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INSTALLATIONAND MAINTENANCEINSTRUCTIONS44996 - 09/15
rev. 1
TRISTAR
2
General InformationTABLE OF CONTENTS
1 GENERAL INFORMATION ................................................................................................................................................................................. 31.1 Symbols used in the manual ........................................................................................................................................................................ 31.2 Appropriate use of appliance ........................................................................................................................................................................ 31.3 Water treatment ............................................................................................................................................................................................. 31.4 Information for user or system manager ...................................................................................................................................................... 31.5 Safety warnings ............................................................................................................................................................................................. 41.6 Technical data plate ...................................................................................................................................................................................... 51.7 General warnings .......................................................................................................................................................................................... 6
2 TECHNICAL FEATURES AND DIMENSIONS ................................................................................................................................................... 72.1 Technical features ......................................................................................................................................................................................... 72.2 Main components .......................................................................................................................................................................................... 72.3 Smoke turbulators ......................................................................................................................................................................................... 82.4 Dimensions .................................................................................................................................................................................................... 925 Operating data according to UNI 10348 .................................................................................................................................................... 14
3 INSTALLATION INSTRUCTIONS ..................................................................................................................................................................... 163.1 General warnings ....................................................................................................................................................................................... 163.2 Installation standards ................................................................................................................................................................................ 173.3 Handling ..................................................................................................................................................................................................... 183.4 Positioning in boiler room .......................................................................................................................................................................... 183.5 Burner ......................................................................................................................................................................................................... 18
3.5.1 - Choosing the burner ...................................................................................................................................................................... 183.5.2 Installing the burner ......................................................................................................................................................................... 19
3.6 Connecting flame sight glass to burner .................................................................................................................................................... 193.7 Flue connection ......................................................................................................................................................................................... 203.8 Condensation drainage ............................................................................................................................................................................. 203.9 Furnace door adjustment, opening and closing ....................................................................................................................................... 21
3.9.1 TST 80÷TST 125 boilers .................................................................................................................................................................. 213.9.2 TST 150÷TST 560 boilers ................................................................................................................................................................ 213.9.3 TST 680÷TST 870 boilers ................................................................................................................................................................ 223.9.4 TST 1000÷TST 3500 boilers ............................................................................................................................................................ 223.9.5 Important note .................................................................................................................................................................................. 22
3.10 Connecting boiler to system ...................................................................................................................................................................... 233.10.1 Recirculation pump ....................................................................................................................................................................... 23
3.11 Filling the system ....................................................................................................................................................................................... 233.12 Connecting gas .......................................................................................................................................................................................... 243.13 Packaging ................................................................................................................................................................................................... 253.14 Assembling casing ..................................................................................................................................................................................... 263.15 Electrical connections ................................................................................................................................................................................ 353.16 Standard panel board ................................................................................................................................................................................ 363.17 Hydraulic and electric system connection ................................................................................................................................................ 373.18 Optional panel board ................................................................................................................................................................................. 393.19 Layout of probe connection on heating control ........................................................................................................................................ 403.20 Programming heating controller ................................................................................................................................................................ 403.21 Hydraulic and electric system connection with optional panel board ..................................................................................................... 433.22 Commissioning .......................................................................................................................................................................................... 453.23 Adjusting the burner .................................................................................................................................................................................. 46
4 INSPECTIONS AND MAINTENANCE .............................................................................................................................................................. 46Inspection and maintenance instructions ......................................................................................................................................................... 46Boiler body maintenance ................................................................................................................................................................................... 47Maintenance of burner ....................................................................................................................................................................................... 47Checking ignition electrode ............................................................................................................................................................................... 47Components to check during yearly inspection ................................................................................................................................................ 47
General Information
3
1.1 -SYMBOLS USED IN THE MANUAL
Pay special attention when reading this manual to the parts marked by the symbols:
NOTE!Suggestions for the user
ATTENTION!Possible hazardous situationfor the product and the environment
DANGER!Serious danger forpersonal safety and life
1.2 -APPROPRIATE USE OF APPLIANCE
The TRISTAR appliance has been built according to the current level of engineering and acknowledgedtechnical safety rules.Nonetheless, if improperly used, dangers could arise for the safety and the very life of the user and otherpersons or damage to the equipment or other objects.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 fullyresponsible for the risk.Use according to the intended purposes also includes careful compliance with the instructions in thismanual.
1.3 -WATER TREATMENT (see specific booklet)
• The hardness of the feed water conditions the frequency at which the domestic hot water exchanger must becleaned.
• If the water has a hardness greater than 15°f, we recommend using water softeners, chosen according to thecharacteristics of the water.
• We recommend checking and cleaning the domestic hot water exchanger at the end of the first year of use andevery two years thereafter; on this occasion, also check the state of wear of the anode.
1.4 - INFORMATION FOR 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 inserted in the
envelope contained in the packaging. The user must keep this documentation so that it is available forfurther consultation.
• Inform the user about the importance of the air vents and the flue gas exhaust system, highlightingtheir essential features and the absolute prohibition of modifying them.
• Inform the user concerning controlling the system’s water pressure as well as operations to restore it.• Inform the user concerning correct temperature control, control units/thermostats and radiators for saving
energy.• Remember that the system must receive regular maintenance at least once a year and a combustion analysis
must be performed in the timetable foreseen by standards in force.• Should the appliance be sold or transferred to a new owner or if you move and leave the appliance, always make
sure that the instruction booklet accompanies it in order to be consulted by the new owner and/or installer.
1 GENERAL INFORMATION
Attention: this manual contains instructions for the exclusive use of the professionally qualified installerand/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 fromfailure to comply with the instructions contained in the manuals supplied with the boiler.
4
General Information
1.5 -SAFETY WARNINGS
ATTENTION!The appliance must be installed, adjusted and maintained by professionally qualified personnel, incompliance 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.Any work must be done by professionally qualified personnel.We recommend stipulating a maintenance contract.Insufficient or irregular maintenance can jeopardise the operating safety of the appliance and causedamage to persons, animals and objects for which the manufacturer cannot be held responsible.
Modifying parts connected to applianceDo not modify the following parts:- the boiler- the gas, air, water and electricity lines- flue gas pipe, safety valves and heating water drain pipe- construction 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 appliancesMake sure that the gas tank has been deaerated before installing the appliance.For state-of-the-art deaeration of the tank, contact the LPG supplier or a person qualified in compliance with law.If the tank has not been professionally deaerated, ignition problems could arise.In that case, contact the supplier of the LPG tank.
Smell of gasShould a smell of gas be perceived, follow these safety guidelines:- do not turn electric switches on or off- do not smoke- do not use the telephone- close the gas shut-off valve- air out the area where the gas leakage has occurred- inform the gas supplier or a company specialised in installation and maintenance of heating systems.
Explosive and easily flammable substancesDo not use or store explosive or easily flammable materials (e.g. petrol, paints, paper) in the room where theappliance is installed.
General Information
5
CE markingThe CE markings 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 adhesive and is included in the document case; it must be applied by the installer on theoutside of the casing.The serial number of the boiler is on the riveted plaque on the front plate of the body:front top right for models TRISTAR 80 and 125 and rear top right for all of the models.
6
General Information
1.7 -GENERAL WARNINGS
The instruction booklet is an integral and essential part of theproduct and must be kept by the user or system manager.
Read the warnings contained in this instruction booklet carefullyas they provide important guidelines regarding installation, useand maintenance safety.
Keep the booklet with care for further consultation.
Installation and maintenance must be performed in compliancewith standards in force according to the instructions of themanufacturer and by qualified and certified personnel incompliance with law.
By professionally qualified personnel we mean: personnel withspecific technical skill in the field of heating system componentsfor civil use, domestic hot water production and maintenance.Personnel must have the qualifications foreseen by currentlegislation.
Incorrect installation or improper maintenance can cause damageto persons, animals or objects for which the manufacturer isnot responsible.
Before performing any cleaning or maintenance, disconnectthe appliance from the energy mains by acting on the switch ofthe system and/or through the specific cut-off devices.
Not obstruct the terminals of the intake/exhaust ducts.
In case of failure and/or malfunctioning of the appliance, switchit off and do not try to repair it or intervene on it directly.Contact only personnel qualified in compliance with law.
Any repairs must be performed solely by personnel authorisedby Unical using original spare parts only.Failure to comply with the above can jeopardise the safety ofthe appliance.
To guarantee appliance efficiency and its correct operation,yearly maintenance must be performed by qualified personnel.
Should you decide not to use the appliance, parts entailingpotential sources of hazard must be made safe.
Should the appliance be sold or transferred to a new owner orif you move and leave the appliance, always make sure thatthe instruction booklet accompanies it in order to be consultedby the new owner and/or installer.
Only original accessories must be used for all appliances withoptionals or kits (including electric).
This appliance is intended solely for the use for which it wasexpressly designed. Any other use is to be considered improperand therefore dangerous.
Technical features and dimensions
7
2.1 -TECHNICAL FEATURES
TRISTAR boilers are the horizontal cylindrical type with flameinversion in furnace and third flue gas pass in tubes.The construction fully complies with prescriptions laid down inEN 303 part 1.The components of the pressurised part, such as sheets andpipes, are made in certified carbon steel, according to theEURONORM 25 and EURONORM 28 tables.Welding devices and procedures are approved by TÜV (D) -UDT (PL) - SA (S) and ISPESL (I).For models TST 80÷ TST 560, the furnace is bonded to therear tube plate.For models TST 680 ÷ TST 870, the furnace is free to expand(it is only sustained by the front tube plate).For models TST 1100÷TST 3500, the furnace is bonded to therear tube plate.The boilers are equipped with an opening door on the right or left.The outer shell is covered with a glass wool insulation mattress(thickness: 60 mm for models TST 80 and 125, 80 mm formodels from TST 150 to TST 560, 100 mm for models from
TST 680 to TST 2350 and 80 mm for models from TST 2700 toTST 3500) in turn protected by a mineral fibre fabric.The top part of the shell is provided with hooks for lifting theboiler.Note: TRISTAR boilers are intended to operate with an ON/OFF
burner; as an alternative, they can be equipped with adual-stage or modulating burner, as long as the minimumheat output that can be reached is not lower than the valueindicated on the technical data plate for the type of fuel used.
The boilers are provided with two ½” attachments for conduitswith an inside diameter of 15 mm (suitable to house 3 bulbseach).The shell has holes at the sides for the cable glands of thepower, pumps, burner cables and those of any other auxiliarydevice.
2 TECHNICAL FEATURESAND DIMENSIONS
2.2 -MAIN COMPONENTS
TRISTAR boilers are equipped with a blind cylindrical furnace,in which the central flame of the burner is reversed peripherallytowards the front, from whence the combustion gases enterthe smoke pipes. At the end of the pipes they are gathered inthe small chamber and sent to the chimney.The combustion chamber is always pressurised while the burneris operating, within the power range of the boiler.For the value of this pressure, see the tables on pages 9÷13,in the column “Flue gas pressure drops”.The chimney must be calculated so that no positive pressureis detected at its base.
