Unical TERNOx 2S Instructions On Installation, Use And Maintenance

TERNOx 2S

INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

Attention: this manual contains instructions for the exclusive use of the professionally qualiﬁed installer and/or maintenance technician in compliance with current legislation. The system manager is NOT authorised to service the boiler. The manufacturer will not be held liable in case of damage to persons, animals or objects resulting from failure to comply with the instructions contained in the manuals supplied with the boiler.

1 GENERAL INFORMATION ................................................................................................................................................................................. 5

1.1 General warnings .......................................................................................................................................................................................... 5

1.2 Symbols used in the manual .........................................................................................................................................................................6

1.3 Appropriate use of appliance ........................................................................................................................................................................ 6

1.4 Information for system manager ................................................................................................................................................................... 6

1.5 Safety warnings ............................................................................................................................................................................................7

1.6 Technical data plate ...................................................................................................................................................................................... 8

1.7 Water treatment ............................................................................................................................................................................................8

2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................9

2.1 Technical features ......................................................................................................................................................................................... 9

2.2 Operation principle ........................................................................................................................................................................................ 9

2.3 Dimensions ................................................................................................................................................................................................. 10

2.4 Operating data according to UNI 10348 ..................................................................................................................................................... 13

General informationTechnical featuresInstallation instructionsMaintenance instructions

3 INSTALLATION INSTRUCTIONS ...........................................17

3.1 General warnings ............................................................17

3.2 Installation standards.......................................................17

3.3 Installation on old or retroﬁttable systems .......................17

3.4 Packaging ........................................................................18

3.5 Handling ..........................................................................18

3.6 Positioning in boiler room ................................................19

3.7 Hydraulic connections .....................................................20

3.8 Filling and emptying the system ......................................20

3.9 Gas connection................................................................21

3.10 Connection to the ﬂue......................................................21

3.11 Furnace door: adjustment, opening, closing....................22

3.12 Burner ..............................................................................22

3.13 Electric panel assembly ...................................................24

3.14 Electrical connections ......................................................25

3.15 STANDARD panel board .................................................26

3.16 Hydraulic and electrical system connection.....................25

4 INSPECTION AND MAINTENANCE ................................................................................................................................................................44

Routine and extraordinary maintenance ............................................................................................................................................................ 44

Inspection and maintenance instructions ........................................................................................................................................................... 45

Maintenance of body ......................................................................................................................................................................................... 45

Troubleshooting.................................................................................................................................................................................................. 46

3.17 Optional MASTER panel board ....................................... 29

3.18 Hydraulic and electrical system connection.....................32

3.19 Example of hydraulic and electrical system connection ..35

3.20 CASCADE panel board ...................................................37

3.21 Hydraulic and electrical system connection

with boilers in cascade ....................................................39

3.22 Commissioning ............................................................. 41

3.23 Burner adjustment ...........................................................42

3.24 Checks during and after commissioning ..........................43

3.25 Alkaline or “boiling” wash .................................................43

3.26 Boiler shutdown ...............................................................43

(This page has been intentionally left blank)

ATTENTION

Wherever the boiler operates with a pressure jet gas burner, the appliance, not belonging to any category among those considered in Annex II of the Legislative Decree 93 of 25/02/2000 (Implementation of the Directive 97/23/EC regarding pressurised equipment), and moreover being considered by the Directive 90/396/EEC (Gas-ﬁred appliances - transposed in Italy with Italian Presidential Decree 661 of 15/11/1996) to which art. 1 comma 3 paragraph “f.5” refers, is excluded from the range of application of the decree itself.

GENERAL INFORMATION

1.1 - GENERAL WARNINGS

The instruction booklet is an integral and essential part of the product and must be kept by the system manager.

Read the warnings contained in this instruction booklet carefully as they provide important guidelines regarding installation, use and maintenance safety.

Keep the booklet with care for further consultation.

Your appliance must be installed and serviced in compliance with the standards in force according to the manufacturer instructions, up to standard and by legally qualiﬁed and certiﬁed personnel. Systems for the production of domestic hot water MUST be constructed entirely with materials that comply with M.D. 174/2004 (taps, pipes, ﬁttings, etc.).

By professionally qualiﬁed personnel we mean: personnel with speciﬁc technical skill in the ﬁeld of heating system components for civil use, domestic hot water production and maintenance. Personnel must have the qualiﬁcations provided for by current legislation.

General information

Any product repairs must be performed solely by personnel authorised by Unical, using original spare parts only. Failure to comply with the above can compromise the safety of the appliance and void the warranty.

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 entailing potential sources of hazard must be made safe.

Before commissioning an appliance that has not been used, wash the domestic hot water production system, making the water ﬂow until it has been fully replaced.

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 manual accompanies it in order to be consulted by the new owner and/or installer.

Only original accessories must be used for all appliances with optionals or kits (including electric).

Incorrect installation or improper maintenance can cause damage to persons, animals or objects for which the manufacturer is not responsible.

Before performing any cleaning or maintenance, disconnect the appliance from the energy mains by acting on the switch of the system and/or through the speciﬁc cut-off devices.

Do not obstruct the terminals of the intake/exhaust ducts. In case of failure and/or malfunctioning of the appliance, switch it off and do not try to repair it or intervene on it directly. Contact only personnel qualiﬁed in compliance with law.

This appliance is intended solely for the use for which it was expressly designed. Any other use is to be considered improper and therefore dangerous.

1.2 - SYMBOLS USED IN THE MANUAL

Pay special attention when reading this manual to the parts marked by the symbols:

DANGER!

Serious danger for

personal safety and life

ATTENTION!

Possible dangerous

situation for the product

and the environment

1.3 - APPROPRIATE USE OF THE APPLIANCE

The TERNOX 2S appliance has been built according to the current level of engineering and acknowledged

technical safety rules.

Nonetheless, if improperly used, dangers could arise for the safety and life of the user and other persons or damage to the equipment or other objects. The appliance is intended to operate in hot water circulation heating systems. Any other use must be considered improper. UNICAL will not be held liable for any damage resulting from improper use. Use according to the intended purposes also includes strict compliance with the instructions in this manual.

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 inside the packaging. The user must keep this documentation safe for future consultation.

• Inform the user about the importance of the air vents and the ﬂue gas exhaust system, highlighting their 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 combustion analysis must be performed every two years (as per national law).

• 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 manual accompanies it in order to be consulted by the new owner and/or installer.

NOTE!

Tips

for the user

The manufacturer will not be held liable in the event of damage to persons, animals or objects resulting from failure to comply with the instructions contained in this manual.

1.5 - SAFETY WARNINGS

ATTENTION! The appliance must not be used by people with reduced physical, sensory and mental abilities, without experience and knowledge. These people must be previously trained and supervised during manoeuvre operations. Children must be supervised so that they do not play with the appliance.

ATTENTION! The appliance must be installed, adjusted and maintained by professionally qualiﬁed personnel, in compliance with the standards and provisions in force. Incorrect installation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.

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

Modifying parts connected to appliance

Do not modify the following parts:

- the boiler

- the gas, air, water and electricity supply lines

- the ﬂue gas pipe, the safety valve and the exhaust pipe

- the 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 appliances

Make sure that the gas tank has been deaerated before installing the appliance. For state-of-the-art tank venting, contact the LPG supplier or person qualiﬁed in compliance with the law requirement. If the tank has not been professionally deaerated, ignition problems could arise. In that case, contact the supplier of the LPG tank.

Smell of gas

Should 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.

General information

Explosive and easily ﬂammable substances

Do not use or store explosive or easily ﬂammable materials (e.g. petrol, paints, paper) in the room where the appliance is installed.

1.6 - TECHNICAL DATA PLATE

The technical data plate is inserted in the document envelope. When installation is ﬁnished, it is MANDATORY that the appliance installer apply it at the front top part.

If lost, ask the Unical Technical Assistance Service for a duplicate. The serial number of the boiler is on the riveted plaque on the front plate of the body (front right top side). If the identiﬁcation plate is tampered with, removed or missing, the product cannot be safely identiﬁed, making any installation and maintenance operation difﬁcult.

CE marking

The CE marking 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)

- CE marking compliant to directives governing the use of

gas-ﬁred appliances - Ts < 110°C.

Boiler type

Serial number

Year of manufacture

Mains: 230V~ 50Hz W:

Fuels (only those with X)

OUTPUTS

Useful

Furnace

P.I.N. code

Approval

* See serial no. on boiler body

1.7 - WATER TREATMENT

Boiler water capacity

Storage tank:

Gas

Category

min. max. min. max.

AG S.P.A.

Max. operating pressure

Max. operating temp. °C

Capacity Max. press. Max. temp.

l °C

Wood

Sup. m²

46033 CASTELDARIO (MN) - Via Roma tel. 0376 57001 - fax 0376 660556 www.unical.ag info@unical-ag.com

Charcoal

bar

Diesel oil

bar

Naphtha

The treatment of the supply water allows to prevent inconveniences and maintain the functionality and efﬁciency of the generator over time. The values displayed in the table can be used as a reference.

TOTAL HARDNESS ppm 10 ALKALINITY mg/l CaCO3 750 PH 8÷9 SILICA ppm 100 CHLORIDES ppm 3500

To minimise corrosion, it is crucial to use a corrosion inhibitor; in order for it to work properly, the metal surfaces must be clean.

ATTENTION! ANY DAMAGE TO THE BOILER CAUSED BY THE FORMATION OF FOULING OR BY CORROSIVE WATER WILL NOT BE COVERED BY THE WARRANTY.

ATTENTION: These appliances are NOT suitable for the production of water for human consumption according to Ministerial Decree D.M. 174/2007.

TECHNICAL FEATURES AND DIMENSIONS

2.1 - TECHNICAL FEATURES

One of the signiﬁcant aspects taken into account when designing the TERNOx 2S series boilers is the reduction of the formation of pollutants in exhaust gases. One of these consists of nitrogen oxides (Nox). In Europe, their emission is governed by several legislative standards and provisions. Welding procedures and devices are approved and certiﬁed according to EN Standards. The main technical elements of the design are:

- An accurate study of geometries, to achieve an ideal ratio between combustion volumes and exchange surfaces.

- The selection of the materials used to guarantee the long life of the boiler. Welding procedures and devices are approved and certiﬁed according to EN Standards. The boilers have pressurised combustion, with 3 ﬂue gas passes with passing ﬂame and wet inversion chamber. The combustion gases produced by the burner, having passed the combustion chamber of the furnace, enter the pipes in the second ﬂue gas pass.

2.2 - OPERATION PRINCIPLE

TERNOX 2S boilers have pressurised combustion, with 3 ﬂue gas passes with passing ﬂame and wet inversion chamber. The combustion gases produced by the burner, having passed the inversion chamber of the furnace, enter the pipes in the second ﬂue gas pass. After the exhaust gases return to the front of the boiler, they again change direction and pass through the pipes of the third ﬂue gas pass towards the ﬂue duct.

