Unical TRIOPREX N Series User guide

26743 - 11/08

rev. 2

TRIOPREX N

INSTALLATION, USE AND

SERVICING INSTRUCTION

(to be kept by the user)

GENERAL INFORMATIONS

Introduction

This manual supplies a summary of what has to be followed during the installation, use and

servicing of the UNICAL boilers, TRIOPREX-N range.

In the course of this text the short name TX-N can be used to indicate theTRIOPREX-N boiler.

Choice of the boiler

For a correct choice and application of the TX-N boilers it is necessary to follow the instructions

given in this manual.

Installation

The installation of the boilers and the auxiliary equipments, related to the heating system,

must be in conformity with all the regulations and rules in force.

It is law that all the gas appliances are installed, commissioned and serviced by a registered

installer in accordance with the regulations below. Failure to install appliances correctly could

lead prosecution. It is in your own interest, and that of the safety, to ensure the law is complied

with.

The following must be complied with:

Current Building Regulations and Clean Air Act.

Water Authority Regulations.

Local Authority Regulations and Regional Bylaws.

Gas Safety Regulations.

Any special regional requirements of local Electricity and Gas undertaking.

Fire Service and Insurance Company requirements.

Commissioning

The main purpose of the commissioning is to verify the correct operation of all the safety and

control devices.

Before leaving the installation the commissioner has to control the operation of the boiler for,

at least, a complete working cycle.

Guarantee

The boiler guarantee is bound to the compliance of the the requirements stated in this manual,

and any non-fulfilment or modification will make it void.

Normative

It is the responsibility of the installer to fulfil all the regulations concerning the boiler house,

the safety devices, the chimney, the fuel supply lines, the electrical installations and all the

other local requirements and safety instructions.

Approvals

The UNICAL boilers, TRIOPREX-N range, have been tested and CE certified for the gas

operation by TECHNIGAS (BELGIUM), who has recognised to these boilers the conformity

certificate according to the following directives:

-Gas Appliances Directive (90/396 CE), compulsory as per 1st January 1996;

-Efficiency Directive (92/42 CE), compulsory as per 1st January 1998;

-The conformity to the Low Voltage Directive (73/23 CE), compulsory as per 1st January

1997 has been verified and ascertained by GASTEC ITALIA.

The conformity to the EMC (Electro Magnetic Compatibility 89/336 CE), compulsory as per

1st January 1996, is not applicable to the TRIOPREX-N boilers because they do not have

electronic components.

For the time beeing there are no European Directives covering the oil fired boilers, except the

Efficiency Directive (92/42 CE).

Data plate and Serial No.

The data plate, supplied in a separate enveloppe with the relevant documents, makes reference to

a serial No, embossed in an aluminium plate riveted to the front tube plate in the lower RH side

corner.

Use of the boiler

This boiler has to be used for heating the water at a temperature not higher than the

boiling temperature in the installation conditions.

WARNING

When the boiler is operated with a pressure jet gas burner, because it does not belong to any of the categories among those listed in the Annex II to

the Directive 97/23/CE (regarding pressure equipment) and beeing, furthermore, mentioned in the Directive 90/396/CE (Gas Appliance Directive)

to which the art. 1, clause 3, paragraph 6.5 makes reference, it is excluded from the scope of the Directive.

GAS SAFETY (INSTALLATION

AND USE) REGULATIONS,

1994

It is law that all gas appliances are installed

and serviced by a CORGI registered installer

in accordance with the above regulations.

Failure to install appliances correctly could

lead to prosecution.

It is in your own interest, and that of safety,

to ensure the law is complied with.

The installation of the boiler MUST also be

in accordance with the latest I.E.E. Wiring

Regulations, local building regulations, byelaws

of the local water authority, the building

regulations and the Building Standards

(Scotland) and any relevant requirements of

the local authority.

Detailed recommendations are contained in the

following British Standard Codes of Practice:

BS 6891 Low pressure installation pipes.

BS 5449 Forced circulation hot water

systems.

