TERSEC TERSEC DUO - Unical AG€¦ · TERSEC TERSEC DUO INSTALLATION, USE ... 2 GENERAL...

28856 - 05/05rev.0

TERSECTERSEC DUO

INSTALLATION, USE ANDSERVICING INSTRUCTION(to be kept by the user)

2

GENERAL INFORMATIONSIntroductionThis manual supplies a summary of what has to be followed during the installation, use and servicing of the UNICAL boilers, TERSEC range.In the course of this text the short name TRS can be used to indicate the TERSEC boiler.Choice of the boilerFor a correct choice and application of the TERSEC boilers it is necessary to follow the instructions given in this manual.InstallationThe installation of the boilers and the auxiliary equipments, related to the heating system, must be in conformity with all the regulations andrules in force.It is law that all the gas appliances are installed, commissioned and serviced by a registered installer in accordance with the regulations below.Failure to install appliances correctly could lead prosecution. It is in your own interest, and that of the safety, to ensure the law is complied with.The following must be complied with:Current Building Regulations and Clean Air Act.Water Authority Regulations.Local Authority Regulations and Regional Bylaws.Gas Safety Regulations.Any special regional requirements of local Electricity and Gas undertaking.Fire Service and Insurance Company requirements.CommissioningThe main purpose of the commissioning is to verify the correct operation of all the safety and control devices.Before leaving the installation the commissioner has to control the operation of the boiler for, at least, a complete working cycle.GuaranteeThe boiler guarantee is bound to the compliance of the the requirements stated in this manual, and any non-fulfilment or modification will makeit void.NormativeIt is the responsibility of the installer to fulfil all the regulations concerning the boiler house, the safety devices, the chimney, the fuel supplylines, the electrical installations and all the other local requirements and safety instructions.ApprovalsThe UNICAL boilers, TERSEC range, have been tested and CE certified for the gas operation according to the following directives:- Gas Appliances Directive (90/396 CE), compulsory as per 1st January 1996;- Efficiency Directive (92/42 CE), compulsory as per 1st January 1998;- The conformity to the Low Voltage Directive (73/23 CE), compulsory as per 1st January 1997 has been verified and ascertained by GASTEC

ITALIA.The conformity to the EMC (Electro Magnetic Compatibility 89/336 CE), compulsory as per 1st January 1996, is not applicable to the TERSECboilers because they do not have electronic components.For the time beeing there are no European Directives covering the oil fired boilers, except the Efficiency Directive (92/42 CE).Data plate and Serial No.The data plate, supplied in a separate enveloppe with the relevant documents, makes reference to a serial No, embossed in an aluminium plateriveted to the front tube plate in the lower RH side corner.Use of the boilerThis boiler has to be used for heating the water at a temperature not higher than the boiling temperature in the installation conditions.

WARNINGWhen the boiler is operated with a pressure jet gas burner, because it does not belong to any of the categories among those listed in the AnnexII to the Directive 97/23/CE (regarding pressure equipment) and beeing, furthermore, mentioned in the Directive 90/396/CE (Gas ApplianceDirective) to which the art. 1, clause 3, paragraph 6.5 makes reference, it is excluded from the scope of the Directive.

3

CONSTRUCTIONAL-DIMENSIONALTECHNICAL CHARACTERISTICS .................... page 51.1 Construction of the TERSEC boilers .................................... page 51.2 Working principle ................................................................... page 51.3 Dimensions and hydraulic connections ................................ page 6

INSTALLATION ................................................................. page 132.1 Packaging .............................................................................. page 132.2 Handling ................................................................................. page 132.3 Positioning in the boiler house .............................................. page 132.4 Connection to the chimney ................................................... page 142.5 Water connections ................................................................. page 14

2.5.1 Water supply ................................................................. page 142.5.2 Feeding water quality ................................................... page 142.5.3 C.H. flow and return connections ................................ page 142.5.4 Connection of filling and drain tap ............................... page 142.5.5 Connection of the pressure relief valve, expansion pipe and vessel ............................................................ page 142.5.6 Shunt pump .................................................................. page 15

