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Unical TERNOx 2S, Instructions On Installation, Use And Maintenance

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Unical TERNOx 2S Instructions On Installation, Use And Maintenance Download Page 27

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eatures and dimensions

3.16 -  HYDRAULIC AND ELECTRICAL 

SYSTEM CONNECTION 

The following figures show the typical layout of the connection 
of the boiler to the heating system with production of domestic 
hot water.
Remember that TERNOX boilers operate with forced circulation.

Key:

Pr = 

recirculation pump 

VM =  zone mixing valve 
Pi = 

heating system pump

VE =   expansion vessel
IR = 

heating system distribution 

Ps =  domestic water recirculation pump
Pc =  domestic hot water production charge pump
TA =  room thermostat 

The standard panel board of the TERNOX boiler automatically 
switches the burner off when the temperature in the boiler reach-
es the value set on the control thermostat.
It also manages the C.H. pump, which will only be activated 
when the minimum boiler temperature of 50°C has been reached 
(anti-condensation protection temperature).
The pump will switch off when the lower threshold of 50°C (de-
creasing) is reached.

The panel is set up to manage dual-stage or modulating burners.
With this layout configuration, the DHW storage tank loading 
pump will have the priority over the heating C.H. pump.

TERNOx BOILER

DOMESTIC HOT WATER 

PRODUCER

Summary of Contents for TERNOx 2S

Page 1: ...TERNOx 2S INSTRUCTIONS ON INSTALLATION USE AND MAINTENANCE ...

Page 2: ...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 ...

Page 3: ... 7 Hydraulic connections 20 3 8 Filling and emptying the system 20 3 9 Gas connection 21 3 10 Connection to the flue 21 3 11 Furnace door adjustment opening closing 22 3 12 Burner 22 3 13 Electric panel assembly 24 3 14 Electrical connections 25 3 15 STANDARD panel board 26 3 16 Hydraulic and electrical system connection 25 2 TECHNICAL FEATURES AND DIMENSIONS 9 2 1 Technical features 9 2 2 Operati...

Page 4: ...4 This page has been intentionally left blank ...

Page 5: ... 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 qualifie...

Page 6: ... 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 concerni...

Page 7: ...or inappropriate tools can cause damage e g water or gas leakage ATTENTION Indications for propane gas fired appliances Make sure that the gas tank has been deaerated before installing the appliance For state of the art tank venting contact the LPG supplier or person qualified in compliance with the law requirement If the tank has not been professionally deaerated ignition problems could arise In ...

Page 8: ...te The serial number of the boiler is on the riveted plaque on the front plate of the body front right top side If the identification plate is tampered with removed or missing the product cannot be safely identified making any installation and maintenance operation difficult 1 7 WATER TREATMENT The treatment of the supply water allows to prevent inconveniences and maintain the functionality and ef...

Page 9: ...nd low content of harmful substances in the flue gas Another advantage of the three flue gas pass structure consists of the fact that combustion products remain less time in high temper ature areas thus limiting harmful emissions of nitrogen oxides The boiler body is thermally insulated by the application of a mineral wool mattress with a high insulation level to reduce heat dispersion to extremel...

Page 10: ...3 77 7 50 3 77 5 73 3 77 Maximum operating pressure boiler bar 6 Weight kg 5500 CONNECTIONS T1 T2 UNI 2278 PN16 T3 UNI 2278 PN16 DN 50 DN 200 T4 ISO 7 1 Rp 1 T5 Øi mm 570 T6 Ø mm Rp 1 2 T7 Ø mm Rp 1 2 2500 2S STD 2200 2S Low NOx 1800 2S Low NOx E E F T1 T6 T8 G H Q D A L B P M N C I T2 T3 T5 T3 T7 T4 2 3 4 1 3500 2S STD 3050 2S Low NOx 2350 2S Low NOx E 1951 2753 1951 2406 1951 2350 3500 2350 3050...

