alkon cargo 35 - unical ag check list before commissioning the boiler ... by pressing this key it is...

ALKONCARGO 35

00332604 - 1st edition - 01/2007

USER’S OPERATINGINSTRUCTIONS

2

Contents

CONTENTS

1 Symbols used in this guide ....................................................................................................................................................... 22 Correct use of the appliance ..................................................................................................................................................... 23 Water treatment ......................................................................................................................................................................... 24 Information to be handed over to the user ................................................................................................................................ 35 Safety warnings ......................................................................................................................................................................... 36 Operating instructions ............................................................................................................................................................... 4

6.1 Control panel ...................................................................................................................................................................... 46.2 Control of the operating parameters .................................................................................................................................. 86.3 Check list before commissioning the boiler ....................................................................................................................... 86.4 Boiler operation .................................................................................................................................................................. 9

DHW production ................................................................................................................................................................. 9CH mode ............................................................................................................................................................................ 9Frost protection mode ........................................................................................................................................................ 9

6.5 Shutting down the boiler ................................................................................................................................................... 106.6 Eliminating the faults ........................................................................................................................................................ 106.7 Servicing request .............................................................................................................................................................. 10

7 Operating instructions for use with E8 Heating controller ...................................................................................................... 117.1 Selection operating mode ................................................................................................................................................ 117.2 General settings ............................................................................................................................................................... 117.3 User’s settings .................................................................................................................................................................. 13

1 - SYMBOLS USED IN THIS GUIDE

When reading this guide particular care has to be given to the parts marked with the followings symbols:

NOTE!Suggestions for the user

WARNING!Indicates a potentially dangerous si-tuation for the product and the en-vironment

DANGER!Indicates serious dan-ger for your personalsafety and for your life

2 - CORRECT USE OF THE APPLIANCE

The ALKON PLUS appliance has been designed utilizing today’s heating technology and in compliancewith the current safety regulations.However, following an improper use, dangers could arise for the safety and life of the user or of otherpeople, 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 and for domestic hotwater production.Any other use of this appliance will be considered improper.UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this casethe 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 followthe instructions indicated in this guide.

3 - WATER TREATMENT

• The hardness of the mains water supply conditions the frequency with which the heat exchanger is cleaned.• In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is recom-

mended. The choice of this device has to be made taking into consideration the water’s characteristics.• In order to improve the resistance to lime scale, it is recommended to adjust the domestic hot water temperatu-

re as near as possible to the one you really require.• The use of a modulating room thermostat reduces the dangers of lime scale formation.• We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the

first year and subsequently, on the basis of the amount of lime scale found, this period can be extended to twoyears.

3

General information

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, placed

inside the envelope contained in the packaging. The user has to keep these documents in a safe place inorder to always have them at hand for future reference.

• Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that is absolutelyforbidden 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 correctpressure.

• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensurethe greatest possible fuel economy.

• Remind the user that, in order to comply to the standards in force, it is necessary to inspect and service theboiler according to the current codes of practice and according to the schedule indicated in this manual by themanufacturer.

• If the appliance is sold or transferred to another owner or if the present user moves home and leaves theappliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted bythe new owner and/or installer.

Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could causeinjury to persons, animals or damage to property. The manufacturer shall not be held liable for any suchinjury and/or damage.

4 - INFORMATION TO BE HANDED OVER TO THE USER (BY THE INSTALLER)

5 - SAFETY WARNINGS

WARNING!The installation, adjustment, and servicing of this appliance must be carried out by a competent personand installed in accordance with the current standards and regulations. Failure to correctly install thisappliance could cause injury to persons, animals or damage to property. The manufacturer shall not beheld liable for any such injury and/or damage.

DANGER!NEVER try to service or repair the appliance yourself.All types of servicing or repairs must be carried out by a professionally qualified person;UNICAL recommends drawing up a service contract.Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injuryto persons, animals or damage to property for which UNICAL shall not be held liable.

Alterations to parts connected to the applianceDo not carry out any alterations to the following parts:- the boiler- to the gas, air, water feed pipes and electrical supply- to the flue outlet pipe, safety relief valve and its drainage pipe- to the constructive components which influence the appliance’s safe operation

Smell of gasIf you smell gas follow these safety indications:- Do not touch any electrical switches- Do no smoke- Do not use the telephone- Close the On/Off gas service cock- Open all windows and doors where the gas leakage has occurred- Inform the gas society or a specialized company

Explosive and easily inflammable substancesDo not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the roomwhere the appliance has been installed.