2.6 Furnace door: adjustment, opening & closing ..................... page 152.6.1 Important note .............................................................. page 15

2.7 Burner .................................................................................... page 162.7.1 Mounting of the two-stage or modulating burners ...... page 16

2.8 Connection of the sightglass to the burner via a cooling line .. page 162.9 Casing assembly ................................................................... page 17

STANDARD PANEL BOARD .................................. page 283.1 Functions descriptions .......................................................... page 283.2 Electrical supply .................................................................... page 28

OPTIONAL PANEL BOARD(WITH OUTER COMPENSATOR) ................................................. page 294.1 Functions description ............................................................ page 294.2 Panel board with outer compensator (on request) .............. page 304.3 Electrical and hydraulic connections of C.H. ....................... page 314.4 Electrical and hydraulic connections of C.H.

and D.H.W. production circuit ................................................ page 324.5 Outer compensator ................................................................ page 32

1

2

STANDARD PANEL BOARD FORTERSEC DUO ..................................................................... page 345.1 Functions description ............................................................ page 345.2 Electrical wiring diagram for single phase burner and pump .. page 35

PANEL BOARD FOR TERSEC DUO (OPTIONAL)(WITH OUTER COMPENSATOR) ................................................. page 366.1 Introduction ............................................................................ page 366.2 Panel board with outer compensator (optional) ................... page 366.3 Electrical and hydraulic connections of C.H.

and D.H.W. production circuit ................................................ page 38

COMMISSIONING AND OPERATION ............ page 397.1 Preliminary check .................................................................. page 397.2 First commissioning .............................................................. page 397.3 Switch OFF of the boiler ....................................................... page 39

MAINTENANCE ................................................................ page 408.1 General rules ......................................................................... page 408.2 Ordinary maintenance ........................................................... page 408.3 Extraordinary maintenance ................................................... page 418.4 Cleaning of the boiler ............................................................ page 418.5 Check of the boiler operation ................................................ page 428.6 Check of the burner operation .............................................. page 428.7 Boiler house ........................................................................... page 42

7

6

5

4

3

8

4

GAS SAFETY (INSTALLATIONAND USE) REGULATIONS,1994

It is law that all gas appliances are installedand serviced by a CORGI registered installerin accordance with the above regulations.Failure to install appliances correctly couldlead to prosecution.It is in your own interest, and that of safety,to ensure the law is complied with.The installation of the boiler MUST also bein accordance with the latest I.E.E. WiringRegulations, local building regulations, byelawsof the local water authority, the buildingregulations and the Building Standards

(Scotland) and any relevant requirements ofthe local authority.Detailed recommendations are contained in thefollowing British Standard Codes of Practice:BS 6891 Low pressure installation pipes.BS 5449 Forced circulation hot water

systems.BS 5546 Installation of gas hot water

supplies for domestic purposes(2nd Family Gases).

BS 6644 Ventilation (for gas appliances ofrated input exceeding 60 kW).

HEALTH & SAFETYDOCUMENT No. 635The Electricity at Work Regulations, 1989.

The manufacturer's notes must NOT betaken, in any way, as overriding statutoryobligations.

IMPORTANT. These appliances are CEcertificated for safety and performance.It is, therefore, important that no externalcontrol devices, e.g. flue dampers, economisersetc., are directly connected to these appliancesunless covered by these Installation andServicing Instructions or as otherwiserecommended by Unical in writing.If in doubt please inquire.

Any direct connection of a control device notapproved by Unical could invalidate thecertification and the normal appliance warranty.

Notes.To obtain the gas consumption:a. For l/s divide the gross heat input (kW) by

C.V. of the gas (MJ/m³).b. For ft³/h divide the gross heat input (Btu/h)

by C.V. of the gas (Btu/ft³).

