D)
• Low water content
• Fast response to load variations
• Flue terminal positionable on 3 sides
• Manifold unified delivery and return (everseble in simple way
p.16)
• Made up of two or more heating elements (2 to 7), cast alu-
minum / silicon / magnesium
• Modulating premix burners total radiation
• Each heating element without hydraulic interceptions
• One gas supply pipe (reversible)
• Modular power from 12 to 50 kW / element
TEMPERATURE CONTROL DEVICES:
• LOCALNTCsensor(eachheatingelement)
• Limitthermostatroom(eachheatingelement)
• flow NTC sensor (General)
• NTC sensor return (General)
• Safety thermostat approved (Order and install on ISPESL
device see page 18)
• FlowsensorBCM
Other safety devices (RACCOLTA R) see 3.6 pag. 18
Control panel (POP-UP) includes:
• ON-OFFswitchseepag.47
• Temperature control / boiler operator E8
• BCM(BoIIerCascadeManager)
• Fuses
• Limitthermostat>(over)350kW
• Airpressurefans
• Condensatelevelsensor
• Gaspressostat
• Smokepressostat(anti-obstruction)
• The whole group has heat sensors NTC control global tem-
perature on the flow and return..
•Integral insulation with synthetic wool hypoallergenic
• Total premixburner,modulatingburner with a“metal sponge”,
ad irraggiamento. Premixing into the fan.Automatic diafra-
ghm backflow of separation from the combustion chamber.
• Noise at maximum power of less than 49 dBA.
• Heatingoperation:determinationofinstantaneouspower
microprocessor control, with preset parameters for compa-
rison between temperature (or calculated from the external
temperatureregulation)andglobaltemperatureow.
• Operationmodes:
Ability to control power of the individual heating elements for
any calibration and / or assistance with access code confi-
dential.
Production of A.C.S. by NTC of priorities for control by
boiler feed pump or by three-way diverter valve controller
E8 included.
• Abilitytocontrolpoweroftheindividualheatingelements
• Controlofheatdemand:setpointtemperatureandlevelof
modulation.
2
• Monitoringofoperatingstatusandtemperature.
• Reportingofalarms.
• Settingparameters.
• Relaycontrolfortheactivationofaxedspeedpump
• Analogoutput0to10Vtocontrolamodulatingpump.
• Operationofemergencypreventsthedetentionfacilityasa
result of the interruption of communication with the control
system or any remote control unit:
• Withthepossibilityoftemperatureselectionthroughemer-
gencyresistorssuppliedwith“constantSetpoint:70°C,max
50%.
• Alarmmanagement
• Alarmresetinput.
• Relaywarningalarm.
• condensatecollectortankwithsiphonstainlesssteel
• Panelscompletewitheasilyremovablestainlesssteelpanels
paintedwithreadaptedforoutdoorinstallation
• condensatecollectiontankwithdraintrapandsmokechamber
in stainless steel.
• Built-inairvent
The application of heat can be generated by the Regolation / E8
operator or alternatively from BCM (boyler Cascade Manager)
The management logic provides the maximum number of
simultaneous operation of heating elements as possible in
order to maximize your productivity. As we provide high ex-
change surface as a function of output power. The items are
made to work so as to share equitably the operating time.
The hot water produced by the pump is pushed on the return
oftheringtotheprimaryowofthehydraulicseparator.From
herea second pump(system - seethediagrams suggested) will
arrange for the distribution to various users. The return chilled
water plant is sucked by the pump on the return through the
hydraulic separator to resume the cycle via the generator.

10
Technical features and dimensions
2.2 - R.H. SIDEVIEW,WITH MAIN COMPONENTS
Should a positioning of the ue connection be necessary on the left hand side of the boiler (the standard
is on the right) so please move the cover ‘A“ with each wiring connection, condensate level sensor, red
pressostat pipe on the rear side of the boiler. The rear side cover (just re-moved) has to be re-placed on the
right side of the boiler.
- Smoke and condensate evacuation connection on the R.H. side (forniture condition), L.H. side, BACK SIDE
order special BACK Flue kit
MODULEX EXT 100 - 116 - 150 - 200 : 00362154
MODULEX EXT 250 - 300 - 350 : 00362076
- C.H. flow connection on the R.H. side (forniture condition), L.H. side
- C.H. return connection on the R.H. side (forniture condition), L.H. side
- Gas connection on the R.H. side (forniture condition), L.H.side