After the exhaust gases return to the front of the boiler, they again change direction and pass through the pipes of the third ﬂue gas pass towards the ﬂue duct. This type of boilers achieves a high average yearly performance and low content of harmful substances in the ﬂue gas. Another advantage of the three ﬂue gas pass structure consists of the fact that combustion products remain less time in high temperature areas, thus limiting harmful emissions of nitrogen oxides. The boiler body is thermally insulated by the application of a mineral wool mattress with a high insulation level to reduce heat dispersion to extremely low levels. It is ﬁnished by aluminium sheets.

The combustion chamber is always pressurised while the burner is operating. For the value of this pressure, see the TECHNICAL DATA table, in the column Flue gas pressure drop. The ﬂue gas duct and the ﬁtting to the ﬂue must be implemented in compliance with Standards and Legislation in force, with rigid ducts resistant to heat, condensation, mechanical stress and airtight.

Technical features

1 Furnace 2 Smoke pipes 3 Door with ﬂame control warning light

(2nd pass) (3rd pass)

4. Smoke chamber

5 Body insulation

2.3 - DIMENSIONS

TERNOX 2500 2S STD - 2200 2S Low NOx - 1800 2S Low NOx E TERNOX 3500 2S STD - 3050 2S Low NOx - 2350 2S Low NOx E

1 Panel board 2 Burner connection ﬂange 3 Smoke chamber cleaning door 4 Flame control warning light

T1 Heating ﬂow T2 Heating return T3 Expansion vessel connection T4 Boiler drain

T5 Chimney connection T6 Probe holder conduit connection T7 Probe holder conduit connection T8 Burner connection

TERNOx 2S

Model

2500 2S STD

2200 2S Low NOx

1800 2S Low NOx E

3500 2S STD

3050 2S Low NOx

2350 2S Low NOx E

Useful output

1800 - 2500 1800 - 2200

1800

2350 - 3500 2350 - 3050

2350

Furnace

furnace

1951 - 2753 1951 - 2406

1951

2537 - 3848 2537 - 3329

2537

Boiler

capacity

3790

4750

Water side

pressure

drop(**)

m.w.c.

0.26 - 0.50

0.26 - 0.39

0.26

0.43 - 0.95

0.43 - 0.72

0.43

(**) Pressure drops corresponding to a thermal variation of 15K.

TERNOx 2S

Model

2500 2S STD

2200 2S Low NOx

1800 2S Low NOx E

3500 2S STD

3050 2S Low NOx

2350 2S Low NOx E

4225

4711

1710

1830

2010

2120

3370

3824

1940

1954

Flue gas pressure

drop

mbar

3.77 - 7.50

3.77 - 5.73

3.77

3.48 - 8.00

3.48 - 5.99

3.48

DIMENSIONS

820

1140

aximum

operating

pressure

boiler

1465

1617

bar

eight

T1 T2

UNI 2278 PN16

5500

6 7000 DN 65DN 200 Rp 1½ 620

420

570

1400

1480

CONNECTIONS

UNI 2278 PN16

DN 50DN 200

1350

1450

800

ISO 7/1

Rp 1½

570

1030

1080

Øi

Rp 1/2

Rp 1/2 Rp 1/2

245

230

250

400

TERNOX 4500 2S STD - 3800 2S Low NOx - 3000 2S Low NOx E TERNOX 5800 2S STD - 5000 2S Low NOx - 4000 2S Low NOx E TERNOX 7000 2S STD - 6300 2S Low NOx - 5100 2S Low NOx E TERNOX 8500 2S STD - 7500 2S Low NOx - 5700 2S Low NOx E TERNOX 10200 2S STD - 9500 2S Low NOx - 8400 2S Low NOx E

T1 T2

T6 T7

1 Panel board 2 Burner connection ﬂange 3 Smoke chamber cleaning door 4 Flame control warning light

TERNOx 2S

Model

4500 2S STD

3800 2S Low NOx

3000 2S Low NOx E

5800 2S STD

5000 2S Low NOx

4000 2S Low NOx E

7000 2S STD

6300 2S Low NOx

5100 2S Low NOx E

8500 2S STD

7500 2S Low NOx

5700 2S Low NOx E

10200 2S STD

9500 2S Low NOx

8400 2S Low NOx E

Useful output

3000 - 4500 3000 - 3800

3000

4000 - 5800 4000 - 5000

4000

5100 - 7000 5100 - 6300

5100

5700 - 8500 5700 - 7500

5700

8400 - 10200

8400 - 9500

8400

3239 - 4951 3239 - 4144

4325 - 6381 4325 - 5457

5529 - 7705 5529 - 6892

6169 - 9377 6169 - 8215

9128 - 11191 9128 - 10377

Furnace

furnace

3239

4325

5529

6169

9128

T1 Heating ﬂow T2 Heating return T3 Expansion vessel connection T4 Boiler drain

Boiler

capacity

6400

8060

9760

11480

14960

Water side

pressure

drop(**)

m.w.c.

0.27 - 0.60

0.27 0.43

0.27

0.44 - 0.93

0.44 - 0.69

0.44

0.72 - 1.36

0.72 - 1.10

0.72

0.90 - 2.00

0.90 - 1.56

0.90

0.96 - 1.41

0.96 - 1.22

0.96

(**) Pressure drops corresponding to a thermal variation of 15K.

T3 T3

Flue gas

pressure

drop

mbar

3.64 - 8.50

3.64 - 5.96

3.64

4.36 - 9.50

4.36 - 6.95

4.36

4.89 - 9.50

4.89 - 7.60

4.89

4.76 - 11.0

4.76 - 8.44

4.76

8.32 - 12.50

8.32 - 10.75

8.32

T5 Chimney connection T6 Probe holder conduit connection T7 Probe holder conduit connection T8 Burner connection

aximum

operating

pressure

boiler

bar

eight

6 10000 DN 80DN 250 Rp 1½ 660

6 11500 DN 100DN 250 Rp 1½ 720

6 13500 DN 100DN 250 Rp 1½ 820

6 17300 DN 100DN 300 Rp 1½ 820

8200

UNI 2278 PN16

CONNECTIONS

UNI 2278 PN16

DN 80DN 250 Rp 1½ 660

ISO 7/1

Øi

Rp 1/2

Rp 1/2 Rp 1/2

Rp 1/2

Rp 1/2 Rp 1/2

Rp 1/2

500

Technical features

TERNOx 2S

Model

4500 2S STD

3800 2S Low NOx

3000 2S Low NOx E

5800 2S STD

5000 2S Low NOx

4000 2S Low NOx E

7000 2S STD

6300 2S Low NOx

5100 2S Low NOx E

8500 2S STD

7500 2S Low NOx

5700 2S Low NOx E

10200 2S STD

9500 2S Low NOx

8400 2S Low NOx E

5134

5639

5875

6420

6772

1980

2180

2320

2400

2650

2360

2580

2700

2870

3080

4174

4626

4840

5330

5632

2017

2451

2505

2035

1406

DIMENSIONS

1380

1400

1510

2590

3450

1737

1788

1860

1795

1916

550

600

550

480

550

1620

1780

1870

1980

2080

1550

1710

1850

1900

2080

800

880

1000

1180

1300

1350

1460

1560

250

300

350

TERNOX 12500 2S STD TERNOX 15000 2S STD

T1 T2

T6 T7

1 Panel board 2 Burner connection ﬂange 3 Smoke chamber cleaning door 4 Flame control warning light

T3 T3

T1 Heating ﬂow T2 Heating return T3 Expansion vessel connection T4 Boiler drain

T5 Chimney connection T6 Probe holder conduit connection T7 Probe holder conduit connection T8 Burner connection

TERNOX

Model

12500 2S STD

15000 2S STD

Useful output

12500

15000

Furnace

furnace

13789

16458

Boiler

capacity

24100

27300 1.46 - 2.20 9.72 - 15.0 6 30000 DN 125DN 350 DN 60 1000

Water side

pressure

drop(**)

m.w.c.

1.31 - 2.00

(**) Pressure drops corresponding to a thermal variation of 15K.