5

1 CONSTRUCTIONAL-DIMENSIONALTECHNICAL CHARACTERISTICS

1.1 - CONSTRUCTION OFTHE TERSEC BOILERS

The TERSEC (short name: TRS), three passboilers, are of horizontal type (oval hape frommodel 65 to 350 and the model 800; eightshape from model 450 to 600 and cylindricalshape from model 1000 to 1200) to whoseinside are placed: in the highest part thecylindrical furnace completely wet, in whichthe first smoke pass takes place; in the lowestpart the flame reversion pipe, used as secondsmoke pass and beside to it, the tube bundle,used as third smoke pass.A special manifold, positioned incorrespondence of the flow ane return pipes,optimises the water circulation and reducesthe stratification phenomenon, facilitating amore homogeneous distribution of the watertemperatures inside the boiler body.The guided route of the combustion gasesallows the maximum exploitation of the thermalexchange surfaces and the uniform balanceof the material stress.The tube bundle is positioned in the lowestand coldest part of the boiler, because madeof special and patented pipes with controlledheat exchange, which are able to impede thecondensate formation.The special geometry of the TERSEC boilers(three pass boiler) and the innovative exchan-ge surfaces (pipes at controlled heat exchan-ge) allow to use these boilers as sliding tempe-rature and Low NOx boilers.In the models TRS 65 and TRS 90 the flowand return connections are place on back side;in the remaining models, on the contrary, theyare placed on the upper part.The sheet metal parts of the pressure vesselare manufactured of certified carbon steel,type S235JRG2, according to EN 10025, with

fig. 1

melting cer tificate 3.1.B, according EN10024; where as the pipes are of steelST 37.0 according to DIN 1626.The welders and the WPS (Welding ProceduresSpecifications) have been approved accordingto EN 287 and EN 288 by TÜV (DE). Theseboilers and production facilities have beenalso approved by - ISCIR (RO), UDT (PL) andGOSGORTEKHNAZDOR (RU).The boilers are equipped with a reversible

1.2 - WORKING PRINCIPLE

The NOx formation process is stronglyaffected by:- the flame temperature;- the time during which the combustion

gases stay in a high temperature zone.- oxygen partial pressure and its

concentration.The provisions to be adopted for the NOxreduction are then:- reduction of combustion temperature;- reduction of the specific thermal input;- permanence time reduction of the gases

in the combustion chamber;- reduction of oxygen concentration.UNICAL, to reduce the NOx formation on theTERSEC range of boilers, has adopted thefollowing construction solutions:- three pass

the furnace is of direct flame type and notof reversal type any more; the burnerflame results more compact and shorter,

thus reducing the permanence time athigh temperature;the direct pass allows a quicker flamecooling down by the water cooled furnacesurfaces;

- specific thermal input reductionthe combustion chamber volume has beenincreased if compared with standardboilers of the same capacity.With the adoption of the modern Low NOxburners a further reduction of the NOxemissions can be obtained with:

- reburninga part of the combustion gases is takenand sent again to the combustion chamberwith the combustion air.In this way the partial oxygen pressure isreduced and the flame temperature isreduced too.

- reduction of the partial oxygen pressurethanks to an air excess reduction.

During the operation of the burner within theoutput range of the boiler, the combustionchamber is always under positive pressure.For the value of this pressure see tables onpages 6 to 12 under the column "Smoke sidepressure losses".The chimney has to be calculated in such away that at its base there is no positivepressure.

hinged door, which can be opened, for thisreason, from L.H. or R.H. side.The outer shell is insulated with a glass woolmatress, thick 80 mm (100 mm for modelsTRS 450 & TRS 600), protected by a textile inmineral fiber.The upper part of the outer shell is equippedwith uplift hook(s).

6

n°4

x M

8 at

45°

on

ø 1

70

ø 1

32

Fiber wool

Ceramic fiber

ø 1

30

95

2

1

3

1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS

TERSEC 65÷90

1 Panel board2 Flame sight glass3 Smoke chamber cleaning door

T1 C.H. flowT2 C.H. returnT3 Expansion vessel connection

T4 Boiler drainT5 Flue connectionT6 Max. burner blast tube dia.