Page 11: ...000 DN 80 DN 250 Rp 1 660 Rp 1 2 Rp 1 2 4325 6381 4325 5457 4325 5100 7000 5100 6300 5100 9760 0 72 1 36 0 72 1 10 0 72 4 89 9 50 4 89 7 60 4 89 6 11500 DN 100 DN 250 Rp 1 720 Rp 1 2 Rp 1 2 7000 2S STD 6300 2S Low NOx 5100 2S Low NOx E 8500 2S STD 7500 2S Low NOx 5700 2S Low NOx E 5529 7705 5529 6892 5529 5700 8500 5700 7500 5700 11480 0 90 2 00 0 90 1 56 0 90 4 76 11 0 4 76 8 44 4 76 6 13500 DN 1...

Page 12: ...sure drop m w c 1 31 2 00 Flue gas pressure drop mbar 8 93 14 0 Maximum operating pressure boiler bar 6 Weight kg 25500 CONNECTIONS DN 125 DN 300 DN 60 820 Rp 1 2 Rp 1 2 12500 2S STD E F G H Q D A L B P M N C I 2 3 4 1 T1 T2 T3 T3 T5 T4 T6 T7 T8 15000 2S STD 13789 15000 27300 1 46 2 20 9 72 15 0 6 30000 DN 125 DN 350 DN 60 1000 Rp 1 2 Rp 1 2 16458 TERNOx Model 12500 2S STD 15000 2S STD DIMENSIONS ...

Page 13: ...25 91 40 92 9 0 60 7 15 0 10 146 46 9 80 2932 8 TERNOX 1800 2S LOW NOx E 1800 1951 92 25 91 40 92 9 0 60 7 15 0 10 156 73 12 80 2987 9 TERNOX 3500 2S STD 2350 3500 2537 3848 92 64 90 95 91 40 93 2 91 7 0 58 071 6 78 8 34 0 10 139 00 171 00 9 80 3813 1 5784 7 TERNOX 3500 2S STD 2350 3500 2537 3848 92 64 90 95 91 40 93 2 91 7 0 58 071 6 78 8 34 0 10 148 67 182 90 12 80 3884 6 5893 1 TERNOX 3050 2S L...

Page 14: ...3 1 0 59 6 91 0 10 151 58 12 80 6622 2 Nominal heat output Thermal output of furnace Heat efficiency at nominal load 100 Heat efficiency at 30 load Combustion efficiency at nominal load 100 Heat loss at casing min max Heat loss at chimney with burner on min max Heat loss at chimney with burner off min max Flue gas temperature tf ta min max CO2 content Flue gas mass flow rate min max kW kW C kg h G...

Page 15: ...92 40 91 40 93 0 0 58 7 02 0 10 153 94 12 80 9446 8 Nominal heat output Thermal output of furnace Heat efficiency at nominal load 100 Heat efficiency at 30 load Combustion efficiency at nominal load 100 Heat loss at casing min max Heat loss at chimney with burner on min max Heat loss at chimney with burner off min max Flue gas temperature tf ta min max CO2 content Flue gas mass flow rate min max k...

Page 16: ...t output Thermal output of furnace Heat efficiency at nominal load 100 Heat efficiency at 30 load Combustion efficiency at nominal load 100 Heat loss at casing min max Heat loss at chimney with burner on min max Heat loss at chimney with burner off min max Flue gas temperature tf ta min max CO2 content Flue gas mass flow rate min max kW kW C kg h DIESEL OIL FIRED Nominal heat output Thermal output...

Page 17: ...ad and direction of the flow of the circulation pumps are appropriate The expansion vessel s can fully absorb dilation of the flu id in the system The fuel adduction line and the tank if any are made ac cording to relevant standards in force The expansion vessels can fully absorb dilation of the fluid in the system The system has been cleaned and cleared of all sludge and scale has been vented and...

Page 18: ...is complete and undamaged The document envelope besides the appliance contains 3 5 HANDLING TERNOX 2S boilers are equipped with lifting eyebolts Pay attention when handling the boiler and use equipment suit able for its weight Hydraulic test certificate Heating system booklet System manager operating instructions Installation and maintenance instruction booklet Warranty Local ventilation requireme...

