Unical NOVAIREX Series User manual

INSTALLATION AND MAINTENANCE INSTRUCTIONS
NOVAIREX
35 - 45 - 55

2
Attention: this manual contains instructions for the exclusive use of the pro-
fessionally qualified installer and/or maintenance technician in compliance
with current legislation.
The system manager is NOT authorised to service the boiler.
The manufacturer will not be held liable in case of damage to persons, animals
or objects resulting from failure to comply with the instructions contained in
the manuals supplied with the boiler.

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1 GENERAL INFORMATION ................................................................................................................................................................................... 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
General informationTechnical featuresInstallation instructionsMaintenance instructions
4 INSPECTION AND MAINTENANCE ................................................................................................................................................................53
Inspection and maintenance instructions........................................................................................................................................................... 53
Maintenance of the body ................................................................................................................................................................................... 54
Cleaning and routine maintenance .................................................................................................................................................................... 54
Maintenance operations .................................................................................................................................................................................... 54
3 INSTRUCTIONS FOR THE INSTALLER................................. 15
3.1 General warnings ............................................................ 15
3.2 Installation rules .............................................................. 15
3.3 Installation on old systems or to be renovated ................ 15
3.4 Packaging........................................................................ 16
3.5 Transport ......................................................................... 16
3.6 Installation ...................................................................... 17
3.7 Connecting the boiler to the system ................................ 18
3.8 Water connections ........................................................... 18
3.9 Connection to the flue...................................................... 23
3.10 Electrical connections...................................................... 26
3.11 Connections..................................................................... 27
3.12 Reference plumbing diagrams......................................... 28
3.13 Panel board ..................................................................... 39
3.14 Filling the system............................................................. 45
3.15 Starting the boiler ............................................................ 46
3.16 Summer operation ........................................................... 49
3.17 Warnings ......................................................................... 49
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................8
2.1 Technical features......................................................................................................................................................................................... 8
2.2 Dimensions and plumbing connections ........................................................................................................................................................ 9
2.3 Technical data............................................................................................................................................................................................. 10
2.4 Main components ....................................................................................................................................................................................... 11
2.5 General ....................................................................................................................................................................................................... 11
2.6 Features of the wood .................................................................................................................................................................................. 14
3.18 Troubleshooting ............................................................... 50
3.19 Alarm diagram and problem solving................................ 51
3.20 Audible alarms................................................................. 52

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

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

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

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General information
1.6 - TECHNICAL DATA PLATE
The technical data plate is adhesive and is included in the
document case; it must be applied by the installer on the
outside of the casing.
The serial number of the boiler is on the riveted plaque on
the front plate of the body (front right top side).

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2TECHNICAL FEATURES
AND DIMENSIONS
2.1 - TECHNICAL FEATURES
The heat generator mod. NOVAIREX is a steel boiler running
with natural wooden logs, total gasification, inverted flame, with
combustion chamber under negative pressure.
It is supplied in the following models:
NOVAIREX 34
NOVAIREX 45
NOVAIREX 55
The NOVAIREX boiler is complete with all the safety and control
devices required by relevant standards.
DESCRIPTION OF COMPONENTS:
• Steel boiler body with combustion chamber partially covered
with refractory material
• Burner in refractory material
• Horizontal smoke ducts
• Front door for loading wood covered with refractory material
• Bottom door covered with refractory material, complete with
combustion air adjustments and fitted with flame sight glass
• Rear smoke chamber with side inspection and ash removal
doors
• Flue gas extraction with intake modulating fan
• Safety heat exchanger
• Boiler body insulated with 50 mm thick mineral wool panels
• Powder painted sheet steel casing
PANEL BOARD COMPONENTS:
• Main switch with light indicating presence of power
• Safety thermostat for boiler overheating
• Main fuse
• Display