11
Technical features and dimensions
FRONT VIEW RIGHT HAND SIDE VIEW (Delivery condition for R.H. side connection)
UPPER VIEW
MODULEX
Dimension
No. of Modules
Height mm
Width ‘’L’’ mm
Width ‘’L1’’ mm
Depth ‘’P’’ mm
Depth ‘’P1’’ mm
Connections
Gas mm (inch)
C.H. system Flow M mm (inch)
C.H. system Return R mm (inch)
Chimney connection ‘’D’’ mm
Condensate drain diameter mm
LEFT HAND SIDE VIEW
M CH flow system
R CH safety system return
2.3 -DIMENSIONS
G Gas inlet
S Outlet condensate drain
150
3
1150
764
706
770
705
50(2 )
64 (2½)
64 (2½)
150
40
200
4
1150
1032
974
770
705
50(2 )
64 (2½)
64 (2½)
150
40
250
5
1150
1032
974
770
705
50(2 )
64 (2½)
64 (2½)
200
40
300
6
1150
1300
1242
770
705
50(2 )
64 (2½)
64 (2½)
200
40
350
7
1150
1300
1242
770
705
50(2 )
64 (2½)
64 (2½)
200
40
100
2
1150
764
706
770
705
50(2 )
64 (2½)
64 (2½)
150
40
(•) ModulexEXT100-200-300 Flueterminal
into the casing

12
Technical features and dimensions
2.4 -PERFORMANCE DATA
Fortheadjustmentdata:NOZZLES-PRESSURE-DIAGRAMS-FLOWRATESrefertotheparagraphADAPTATIONTOOTHER
TYPESOFGAS.
MODULEX EXT100 EXT150 EXT200 EXT250 EXT300 EXT350
Boiler category II2H3P II2H3P II2H3P II2H3P II2H3P
Modulation ratio 1:8,3 1:12,5 1:16,7 1:20,8 1:25 1:29
Rated heat output on P.C.I. Qn kW 100 150 200 250 300 348
Minimum heat output on P.C.I. Qmin kW 12 12 12 12 12 12
Rated useful power (Tr 60 / Tm 80 °C) Pn kW 97,2 146,1 195,2 244,5 294 341,7
Minimum useful power (Tr 60 / Tm 80 °C) Pn min kW 11,7 11,7 11,7 11,7 11,7 11,7
Rated useful power (Tr 30 / Tm 50 °C) Pcond kW 100,1 150 200,4 251,3 302,7 354,6
Minimum useful power (Tr 30 / Tm 50 °C) Pcond min kW 12,8 12,8 12,8 12,8 12,8 12,8
Rated power performance (Tr 60 / Tm 80°C) % 97,2 97,4 97,6 97,8 98,0 98,2
Minimum power performance (Tr 60 / Tm 80°C) % 97,16 97,16 97,16 97,16 97,16 97,16
Rated power performance (Tr 30 / Tm 50°C) % 100,1 100,0 100,2 100,5 100,9 101,9
Minimum power performance (Tr 30 / Tm 50°C) % 106,5 106,5 106,5 106,5 106,5 106,5
Performance at 30% of the load (Tr 30°C) 107,3 107,3 107,3 107,3 107,3 107,3
Combustionefciencyatnominalload %97,8 97,8 97,8 98,0 98,1 98,3
Combustionefciencywithreducedload % 98,3 98,3 98,3 98,3 98,3 98,3
Casing heat loss with burner operating (Qmin) % 1,2 1,2 1,2 1,2 1,2 1,2
Casing heat loss with burner operating (Qn) % 0,6 0,4 0,2 0,2 0,1 0,1
Netuegastemperaturetf-ta(min)(**) °C 33,4 33,4 33,4 33,4 33,4 33,4
Netuegastemperaturetf-ta(max)(**) °C 44,2 45,1 46,5 47,3 48,2 49,1
Maximum permitted temperature °C 100 100 100 100 100 100
Maximum operating temperature °C 85 85 85 85 85 85
Fluegasmassowrate(min) kg/h 19,6 19,6 19,6 19,6 19,6 19,6
Fluegasmassowrate(max) kg/h 163 245 327 409 490 569
Excess air % 25,5 25,5 25,5 25,5 25,5 25,5
Heat loss at chimney with burner on (min) % 1,7 1,7 1,7 1,7 1,7 1,7
Heat loss at chimney with burner on (max) % 2,2 2,2 2,2 2,2 1,9 1,7
Minimum heating circuit pressure bar 0,5 0,5 0,5 0,5 0,5 0,5
Maximum heating circuit pressure bar 6 6 6 6 6 6
Water content l 10,1 14,2 18,3 22,4 26,5 30,6
MethanegasconsumptionG20(pow.sup.20mbar)atQn m3/h 10,6 15,9 21,1 26,4 31,7 36,8
MethanegasconsumptionG20(pow.sup.20mbar)atQmin m3/h 1,3 1,3 1,3 1,3 1,3 1,3
GasconsumptionG25(pow.sup.20/25mbar)atQn m3/h 12,3 18,4 24,6 36,7 36,9 42,8
GasconsumptionG25(pow.sup.20/25mbar)atQmin m3/h 1,5 1,5 1,5 1,5 1,5 1,5
Propanegasconsumption(pow.sup.37/50mbar)atQn kg/h 7,8 11,6 15,5 19,4 23,3 27
Propanegasconsumption(pow.sup.37/50mbar)atQmin kg/h 0,9 0,9 0,9 0,9 0,9 0,9
Chimney base maximum pressure available Pa 100 100 100 100 100 100
Max condensate production kg/h 15,3 23 30,6 38,3 45,9 53,6
Emissions
CO at maximum heat output with 0% of O2 mg/kWh 83 83 83 83 83 83
NOx at maximum heat output with 0% of O2 mg/kWh 77 77 77 77 77 77
NOx Class 5 5 5 5 5 5
Electrical data
Power supply voltage/frequency V/Hz 230 / 50 230 / 50 230 / 50 230 / 50 230 / 50 230 / 50
Fuse on the power supply A (R) 6,3 / 10 6,3 / 10 6,3 / 10 6,3 / 10 6,3 / 10 6,3 / 10
(**) Protection rating IP X5D X5D X5D X5D X5D X5D
Room Temperature = 20°C
(*)Temperaturedetectedwithapplianceoperationowrate80°C/ret.60°C
CO2 (min/max) See table ‘’NOZZLES - PRESSURE’’
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
(**) The protection IP is obtained with cap down