TERNOx

Model

12500 2S STD

15000 2S STD

7211

7761

3210

3320

3715

3910

6236

6736

1643

1693

Flue gas pressure

drop

mbar

8.93 - 14.0

DIMENSIONS

3500

4000

aximum

operating

pressure

boiler

bar

2068

eight

T1 T2

UNI 2278 PN16

25500

650

2700

2750

CONNECTIONS

UNI 2278 PN16

DN 125DN 300 DN 60 820

2400

2500

1470

ISO 7/1

Rp 1/2

400

650

1480

1583

Øi

Rp 1/2

Rp 1/2 Rp 1/2

230

2.4 - OPERATING DATA ACCORDING TO UNI 10348

GAS-FIRED

TERNOX 2500

2S STD

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

CO2 content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

1800 - 2500

1951 - 2753

92.25 - 90.80

91.40

92.9 - 91.5

0.60 - 0.71

7.15 - 8.49

0.10

146.46 - 174

9.80

2932.8 - 4138.6

DIESEL OIL-FIRED TERNOX 2500

2S STD

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

1800 - 2500

1951 - 2753

92.25 - 90.80

91.40

92.9 - 91.5

0.60 - 0.71

7.15 - 8.49

0.10

156.73 - 186.20

12.80

2987.9 - 4216.3

TERNOX 2200

2S LOW NOx

1800 - 2200

1951 - 2406

92.25 - 91.45

91.40

92.9 - 92.1

0.60 - 0.65

7.15 - 7.90

0.10

146.46 - 161.92

9.80

2932.8 - 3616.1

TERNOX 2200

2S LOW NOx

1800 - 2200

1951 - 2406

92.25 - 91.45

91.40

92.9 - 92.1

0.60 - 0.65

7.15 - 7.90

0.10

156.73 - 173.27

12.80

2987.9 - 3684.0

TERNOX 1800

2S LOW NOx E

1800

1951

92.25

91.40

92.9

0.60

7.15

0.10

146.46

9.80

2932.8

TERNOX 1800

2S LOW NOx E

1800

1951

92.25

91.40

92.9

0.60

7.15

0.10

156.73

12.80

2987.9

Technical features

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

°C

kg/h

TERNOX 3500

2S STD

2350 - 3500

2537 - 3848

92.64 - 90.95

91.40

93.2 - 91.7

0.58 - 071

6.78 - 8.34

0.10

139.00 - 171.00

9.80

3813.1 - 5784.7

TERNOX 3500

2S STD

2350 - 3500

2537 - 3848

92.64 - 90.95

91.40

93.2 - 91.7

0.58 - 071

6.78 - 8.34

0.10

148.67 - 182.90

12.80

3884.6 - 5893.1

TERNOX 3050

2S LOW NOx

2350 - 3050

2537 - 3329

92.64 - 91.62

91.40

93.2 - 92.3

0.58 - 0.65

6.78 - 7.73

0.10

139.0 - 158.35

9.80

3913.1 - 5003.7

TERNOX 3050

2S LOW NOx

2350 - 3050

2537 - 3329

92.64 - 91.62

91.40

93.2 - 92.3

0.58 - 0.65

6.78 - 7.73

0.10

148.67 - 169.37

12.80

3884.6 - 5097.5

TERNOX 2350

2S LOW NOx E

2350

2537

92.64

91.40

93.2

0.58

6.78

0.10

139

9.80

3813.1

TERNOX 2350

2S LOW NOx E

2350

2537

92.64

91.40

93.2

0.58

6.78

0.10

148.67

12.80

3884.6

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

TERNOX 4500

2S STD

3000 - 4500

3239 - 4951

92.62 - 90.90

91.40

93.2 - 91.6

0.58 - 0.71

6.80 - 8.39

0.10

139.31 - 172.00

9.80

4868.5 - 7441.4

TERNOX 3800

2S LOW NOx

3000 - 3800

3239 - 4144

92.62 - 91.70

91.40

93.2 - 92.4

0.58 - 0.65

6.80 - 7.65

0.10

139.31 - 156.79

9.80

4868.5 - 6228.9

TERNOX 3000

2S LOW NOx E

3000

3239

92.62

91.40

93.2

0.58

6.80

0.10

139.31

9.80

4868.5

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

°C

kg/h

TERNOX 4500

2S STD

3000 - 4500

3239 - 4951

92.62 - 90.90

91.40

93.2 - 91.6

0.58 - 0.71

6.80 - 8.39

0.10

149.03 - 184.00

12.80

4959.9 - 7581.0

TERNOX 5800

2S STD

4000 - 5800

4324 - 6381

92.50 - 90.90

91.40

93.1 - 91.6

0.59 - 0.71

6.91 - 8.39

0.10

141.70 - 172.00

9.80

6500.2 - 9591.1

TERNOX 3800

2S LOW NOx

3000 - 3800

3239 - 4144

92.62 - 91.70

91.40

93.2 - 92.3 0.58 -

0.65

6.80 - 7.65

0.10

149.03 - 167.73

12.80

4959.9 - 6345.8

TERNOX 5000

2S LOW NOx

4000 - 5000

4324 - 5457

92.50 - 91.62

91.40

93.1 - 92.3

0.59 - 0.65

6.91 - 7.73

0.10

141.70 - 158.42

9.80

6500.2 - 8203.0

TERNOX 3000

2S LOW NOx E

3000

3239

92.62

91.40

93.2

0.58

6.80

0.10

149.03

12.80

4959.9

TERNOX 4000

2S LOW NOx E

4000

4324

92.50

91.40

93.1

0.59

6.91

0.10

141.70

9.80

6500.2

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

TERNOX 5800

2S STD

4000 - 5800

4324 - 6381

92.50 - 90.90

91.40

93.1 - 91.6

0.59 - 0.71

6.91 - 8.39

0.10

151.58 - 184.00

12.80

6622.2 - 9771.1

TERNOX 5000

2S LOW NOx

4000 - 5000

4325 - 5457

92.50 - 91.62

91.40

93.1 - 92.3

0.59 - 0.65

6.91 - 7.73

0.10

151.58 - 169.47

12.80

6622.2 - 8356.9

TERNOX 4000

2S LOW NOx E

4000

4324

92.50

91.40

93.1

0.59

6.91

0.10

151.58

12.80

6622.2

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

TERNOX 7000

2S STD

5100 - 7000

5529 - 7705

92.25 - 90.85

91.40

92.9 - 91.6

0.61 - 0.71

7.15 - 8.44

0.10

146.49 - 173.00

9.80

8310.3 - 11581.7

TERNOX 6300

2S LOW NOx

5100 - 6300

5529 - 6892

92.25 - 91.41

91.40

92.9 - 92.1

0.61 - 0.65

7.15 - 7.94

0.10

146.49 - 162.81

9.80

8310.3 - 10360.0

TERNOX 5100

2S LOW NOx E

5100

5529

92.25

91.40

92.9

0.61

7.15

0.10

146.48

9.80

8310.3

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

°C

kg/h

TERNOX 7000

2S STD

5100 - 7000

5529 - 7705

92.25 - 90.85

91.40

92.9 - 91.6

0.61 - 0.71

7.15 - 8.44

0.10

156.65 - 185.00

12.80

8465.9 - 11798.7

TERNOX 8500

2S STD

5700 - 8500

6169 - 9376

92.40 - 90.65

91.40

93.0 - 91.4

0.58 - 0.71

7.01 - 8.64

0.10

143.78 - 177.00

9.80

9272.2 - 14093.8

TERNOX 6300

2S LOW NOx

5100 - 6300

5529 - 6892

92.25 - 91.41

91.40

92.9 - 92.1

0.61 - 0.65

7.15 - 7.94

0.10

156.65 - 174.10

12.80

8465.9 - 10554.1

TERNOX 7500

2S LOW NOx

5700 - 7500

6169 - 8214

92,40 - 91,30

91.40

93.0 - 92.0

0.58 - 0.65

7.01 - 8.04

0.10

143.78 - 164.93

9.80

9272.2 - 12347.4

TERNOX 5100

2S LOW NOx E

5100

5529

92.25

91.40

92.9

0.61

7.15

0.10

156.65

12.80

8465.9

Technical features

TERNOX 5700

2S LOW NOx E

5700

6169

92.40

91.40

93.0

0.58

7.01

0.10

143.78

9.80

9272.2

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

TERNOX 8500

2S STD

5700 - 8500

6169 - 9377

92.40 - 90.65

91.40

93.0 - 91.4

0.58 - 0.71

7.02 - 8.64

0.10

153.94 - 189.50

12.80

9446.8 - 14359.4

TERNOX 7500

2S LOW NOx

5700 - 7500

6169 - 8215

92.40 - 91.29

91.40

93.0 - 91.9

0.58 - 0.65

7.02 - 8.06

0.10

153.94 - 176.58

12.80

9446.8 - 12579.9

TERNOX 5700

2S LOW NOx E

5700

6169

92.40

91.40

93.0

0.58

7.02

0.10

153.94

12.80

9446.8

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

TERNOX 10200

2S STD

8400 - 10200

9128 - 11191

92.02 - 91.14

91.40

92.7 - 91.9

0.64 - 0.71

7.33 - 8.15

0.10

150.34 - 167.00

9.80

13721.2 - 16822.0

TERNOX 9500

2S LOW NOx

8400 - 9500

9128 - 10377

92.02 - 91.55

91.40

92.7 - 92.2

0.64 - 0.65

7.33 - 7.80

0.10

150.34 - 159.88

9.80

13721.2 - 15579.9

TERNOX 8400

2S LOW NOx E

8400

9128

92.03

91.40

92.7

0.64

7.33

0.10

150.34

9.80

13720.5

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

GAS-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

°C

kg/h

TERNOX 10200

2S STD

8400 - 10200

9128 - 11191

92.02 - 91.14

91.40

92.7 - 91.9

0.64 - 0.71

7.33 - 8.15

0.10

160.78 - 178.60

12.80

13978.3 - 17137.3

TERNOX 12500

2S STD

10100 - 12500

11012 - 13789

91.72 - 90.65

91.40

92.3 - 91.4

0.58 - 0.71

7.70 - 8.64

0.10

157.83 - 177.00

9.80

16552,5 - 20726,2

TERNOX 9500

2S LOW NOx

8400 - 9500

9128 - 10377

92.02 - 91.55

91.40

92.7 - 92.2

0.64 - 0.65

7.33 - 7.80

0.10

160.78 - 170.98

12.80

13978.3 - 15890.1

TERNOX 15000

2S STD

12200 - 15000

13251 - 16458

92.07 - 91.14

91.40

92.7 - 91.9

0.64 - 0.71

7.29 - 8.15

0.10

149.40 - 167.00

9.80

19918.5 - 24738.3

TERNOX 8400

2S LOW NOx E

8400

9128

92.03

91.40

92.7

0.64

7.33

0.10

160.78

12.80

13977.6

DIESEL OIL-FIRED

Nominal heat output

Thermal output of furnace

Heat efﬁciency at nominal load (100%)

Heat efﬁciency at 30% load

Combustion efﬁciency at nominal load (100%)

Heat loss at casing (min.-max.)

Heat loss at chimney with burner on (min.-max.)

Heat loss at chimney with burner off (min.-max.)

Flue gas temperature tf-ta (min.-max.)

content

Flue gas mass ﬂow rate (min.-max)

°C

kg/h

TERNOX 12500

2S STD

10100 - 12500

11012 - 13789

91.71 - 90.65

91.40

92.3 - 91.4

0.58 - 0.71

7.70 - 8.64

0.10

168.89 - 189.40

12.80

16863.5 - 21115.7

TERNOX 15000

2S STD

12200 - 15000

13251 - 16458

92.07 - 91.14

91.40

92.7 - 91.9

0.64 - 0.71

7.29 - 8.15

0.10

159.78 - 178.60

12.80

20291.8 - 25201.8

INSTRUCTIONS FOR INSTALLATION

3.1 - GENERAL WARNINGS

ATTENTION! This boiler is intended solely for the use for which it was expressly designed. Any other use is to be considered improper and therefore dangerous. This boiler heats water at a temperature lower than the atmospheric pressure boiling temperature.

Before connecting the boiler, have professionally qualiﬁed personnel:

a) Thoroughly wash all the piping of the system

to remove any residues or impurities which could jeopardise proper operation of the boiler, even from a hygienic point of view.

b) Check that boiler is set up to operate with the

available type of fuel.

The type of fuel can be seen written on the

package and on the technical feature plate.

c) Check that the chimney/ﬂue has an appropri-

ate draught, without any bottlenecks, and that no exhausts from other appliances are inserted, unless the ﬂue has been implemented to accommodate several utilities according to speciﬁc standards and prescriptions in force. Only after this check can the ﬁtting between the boiler and chimney/ﬂue be mounted.

ATTENTION! In rooms with the presence of aggressive vapours or dust, the appliance must operate independently from the air inside the installation room!

ATTENTION! The appliance must be installed by a qualiﬁed technician with the technical-professional requirements according to law 46/90 which, under his own responsibility, guarantees compliance with standards according to good practice rules.

ATTENTION! Mount the appliance respecting the minimum distances required for installation and maintenance.

The boiler must be connected to a heating system compatible with its performance and output.

3.2 - INSTALLATION STANDARDS

It must be installed by a professionally qualiﬁed technician, who shall take the responsibility of observing all local and/or national laws published in the ofﬁcial journal, as well as applicable technical standards.

