44996 rev 1 tristar installatore gb - unical ag

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


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


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



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


fig. 5 fig. 6

T7Øemm

4040

10


Fiber wool

Ceramic fiber



ø 1

80

ø 1

80

95

TRISTAR 150÷560




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


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


fig. 8

fig. 7

fig. 9

T7Øemm

40

40

40

40

40

40

40


11

Refractory cement

Ceramic fiber



ø 2

70

ø 2

70

150

Imm






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


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


Refractory cement



ø 3

80

ø 3

80

190

Refractory cement



ø 3

20

ø 3

20

180

Refractory cement



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


TRISTAR 1000÷2350

TST 1000

TST 1180

TST 1400

TST 1650

TST 2000

TST 2350

TRISTAR

Model




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


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


13

Refractory cement



ø 3

80

ø 3

80

210

T1T2

UNI 2278 PN16

Hmm


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


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



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


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


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


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


15


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



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


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.


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


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.


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


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


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


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.


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.


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


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.


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


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.



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


29



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



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.


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.


31

TRISTAR 1000÷2000

fig. 32

2

5

3b3c

9

10

11

7

4a 51

4c

4b

3a

32


TRISTAR 2350


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.


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


33


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


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


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


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


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


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


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


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


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


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


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, 01 (OFF / ON) 00 = OFF

00, 01 (OFF / ON) 00 = OFF

42



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



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


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


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


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


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


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.

44996 rev 1 tristar installatore gb - unical ag

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