BS 5546 Installation of gas hot water

supplies for domestic purposes

(2nd Family Gases).

BS 6644 Ventilation (for gas appliances of

rated input exceeding 60 kW).

HEALTH & SAFETY

DOCUMENT No. 635

The Electricity at Work Regulations, 1989.

The manufacturer's notes must NOT be

taken, in any way, as overriding statutory

obligations.

IMPORTANT. These appliances are CE

certificated for safety and performance.

It is, therefore, important that no external

control devices, e.g. flue dampers, economisers

etc., are directly connected to these appliances

unless covered by these Installation and

Servicing Instructions or as otherwise

recommended by Unical in writing.

If in doubt please inquire.

Any direct connection of a control device not

approved by Unical could invalidate the

certification and the normal appliance warranty.

Notes.

To obtain the gas consumption:

a. For l/s divide the gross heat input (kW) by

C.V.of the gas (MJ/m³).

b. For ft³/h divide the gross heat input (Btu/h)

by C.V.of the gas (Btu/ft³).

CONSTRUCTIONAL-DIMENSIONAL

TECHNICAL CHARACTERISTICS .................... page 5

1.1 Construction of the TRIOPREX-N boilers ............................ page 5

1.2 Working principle ................................................................... page 5

1.3 Dimensions and hydraulic connections ................................ page 6

INSTALLATION .................................................................. page 11

2.1 Packaging .............................................................................. page 11

2.2 Handling ................................................................................. page 11

2.3 Positioning in the boiler house .............................................. page 11

2.4 Connection to the chimney................................................... page 12

2.5 Water connections ................................................................. page 12

2.5.1 Feeding water quality ................................................... page 12

2.5.2 C.H. flow and return connections ................................ page 12

2.5.3 Connection of filling & drain tap .................................. page 12

2.5.4 Connection of the pressure relief valve...................... page 12

2.5.5 Connection of the expansion pipe and vessel ............ page 12

2.5.6 Shunt pump .................................................................. page 13

2.6 Furnace door:adjustment, opening and closing .................. page 13

2.6.1 Important note .............................................................. page 13

2.7 Burner .................................................................................... page 13

2.7.1 Conformity of the burner .............................................. page 13

2.7.2 Choice of the burner .................................................... page 13

2.7.3 Burner installation ........................................................ page 13

2.8 Connection of the sightglass to the burner via a cooling line .. page 14

2.9 Casing assembly ................................................................... page 15

STANDARD PANEL BOARD .................................. page 24

3.1 Panel board type 21056/21057 - functions description ....... page 24

3.2 Electrical wiring diagram for single phase burner & pump .. page 24

3.3 Introduction of the electronic panel board type 30688 ........ page 25

3.4 Panel board type 30688 - description of functions .............. page 25

3.5 Electrical wiring diagram for single phase burner & pump .. page 26

3.6 Outer compensator ................................................................ page 27

3.7 Electrical and hydraulic connections of C.H. ........................ page 32

3.8 Electrical and hydraulic connections for C.H. system

and D.H.W.production circuits .............................................. page 32

COMMISSIONING AND OPERATION ............ page 33

4.1 Positioning of the turbulators ................................................ page 33

4.2 Preliminary check.................................................................. page 34

4.3 First commissioning .............................................................. page 34

4.4 Operation of the boiler ........................................................... page 34

4.5 Switch Off of the boiler .......................................................... page 34

MAINTENANCE ................................................................ page 35

5.1 General rules ......................................................................... page 35

5.2 Ordinary maintenance ........................................................... page 35

5.3 Extraordinary maintenance ................................................... page 35

5.4 Cleaning of the boiler ............................................................ page 36

5.5 Check of the boiler operation ................................................ page 36

5.6 Check of the burner operation .............................................. page 36

5.7 Boiler house ........................................................................... page 36

1CONSTRUCTIONAL-DIMENSIONAL

TECHNICAL CHARACTERISTICS

1.1 - CONSTRUCTION

OF THE TRIOPREX-N

BOILERS

The TRIOPREX-N, three pass

boilers, are

of horizontal type (oval shape from model 65

to 380 and the model 840; eight shape from

model 500 to 730 and cylindrical shape from

model 1100 to 1900), with direct flame in the

combustion chamber.