Page 19: ... the smoke circuit a free space must be left in front of the boiler no less than the length of the boiler body and in any case never less than 1300 mm It must be checked that with the door s open 90 the distance between the door and the adjacent wall X is at least equal to the length of the burner The boiler must rest on a perfectly level surface It is advisable to provide a flat level cement base...

Page 20: ...ust not take the weight of the connecting pipes of the sys tem suitable supporting devices should be installed to do this The dimensions of the supply and return pipes for each boiler model are given in the DIMENSIONS table Check that the system is fitted with a sufficient number of air release valves Connection of expansion vessel TERNOX 2S boilers are suitable for operating with forced water cir...

Page 21: ...sulated exhaust pipes are a potential source of risk The seals of the junctions must be made with materials resist ant to temperatures of at least 250 C Along the section connecting the boiler to the flue there must be suitable points for measuring flue gas temperature and ana lysing combustion products Refer to national and local regulations in force for that which regards the cross section and h...

Page 22: ...ing oil burners of the monobloc type UNI EN 676 air blown burners for gaseous fuel Efficiency Directive 92 42 EEC The door is hinged and fixed according to the indicated diagram In these cases the two hinges on the left are normally used as rotation hinges from right to left while the two on the right are used as closing hinges It will be exactly the opposite when the door is opened from left to r...

Page 23: ...cially those approved based on the standards indicated above Should a cone larger than the diameter of the blast tube be mounted it must be removed before mounting the burner on the support plate and put back afterwards With the burner mounted check that the flexible hoses of the liquid fuel and the electric cables are long enough to allow the door to open 90 For gas fired burners flexible hoses c...

Page 24: ...el board frontwards after having removed the two screws on the side and insert the electric inlet cables and the outlet probe capillaries through the slots at the base Insert the thermostat probe capillaries in the tube designed for their passage that is placed under the casing see detail A Pay special attention when unrolling the capillaries and insert the bulbs in the two holders inserting the c...

Page 25: ...he appliance Use of any type of component using electric energy requires the observance of some fundamental rules such as do not touch the appliance with wet and or moist parts of the body and or in bare feet do not pull the electric cables do not leave the appliance exposed to atmospheric agents rain sun etc unless expressly designed do not allow children or unskilled persons to use the appli anc...

Page 26: ...2 If the Room thermostat is mounted remove bridge 11 12 The main switch 11 powers the board and the equipment con nected to it Switches 12 and 13 in turn cut power to the burner and to the C H pump Thermostat 32 adjusts the working temperature of the boiler The working thermostat is provided with two switching contacts to control the two stage burners The differential between the two contacts is 6...

Page 27: ...oduction charge pump TA room thermostat The standard panel board of the TERNOX boiler automatically switches the burner off when the temperature in the boiler reach es the value set on the control thermostat It also manages the C H pump which will only be activated when the minimum boiler temperature of 50 C has been reached anti condensation protection temperature The pump will switch off when th...

Page 28: ...E With absorption beyond 4A place adequate contactors between the panel board and the loads POWER SUPPLY POWER SUPPLY POWER SUPPLY TO THE 7 POLE SOCKET OF THE BURNER TERNOx BOILER DOMESTIC HOT WATER PRODUCER ...

Page 29: ...ler It also manages the pump to fill a storage tank for DHW pro duction The heating systems are managed automatically based on the data detected by the boiler external ambient and flow probes The high temperature zone C H pump is made ready for oper ation by the control switch pos 20 and will only switch off when the temperature set on the heating controller has been reached The low temperature zo...

Page 30: ...56 57 C 32 25 30 31 26 37 27 38 39 40 41 teleruttore pompa zona 1 teleruttore pompa ricircolo teleruttore pompa zona 2 teleruttore pompa boiler teleruttore valvola mix zona 2 L1 L L L L L2 N N N N N Pz1 Pr Pz2 Pb Zona mix 2 24 36 Ipz1 Ip1 Ipz2 20 19 21 29 43 c E 1 2 44 45 34 35 H L 22 23 33 Nero Blu Marrone Bianco Rosso Grigio Blu Marrone Nero Bianco 1 2 8 6 10 5 9 11 II 2 II 3 II 4 II 5 II 6 II 7...

