Flue gas condensation...

1

2

3

4

5

1 - Smoke ways2 - Cold wall3 - Condensate drops from cold wall4 - Smokes sent to the flue duct,

practically without any water steam5 - Condensate drain

The combustion process occurs when theoxygen in the air, supporting thecombustion, and the gas are brought toa temperature such to start a reaction.This reaction is of exothermic type, thatmeans heat releasing. A cubic meter ofmethane during combustion produces10.13 kWh under form of thermal energy(sensitive heat), 1.6 kg of water understeam form (H20) and carbon dioxide(CO2).

Latent heat recoveryIn traditional combustion boilers the steam,and its latent heat, is evacuated throughthe flue together with the flue gases.The purpose of the condensationtechnique is primarily to drastically reducethe latent heat dispersed in the flue gases,exploiting to the full the energy held inthe fuel to obtain high efficiencies,impossible to reach using traditionalsystems.

Use of energyin the flue gasesTo recover the energy accumulated in theflue gases as latent heat (or of vaporization)the condensing boiler is equipped withan extra large heat exchanger.This exchanger is designed so that thecold water, returning from the C.H. system,runs through its terminal part: the contactof the flue gases with this cold surfaceturns them from steam to liquid state(condensation), with relevant heat transferto the water. This process means that itis possible to recover about 11% of theheat that generally would be lost in theflue gases, thus obtaining from thecombustion of one cubic meter of methanea thermal energy of 11.25 kWh insteadof 10.13 kWh.

…for the maximum energyexploitation (efficiency = 107%)

TRADITIONAL BOILER

KONDENSAL

EFFICIENCY

Output (kW)

Effic

ienc

y (%

)

The amount of heat that can be recoveredfrom the flue gases, and therefore theamount of condensation produced, isinversely proportional to the workingtemperature of the system.The condensation technique is thusideally suited in systems where thereturn temperature is as low as possible:the ideal system is, as a result, theheating system using radiant panels(floor heating systems).

Efficiency higherthan 100%The capacity of a fuel to produce thermalenergy during the combustion processis calculated by its Calorific Value.In general it can be said that the C.V.is the quantity of heat developed in thecombustion of a unitary quantity of fuel- 1 m3 in the case of natural gas.Usually a distinction is made betweenG.C.V. (Gross Calorific Value) and N.C.V.(Net Calorific Value):the G.V.C. is the quantity of heat, freedthrough the complete combustion of1 m3 of gas, supposing to recover thelatent heat contained in the steam presentin the flue gases as well; the N.V.C. is theamount of heat, freed by the combustionof 1 m3 of gas supposing that all the watercontained in the flue gases, as steam,stays steam. The difference betweenthe two calorific values is thus given bythe value of the steam condensation heatheld in the flue gases.Up until now, as it had never been possibleto recover this heat with traditional boilers,only the N.C.V. was calculated whenevaluating the efficiency.This is why, when speaking of condensingboilers, efficiencies higher than 100% canbe reached.

An aluminum motor

A high performanceenbloc bodyLike the new car engines, the coreof KONDENSAL is a single blockmade of die-cast aluminum,extremely light and resistant.

Advantages:• highly corrosion resistant, therefore long-lasting• compactedness• maintenance almost zero• high silentness

WOOD

15

CLOCK

KONDENSAL

LIBRARY

OFFICE

TELEVISION

20

42

50

70

75

(dBA)(dBA)NOISE LEVELNOISE LEVEL

4242

Premix combustion:intelligent and ecological output

The output of KONDENSAL variesaccording to the speed of the electronicallycontrolled fan.Whatever the output level, thereforewhatever the number of rotations of thefan, the air-gas mixture is always right.

Advantages:• a high powered fan means that longand complex flue ducts can be used• maximum output is automatically self adapting to the length of air-flue gas ducts, ensuring perfect combustion (CO2=9,4%)• the modulation range is very wide• all over the modulation range the combustion is always perfect and with low polluting emissions• higher efficiency, due to the pre-mix combustion• high temperature of the dew point

maximumenvironment respect

The special structure of the burner, madeof stainless steel wool net generates acombustion at a temperature of 1100°Cand allows:

• NOx emissions < 20 ppm• CO emissions < 8 ppm

and consequently a very lowenvironmental impact.