13
Instructions for the installer
2.4.1 - PERFORMANCE DATA ErP DIRECTIVE
MODULEX EXT100 EXT150 EXT200 EXT250 EXT300 EXT350
Element Symbol Unit
Effective nominal output Pnominale kW 97 146 195 244 294 342
Seasonalenergyefciencytoheat
the room ƞs% 92 92 92 92 92 92
Season efciency class to
discharge A A A A 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 97,2 146,1 195,2 244,5 294,0 341,7
Ratedheatoutputefciency
with high temperature capacity
(Tr 60 °C / Tm 80 °C) ƞ4% 88 87,7 87,7 88,1 88,3 88,5
Useful power at 30% of the rated heat
output with low temperature
capacity (Tr 30 °C) P1kW 32,2, 49,3 64,4 80,5 96,6 112
Performance at 30% of the rated heat
output with low temperature
capacity (Tr 30 °C) ƞ1%96,7 96,7 96,7 96,7 96,7 96,7
Boiler with output range adjustment:
YES / NO NO NO NO NO NO NO
Auxiliary electricity consumption
With a full load elmax kW 0,145 0,210 0,290 0,362 0,435 0,507
With a partial load elmin kW 0,040 0,040 0,040 0,040 0,040 0,040
Standby mode PSB kW 0,010 0,010 0,010 0,010 0,010 0,010
Other elements
Heat dispersion on standby Pstb kW 0,787 0,94 0,98 1,10 1,15 1,39
Nitrogen oxides emissions NOx
Mg/kWh 54 54 54 54 54 54
For mixed heating appliances
Declaredloadprole - - - - - -
Waterheatingenergyefciency ƞwh % - - - - - -
Daily consumption of electricity Qelec kWh - - - - - -
Daily consumption of fuel Qfuel kWh - - - - - -
Internal sound power level Lwa dB (A) - - - - - -
Seasonal DHW efciency class - - - - - -
*Appliances not covered by Directive 2009/15 / EC