Page 31: ...zona 2 L L L L1 L2 N N N N Pb Pz2 Pz1 Pr 53 50 47 16 E8 5064 1 M 13 14 15 16 19 20 21 22 23 24 25 L CAN BUS H 1 3 6 7 8 9 10 11 12 AF VF KF2 KF1 SPF 2 N L1 N L1 T3 T4 2 T2 T1 1 4 5 2 1K PTC 65 C 5K NTC 60 OFF min 40 fix 24h fix Lago Basic 0201RV1 SONDA DI CALDAIA Ipz1 Ipz2 Ib Ts 11 C Te 0 100 C c 1 2 Ip1 Ig F1 max 6A c 2 B C A 16 35 33 18 14 19 21 20 Nero Blu Marron Bianco Rosso Grigio Blu Marron ...

Page 32: ...N T HS1 MIN T HEADER 01 ON 95 C 10 C 0 01 BUS CONNECTION 01 00 01 off on BUS SUPPLY 01 ON 2K 20K P HYSTERESIS 00 30 min HYSTERESIS TIME 00 01 02 MINIMUM LIMIT 5 00 min 00 30 C 110 C MAX T HS2 95 C 01 08 BOILER BUS ID 10 C 80 C MIN T HS2 10 C 0 11 VOLTAGE CURVE 11 0 00 10 00V CURVE 11 U2 0V 0 00 10 00V CURVE 11 U2 10V 00 120 C CURVE 11 T1 0 00 120 C CURVE 11 T2 100 C 0 00 10 00V CURVE 11 UA 0V 10 C...

Page 33: ...boiler stages must be disabled See E8 5064 heating controller instruction manual Default Individual values Value range Description DOMESTIC HOT WATER PRODUCTION 00 01 OFF ON CHARGE PUMP 01 ON 00 01 02 03 PARALLEL PUMP RUNNING 01 00K 50K T DHW 20K 5K 30K DHW HYSTERESIS 5 degrees 00 min 30 min DHW FOLLOWUP 00 min 00 01 OFF ON THERMOSTAT INPUT 00 OFF 00 01 OFF ON THERMOSTAT FUNCTION 00 OFF Exit level...

Page 34: ... MF 1 4 T NOM 30 C 5 25 MF 1 4 HYSTERESIS 5 C 5 25 F 15 FUNCTION 0 Exit level using RETURN C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 PARAMETERS PROGRAMMABLE BY TECHNICIAN FOR HEATING CONTROLLER Lago Basic 0201 RV 1 1 2 3 1 1 Switch selector to burner 1 2 Press ok 2 3 Turn the knob 3 until mm appears on the display modulating burner 4 Press ok 2 2 1 Switch selector 1 to mixer valve symbol 2 P...

Page 35: ...24h fix Lago Basic 0201RV1 Pz1 Pz2 Key Pr recirculation pump VM2 zone mixing valve Pz1 direct zone heating system pump Pz2 mixed zone heating system pump VE expansion vessel IR1 direct zone heating system distribution IR2 mixed zone heating system distribution Ps domestic water recirculation pump Pb DHW production charge pump SPFS storage tank probe KF boiler probe E8 heating control KF1 boiler pr...

Page 36: ...201RV1 2 3 4 5 6 7 1 8 9 10 2 3 4 5 1 50Hz 230V 2 1 VI II IV A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 1 L1 L1 1 2 M M 2 T1 T2 2 T3 T4 1 1 2 3 4 2 2 n N 2 4 3 2 1 3 2 1 2 1 2 1 4 3 2 1 8 7 6 5 10 9 2 1 L Bus H PT1000 VF AF KF SPF VF IX III 2 3 1 FBR IMP Licht 0 10V SPF eBUS 0 10V VIII V F17 F15 F14 F13 F12 F11 I VII F9 F8 F6 F5 F1 F2 F3 1 4 3 2 1 1 1 1 3 1 FBR E8 5064 Pz1 Pz2 NOTE With absorption beyond ...