3.3 - INSTALLATION ON OLD OR RETROFITTABLE SYSTEMS

Before installing this appliance on old systems, check that:

- The ﬂue is able to withstand the temperature generated by the combustion products, has been measured and designed according to the regulations in force, is airtight and insulated, and does not feature obstructions or constrictions.

- The ﬂue has a device for releasing condensation.

- The electrical system has been set up by a qualiﬁed technician in compliance with the rules in force.

- The rate, head and direction of the ﬂow of the circulation pumps are appropriate.

- The expansion vessel(s) can fully absorb dilation of the ﬂuid in the system.

- The fuel adduction line and the tank, if any, are made ac-

cording to relevant standards in force.

- The expansion vessels can fully absorb dilation of the ﬂuid

in the system.

- The system has been cleaned and cleared of all sludge and scale, has been vented, and all its seals have been checked.

- There is a treatment system for feed/recirculation water (see reference values).

Technical features and dimensions

3.4 - PACKAGING

TERNOX 2S boilers are supplied with casing and with the door

and smoke chamber assembled.

The panel and accessories are inside the combustion chamber.

Upon reception, make sure that the supply is complete and undamaged.

The document envelope, besides the appliance, contains:

- Hydraulic test certiﬁcate

- Heating system booklet

- System manager operating instructions

- Installation and maintenance instruction booklet

- Warranty

- Local ventilation requirements label.

3.5 - HANDLING

TERNOX 2S boilers are equipped with lifting eyebolts. Pay attention when handling the boiler and use equipment suitable for its weight.

3.6 - POSITIONING IN BOILER ROOM

TERNOX 2S boilers must be installed in rooms for exclusive use complying with Technical Standards and Legislation in force and with sufﬁciently sized air vents.

The ventilation openings must be permanent, communicating directly with the outside and must be positioned high or low according to standards in force.

The location of the ventilation openings, the fuel supply trains, electric energy supply and lighting must comply with current legal provisions in relation to the type of fuel used.

To make it easier to clean the smoke circuit, a free space must be left in front of the boiler no less than the length of the boiler body and, in any case, never less than 1300 mm. It must be checked that with the door/s open 90°, the distance between the door and the adjacent wall X is at least equal to the length of the burner.

The boiler must rest on a perfectly level surface.

It is advisable to provide a ﬂat, level cement basement capable of bearing the weight of the boiler full of water. For the dimensions of the basement, see the dimensions R x B (dimensions table).

If the burner is fed with fuel gas weighing more than air, the electrical parts must be placed higher than 500 mm above the ground.

The appliance cannot be installed outdoors as it was not so designed and does not have automatic antifreeze systems.

Technical features and dimensions

3.7 - HYDRAULIC CONNECTIONS

ATTENTION! Before connecting the boiler to the heating system, thoroughly clean the piping with an appropriate product compliant with UNI-CTI 8065, in order to eliminate metallic residue from processing and welding, oil and grease which could be present and which, reaching the boiler, could alter its functioning.

Attention! The ﬁttings of the boiler must not take the weight of the connecting pipes of the system; suitable supporting devices should be installed to do this.

The dimensions of the supply and return pipes for each boiler model are given in the DIMENSIONS table.

The connection pipes of the expansion vessel will start from the T3 attachment (see DIMENSIONS TABLES) and must have no shut-off valve.

Safety valve drain

Install a safety pressure valve on the ﬂow pipe within 0.5 m of the starting ﬂange, sized according to the capacity of the boiler and in compliance with local standards in force.

It is prohibited to place any type of shut-off valve between the boiler and expansion vessel or between the boiler and safety pressure valves. The valves used must be adjusted to trigger not beyond the maximum allowed operating pressure.

3.9.1 - RECIRCULATION PUMP

Check that the system is ﬁtted with a sufﬁcient number of air release valves.

Connection of expansion vessel

TERNOX 2S boilers are suitable for operating with forced water circulation both with the expansion vessel opened or closed.

An expansion vessel is always necessary to compensate the increase in water volume due to heating.

In the ﬁrst case, the hydrostatic column must be at least 3 m above the casing of the boiler and sufﬁcient to contain the volume increase of all the water of the system between the exposed surface of the water in the tank and the overﬂow pipe.

3.8 - FILLING AND EMPTYING THE SYSTEM

Attention! Do not mix the heating water with incorrect concentrations of antifreeze or anti-corrosion substances! This could damage the gaskets and cause noise during operation. Unical will not be held liable for damage to persons, animals or objects due to failure to comply with the above instruction.

TERNOX 2S boilers must always operate with forced water circulation and a minimum return temperature of 55°C. It is therefore recommended to use a recirculation pump, which also has an anti-condensation function, installed between the ﬂow and return connections upstream the mixing valve. This pump is dimensioned according to the formula:

Q = P x 22

where Q = Flow rate in l/hr P = Nominal output of boiler in kW and head 1÷2 m H2O

The values displayed in the table can be used as a reference.

TOTAL HARDNESS ppm 10 ALKALINITY mg/l CaCO3 750 PH 8÷9 SILICA ppm 100 CHLORIDES ppm 3500

When all system connections have been completed, the circuit can be ﬁlled.

A speciﬁc tap can be connected to the T4 attachment at the rear of the boiler for ﬁlling and draining.

ATTENTION! ANY DAMAGE TO THE BOILER CAUSED BY THE FORMATION OF FOULING OR BY CORROSIVE WATER WILL NOT BE COVERED BY THE WARRANTY.

3.9 - GAS CONNECTION

Connecting Gas

Danger! The gas connection must be carried out only by a qualiﬁed installer who must respect and apply that foreseen by relevant laws in force in the local prescriptions of the supply company. Incorrect installation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.

Before installation, we recommend a thorough inner cleaning of all fuel adduction piping to remove any residue which could jeopardise proper operation of the boiler.

If you smell gas: a) Do not turn electric switches on or off, use

a telephone or any other object which can create sparks;

b) Immediately open doors and windows to

create an air current to air out the room; c) Shut the gas cocks; d) Request the intervention of professionally

qualiﬁed personnel.

3.10 - CONNECTION TO THE FLUE

The TERNOX 2S boiler can be attached to the chimney in different ways; straight pipes or elbows can be used to exit from the rear, on the left, on the right, or else vertically to enter the ﬂue at a higher level. It is recommended to insulate the pipe connecting to the chimney to reduce heat loss and noise.

Along the section connecting the boiler to the ﬂue there must be suitable points for measuring ﬂue gas temperature and analysing combustion products.

The ﬂue gas duct and the ﬁtting to the ﬂue must be implemented in compliance with Standards and Legislation in force, with rigid ducts resistant to heat, condensation, mechanical stress and airtight.

The ﬂue must guarantee the minimum negative pressure foreseen by Standards in force, considering “zero” pressure at the ﬂue duct ﬁtting.

Inadequate or improperly sized ﬂues and ﬂue ducts can amplify combustion noise, generate condensation problems and negatively affect combustion parameters.

Non-insulated exhaust pipes are a potential source of risk.

The seals of the junctions must be made with materials resistant to temperatures of at least 250°C.

Along the section connecting the boiler to the ﬂue there must be suitable points for measuring ﬂue gas temperature and analysing combustion products.

Refer to national and local regulations in force for that which regards the cross-section and height of the chimney.

Technical features and dimensions

3.11 - FURNACE DOOR: ADJUSTMENT, OPENING AND CLOSING

IMPORTANT

- The door of the boiler must be opened when it is cooled off to avoid thermal shocks.

- The rear factory material of the door can show cracks after a short time of operation; this however does not reduce its insulation capacity nor jeopardise its lifespan.

The door is hinged and ﬁxed according to the indicated diagram: In these cases, the two hinges on the left are normally used as rotation hinges (from right to left), while the two on the right are used as closing hinges. It will be exactly the opposite when the door is opened from left to right. To invert rotation, just move the door support lock nut. The following adjustments can be made on the door: A) Adjustment in the vertical direction: by acting on the nut

of the upper hinge pin on which the door turns.

B) Adjustment in the transverse direction: loosen the hinges

ﬁxed on the front plate of the boiler and move them sideways.

C) Adjustment in the axial direction: by adjusting the tightening

nuts.

3.12 - BURNERS

The burners operating with the TERNOX 2S boilers must have the EC certiﬁcation and comply with:

- Gas appliance directive (90/396/EEC);

- EMC Directive - Electromagnetic Compatibility (89/336/EEC).

They must also be approved according to the speciﬁcations:

- UNI EN 267 - test methods for atomizing oil burners of the monobloc type.

- UNI EN 676 - air-blown burners for gaseous fuel.

- Efﬁciency Directive (92/42 EEC).

3.12.1 - SELECTING THE BURNER

Ø A

The correct choice and adjustment of the burner are fundamental for optimal operation of the boiler and therefore must be done carefully and not underestimated.

The burner must be chosen verifying that its ﬁring rate (fuel capacity - combustion chamber pressure) is compatible with the same features declared for the boiler.

Remember that pressure drops on the ﬂue side of the boiler, namely combustion chamber counter pressure, refer to zero pressure at the base of the chimney.

It is also recommended that the burner blast tube be no shorter than the minimum dimension shown in the following table and that the ﬂame which must be implemented be suitable for the characteristics of the combustion chamber.

The manufacturing companies of the burners can supply the dimensions of the ﬂames which their appliances develop, especially those approved based on the standards indicated above.

DIMENSIONS OF BURNER BLAST TUBE

TERNOx

2500

3500

4500

5800

7000

8500

10200

12500

15000

øA

mmL mm (min) 400

400

500

650

370

410

450

mm (max)

520

560

650

3.12.2 - INSTALLATION OF THE BURNER

The burner must be mounted to the door of the boiler guaranteeing perfect sealing of the combustion products.

The burner is supplied with a piece of ceramic ﬁbre cord which

must be placed on the blast tube of the burner to fully seal the space between the blast tube and the slot in the door.

Make sure that no gaps remain between the blast tube and the slot on the refractory material inside the door.

3.12.3 - CONNECTING FLAME CONTROL

WARNING LIGHT TO BURNER

The ﬂame control warning light is supplied with a threaded 1/8” connection with a 9mm pressure test nipple mounted on it, to be used with a silicone tube to measure back pressure in the combustion chamber. In place of this test nipple, which must be kept, an appropriate ﬁtting will be mounted to connect the ﬂame control warning light directly to the pressure chamber downstream the burner fan by means of a copper tube. The air blown by the fan will conveniently cool the warning light glass and keep it from blackening. If the cooling tube is not connected to the warning light, it could break.

Should a cone larger than the diameter of the blast tube be mounted, it must be removed before mounting the burner on the support plate and put back afterwards.

With the burner mounted, check that the ﬂexible hoses of the liquid fuel and the electric cables are long enough to allow the door to open 90°.