50 m

65 m

75 m

100%

73%

30%

MAXIMUM LENGTH OF DUCTS (total) LOAD

EMISSION COMPARISON

traditionalboiler

MAX OUTPUT

REDUCED OUTPUT

REDUCED OUTPUT

traditionalboiler

Personalized comfortwith high energy saving

Display

DHW temperature regulation

Push buttons for increasing/decreasingselected values

Reset push button

On-Off main switch

Mode selection

CH temperature regulation

Panel board

Digital manometer

Digital thermometer (CH and DHW)

Possibility of thermoregulation connection

created by the fan - always guaranteesthe ideal air/gas ratio and thus a constantlyhigh efficiency at whatever level.KONDENSAL becomes a refined thermalregulating system when connectedto an appropriate outer sensoror to a modulating thermostat(provided as an option).This makes it possible, for the roomtemperature, to be kept constant despitevariations in the external temperature,by regulating the temperatureof the heating systems (radiators etc.)completely automatically.KONDENSAL guarantees to the user fullyautomatic maximum performances.

KONDENSAL is fitted with a modernmicroprocessor that controls all thefunctions. It can be approached througha simple luminous display and six pushbuttons.Basic operating values(Combustion ratio, automatically self-adjusting heating program) are pre-set.The real value of the boiler temperatureis compared with the temperaturecalculated by the microprocessor duringthe heating or domestic hot water modeby means of the C.H. flow, return andD.H.W. temperature sensors.When the data have been collected themicroprocessor regulates the fan speedand then the supply of combustion air.Consequently the burner, designed torecall the exact amount of gas needed ineach moment - thanks to negative pressure

The KONDENSAL electronic managementevolution allows, in a simple, efficientand economic way, to solve the problemsof heating zones at different temperatures.The possibility of connection to theelectronic card of the modulatingchronothermostat TM 2000 allows,as indicated into the figure, to managedifferent zones at different temperaturesand priorities.The connection flexibility is so highthat engineers and installers can choosecompletely automatic functionscontrolled at distance by TM 2000,a real remote control.By connecting an outdoor sensor,it will be possible a temperature adjustingas a function of the outdoor temperature.

TM 2000 (optional):The information appearing on the maindisplay, always of easy interpretation,indicates all the available data sent bythe boiler electronic card.The three push buttons give accessto the different modes on the pre-setprograms:• antifrost protection mode• heating program 1 and 2• setpoint• timings for switching ON and OFF the boiler• continuous regulation• economic reduction

By opening the small front cover,in correspondence of the three pushbuttons appear other symbols,that allow to modify the parameters;these functions are also used by techniciansfor an easier starting up and maintenanceof the boiler.Besides the functions of modulatingroom chronothermostat, the remote controlallows:

for the user:• the visualization and selection of all the control parameters the remote ignition, by phone, using a dedicated interface (not yet available).

for the service men:• the visualization and selection of all the operation and safety parameters• the store of the 4 latest lock-out codes detectes.

Installation at low temperature for floor heating system

Installation at high temperature for radiators

65

KONDENSAL R TFS 30

KONDENSAL R TFS 30 is a condensing,wall hung, gas boiler, for heating only.Fitted with a premix burner,it works either with natural gas or LPGand reaches an output of 30,4 kWin condensing conditions.The combustion chamber is air-tight,making the boiler suitable for installationin any room, with or without ventilation,with complete safety.It can work at very low temperaturesand consequently offers high efficiency,thanks to maximum exploitationof condensation energy.This makes it ideal for floor heatingsystems.The R version can be fitted withan optional kit, composed of a three-wayvalve and control sensor for a remotedomestic hot water tank.This makes possible to have the mostof the boiler’s small size and alsoprofit from its high capacity to producedomestic hot water.Furthermore, it’s possible to connectthis boiler to the exclusive D.H.W. Unicalstorage tank DSP 120.