1 Furnace2 Smoke pipes with smoke diverters3 Door with flame sight glass4 Smoke chamber5 Body insulation6 Panel board fig. 1
8
Technical features and dimensions
2.3 -SMOKE TURBULATORS
TRISTAR boilers are designed to be used within an output rangein order to improve seasonal efficiency and coupling with eachheating system.The heat output must therefore be adjusted upon commissioning,based on the guidelines of the Thermotechnical Engineer, andalways within the range provided for each boiler on pages 9 - 13,by the burner technician who will determine the fuel flow rate.In all cases, the turbulators will be positioned, using a specificinserter pipe, inside the respective smoke pipes respect tothe front wire, as shown in the table below.While operating the boiler at minimum output, the flue gas
POSITIONING TURBULATOR INSIDE PIPE (quota A, referring to front wire of pipe)
fig. 2
temperature must not be less than that indicated on pages 14and 15.If not, make sure that all the turbulators are inside the respectivesmoke pipes before contacting our After-Sales Service.The burner must be commissioned under the responsibility ofa qualified burner technician authorised by the manufacturer.On that occasion, a complete operating report must be drafted.
Detail 2:Screw the extractoronto the turbulator.
Extraction of turbulators
Detail 3:Remove the turbulator.
Detail 1:Mount the brush rodon the turbulator extractor.
fig. 3
TST
80A
= 6
0
TST
125
A =
45
TST
150
A =
70
TST
215
A =
70
TST
260
A =
135
TST
300
A =
135
TST
370
A =
200
TST
450
A =
200
TST
560
A =
190
TST
680
A =
210
TST
780
A =
210
TST
870
A =
210
TST
1000
A =
130
TST
1180
A =
140
Technical features and dimensions
9
Fiber wool
Ceramic fiber
Blind burner plate 250x250
Burner plate insulation gasket 250x250
ø 1
80
ø 1
50
75
Fiber wool
Ceramic fiber
Blind burner plate 200x200
Burner plate insulation gasket 200x200
ø 1
30
ø 1
30
75
2.4 -DIMENSIONS - TRISTAR 80÷125
1 Panel board2 Burner connection flange3 Smoke chamber cleaning door4 Flame sight glass
T1 Central Heating flowT2 Central Heating returnT3 Expansion vessel connectionT4 Boiler drain
T5 Chimney connectionT6 Burner connectionT7 Condensation drain
fig. 4
Nominaloutput
kW
60÷80
93,8÷125
CONNECTIONST1T2
ISO 7/1
T4
ISO 7/1
T5Øemm
T6Ø
mm
Rp 1½
Rp 2
Rp 3/4
Rp 3/4
200
200
130
180
TST 80
TST 125
TRISTAR
Model
Nominalinput
kW
63,3÷85,2
98,5÷132,6
Boilercapacity
l
120
176
Waterpressuredrops(**)
m w.c.
0,11÷0,16
0,16÷0,20
6,9÷7,2
7,8÷12,2
Flue gaspressure
drop
mm w.c.
Maximumboiler
workingpressure
bar
5
5
Weight
kg
241
353
TRISTAR
ModelTST 80
TST 125
DIMENSIONS
Amm690
760
Bmm753
933
722
812
Cmm
190
190
Dmm
104
104
Emm
Fmm138
173
Gmm389
404
Hmm429
484
Imm995
1210
Lmm105
117
722
813
M*mm
147
157
Nmm
230
350
Omm
630
700
Q*mm
710
890
R*mm
(*) Minimum dimensions for boiler room access.(**) Pressure drops corresponding to a thermal drop of 15K.
DETAIL FOR DOOR DRILLINGTST 80
DETAIL FOR DOOR DRILLINGTST 125
fig. 5 fig. 6
T7Øemm
4040
10
Technical features and dimensions
Fiber wool
Ceramic fiber
Blind burner plate 250x250
Burner plate insulation gasket 250x250
ø 1
80
ø 1
80
95
TRISTAR 150÷560
1 Panel board2 Burner connection flange3 Smoke chamber cleaning door4 Flame sight glass
T1 Central Heating flowT2 Central Heating returnT3 Expansion vessel connectionT4 Boiler drain
T5 Chimney connectionT6 Burner connectionT7 Condensation drain
DETAIL FOR DOOR DRILLINGTST 150-215
DETAIL FOR DOOR DRILLINGTST 260÷560
Nominaloutput
kW
112,5÷150
161,3÷215
195÷260
225÷300
277,5÷370
337,5÷450
420÷560
CONNECTIONST1T2
UNI 2278 PN16
T3
ISO 7/1
T4
ISO 7/1
T5Øi
mm
T6Ø
mm
DN 65
DN 65
DN 80
DN 80
DN 100
DN 100
DN 100
Rp 1½
Rp 1½
Rp 2
Rp 2
Rp 2
Rp 2
Rp 2
Rp ¾
Rp ¾
Rp ¾
Rp ¾
Rp ¾
Rp ¾
Rp ¾
200
200
250
250
250
250
300
180
180
220
220
220
220
220
TST 150
TST 215
TST 260
TST 300
TST 370
TST 450
TST 560
TRISTAR
Model
Nominalinput
kW
118÷158,8
168,6÷226,9
203,5÷273,9
234,5÷315,6
288,6÷388,5
350,8÷472,1
436,6÷587,6
Boilercapacity
l
192
254
269
304
402
468
572
Waterpressuredrops(**)
m w.c.
0,09÷0,15
0,19÷0,33
0,12÷0,21
0,16÷0,28
0,09÷0,17
0,14÷0,25
0,21÷0,38
10,2÷15,5
16,9÷22,2
20,4÷25,7
23÷28,3
26,9÷32,2
30,5÷35,8
34,5÷42
Flue gaspressure
drop
mm w.c.
Maximumboiler
workingpressure
bar
6
6
6
6
6
6
6
Weight
kg
444
566
632
688
888
1002
1432
TRISTAR
ModelTST 150
TST 215
TST 260
TST 300
TST 370
TST 450
TST 560
DIMENSIONS
Amm820
820
860
860
890
890
890
Bmm885
1145
1080
1210
1275
1470
1780
1082
1082
1182
1182
1352
1352
1352
Cmm
190
190
190
190
190
190
190
Dmm
139
139
140
140
140
140
140
Emm
Fmm190
190
191
191
192
192
192
Gmm277
277
296
296
323
323
323
Hmm695
695
775
775
915
915
915
Imm1214
1474
1414
1541
1608
1803
2113
Lmm80
80
85
85
90
90
90
1165
1165
1265
1265
1450
1450
1450
M*mm
175
175
215
215
255
255
255
Nmm
130
390
210
340
285
480
790
Omm
185
185
250
250
315
315
315
Pmm
710
710
750
750
780
780
780
Q*mm
785
1045
982
1112
1179
1374
1684
R*mm
(*) Minimum dimensions for boiler room access.(**) Pressure drops corresponding to a thermal drop of 15K.
fig. 8
fig. 7
fig. 9
T7Øemm
40
40
40
40
40
40
40
Technical features and dimensions
11
Refractory cement
Ceramic fiber
Blind burner plate 330x330
Burner plate insulation gasket 330x330
ø 2
70
ø 2
70
150
Imm
(*) Minimum dimensions for boiler room access.(**) Pressure drops corresponding to a thermal drop of 15K.
1 Panel board2 Burner connection flange3 Smoke chamber cleaning door4 Flame sight glass
T1 Central Heating flowT2 Central Heating returnT3 Expansion vessel connectionT4 Boiler drain
T5 Chimney connectionT6 Burner connectionT7 Condensation drain
DETAIL FOR DOOR DRILLINGTST 680÷870
Nominaloutput
kW510÷680
585÷780
652,5÷870
CONNECTIONST1T2
UNI 2278 PN16
T3
UNI 2278 PN16
T4
ISO 7/1
T5Øi
mm
T6Ø
mm
DN 125
DN 125
DN 125
DN 65
DN 65
DN 65
Rp 1
Rp 1
Rp 1
350
350
350
TST 680TST 780TST 870
TRISTAR
Model
Nominalinput
kW
530,1÷713,5
608,1÷818,4
678,2÷912,8
Boilercapacity
l
678
762
845
Waterpressuredrops(**)
m w.c.
0,15÷0,26
0,19÷0,33
0,24÷0,41
38,5÷49,3
43,7÷54,5
47,8÷58,6
Flue gaspressure
drop
mm w.c.
Maximumboiler
workingpressure
bar
6
6
6
Weight
kg
1586
1753
1939
TRISTAR 680÷870
fig. 10
fig. 11
270
270
270
T7Øemm
40
40
40
TRISTAR
ModelTST 680
TST 780
TST 870
DIMENSIONS
Amm1122
1122
1122
Bmm1605
1800
1995
1432
1432
1432
Cmm
190
190
190
Dmm
194
194
194
Emm
Fmm191
191
191
Gmm442
442
442
Hmm960
960
960
1990
2185
2380
Lmm125
125
125
1540
1540
1540
M*mm
298
298
298
Nmm
435
630
825
Omm
440
440
440
Pmm
1020
1020
1020
Q*mm
1505
1700
1895
R*mm
12
Technical features and dimensions
Refractory cement
Blind burner plate 450x450
Burner plate insulation gasket 450x450
ø 3
80
ø 3
80
190
Refractory cement
Blind burner plate 380x380
Burner plate insulation gasket 380x380
ø 3
20
ø 3
20
180
Refractory cement
Blind burner plate 380x380
Burner plate insulation gasket 380x380
ø 3
20
ø 3
20
160
Imm
T1T2
UNI 2278 PN16
T2 Central Heating returnT3 Expansion vessel connectionT4 Boiler drainT5 Chimney connectionT6 Burner connection
T7 Condensation drainT8 Boiler air bleedT9 Inspection door
(*) Minimum dimensions for boiler room access.(**) Pressure drops corresponding to a thermal drop of 15K.
TRISTAR 1000÷2350
TST 1000
TST 1180
TST 1400
TST 1650
TST 2000
TST 2350
TRISTAR
Model
DETAIL FOR DOOR DRILLINGTST 1000÷1180
DETAIL FOR DOOR DRILLINGTST 2000÷2350
DETAIL FOR DOOR DRILLINGTST 1400÷1650
Nominaloutput
kW750÷1000
885÷1180
1050÷1400
1237,5÷1650
1500÷2000
1762,5÷2350
Nominalinput
kW779,6÷1049,2
919,9÷1238,1
1091,4÷1468,9
1286,3÷1731,2
1559,1÷2098,4
1832÷2465,7
Boilercapacity
l995
1197
1363
1564
2024
2264
Waterpressuredrops(**)
m w.c.018÷0,30
0,2÷0,35
0,19÷0,35
0,26÷0,45
0,21÷0,34
0,28÷0,48
1 Panel board2 Burner connection flange3 Smoke chamber cleaning door4 Flame sight glassT1 Central Heating flow
Flue gaspressure
drop
mm w.c.53÷63,9
60,4÷68,6
65,2÷73,4
69,9÷78,1
40÷60
40÷65
Maximumboiler
workingpressure
bar6
6
6
6
6
6
Weight
kg2353
2575
3304
3743
4756
5163
CONNECTIONST3
UNI 2278 PN16
DN 80
DN 80
DN 100
DN 100
DN 125
DN 125
DN 150
DN 150
DN 175
DN 175
DN 200
DN 200
T4
ISO 7/1
Rp 1½
Rp 1½
Rp 1½
Rp 1½
Rp 1½
Rp 1½
T5Øi
mm
400
400
450
450
520
520
T6Ø
mm
320
320
320
320
380
380
fig. 12
fig. 13 fig. 14 fig. 15
T8 / T9Ø
mm
135
135
135
135
135
135
T7Øemm
40
40
40
40
40
40
TRISTAR
ModelTST 1000
TST 1180
TST 1400
TST 1650
TST 2000
TST 2350
DIMENSIONS
Amm1352
1352
1462
1462
1622
1622
Bmm1952
2292
2282
2652
2692
3014
1432
1432
1542
1542
1702
1702
Cmm
190
190
190
190
190
190
Dmm
207
207
227
227
259
258
Emm
Fmm187
187
272
272
274
273
Gmm698
698
880
880
950
950
Hmm895
895
960
960
1070
1070
2346
2686
2781
3151
3325
3545
Lmm180
180
75
75
75
75
1540
1540
1650
1650
1810
1810
M*mm
461
461
561
561
661
662
Nmm
330
670
510
880
670
990
Omm
500
500
550
550
700
700
Pmm
1250
1250
1360
1360
1520
1520
Q*mm
1846
2186
2176
2546
2590
2910
R*mm
200
200
145
145
145
145
Smm
Technical features and dimensions
13
Refractory cement
Blind burner plate 450x450
Burner plate insulation gasket 450x450
ø 3
80
ø 3
80
210
T1T2
UNI 2278 PN16
Hmm
(*) Minimum dimensions for boiler room access.(**) Pressure drops corresponding to a thermal drop of 15K.