14
Instructions for the installer
3INSTRUCTIONS FOR
THE INSTALLER
3.1 - GENERAL WARNINGS
WARNING!
This boiler has to be destined for the use for
which it has been expressively designed for.
Any other use shall be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.
Before installing the boiler the following points
have to be carried out by a competent engineer:
a) An accurate washing of all the pipes of the
installation to remove possible residues or im-
purity that could jeopardize the good operation
of the boiler, also from the sanitary point of view.
b) Check that the boiler has been preset for
operating with the gas type available.
Thisisveriableviatheindicationonthepak-
kaging and on the data badge;
c) Checkthatthechimney/uepipehasanade-
quate draught,does not have any constrictions,
andthatnootherappliance’sueoutletshave
beentted,unlessthechimney
is serving more than one heating appliance,
accordingto thespecicstandardsand
regulations in force.
Theconnection between theboiler andchimney/
ueoutletcanbemadeonlyafterthis
vericationhasbeencarriedout.
WARNING!
In rooms where there is the presence of ag-
gressive vapours or dust the appliance must
operate independently from the air present in
the boiler’s location room!
WARNING!
The appliance must be installed by a qualied
engineer, who complies to the technical-
professional requirements according to the
national applicable law and who, under his
own responsibility, guarantees the comp-
liance with the standards according to the
latest regulations.
WARNING!
Install the appliance respecting the minimum
clearances for operation and servicing.
The boiler must be connected to a heating system
whichis compatibletoits performancesand output.

15
Instructions for the installer
3.2 - PACKAGING
The boiler MODULEX is delivered assembled
and protected by a plastic bag inside a strong
cardboard box and fixed on pallet.This allows the
boiler to be handled also by forklift.
Remove bothstrapsandfinally thecardboardbox
fromabove, makingsurethe productisintact.The
packingelements(cardboard box,straps,plastic
bags,etc…)shall not be left to children’s hand
since they may be dangerous.
Inside the packing you can nd:
on the boiler front:
- thesmokechamber terminal screwedto thefront longeron
of the frame
- a carton box containing:
 •Thesealinggasketforconnectionbetweencondensate
tray and terminal
 •Thesealinggasketforuesocket
 •2bends+1Teepiece+1plasticplug,Ø40mmfor
condensate drain.
 •thescrewsnecessaryforxingthesmokechamber
terminal
- The Outer sensor - Flow sensor and the D.H.W. storage
tank sensor
- Nipple for smokes sampling test
- Resistances kit for emergency operation
- Cable glands and for electrical supply
- a carton box containing:
4 feet of support
3 caps for any reversal collectors
3 gaskets insulation for collectors
(for installation in outside).
on the boiler right side:
- One pipe for the condensate evacuation system of 1 m
-Left and right side basement
on the back of the boiler
- Socket front and rear
on the boiler top:
- a plastic bag containing:
• Thisinstructionsmanualfortheinstaller
• Instructionsmanualfortheuser
• InstructionmanualfortheuseoftheE8controller
• Pinstostopthefanassemblyinraisedposition

16
Instructions for the installer
3.4 - BOILER LOCATION INSIDE A BOILER ROOM
Special attention shall be paid to local regulations and laws
about boiler houses and particularly to the obligation of keeping
minimum clearances and empty space around the boiler. The
installation shall be in compliance with all latest regulations and
laws about boiler houses, installations of heating and hot-water
systems, ventilation, chimneys capable of evacuating the flue
gases of condensing boilers and any other applicable require-
ment.
The boiler can be put on a flat and sufficiently strong base with
the same dimensions as the boiler ones and at least 100 mm
high (see fig. 2), in order to assemble the condensate drain
siphon. An alternative to this base may be a 100mm deep well
next to the boiler as siphon housing (see fig.2).After installation
the boiler shall be perfectly horizontal and stable, to reduce any
possible vibrations or noises.
- Remove the casing of the boiler
- Lift the boiler with a hoist or forklift bands
- Remove the 4 screws’’A’’
- Insert the 4 feet (contents into the box)
- Attach the feet to the chassis by 4 screws’’A’’previously
removed.
- Place the boiler on concrete slab and mount the casing.
3.3 - REMOVAL FROMTHE BOILER BED AND INSERT FOOT
1
2
3
4

17
Instructions for the installer
Give the boiler the minimum clearances as shown
in the drawing, in order to be able to make the
normal service and cleaning operations.