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Technical features
2.2 - HYDRAULIC DIMENSIONS AND CONNECTIONS
T7 -T8
1. Panel board
2. Primary air adjustment
3. Secondary air adjustment
4. Flame sight glass
5. Cleaning doors
6. Rear smoke chamber
7. Loading door
8. Modulating fan
9. Bottom inspection and cleaning door
DIMENSIONS
A
B
C
D
E
F
G
510
680
610
680
610
880
1230 1380
190
81
190
78
1025
628
1380
190
81
11501150
628 828
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
CONNECTIONS T1 - T2
T5
T6
T3 - T4 - T7 - T8
UNI ISO 228/1
(Ø mm)
UNI ISO 228/1
G 1¼
150
G ½
G ½
G 1½
200
G ½
G ½
UNI ISO 228/1
H65 65
(mm)
G 1½
200
G ½
G ½
65
NOVAIREX 34 NOVAIREX 45 NOVAIREX 55
T1. Central heating flow
T2. Central heating return
T3. Safety thermostat probe bulb holder, boiler flow probe
T4. Connection for any temperature relief valve probe bulb
holder
T5. Chimney connection
T6. Safety heat exchanger connections
T7. Boiler drain
T8. Return probe connection

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MODELS NOVAIREX 34 NOVAIREX 45 NOVAIREX 55
MAXIMUM NOMINAL OUTPUT* (kW) 30.61 40.09 49.10
FURNACE MAXIMUM OUTPUT (kW) 34.2 45.05 55.16
* Power achieved with good quality wood with 15% humidity content.
** Considering a thermal power requirement of 30 kcal/m3
WATER SIDE PRESSURE DROPS (10K)
WATER SIDE PRESSURE DROPS (20K)
BOILER WATER CONTENT
EMPTY BOILER WEIGHT
MAXIMUM OUTPUT
OUTPUT IN STAND-BY
BOILER CLASS ACCORDING TO EN 303-5
(m.w.c.) 0.2 0.4 0.5
0.070.070.05
(m.w.c.)
(l)
(kg)
(W)
(W)
59
363
146
5
71
475
146
5
93
623
146
5
5 5 5
DURATION OF COMBUSTION
WOOD STORAGE VOLUME
MAX OPERATING PRESSURE
LOADING OPENING
LOG LENGTH
(h) 5 6 6
218160108
(l)
(bar)
(mm)
(cm)
3
334 x 419
50
3
434 x 519
50
3
434 x 519
70
NOISE LEVEL (dB) <50 <50 <50
MINIMUM DRAUGHT REQUIRED BY CHIMNEY (Pa) 20 20 20
MIN. FLOW TEMPERATURE (°C) 70 70 70
MAX. FLOW TEMPERATURE (°C) 85 85 85
MIN. RETURN TEMPERATURE (°C) 55 55 55
NOMINAL LOADING FLUE TEMPERATURE (°C) 171 177 178
NOMINAL LOADING FLUE GAS MASS FLOW RATE (kg/s) 0.02 0.026 0.032
EFFICIENCY (%) 89.5 89.0 89.0
O2 (%) 4.73 5.05 6.12
CO2 (%) 13.9 13.74 13.6
2.3 - TECHNICAL DATA
CO 10% (mg/Nm3)361 469 367
CO 13% (mg/Nm3)263 342 267
NOx 10% (mg/Nm3)216 213 220
NOx 13% (mg/Nm3)157 155 160
Hc 10% (mg/Nm3)1 10 11
Hc 13% (mg/Nm3)1 8 8
Dust 10% (mg/Nm3)28 29 29
Dust 13% (mg/Nm3)21 21 21
FUEL CHARACTERISTICS See par. 2.7
THERMAL STORAGE VOLUME
(If Qmin > 30% of Qn)
(l) 1683 2205 2700
MAX. SUPPLY WATER TEMPERATURE
SAFETY HEAT EXCHANGER
(°C) 15 15 15
SUPPLY WATER PRESSURE
SAFETY HEAT EXCHANGER
(bar) 2 2 2
BOILER OPERATION WITH FAN
COMBUSTION CHAMBER OPERATION UNDER NEGATIVE PRESSURE
OPERATION IN CONDENSATION NO
MAXIMUM HEATABLE VOLUME ** (m3)900 1179 1444