Unical Tristar 2S Installer And Maintenance Technician Instructions
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Unical Tristar 2S Installer And Maintenance Technician Instructions

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00334513 - 03/13
rev. 0
TRISTAR 2S
INSTALLER AND
MAINTENANCE
TECHNICIAN
INSTRUCTIONS

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Summary of Contents for Unical Tristar 2S

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

  • Page 2: Table Of Contents

    General information TABLE OF CONTENTS 1 GENERAL INFORMATION ....................................3 1.1 Symbols used in the manual ..................................3 1.2 Appropriate use of appliance ..................................3 1.3 Water treatment ......................................3 1.4 Information for user or system manager ............................... 3 1.5 Safety warnings ......................................4 1.6 Technical data plate ......................................

  • Page 3: General Information

    The appliance is intended to operate in hot air circulation heating systems. Any other use must be considered improper. UNICAL shall not be held liable for any damage resulting from improper use; in this case the user is fully responsible for the risk.

  • Page 4: Safety Warnings

    General information 1.5 - SAFETY WARNINGS ATTENTION! The appliance must be installed, adjusted and maintained by professionally qualified personnel, in compliance with standards and provisions in force. Incorrect installation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible. DANGER! NEVER attempt performing maintenance or repairs on the boiler on your own initiative.

  • Page 5: Technical Data Plate

    Fuels (only those with X) OUTPUTS min. min. max. max. Useful Furnace Sup. m² P.I.N. code Approval  See serial no. on boiler body 46033 CASTELDARIO (MN) - Via Roma tel. 0376 57001 - fax 0376 660556 S.P.A. www.unical.ag info@unical-ag.com...

  • Page 6: General Warnings

    Any repairs must be performed solely by personnel authorised as they provide important guidelines regarding installation, use by Unical using original spare parts only. Failure to comply with and maintenance safety. the above can jeopardise the safety of the appliance.

  • Page 7: Technical Features And Dimensions

    TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES TRISTAR 2S boilers are the horizontal cylindrical type with flame mm thick (from model TST 2700 2S to model TST 3500 2S), in inversion in furnace and third flue gas pass in tubes.

  • Page 8: Smoke Turbulators

    Technical features and dimensions 2.3 - SMOKE TURBULATORS TRISTAR boilers are designed to be used within an output range in order to improve seasonal efficiency and coupling with each heating system. The heat output must therefore be adjusted upon commissioning, based on the guidelines of the Thermotechnical Engineer, and always within the range provided for each boiler on pages 9 -...

  • Page 9: Dimensions

    T5 Boiler drain 2 Burner connection flange T2 Heating return T6 Condensation drain 3 Smoke chamber cleaning door T3 Chimney connection 4 Flame control warning light T4 Burner connection TRISTAR 2S CONNECTIONS Useful Furnace Boiler Water side Flue gas Maximum...
  • Page 10 2 Burner connection flange T2 Heating return T6 Burner connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Condensation drain 4 Flame control warning light T4 Boiler drain TRISTAR 2S CONNECTIONS Useful Furnace Boiler Water side Flue gas Maximum...
  • Page 11 2 Burner connection flange T2 Heating return T6 Burner connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Condensation drain 4 Flame control warning light T4 Boiler drain CONNECTIONS TRISTAR 2S Furnace Furnace Boiler Flue gas Flue gas Maximum Weight output...
  • Page 12 T2 Heating return T6 Burner connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Boiler air bleed 4 Flame sight glass T4 Boiler drain T8 Inspection door CONNECTIONS TRISTAR 2S Useful Furnace Boiler Water side Flue gas Maximum Weight output...
  • Page 13 T7 Boiler air bleed T3 Expansion vessel connection 4 Flame sight glass T8 Inspection door T4 Boiler drain Useful Furnace Boiler Water side Flue gas Maximum Weight CONNECTIONS TRISTAR 2S output output capacity pressure pressure operating drop(**) drop pressure boiler Øi Ø...
  • Page 14 T2 Heating return T6 Burner connection 3 Smoke chamber cleaning door T3 Expansion vessel connection T7 Inspection door 4 Flame sight glass T4 Boiler drain T8 Condensation drain CONNECTIONS TRISTAR 2S Useful Furnace Boiler Water side Flue gas Maximum Weight output...

  • Page 15: Operating Data According To Uni 10348

    Technical features and dimensions...
  • Page 16 Technical features and dimensions...

  • Page 17: Installation Instructions

    Installation instructions INSTALLATION INSTRUCTIONS 3.1 - GENERAL WARNINGS ATTENTION! In rooms with the presence of aggressive vapours or dust, the appliance must operate ATTENTION! independently from the air inside the This boiler is intended solely for the use installation room! for which it was expressly designed.

  • Page 18: Installation Standards

    DPR551/99, (0.4 m² ventilation). applicable technical standards. Directives concerning boiler rooms, building regulations and TRISTAR 2S is a steel boiler which can be combined with air- combustion heating provisions in the country of installation must blown burners fired by gas of category II2H3+.