The construction completely satisfies the

requirements of the EN 303- part 1.

The sheet metal parts of the pressure vessel

are manufactured of certified carbon steel,

type S235JRG2, according to EN 10025, with

melting certificate 3.1.B, according EN

10024; whereas the pipes are of steel ST 37.0

according to DIN 1626.

The welders and the WPS (Welding

Procedures Specifications) have been

approved according to EN 287 and EN 288

by TUEV (DE).These boilers have been also

approved by - ISCIR (RO).

Up to the model TX-N 380 the furnace is

linked to the rear tube plate.

For larger models (TX-N 500 to TX-N 3500)

the furnace is free to dilatate (it is supported

only by the double welding seam (inner and

outer) to the front tube plate.

The boilers are equipped with a reversible

hinged door, which can be opened, for this

reason, from L.H. or R.H. side.

The outer shell is insulated with a glass wool

matress, thick 100 mm (80 mm for models

TX-N65 & TX-N 85), protected by a textile

in mineral fiber.

The upper part of the outer shell is equipped

with uplift hook(s).

fig. 1

Note: The TRIOPREX-N boilers are to be

equipped with ON/OFF burner;alternatively

they can be equipped with a two stage or

modulating burner, provided the minimum

reachable heat input is not lower than the figure

shown on the data plate for the fuel used on

site.

For two stage or modulating burner see

paragraph 2.7.1.

1.2 - WORKING PRINCIPLE

The NOx formation process is strongly

affected by:

-the flame temperature;

-the time during which the combustion gases

stay in a high temperature zone.

-oxygen partial pressure and its

concentration.

The provisions to be adopted for the NOx

reduction are then:

-reduction of combustion temperature;

-reduction of the specific thermal input;

-permanence time reduction of the gases

in the combustion chamber;

-reduction of oxygen concentration.

UNICAL, to reduce the NOx formation on the

TRIOPREX-N range of boilers, has adopted

the following construction solutions:

-three pass

the furnace is of direct flame type and not

of reversal type any more; the burner flame

results more compact and shorter, thus

The boilers are provided with two 1/2" bulb

holders with inner diameter of 15 mm (for 3

bulbs each), suitable to locate the thermostats

and thermometer bulbs.

The casing side panels are provided with

holes for the cables of the electrical supply,

of the pumps, of the burner and any other

auxiliary equipment.

reducing the permanence time at high

temperature;

the direct pass allows a quicker flame

cooling down by the water cooled furnace

surfaces;

-specific thermal input reduction

the combustion chamber volume has been

increased if compared with standard boilers

of the same capacity.

With the adoption of the modern Low NOx

burners a further reduction of the NOx

emissions can be obtained with:

-reburning

a part of the combustion gases is taken

and sent again to the combustion chamber

with the combustion air.

In this way the partial oxygen pressure is

reduced and the flame temperature is

reduced too.

-reduction of the partial oxygen pressure

thanks to an air excess reduction

During the operation of the burner within the

output range of the boiler, the combustion

chamber is always under positive pressure.

For the value of this pressure see tables on

pages 6 to 10 under the column "Smoke side

pressure losses".

The chimney has to be calculated in such a

way that at its base there is no positive

pressure.

n°4x M8 at 45°

on ø 170

ø 132

Fiber wool

Ceramic fiber

ø 130

132

TX N 65

TX N 85

1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS FOR TRIOPREX-N

TRIOPREX-N 65÷85

Output

min/max

ISO 7/1

Rp 1½

Rp 1

Rp ¾

150

TRIOPREX N

Type

Input

min/max

59,8÷71

78,3÷93

Boiler

water

content

131

187

Water side

pressure

drop (*)

mw.c.