For gas-ﬁred burners, ﬂexible hoses cannot be used for connections. Therefore it must be equipped with a threaded or ﬂanged joint for disconnecting the ﬁnal section of the gas adduction tube.

Technical features and dimensions

ATTENTION: the ﬂame control warning light can be very hot; therefore pay the utmost attention.

3.13 - MOUNTING ELECTRIC PANEL

TERNOX 2S boilers are supplied with casing. Therefore to mount

the panel board, proceed as follows:

A) Dismount the right upper walkways (pos. 1 and 2). B) Fix the support box of the panel board to the bracket on the

right side of the boiler.

C) Remove the lower cover pos. 4 from the support box of the

panel board.

Fasten the panel board (pos. 5) to the support box pos. 3. D) Rotate the cover of the panel board frontwards after having

removed the two screws on the side and insert the electric inlet cables and the outlet probe capillaries through the slots at the base.

Insert the thermostat probe capillaries in the tube designed

for their passage, that is placed under the casing (see detail “A”).

Pay special attention when unrolling the capillaries and insert

the bulbs in the two holders, inserting the contact springs and blocking the capillaries with the ﬁxing springs.

E) After having carried out the electric connections, close the

panel board and reposition the lower cover of the support box.

F) Remount the upper walkways.

3.14 - ELECTRICAL CONNECTIONS

General warnings

The electrical safety of the appliance is guaranteed only when it has been properly connected to an efﬁcient earthing system carried out as intended by safety standards in force: pipes of the gas, water and heating systems are absolutely unsuitable as earthing electrodes.

It is necessary to verify this fundamental safety requirement. If in doubt, have the electric system carefully checked by professionally qualiﬁed personnel as the manufacturer is not liable for damage caused by failure to provide an earthing system.

Have professionally qualiﬁed personnel check that the electric system is adequate for the maximum power absorbed by the appliance, indicated on the data plate. Make sure in particular that the cross-section of the cables is suitable for the power absorbed by the appliance.

Use of any type of component using electric energy requires the 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 appli-

ance.

230V electric power supply connection

The electrical connections are illustrated in chap. 3.15 .... 3.19.

The boiler installation requires a connection to a 230 V - 50 Hz electric mains: this connection must be properly carried out as provided for by current IEC regulations.

Danger! Only a qualiﬁed technician may perform the electrical installation. Before performing connections or any type of operation on electrical parts, always disconnect electrical power and make sure that it cannot be reconnected accidentally.

Remember that a bipolar switch must be installed on the boiler power line with over 3 mm between contacts, easy to access, making maintenance quick and safe.

Technical features and dimensions

3.15 - STANDARD PANEL BOARD

The main switch 11 powers the board and the equipment connected to it. Switches 12 and 13 in turn cut power to the burner and to the C.H. pump. Thermostat 32 adjusts the working temperature of the boiler. The working thermostat is provided with two switching contacts to control the two-stage burners. The differential between the two contacts is 6°C (not adjustable).

11 Main switch with indicator light 12 Burner switch 13 System pump switch 31 Safety thermostat

The minimum thermostat, which can only be accessed after having lifted the cover of the electric control board, stops the C.H. pump until the boiler reaches the temperature of 50°C. The electric power line of the boiler's control board must have a switch with protective fuses.

32 Working thermostat 41 General fuse 42 Boiler thermometer

For use of the panel board, see the system manager instruction manual

If the Room thermostat is mounted, remove bridge 11-12

7-pole plug

Plug stage 2

(optional)

Ph Phase (230V ~50Hz) N Neutral F1 General fuse (max 4A) Ib Burner switch IG Main switch with indicator light Ipi System pump switch Ta Room thermostat

Te1 Working thermostat stage 1 (60°C÷90°C) Te2 Working thermostat stage 2

(54°C÷84°C) Tm Minimum thermostat (50°C) Ts Safety thermostat (100°C)

Pi System pump A Possible repetition of burner block B Possible working hour counter stage 1 C Possible working hour counter stage 2

3.16 - HYDRAULIC AND ELECTRICAL SYSTEM CONNECTION

The following ﬁgures show the typical layout of the connection of the boiler to the heating system with production of domestic hot water. Remember that TERNOX boilers operate with forced circulation.

TERNOx BOILER

Key:

Pr = recirculation pump VM = zone mixing valve Pi = heating system pump VE = expansion vessel IR = heating system distribution Ps = domestic water recirculation pump Pc = domestic hot water production charge pump TA = room thermostat

The standard panel board of the TERNOX boiler automatically switches the burner off when the temperature in the boiler reaches the value set on the control thermostat. It also manages the C.H. pump, which will only be activated when 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.

DOMESTIC HOT WATER

PRODUCER

The panel is set up to manage dual-stage or modulating burners. With this layout conﬁguration, the DHW storage tank loading pump will have the priority over the heating C.H. pump.

Technical features and dimensions

POWER SUPPLY

TO THE 7-POLE SOCKET OF THE BURNER

POWER SUPPLY

TERNOx BOILER

DOMESTIC HOT WATER

PRODUCER

NOTE: With absorption beyond 4A, place adequate contactors between the panel board and the loads

3.17 - OPTIONAL MASTER PANEL BOARD

The main switch 14 powers the board and the equipment connected to it. The switches 18 and 19 control the burner and P1 pump if the boiler operates in cascade. The switches 20 and 21 control the Z1 pump (direct) and Z2 pump (mixed). The thermostat adjusts the working temperature of the boiler: to achieve this, the thermostat must be placed at maximum full-scale pos. 33 .

Modulation of the burner will be managed by heat control. The electric power line of the boiler's control board must have a switch with protective fuses.

User

System

Service

Visual Inf.

Date/Time/Holiday

Solar/MF

Hot Water

Technician

Time Progr.

Heating circuit I

Heating circuit II

14 Main switch with indicator light 16 General fuse 18 Burner switch 19 P1 C.H. pump switch (cascade)

20 Pz1 direct zone C.H. pump switch 21 Pz2 mixed zone C.H. pump switch 33 Working thermostat 35 Safety thermostat

For use of the panel board, see the system manager instruction manual

The heating controller probes (boiler, storage tank, external, ﬂow) are included in the supply; the ambient probes 1 and 2 are optional; the mixing valve and relative control motor are not included in the supply.

The optional panel board of the TERNOX 2S boiler automatically switches the burner off when the temperature in the boiler reaches the value set on the heating controller. It also manages the pump to ﬁll a storage tank for DHW production. The heating systems are managed automatically based on the data detected by the boiler, external, ambient and ﬂow probes. The high temperature zone C.H. pump is made ready for operation by the control switch pos. 20, and will only switch off when the temperature set on the heating controller has been reached. The low temperature zone C.H. pump is made ready for operation by the control switch pos. 21, and will only switch off when the temperature set on the heating controller has been reached. The storage tank charge pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached.

Should ambient probes be mounted (optional), the room temperature will only be determined with the boiler curve set by the program.

The panel is set up to manage the modulating burners. With this system conﬁguration, the heating controller is capable of checking:

- direct zone system; the control unit commands the C.H. pump. The room temperature is controlled by the programming curves set in the heating controller;

- one zone system with motorised mixing valve: the ﬂow probe (downstream the mixing valve) must be ﬁtted; the control unit commands the C.H. pump and the mixing valve. The room temperature is controlled by the programming curves set in the heating controller;

- DHW production through storage tank;

- anti-legionella function with increase of water temperature in storage tank (function not enabled in factory, but can be enabled by customer).

Technical features and dimensions

L1 T2N S3T1 B4

7695810

28 42

(0°÷100°C)

(110°C)

230V~ 50Hz

(max 4A)

Spina a 7 poli

F1 (max 6 A)

B5 T7 T8

Spina a 4 poli

14 15 16 17 18 19 20 21 46 47 48 49 50 51 52 53 54 55

32 25

30 31 26

3727 38 39 40

teleruttore pompa

zona 1

teleruttore

pompa ricircolo

teleruttore pompa

zona 2

teleruttore pompa

boiler

teleruttore valvola

mix. zona 2

L1LLL

L2 NNNN

Pz1

Pz2 Pb

Zona mix 2

24 36

Ipz1

Ip1

Ipz2

29 43

44 45

HL-+

22 23

Nero

Blu

Marrone

Bianco

Rosso

Grigio

Blu

Marrone

Nero

Bianco

2 8

9 11

-2

-3

-4

-5

-6

-7

-8

MORSETTI DEL TERMOREGOLATORE

Lago Basic 0201 RV1

.....

MORSETTI DEL TERMOREGOLATORE

E8.5064

Can bus

-1

mix. zone 2

valve contactor

Zone mix 2

HEATING CONTROLLER TERMINALS

E8.5064

HEATING CONTROLLER TERMINALS

Lago Basic 0201 RV1

storage tank

pump contactor

zone 2

pump contactor

zone 1

pump contactor

contactor

recirculation pump

White

Black

Brown

Blue

Grey

Red

White

Brown

Blue

Black

4-pole plug

7-pole plug

Ipz1 System pump zone 2 switch

Pz1 System pump zone 1

Pz2 System pump zone 2

Pb Storage tank pump

Pr Recirculation pump

Ip1 Main ring pump switch

Mix zone 2 Mixing valve zone n° 2

Ph Phase (230V ~50Hz)

N Neutral

F1 General fuse (max 4A)

IG Main switch with indicator light

Ib Burner switch

Te Working thermostat (0°C÷90°C)

Ts Safety thermostat (100°C)

Ipz1 System pump zone 1 switch

Ipz1

Can bus

mix. zona 2

mix. zone 2

valve contactor

teleruttore valvola

535047

boiler

storage tank

pump contactor

teleruttore pompa

Ipz2

zone 2

zona 2

pump contactor

teleruttore pompa

zone 1

zona 1

LLLL1 L2NNNN

pump contactor

teleruttore pompa

PbPz2Pz1

VII

eBUS

0- 10V

A11

VIII IVA1 A2 A3 A4 A5 A6 A7 A8 A9 A10

23456718910 2345

3 4

FBR

1 2

T3 T4

KF/SPF

4 3 2 1

FBR

F9 F8 F6 F5 F1F2F3

SPF

VIII

PT1000

Licht

0-10V

III

21 2121 4321876510 921 3

F17 F15 F14 F13 F12 F11

IMP

T1 T2

L1 L1'

SONDA DI MANDATA

VALVOLA MISCELATRICE 2

FLOW PROBE

MIXING VALVE 2

E8.5064

SONDA DI COLLETTORE O DI CALDAIA

SE È PRESENTE UNA SOLA CALDAIA

EVENTUALE

SONDA BOILER

(IF INCLUDED)