Power and flexibilityfor floor heating systems

The main components• Silicon aluminum heat exchanger• Flame modulation controlled according to absorbed power• Circulating pump• Panel board with insulation IP X 4D• Safety pressure switch against lack of water• Pressure indicator (display)• Drain cock• Filling cock• Automatic air-vent• Temperature range in heating mode from 20 to 85 °C• Ready for managing a separate D.H.W. storage tank• Expansion vessel• Modulating P.C.B. (Printed Circuit Board) for electronic control (regulation, diagnostic, safeties)• C.H. flow temperature NTC limit thermistor• C.H. return temperature NTC limit thermistor• Anti-frost protection• Multi-function digital display• Template for plumbing connections• Optional: - kit for separate DHW tank, including three-way valve and connection pipes - DHW tank DSP 120 with accessories

KONDENSAL C TFS 30

KONDENSAL CTFS 30 is a condensing,wall hung gas boiler, equippedwith a premix burner, for operationwith natural gas or LPG.Max. output is 30,4 kW, both duringheating and instantaneous D.H.W.production.It is room sealed, fan assisted.Suction of combustion air and evacuationof combustion gases can be effectuatedeither by using coaxial type or separateducts.All models have electronic ignition.

Main components• Silicon aluminum heat exchanger• Flame modulation, controlled according to absorbed power• Circulating pump• Panel board with insulation IP X 4D• Safety pressure switch against lack of water• Bargraph pressure indicator (display)• Drain cock• Filling cock• Automatic air-vents• Heating temperature adjustable from 20 to 85°C• Hot water temperature adjustable from 35 to 65°C• Expansion vessel• Modulating P.C.B. (Printed Circuit Board) for electronic control (regulation, diagnostic, safeties)• Thermostatic mixer in the DHW outlet• Motorized three-way diverting valve• Anti-frost protection• C.H. flow temperature and return NTC limit thermistors• Multi-function digital display• Template for plumbing connections

Constant temperature duringdomestic hot water drawing

The KONDENSAL C TFS 30’s specialconstruction has brilliantly resolvedone of the main problems of instantaneousD.H.W. production boilers: the constanttemperature during hot water drawing.To heat a primary tank having a 13 litercapacity (with inside a copper coil -internal diameter 13 mm - externaldiameter 15 mm and containing 1.3 litersof D.H.W.), insulated with highdensity polystyrene foam,KONDENSAL C TFS 30 exploits itscontinuous modulatingoutput and characteristic thermal inertiapresent in the exchanger aluminium bodymass.The maximum temperature factorypreset is 65°C, but it can be regulateddown to 35°C.The D.H.W. storage tank is keptat a constant temperature (factory pre-setat 65°C, can be regulated down to 35°C).Careful design ensures that exchangeand insulation are very high.The domestic water to be heatedenters the coil from the bottom and travelsupwards through the 11 loops in counter-current to the primary flow.At the outlet, a device, pre-set at 60°C,mixes the water to be used with coldwater to avoid thermal shocks and suddenchanges in temperature.The maximum domestic hot water flowrate that can be drawn with ∆t of 25 Kis 16,5 liters/minute.

KONDENSAL B TFS 30

KONDENSAL B TFS 30 is a condensing,wall hung gas boiler for central heatingand D.H.W. production with a 60 literstorage tank and output of 30,4 kW.This model has an extremely powerfulsystem for domestic hot water production.The vertical storage tank is enameledaccording to the Bayer method and offersthe following characteristics:• 60 liter domestic hot water always readily available at 65 °C, adjustable up to 35°C.• 9 minute max recovery time• continuous flow rate of 16,3 liters/minute.

The domestic hot waterproductionInside the enameled storage tank is presenta steel coil of about 10 m in length,also enameled, which, together withthe output of 30,4 kW exchangedin instantaneous D.H.W. productionprovides the fullest guaranteeof hot water availability whenrequired from more than one tapat the same time.

Flame modulationThe flame regulation that KONDENSALuses even during domestic hot waterproduction allows considerableenergy saving.This permits heat delivery to beproportionate and electronically controlledaccording to the temperature of thedomestic hot water in the storage tank.The lower the temperature, the greaterthe energy delivered.