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User’s operating instructions

6 - OPERATING INSTRUCTIONS

6.1 - CONTROL PANEL

A = Tasto diminuzione valore temperaturaA = Temperature decrease keyB = Central heating adjustment keyC = Domestic hot water adjustment keyD = Domestic hot water mode indicator ledE = Temperature increase keyF = DisplayG = Lock-out led indicatorH = Reset /chimney-sweeper keyI = Operating mode selector key:

Frost protection/Central Heating/DHW/CH+DHWL = Central Heating mode indicator ledM = E8 heating controllerN = Activation “Chimney-sweeper” function indicator ledO = Activation DHW request indicator ledP = Activation Central Heating request indicator ledQ = Power On indicator ledR = Fault indicator ledS = Burner On indicator ledT = Digital system pressure gaugeU = Digital temperature control/Error code display/Servicing

request indicator

DISPLAY

P

N

Q

S

R

T

U

I

H

L

G

B

C

A

D

E F

M

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Operating mode selection key

By pressing this key it is possible to select the type of boileroperation desired. Every time you press this key it selects theboiler’s operating mode according to the following sequence:

- Only Central heating:In this mode the boiler will operate only for heatingthe system.In this mode the led “L” indicator is illuminated.

- Only Domestic hot water (Summer mode):In this mode the boiler will operate only for domestichot water production.In this mode the led “D “ indicator is illuminated.

- DHW + CH (Winter mode):In this mode the boiler will operate fordomestic hot water production and forcentral heating.In this mode both the “D” and “L”indicator leds are illuminated.

- Only frost protection mode:In this mode the frost protection is enabled.In this mode both the “D” and “L” indicator leds areswitched off.

Central Heating temperature display/adjustmentkey

By keeping this key pressed, the set operating temperature ofthe CH circuit will appear on the display “U”.

DHW temperature display/adjustment key

By keeping this key pressed, the set operating temperature ofthe DHW circuit will appear on the display “U”.

Temperature adjustment keys

By pressing the following keys it is possible to increase (key”+”)o reduce (key “-”) the central heating or domestic hot watertemperature.

SET

SET

T °C

SET

SET

T °C

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Temperature control /error code display

This displays:- The DHW temperature (during the draw-off phase)- The CH circuit temperature (during central heating

operation)- The DHW set temperature (by pressing the PURPLE “C”

key)- The set temperature of the CH circuit (by pressing the

YELLOW “B” key)- The error code (by pressing the LIGHT BLUE “H” key)

Reset key/fault code display

This key has a dual function:

- it will reset correct boiler operation after the cut-off devicehas shutdown the boiler (red “G” led indicator illumina-ted).

Domestic hot water temperature adjustment

The DHW temperature can be adjusted by keeping the PURPLE“C” key pressed down and simultaneously pressing the “+”key to increase the temperature

or the “-” key to reduce it.

The set temperature value appears on the display “U”.

The temperature can be adjusted between 30°C minimum and85°C maximum.

or the “-” key to reduce it.

If the cut-off device intervenes more than 3times, causing boiler shutdown, do not tryto reset the boiler yourself. Contact yournearest Unical authorized After Sales Ser-vice Centre.

- it will display the boiler’s fault code, in place of thetemperature “U”, after the fault indicating led “R” hasilluminated.

Central heating temperature adjustment

The central heating temperature can be adjusted by keepingthe YELLOW “B” key pressed down and simultaneouslypressing the “+” key to increase the temperature

The set temperature value appears on the display “U”.

The temperature can be adjusted between 35°C minimum and60°C maximum.

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Central heating mode indicator led

The led indicator “P” will illuminate when there is a request forcentral heating.

“Chimneysweeper” function indicator led

WARNING!This operation can be carried out exclusivelyby an authorized After Sales Service Centre.The user is NOT authorized to activate thefollowing described function.

This “N” indicator led will i l luminate when the“Chimneysweeper” function is activated by a qualifiedprofessional service engineer. This means that the boiler willbe forced to operate at the maximum (or minimum) output soas to permit the adjustment operations and combustionanalysis.

Domestic hot water mode indicator led

The led indicator “O” will illuminate when there is a request fordomestic hot water.

Power On indicator led

The led indicator “Q” will illuminate when the boiler is connectedto the electricity supply.

Fault indicator led

When the led “R” is illuminated on the display it indicates thatthe boiler has detected a failure in normal boiler operation oris in lock-out due to a permanent failure.

The code which identifies the cause can be viewed in place ofthe centigrade temperature scale by pressing the LIGHT BLUE“H” reset key (for the list of error codes refer to paragraph 5 –“Error codes” in the servicing and installation instructionsmanual).

