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

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TERNOx 2S
INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

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Summary of Contents for Unical TERNOx 2S

  • Page 1 TERNOx 2S INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE...
  • Page 2 Attention: this manual contains instructions for the exclusive use of the pro- fessionally qualified installer and/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: Table Of Contents

    1 GENERAL INFORMATION ....................................5 1.1 General warnings ......................................5 1.2 Symbols used in the manual ..................................6 1.3 Appropriate use of appliance ..................................6 1.4 Information for system manager ................................... 6 1.5 Safety warnings ......................................7 1.6 Technical data plate ...................................... 8 1.7 Water treatment ......................................

  • Page 5: General Information

    Any product repairs must be performed solely by personnel The instruction booklet is an integral and essential part of the authorised by Unical, using original spare parts only. Failure to product and must be kept by the system manager. comply with the above can compromise the safety of the appli- ance and void the warranty.

  • Page 6: Symbols Used In The Manual

    The appliance is intended to operate in hot water circulation heating systems. Any other use must be considered improper. UNICAL will not be held liable for any damage resulting from improper use. Use according to the intended purposes also includes strict compliance with the instructions in this manual.

  • Page 7: Safety Warnings

    DANGER! The boiler must be serviced or repaired by professionally qualified personnel, authorised by Unical. We recommend stipulating a maintenance contract. Insufficient or irregular maintenance can jeopardise the operating safety of the appliance and cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.

  • Page 8: Technical Data Plate

    If lost, ask the Unical Technical Assistance Service for a duplicate. The serial number of the boiler is on the riveted plaque on the front plate of the body (front right top side).

  • Page 9: Technical Features And Dimensions

    One of the significant aspects taken into account when design- After the exhaust gases return to the front of the boiler, they ing the TERNOx 2S series boilers is the reduction of the forma- again change direction and pass through the pipes of the third tion of pollutants in exhaust gases.

  • Page 10: Dimensions

    T6 Probe holder conduit connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Probe holder conduit connection 4 Flame control warning light T4 Boiler drain T8 Burner connection CONNECTIONS TERNOx 2S Useful Furnace Boiler Water side Flue gas Maximum Weight...
  • Page 11 T6 Probe holder conduit connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Probe holder conduit connection 4 Flame control warning light T4 Boiler drain T8 Burner connection TERNOx 2S Useful Furnace Boiler Water side Flue gas Maximum...
  • Page 12 TERNOX 12500 2S STD TERNOX 15000 2S STD T6 T7 1 Panel board T1 Heating flow T5 Chimney connection 2 Burner connection flange T2 Heating return T6 Probe holder conduit connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Probe holder conduit connection 4 Flame control warning light T4 Boiler drain...

  • Page 13: Operating Data According To Uni 10348

    2.4 - OPERATING DATA ACCORDING TO UNI 10348 GAS-FIRED TERNOX 2500 TERNOX 2200 TERNOX 1800 2S STD 2S LOW NOx 2S LOW NOx E Nominal heat output 1800 - 2500 1800 - 2200 1800 Thermal output of furnace 1951 - 2753 1951 - 2406 1951 Heat efficiency at nominal load (100%)
  • Page 14 GAS-FIRED TERNOX 4500 TERNOX 3800 TERNOX 3000 2S STD 2S LOW NOx 2S LOW NOx E Nominal heat output 3000 - 4500 3000 - 3800 3000 Thermal output of furnace 3239 - 4951 3239 - 4144 3239 Heat efficiency at nominal load (100%) 92.62 - 90.90 92.62 - 91.70 92.62...
  • Page 15 GAS-FIRED TERNOX 7000 TERNOX 6300 TERNOX 5100 2S STD 2S LOW NOx 2S LOW NOx E Nominal heat output 5100 - 7000 5100 - 6300 5100 Thermal output of furnace 5529 - 7705 5529 - 6892 5529 Heat efficiency at nominal load (100%) 92.25 - 90.85 92.25 - 91.41 92.25...
  • Page 16 GAS-FIRED TERNOX 10200 TERNOX 9500 TERNOX 8400 2S STD 2S LOW NOx 2S LOW NOx E Nominal heat output 8400 - 10200 8400 - 9500 8400 Thermal output of furnace 9128 - 11191 9128 - 10377 9128 Heat efficiency at nominal load (100%) 92.02 - 91.14 92.02 - 91.55 92.03...