Page 37: ...ascade The thermostat adjusts the working temperature of the boiler 2 to achieve this the thermostat must be placed at maximum full scale pos 32 Modulation of the burner will be managed by heat control The electric power line of the boiler s control board must have a switch with protective fuses For use of the panel board see the system manager instruction manual As far as the practical connection...

Page 38: ... Press ok 2 3 Turn the knob 3 until mm appears on the display 4 Press ok 2 2 1 Switch selector 1 to mixer valve symbol 2 Press ok 2 3 Turn the knob 3 until the number 15 appears on the display burner servomotor time 4 Press ok 2 3 1 Switch the selector 1 to BUS ID 2 Press ok 2 3 Turn the knob 3 until the number 2 appears on the display boiler ID 4 Press ok 2 Turn the knob 1 back to RUN ...

Page 39: ...water recirculation pump P1 circulation pump Pb DHW production charge pump SPF storage tank probe KF E8 5064 heat control boiler probe KF 1 Lago Basic 0201 RV 1 heat control boiler probe VF flow probe AF external probe P1 C OK 1 2 1 2 1s C C C BUS ID 1 2 11 Mod Run 2 1 31 42 11 41 12 13 32 Ps PRODUTTORE ACQUA CALDA SANITARIA Pb Pz1 P1 IR BT Pz2 Vmix2 IR AT SPF VF SONDA ESTERNA AF 14 15 16 17 35 33...

Page 40: ...k charge pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached The panel is set up to manage the modulating burners With this system configuration the heating controller is capable of checking direct zone system the control unit commands the C H pump The room temperature is controlled by the programming curves...

Page 41: ...ner and the electrical equipment of the boiler is the burner assembled according to the instructions in the manufacturer s manual has the burner blast tube infill been performed correctly Is the system full of water and does not contain any air Are the drain valves closed and the system cut off devices fully open is the gas supply cock open models with gas burner has gas leakage been checked model...

Page 42: ...ature and on the other without dropping below 160 C 3 22 2 Ignition and extinction Ignition When the checks indicated in the previous paragraph are suc cessful the burner can be commissioned by a technician quali fied and acknowledged by the Manufacturer of the burner The technician takes on all responsibility regarding calibration within the declared and approved output range of the boiler After ...

Page 43: ...system increases during operation make sure that its maximum value does not exceed the design pressure of the boiler Instruments pressure switch pressure gauge etc must be excluded before starting the wash Introduce 0 3 to 1 of caustic soda sodium carbonate or trisodium triphosphate into the total content of the water Specific surfactants must be added to these substances ranging from 0 05 to 0 15...

Page 44: ...e of fuel Gas fired boilers once a year Diesel oil fired boilers twice a year Fuel oil boilers every 300 hours of operation In any case local standards regarding maintenance must be respected During routine maintenance operations the tube bundle and furnace must be brushed Remove deposits built up in the flue gas casing by opening the inspection doors For more energetic actions remove the rear smo...

Page 45: ...mbustion chamber remove the smoke chamber access door brush the smoke ducts energetically to remove any trace of filth Check condition of gaskets and insulation fibres The insulation fibre of the door can show cracks after a short time of operation this however does not reduce its insulation capacity nor jeopardise its lifespan Check the condition of the seal gas ket which must not show signs of d...

Page 46: ... analysis check the amount of fuel check clogging of the chimney and cleanliness of the burner air path dust SOLUTIONS check sealing of the fuel supply system if gas check sealing of the flue gas circuit inspection doors burner plate flue gas casing boiler chimney fitting check that the rubber holder on the flame warning light is connected to the air sock et of the burner or if it is plugged SOLUT...

Page 47: ...47 ...

Page 48: ...rs It reserves the right to modify its products as deemed necessary or useful without jeopardising their essential features 46033 casteldario mantova Italy tel 39 0376 57001 telefax 39 0376 660556 info unical ag com export unical ag com www unical eu AG S p A 00335304 1 st edition 08 14 www unical eu ...

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