  • Page 19: Handling

    Installation instructions 3.3 - HANDLING The boiler can be handled easily, lifting it by means If necessary for clearance purposes, the door and the smoke of upper hook/s or shifting it on rollers underneath chamber can be removed to make it easier to enter the boiler the sturdy base longerons.

  • Page 20: Installing The Burner

    Installation instructions The manufacturing companies of the burners can supply the øA BOILER TYPE dimensions of the flames which their appliances develop, especially those approved based on the standards indicated TST 80 2S above. TST 120÷250 2S Further information is provided in the chapter “Commissioning”. TST 300÷560 2S TST 680÷870 2S TST 1000÷1180 2S...

  • Page 21: Furnace Door: Adjustment, Opening, Closing

    Installation instructions 3.7 - FURNACE DOOR: ADJUSTMENT, OPENING AND CLOSING IMPORTANT - The door of the boiler must be opened when it is cooled off to avoid damaging the fibre due to thermal shock. - The insulation fibre of the door can show cracks after a short time of operation;...

  • Page 22: Tst 680 2S÷Tst 870 2S Boilers

    Installation instructions 3.7.3 - “TST 680 2S÷TST 870 2S” BOILERS For all these models, the door is hinged and fixed according to the layout in fig. 24. 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.

  • Page 23: Connecting Flue Exhaust Pipe

    4 and 7131 point 5). The supplier will have no contractual or extra- The TRISTAR 2S boiler can be attached to the chimney in contractual liability for damage caused due different ways; straight pipes or elbows can be used to exit from...

  • Page 24: Connecting Boiler To System

    3.9.1 - RECIRCULATION PUMP Attention! Make sure that there are no mechanical TRISTAR 2S boilers must always operate with forced water tension points while connecting the pipes to circulation and a minimum return temperature of 55°C. avoid the risk of leakage!

  • Page 25: Gas Connection

    Installation instructions As a precaution against gas leaks, we after commissioning the boiler and bringing the system to recommend installing a monitoring and the operating temperature, stop the pumps and repeat the air bleed operations; protection system consisting of a gas leak let the system cool off and, if necessary, return the water detector coupled with a shut-off solenoid pressure to 1 bar.

  • Page 26: Packaging

    Installation instructions 3.12 - PACKAGING - ceramic fibre cord to insulate between burner blast tube and TRISTAR 2S boilers are supplied complete with the door and door. smoke chamber assembled, while the casing and insulation are included in separate cardboard package(s).

  • Page 27: Assembly Of Casing

    Installation instructions 3.13 - ASSEMBLY OF CASING TRISTAR 80÷250 2S fig. 27 Assembly sequence (Ref. fig. 27 and 28) A) Mount the insulation (pos. 1) of the boiler body and secure E) Fix the reinforcement pos. 6, to the top panel pos. 5 and press the 2 edges with the contact springs (pos.
  • Page 28 Installation instructions 1 Thermometer probe 2 Working thermostat probe 3 Safety thermostat probe 4 Minimum thermostat probe 5 Probe bulb holders fig. 28 6 Capillaries fixing spring Assembly sequence (Ref. fig. 29) A) Mount the insulation (pos. 1) of the boiler body and secure G) Fit the upper longitudinal panels (pos.
  • Page 29 Installation instructions TRISTAR 340÷560 2S fig. 29 4 11 1 Thermometer probe 2 Working thermostat probe 3 Safety thermostat probe fig. 30 4 Minimum thermostat probe 5 Safety spring 6 Contact spring...
  • Page 30 Installation instructions Assembly sequence (Ref. fig. 31) A) Mount the insulation (pos. 1) of the boiler body and secure Fix the panel board to the upper panel (pos. 12). the 2 edges with the elastic straps (pos. 2) supplied in the Fit the upper panel pos.
  • Page 31 Installation instructions Assembly sequence (Ref. fig. 32) A) Mount the insulation (pos. 1) of the boiler body and secure Fit the upper panel pos. 9, complete with panel board, to the the 2 edges with the elastic straps (pos. 2) supplied in the two sides of the casing.
  • Page 32 Installation instructions TRISTAR 2350 2S fig. 33 Assembly sequence (Ref. fig. 33) E) Insert into the conduits the bulbs of the instruments as A) Mount the insulation (pos. 1) of the boiler body and secure the 2 edges with the elastic straps (pos. 2) supplied in the indicated in fig.
  • Page 33 Installation instructions TRISTAR 2700 - 3500 fig. 34 Assembly sequence (Ref. fig. 34) A) Mount the insulation (pos. 1) of the boiler body and secure D) Fix the panel board to the side panel (pos. 6. the 2 edges with the elastic straps supplied in the accessory Rotate the cover of the panel board frontwards after having box, hooking them to the external fabric part of the insulation.
  • Page 34 Installation instructions Probe insertion sequence Following this sequence, insert the probes of the instruments in the bulb holder/s 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.
  • Page 35 Installation instructions Assembly sequence (Ref. fig. 36) The TRISTAR 3900 2S ÷ TRISTAR 6100 2S boilers are supplied Insert the thermostat probe capillaries in the tube designed with casing, for the mounting of the panel board, do the following: for their passage, that is placed under the casing (see detail “A”).