  • Page 17: Installation Instructions

    INSTRUCTIONS FOR INSTALLATION 3.1 - GENERAL WARNINGS ATTENTION! In rooms with the presence of aggressive ATTENTION! vapours or dust, the appliance must operate This boiler is intended solely for the use for independently from the air inside the instal- which it was expressly designed. Any other lation room! use is to be considered improper and there- fore dangerous.

  • Page 18: Packaging

    3.4 - PACKAGING TERNOX 2S boilers are supplied with casing and with the door and smoke chamber assembled. The panel and accessories are inside the combustion chamber. Upon reception, make sure that the supply is complete and undamaged. The document envelope, besides the appliance, contains:...

  • Page 19: Positioning In Boiler Room

    3.6 - POSITIONING IN BOILER ROOM The boiler must rest on a perfectly level surface. TERNOX 2S boilers must be installed in rooms for exclusive use complying with Technical Standards and Legislation in force and with sufficiently sized air vents.

  • Page 20: Hydraulic Connections

    This pump is dimensioned according to the formula: TERNOX 2S boilers are suitable for operating with forced water Q = P x 22 circulation both with the expansion vessel opened or closed.

  • Page 21: Gas Connection

    Non-insulated exhaust pipes are a potential source of risk. The seals of the junctions must be made with materials resist- The TERNOX 2S boiler can be attached to the chimney in dif- ant to temperatures of at least 250°C. ferent ways; straight pipes or elbows can be used to exit from...

  • Page 22: Furnace Door: Adjustment, Opening, Closing

    C) Adjustment in the axial direction: by adjusting the tightening nuts. 3.12 - BURNERS The burners operating with the TERNOX 2S boilers must have the EC certification and comply with: - Gas appliance directive (90/396/EEC); - EMC Directive - Electromagnetic Compatibility (89/336/EEC).
  • Page 23 3.12.1 - SELECTING THE BURNER The correct choice and adjustment of the burner are fundamental for optimal operation of the boiler and therefore must be done carefully and not underestimated. The burner must be chosen verifying that its firing rate (fuel capacity - combustion chamber pressure) is compatible with the same features declared for the boiler.

  • Page 24: Electric Panel Assembly

    3.13 - MOUNTING ELECTRIC PANEL TERNOX 2S boilers are supplied with casing. Therefore to mount the panel board, proceed as follows: A) Dismount the right upper walkways (pos. 1 and 2). B) Fix the support box of the panel board to the bracket on the right side of the boiler.

  • Page 25: Electrical Connections

    3.14 - ELECTRICAL CONNECTIONS General warnings 230V electric power supply connection The electrical safety of the appliance is guaran- The electrical connections are illustrated in chap. 3.15 ..3.19. teed only when it has been properly connected to an efficient earthing system carried out as intended by safety standards in force: pipes of the The boiler installation requires a connection to a 230 V - 50 Hz gas, water and heating systems are absolutely...

  • Page 26: Standard Panel Board

    3.15 - STANDARD PANEL BOARD The main switch 11 powers the board and the equipment con- The minimum thermostat, which can only be accessed after nected to it. having lifted the cover of the electric control board, stops the Switches 12 and 13 in turn cut power to the burner and to the C.H.
  • Page 27 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. DOMESTIC HOT WATER TERNOx BOILER PRODUCER Key:...
  • Page 28 POWER SUPPLY TO THE 7-POLE SOCKET OF THE BURNER POWER SUPPLY POWER SUPPLY TERNOx BOILER DOMESTIC HOT WATER PRODUCER NOTE: With absorption beyond 4A, place adequate contactors between the panel board and the loads...

  • Page 29: Optional Master Panel Board

    The optional panel board of the TERNOX 2S boiler automati- The panel is set up to manage the modulating burners. cally switches the burner off when the temperature in the boiler With this system configuration, the heating controller is capable reaches the value set on the heating controller.

