Unical Tristar 2S Installer And Maintenance Technician Instructions Download

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INSTALLER AND
MAINTENANCE
TECHNICIAN
INSTRUCTIONS

00334513

rev. 0

TRISTAR 2S

Summary of Contents for Tristar 2S

Page 1: ...INSTALLER AND MAINTENANCE TECHNICIAN INSTRUCTIONS 00334513 03 13 rev 0 TRISTAR 2S ...

Page 2: ...2S boilers 21 3 7 2 TST 300 2S TST 560 2S boilers 21 3 7 3 TST 680 2S TST 870 2S boilers 22 3 7 4 TST 1000 2S TST 6100 2S boilers 22 3 7 5 Important note 22 3 8 Connecting flue exhaust pipe 23 3 9 Condensation drainage 23 3 9 Connecting boiler to system 24 3 9 1 Recirculation pump 24 3 10 Filling the system 24 3 11 Gas connection 25 3 12 Packaging 26 3 13 Assembly of casing 27 3 14 Electrical conn...

Page 3: ...xclusive use of the professionally qualified installer and or maintenance technician in compliance with current legislation The user is NOT qualified to intervene on 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 The user must be instructed c...

Page 4: ...n 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 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 deaeration of...

Page 5: ...y kW kW Sup m See serial no on boiler body Approval min max min max CE marking The CE marking certifies that the boilers meet The essential requirements of the gas appliance directive 90 396 EEC The essential requirements of the electromagnetic compatibility directive 89 336 EEC The essential requirements of the efficiency directive 92 42 EEC 1 6 TECHNICAL DATA PLATE The technical data plate is ad...

Page 6: ...o repair it or intervene on it directly Contact only personnel qualified in compliance with law Any repairs must be performed solely by personnel authorised by Unical using original spare parts only Failure to comply with the above can jeopardise the safety of the appliance To guarantee appliance efficiency and its correct operation yearly maintenance must be performed by qualified personnel Shoul...

Page 7: ...n turn protected by an aluminium sheet The top part of the shell is provided with hooks for lifting the boiler Note TRISTAR 3G 2S boilers are intended to operate with ON OFF type GAS burners as an alternative they can be equipped with a dual stage or modulating burner as long as the minimum heat output in the first flame or in modulation does not drop below 60 the furnace load The boilers are prov...

Page 8: ...for each boiler on pages 9 14 by the burner technician who will determine the fuel flow rate In all cases turbulators must be positioned inside their respective smoke pipes resting on the internal aluminium profiles The burner must be commissioned under the responsibility of a qualified burner technician authorised by the manufacturer On that occasion a complete operating report must be drafted PO...

Page 9: ...m 722 812 812 937 937 995 1210 1390 1442 1692 C mm 190 190 190 190 190 D mm 305 350 350 421 421 E mm F mm 480 500 500 580 580 G mm 115 130 130 165 165 H mm 1487 1737 I mm 147 157 157 258 258 In the TRISTAR 200 2S and TRISTAR 250 2S models connections T1 and T2 are flanged Pressure drops corresponding to a thermal variation of 15K fig 4 fig 3 fig 5 E B D A 4 2 1 T3 T6 F G T2 T5 121 I T1 T4 C H 3 La...

Page 10: ...8 1 32 2 20 2 35 8 23 7 42 1 Flue gas pressure drop mm w c Maximum operating pressure boiler bar 6 6 6 6 Weight kg 665 845 986 1119 TRISTAR 2S Model DIMENSIONS A mm 860 890 890 890 B mm 1210 1275 1470 1780 1182 1352 1352 1352 C mm 190 190 190 190 D mm 140 140 140 141 E mm F mm 191 191 191 192 G mm 708 748 748 748 H mm 400 440 440 440 I mm 1541 1606 1801 2113 L mm 130 125 125 125 1310 1485 1485 148...

Page 11: ...504 1699 1894 R mm Furnace output kW 510 680 585 780 652 5 870 CONNECTIONS T1 T2 UNI 2278 PN16 T3 UNI 2278 PN16 T4 UNI 228 T5 Øi mm T6 Ø mm DN 125 DN 125 DN 125 DN 65 DN 65 DN 65 G 1 G 1 G 1 350 350 350 270 270 270 TST 680 2S TST 780 2S TST 870 2S TRISTAR 2S Model Furnace output kW 530 4 713 9 608 4 818 9 678 6 913 4 Boiler capacity l 671 753 836 Flue gas pressure drop m w c 0 12 0 21 0 15 0 27 0 ...