TRISTAR 2700÷3500
TST 2700
TST 3100
TST 3500
TRISTAR
Model
Nominaloutput
kW2025÷2700
2325÷3100
2625÷3500
Nominalinput
kW2104,8÷2832,9
2416,7÷3252,6
2728,5÷3672,2
Boilercapacity
l2488
4142
4455
Waterpressuredrops(**)
m w.c.0,36÷0,62
0,54÷0,84
0,54÷0,84
Flue gaspressure
drop
mm w.c.50÷70
60÷75
65÷78
Maximumboiler
workingpressure
bar6
6
6
Weight
kg6133
7705
8675
CONNECTIONST3
UNI 2278 PN16
DN 125
DN 125
DN 125
DN 200
DN 200
DN 250
T4
ISO 7/1
Rp 1½
Rp 1½
Rp 1½
T5Øi
mm
570
620
620
T6Ø
mm
380
400
400
DETAIL FOR DOOR DRILLINGTST 2700
DETAIL FOR DOOR DRILLINGTST 3100÷3500
fig. 17 fig. 18
T2 Central Heating returnT3 Expansion vessel connectionT4 Boiler drainT5 Chimney connectionT6 Burner connection
T7 Condensation drainT8 Boiler air bleedT9 Inspection door
1 Panel board2 Burner connection flange3 Smoke chamber cleaning door4 Flame sight glassT1 Central Heating flow
T8 / T9Ø
mm
135
135
135
fig. 16
T 7Øemm
40
40
40
TRISTAR
ModelTST 2700
TST 3100
TST 3500
DIMENSIONS
Amm1720
1970
1970
Bmm3230
3194
3594
1830
2090
2090
Cmm
190
190
190
Dmm
295
325
325
Emm
Fmm310
360
360
Gmm1315
1535
1535
1128
1295
1295
Imm3835
3879
4279
Lmm115
144
144
1990
2271
2271
M*mm
325
377
777
Nmm
1100
1060
1060
Omm
1470
1420
1420
Pmm
1620
1870
1870
Q*mm
3200
3164
3564
R*mm
14
Technical features and dimensions
Nominal heat outputNominal heat inputHeat efficiency at nominal load (100%)Heat efficiency at 30% loadNumber of stars (according to 92/42 EEC)Combustion efficiency at nominal load (100%)Heat loss at casingHeat loss at chimney with burner onHeat loss at chimney with burner offFlue gas temperature tf-taCO2 contentFlue gas mass flow rate
TST 370
277,5÷370288,6÷388,5
96,1÷95,295,9÷95
396,4÷95,5
0,2÷0,23,6÷4,50,1÷0,180÷99
12,8÷12,8442÷594
TST 450
337,5÷450350,8÷472,1
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,8537÷723
TST 560
420÷560436,6÷587,6
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,8668÷899
TST 680
510÷680530,1÷713,5
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,8811÷1092
TST 780
585÷780608,1÷818,4
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,8931÷1253
TST 1650
1237,5÷16501286,3÷1731,2
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,81969÷2651
TST 2000
1500÷20001559,1÷2098,4
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,82387÷3213
TST 2350
1762,5÷23501832÷2465,7
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,82805÷3775
TST 2700
2025÷27002104,8÷2832,,9
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,83223÷4338
TST 3100
2325÷31002416,7÷3252,6
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,83700÷4980
TST 3500
2625÷35002728,5÷3672,2
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,84178÷5623
Nominal heat outputNominal heat inputHeat efficiency at nominal load (100%)Heat efficiency at 30% loadNumber of stars (according to 92/42 EEC)Combustion efficiency at nominal load (100%)Heat loss at casingHeat loss at chimney with burner onHeat loss at chimney with burner offFlue gas temperature tf-taCO2 contentFlue gas mass flow rate
kWkW%%n.%%%%°C%kg/h
TST 150
112,5÷150118÷158,895,3÷94,495,1÷94,2
395,7÷94,9
0,3÷0,44,2÷5,10,1÷0,194÷112
12,8÷12,8180÷243
DIESEL OIL-FIRED TST 215
161,3÷215168,6÷226,9
95,6÷94,795,4÷94,5
395,9÷95,1
0,2÷0,34,1÷4,90,1÷0,190÷108
12,8÷12,8258÷347
TST 260
195÷260203,5÷273,9
95,8÷94,995,6÷94,7
396÷95,20,1÷0,24÷4,7
0,1÷0,188÷105
12,8÷12,8311÷419
TST 300
225÷300231,5÷315,6
95,9÷9595,7÷94,8
396,1÷95,3
0,1÷0,23,8÷4,60,1÷0,185÷102
12,8÷12,8359÷483
2.5 - OPERATING DATA
kWkW%%n.%%%%°C%kg/h
TST 870
652,5÷870678,2÷912,8
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,81038÷1397
TST 1000
750÷1000779,6÷1049,2
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,81193÷1606
TST 1180
885÷1180919,9÷1238,1
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,81408÷1895
TST 1400
1050÷14001091,4÷1468,9
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,13,6÷4,50,1÷0,180÷99
12,8÷12,81671÷2249
DIESEL OIL-FIRED
TST 125
93,8÷12598,5÷132,695,1÷94,394,9÷94,1
395,4÷94,6
0,2÷0,34,5÷5,30,1÷0,1100÷118
12,8÷12,8150÷203
TST 80
60÷8063,3÷85,294,7÷93,994,5÷93,7
395,4÷94,6
0,6÷0,74,5÷5,30,1÷0,1100÷118
12,8÷12,896÷130
Technical features and dimensions
15
Nominal heat outputNominal heat inputHeat efficiency at nominal load (100%)Heat efficiency at 30% loadNumber of stars (according to 92/42 EEC)Combustion efficiency at nominal load (100%)Heat loss at casingHeat loss at chimney with burner onHeat loss at chimney with burner offFlue gas temperature tf-taCO2 contentFlue gas mass flow rate
TST 370
277,5÷370288,6÷388,5
96,1÷95,295,9÷95
396,4÷95,5
0,2÷0,23,6÷4,50,1÷0,174÷93
9,8÷9,8433÷584
TST 450
337,5÷450350,8÷472,1
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,8527÷709
TST 560
420÷560436,6÷587,6
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,8656÷883
TST 680
510÷680530,1÷713,5
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,8796÷1072
TST 780
585÷780608,1÷818,4
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,8914÷1230
TST 1650
1237,5÷16501286,3÷1731,2
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,81933÷2602
TST 2000
1500÷20001559,1÷2098,4
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,82343÷3154
TST 2350
1762,5÷23501832÷2465,7
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,82753÷3706
TST 2700
2025÷27002104,8÷2832,,9
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,83163÷4258
TST 3100
2325÷31002416,7÷3252,6
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,83632÷4889
TST 3500
2625÷35002728,5÷3672,2
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,84101÷5519
Nominal heat outputNominal heat inputHeat efficiency at nominal load (100%)Heat efficiency at 30% loadNumber of stars (according to 92/42 EEC)Combustion efficiency at nominal load (100%)Heat loss at casingHeat loss at chimney with burner onHeat loss at chimney with burner offFlue gas temperature tf-taCO2 contentFlue gas mass flow rate
kWkW%%n.%%%%°C%kg/h
TST 150
112,5÷150118÷158,895,3÷94,495,1÷94,2
395,7÷94,9
0,3÷0,44,3÷5,10,1÷0,189÷1059,8÷9,8177÷238
GAS-FIRED TST 215
161,3÷215168,6÷226,9
95,6÷94,795,4÷94,5
395,9÷95,1
0,2÷0,34,1÷4,80,1÷0,184÷1009,8÷9,8253÷341
TST 260
195÷260203,5÷273,9
95,8÷94,995,6÷94,7
396÷95,20,2÷0,23,9÷4,70,1÷0,181÷98
9,8÷9,8305÷411
TST 300
225÷300231,5÷315,6
95,9÷9595,7÷94,8
396,1÷95,3
0,1÷0,23,8÷4,60,1÷0,179÷96
9,8÷9,8352÷474
kWkW%%n.%%%%°C%kg/h
TST 870
652,5÷870678,2÷912,8
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,81019÷1372
TST 1000
750÷1000779,6÷1049,2
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,81171÷1577
TST 1180
885÷1180919,9÷1238,1
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,81382÷1861
TST 1400
1050÷14001091,4÷1468,9
96,2÷95,396÷95,1
—96,4÷95,5
0,1÷0,23,6÷4,40,1÷0,174÷92
9,8÷9,81640÷2208
GAS-FIRED
TST 125
93,8÷12598,5÷132,695,1÷94,394,9÷94,1
395,4÷94,6
0,2÷0,34,5÷5,30,1÷0,194÷1109,8÷9,8148÷199
TST 80
60÷8063,3÷85,294,7÷93,994,5÷93,7
395,4÷94,6
0,5÷0,74,6÷5,30,1÷0,195÷1109,8÷9,895÷128
16
Installation instructions
3 INSTALLATIONINSTRUCTIONS
3.1 -GENERAL WARNINGS
ATTENTION!This boiler is intended solely for the use forwhich it was expressly designed.Any other use is to be considered improperand therefore dangerous.This boiler heats water at a temperaturelower than the atmospheric pressure boilingtemperature.
ATTENTION!The appliances are designed to be installedinside suitable rooms or technical spacesonly. The appliances cannot be installed oroperate outdoors. Outdoor installation cancause malfunctioning and be dangerous.Choose specifically designed appliances foroutdoor installation.
Before connecting the boiler, have professionallyqualified personnel:a) Thoroughly wash all the piping of the system
to remove any residue or impurities whichcould jeopardise proper operation of theboiler.
b) Check that boiler is set up to operate withthe available type of fuel.This can be seen written on the package andon the technical feature plate.
c) Check that the chimney/flue has an appropriatedraught, without any bottlenecks, and that noexhausts from other appliances are inserted,unless the flue has been implemented toaccommodate several utilities according tospecific standards and prescriptions in force.Only after this check can the fitting betweenthe boiler and chimney/flue be mounted.
ATTENTION!In rooms with the presence of aggressivevapours or dust, the appliance must operateindependently from the air inside theinstallation room!