FOTOITALIA

High performancesin the D.H.W. storage

Main components• Silicon aluminum heat exchanger• 60 liter glass lined storage tank, with high density CFC free PU insulation• Flame modulation regulated according to output absorbed• Circulating pump• Panel board with insulation IPX4D• Safety pressure switch against lack of water• Bargraph pressure indicator (display)• Drain cock• Filling cock• Automatic air-vents• Heating temperature adjustable from 20 to 85°C• Hot water temperature adjustable from 35 to 65°C• Expansion vessel• Modulating P.C.B. (Printed Circuit Board) for electronic control (regulation, diagnostic, safeties)• Motorized three-way diverting valve• C.H. flow temperature NTC limit thermistor• C.H. return temperature NTC limit thermistor• NTC sensor for DHW temperature control• Anti-frost protection• Multifunction digital display• Template for plumbing connections.• Optional: - DHW expansion vessel kit

The fan withhigh manometric head

The boiler is designed to operate atconstant efficiency regardless of the lengthof the air/flue ducts. KONDENSAL isequipped with a high power fan able toreach a net available manometric headof 80 Pa. When the length and geometryof the air suction and flue ductsvaries it self-adjusts.The length withseparate ducts of 80 mm dia. in a straightline can reach, at the maximum output,up to 50 meters.

L’auto-adaptationannule tous les problèmesd’évacuationThe longer the air/flue ducts are andtherefore the higher the pressure lossesare, the greater the pressure of the fanwill be to discharge the combustion gasesand, consequently, the lower the gas flowrate sucked in will be.In case of difficult evacuations maximumoutputs will be lower than those declared,but always with the maximum efficiency.

Electronically controlled fan detail

Air/flue ducts

DISCHARGE OF FLUE GAS INTO HORIZONTALCOAXIAL DUCTS ( ø 60/100 mm)

DISCHARGE OF FLUE GAS INTO VERTICALCOAXIAL DUCTS ( ø 80/125 mm)

Air/flue coaxial ducts(type A accessories)The maximum length of the coaxial ductsis 3.5 meters with pipes 60/100 mm dia.,and 8.5 m with pipes 80/125 mm dia.;for every bend added the maximumlength allowed must be reducedby 1 meter.With Kondensal boilers,all the problems of flue gas evacuationeliminated by self-adjustment.

Max. length, included coaxial adaptoron the boiler= 3,5 m

Hauteur maximale,y compris le terminald’évacuation = 8,5 m

Air/flue separate ductsø 80/80 (type B accessories)The max. length of separateducts is 50 meters;for every bend added maximum lengthmust be reduced by 1 meter.

Max. heigth,included coaxialterminal = 8,5 m

MG

RM

C GF

R

MC

G

F

R

Easy to install ...

In order to facilitate the boiler installation,Unical provides an optional plumbingtemplate. This allows a quick and easyboiler connection. By fixing to the wallthe provided mounting jig with its centerline in vertical position, it is possible to

Optional kit for a DHW storage tank connection (NTC sensor for DHW priority, motorized3 way valve, connection pipes, wiring).

determine the exact positioning ofall the pipes connections.The template will then allow you toeffectuate all connections and carryout soundness tests without havingto assemble the boiler.

Optional DHW expansion vessel kit for kondensal BTFS 30.

Optional plumbing templates

KONDENSAL R - C cod. 00371030

KONDENSAL B cod. 00371031

Boiler fixing supports

Key:

G - Gas connection 3/4”C - D.H.W. outlet 1/2”F - D.C.W. inlet 1/2”M - C.H. flow 3/4”R - C.H. return 3/4”

Optional accessories for temperature control• Outdoor sensor• Modulating chronothermostat TM 2000• On-Off room thermostat• On-Off weekly programmable room thermostat

Special optional accessory• Wall fixing kit complete with siphon• Conversion kit from Nat to LPG• Positioning template kit• Expansion vessel anti water hammer