Page 12: ...38 8 1092 1469 8 1287 1732 3 1560 2099 7 1833 2467 1 Boiler capacity l 1040 1242 1418 1617 2086 2324 Water side pressure drop m w c 0 11 0 19 0 15 0 26 0 15 0 26 0 20 0 36 0 16 0 28 0 21 0 38 1 Panel board 2 Burner connection flange 3 Smoke chamber cleaning door 4 Flame sight glass Flue gas pressure drop mm w c 35 9 63 9 38 6 68 6 42 1 74 9 45 5 80 9 40 5 72 43 2 76 9 Maximum operating pressure bo...

Page 13: ...3254 5 2730 1 3674 5 Boiler capacity l 2667 4142 4455 Water side pressure drop m w c 0 28 0 50 0 37 0 66 0 37 0 65 1 Panel board 2 Burner connection flange 3 Smoke chamber cleaning door 4 Flame sight glass Flue gas pressure drop mm w c 45 6 81 43 3 76 9 50 4 89 5 Maximum operating pressure boiler bar 6 6 6 Weight kg 5370 6990 7790 CONNECTIONS T1 T2 UNI 2278 PN16 T3 UNI 2278 PN16 DN 125 DN 125 DN 1...

Page 14: ...9 Water side pressure drop m w c 0 28 0 50 0 35 0 63 0 42 0 75 0 50 0 88 0 59 1 05 0 68 1 21 Flue gas pressure drop mm w c 44 4 78 6 56 6 100 5 50 5 92 2 59 3 105 4 49 5 90 5 56 7 100 7 Maximum operating pressure boiler bar 6 6 6 6 6 6 Weight kg 8630 8630 9675 9675 13060 13060 CONNECTIONS T1 T2 UNI 2278 PN16 T3 UNI 2278 PN16 DN 125 DN 125 DN 125 DN 125 DN 125 DN 125 DN 250 DN 250 DN 250 DN 250 DN ...

Page 15: ...0 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 CO 2 content Flue gas mass flow rate min max 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 w...

Page 16: ...6 1 95 2 96 3 95 4 96 3 95 5 0 2 0 2 3 7 4 5 0 1 0 1 75 4 93 4 9 8 9 8 5159 6943 TST 4800 2S 3600 4800 3744 1 5039 3 96 1 95 2 96 3 95 4 96 3 95 5 0 2 0 2 3 7 4 5 0 1 0 1 75 4 93 4 9 8 9 8 5628 7575 TST 5200 2S 3900 5200 4056 1 5459 2 96 1 95 2 96 3 95 4 96 3 95 5 0 2 0 2 3 7 4 5 0 1 0 1 75 4 93 4 9 8 9 8 6097 8206 Nominal heat output Thermal output of furnace Heat efficiency at nominal load 100 H...

Page 17: ...b Check that boiler is set up to operate with the available type of fuel This can be seen written on the package and on the technical feature plate c Checkthatthechimney fluehasanappropriate draught without any bottlenecks and that no exhausts from other appliances are inserted unless the flue has been implemented to accommodate several utilities according to specific standards and prescriptions i...

Page 18: ... h LAW March 5 1990 N 46 and relative applicative regulation by Italian Presidential Decree 447 of December 6 1991 and subsequent amendments Safety standards for systems FIELD OF APPLICATION without thermal potential limits STANDARD UNI EN 676 November 1998 Air blown gas fired burners Safety prescriptions LAW January 9 1990 N 10 and relative applicative regulation by Italian Presidential Decree 41...

Page 19: ...dled easily lifting it by means of upper hook s or shifting it on rollers underneath the sturdy base longerons 1000 X XX XX 600 600 3 5 BURNER The burners operating with the TRISTAR 3G 2S boilers must have the EC certification and comply with Gas appliance directive 90 396 EEC EMC Directive Electromagnetic Compatibility 89 336 EEC They must also be approved according to the specifications UNI EN 6...

Page 20: ...e warning light it could break ATTENTION the flame control warning light can be very hot therefore pay the utmost attention fig 22 3 5 2 INSTALLING THE BURNER Before assembling the burner it is necessary to check the position of the turbulators inside the pipes each tube must be provided with its own turbulator and this must be positioned as shown in the table at page 8 The burner must be mounted ...

Page 21: ...m after the adjustment Adjustment in the axial direction by adjusting the locking screws 3 7 2 TST 300 2S TST 560 2S BOILERS For all these models the door is hinged and fixed according to the layout in fig 23 In these cases the door is mounted with four identical hinges the two on the left side with pin inserted are normally used as rotation hinges from right to left while the two on the right are...

Page 22: ...or is hinged and fixed according to the layout in fig 25 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 right To invert rotation just move the door support bushings The following adjustments can be made on the door of these bo...

Page 23: ...e condensation drainage in the sewer must be implemented as to prevent releasing gaseous combustion products into the environment or sewer siphoning dimensioned and implemented to allow the correct outflow of liquid waste preventing any leakage installed in such a way as to prevent the liquid contained in it from freezing in the intended operating conditions mixed for example with household waste ...