DIMENSIONSTERSEC

Type

(*) Hydraulic resistance for delta T 15K.

TRS 65

TRS 90

TERSEC

Type

TRS 65

TRS 90

130

130

T6Øi

mm

T5Øi

mm

150

150

T4

ISO 7/1

Rp¾"

Rp¾"

T3

ISO 7/1

Rp1”

Rp1”

T1T2

ISO 7/1

Rp1½"

Rp1½"

Weight

kg

326

398

Maximumboiler working

pressure

bar

5

5

Smoke sidepressure drop

mm w.c.

4÷6,5

5÷7,5

Water side pressure

drop(*)

m w.c.

0,04÷0,06

0,05÷0,07

Boilerwater

content

l

132

188

Inputmin/max

kW

54,2÷71,1

76÷98,4

Outputmin/max

kW

50÷65

70÷90

740

740

Amm

Bmm

690

950

Cmm

950

950

Dmm

Emm

Fmm

Gmm

Hmm

585

585

Imm

120

120

L

M 8

M 8

Mmm

190

190

Nmm

90

90

Omm

190

190

Pmm

786

786

Rmm

660

660

Smm

588

848

fig. 2

DETAIL FOR DOOR DRILLINGTRS 65 - 90

437

437

145

145

140

140

190

190

fig. 3

A

I

n°4 "L"

M

I

H

G

CD

T6

T2T4

T1T3

BF E

H

T1T3

T5

T2T4 N

P

T1

O

T5

SR

CONNECTIONS

7

Fiber wool

Ceramic fiber

Blind burner plate 250x250

Burner plate insulation gasket 250x250

ø 1

80

ø 1

50

95

n°4

x M

8 at

45°

on

ø 1

70

ø 1

32

Fiber wool

Ceramic fiber

ø 1

30

95

2

1

3

TERSEC 120÷350




DIMENSIONSTERSEC

Type


130

130

180

180

180

180

TRS 120

TRS 150

TRS 180

TRS 240

TRS 300

TRS 350

TERSEC

Type

T6Øi

mm

T5Øi

mm

T4

ISO 7/1

T3

ISO 7/1

T1T2

UNI 2278 PN16

Weight

kg


pressure

bar


mm w.c.

Water side pressure

drop(*)

m w.c.

Boilerwater

content

l

Inputmin/max

kW

Outputmin/max

kW

90÷120

120÷150

150÷180

180÷240

240÷300

300÷350

97÷131

129,6÷163,5

162÷196

194÷261,2

259÷326

324÷380

201

266

289

320

413

479

0,06÷0,08

0,08÷0,10

0,11÷0,15

0,14÷0,25

0,14÷0,22

0,22÷0,30

6,5÷11

11÷17

13÷19

15,5÷27

19÷30

23÷31

5

5

5

5

5

5

486

575

626

739

949

1118

DN 50

DN 50

DN 65

DN 65

DN 80

DN 80

Rp1¼”

Rp1¼"

Rp1½”

Rp1½"

Rp2”

Rp2"

Rp¾"

Rp¾"

Rp¾"

Rp¾"

Rp¾"

Rp¾"

180

180

180

180

225

225

820

820

860

860

890

890

Amm

885

1145

1080

1210

1275

1470

Bmm

Cmm

1082

1082

1182

1182

1352

1352

Dmm

190

190

190

190

190

190

Emm

140

140

140

140

140

140

Fmm

153

153

153

153

153

153

Gmm

532

532

757

757

897

897

Hmm

695

695

775

775

915

915

Imm

120

120

200

200

200

200

L

M 8

M 8

M 10

M 10

M 10

M 10

Mmm

1215

1215

1315

1315

1470

1470

Nmm

175

175

215

215

255

255

130

390

210

340

285

480

Omm

185

185

250

250

315

315

Pmm

Rmm

710

710

750

750

780

780

Smm

786

1046

981

1111

1177

1372

TRS 120

TRS 150

TRS 180

TRS 240

TRS 300

TRS 350

fig. 4



fig. 5 fig. 6

A

I

I

H

G

CD

T6

T4

T5

T1BF

N

E

H

T4

T6

O P

T5

T1-T3-T2

M

T3 T2

n°4 "L"

SR

CONNECTIONS

8

ø 2

10

Fiber wool

Ceramic fiber

ø 2

00

115



2

1

3

TERSEC 450÷600




DIMENSIONSTERSEC

Type

920

920

1605

1800

1645

1645

190

190

140

140

176

176

690

690

1130

1130

1735

1735

298

298

435

630

440

440

Amm

Bmm

Cmm

Dmm

Emm

Fmm

Gmm

Hmm

Mmm

Nmm

Omm


210

210

TRS 450

TRS 600

TRS 450

TRS 600

TERSEC

Type

T6Øi

mm

T5Øi

mm

T4

ISO 7/1

T3

UNI 2278 PN16

T1T2

UNI 2278 PN16

Weight

kg


pressure

bar


mm w.c.

Water side pressure

drop(*)

m w.c.

Boilerwater

content

l

Inputmin/max

kW

Outputmin/max

kW

DN 100

DN 100

DN 65

DN 65

Rp1¼"

Rp1¼"

250

250

400÷450

500÷600

430÷488

539÷650

688

770

0,26÷0,44

0,25÷0,42

29÷36

36÷52

5

5

1545

1755

Pmm

Smm

Rmm

790

790

1504

1699

fig. 7


fig. 8

A

CD

H

BF E

G

M

T1N O PT3 T2

H

T6

T4

T5

T1-T3-T2

T4

T5

T6

SR

CONNECTIONS

9

Refractory cement

Ceramic fiber



ø 2

70

ø 2

70

150

TERSEC 800




DIMENSIONSTERSEC

Type

1122 2115 1432 190 195 195 790 960 1540 298 945 440

Amm

Bmm

Cmm

Dmm

Emm

Fmm

Gmm

Hmm

Mmm

Nmm

Omm


270TRS 800

TRS 800

TERSEC

Type

T6Øi

mm

T5Øi

mm

T4

ISO 7/1

T3

UNI 2278 PN16

T1T2

UNI 2278 PN16

Weight

kg


pressure

bar


mm w.c.

Water side pressure

drop(*)

m w.c.

Boilerwater

content

l

Inputmin/max

kW

Outputmin/max

kW

DN 100 DN 65 Rp1" 250650÷800 700÷866,7 910 0,26÷0,44 37÷56 5 1885

Pmm

fig. 9

DETAIL FOR DOOR DRILLINGTRS 800

Smm

2014

Rmm

1020

fig. 10

2

1

3

H

T6

A

DC

R

G

T4

T5

T1BF

N

E

H

T6

O P

M

T3 T2

S

T4

T5

T1-T3-T2

50

CONNECTIONS

10

Refractory cement

Ceramic fiber



ø 2

70

ø 2

70

180

G

T4

T5

T3BF

N

E

H

T6

O P

M

T1 T2

S

A

R

T4

T5

DC

T3-T1-T2

H

T6

75

TERSEC 1000÷1200




DIMENSIONSTERSEC

Type

1462

1462

2282

2652

1542

1542

190

190

230

230

400

400

980

980

1035

1035

1650

1650

561

561

510

880

550

550

Amm

Bmm

Cmm

Dmm

Emm

Fmm

Gmm

Hmm

Mmm

Nmm

Omm


270

270

TRS 1000

TRS 1200

TRS 1000

TRS 1200

TERSEC

Type

T6Øi

mm

T5Øi

mm

T4

ISO 7/1

T3

UNI 2278 PN16

T1T2

UNI 2278 PN16

Weight

kg


pressure

bar


mm w.c.

Water side pressure

drop(*)

m w.c.