Burner On indicator led

When the “S” led is illuminated it indicates that the burner isfunctioning correctly, both in central heating request mode andin domestic hot water production mode.

Example of display readout:

System digital pressure gauge

This displays the water pressure inside the central heatingcircuit; the pressure should not fall below 0,8/1 bar (when thesystem is cold).

If the system pressure falls below 0,8/1 bar it will be necessaryto re-pressurise the system by regulating the filling valve. Thisoperation has to be carried out when the system is cold.

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Heating system pressure

By simultaneously pressing the YELLOW and PURPLE keyson the control panel it is possible to control the value of thewater pressure inside the CH circuit.

6.3 - CHECK LIST BEFORE COMMISSIONINGTHE BOILER

Before commissioning the appliance it is recommended tocheck the following points:- Check that the On-Off gas valve, positioned upstream of

the boiler, is in the On position.- Check that any On-Off valves fitted on the flow and return

pipes for servicing purposes are in the On position.- Check that any On-Off valves fitted on the cold water inlet

for servicing purposes are in the On position.- Check that the pressure relief valve drainage pipe is

connected to the sewage system.- Check that the boiler is connected to the electrical supply;

the green indicator led “F” on the control panel must beilluminated.

- Check the heating system pressure, indicated by thepressure gauge. For correct operation the pressure shouldbe between 0,8 and 1 bar (with the pump not running).If thepressure falls below 0,7 bar, when the system is cold, re-pressurise the system by regulating the filling valve (referto paragraph 6.6).

6.2 - CONTROL OF THE OPERATINGPARAMETERS

Domestic hot water circuit temperature

By pressing the PURPLE key on the control panel it is possibleto control the stored value of the DHW circuit temperature(value between 35° and 60°).

Error codes

When the fault indicator led “Q” is illuminated on the display,by pressing the LIGHT BLUE key on the control panel it ispossible to control the error codes (for the list of error codesrefer to paragraph 5.1 – “Error codes” in the servicing andinstallation instructions manual).

Central Heating circuit temperature

By pressing the YELLOW key on the control panel it is possibleto control the stored value of the CH circuit temperature(value between 00° and 85°).

Lock-out indicator led

When the led G is illuminated it indicates that the burner’s safetycut-off device has shut-down the boiler, due to the followingcauses:- presence of air in the piping (if it is a new system or after a

long inactivity of the boiler)- no gas supply: If this is the case, and the burner fails to

light, it will be necessary to check that the gas supply cockis in the On position.

If the cut-off device intervenes more than 3times, causing boiler shutdown, do not tryto reset the boiler yourself. Contact yournearest Unical authorized After SalesService Centre.

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User’s operating instructions6.4 - BOILER OPERATION

Domestic hot water production

Press the BLUE “I” key and select the mode: Summer (thegreen indicator led “D” will illuminate) or Winter (the greenindicator leds “D” and “L” will illuminate).

You can adjust the DHW draw-off temperature by keeping thePURPLE “C” key pressed down, and simultaneously pressingthe keys “+” to increase the temperature or “-” to reduce it.

Note:Adjusting the DHW temperature at atemperature very close to the one actuallyused will avoid mixing hot water with coldwater, thus resulting in fuel savings and asignificant reduction in lime scale formation.

In this case, the boiler will fire until the water contained in thetank has reached the desired set temperature.

When a hot water tap or shower is turned on the appliance willprovide domestic hot water at the desired temperature.

Central heating mode

Press the BLUE “I” key and select the mode: Central Heating(the green indicator led “L” will illuminate) or Winter (the greenindicator leds “D” and “L” will illuminate).

You can adjust the CH temperature by keeping the YELLOW“B” key pressed down, and simultaneously pressing the keys“+” to increase the temperature or “-” to reduce it.

Frost protection mode

Ensure yourself that the boiler is in the frost protection mode(led indicator “D” + led indicator “L” switched off).

In these conditions the boiler will not operate either in the CHor DHW mode.

The boiler is fitted with a frost protection system which willoperate automatically when the system temperature falls below6°C: the led indicator “D” star ts to flash, the burner isautomatically fired and the pump will run until the temperaturedetected by the sensor fitted on to the return pipe has risen to16°C.

If the temperature detected by the CH sensor falls below 2°C,due to no electricity supply or a lack of gas supply, when thesefactors are restored, burner operation is automatically impededuntil the temperature has risen to 5°C.