18
Instructions for the installer
3.6 - BOILER CONNECTION
At its delivery the boiler MODULEX has all the connections,
i.e.:C.H.ow&return,gas,andsmokeoutletonitsR.H.side.
To move hydraulic and
gas pipe (only one or
both) from the Right
(Location of supply
standard) to the left side
you must remove
part of the hole, in
correspondence of
attacks that will be
move on the opposite
side and close the right
side coat with the caps
of the boiler.
C.H. Flow & Return connections reversibility
To move the smoke outlet from the R.H. side (std.
delivery position) to the L.H. side it is necessary
to change each other L.H side panel with R.H
side panel.
To move the C.H. Flow & Return
connections from the R.H. side
(std. delivery position) to the L.H.
side, it is necessary to change each
other the two anges screwed on the
C.H. Flow &/or Return
manifold ends.
ONLY FOR MODULEX 250 - 300 - 350
To move the smoke outlet from the R.H. side (std.
delivery position) to the rear position, it is neces-
sarytorequestthesmokekit,codeNo.00362076,
madeofaTeepiecevisibleinthegureandthe
hole closing kit, for the closing of the casing R.H.
side panel.
ONLY FOR MODULEX 100 - 150 - 200
It is necessary to request the smoke kit, code No.
00362154 for the closing of the casing R.H. side
panel.
Gas reversibility
To move the gas connection, from the
R.H. side (std. delivery position)
to the L.H. side, it is necessary to
changeeachotherthetwoanges
screwed on the gas manifold ends.

19
Instructions for the installer
3.7 - GAS CONNECTION
The gas supply pipe must be connected to the boiler via the
respective pipe connection R 1½ as indicated on page 8.
The gas supply pipe must have a section which is identical
or greater then the one used on the boiler and must assure a
correct gas pressure.
Itishoweverimportanttocomplywiththespecicnormsand
requirementsinforce,foreseeingon-offvalves,gaslter,anti-
vibrating joint etc.
WARNING:
In order to protect the boiler it is suggested
to install a filter at the connection of the gas
feeding pipe.
This filter has to be easily inspectable and
convenientlysizedin order tograntthe sup-
ply pressure required by the boiler.
Before commissioning an internal gas distribution system and
therefore before connecting it to the gas meter, the complete
installation must be tested for gas soundness.
If any part of the system is concealed from view the gas sound-
ness test must be carried out before covering the pipes.
Before installing the boiler it is recommended to
thoroughly clean all the supply piping in order to
removeany eventual residualgrimewhich could
compromise the boilers correct functioning.
If you smell gas:
a. Donot turnon oroffelectricalswitches,use
the telephoneor anyother objectwhich can
provoke sparks;
b. Open all doors and windows in order to
allow fresh air to enter and purify the room;
c. Close all gas cocks
d. Contactaserviceengineer,qualied
installer or the gas supply company.
As a safety measure against gas leaks, Unical
recommends installing a surveillance and protec-
tive system made up of a gas leakage detector
combined with an on-off selenoid valve on the
gas supply line.
1. On-off gas supply valve
2. Double membrane regulator
3.Gaslter
4. Anti-vibrating joint
5. Selenoid valve
6. On-off cock
EXAMPLE OF A GAS SUPPLY SYSTEM
INSIDE
BOILER
ROOM
OUTSIDE
BOILER
ROOM
DANGER!
The gas connection must be carried out by a
registered engineer who will have to respect
and comply to the regulations in force and
to the requirements indicated by the local
gas supplier. An incorrect installation could
cause injury to persons, animals or damage
to property. The manufacturer shall not be
held liable for any injury and/or damage.

20
Instructions for the installer
3.8 - FLOW AND RETURN PIPE CON-
NECTIONS
TheCHowand return circuits have to beconnectedtothe
boiler via the respective connections 2½“ M and R as indicated
on page 11.
Whendetermining thesize ofthe CHcircuitpipesitis essentialto
bearin mind thepressure losses inducedbyany of thesystem’s
componentsandbythecongurationofthesamesystem.
The route of the piping has to be conceived taking all the ne-
cessary precautions in order to avoid air locks and to facilitate
the continuous purging of the system.
WARNING!
IT IS ABSOLUTELY FORBIDDEN TO FIT ON-
OFF VALVES ON THE GENERATOR TO THE
FORE OF THE SAFTEY DEVICES
WARNING!
Before installing the boiler we recommend
that the system is ushed out with a suitable
product in order to eliminate any metallic
tooling or welding residues, oil and grime
which could reach the boiler and affect the
proper running of the boiler.
Non-observance of these instructions could cause injury
to persons, animals or damage to property.
The manufacturer shall not be held liable for
any such injury and/or damage.
Ensure yourself that the system’s piping is not
used as the earth clamps for the electrical or te-
lephonicsystem.Theyare absolutelyunsuitable
for this use. In a short time this could cause se-
rious damage to the piping, boiler and radiators.