STORAGE TANK PROBE

MANIFOLD OR BOILER PROBE

IF THERE IS ONLY ONE BOILER

SONDA ESTERNA

EXTERNAL PROBE

Bus

~50Hz 230V

+- L

43 21

F1 (max 6A)

Te (0°-100°C)

Ip1

Ts (11°C)



KF1

SPF

CAN-BUS

KF2

L1’

5K NTC

min

OFF

65°C

1K PTC

fix

fix 24h

contactor

teleruttore

Recirculation pump

White

Black

Bianco

Nero

Marron

Brown

Blu

Blue

Grigio

Grey

Rosso

Red

Bianco

White

Marron

Brown

Blu

Blue

Nero

Black

Pompa ricircolo

T8 T7 T6

STAGE 2

2° STADIO

STAGE 1

1° STADIO

B4 S3 T2 T1 NL1

ALLA PRESA A 4 POLI

DEL BRUCIATORE

TO THE 4-POLE SOCKET

OF THE BURNER

ALLA PRESA A 7 POLI

DEL BRUCIATORE

TO THE 7-POLE SOCKET

OF THE BURNER

T8T7T6B5

LNT1 S3T2 B4

SONDA DI CALDAIA

BOILER PROBE

Lago Basic

0201RV1

Technical features and dimensions

123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354555657H L- +

230V ~ 50Hz

POWER SUPPLY

ALIMENTAZIONE

Ph Phase (230V ~50Hz)

N Neutral

F1 General fuse (max 4A)

IG Main switch with indicator light

Ib Burner switch

Te Working thermostat (0°C÷90°C)

Ts Safety thermostat (100°C)

Ipz1 System pump zone 1 switch

Ipz1 System pump zone 2 switch

Pz1 System pump zone 1

Pz2 System pump zone 2

Pb Storage tank pump

Pr Recirculation pump

Ip1 Main ring pump switch

Mix zone 2 Mixing valve zone n° 2

3.18 - PROGRAMMING THE HEATING CONTROLLERS

For that which concerns adjustment or programming of the heating controllers, see the instruction manual attached to the individual heating controller. The following are the default parameters which cannot be modiﬁed.

As far as parameters which can be programmed by the user ac cording to his requirements, see the system manager instruction book.

PARAMETERS PROGRAMMABLE BY TECHNICIAN AND PROTECTED BY ACCESS CODE FOR HEATING CONTROLLER type E8.5064

INSTALLATION

Default Individual valuesValue rangeDescription

CODE NUMBER ENTRY

CODE NUMBER (variation) 0000

BOILER BUS ID ----

BUS ID 1

BUS ID 2 AF SUPPLY 01 (ON)

BUS CONNECTION 01

BUS SUPPLY 01 (ON)

TEMPERATURE MASTER

MAX-T HS1 MAX T-HEADER

MIN-T HS1 MIN T-HEADER

MAX-T HS2 95 °C MIN-T HS2 10 °C

VOLTAGE CURVE 11

CURVE 11-U2 0V CURVE 11-U2 10V CURVE 11-T1 0 ℃ CURVE 11-T2 100 °C

CURVE 11-UA 0V

T-WARM-UP 10

MINIMUM LIMIT HYSTERESIS HYSTERESIS TIME BOILER DETECTED OUTPUT LEVEL * see note

NEW CONFIGURATION MINIMUM MODULATION CASCADE 00 DHW LEVELS 00 CONTROL VARIANCE VIEW

NOMINAL OUTPUT INDEX VIEW

SWITCH VALUE VIEW BLOCK TIME VIEW

MAXIMUM BOILER TEMPERATURE 85

BOILER DYNAMICS UPWARD 30K

BOILER DYNAMICS DOWNWARD 20K

RESET TIME 50 MODULATION MAX 80%

MODULATION MIN 50% MIN MODULATION HS 0% IGNITION MODULATION INDEX 80% BOILER SEQUENCE 1 12345678 BOILER SEQUENCE 2 87654321

0000 - 9999

......, 01 - 08

(00), 01 - 015

(00), 01 - 016

00,01 (off/on)

0.01

00,01 (off/on)

00, 01 (OFF / ON)

30 °C - 110 °C

10 °C - 80 °C

30 °C - 110 °C

10 °C - 80 °C

0 - 11

0.00-10.00V

0.00-10.00V 00 - 120 °C 00 - 120 °C

0.00-10.00V

10 °C - 85 °C

00, 01, 02

2K - 20K<P>

00 - 30 min

VIEW ONLY

00 - 1000kW

00,01 (off/on)

00 - 100

00 - 08

(K)

0 - 100%

(-99) - 0 - (99)

REMAINING (min)

50 - 110°C

20 - 500K

5 - 500 0% - 100%

0% - 100% 0% - 100%

40% - 100%

----

01 (ON)

95 °C

10 °C

00 min

Default Individual valuesValue rangeDescription

SEQUENCE MODE 01

SEQUENCE CHANGE

CYCLE BLOCK

HYSTERESIS BURNER 2

BOILER COOLING FUNCTION

BOILER COOLING TEMPERATURE

HS 1 TYPE

HS 1 BUS

HS 2 TYPE

HS 2 STORAGE TANK

PUFFER

SCREED

SCREED PROGRAM

* For only one modulating boiler, set the ﬁrst stage value of the boiler at 1, in the second leave the dashes. For two modulating boilers in cascade, set the ﬁrst stage value at 1 for both boilers and in the second leave the dashes. All other boiler stages must be disabled.

** See E8.5064 heating controller instruction manual

01 - 06

10 - 800 HOURS

00 min - 30 min

2K - 20K<P>

00 - 01

30°C - 120°C

00 - 06

00 - 04

00 - 05

01 - 03

01 - 01 - 02

00, 01 (OFF - ON)

** see note

200 HOURS

00 min

00 OFF

DOMESTIC HOT WATER PRODUCTION

Default Individual valuesValue rangeDescription

CHARGE PUMP 01 (ON)

PARALLEL PUMP RUNNING 01

T DHW 20K

DHW HYSTERESIS 5 degrees

DHW FOLLOWUP 00 min

THERMOSTAT INPUT 00 OFF

THERMOSTAT FUNCTION 00 OFF

LOADING 00 OFF

RETURN

HEATING CIRCUIT FUNCTION 0

PUMP FUNCTION 0

MIXER OPEN ----

MIXER CLOSED ----

MAX FLOW TEMPERATURE 95 °C

MIN FLOW TEMPERATURE 30 °C

FROST PROTECTION TEMP 0 ℃

OUTSIDE TEMP DELAY 0.00

HEATING SLOPE DISTANCE 5 °C

MANDATORY REDUCTION 01

00 - 01 (OFF / ON)

00 , 01, 02, 03

00K - 50K

5K - 30K

00 min - 30 min

00, 01 (OFF / ON)

Exit level using

HEATING CIRCUIT 1

Default Individual valuesValue rangeDescription

00 - 04

00 - 03

5 - 25

20 °C - 110 °C

10 °C - 110 °C

(-15)°C - (5)°C

0:00 - 24:00

00K - 50K

00 - 01 (OFF / ON)

Technical features and dimensions

RETURN

Exit level using

HEATING CIRCUIT 2

°C

>1s

°C

BUS ID 1/2/11/Mod

Run

Default Individual valuesValue rangeDescription

HEATING CIRCUIT FUNCTION 0

PUMP FUNCTION 0

MIXER OPEN ----

MIXER CLOSED ----

MAX FLOW TEMPERATURE 45 °C

MIN FLOW TEMPERATURE 10 °C

FROST PROTECTION TEMP 0 ℃

OUTSIDE TEMP DELAY 0.00

HEATING SLOPE DISTANCE 5 °C

MANDATORY REDUCTION 01

00 - 04

00 - 03

5 - 25

20 °C - 110 °C

10 °C - 110 °C

(-15)°C - (5)°C

0:00 - 24:00

00K - 50K

00 - 01 (OFF / ON)

RETURN

Exit level using

SOLAR M/F

Default Individual valuesValue rangeDescription

MF (1-4) FUNCTION 00,00,01,02

MF (1-4) T- NOM 30°C

MF (1 - 4) HYSTERESIS 5°C

F 15 FUNCTION 0

RETURN

Exit level using

00 - 26

00 - 03

5 - 25

PARAMETERS PROGRAMMABLE BY TECHNICIAN FOR HEATING CONTROLLER Lago Basic 0201 RV 1

1 1) Switch selector to burner (1)

2) Press ok (2)

3) Turn the knob (3) until mm appears on the display (modulating burner)

4) Press ok (2) 2 1) Switch selector (1) to mixer valve symbol

2) Press ok (2)

3) Turn the knob (3) and set the burner damper time (time necessary to switch from minimum output to maximum output)

4) Press ok (2) 3 1) Switch the selector (1) to BUS ID

2) Press ok (2)

3) Turn the knob (3) until the number 1 appears on the display (boiler ID)

4) Press ok (2). Turn the knob 1 back to pos. RUN.

3.19 - HYDRAULIC AND ELECTRICAL

CALDAIA TERNOx

CAN-BUS

KF2

KF1

SPF



L1’

1K PTC

65°C

5K NTC

OFF

min

fix 24h

fix

Lago Basic

0201RV1

Pz1 Pz2

SYSTEM CONNECTION

The following ﬁgures show the typical layout of the connection of the boiler to the heating system consisting of 2 zones one of which controlled by a motorised mixing valve. DHW production can also be managed.

ROOM PROBE 1 (FBR1)

FLOW PROBE 2 (VFAS)

STORAGE TANK PROBE (SPFS)

BOILER PROBE (KFS)

EXTERNAL PROBE (AFS)

ROOM PROBE 2 (FBR1)

Remember that TERNOX 2S boilers operate with forced circulation.