0,04÷0,06

0,05÷0,07

3÷4

4,5÷6

Smoke side

pressure

drop

mm w.c.

Maximum

boiler working

pressure

bar

Weight

with

packaging

307

348

55÷65

72÷85

TX N 65

TX N 85

1Panel board

2Smoke chamber cleaning door

3Flame sight glass

T1 C.H. flow

T2 C.H. return

T3 Expansion vessel connection

T4 Boiler drain

T5 Flue connection

T6 Max. burner blast tube dia.

DIMENSIONS

TRIOPREX N

Type

fig. 2

740

690

950

190

140

145

660

345

120

M 8

470

310

190

846

(*) Hydraulic resistance for delta T 15K.

660

590

850

DETAIL FOR DOOR DRILLING

TX N 65 - 85

CONNECTIONS

fig. 3

n°4 "L"

T6 T2

BF E

120

Fiber wool

Ceramic fiber

Blind burner plate 250x250

Burner plate insulation gasket 250x250

ø 180

ø 150

n°4x M8 at 45°

on ø 170

ø 132

Fiber wool

Ceramic fiber

ø 130

Fiber wool

Ceramic fiber

Blind burner plate 250x250

Burner plate insulation gasket 250x250

ø 180

ø 165

T1-T3-T2

T3 T2

n°4 "L"

Q R

TRIOPREX-N 110÷380

1Panel board

2Smoke chamber cleaning door

3Flame sight glass

T1 C.H. flow

T2 C.H. return

T3 Expansion vessel connection

T4 Boiler drain

T5 Flue connection

T6 Max. burner blast tube dia.

Output

min/max

UNI 2278 PN 16

ISO 7/1

DN 50

DN 65

DN 80

Rp 1¼

Rp 1½

Rp 2

Rp ¾

180

225

132

180

TRIOPREX N

Type

Input

min/max

101÷120

137,7÷163

170÷202

207÷245

276÷327

350÷414

Boiler

water

content

204

270

285

322

408

475

Water side

pressure

drop (*)

mw.c.

0,06÷0,08

0,08÷0,10

0,10÷0,18

0,17÷0,20

0,22÷0,35

0,32÷0,53

5,5÷7,5

12÷16

9÷12

12,5÷17,5

9÷12

15÷21

Smoke side

pressure

drop

mm w.c.

Maximum

boiler working

pressure

bar

Weight

with

packaging

426

503

564

621

812

906

93÷110

127÷150

157÷185

191÷225

255÷300

323÷380

TX N 110

TX N 150

TX N 185

TX N 225

TX N 300

TX N 380

DIMENSIONS

TRIOPREX N

Type

TX N 110

TX N 150

TX N 185

TX N 225

TX N 300

TX N 380

fig. 4

820

860

890

885

1145

1080

1210

1275

1470

1082

1182

1352

190

140

145

748

828

928

380

400

440

120

M 8

1210

1310

1485

175

215

255

130

390

210

340

285

480

185

250

315

710

750

780

786

1046

981

1111

1177

1372

DETAIL FOR DOOR DRILLING

TX N 110 - 150

DETAIL FOR DOOR DRILLING

TX N 185 - 225

(*) Hydraulic resistance for delta T 15K.

fig. 5 fig. 6

CONNECTIONS

DETAIL FOR DOOR DRILLING

TX N 300 - 380

fig. 7

TRIOPREX-N 500÷730

Output

min/max

UNI 2278 PN 16

ISO 7/1

Øi

DN 100

DN 65

Rp 1

250

220

TRIOPREX N

Type

Input

min/max

460÷545

579÷686

671÷795

Boiler

water

content

656

737

807

Water side

pressure

drop (*)

mw.c.

0,10÷0,15

0,16÷0,23

0,23÷0,33

25÷35

32÷45

35÷49

Smoke side

pressure

drop

mm w.c.