WARNING!This feature will operate only if the electricalsupply to the boiler is On (green Power Onled illuminated) and the gas cock is in theon position.However, further frost protection can beincorporated by using specific frostprotection products, suitable for multi-metalsystems. Do not use anti-frost productsdesigned for motor vehicles because theycould seriously damage the water gaskets.If, for any reason, there is no gas or electricalsupply, the above described frost protectionmode will not be active.

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Lock-out code

Cause:Excessive water pressure in the central heating circuit.

Solution:Check that the filling system cock is in the Off position.Re-pressurise the system by bleeding some water from theradiators (for correct boiler operation the pressure value shouldbe between 0,8 and 1 bar).

When the minimum pressure value has been reached(0,6 bar),correct boiler operation will be restored.

If the heating system pressure has to befrequently re-pressurised please contact anauthorized Unical After Sales Service Centre.

6.5 - SHUTTING DOWN THE BOILER

6.6 - ELIMINATING THE FAULTS

When the “R” led is illuminated on the control panel display, itindicates that the boiler has detected a failure in normal boileroperation or is in lock-out due to a permanent failure.

The code which identifies the cause can be viewed in place ofthe centigrade temperature scale by pressing the LIGHT BLUE“H” reset key (for the list of error codes refer to Chapter 5 –“Error codes” in the servicing and installation instructionsmanual).

If the boiler goes into lock-out the user can reset the boileronly in the following cases:- Code “HP” = The heating system pressure is too high- Code “LP” = The heating system pressure is too low- Burner Off indicator led illuminated

For all the other error codes, the user is NOTauthorized to reset boiler operation. Yournearest Unical authorized Afters Sales ServiceCentre should be contacted as soon aspossible.

If the boiler is completely shut down, the CH mode and DHWmode will be completely disenabled.

To completely shut down the boiler switch off the electricitysupply by means of an on/off switch.

If the boiler will remain shut down for a longer period, turn theOn/Off gas cock into the Off position and, if fitted, turn the coldwater supply cock into the Off position.

Lock-out code

Cause:Insufficient water pressure in the central heating circuit.

Solution:Re-pressurise the system by regulating the boiler’s filling cock(for correct boiler operation the pressure should be between0,8 and 1 bar).When the correct pressure value has been reached correctboiler operation will be restored.

If the heating system pressure has to befrequently re-pressurised please contact anauthorized Unical After Sales Service Centre.

Burner lock-out led illuminated

Cause:The burner’s lock-out device has intervened due to:- no gas supply- presence of air in the piping (if it is a new system or after along inactivity of the boiler).

Solution:Check that the gas service cock is in the On position and pressthe reset key to restore correct boiler operation.

If the cut-off device operates 3 times,causing boiler shutdown, do not try to relightthe boiler yourself. Contact your nearestUnical authorized After Sales Service Centre.

6.7 - SERVICING REQUEST

Code (flashing)

Cause:The appliance needs servicing

This request is signalled after 10.000 ignitions or 2.000 hoursof burner operation.

Note: The code flashing will not impedecorrect boiler operation.

Please contact an authorized Unical After Sales ServiceCentre for servicing the boiler at regular intervals.

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7 - OPERATING INSTRUCTIONS for USE WITH E8 HEATING CONTROLLER

WARNING:HERE BELOW YOU CAN FIND INDICATED THE BASIC FUNCTIONS. FOR FURTHER AND MORE DETAILEDINSTRUCTIONS PLEASE REFER TO THE “USER’S INSTRUCTIONS” SUPPLIED TOGETHER WITH THEHEATING CONTROLLER E8.5064 V1

A DisplayB PC connection via optical adapterC Programming keyD Change LedE Automatic/Manual operating switchF Rotary knob = used to search for value/level or change

value

G Display of the active heating programH eBUS connectionI Display indicating the selected area menuL Operating modeM Display of current temperatureN Display of number of active heat generatorsO Freely selectable display (refer to “DISPLAY SEL”

parameter)P Status displayQ Current time

By turning the “rotary knob” (F) it is possibleto select the required operating mode:

Standby/OFF (frost protection mode enabled)

1 Automatic mode 1

2 Automatic mode 2

Summer mode

Day mode

Night mode

Service mode

7.1 - OPERATING MODE SELECTION (withdisplay cover closed)

DATE/TIME SETTING

Open the E8 heating controller’s display cover.

Turn the rotary knob (F) until the triangle “selected level” (I) ispositioned on DATE/TIME/HOLIDAY

7.2 - GENERAL SETTINGS

Press the programming key (C) once again, the red ChangeLed will illuminate (D); at this point it is possible to proceedand change the values.