Key:

Pr = recirculation pump VM2 = zone mixing valve Pz1 = direct zone heating system pump Pz2 = mixed zone heating system pump VE = expansion vessel IR1 = direct zone heating system distribution IR2 = mixed zone heating system distribution Ps = domestic water recirculation pump Pb = DHW production charge pump SPFS = storage tank probe KF = boiler probe (E8 heating control) KF1 = boiler probe (Lago Basic heating control) VFAS = ﬂow probe 2

TERNOx BOILER

DOMESTIC HOT WATER

PRODUCER

Technical features and dimensions

LNT1 S3T2 B4

ALLA PRESA A 4 POLI

DEL BRUCIATORE

2° STADIO

8910

11 12

15 16

18 19 20

21 22

25 26

28 29 30 31 32 33 34 35 36 37 38 39 40

41 42

45 46

48 49 50 51 52 53 54 55 56 57

NL1

ALLA PRESA A 7 POLI

DEL BRUCIATORE

1° STADIO

T8T7T6B5

ALIMENTAZIONE

230V ~ 50Hz

Nero

Blu

Marron

Bianco

Rosso

Grigio

Blu

Marron

Nero

Bianco

CALDAIATERMAX

CAN-BUS

678

KF2

KF1

SPF



L1’NL1

452

1K PTC

65°C

5K NTC

OFF

min

fix 24h

fix

Lago Basic

0201RV1

2 3 4 5 6 71 8 9 10

2 3 4 5

~50Hz 230V

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

A11

L1 L1'

T1 T2

T3 T4

4 3 2 1

2 1 2 1 2 1

4 3 2 18 7 6 510 9

2 1

+ - L

Bus

PT1000

KF/SPF

III

3 1

FBR

IMP

Licht

0-10V

SPF

eBUS

0- 10V

VIII

F17 F15 F14 F13 F12 F11

VII

F9 F8 F6 F5 F1F2F3

3 1

FBR

E8.5064

Pz1 Pz2

230V - 50 Hz

POWER SUPPLY

PRODUCER

DOMESTIC HOT WATER

White

Black

Brown

Blue

Grey

Red

White

Brown

Blue

Black

POWER SUPPLY

STAGE 2

STAGE 1

TO THE 4-POLE SOCKET

TO THE 7-POLE SOCKET

OF THE BURNER

TERMAX BOILER

ROOM PROBE 1

(FBR1)

FLOW PROBE 2

(VFAS)

STORAGE TANK PROBE

(SPFS)

BOILER PROBE (KF)

EXTERNAL PROBE (AFS)

ROOM PROBE 2

(FBR1)

NOTE: With absorption beyond 4A, place adequate contactors between the panel board and the loads

°C

>1s

°C

BUS ID 1/2/11/Mod

Run

3.20 - CASCADE PANEL BOARD

The main switch 11 powers the board and the equipment connected to it. The switches 12 and 13 control the burner and P1 pump if the boiler operates in cascade.

The thermostat adjusts the working temperature of the boiler 2: to achieve this, the thermostat must be placed at maximum full-scale pos. 32 . Modulation of the burner will be managed by heat control. The electric power line of the boiler's control board must have a switch with protective fuses.

11 Main switch with indicator light 12 Burner switch 13 P1 C.H. pump switch (cascade)

32 Working thermostat 41 General fuse 42 Thermometer

31 Safety thermostat

For use of the panel board, see the system manager instruction manual. As far as the practical connection and operating diagrams are concerned, see the documentation supplied inside the panel board.

The boiler probe is included in the supply.

Technical features and dimensions

°C

>1s

°C

BUS ID 1/2/11/Mod

Run

PARAMETERS PROGRAMMABLE BY TECHNICIAN FOR HEATING CONTROLLER Lago Basic 0201 RV 1 ON BOILER N°2

1 1) Switch selector to burner (1)

2) Press ok (2)

3) Turn the knob (3) until mm appears on the display

4) Press ok (2) 2 1) Switch selector (1) to mixer valve symbol

2) Press ok (2)

3) Turn the knob (3) until the number 15 appears on the display (burner servomotor time)

4) Press ok (2) 3 1) Switch the selector (1) to BUS ID

2) Press ok (2)

3) Turn the knob (3) until the number 2 appears on the display (boiler ID)

4) Press ok (2). Turn the knob 1 back to RUN.

DELL’IMPIANTO

SPF

CALDA SANITARIA

PRODUTTORE ACQUA

DOMESTIC HOT

WATER PRODUCER

IR/BT

Pz2

Vmix2

IR/AT

OF THE SYSTEM

HYDRAULIC SEPARATOR

Pz1

FOR PERFECT BALANCING

PER IL PERFETTO BILANCIAMENTO

EVENTUALE SEPARATORE IDRAULICO

Ps = domestic water recirculation pump

P1 = circulation pump

Pb = DHW production charge pump

SPF = storage tank probe

KF = E8.5064 heat control boiler probe

KF 1= Lago Basic 0201 RV 1 heat control boiler probe

VF = ﬂow probe

AF = external probe

PANNELLO STRUMENTI

CASCATA

PANEL BOARD

CASCADE

°C

Run

BUS ID 1/2/11/Mod

°C

>1s

can bus

Solare/M

isc.

Circuito r

isc.

Circuito r

Acqua Calda

pianto

21.0

Tecnico

r.Tem

Prog

Utente

Visual Inf

acanz

a/V

Data/Or

vizio

Ser

°C

Run

BUS ID 1/2/11/Mod

°C

>1s

18 19 20 21 22 23

14 15 16 17

PROBE

EXTERNAL (AF)

SONDA

ESTERNA (AF)

3.21 - HYDRAULIC AND ELECTRIC SYSTEM CONNECTION WITH BOILERS IN CASCADE

The ﬁgure shows the typical layout of the connection of the boiler to the heating system consisting in 2 boilers in cascade serving 1 high temperature zone + 1 low temperature

zone controlled by a motorised mixing valve + domestic hot water production.

Boiler n°1 is equipped with a MASTER panel board, boiler n°2 with a CASCADE panel board.

PANNELLO STRUMENTI

MASTER

PANEL BOARD

MASTER

TERNOX 2S 2 BOILER

CALDAIA TERNOX 2S 2

Technical features and dimensions

TERNOX 2S 1 BOILER

CALDAIA TERNOX 2S 1

Key:

M = ﬂow

Rat = HIGH temperature return (NOT USED)

Rbt = LOW temperature return

Vmix2 = zone mixing valve (motorised)

Pz1 = HIGH TEMPERATURE zone heating system pump

Pz2 = LOW TEMPERATURE zone heating system pump

VE = expansion vessel

IR/AT = HIGH TEMPERATURE heating system distribution

IR/BT = LOW TEMPERATURE heating system distribution

The panel boards of the XC-K boilers (in cascade) automatically switch the burners off when the temperature in the boiler reaches the value set on the heating controller. They also manage the pump to ﬁll a storage tank for DHW production. The heating systems are managed automatically based on the data detected by the boiler, external, ambient and ﬂow probes. The high temperature zone C.H. pump is made ready for operation by the control switch pos. 20 of the MASTER board, and will only switch off when the temperature set on the heating controller has been reached. The low temperature zone C.H. pump is made ready for operation by the control switch pos. 21 of the MASTER board, and will only switch off when the temperature set on the heating controller has been reached. The storage tank charge pump for DHW production switches on automatically and will only switch off when the temperature set on the heating controller has been reached. The panel is set up to manage the modulating burners. With this system conﬁguration, the heating controller is capable of checking:

- direct zone system; the control unit commands the C.H. pump. The room temperature is controlled by the programming curves set in the heating controller;

- DHW production through storage tank;

- anti-legionella function with increase of water temperature in storage tank (function not enabled in factory, but can be enabled by customer).

For practical connections, both electrical and of the probes, see the diagrams supplied with the MASTER and CASCADE panel boards.

3.22 - COMMISSIONING

3.22.1 - Preliminary checks

Commissioning must be done by professionally qualiﬁed personnel. Unical will not be held liable for damage to persons, animals or objects due to failure to comply with the above instruction.

After connecting the hydraulic and electrical system and the fuel line to the boiler, and before starting up the boiler, it is advisable to check the following:

Have all the hydraulic and electrical systems and the safety devices and fuel been connected in compliance

with the domestic and local laws in force?

Are the expansion vessel and the safety valve (when applicable) connected correctly and cannot be shut off?

Are the bulbs of the operating, safety, minimum thermostats and that of the thermometer inserted in their

conduits?

Are the control and safety devices working and conﬁgured correctly?

Are the refractory coverings intact?

Are the combustion air intake line and the ﬂue gas evacuation line compliant with the applicable standards in

force?

does the gas used (models with gas burner) correspond to boiler calibration?

is the fuel supply system sized according to the capacity required by the boiler? is it equipped with all safety and control devices required by the standards in force?

are the mains voltage and frequency compatible with the burner and the electrical equipment of the boiler?

is the burner assembled according to the instructions in the manufacturer's manual?

has the burner blast tube inﬁll been performed correctly?

Is the system full of water and does not contain any air?

Are the drain valves closed and the system cut-off devices fully open?

is the gas supply cock open (models with gas burner)?

has gas leakage been checked (models with gas burner)?

Is the outside main switch ON? Is the pump/are the pumps working correctly?

has the system been checked for water leaks?

Are the ventilation conditions and minimum distances to perform any maintenance guaranteed?

Technical features and dimensions

Has the operator been trained and has the documentation been supplied?

Please tick the operations performed

3.22.2 - Ignition and extinction

Ignition

When the checks indicated in the previous paragraph are successful, the burner can be commissioned by a technician qualiﬁed and acknowledged by the Manufacturer of the burner.

The technician takes on all responsibility regarding calibration within the declared and approved output range of the boiler.

After having opened the fuel shut-off valves and made sure there are no leaks in the adduction circuit, set all switches at ON.

The burner is now ready for commissioning and adjustment, performed solely by the above-mentioned technician.

During commissioning, you must check that the door, the burner ﬂange and connections with the chimney are airtight and that there is a slight negative pressure at the base of the ﬂue.

The fuel ﬂow rate must correspond to the plate data of the boiler. It must by no means exceed the maximum declared nominal output value.

The ﬂue gas temperature must never drop below 160°C.

Extinction

- Set the operating thermostat at minimum.

- Disconnect power to the burner and close the fuel supply.

- Leave the pumps running until they are stopped by the mini-

mum thermostat.

- Disconnect power to the electric panel.

3.23 - ADJUSTING THE BURNER

The following instructions are intended exclusively for service personnel authorised by the manufacturer of the burner.

Burner calibration and preliminary operations are described in the burner's instruction booklet.

Gas-ﬁred burners are equipped with a gas valve with which the ﬂow rate can be determined: upon commissioning the actual thermal ﬂow rate must always be controlled by means of the counter on the main piping, making sure it is not below the minimum value on the data plate of the boiler.

When the burner is adjusted properly, the following values should be obtained, measured at the chimney by a speciﬁc analyser:

for diesel oil with max visc. 1.5°E at 20°C:

- CO2 ~ 12÷13%

- Bacharach ﬂue gas index ‹1

- Flue gas temperature ~ 190÷210 °C

2) with natural gas:

- CO2 ~ 9÷10%

- Flue gas temperature ~ 180÷200°C

(values for boiler cleaned with water at ~ 70°C).

The ﬂow rate of the fuel should be adjusted to the actual requirement of the system without, on the one hand, exceeding the indicated ﬂue gas temperature and on the other, without dropping below 160°C.

3.24 - CHECKS DURING AND AFTER COMMISSIONING

When the appliance has been commissioned, check that it performs a shutdown and subsequent ignition:

- by modifying the boiler thermostat calibration;

- by intervening on the main switch of the panel board.

Check tightness of all the gaskets on the water and ﬂue gas side. They must be further tightened when hot to guarantee perfect sealing.