  • Page 36: Electrical Connections

    Installation instructions 3.14 - ELECTRICAL CONNECTIONS 230V electric power supply connection The electrical connections are illustrated in chap. 3.16, 3.17, General warnings 3.18, 3.19, 3.21. The electrical safety of the appliance is guaranteed only when it has been properly connected to an efficient earthing system The boiler installation requires a connection to a 230 V - 50 Hz carried out as intended by safety standards in force: pipes of electric mains: this connection must be properly carried out as...

  • Page 37: Panel Board

    Installation instructions 3.15 - STANDARD PANEL BOARD The main switch 11 powers the board and the equipment con- The differential between the two contacts is 6°C (not adjustable). nected to it. The minimum thermostat, which can only be accessed after Switches 12 and 13 in turn cut power to the burner and to the having lifted the cover of the electric control board, stops the system pump.

  • Page 38: Hydraulic And Electrical System Connection

    TA = room thermostat The standard panel board of the TRISTAR 2S boiler automatically The panel is set up to manage dual-stage or modulating burners. switches the burner off when the temperature in the boiler With this layout configuration, the DHW storage tank loading reaches the value set on the control thermostat.
  • Page 39 POWER SUPPLY 230V ~ 50Hz 230V ~ 50HZ ALIMENTAZIONE POWER SUPPLY 230V ~ 50Hz 230V ~ 50HZ CALDAIA TRISTAR 2S PRODUTTORE ACQUA DOMESTIC HOT WATER TRISTAR 2S BOILER fig. 40 CALDA SANITARIA PRODUCER NOTE: With absorption beyond 4A, place adequate contactors between the panel board and the loads...

  • Page 40: Optional Panel Board

    Installation instructions 3.17 - OPTIONAL PANEL BOARD The main switch 11 powers the board and the equipment Any operation of the second stage of the burner will be managed connected to it. by the heat control. Switches 12 and 13 in turn control the burner and the mixed The default setting of the heating controller stops the system zone system pump.

  • Page 41: Layout Of Probe Connection On Heating Controller

    Installation instructions 3.18 - LAYOUT OF PROBE CONNECTION ON HEATING CONTROLLER code 30680 2 3 4 5 8 9 10 2 3 4 5 T1 T2 T3 T4 N L1 L1' FBR1 FBR1 VFAS VFAS VFAS 3 VIII 3 2 1 8 7 6 fig.
  • Page 42 Installation instructions PARAMETERS PROGRAMMABLE BY TECHNICIAN AND PROTECTED BY ACCESS CODE INSTALLATION Description Value range Default Individual values CODE NUMBER 0000 - 9999 ENTRY CODE NUMBER (variation) 0000 - 9999 0000 (00), 01 - 15 BUS ID 1 (00), 01 - 15 BUS ID 2 AF SUPPLY 00,01 (off/on)
  • Page 43 Installation instructions HEATING CIRCUIT 1 Description Value range Default Individual values HEATING CIRCUIT FUNCTION 00 - 04 PUMP FUNCTION 00, 03 MIXER OPEN 5 - 25 (not in hot water circuit) MIXER CLOSED 5 - 25 (not in hot water circuit) MAX FLOW TEMPERATURE 80 °C 20 °C - 110 °C...

  • Page 44: Hydraulic And Electric System Connection With Optional Panel Board

    TRISTAR 2S BOILER PRODUTTORE ACQUA PRODUCER CALDA SANITARIA The optional panel board of the TRISTAR 2S boiler automatically The heating controller is capable of controlling various system switches the burner off when the temperature in the boiler configurations: reaches the value set on the heating controller.
  • Page 45 Installation instructions...

  • Page 46: Commissioning

    TRISTAR 2S boilers are forced circulation boilers: it is therefore necessary to make sure that water circulates while the gas feed valves are open;...

  • Page 47: Adjustment Of Burner

    3.23 - REMOVING FLUE GAS TURBULATORS TRISTAR 2S boilers have been designed to be used at the Upon commissioning, after at least 30 minutes, it is advisable to declared nominal output.

  • Page 48: Inspection And Maintenance

    Unical spare parts must be used. its long life. Yearly maintenance of the appliance is Before proceeding with maintenance, always perform the mandatory in compliance with Laws in force.

  • Page 49: Boiler Body Maintenance

    Inspections and maintenance Boiler body maintenance Check condition of gaskets and insulation fibres The insulation fibre of the door can show cracks Danger! after a short time of operation; this however does Before performing any maintenance, make not reduce its insulation capacity nor jeopardise sure the boiler and its components have its lifespan.
  • Page 50 Inspections and maintenance...
  • Page 51 Inspections and maintenance...
  • Page 52 46033 casteldario - mantova - italy - tel. 0376/57001 (r.a.) - telefax 0376/660556 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.

This manual is also suitable for:

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