. . . with mounting andplumbing template

189 59

G

883

509

C G F R

909

M

389

65 6565 65

R M C F

7865

Technical data

(*) reference value at 15°C/1013 mbar

(**)calculated for a max. temperature of 90°C

R TFS 30KONDENSAL C TFS 30 B TFS 30 R TFS 30 C TFS 30 B TFS 30

8,8÷28,4

9,2÷29,2

CE

5

30

97,1

107,3

8,9 ÷ 9,1

10,2 ÷ 10,3

53 ÷ 54

35 ÷ 65

12

16,3

90

10

-

8

60

3

0,5

7

230/50

130

1312 BM 3473

100

186

42

20

37

0,97 - 3,09

0,71 - 2,27

1900-5900

X 4D

10÷30,4

9,2÷29,2

CE

5

30

104,6

107,9

8,9 ÷ 9,1

10,2 ÷ 10,3

53 ÷ 54

35 ÷ 65

12

16,3

90

10

-

8

60

3

0,5

7

230/50

130

1312 BM 3473

100

186

42

20

37

0,97 - 3,09

0,71 - 2,27

1900-5900

X 4D

8,8÷28,4

9,2÷29,2

CE

5

30

97,1

107,3

8,9 ÷ 9,1

10,2 ÷ 10,3

53 ÷ 54

-

-

-

-

90

4

-

8

-

3

0,5

-

230/50

130

1312 BM 3473

65

186

42

20

37

0,97 - 3,09

0,71 - 2,27

1900-5900

X 4D

10÷30,4

9,2÷29,2

CE

5

30

104,6

107,9

8,9 ÷ 9,1

10,2 ÷ 10,3

53 ÷ 54

-

-

-

-

90

4

-

8

-

3

0,5

-

230/50

130

1312 BM 3473

65

186

42

20

37

0,97 - 3,09

0,71 - 2,27

1900-5900

X 4D

10÷30,4

9,2÷29,2

CE

5

30

104,6

107,9

8,9 ÷ 9,1

10,2 ÷ 10,3

53 ÷ 54

35 ÷ 65

ADJUSTABLE

12

16,3

90

15

12

8

-

3

0,5

7

230/50

130

1312 BM 3473

65

186

42

20

37

0,97 - 3,09

0,71 - 2,27

1900-5900

X 4D

8,8÷28,4

9,2÷29,2

CE

5

30

97,1

107,3

8,9 ÷ 9,1

10,2 ÷ 10,3

53 ÷ 54

35 ÷ 65

ADJUSTABLE

12

16,3

90

15

12

8

-

3

0,5

7

230/50

130

1312 BM 3473

65

186

42

20

37

0,97 - 3,09

0,71 - 2,27

1900-5900

X 4D

Condensing conditions operation ∆t 50/30°C

Traditional operation ∆t 80/60°C

kW

kW

ppm

%

%

%

%

°C

°C

°C

l/min

l/min

°C

l

l

l

l

bar

bar

bar

V/Hz

W

kg

l

dBA

mbar

mbar

m3/h

kg/h

rpm

Nominal output

Nominal input

Efficiency category (According EEC Directive 92/42)

NOx class (according EN 483)

NOx (value according EN 483)

Water efficiency at full load (100%)*

Water efficiency at part load (30%)*

CO2 level with G20

CO2 level with LPG

Dew point with G20

DHW temperature setpoint range

Thermostatic mixer preset to:

DHW Flow restrictor

DHW production in continuous operation with ∆t 25 K

Max. boiler temperature

Water content primary circuit

Water content CH tank

Expansion vessel capacity

Water content DHW storage tank

Max. pressure in CH circuit

Min. pressure in CH circuit

Max. DHW. pressure

Electrical supply

Maximum absorbed power

CE approval P.I.N.

Net weight

Max. water content CH circuit (90°C)**

Max. acoustic emissions

Gas pressure with G20

Gas pressure with G31

Gas consumption with G20

Gas consumption with G31

Fan speed

Insulation Protection degree (IP)

DIAGRAM FLOW RATE/MANOMETRIC HEADAVAILABLE FOR THE C.H. SYSTEM

max

min.

Dimensions

KONDENSAL R/C

KONDENSAL B Cod

. 282

16G

B E

d.2

- 11

/200

4

473600

385

8523

2.5

85120 120

282

141 BOTTOM VIEW

BOTTOM VIEW

913

880

930

898

480

K

145

120 85 120

144

K

GM C F

57.5 79 65 110.5 95.5 72.5

85

R

Key:

G - Gas connection C - D.H.W. outletF - D.C.W. inletM - C.H. flowR - C.H. returnB - Connection for external DHW tank

Flow rate Q (l/h)

Man

omet

ric h

ead

(m)

UPPER VIEW

UPPER VIEW

Unical AG declines any liability for the inaccuracies that may appear due to errors in transcription or printing. It also reserves the right to introduce thosemodifications to its products that it considers necessary or useful, without compromising the essential characteristics of the said products.