ATTENTION!The appliance must be installed by a qualifiedtechnician with the technical-professionalrequirements according to law which, under hisown responsibility, guarantees compliancewith standards according to good practicerules.
The boiler must be connected to a central heatingsystem and/or domestic hot water supply networkcompatible with its efficiency and output.
Installation instructions
17
3.2 - INSTALLATION STANDARDS
The appliance must be installed in compliance with the instruc-tions provided in this manual.
It must be installed by a professionally qualified technician,who shall assume the responsibility of respecting all lo-cal and/or national laws published in the official journal,as well as applicable technical standards.
TRISTAR is a steel boiler which can be combined with air-blown burners fired by diesel oil or gas of category II2H3+.
Contact the gas supplying company before installing theappliance.
Directives concerning boiler rooms, building regulations andcombustion heating provisions in the country of installation mustalso be respected.
The appliance must be installed, commissioned and undergomaintenance according to the current “state-of-the-art”.This also holds for the hydraulic system, the flue exhaustsystem and the installation room.
18
Installation instructions
x = not less than the length of the boiler body(dimensions in mm); in any case, never less than 1300 mm.xx = see instructions to the side.
3.4 -POSITIONING INBOILER ROOM
The boiler must be installed in compliance with standards andprescriptions in force.The room must be well ventilated by openings with a total surfaceno less than 1/30 the surface of the boiler room, with a minimumof 0.5 m².The ventilation openings must be permanent, communicatedirectly with the outside and be positioned high or low accordingto standards in force.The location of the ventilation openings, the fuel supply circuits,electric energy supply and lighting must comply with currentlegal provisions in relation to the type of fuel used.It is recommended to install the boiler as close to the chimneyconnection as possible.To make it easier to clean the smoke circuit, in front of the boiler,there must be a free space no less than the length of the boilerbody and, in any case, never less than 1300 mm. Check thatwith the door opened 90°, the distance between the door andthe adjacent wall is at least the length of the burner.The boiler can be placed directly on the floor as it is equippedwith a base.However it is useful to provide a flat, level cement plinth capableof bearing the weight of the boiler full of water.When positioned on the plinth, the dimensions must be at leastQ x R (see dimensions table).When installation has been performed, the boiler must be perfectlyhorizontal and stable (to reduce vibrations and noise).
fig. 19
3.3 -HANDLING
The boiler can be handled easily, lifting it by meansof upper hook/s or shifting it on rollers underneaththe sturdy base longerons.
3.5 -BURNER
The burners operating with the TRISTAR boilers must havethe 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 267 - methods of test for atomizing oil burners
of the monobloc type- UNI EN 676 - air-blown burners for gaseous fuel.- Efficiency Directive (92/42 EEC).
3.5.1 - CHOOSING THE BURNER
The correct choice and adjustment of the burner are fundamentalfor optimal operation of the boiler and therefore must be donecarefully and not underestimated.The burner must be chosen verifying that its firing rate (fuel
capacity - combustion chamber pressure) is compatible withthe same features declared for the boiler.Remember that pressure drops on the flue side of the boiler,namely combustion chamber backpressure, refer to zero pressureat the base of the chimney.It is also recommended that the burner blast tube be no shorterthan the minimum dimension shown in the following table andthat the flame which must be implemented be suitable for thecharacteristics of the combustion chamber.In order to take advantage of the whole heat exchange surfaceof the blind bottom furnaces, use burners capable of providinga “long and narrow” flame in any operating condition, namelyeven at the minimum output when controlling two or more stagesor modulating.Flames which are too short cause overheating in the front ofthe furnace and combustion products, not sufficiently cooled,entering the smoke pipes at too high temperatures can seriouslydamage the generator.
If necessary for clearance purposes, the door and the smokechamber can be removed to make it easier to enter the boilerroom.
Installation instructions
19
The manufacturing companies of the burners can supply thedimensions of the flames which their appliances develop,especially those approved based on the standards indicatedabove.Further information is provided in the chapter “Commissioning”.
BOILER TYPE øAmm
Lmm
fig. 20
DIMENSIONS OF BURNER BLAST TUBE
3.6 -CONNECTING FLAME SIGHT GLASSTO BURNER
The flame sight glass is provided with a 1/8" threaded connection(pos. 1) upon which a 9 mm pressure test nipple is mounted.It can be used with a silicon tube to measure the backpressurein the combustion chamber.In place of this test nipple, which must be kept, an appropriatefitting will be mounted to connect the flame sight glass directlyto the pressure chamber downstream the burner fan by meansof a copper tube (pos.2).The air blown by the fan will conveniently cool the sight glassand keep it from blackening.If the cooling tube is not connected to the sight glass, it couldbreak.ATTENTION: the flame sight glass can be very hot; thereforepay the utmost attention.
fig. 21
3.5.2 - INSTALLING THE BURNER
The burner must be mounted to the door of the boiler guaranteeingperfect sealing of the combustion products.The burner is supplied with a piece of ceramic fibre cordwhich must be placed on the blast tube of the burner tofully seal the space between the blast tube and the slot inthe door.Make sure that no gaps remain between the blast tube and theslot on the refractory material inside the door.Should a cone larger than the diameter of the blast tube bemounted, it must be removed before mounting the burner on
the support plate and put back afterwards.With the burner mounted, check that the electric cables arelong enough to allow the door to open 90°.For gas-fired burners, flexible hoses cannot be used forconnections. Therefore it must be possible to disconnect thefinal section of the gas adduction tube by means of a threadedor flanged joint.
TRISTAR 2000÷2350 380 350
TRISTAR 1400÷1650 320 320
TRISTAR 1000÷1180 320 300
TRISTAR 680÷870 270 270
TRISTAR 260÷560 220 250
TRISTAR 150÷215 180 250
TRISTAR 2700 380 400
TRISTAR 3100÷3500 400 400
TRISTAR 125 150 170
TRISTAR 80 130 150
20
Installation instructions
150
150
25*
**
FLOOR HEATINGPLANT
TO CONDENSATEDRAIN
SOCKET (H min 100 mm)
FILLING PLUG INITIALOF THE SIPHON
SMOKE CHAMBER The upper generatrix of the exhaust pipe mustnot be at a higher level the bottom of thesmoke chamber.
To connect the flue gas exhaust pipe, local and national standardsmust be respected.
The TRISTAR boiler can be attached to the chimney in differentways; straight pipes or elbows can be used to exit from therear, on the left, on the right, or else vertically to enter into theflue at a higher level.It is recommended to insulate the pipe connecting to the chimneyto reduce heat loss and noise.Along the section connecting the boiler to the flue theremust be suitable points for measuring flue gas temperatureand analysing combustion products.
Use only exhaust pipes suitable for the typeof fuel used.The supplier will have no contractual or extra-contractual liability for damage caused due toincorrect installation and use and anyway failureto comply with the instructions provided bythe manufacturer.
When performing replacement installations, ALWAYSreplace the flue gas exhaust accessory as well.
The flue must comply with standards in force.
3.7 - FLUE CONNECTION
CONDENSATION UPON COMMISSIONING
While the boiler is reaching the operating temperature, a goodamount of condensation can be formed due to the lowtemperature of the flue gas.In these conditions, it could be useful to have the condensationdrained into the sewer. For this purpose, the smoke chamberis equipped with an attachment which the exhaust pipes willbe connected to according to the following notesWhen the operating temperature has been reached - see notesin chap. 3.22 “COMMISSIONING” - it is important to checkwhether more condensation has been formed.This can be checked by direct inspection through the cleaningdoors of the smoke chamber.If not, after having verified the actual fuel flow rates, the operatingtemperature 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
outflow of liquid waste preventing any leakage;- installed in such a way to prevent liquid from freezing
in the intended operating conditions;- mixed for example with household wastewater (washer,
dishwasher drainage, etc.) for the most part with basicpH in order to form a buffer solution to then be introducedin the sewer system.
Condensation must not stagnate in the combustion productdrainage system (for this reason the evacuation duct must slopeat least 30 mm/m towards the drain) except for a liquid seal,present in the drainage siphon for the evacuation of combustionproducts (which must be filled after assembly and must remainat least 25 mm high with the boiler running - see fig. 22).Do not discharge condensation through gutter drainpipes dueto the risk of turning into ice and the deterioration of the materialsusually used to make the drainpipes (consult local hygieneregulations).The drain fitting must be visible.Due to the acidity level of the condensation (pH from 3 to 5)only suitable plastic materials must be used for the drain piping(special optional kits with neutralizer salts for acid condensationare available).
* Minimum safety siphon set by the standard** Minimum head with boiler running at maximum power.
If you do not want to or cannot create a plinth, the boilercan be mounted at ground level and a sump at least 100mm deep can be made to house the siphon.
fig. 22
3.8 - DRAINING CONDENSATION
Installation instructions
21
3.9 -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; this however does not reduce its insulationcapacity nor jeopardise its lifespan.
3.9.1 “TST 80÷TST 125” BOILERS
For all these models, the door is hinged andfixed according to the layout in fig. 23.In these cases, the door is mounted with tworotation hinges on the left, and two closingpins on the right; the two hinges on the leftallow the door to be closed from this sideas well, by means of 4 screws (pos. C).It will be exactly the opposite when the door isopened from the left to the right.To invert rotation, just swap the hinges.The following adjustments can be made on thedoor of these boiler models:A) Vertical adjustment: by loosening the screws
“A” and lifting the door; then fasten the screws “A”.B) Crosswise rotation: loosening the hinges “B” fixed on the
front plate of the boiler and moving them sideways.C) Axial rotation: screwing different tightening screws “C”.
fig. 23
- The door fibre is easy to replace and is covered by atwo-year warranty.
3.9.2 - “TST 150÷TST 560” BOILERS
For all these models, the door is hinged andfixed according to the layout in fig. 24.In these cases, the door is mounted with fourequal hinges: the two on the left side, with the pininserted are normally used as rotation hinges(from right to left), while the two on the right areused as closing hinges; the door is then securedwith 4 screws.It will be exactly the opposite when the door isopened from the left to the right.To invert rotation, just move the pins to the oppositeside.The following adjustments can be made on the door ofthese boiler models:A) Vertical adjustment: only by inserting suitably thick washers
below the hinge which the door turns on.B) Crosswise rotation: loosening the hinges fixed on the front
plate of the boiler and moving them sideways.C) Axial rotation: screwing different tightening screws.
fig. 24
22
Installation instructions
3.9.3 - “TST 680÷TST 870” BOILERS
For all these models, the door is hinged and fixed according tothe layout in fig. 25.In these cases, the two hinges on the left are normally used asrotation hinges (from right to left), while the two on the rightare used as closing hinges.It will be exactly the opposite when the door is opened fromthe left to the right.To invert rotation, just move the rear locknuts to the opposite side.The following adjustments can be made on the door of theseboiler models:A) Vertical adjustment: by acting on the nut of the upper hinge
pin which the door turns on.B) Crosswise rotation: loosening the hinges fixed on the front
plate of the boiler and moving them sideways.C) Axial rotation: screwing different tightening nuts.
fig. 25
3.9.4 - “TST 1000÷TST 3500” BOILERS
For all these models, the door is hinged and fixed according tothe layout in fig. 26:In these cases, the two hinges on the left are normally used asrotation hinges (from right to left), while the two on the rightare used as closing hinges.It will be exactly the opposite when the door is opened from theleft to the right.To invert rotation, just move the door support bushings.The following adjustments can be made on the door of theseboiler models:A) Vertical adjustment: by acting on the nut of the upper hinge
pin which the door turns on.B) Crosswise rotation: loosening the hinges fixed on the front
plate of the boiler and moving them sideways.C) Axial rotation: screwing different tightening nuts.
fig. 26
3.9.5 - IMPORTANT NOTE
Before opening the door of the furnace, take the following safetymeasures:- Close the fuel supply to the burner.- Cool the boiler off by having water circulate and then
disconnect electrical power.- Place a sign on the boiler with the following text: DO NOT
USE, BOILER MAINTENANCE UNDERWAY, OUT OFSERVICE.
Installation instructions
23
3.10 - CONNECTING BOILER TO SYSTEM
Attention!Before connecting the boiler to the heatingsystem, thoroughly clean the piping with anappropriate product in order to eliminatemetallic residue from processing and welding,oil and grease which could be present andwhich, reaching the boiler, could alter itsfunctioning.Do not use solvents to wash the system asthey could damage the system and/or itscomponents.Failure to comply with the instructions of thefollowing manual can cause damage topersons, animals and objects for which themanufacturer cannot be held responsible.
Attention!Make sure that there are no mechanicaltension points while connecting the pipesto avoid the risk of leakage!
Heating flow and return pipes must be connected to the boilerat the respective fittings as indicated on pages 9, 10, 11, 12and 13.
For the dimensioning of the heating circuit pipes, you musttake into account pressure drops caused by radiators,thermostatic valves, radiator stopping valves and by theconfiguration of the system.
The laying of the pipes must be designed taking every necessaryprecaution to avoid air pockets and to facilitate continuousdegassing of the system.
Make sure that the pipes of the water and heatingsystem are not used as earthing electrodes ofthe electric or telephone system.They are absolutely not suitable for this type ofuse. Serious damage could result for the piping,boiler and radiators in a short amount of time.
Heating system safety valve drain
Provide a drain pipe with a funnel and a siphon leading to anappropriate drainage at the heating safety valve.This drainage must be controlled on sight.
Attention!If this precaution is not taken, triggering ofthe safety valve can cause damage topersons, animals and objects for which themanufacturer cannot be held responsible.
Connection of expansion vessel
TRISTAR boilers are suitable for operating with forced watercirculation both with the expansion vessel opened or closed.An expansion vessel is always necessary to compensate theincrease in water volume due to heating.
The connection pipes of the expansion vessel willstart from the T3 attachment (see DIMENSIONSTABLES) and must have no shut-off valve.
Connection of filling/draining tap
A specific tap can be connected to the T4 attachment at therear of the boiler for filling and draining.
3.10.1 - RECIRCULATION PUMP
TRISTAR boilers must always operate with forced water circulationand an average temperature of 50°C or higher.It is therefore recommended to use a recirculation pump, whichalso has an anti-condensation function, installed between theflow and return connections upstream the mixer valve.This pump should be dimensioned according to the formula:
Q = P x 22
where Q = Flow rate in l/hrP = Nominal output of boiler in kW
and head 1÷2 m H2O
3.11 - FILLING THE SYSTEM
Attention!Do not mix the heating water with incorrectconcentrations of antifreeze or anti-corrosionsubstances! This could damage the gasketsand cause noise during operation.Unical will not be held liable for damage topersons, animals or objects due to failureto comply with the instruction above.
When all system connections have been completed, the circuitcan be filled.This operation must be performed carefully, respecting thefollowing phases:- Open the radiator air release valves.- Open the filling tap gradually, making sure that the automatic
air release valves installed on the system work properly.- Close the radiator air release valves as soon as water
24
Installation instructionsomes out.- Check the pressure gauge until pressure reaches approxi-
mately 1 bar.- Close the filling tap and bleed air once again through the
radiator air release valves.- Make sure that all the connections are watertight.- After commissioning the boiler and bringing the system to
the operating temperature, stop the pumps and repeat theair bleed operations.
- Let the system cool off and, if necessary, return the waterpressure to 1 bar.
NOTEThe water pressure in the heating system mustnot be drop below 1 bar; open the filling tap onthe boiler when pressure is too low.This operation must be performed with the sy-stem cool.
NOTEIf the boiler was without electric power, after acertain idle period, the pump could be blocked.Before turning on the main switch, the pump mustbe unblocked by operating as follows:Introduce a screwdriver in the hole below the pro-tective screw in the centre of the pump intendedfor this purpose and turn the pump shaftclockwise.After having unblocked the pump, tighten the pro-tective screw and make sure there is no waterleakage.
ATTENTION!After removing the protective screw, a smallamount of water could leak out. Dry off all wetsurfaces before powering the boiler.
3.12 - CONNECTING GAS
Danger!The gas connection must be carried out onlyby a qualified installer who must respect andapply that foreseen by relevant laws in forcein the local prescriptions of the supply com-pany. Incorrect installation can cause dama-ge to persons, animals and objects for whi-ch the manufacturer cannot be held respon-sible.
Before installation, we recommend a thorou-gh inner cleaning of all fuel adduction pi-ping to remove any residue which could jeo-pardise proper operation of the boiler.
Attention!Make sure that there are no mechanical ten-sion points while connecting gas to avoid therisk of leakage!
Perceiving the smell of gas:a) Do not turn electric switches on or off,
use a telephone or any other object whi-ch can create sparks.
b) Immediately open doors and windows tocreate an air current to air out the room;
c) Shut the gas cocks.d) Request the intervention of professional-
ly qualified personnel.
As a precaution against gas leaks, we recom-mend installing a monitoring and protectionsystem consisting in a gas leak detector cou-pled with a shut-off solenoid valve on the gasfeed line.
The supply pipes must have a cross-section sufficient for theflow rate of the burner.
You should nonetheless comply with the “General installationregulations” laid down in the standards.
Before commissioning an internal gas distribution system andtherefore before connecting it to the gas meter, check its sealingcarefully.
If any part of the system is out of sight, the sealing test mustbe done before the pipes are covered.
Before connecting the appliances, the system must be testedwith air or inert gas at a pressure of at least 100 mbar.
The following operations and checks must also be performedwhile commissioning the system:- Open the meter and air release valve to bleed the air from
the piping of the appliances, proceeding one appliance afteranother.
- With the appliances closed, check that there are no gasleaks. The pressure gauge must show no pressure dropduring the second quarter of an hour from the start of thetest. Gas leaks must be found with a soapy solution orsimilar product and eliminated.Never look for gas leaks with an open flame.
Installation instructions
25
3.13 - PACKAGING
TRISTAR boilers are supplied complete with the door and smokechamber assembled, while the casing and insulation are includedin separate cardboard packs.The panel and accessories are inside the combustion chamber.Before starting installation, make sure that the length and widthof the boiler body received correspond respectively to thedimensions M, Q and R of the boiler you have ordered, providedon the previous tables, and that the boxes containing the casing,or part of it, are marked as in the table at the bottom of thepage.The casing of boilers from TST 80 to TST 450, complete withinsulation mattresses, is contained in one box.The casing of boilers from TST 560 to TST 2000 is containedin 3 boxes.The casing of TST 2350 boilers is contained in 4 boxes.The casing of TST 2700 and TST 3100 boilers is containedin 3 boxes.The casing of TST 3500 boilers is contained in 4 boxes.In addition to the panel board packed in its own box, thefollowing accessories are found in the combustion chamber:- 1 box containing hydraulic connection flanges, with
relative gaskets and bolts.- ceramic fibre cord to insulate between burner blast tube
and door.- 1 bag containing the condensation drainage kit.
Upon reception, make sure that the supply iscomplete and undamaged.
Keep the packaging material (cardboardbox, straps, plastic bags,etc.) out of the reach of children as they arepotential sources of danger.Unical will not be held liable for damage topersons, animals or objects due to failure tocomply with the instruction above.
The document envelope contains:- Hydraulic test certificate- Heating system booklet- System manager operating instructions- Installation and maintenance instruction booklet- Warranty- Local ventilation requirements label
N.B. For models from TST 80 to TST 450 (ref. fig. 27, 28, 29and 30), the casing and insulation are contained in 1 boxmarked:
31825 (TRISTAR 80)31826 (TRISTAR 125)50053 (TRISTAR 150)50054 (TRISTAR 215)50055 (TRISTAR 260)50056 (TRISTAR 300)50057 (TRISTAR 370)50058 (TRISTAR 450)
N.B. For model TST 560 (ref. fig. 29 and 30), for models fromTST 680 to TST 870 (ref. fig. 31 and 30) and for modelsfrom TST 1000 to TST 2000 (ref. fig. 32 and 35), the casingand insulation are contained in 3 boxes marked:
50059 (front casing TRISTAR 560)50060 (rear casing TRISTAR 560)50061 (top casing TRISTAR 560)50062 (front casing TRISTAR 680)50063 (rear casing TRISTAR 680)50064 (top casing TRISTAR 680)50062 (front casing TRISTAR 780)50065 (rear casing TRISTAR 780)50066 (top casing TRISTAR 780)50062 (front casing TRISTAR 870)50067 (rear casing TRISTAR 870)50068 (top casing TRISTAR 870)50069 (front casing TRISTAR 1000)50070 (rear casing TRISTAR 1000)50071 (top casing TRISTAR 1000)50069 (front casing TRISTAR 1180)
50072 (rear casing TRISTAR 1180)50073 (top casing TRISTAR 1180)50074 (front casing TRISTAR 1400)50075 (rear casing TRISTAR 1400)50076 (top casing TRISTAR 1400)50074 (front casing TRISTAR 1650)50077 (rear casing TRISTAR 1650)50078 (top casing TRISTAR 1650)50079 (front casing TRISTAR 2000)50080 (rear casing TRISTAR 2000)50081 (top casing TRISTAR 2000)
N.B. For the TST 2350 model (ref. fig. 33 and 35) the casingand insulation are contained in 4 boxes marked:For models TST 2700 and TST 3100 (ref. fig. 34 e 35), thecasing and insulation are contained in 3 boxes.For the model TST 3500 (ref. fig. 34 and 35) the casingand insulation are contained in 4 boxes marked:
50079 (front casing TRISTAR 2350)50082 (rear casing TRISTAR 2350)50084 (top casing TRISTAR 2350)50083 (central casing TRISTAR 2350)30111 (front casing TRISTAR 2700)30112 (rear casing TRISTAR 2700)30113 (central casing TRISTAR 2700)30114 (front casing TRISTAR 3100)30115 (rear casing TRISTAR 3100)30116 (central casing TRISTAR 3100)30114 (front casing TRISTAR 3500)30115 (rear casing TRISTAR 3500)30116 (central casing TRISTAR 3500)30543 (rear casing TRISTAR 3500)
26
Installation instructions
3.14 - ASSEMBLING CASING
TRISTAR 80÷125
fig. 27
Close the cover of the electric control board.E) Mount the top crosspiece pos. 6, fitting it onto the top front
panel pos. 5 and placing it on the sides..Mount the rear panel pos. 7 fitting it on the crosspiece pos. 6and pressing the back to join the junction pin with the sides.
F) Fix the boiler data plates (pos.8) to the side panel after havingdegreased the relevant part with the specific solvent.The plates are included in the document envelope.
Assembly sequence (Ref. fig. 27)
A) Mount the insulation (pos. 1) of the boiler body and securethe 2 edges with the elastic straps (pos. 2) supplied in theaccessory box, hooking them to the external fabric part ofthe insulation.
B) Position the side panels (pos. 3 e 4) with the lower bendinside the L-shaped profile at the base of the boiler bodyand hook the upper part in the plate cuts.To determine which is the right side and which is the leftside, refer to the cable glands: they must face the front ofthe boiler.
C) Rotate the cover of the panel board frontwards after havingremoved the two screws on the side and insert the electricinlet cables and the outlet probe capillaries through the slotsat the base.Fit the panel board to the upper panel (pos. 5).Fit the upper panel (pos. 5), complete with panel board, tothe two sides of the casing.
D) Insert the bulbs of the instruments into the conduits asindicated in fig. 28, pass the electric cables through theside cable glands from the preferred side and wire the panelboard to the power line, to the burner and to any pumps,etc.
Installation instructions
27
fig. 28
1 Thermometer probe2 Working thermostat probe3 Safety thermostat probe4 Minimum thermostat probe5 Safety spring6 Probe bulb holders
TRISTAR 150÷560
fig. 294 91
2
8
1011
12
9
6
3
28
Installation instructions
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. 9) on thepreferred side and secure the cable with the cable glandsupplied.Fasten the plates (pos. 9) to the sides of the casing.Secure the electric cables coming out from the rear of theboiler with the cable clamps, tightening them moderately.
F) Fit the upper longitudinal panels (pos. 10 and 11) hookingthem to the sides.
G) Fix the boiler data plates (pos.12) to the side panel after havingdegreased the relevant part with the specific solvent.The plates are included in the document envelope.
Assembly sequence (Ref. fig. 29)
A) Mount the insulation (pos. 1) of the boiler body and securethe 2 edges with the elastic straps (pos. 2) supplied in theaccessory box, hooking them to the external fabric part ofthe insulation.
B) Position the side panels (pos. 3 e 4) with the lower bendinside the L-shaped profile at the base of the boiler bodyand hook the upper part in the plate cuts.To determine which is the right side and which is the leftside, refer to the cable gland plates (pos. 9): they must facethe front of the boiler.
C) Fit the upper rear panel (pos. 6) with the specific self-threadingscrews.
D) Rotate the cover of the panel board frontwards after havingremoved the two screws on the side and insert the electricinlet cables and the outlet probe capillaries through the slotsat the base.Fit the panel board to the upper panel (pos. 8).Fit the upper panel (pos. 8), complete with panel board, tothe two sides of the casing.
E) Insert the bulbs of the instruments into the conduits asindicated in fig. 30 and wire the panel board to the power
fig. 30
1 Thermometer probe2 Working thermostat probe3 Safety thermostat probe4 Minimum thermostat probe5 Safety spring6 Probe bulb holders
Installation instructions
29
Assembly sequence (Ref. fig. 31)
A) Mount the insulation (pos. 1) of the boiler body and securethe 2 edges with the elastic straps (pos. 2) supplied in theaccessory box, hooking them to the external fabric part ofthe insulation.
B) Position the side panels (pos. 3a, 3b and 4a, 4b) with thelower bend inside the L-shaped profile at the base of theboiler body and hook the upper part to plate junction profiles.To determine which is the right side and which is the left side,refer to the cable gland plates on the front panels (pos. 5):they must face the front of the boiler.Fasten the 4 countersunk screws (pos. 7) to the two sides3b and 4b on the inner rear side.
C) Fasten 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 electricinlet cables and the outlet probe capillaries through theslots at the base.Fit the panel board to the upper panel (pos. 10).Fit the upper panel (pos. 10), complete with panel board, tothe two sides of the casing.
E) Insert the bulbs of the instruments into the conduits asindicated in fig. 30 and wire the panel board to the powerline, to the burner and to any pumps, etc.Close the cover of the electric control board.
TRISTAR 680÷870
fig. 31
2
3a
3b / 4b
3b
11 12
4a
4b
51
8
13
7
5
10
30
Installation instructions
Assembly sequence (Ref. fig. 32)
A) Mount the insulation (pos. 1) of the boiler body and securethe 2 edges with the elastic straps (pos. 2) supplied in theaccessory box, hooking them to the external fabric part ofthe insulation.Perform a sufficient cut on the top part near the bulb holders.
B) Position the side panels (pos. 3a, 3b and 4a, 4b) with thelower bend inside the L-shaped profile at the base of theboiler body and hook the upper part to plate junction profiles.To determine which is the right side and which is the left side,refer to the cable gland plates on the front panels (pos. 5):they must face the front of the boiler.
C) Fit the upper rear panel (pos. 7).D) Rotate the cover of the panel board frontwards after having
removed the two screws on the side and insert the electricinlet cables and the outlet probe capillaries through the slotsat the base.Fit the panel board to the upper panel (pos. 9).Fit the upper panel (pos. 9), complete with panel board, tothe two sides of the casing.
E) Insert the bulbs of the instruments into the conduits asindicated in fig. 35 and wire the panel board to the powerline, 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 thepreferred side and secure the cable with the cable glandsupplied.Fasten the plates (pos. 5) to the sides of the casing.Secure the electric cables coming out from the rear of theboiler with the cable clamps, tightening them moderately.
F) Fit the upper longitudinal panels (pos. 10 and 11) to thesides of the casing.
G) Fix the boiler data plates (pos.12) to the side panel afterhaving degreased the relevant part with the specific solvent.The plates are included in the document envelope.
Guide the burner plug through the side plate (pos. 5) on thepreferred side and secure the cable with the cable glandsupplied.Fasten the plates (pos. 5) to the sides of the casing.Secure the electric cables coming out from the rear of theboiler with the cable clamps, tightening them moderately.
F) Fit the upper longitudinal panels (pos. 11 and 12) to thesides of the casing.
G) Fix the boiler data plates (pos.13) to the side panel after havingdegreased the relevant part with the specific solvent.The plates are included in the document envelope.
Installation instructions
31
TRISTAR 1000÷2000
fig. 32
2
5
3b3c
9
10
11
7
4a 51
4c
4b
3a
32
Installation instructions
TRISTAR 2350
Assembly sequence (Ref. fig. 33)
A) Mount the insulation (pos. 1) of the boiler body and securethe 2 edges with the elastic straps (pos. 2) supplied in theaccessory box, hooking them to the external fabric part ofthe insulation.Perform a sufficient cut on the top part near the bulb holders.
B) Position the side panels (pos. 3a, 3b, 3c and 4a, 4b, 4c)with the lower bend inside the L-shaped profile at the baseof the boiler body and hook the upper part to plate junctionprofiles.To determine which is the right side and which is the leftside, refer to the cable gland plates on the front panels (pos. 5):they must face the front of the boiler.
C) Fit the upper rear panel (pos. 6).D) Rotate the cover of the panel board frontwards after having
removed the two screws on the side and insert the electricinlet cables and the outlet probe capillaries through the slotsat the base.Fit the panel board to the upper panel (pos. 8).Fit the upper panel (pos. 8), complete with panel board, tothe two sides of the casing.
E) Insert the bulbs of the instruments in the conduits asindicated in fig. 35 and wire the panel board to the powerline, 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 thepreferred side and secure the cable with the cable glandsupplied.Fasten the plates (pos. 5) to the sides of the casing.Secure the electric cables coming out from the rear of theboiler with the cable clamps, tightening them moderately.
F) Fit the upper longitudinal panels (pos. 9 and 10) to thesides of the casing.
G)Mount the top panel support (pos. 11), inserting it belowthe top panels - rear side.
H) Fit the upper longitudinal panels (pos. 12 and 13) to thesides of the casing.
I) Fix the boiler data plate (pos.14) to the side panel after havingdegreased the relevant part with the specific solvent.The plates are included in the document envelope.
fig. 33
Installation instructions
33
Assembly sequence (Ref. fig. 34)
A) Mount the insulation (pos. 1) of the boiler body and securethe 2 edges with the elastic straps supplied in the accessorybox, hooking them to the external fabric part of the insulation.Perform a sufficient cut on the top part near the bulb holders.
B) Note: for the model TST 3500, aside from the rear panelspos. 3 (2 per side), 2 side panels are supplied (400 mmlong)(not viewed) which must be mounted on the backof the boiler, 1 each side.Position the left side panels (pos. 2 and 3) with the lowerbend inside the L-shaped profile at the base of the boilerbody and hook the upper part in the screws fastened on thetop longitudinal pipe.To determine which of the front sides is right and which isleft, refer to the holes to fix the panel board; it must face thefront of the boiler.The hole-covering panel pos. 4 is already mounted.
C) Position the right side panels (pos. 6 and 3) with the lowerbend inside the L-shaped profile at the base of the boilerbody and hook the upper part in the screws fastened on thetop longitudinal pipe.
D) Fit the panel board to the side panel (pos. 6.Rotate the cover of the panel board frontwards after havingremoved the two screws on the side and insert the electricinlet cables and the outlet probe capillaries through the slotsat the base.
E) Insert the bulbs of the instruments in the conduits as indicatedin fig. 35 and wire the panel board to the power line, to theburner and to any pumps, etc.Close the cover of the electric control board.Guide the burner plug through the side plate (pos. 7) on thepreferred side and secure the cable with the cable gland.Fasten the plates (pos. 7) to the sides of the casing.
F) Fix the boiler data plates to the side panel after havingdegreased the relevant part with the specific solvent.The plates are included in the document envelope.
TRISTAR 2700 - 3500
fig. 34
34
Installation instructions
Probe insertion sequence
Following this sequence, insert the probes of theinstruments in the bulb holder/s on the top of theboiler (ref. fig. 35): of the thermometer (pos.1), of theworking thermostat (pos. 2), of the safety thermostat(pos. 3), of the minimum thermostat (pos. 4).It is recommended to insert the probes all the wayin the relative bulb holders for best contact.Then insert the contact spring (pos. 6) and fasten thecapillaries with the fixing clip/s (pos. 5).
fig. 35
Installation instructions
35
3.15 - ELECTRICAL CONNECTIONS
General warnings
The electrical safety of the appliance is guaranteed only whenit has been properly connected to an efficient earthing systemcarried out as intended by safety standards in force: pipes ofthe gas, water and heating systems are absolutely unsuitableas earthing electrodes.
It is necessary to verify this fundamental safety requirement.If in doubt, have the electric system carefully checked byprofessionally qualified personnel as the manufacturer is notliable for damage caused by failure to provide an earthingsystem.
Have professionally qualified personnel check that the electricsystem is adequate for the maximum power absorbed by theappliance, indicated on the data plate. Make sure in particularthat the cross-section of the cables is suitable for the powerabsorbed by the appliance.
Adapters, multiple sockets and/or extension cords cannot beused to power the appliance.
Use of any type of component using electric energy requiresthe 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
The electrical connections are illustrated in chap. 3.16, 3.17,3.18, 3.19, 3.21.
Boiler installation requires connection to a 230 V - 50 Hz electricmains: this connection must performed up to standard asintended by current IEC regulations.
Danger!Only a qualified technician may perform theelectrical installation.Before performing connections or any typeof operation on electrical parts, alwaysdisconnect electrical power and make surethat it cannot be reconnected accidentally.
Remember that a bipolar switch must be installed on the boilerpower line with over 3 mm between contacts, easy to access,making maintenance quick and safe.
The power cable must be replaced by authorisedtechnical personnel. Failure to comply with theabove can jeopardise the safety of the appliance.
36
Installation instructions
E
E
E E
L1 T2N S3T1 B4
IG
11 41
3232
12
13
31
230V~ 50Hz
2
1
3
4
4-4
24 14
C
2 1
22 12
21 11
C
2
G-V
6-6
7-7
8-8
9-9
10-1
0
Ts
7 14 15 166 95 8 10
BA
20 21
24
Pi
18
1723
22
19
11
12
Ipi
Ib
(50°C)
(60°÷90°C) (54°÷84°C)
(100°C)Tm
Te1
F1 (max 4 A)
Te2
13
C
N
Ph
B5 T6 T7 T8
1 stage burner plugst 2 stage burner plug (optional)nd
3.16 - STANDARD PANEL BOARD
fig. 3611Main switch with indicator light12Burner switch13System pump switch31Safety thermostat
32Working thermostat41General fuse42Boiler thermometer
Ta Room thermostatTe1 Working thermostat stage 1
(60°C÷90°C)Te2 Working thermostat stage 2
(54°C÷84°C)Tm Minimum thermostat (50°C)
PhPhase (230V ~50Hz)N NeutralF1General fuse (max 4A)Ib Burner switchIG Main switch with indicator lightIpi System pump switch
fig. 37
TsSafety thermostat (100°C)Pi System pumpA Possible repetition of burner blockB Possible working hour counter stage 1C Possible working hour counter stage 2
If the Room thermostat is mounted,remove the bridge 11-12
The main switch 11 powers the board and the equipmentconnected to it.The switches 12 and 13 in turn cut power to the burner andto the system pump.The thermostat 32 adjusts the working temperature of theboiler.The working thermostat is provided with two switchingcontacts 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 afterhaving lifted the cover of the electric control board, stops thesystem pump until the boiler reaches the temperature of 50°C.The electric power line of the boiler’s control board must have aswitch with protective fuses.
For use of the panel board, see the system manager instruction booklet
Installation instructions
37
3.17 - HYDRAULIC AND ELECTRIC SYSTEMCONNECTION
Fig. 38 and 39 show the typical layout of the connection of theboiler to the heating system with production of domestic hotwater.Remember that TRISTAR boilers operate with forced circulation.
Key:Pr = recirculation pumpVM = zone mixer valvePi = heating system pumpVE = open expansion vesselIR = heating system distributionPs = DHW recirculation pumpPc = DHW production charge pumpTA = room thermostat
The standard panel board of the TRISTAR boiler automaticallyswitches the burner off when the temperature in the boilerreaches the value set on the control thermostat.It also manages the system pump, which will only be activatedwhen 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-stage or modulating burners.With this layout configuration, the DHW storage tank loadingpump will have the priority over the heating system pump.
fig. 38
TRISTAR BOILER DOMESTIC HOT WATER PRODUCER
38
Installation instructions
fig. 39
NOTE: With absorption beyond 4A, place adequate contactors between the panel board and the loads
TRISTAR BOILER DOMESTIC HOT WATER PRODUCER
POWER SUPPLY
POWER SUPPLY
POWER SUPPLY
TO THE 7-POLE SOCKETOF THE BURNER
Installation instructions
39
fig. 40
3.18 - OPTIONAL PANEL BOARD
11Main switch with indicator light12Burner switch13Mixed zone system pump switch14Direct zone system pump switch15Storage tank pump switch
31Safety thermostat32Working thermostat41General fuse42Boiler thermometer
fig. 41
The main switch 11 powers the board and the equipmentconnected to it.Switches 12 and 13 in turn control the burner and the mixedzone system pump.Switches 14 and 15 control the direct zone system pumpand the storage tank pump.The working temperature of the boiler is regulated by theheating controller: to achieve this, the thermostat must beplaced at maximum full-scale pos. 32 .
Eventual operation of the second stage of the burner will bemanaged by the heat control.The default setting of the heating controller stops the systempump until the boiler reaches the temperature of 50°C.The electric power line of the boiler’s control board must havea switch with protective fuses.
For use of the panel board, see the system manager instruction booklet
Ipi2 System pump 2 switchIpb Storage tank pump switchPb Storage tank pumpPi1 Direct zone system pumpPi2 Mixed zone system pumpTe Working thermostat
PhPhase (230V ~50Hz)N NeutralF1General fuse (max 4A)Ib Burner switchIG Main switch with indicator lightIpi1 System pump 1 switch
Tm Minimum thermostatTsSafety thermostat (100°C)Vm2 Mixer valveA Possible repetition of burner blockB Possible working hour counter stage 1
TERMINALS OF KROMSCHÖDERHEATING CONTROLLER
7-pole plug
40
Installation instructions
2 3 4 5 6 71 8 9 10 2 3 4 51IVII
1
N L1 L1'1
1 12
2
2
M M
2 T1 T2
4 3 2 1 3 2 1 2 1 2 1 4 3 2 18 7 6 510 9 2 1VIIIVVIIIIIIIX
+ - L 3Bus
H 1FBR VF VF AF KF/SPF VF 3 1
FBR DCF
II1
II1
II2
II2
II3
II3
II8
II8
II7
II7
II5
II5
II4
II4
II6
II6
IV4 IV3 II10
II10
II9
II9
47 41 4648 39 4448 3842 40 4345
IV4IV3
21VI
1
2
T3 T4
IV2IV1
12
- +-
1
FLO
WS
EN
SO
R 2
(V
F)
OU
TE
RS
EN
SO
R (
AF
)
RO
OM
SE
NS
OR
2 (
FB
R)
RO
OM
SE
NS
OR
1 (
FB
R)
BO
ILE
RS
EN
SO
R (
KF
)
D.H
.W.T
AN
KS
EN
SO
R (
SP
F)
3.19 - LAYOUT OF PROBE CONNECTION ON HEATING CONTROLLER code 30680
The heating controller probes (boiler, storage tank, external,flow) are included in the supply; the ambient probes 1 and 2are optional; the mixer valve and relative control motor are notincluded in the supply.Should ambient probes be mounted (optional), the room
temperature will only be determined with the boiler curve setby the program.If you intend on mounting 2 boilers in cascade, pleasecontact our after-sales service.
3.20 - PROGRAMMINGHEATING CONTROLLER
For that which concerns adjustment or programming of theheating controller, see the instruction booklets attached to thedevice.The following are the default parameters which cannot bemodified.As far as parameters which can be programmed by the useraccording to his requirements, see the system managerinstruction book.
fig. 42
Installation instructions
41
Default Individual valuesValue rangeDescription
INSTALLATION
CODE NUMBER
CODE NUMBER (adjustment)
BUS ID 11111
Exit level using
BUS ID 22222
AF SUPPLY
TEMPERATURE MASTER
MAX-BOILER
PARAMETERS PROGRAMMABLE BY TECHNICIAN AND PROTECTED BY ACCESS CODE
MIN-BOILER
T-WARM-UP
HYSTERESIS
HYSTERESIS TIME
BURNER TIME 2
BURNER HYSTERESIS 2
HEAT SEQ TEMP (*)
RELAY FUNCT
T MULTI-PROBE
MFR HYSTERESIS
RELAY 2 FUNCT
SCREED
see heating controller bookletSCREED PROGRAM
RETURN
Default Individual valuesValue rangeDescription
DOMESTIC HOT WATER PRODUCTION
CHARGE PUMP
PARALLEL PUMP
DHW TEMPERATURE
DHW HYSTERESIS
DHW TIME
INLET TEMPERATURE
THERM FUNCT
Exit level usingRETURN
L. MIN.
* NOTE: For cascade boilers, the technical installation parameter HEAT SEQ TEMP is 250h
0000 - 9999 ENTRY
0000 - 9999 0000
(00), 01 - 15 01
(00), 01 - 15 02
00,01 (OFF / ON) 01 = ON
00, 01 (OFF / ON) 00 = OFF
30 °C - 110 °C 80 °C
10 °C - 80 °C 60 °C
10 °C - 85 °C 50 °C
5K - 20K 5 degrees
00 min - 30 min 10 min
00 min - 30 min 10 min
2K - 20K 2 degrees
0h - 250h 0h (*)
00 - 08 00
30 °C - 90 °C 30 °C
2K - 10K 5 degrees
00
00 - 01 (OFF / ON) 00 = OFF
00, 01, 02 00
00 - 03
00 - 01 (OFF / ON) 01 = ON
00 , 01, 02, 03 00
00 °C - 50 °C 20 °C
5K - 30K 5 degrees
00 min - 30 min 00 min
00, 01 (OFF / ON) 00 = OFF
00, 01 (OFF / ON) 00 = OFF
42
Installation instructions
Default Individual valuesValue rangeDescription
HEATING CIRCUIT 2
HEATING CIRCUIT FUNCTION
PUMP MODE
MIXER OPEN(not in hot water circuit)MIXER CLOSED(not in hot water circuit)
MAX FLOW TEMPERATURE
MIN FLOW TEMPERATURE
FROST PROTECTION TEMP
OUTSIDE TEMP DELAY
HEATING SLOPE DISTANCE
REDUCTION
Exit level usingRETURN
Default Individual valuesValue rangeDescription
HEATING CIRCUIT 1
HEATING CIRCUIT FUNCTION
PUMP MODE
MIXER OPEN(not in hot water circuit)MIXER CLOSED(not in hot water circuit)
MAX FLOW TEMPERATURE
MIN FLOW TEMPERATURE
FROST PROTECTION TEMP
OUTSIDE TEMP DELAY
HEATING SLOPE DISTANCE
REDUCTION
Exit level usingRETURN
00 - 04 00
00 , 03 00
5 - 25 16
5 - 25 12
20 °C - 110 °C 80 °C
10 °C - 110 °C 10 °C
- - - -(-15)°C - (5)°C
0 °C
0:00 - 24:00 1
0K - 50K 5 degrees
00 - 01 (OFF / ON) 01 = ON
00 - 04 00
00 , 03 00
5 - 25 16
5 - 25 12
20 °C - 110 °C 45 °C
10 °C - 110 °C 10 °C
- - - -(-15)°C - (5)°C
0 °C
0:00 - 24:00 1
0K - 50K 5 degrees
00 - 01 (OFF / ON) 01 = ON
Installation instructions
43
VM2
Ps
Pi2
Pb
IR2
VFAS
SPFS
VE Pr
KFS
Pi1
IR1
23
45
67
18
910
23
45
1IV
II
1
NL1
L1'
1
11
2
2
2
MM
2T
1T
2
43
21
32
12
12
14
32
18
76
510
92
1V
III
VV
IIIIII
IX
+-
L3
Bus
H1
FB
R1
VFA
SV
FAS
AF
SK
FS/S
PFS
VFA
S3
1F
BR
1D
CF
12
3
21
VI
1
2
T3
T4
DOMESTIC HOT WATERPRODUCER
FLOWPROBE 2 (VFAS)
EXTERNALPROBE (AFS)
ROOMPROBE 2 (FBR1)
ROOMPROBE 1 (FBR1)
BOILERPROBE (KFS)
STORAGE TANKPROBE (SPFS)
TRISTAR BOILER
3.21 - HYDRAULIC AND ELECTRIC SYSTEMCONNECTION WITH OPTIONAL PANELBOARD
Fig. 43 and 44 show the typical layout of the connection of theboiler to the heating system consisting in 2 zones one of whichcontrolled by a motorised mixer valve.