Page 24: ...ns animals and objects for which the manufacturer cannot be held responsible Connection of expansion vessel TRISTAR 2S boilers are suitable for operating with forced water circulation both with the expansion vessel opened or closed An expansion vessel is always necessary to compensate the increase in water volume due to heating The connection pipes of the expansion vessel will start from the T3 at...

Page 25: ...the boiler Attention Make sure that there are no mechanical tension points while connecting gas to avoid the risk of leakage If you smell gas a Do not turn electric switches on or off use a telephone or any other object which can create sparks b Immediately open doors and windows to create an air current to air out the room c Shut the gas cocks d Request the intervention of professionally qualifie...

Page 26: ...ance instruction booklet Warranty Local ventilation requirements label N B For models from TST 80 2S to TST 250 2S ref fig 27 and 28 and from TST 300 2S toTST 450 2S ref fig 29 and 30 the casing and insulation are contained in 1 marked box 29658 TST 80 2S 29659 TST 120 2S 29660 TST 160 2S 29661 TST 200 2S 29662 TST 250 2S 29884 TST 300 2S 29885 TST 370 2S 29886 TST 450 2S N B For the TST 560 2S mo...

Page 27: ...bend inside the L shaped profile at the base of the boiler body and hook the upper part in the plate cuts To determine which is the right side and which is the left side refer to the cable glands they must face the front of the boiler C Rotate the cover of the panel board frontwards after having removed the two screws on the side and insert the electric inlet cables and the outlet probe capillarie...

Page 28: ...r door and mount the front insulation pos 5 inserting the hinges in the specific cuts Insert the side edges of insulation under the bend of the two sides pos 3 and 4 D Mount the rear insulation pos 6 fix the bottom rear panel pos 7 the middle rear panel pos 15 and the top rear panel pos 8 with the specific self threading screws Mount the cable clamps pos 9 to the upper rear panel E Rotate the cove...

Page 29: ...tions 1 3 2 4 5 6 5 TRISTAR 340 560 2S fig 29 11 4 11 1 6 7 8 9 2 10 12 13 5 3 14 15 fig 30 1 Thermometer probe 2 Working thermostat probe 3 Safety thermostat probe 4 Minimum thermostat probe 5 Safety spring 6 Contact spring ...

Page 30: ...the upper rear panel E Rotate the cover of the panel 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 Fix the panel board to the upper panel pos 12 Fit the upper panel pos 12 complete with panel board to the two sides of the casing F Insert into the conduits the bulbs of the instrume...

Page 31: ... cover of the panel 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 Fix the panel board to the upper panel pos 9 Fit the upper panel pos 9 complete with panel board to the two sides of the casing F Insert into the conduits the bulbs of the instruments as indicated in fig 35 and wire...

Page 32: ...e electric inlet cables and the outlet probe capillaries through the slots at the base Fix the panel board to the upper panel pos 8 Fit the upper panel pos 8 complete with panel board to the two sides of the casing E Insert into the conduits the bulbs of the instruments as indicated in fig 35 and wire the panel board to the power line to the burner and to any pumps etc Close the cover of the elect...

Page 33: ...os 4 is already mounted C Position the right side panels pos 6 and 3 with the lower bend inside the L shaped profile at the base of the boiler body and hook the upper part in the screws fastened on the top longitudinal pipe D Fix the panel board to the side panel pos 6 Rotate the cover of the panel board frontwards after having removed the two screws on the side and insert the electric inlet cable...

Page 34: ... on the top of the boiler Ref fig 35 of the thermometer pos 1 of the working thermostat pos 2 of the safety thermostat pos 3 of the minimum thermostat pos 4 It is recommended to insert the probes all the way in the relative bulb holders for best contact Then insert the contact spring pos 6 and fasten the capillaries with the spring s pos 5 fig 35 ...

Page 35: ...he panel 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 fig 36 TRISTAR 3900 6100 2S A 3 4 1 2 5 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 inser...

Page 36: ...t 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 appliance 230V electric power supply connection T...

Page 37: ...t power to the burner and to the system 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 C not adjustable The minimum thermostat which can only be accessed after having lifted the cover of the electric control board stops the system pump unt...

Page 38: ...domestic hot water production charge pump TA room thermostat The standard panel board of theTRISTAR 2S boiler automatically switches the burner off when the temperature in the boiler reaches the value set on the control thermostat It also manages the system pump which will only be activated when the minimum boiler temperature of 50 C has been reached anti condensation protection temperature The pu...

Page 39: ...C 1 2 ALIMENTAZIONE 230V 50Hz L1 N ALLA PRESA A 7 POLI DEL BRUCIATORE N L1 CALDAIA TRISTAR 2S fig 40 NOTE With absorption beyond 4A place adequate contactors between the panel board and the loads TRISTAR 2S BOILER POWER SUPPLY 230V 50HZ POWER SUPPLY 230V 50HZ POWER SUPPLY 230V 50HZ TO THE 7 POLE SOCKET OF THE BURNER DOMESTIC HOT WATER PRODUCER ...

Page 40: ...ler to achieve this the thermostat must be placed at maximum full scale pos 32 Any operation of the second stage of the burner will be managed by the heat control The default setting of the heating controller stops the system pump until the boiler reaches the temperature of 50 C The electric power line of the boiler s control board must have a switch with protective fuses For use of the panel boar...

Page 41: ...tive control motor are not included in the supply Should ambient probes be mounted optional the room temperature will only be determined with the boiler curve set by the program If you intend on mounting 2 boilers in sequence please contact our after sales service 3 19 PROGRAMMING THE HEATING CONTROLLER For that which concerns adjustment or programming of the heating controller see the instruction...

Page 42: ... min P BURNER TIME 2 10 min 2K 20K P BURNER HYSTERESIS 2 2 degrees 0h 250h HEAT SEQ TEMP 0h 00 08 RELAY FUNCT 00 30 C 90 C T MULTI PROBE 30 C 2K 10K MFR HYSTERESIS 5 degrees 00 03 RELAY 2 FUNCT 00 00 01 OFF ON SCREED 00 OFF see heating controller booklet SCREED PROGRAM RETURN Default Individual values Value range Description DOMESTIC HOT WATER PRODUCTION 00 01 OFF ON CHARGE PUMP 01 ON 00 01 02 03 ...

Page 43: ...0 OUTSIDE TEMP DELAY 1 0K 50K HEATING SLOPE DISTANCE 5 degrees 00 01 OFF ON REDUCTION 01 ON Exit level using RETURN Default Individual values Value range Description HEATING CIRCUIT 1 00 04 HEATING CIRCUIT FUNCTION 00 00 03 PUMP FUNCTION 00 5 25 MIXER OPEN not in hot water circuit 16 5 25 MIXER CLOSED not in hot water circuit 12 20 C 110 C MAX FLOW TEMPERATURE 80 C 10 C 110 C MIN FLOW TEMPERATURE ...

Page 44: ... Two distinct heating zones are managed automatically based on the data detected by the boiler external ambient and flow probes The main system pump mixed zone 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 decreasing is reached The panel is set up to manage dual ...

Page 45: ... 8 7 6 5 10 9 2 1 VII I V VIII III IX L 3 Bus H 1 FBR1 VFAS VFAS AFS VFAS 3 1 FBR1 DCF 1 2 3 2 1 VI 1 2 T3 T4 VM2 Pi2 IR2 VFAS KFS CALDAIA TRISTAR 2S NOTE With absorption beyond 4A place adequate contactors between the panel board and the loads fig 45 ROOM PROBE 1 FBR1 FLOW PROBE 2 VFAS STORAGE TANK PROBE SPFS BOILER PROBE KFS EXTERNAL PROBE AFS ROOM PROBE 2 FBR1 TRISTAR 2S BOILER DOMESTIC HOT WAT...

Page 46: ... the air vents and the flue gas exhaust system highlighting their essential features and the absolute prohibition of modifying them Inform the system manager concerning control of the system s water pressure as well as operations to restore it Inform the system manager concerning correct control of temperatures control units thermostats and radiators to save energy Remember that the system must re...

Page 47: ...ers have been designed to be used at the declared nominal output TRISTAR 2S boilers are equipped with flue gas turbulators inside each smoke duct see page 8 The correct position of the turbulators inside the smoke pipes determines the heat output of the boiler and therefore the flue gas temperature at the chimney Upon commissioning after at least 30 minutes it is advisable to check the flue gas te...

Page 48: ...page 49 Inspection and maintenance instructions To assure long term functioning of your appliance and to avoid altering its approved status only original Unical spare parts must be used Before proceeding with maintenance always perform the following operations Disconnect the electric mains switch Isolate the appliance from the electric mains by means of an isolated device with a contact opening of...

Page 49: ...f deterioration if so it must be replaced using only original spare parts Check the condition of the smoke chamber inspection cover gasket Replace it if worn using only original spare parts Maintenance of burner Burner maintenance must be carried out by personnel authorised by its manufacturer or else the warranty shall be terminated Checking ignition electrode Burner maintenance must be carried o...

Page 50: ...50 Inspections and maintenance ...

Page 51: ...51 Inspections and maintenance ...

Page 52: ...www unical eu info unical ag com Unical will not be held responsible for possible inaccuracies if due to transcription or printing errors It also reserves the right to modify its products as deemed necessary or useful without jeopardising their essential features AG S P A ...

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