Press the programming key (C), the TIME—DATE level will bedisplayed.

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Turn the rotary knob (F) to change the value.

Press the programming key (C) again (the red Change Led (D)will remain illuminated) to save the adjustment and pass on tochanging the successive value.

In the TIME-DATE level it is possible to change, following thesteps previously described, these values: minutes > time >year > month > day

To return to the superior level DATE/TIME turn the rotary knob(F) until RETURN is viewed on the display, therefore pressthe programming key (C).

HOLIDAY SETTINGOpen the E8 heating controller’s display cover.

Turn the rotary knob (F) until the triangle “ selected level “ (I) ispositioned on DATE/TIME/HOLIDAY

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Press the programming key (C), the TIME-DATE level will bedisplayed.

Turn the rotary knob (F) until the HOLIDAY level is displayed.

Press the programming key (C), the red Change Led will beilluminated (D); at this point it is possible to proceed and changethe values.


Press the programming key (C) again (the red Change Led (D)will remain illuminated) to save the adjustment and pass on tochanging the successive value.

In the HOLIDAY level it is possible to change, following thesteps previously descr ibed, these values:STARTYEAR>START MONTH>START DAY>STOP YEAR>STOPMONTH>STOP DAY

To return to the superior level DATE/TIME turn the rotary knob(F) until RETURN is viewed on the display, then press theprogramming key (C).

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SUMMER TIMEOpen the E8 heating controller’s display cover.

Turn the rotary knob (F) until the triangle “selected level” (I) ispositioned on DATE/TIME/HOLIDAY

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arBy pressing the programming key (C), the TIME-DATE levelwill be displayed.

Turn the rotary knob (F) until the SUMMER TIME level isdisplayed.

Press the programming key (C), the red Change Led will beilluminated (D); at this point it is possible to proceed and changethe values.


Press the programming key (C) again (the red Change Led(D) will remain illuminated) to save the adjustment and passon to changing the successive value.

In the SUMMER TIME level it is possible to change, followingthe steps previously described, these values:START MONTH>START DAY>STOP MONTH>STOP DAY

To return to the superior level DATE/TIME turn the rotary knob(F) until RETURN is viewed on the display, then press theprogramming key (C).

Open the E8 heating controller’s display cover.

Turn the rotary (F) until the triangle “selected level” (I) ispositioned on USER.

7.3 - USER’s SETTINGS

For several seconds the word USER is viewed on the displaythen the word INSTALLAT will appear.

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By turning the rotary knob (F) the following levels of the USERarea will be displayed:INSTALLAT>HOT WATER>HEATING CIRCUIT I>HEATINGCIRCUIT II>SOLAR/MF

”INSTALLAT.” AREA MENUPress the programming key (C) to pass to the lower level.

By turning the rotary knob (F) it is possible to change thefollowing sub-levels:LANGUAGE>CONTRAST>DISPLAY SEL>RETURN

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Turn the rotary knob (F) to select the language.

Press the programming key (C) again to save the adjustment(the red Change Led (D) will turn off).

Contrast selectionBy turning the rotary knob (F) it is possible to pass onto thesuccessive parameter CONTRAST.

Turn the rotary knob (F) to adjust the contrast (from -20 to 20).


Display selectionBy turning the rotary knob (F) it is possible to pass onto thesuccessive parameter DISPLAY SEL.

Turn the rotary knob (F) to select the supplemental display.It is possible to select the following displays: T OUTSIDE > T—FLOW > T—DHW > T—BOILER > T—ROOM > ——>WEEKDAY


By pressing the programming key (C), the red Change Led willilluminate (D); at this point it is possible to adjust theCONTRAST.

By pressing the programming key (C), the red Change Led willilluminate (D); at this point it is possible to proceed and selectthe supplemental display in standard operation.

To return to the superior level INSTALLAT turn the rotary knob(F) until RETURN appears on the display, then press theprogramming key (C).

Language selectionBy pressing the programming key (C), the red Change Led willilluminate (D); at this point it is possible to proceed and changethe language.

NOTE: ............................................................................................................................................

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The Unical declines every responsibility for the possible inaccuracies if owed to errors of transcr ipt or press. Also reserves the r ightto bring those changes that it will hold necessary to it own products or profits, without jeopardizing its essential character istics.

AG S.P.A.46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - fax 0376/660556

www.unical.ag - [email protected]

alkon cargo 35 - unical ag check list before commissioning the boiler ... by pressing this key it is...

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