Key:Pr = recirculation pumpVM2 = zone mixer valvePi1 = direct zone heating system pumpPi2 = mixed zone heating system pumpVE = open expansion vesselIR1 = direct zone heating
system distributionIR2 = mixed zone heating
system distributionPs = DHW recirculation pumpPb = DHW production charge pumpSPFS = storage tank probeKFS = boiler probeVFAS = flow probe 2
The optional panel board of the TRISTAR boiler automaticallyswitches the burner off when the temperature in the boiler reachesthe value set on the heating controller.It also manages the pump to fill a storage tank for DHWproduction.Two distinct heating zones are managed automatically basedon the data detected by the boiler, external, ambient and flowprobes.The main system pump (mixed zone) will only be activatedwhen 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-stage or modulating burners.With this layout configuration, the DHW storage tank loadingpump will have the priority over the heating system pump.The heating controller is capable of controlling various system
configurations:- One direct zone system without mixer valve: the flow probe
must not be mounted; the control unit only commands thesystem pump 1.
- One zone system with motorised mixer valve: the flow probe(downstream the mixer valve) must be fitted; the control unitcommands the system pump 2 and the mixer valve 2.
- 2 zone system: one direct and one with mixer valve; the controlunit controls: the system pump of the direct zone 1, the mixervalve 2 and the system pump 2 of the mixed zone.
fig. 43
DHW production can also be managed.Remember that TRISTAR boilers operate with forced circulation.
44
Installation instructions
11
1312
12
34
56
78
910
1112
1314
1516
1718
1920
2122
2324
L1N
L1N
L1N
NL1
T1T2
S3B4
LN
T1S3
T2B4
16
2526
2728
3029
3231
3534
3336
VE
Ps
Pr
Pb
IR1
SP
FS
1718P
i1
13
14 15
19
234567 189102345 1IV II
1
NL1L1'1
11 2
2
2
MM
2T1T2
432132121214321 8765 10921VII I V VIII III IX
+-L3Bus
H1FBR1
VFASVFASAFSKFS/SPFSVFAS31FBR1
DCF
123
2 1VI
1
2
T3T4
22
20
21V
M2
Pi2
IR2
VFA
S
KF
S
L1
L1
T2L
1L
1N
NN
L1L
1N
NT1
S3B4
TATA
T6T7
T8N
L1
L1
DO
ME
ST
IC H
OT
WAT
ER
PR
OD
UC
ER
FLO
WP
RO
BE
2 (
VFA
S)
EX
TE
RN
AL
PR
OB
E (
AF
S)
RO
OM
PR
OB
E 2
(F
BR
1)
RO
OM
PR
OB
E 1
(F
BR
1)
BO
ILE
RP
RO
BE
(K
FS
)
ST
OR
AG
ETA
NK
PR
OB
E (
SP
FS
)
PO
WE
R S
UP
PLY
230V
~ 5
0Hz
PO
WE
R S
UP
PLY
230V
~ 5
0Hz
PO
WE
R S
UP
PLY
230V
~ 5
0Hz
TOT
HE
7-P
OLE
SO
CK
ET
OF
TH
E B
UR
NE
R
TR
ISTA
R B
OIL
ER
NO
TE: W
ith a
bsor
ptio
n be
yond
4A
, pla
ce a
dequ
ate
cont
acto
rs b
etw
een
the
pane
l boa
rd a
nd th
e lo
ads
fig. 4
4
Installation instructions
45
3.22 - COMMISSIONING
Preliminary checks
Commissioning must be done by professio-nally qualified personnel. Unical will not beheld liable for damage to persons, animalsor objects due to failure to comply with theinstruction above.
Before commissioning the boiler, check that:
- installation complies with standards for the gas part andfor the electrical power;
- the adduction of combustion air and flue gas evacuation areperformed correctly according to that laid down by standardsin force;
- the fuel feed system is dimensioned according to the flowrate required for the boiler and is provided with all safetyand control systems prescribed by current standards;
- the power supply of the boiler is 230V - 50Hz;
- the system is filled with water (approximately 1 bar pressureon the pressure gauge with the pump stopped);
- any system shut-off gate valves are open;
- the gas used (TRISTAR with gas burner) corresponds toboiler calibration: if not, modify the boiler to use type of gasavailable; this operation must be carried out by qualifiedtechnical personnel according to standards in force;
- the gas feed valves (TRISTAR with gas burner) are open;
- there is no gas leakage (TRISTAR with gas burner);
- the external main switch is connected;
- the system safety valves are not blocked and are connectedto the sewer system drainage;
- there is no water leakage;
- ventilation conditions and minimum distances are guaranteedto perform maintenance should the boiler be enclosedbetween furniture or in a niche.
Switching boiler on and off
To switch the boiler on and off, see the “SYSTEM MANAGEROPERATING INSTRUCTIONS”.
Information for system manager
The system manager must be instructed concerning the useand operation of his heating system, in particular:• Give the system manager the “SYSTEM MANAGER
OPERATING INSTRUCTIONS”, as well as the other appliancedocuments inserted in the envelope inside the packaging.The system manager must keep this documentation forfuture consultation.
• Inform the system manager about the importance of the airvents and the flue gas exhaust system, highlighting theiressential features and the absolute prohibition of modifyingthem.
• Inform the system manager concerning control of the system’swater pressure as well as operations to restore it.
• Inform the system manager concerning correct control oftemperatures, control units/thermostats and radiators tosave energy.
• Remember that the system must receive regular maintenanceat least once a year and a combustion analysis must beperformed in the timetable foreseen by standards in force.
• Should the appliance be sold or transferred to a new owneror if you move and leave the appliance, always make surethat the instruction booklet accompanies it in order to beconsulted by the new owner and/or installer.
TRISTAR boilers are forced circulation boilers: It is thereforenecessary to make sure that water circulates while theboiler is running.Do not allow the burner to run without the system pump beingactivated; otherwise the safety thermostat could be triggered.The return temperature must not drop below 47°C to avoid,or at least limit, flue gas condensation which causes prematuredeterioration of the boiler.The working temperature of the boiler can therefore beadjusted between 60 and 80°C. Room temperature will beregulated by the mixer valve commanded by the heating controller.The system must slowly reach the operating temperature, withthe eventual insertion in the secondary ring circuit, to avoidthe temperature from dropping below 47°C.It is always recommended to install an anti-condensation orrecirculation pump (between the flow and return lines of theboiler).Returns to low temperatures, below 47°C, cause the flue gasto condense corroding the heat exchange surfaces. You musttherefore pay the utmost attention while operating the system.Corrosion caused by acid condensation of combustionproducts is not covered by the warranty as it is attributableto operation of the system alone.
46
Installation instructions
3.23 - ADJUSTING THE BURNER
The following instructions are intended exclusivelyfor service personnel authorised by themanufacturer of the burner.
Burner calibration and preliminary operations are provided inthe burner’s instruction booklet.Gas-fired burners are equipped with a gas valve with which theflow rate can be determined: upon commissioning, the actual
thermal flow rate must always be controlled by means of thecounter on the main piping, making sure it is not below theminimum value on the data plate of the boiler.When the burner is adjusted properly, the values measured onthe chimney by the specific analyser should correspond to thoseon the tables on pages 14 and 15.
Inspections and maintenance performedprofessionally and according to a regularschedule as well as the use of original spareparts are of the utmost importance for fault-free operation of the boiler and to guaranteeits long life.Yearly maintenance of the appliance ismandatory in compliance with Laws in force.
Failure to perform Inspections andMaintenance can entail material and personaldamage.
We therefore recommend stipulating an inspection or maintenancecontract.
Inspections help to determine the actual status of the applianceand to compare it with the nominal status. This is done throughmeasuring, controls and observation.
Maintenance is required to eliminate any differences betweenthe actual status and the nominal status. This is normally doneby cleaning, setting and replacing individual components subjectto wear.
Maintenance intervals and their extent are determined by aspecialist based on the status of the appliance ascertainedthrough inspection.
Inspection and maintenance jobs must be performed in theorder shown on page 47.
Inspection and maintenance instructions
To assure long-term functioning of your applianceand to avoid altering its approved status, onlyoriginal Unical spare parts must be used.
Before proceeding with maintenance, always perform the followingoperations:• Disconnect the electric mains switch.• Isolate the appliance from the electric mains by means of
an isolated device with a contact opening of at least 3 mm(e.g. safety devices or power switches) and make sure thatit cannot be re-connected accidentally.
• Close the gas shut-off valve upstream the boiler.• Close any shut-off valves on the heating flow and return
pipes.
After having completed all maintenance work, always performthe following operations:• Open the heating flow and return pipes.• If necessary, restore the heating system pressure until it
reaches the static pressure relative to the highest point ofthe system.
• Open the gas shut-off valve.• Reconnect the appliance to the electric mains and engage
the switch.• Make sure the appliance is gas tight and watertight.• Vent the heating system and restore pressure if necessary.
Should you decide to temporarily deactivate the boiler, youmust:a) shut off the various supplies: electric, water and fuel;b) empty the water system if antifreeze is not used.
4 INSPECTIONS ANDMAINTENANCE
Inspections and maintenance
47
Boiler body maintenance
Danger!Before performing any maintenance, makesure the boiler and its components havecooled off.
Disconnect the boiler from the electric mainsand shut the gas supply to the appliance.
Attention!Before cleaning the boiler body, protect thepanel board against any water sprays.
Once a year, at the end of the heating season, the boiler mustreceive a general cleaning.Before performing any maintenance, make sure that all theprecautions referred to in the previous point have been taken.To proceed with maintenance you must:- disconnect power by acting on the main switch;- remove the burner, which could be overhauled at the
same time;- open the furnace door to access the combustion
chamber;- remove the smoke chamber access door;- make sure the internal parts are intact.
Checking status of gaskets and insulation fibres
The insulation fibre of the door can show cracksafter a short time of operation; this however doesnot reduce its insulation capacity nor jeopardiseits lifespan. Check the status of the seal gasketwhich must not show signs of deterioration; ifso, it must be replaced, using only original spareparts.
Check the status of the smoke chamber inspection covergasket.Replace it if worn, using only original spare parts.
Maintenance of burner
Burner maintenance must be carried out by personnel authorisedby its manufacturer (or else the warranty shall be terminated).
Checking ignition electrode
Burner maintenance must be carried out by personnel authorisedby its manufacturer (or else the warranty shall be terminated).
COMPONENT:
Ts (safety thermostat)
System expansion vessel
Door gaskets
Smoke chamber gaskets
VERIFY:
Does the thermostat place the boiler insafety when overheating?
Does the vessel contain the right amountof air?
Does smoke seep through the doorgaskets?
Does smoke seep through the smokechamber gaskets?
CONTROL/INTERVENTION MEASURE:
Bring the boiler to operating temperaturewith the pumps stopped.
Check the nitrogen pressure.Pressurise the boiler (open the pumpbleeder). Open the heating circuit closingvalves.
Further tighten the door screws.Replace the sealing gasket and possibly theinternal gasket of the door.
Further tighten the smoke chamber nuts.Replace the sealing gaskets.
Components to check during yearly inspection
46033 Casteldario - Mantova - ITALIA - tel. ++39.0376.57001 - telefax ++39.0376.660556www.unical.eu [email protected]
Unical will not be held responsible for possible inaccuracies if due to transcription or printing errors. It also reserves theright to modify its products as deemed necessary or useful, without jeopardising their essential features.
AG S.P.A.