This operation is crucial for the gasket of the doors, of the burner plate and of the ﬂue gas casing so that toxic and dangerous combustion fumes do not escape from the boiler room.

Then tighten them when hot to guarantee perfect sealing.

3.25 - ALKALINE OR “BOILING” WASH

This is a treatment carried out by specialised companies on the new boiler.

It removes deposits consisting of residual oil, grease and metal oxides caused by processing and assembly of the boiler.

If these substances are not eliminated, corrosion is caused due to the obstruction of the formation of a passivation coating on surfaces exposed to water.

Execution of alkaline wash:

- Fill the boiler with water.

It is also very important to check sealing of the boiler/chimney ﬁtting for the reasons expressed above.

It is also extremely important to progressively tighten the gasket of the railing and manhole of the generator as the temperature increases for perfect sealing: otherwise the ﬁrst time it leaks, the gasket would need to be replaced.

Check that the appliance fully stops when acting on the main switch of the system.

After all these conditions have been met, the burner must be properly calibrated at the maximum output allowed by the boiler, analysing the ﬂue gas to achieve correct combustion and as few polluting emissions as possible.

As the pressure of the water in the system increases during operation, make sure that its maximum value does not exceed the design pressure of the boiler.

- Instruments (pressure switch, pressure gauge etc.) must be

excluded before starting the wash.

- Introduce 0.3 to 1% of caustic soda, sodium carbonate or

trisodium triphosphate into the total content of the water.

- Speciﬁc surfactants must be added to these substances

ranging from 0.05 to 0.15% of the total content of the water.

- Switching on the burner, bring the water to a temperature of

80-90°C and have it circulate in the boiler for 12-14 hours.

- Slowly empty the content and simultaneously introduce cold

water to rinse it properly.

3.26 - BOILER SHUTDOWN

To shut down the boiler for a long period, proceed as follows:

- perform the preservation procedure of the water side, which can be wet or dry;

- turn off the main switch of the electric panel and disconnect the power supply;

- close the fuel shut-off valve;

- perform the ﬂue gas side preservation procedure;

- protect all control, adjustment and safety devices from dust and humidity.

"Wet preservation" entails completely ﬁlling the boiler and adding preserving or neutralising products to the water.

Then the system must be sealed by closing all the shut-off valves.

This type of preservation is not recommended if there is a risk of freezing.

"Dry preservation" requires emptying the boiler.

Open the railing, completely dry the inside of the boiler by blowing air and insert highly hygroscopic substances (e.g. quick lime).

Close all the shut-off valves and the railing, thus sealing the generator.

Preservation of the ﬂue gas side is performed as follows: open the inspection doors, remove the burner and disassemble the cap, clean all surfaces from soot (which could contain sulphur which becomes sulphuric acid when it becomes moist) and insert highly hygroscopic substances (e.g. quick lime) into the furnace and ﬂue gas casing.

Hermetically close all the inspection doors, put the burner cap and burner back in place.

Maintenance instructions

INSPECTIONS AND MAINTENANCE

Routine maintenance is essential in the interest of the safety, efﬁciency and durability of the appliance. All maintenance must be carried out by qualiﬁed personnel. Yearly maintenance of the appliance is mandatory in compliance with Laws in force.

Failure to perform Inspections and Maintenance can entail material and personal damage.

All cleaning and maintenance operations must be preceded by closing the fuel supply, after having disconnected electricity. In order to make the most of the boiler, you should properly clean the combustion chamber, smoke pipes and smoke chamber.

IMPORTANT NOTE

Before opening the furnace door, it is necessary to take the following safety measures:

- Close the fuel supply (diesel oil or gas) 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 OF SERVICE.

Inspections help to determine the actual status of the appliance and to compare it with the nominal status. This is done through measuring, controls and observation.

Maintenance is required to eliminate any differences between the actual status and the nominal status. This is normally done by cleaning, setting and replacing individual components subject to wear.

Maintenance intervals and their extent are determined by a specialist based on the status of the appliance ascertained through inspection.

Routine maintenance

Maintenance must be established based on the fuel used, the number of ignitions, the features of the system, etc. Therefore it is not possible to establish beforehand the frequency of maintenance.

The following cleaning intervals are recommended depending on the type of fuel:

- Gas-ﬁred boilers: once a year.

- Diesel oil-ﬁred boilers: twice a year.

- Fuel oil boilers: every 300 hours of operation.

In any case, local standards regarding maintenance must be respected. During routine maintenance operations, the tube bundle and furnace must be brushed. Remove deposits built up in the ﬂue gas casing by opening the inspection doors. For more energetic actions, remove the rear smoke chamber and replace the ﬂue gas gasket if worn. Check that the condensation discharge is not obstructed. Check that the control and measurement devices serving the generator work properly. On this occasion, the amount of recirculation water used must be detected. After having analysed the water, perform preventive descaling. Calcium and magnesium salts dissolved in the water with repeated top ups give rise to deposits in the boiler and cause the sheet-metal to overheat, with possible damage which cannot be attributed to the materials or manufacturing, and therefore is not covered by warranty. After having performed maintenance and cleaning operations and subsequent ignition, check the seals of the door and of the smoke chamber. If any combustion products leak, replace the relative gaskets. The operations carried out must be written in the boiler room booklet.

Extraordinary maintenance

Extraordinary maintenance at end of season or for long idle periods. All the operations described in the previous chapter must be carried out, plus:

- After cleaning the ﬂue gas circuit, pass a rag soaked with a solution diluted with caustic soda. After leaving it to dry, repass all the surfaces with a rag soaked in oil.

- It is recommended to place hygroscopic substances inside the furnace (quick lime, silicon gel in small containers) and to close it hermetically so that no air enters.

- Do not empty the system and the boiler.

- Protect screws, nuts and pins of the door with graphite grease.

The operations carried out must be written in the boiler room booklet.

Inspection and maintenance instructions

To assure long-term functioning of your appliance and to avoid altering its approved status, only original Unical spare parts must be used.

Before proceeding with maintenance, always perform the following operations:

• 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 that it cannot be re-connected accidentally.

• Close the gas shut-off valve upstream the boiler (where

present).

• Close any shut-off valves on the heating ﬂow and return pipes.

Boiler body maintenance

Danger! Before performing any maintenance, make sure the boiler and its components have cooled down.

Disconnect the boiler from the electric mains and shut the gas supply (if any) to the appliance.

Attention! Before cleaning the boiler body, protect the panel board against any water sprays.

After having completed all maintenance work, always perform the 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 of the system.

• Open the gas shut-off valve (where present).

• Reconnect the appliance to the electric mains and engage the switch.

• Check tightness of the appliance on the gas side (where

present) and on the water side.

• Vent the heating system and restore pressure if necessary.

Should you decide to temporarily deactivate the boiler, you must:

a) intercept the supplies: electric, water and fuel; b) empty the water system if antifreeze is not used.

Check condition of gaskets and insulation ﬁbres

The insulation ﬁbre of the door can show cracks after a short time of operation; this however does not reduce its insulation capacity nor jeopardise its lifespan. Check the condition of the seal gasket which must not show signs of deterioration; if so, it must be replaced, using only original spare parts.

Check the condition of the smoke chamber inspection cover gasket. Replace it if worn, using only original spare parts.

Once a year, at the end of the heating season, the boiler must receive a general cleaning. Before performing any maintenance, make sure that all the precautions 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;

- brush the smoke ducts energetically to remove any trace of ﬁlth.

Maintenance of burner

Burner maintenance must be carried out by personnel authorised by its manufacturer (or else the warranty shall be terminated).

Checking ignition electrode

Burner maintenance must be carried out by personnel authorised by its manufacturer (or else the warranty shall be terminated).

Maintenance instructions

TROUBLESHOOTING

The following are the most common causes of faults and their solutions.

FAULT:

The burner does not switch on.

FAULT:

The burner switches on regularly but shuts down immediately.

FAULT:

Difﬁculty in adjusting the burner and/or lack of efﬁciency.

FAULT:

The burner is easily soiled with soot.

FAULT:

Smell of gas and/or unburnt products.

SOLUTIONS:

- check the electrical connections;

- check the regular ﬂow of fuel;

- check that the fuel feeding system is intact and clean, and that it is deaerated;

- check that ignition sparks are performed regularly and operation of the burner appliance;

- check triggering of the boiler safety thermostat with manual rearming;

- check calibration of the adjustment thermostat.

SOLUTIONS:

- check ﬂame detection, air calibration and operation of the burner appliance.

SOLUTIONS:

- check that the burner, boiler, boiler/chimney duct and chimney are clean;

- check sealing of the ﬂue gas circuit (inspection doors, burner plate, ﬂue gas casing, boiler/chimney ﬁtting);

- check the regular ﬂow of fuel and the real output supplied by the burner;

- check for any scales and perform a chemical wash.

SOLUTIONS:

- check burner adjustment (ﬂue gas analysis);

- check the amount of fuel;

- check clogging of the chimney and cleanliness of the burner air path (dust).

SOLUTIONS:

- check sealing of the fuel supply system (if gas);

- check sealing of the ﬂue gas circuit (inspection doors, burner plate, ﬂue gas casing, boiler/chimney ﬁtting);

- check that the rubber holder on the ﬂame warning light is connected to the air socket of the burner or if it is plugged.

FAULT:

The boiler does not reach operating temperature.

FAULT:

The boiler is at operating temperature but the heating system is cool.

FAULT : The safety thermostat triggers.

FAULT:

The boiler safety valve triggers.

FAULT:

Overheating of members due to lack of water in boiler.

FAULT:

Water on ﬂoor near ﬂue gas casing (condensation).

SOLUTIONS:

- check that the ﬂue gas side and water side of the boiler are clean;

- check coupling, adjustment and efﬁciency of the burner;

- check the temperature set on the thermostats and their correct operation;

- check positioning of the thermostat probes;

- make sure that the boiler has sufﬁcient output for the system.

SOLUTIONS:

- check that the system is deaerated;

- check that the circulation pumps work properly.

SOLUTIONS:

- check that electric wiring is correct;

- check positioning of the thermostat probes;

- check the calibration of the thermostats and their correct operation.

SOLUTIONS:

- check the pre-load pressure of the system;

- check that the expansion vessel is sized correctly;

- check that the safety pressure valves are calibrated correctly.

SOLUTIONS:

- switch off the burner, do not introduce water or open the inspection doors and wait for return to room temperature before performing any operation.

SOLUTIONS:

- check the correct positioning of the probes, correct operation and calibration of the boiler adjustment thermostat (minimum 60°C);

- check that the exhaust in the ﬂue gas casing is connected to a collection recipient;

- check that the anti-condensation pump (if present) works correctly and is properly adjusted;

- check that the water temperature returning from the system is no less than 50 °C.

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Unical TERNOx 2S Instructions On Installation, Use And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual