Unical TRISTAR 3G Installation And Maintenance Instructions Manual Download

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Inspections and maintenance

Summary of Contents for TRISTAR 3G

Page 1: ...INSTALLATION AND MAINTENANCE INSTRUCTIONS 00334572 09 15 rev 1 TRISTAR 3G ...

Page 2: ...nace door adjustment opening closing 19 3 9 1 TRISTAR 3G 110 TRISTAR 3G 380 boilers 19 3 9 2 TRISTAR 3G 500 TRISTAR 3G 840 boilers 19 3 9 3 TRISTAR 3G 1100 TRISTAR 3G 3000 boilers 20 3 9 4 Important note 20 3 10 Connecting boiler to system 21 3 10 1 Recirculation pump 21 3 11 Filling the system 21 3 12 Connecting gas 22 3 13 Packaging 23 3 14 Assembling casing 24 3 15 Electrical connections 32 3 1...

Page 3: ...is occasion also check the state of wear of the anode 1 4 INFORMATION TO PROVIDE TO THE SYSTEM MANAGER 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 included in the envelope inside the packaging The user must keep this documentation for future consultation I...

Page 4: ...the parts of the device which affect the operating safety of the appliance Attention To tighten or loosen the screwed fittings use only appropriate fixed spanners Non compliant use and or inappropriate tools can cause damage e g water or gas leakage ATTENTION Instructions for appliances fuelled by propane gas Make sure that the gas tank has been deaerated before installing the appliance For state ...

Page 5: ...l requirements of the efficiency directive 92 42 EEC 1 6 TECHNICAL DATA PLATE The technical data plate is adhesive and is included in the document envelope it must be applied by the installer on the outside of the case The serial number of the boiler is on the riveted plate on the front plate of the body lower right front for models between TRISTAR 3G 110 and TRISTAR 3G 1900 upper right front for ...

Page 6: ... qualified in compliance with law Any repairs must be performed solely by personnel authori sed by Unical using original spare parts only Failure to com ply 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 person nel Should you decide not to use the appliance parts entailing poten...

Page 7: ...tage or modulating burner as long as the minimum heat output that can be reached is not lower than the value indicated on the technical data plate for the type of fuel used The boilers are equipped with two connections for condui ts with an inside diameter of 15 mm suitable to house 3 bulbs each The shell has holes at the sides for the cable glands of the power pumps burner cables and those of any...

Page 8: ...sure bar 5 5 Weight kg __ __ TRISTAR 3G Model TST 3G 110 TST 3G 150 A mm 820 820 B mm 885 1145 1082 1082 C mm 190 190 D mm 140 140 E mm F mm 155 155 G mm 532 532 H mm 695 695 I mm 120 120 L mm M8 M8 1215 1215 M mm 175 175 N mm 390 390 O mm 185 185 P mm 710 710 R mm Minimum dimensions for boiler room access Pressure drops corresponding to a thermal drop of 15K DETAIL FOR DOOR DRILLING TST 3G 110 15...

Page 9: ... 28 4 18 4 32 7 Fluegas pressure drops mm c a Boiler max operating pressure bar 5 5 5 5 Weight kg TRISTAR 3G Model TST 3G 185 TST 3G 240 TST 3G 300 TST 3G 380 A mm 860 860 890 890 B mm 1080 1210 1275 1470 1182 1182 1352 1352 C mm 190 190 190 190 D mm 140 140 140 140 E mm F mm 155 155 155 155 G mm 757 757 897 897 H mm 775 775 915 915 1315 1315 1470 1470 M mm 215 215 255 255 N mm 210 340 285 480 O m...

Page 10: ... kW 375 500 472 5 630 630 840 T1 T2 UNI 2278 PN16 T3 UNI 2278 PN16 T4 ISO 7 1 T5 Øi mm T6 Ø mm DN 100 DN 100 DN 100 Rp 1 Rp 1 Rp 1 300 300 300 TST 3G 500 TST 3G 630 TST 3G 840 TRISTAR 3G Model Heat input k W 391 524 1 492 7 660 4 656 9 880 5 Boiler capacity l 693 779 908 Pressure drops on water side m c a 0 09 0 17 0 14 0 25 0 21 0 38 21 3 37 8 26 1 46 5 32 2 57 3 Fluegas pressure drops mm c a Boi...

Page 11: ...ETAIL FOR DOOR DRILLING TST 3G 1600 1900 Nominal output kW 825 1100 990 1320 1200 1600 1425 1900 Heat input k W 860 2 1153 1032 3 1383 6 1251 3 1677 1 1485 9 1991 5 Boiler capacity l 1546 1762 2197 2450 Pressure drops on water side m c a 0 15 0 26 0 19 0 33 0 24 0 41 0 18 0 30 1 Panel board 2 Burner connection flange 3 Smoke chamber cleaning door 4 Flame control warning light Fluegas pressure drop...

Page 12: ...Weight kg 5350 7070 7600 T1 T2 UNI 2278 PN16 T3 UNI 2278 PN16 DN 125 DN 125 DN 125 DN 200 DN 200 DN 200 T4 ISO 7 1 Rp 1 Rp 1 Rp 1 T5 Øi mm 570 620 620 T6 Ø mm 320 380 380 DETAIL FOR DOOR DRILLING TST 3G 2300 DETAIL FOR DOOR DRILLING TST 3G 2650 3000 fig 12 fig 13 T1 Heating flow T2 Heating return T3 Expansion vessel connection T4 Boiler drain T5 Chimney connection T6 Burner connection T7 Condensat...

Page 13: ... 1 95 8 95 3 3 96 1 95 4 0 4 0 2 3 9 4 6 0 1 0 1 80 95 9 8 9 8 353 6 473 9 TST 3G 380 285 380 297 3 398 5 95 9 95 4 96 1 95 6 3 96 3 95 6 0 4 0 2 3 7 4 4 0 1 0 1 76 91 9 8 9 8 446 9 599 2 4 OPERATING DATA ACCORDING AS PER UNI 10348 kW kW n C kg h GAS FIRED TST 3G 150 112 5 150 118 4 158 6 95 94 5 95 2 94 7 3 95 9 95 2 0 8 0 6 4 1 4 8 0 1 0 1 84 99 9 8 9 8 177 9 238 5 TST 3G 110 81 7 109 86 3 115 7...

Page 14: ...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 Check that the chimney flue has an appro priate draught without any bottlenecks and that no exhausts from other appliances are inserted unless the flue has been implemen ted to accommodate several utilities according to specific standards and prescript...

Page 15: ...quipment FIELD OF APPLICATION appliances fed by liquid fuels naphtha diesel oil combustible oil and solids Standard UNI 10847 of March 2000 Single flue systems for generators fed by solid and liquid fuels Maintenance and control Guidelines and procedures LAW January 9 1990 N 10 and relative applicative regula tion by Italian Presidential Decree 412 of 26 August 1993 and subsequent modifications It...

Page 16: ... can be handled easily lifting it by means of upper hook s or shifting it on rollers underneath the sturdy base longerons 3 5 BURNER The burners operating with the TRISTAR 3G 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 676 air blown ...

Page 17: ... tube pos 2 The air blown by the fan will conveniently cool the sight glass and keep it from blackening If the cooling tube is not connected to the sight glass it could break ATTENTION the flame control warning light can be very hot therefore pay the utmost attention fig 16 3 5 2 INSTALLING THE BURNER The burner must be mounted to the door of the boiler guaran teeing perfect sealing of the combust...

Page 18: ...If not after having verified the actual fuel flow rates the opera ting temperature should be increased The 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 out flow of liquid waste preventing any leakage installed in such a way as to prevent the liquid ...

Page 19: ...the opposite side The following adjustments can be made on the door of these boiler models A Vertical adjustment only by inserting suitably thick washers below the hinge which the door turns on B Crosswise rotation loosen the hinges fixed on the front plate of the boiler and move them sideways C Adjustment in the axial direction by adjusting the tighte ning screws fig 18 3 9 2 TST 3G 500 TST 3G 84...

Page 20: ...wing adjustments can be made on the door of these boiler models A Vertical adjustment by acting on the nut of the upper hinge pin which the door turns on B Crosswise rotation loosen the hinges fixed on the front plate of the boiler and move them sideways C Adjustment in the axial direction by adjusting the tighte ning nuts fig 20 3 9 4 IMPORTANT NOTE Before opening the door of the furnace take the...

Page 21: ...tention If this precaution is not taken triggering of the safety valve can cause damage to per sons animals and objects for which the ma nufacturer cannot be held responsible Connection of expansion vessel TRISTAR 3G boilers are suitable for operating with forced wa ter circulation both with the expansion vessel opened or clo sed An expansion vessel is always necessary to compensate the increase i...

Page 22: ...er cleaning of all fuel adduction piping to remove any residue which could jeopardi se proper operation of the boiler Attention Make sure that there are no mechanical ten sion 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 a...

Page 23: ...ns Installation and maintenance instruction booklet Warranty Local ventilation requirements label N B For models from TST 3G 110 and TST 3G 380 ref fig 21 and 22 the casing and insulation are contained in 1 box marked 50053 TRISTAR 3G 110 50054 TRISTAR 3G 150 50055 TRISTAR 3G 185 50056 TRISTAR 3G 240 50057 TRISTAR 3G 300 50058 TRISTAR 3G 380 N B For models from TST 3G 500 to TST 3G 840 ref fig 23 ...

Page 24: ...pos 2 supplied in the accessory box hooking them to the external fabric part of the insulation B Position the side panels pos 3 e 4 with the lower 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 gland plates pos 11 they must face the front of the boiler C Fix...

Page 25: ...25 Technical features and dimensions fig 22 1 Thermometer probe 2 Working thermostat probe 3 Safety thermostat probe 4 Minimum thermostat probe 5 Safety spring 6 Probe bulb holders ...

Page 26: ...es on the front panels pos 5 they must face the front of the boiler Fasten the 4 countersunk screws pos 7 to the two sides 3b and 4b on the inner rear side C Fit the upper rear panel pos 8 to the screws pos 7 D 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...

Page 27: ...wire the panel board to the power line to the burner and to any pumps etc Close the cover of the electric control board Guide the burner plug through the side plate pos 5 on the preferred side and secure the cable with the cable gland supplied Fasten the plates pos 5 to the sides of the casing Secure the electric cables coming out from the rear of the boiler with the cable clamps tightening them m...

Page 28: ...28 Technical features and dimensions TRISTAR 3G 1100 1600 fig 24 2 5 3b 3c 9 10 11 7 4a 5 1 4c 4b 3a ...

Page 29: ...the base Fit 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 indi cated in fig 27 and wire the panel board to the power line to the burner and to any pumps etc Close the cover of the electric control board Guide the burner plug through the side plate pos 5 on the p...

Page 30: ...overing panel pos 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 elect...

Page 31: ...the top of the boiler Ref Fig 27 of the thermometer pos 1 of the working thermostat pos 2 of the safety thermostat pos 3 and of the minimum thermostat pos 4 It is recommended to insert the probes all the way in the relative bulb holders for best contact Insert the contact spring pos 6 and fasten the capillaries with the fixing clip s pos 5 fig 27 ...

Page 32: ...nent 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 agen ts rain sun etc unless expressly designed do not allow children or unskilled persons to use the ap pliance 230V electric power supply connect...

Page 33: ...ounter stage 2 If the Room thermostat is mounted remove the bridge 11 12 The main switch 11 powers the board and the equipment connected to it The switches 12 and 13 in turn cut power to the burner and to the system pump The thermostat 32 adjusts the working temperature of the boiler The working thermostat is provided with two switching con tacts to control the two stage burners The differential b...

Page 34: ...p TA room thermostat The standard panel board of the TRISTAR 3G boiler automa tically 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 activa ted when the minimum boiler temperature of 50 C has been reached anti condensation protection temperature The pump will switch off when the lower thr...

Page 35: ...h absorption beyond 4A place adequate contactors between the panel board and the loads CALDAIA TRISTAR 3G TRISTAR 3G BOILER DOMESTIC HOT WATER PRODUCER TO THE 7 POLE SOCKET OF THEBURNER POWER SUPPLY 230V 50Hz POWER SUPPLY 230V 50Hz POWER SUPPLY 230V 50Hz ...

Page 36: ...ntual 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 board see the system manager instruction booklet Ipi2 System pump 2 switch Ipb St...

Page 37: ...e boiler curve set by the program If you intend to mounting 2 boilers in cascade please con tact our after sales service 3 20 PROGRAMMING THE HEATING CONTROLLER For that which concerns adjustment or programming of the heating controller see the instruction booklets attached to the device The following are the default parameters which cannot be modified As far as parameters which can be programmed ...

Page 38: ... min 00 min 30 min BURNER TIME 2 10 min 2K 20K 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...

Page 39: ...STANCE 5 degrees 00 01 OFF ON REDUCTION 01 ON Exit level using RETURN HEATING CIRCUIT 1 00 04 HEATING CIRCUIT FUNCTION 00 00 03 PUMP MODE 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 10 C 15 C 5 C FROST PROTECTION TEMP 0 C 0 00 24 00 OUTSIDE TEMP DELAY 1 0K 50K HEATING SLOPE DISTANC...

Page 40: ...xed zone will only be activated when the minimum boiler temperature of 50 C has been re ached 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 stage or modulating burners With this layout configuration the DHW storage tank loading pump will have the priority over the heating system pump The h...

Page 41: ...3 4 5 6 7 1 8 9 10 2 3 4 5 1 IV II 1 N L1 L1 1 1 1 2 2 2 M M 2 T1 T2 4 3 2 1 3 2 1 2 1 2 1 4 3 2 1 8 7 6 5 10 9 2 1 VII I V VIII III IX L 3 Bus H 1 FBR1 VFAS VFAS AFS KFS SPFS VFAS 3 1 FBR1 DCF 1 2 3 2 1 VI 1 2 T3 T4 22 20 21 VM2 Pi2 IR2 VFAS KFS CALDAIA TRISTAR L1 L1 T2 L1 L1 N N N L1L1 N N T1 S3B4 TA TA T6 T7 T8 N L1 L1 NOTE With absorption beyond 4A place adequate contactors between the panel b...

Page 42: ...ide the packa ging The system manager must keep this documenta tion for future reference Inform the system manager 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 system manager concerning control of the sy stem s water pressure as well as operations to restore it Inform the system...

Page 43: ...he actual status and the nominal status This is normally done by cleaning setting and replacing individual compo nents subject to wear Maintenance intervals and their extent are determined by a specialist based on the status of the appliance ascertained through inspection Inspection and maintenance jobs must be performed in the order shown on page 44 Inspection and maintenance instructions To assu...

Page 44: ... seal gasket which must not show signs of 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 autho rised by its manufacturer or else the warranty shall be termi nated Checking ignition elec...

Page 45: ...45 Inspections and maintenance ...

Page 46: ...46 Inspections and maintenance ...

Page 47: ...47 Inspections and maintenance ...

Page 48: ... 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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