  • Page 32: Hydraulic And Electrical System Connection

    3.18 - PROGRAMMING THE HEATING CONTROLLERS For that which concerns adjustment or programming of the heating As far as parameters which can be programmed by the user ac- cording to his requirements, see the system manager instruction controllers, see the instruction manual attached to the individual book.
  • Page 33 Description Value range Default Individual values SEQUENCE MODE 01 - 06 SEQUENCE CHANGE 10 - 800 HOURS 200 HOURS CYCLE BLOCK 00 min - 30 min 00 min HYSTERESIS BURNER 2 2K - 20K<P> BOILER COOLING FUNCTION 00 - 01 BOILER COOLING TEMPERATURE 30°C - 120°C HS 1 TYPE...
  • Page 34 HEATING CIRCUIT 2 Description Value range Default Individual values HEATING CIRCUIT FUNCTION 00 - 04 PUMP FUNCTION 00 - 03 MIXER OPEN 5 - 25 ---- MIXER CLOSED 5 - 25 ---- MAX FLOW TEMPERATURE 20 °C - 110 °C 45 °C MIN FLOW TEMPERATURE 10 °C - 110 °C...
  • Page 35 The following figures show the typical layout of the connection of the boiler to the heating system consisting of 2 zones one of Remember that TERNOX 2S boilers operate with forced circu- which controlled by a motorised mixing valve. lation.

  • Page 37: Cascade Panel Board

    3.20 - CASCADE PANEL BOARD The main switch 11 powers the board and the equipment con- nected to it. The switches 12 and 13 control the burner and P1 pump if the boiler operates in cascade. The thermostat adjusts the working temperature of the boiler 2: to achieve this, the thermostat must be placed at maximum full-scale pos.
  • Page 38 PARAMETERS PROGRAMMABLE BY TECHNICIAN FOR HEATING CONTROLLER Lago Basic 0201 RV 1 ON BOILER N°2 °C °C °C °C BUS ID 1/2/11/Mod >1s 1 1) Switch selector to burner (1) Press ok (2) Turn the knob (3) until mm appears on the display Press ok (2) 2 1) Switch selector (1) to mixer valve symbol...
  • Page 40 The panel boards of the XC-K boilers (in cascade) automatically - one zone system with motorised mixing valve: the flow probe switch the burners off when the temperature in the boiler reaches (downstream the mixing valve) must be fitted; the control unit the value set on the heating controller.

  • Page 41: Commissioning

    3.22 - COMMISSIONING 3.22.1 - Preliminary checks Commissioning must be done by profession- ally qualified personnel. Unical will not be held liable for damage to persons, animals or objects due to failure to comply with the above instruction. After connecting the hydraulic and electrical system and the fuel line to the boiler, and before starting up the boiler, it is advisable...

  • Page 42: Burner Adjustment

    3.22.2 - Ignition and extinction Extinction Ignition - Set the operating thermostat at minimum. When the checks indicated in the previous paragraph are suc- cessful, the burner can be commissioned by a technician quali- - Disconnect power to the burner and close the fuel supply. fied and acknowledged by the Manufacturer of the burner.

  • Page 43: Checks During And After Commissioning

    3.24 - CHECKS DURING AND AFTER COMMISSIONING When the appliance has been commissioned, check that it It is also very important to check sealing of the boiler/chimney performs a shutdown and subsequent ignition: fitting for the reasons expressed above. - by modifying the boiler thermostat calibration; - by intervening on the main switch of the panel board.

  • Page 44: Inspection And Maintenance

    INSPECTIONS AND MAINTENANCE Routine maintenance is essential in the in- Routine maintenance terest of the safety, efficiency and durability Maintenance must be established based on the fuel used, the of the appliance. number of ignitions, the features of the system, etc. Therefore it All maintenance must be carried out by qual- is not possible to establish beforehand the frequency of main- ified personnel.

  • Page 45: Inspection And Maintenance Instructions

    To assure long-term functioning of your appliance After having completed all maintenance work, always perform and to avoid altering its approved status, only the following operations: original Unical spare parts must be used. • Open the heating flow and return pipes. •...

  • Page 46: Troubleshooting

    TROUBLESHOOTING The following are the most common causes of faults and their solutions. SOLUTIONS: FAULT: The burner does not switch on. check the electrical connections; check the regular flow of fuel; check that the fuel feeding system is intact and clean, and that it is deaerated; check that ignition sparks are performed regularly and operation of the burner ap- pliance;...
  • Page 48 46033 casteldario - mantova - Italy - tel. +39 0376 57001 - telefax +39 0376 660556 S.p.A. info@unical-ag.com - export@unical-ag.com - www.unical.eu Unical will not be held responsible for possible inaccuracies due to transcription or printing errors. It reserves the right to modify its products as deemed necessary or useful, without jeopardising their essential features.

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