Maximum

boiler working

pressure

bar

Weight

with

packaging

1198

1304

1431

425÷500

535÷630

620÷730

TX N 500

TX N 630

TX N 730

DIMENSIONS

TRIOPREX N

Type

TX N 500

TX N 630

TX N 730

(*) Hydraulic resistance for delta T 15K.

fig. 8

1Panel board

2Smoke chamber cleaning door

3Flame sight glass

T1 C.H. flow

T2 C.H. return

T3 Expansion vessel connection

T4 Boiler drain

T5 Flue connection

T6 Max. burner blast tube dia.

CONNECTIONS

920

1605

1800

1995

1645

190

135

195

1110

480

1735

298

435

630

825

440

790

1505

1790

1895

DETAIL FOR DOOR DRILLING

TX N 500 - 730

fig. 9

860

Refractory cement

Ceramic fiber

Blind burner plate 330x330

Burner plate insulation gasket 330x330

ø 270

150

TRIOPREX-N 840

Output

min/max

UNI 2278 PN 16

ISO 7/1

Øi

DN 100 DN 65 Rp 1¼ 250 270

TRIOPREX N

Type

Input

min/max

772÷915

Boiler

water

content

932

Water side

pressure

drop (*)

mw.c.

0,35÷0,52 42÷58

Smoke side

pressure

drop

mm w.c.

Maximum

boiler working

pressure

bar

Weight

with

packaging

1581714÷840

DIMENSIONS

TRIOPREX N

Type

(*) Hydraulic resistance for delta T 15K.

fig. 10

1Panel board

2Smoke chamber cleaning door

3Flame sight glass

T1 C.H. flow

T2 C.H. return

T3 Expansion vessel connection

T4 Boiler drain

T5 Flue connection

T6 Max. burner blast tube dia.

CONNECTIONS

1122

2115

1432

190

195

1025

480

1540

298

945

440

1020

2014

DETAIL FOR DOOR DRILLING

TX N 840

fig. 11

O P

T3 T2

T1-T3-T2

125

Refractory cement

Ceramic fiber

Blind burner plate 330x330

Burner plate insulation gasket 330x330

ø 270

180

Refractory cement

Ceramic fiber

Blind burner plate 380x380

Burner plate insulation gasket 380x380

ø 285

200

TRIOPREX-N 1100÷1900

Output

min/max

UNI 2278 PN 16

ISO 7/1

Øi

DN 150

DN 175

DN 80

DN 100

Rp 1½

350

400

TRIOPREX N

Type

Input

min/max

1012÷1198

1214÷1438

1470÷1743

1745÷2070

1580

1791

2297

2496

0,15÷0,21

0,21÷0,30

0,20÷0,28

0,27÷0,39

45÷62

61÷85

40÷55

52÷73

Smoke side

pressure

drop

mm w.c.

Maximum

boiler working

pressure

bar

Weight

with

packaging

2444

2965

3685

4089

935÷1100

1122÷1320

1360÷1600

1615÷1900

DIMENSIONS

TRIOPREX N

Type

(*) Hydraulic resistance for delta T 15K.

fig. 12

1Panel board

2Smoke chamber cleaning door

3Flame sight glass

T1 C.H. flow

T2 C.H. return

T3 Expansion vessel connection

T4 Boiler drain

T5 Flue connection

T6 Max. burner blast tube dia.

CONNECTIONS

1462

1622

2282

2652

2692

3014

1542

1702

190

230

260

290

1120

1245

565

605

1650

1810

561

661

662

510

880

670

990

550

700

1360

1520

2176

2546

2590

2910

DETAIL FOR DOOR DRILLING

TX N 1100 - 1320

DETAIL FOR DOOR DRILLING

TX N 1600 - 1900

TX N 1100

TX N 1320

TX N 1600

TX N 1900

TX N 1100

TX N 1320

TX N 1600

TX N 1900

270

285

fig. 13 fig. 14

O P

T1 T2

T3-T1-T2

185

Boiler

water

content

Water side

pressure

drop (*)

mw.c.

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