Boilerwater

content

l

Inputmin/max

kW

Outputmin/max

kW

DN 150

DN 150

DN 80

DN 80

Rp1½"

Rp1½"

350

350

850÷1000

1000÷1200

916÷1082

1075÷1298,7

1552

1805

0,26÷0,54

0,25÷0,64

48÷66

48÷68

6

6

2873

3257

Pmm

Smm

Rmm

1360

1360

2176

2546

fig. 11


1

2

3

fig. 12

CONNECTIONS

11

T6 T6

T1 T3 T2

T6

T4

T5

W

A

C

M

B

Z

EF

T6

T4

T5

T1

T6

T3 T2

T6

W

AM C

B

Z

F E

TERSEC DUO 360÷700

TERSEC DUO 900÷1200

T1 C.H. flowT2 C.H. return

T3 Expansion vessel connectionT4 Boiler drain

T5 Flue connectionT6 Max. burner blast tube dia.


360

480

600

700

900

1200

TERSEC DUO

Type

fig. 14

1373

1503

1568

1764

1921

2116

Z

mm

870

870

900

900

930

930

Note: For the dimensions C, E, F, M, see the previous tables related to the different models.

W

mm

B

mm

1080

1210

1275

1470

1605

1800

A

mm

1730

1730

1790

1790

1850

1850


pressure

bar

5

5

5

5

5

5


mm w.c.

13÷19

15,5÷27

19÷30

23÷31

29÷36

36÷52

Water side pressure

drop(*)

m w.c.

0,11÷0,15

0,14÷0,25

0,14÷0,22

0,22÷0,30

0,26÷0,44

0,25÷0,42

578

640

826

958

1376

1540

Boilerwater

content

l

Inputmin/max

kW

324÷392

388÷522,4

518÷652

648÷760

860÷976

1078÷1300

Outputmin/max

kW

300÷360

360÷480

480÷600

600÷700

800÷900

1000÷1200

Ass.yformed by

n°2

TRS 180

TRS 240

TRS 300

TRS 350

TRS 450

TRS 600

fig. 13

DIMENSIONS

12

T1 C.H. flowT2 C.H. return

T3 Expansion vessel connectionT4 Boiler drain

T5 Flue connectionT6 Max. burner blast tube dia.


1600

2000

2400

TERSEC DUO

Type

2505

2912

3282

Z

mm

1132

1472

1472

Note: For the dimensions C, E, F, M, see theprevious tables related to the different models.

W

mm

B

mm

2115

2282

2652

A

mm

2254

2934

2934


pressure

bar

5

6

6


mm w.c.

37÷56

48÷66

48÷68

Water side pressure

drop(*)

m w.c.

0,26÷0,44

0,26÷0,54

0,25÷0,64

1820

3104

3610

Boilerwater

content

l

Inputmin/max

kW

1400÷1733,4

1832÷2164

2150÷2597,4

Outputmin/max

kW

1300÷1600

1700÷2000

2000÷2400

Ass.yformed by

n°2

TRS 800

TRS 1000

TRS 1200

T4

T5

T3

BF E

T6

T1 T2

T6

A

CM

T6

W

Z


fig. 15

DIMENSIONS

13

2 INSTALLATION

2.1 - PACKAGING

The TRS boilers are supplied complete withdoor and smoke chamber already fitted, whilstthe casing with the insulation matress arecontained in separate cardboard packaging(s).The panel board and the accessories are insidethe combustion chamber.Before starting the installation make sure thatthe length and the width of the boiler bodyreceived correspond to the dimensions R &S of the ordered boiler, shown in the previoustables and that the cartons, containing thecasing, or part of it, are marked with the

code(s) shown on pages 17.In addition to the a. m. panel board, packagedin its own carton, in the combustion chamber,as accessories, there are also:- a carton containing the flanges for flow,

return and safety connections (if applicable)with relevant gaskets and bolts, theoval brush for the cleaning of the smokepipes;

- cleaning brush handle extension;- the turbulator introducer (as per model

TERSEC 180 and on).

2.2 - HANDLINGThe boiler can be moved into position by lifting,through the upper hooks(s), or by the use ofrollers placed under the strong L profiles ofthe basement.

If it necessary, due to the dimensions of theboiler, it is possible to remove the front doorand the smoke chamber to facilitate theintroduction in the boiler house.

2.3 - POSITIONING IN THEBOILER HOUSE

The installation of the boiler must be inaccordance with the relevant requirementsof the Gas Safety Regulations, current I.E.E.Regulations, local water authority bye-lawsand it should also comply with any relevantrequirements of the local gas supplier, localauthority and the relevant Standard Codesof Practice and building regulations.The boiler house must be ventilated throughpermanent openings having a total surfacenot lower than 1/30th of the floor area of theboiler house, with a minimum of 0.5 m2.Ventilation by grilles communicating directlywith the outside air is required at both, highand low levels.The boiler must be positioned so that thereis enough space available for the following:- Access around the boiler for servicing.- Space to open the boiler front door.- Space to access the burner.The installation of the boiler as close aspossible to the chimney position is highlyrecommended.To allow the cleaning of the smoke pipes, infront of the boiler a clearance equal to thelength of the boiler, has to be available.With the boiler door opened at 90°, the distancebetween the front of the door and the adjacentwall must be equal, at least, at the length ofthe burner.The boiler must stand on a non-combustiblefloor (i.e. concrete or brick), of dimensionsR x S (see dimensions table) which must beflat, level and of a suitable load bearingcapacity to support the weight of the boiler(when filled with water) and any ancillaryequipment.

x = Not shorter than the boiler bodyxx = Sufficient to allow accessibility to all the regulation, safety and control devices.

fig. 16

X

XX

XX

XX

- turbulators extractor (see page 39);- ceramic fiber rope for the insulation between

the door and burner blast tube;- the contact springs for the bulbs of the

protection and control devices.

Once the installation has been made theboiler must result perfectly horizontal and wellstable (to avoid vibrations and noise).

14

2.4 - CONNECTION TO THECHIMNEY

The chimney has a foundamental importancefor the good operation of the boiler.Due to the low temperature of the smokesduring the intermittent operation, it is necessarythat the chimney is perfectly impermeable tothe condensate of the combustion productsand manufactured with corrosion resistantmaterials.

The different connections must be sealed withan approved boiler putty so that the inlet offresh air, with consequent increase of thepossibility of condensate formation, is avoided.Furthermore the possible condensate or rainwater comming from the chimney must beavoided from entering the smoke chamberof the boiler.As far as the cross section and the high ofthe chimney is concerned, it is necessary to

make reference to the local and national rulesin force.In the flue pipe, between the boiler andthe chimney, convenient sampling pointsfor smoke temperature and combustionproducts analysis must be provided.

2.5 - WATER CONNECTIONS

2.5.1 - WATER SUPPLY

The boiler components fed with water arenormally connected to the water mains througha PRV.Ascertain that the hydraulic pressure measureddownstream the PRV is not higher than theMaximum Allowed Working Pressure of theboiler (see boiler data plate).Because during the operation of the boilerthe pressure of the water contained in theC.H. system increases, ascertain that thisvalue does not exceed the a.m. MAWP of the

boiler.Make sure the drain of the safety valve hasbeen connected to a discharge hopper; if notconnected to a discharge hopper, the safetyvalve can flood the floor of the room in whichthe boiler is installed. The boiler manufactureris not responsible for such a damage.Make sure the installation pipes are not usedas earthing points for the electrical or telephoneinstallations. In a short time the installationpipes, the boiler and the radiators could sufferserious damages.Once the C.H. system, of closed type, has

been filled, the filling valve has to be closedand kept in this position. Eventual water leakswill be shown by a decrease of the waterpressure at the boiler pressure gauge.

2.5.2 - FEEDING WATER QUALITY

- The chemical-physical characteristics ofthe C.H. system and reinstatement waterare foundamental for the good operationand safety of the boiler.

- Among the inconvenients caused by thebad quality of the feeding water the mostfrequent and serious is the scaling of theheat exchange surfaces.

- Less frequent, but also dangerous, is thecorrosion of the water side surfaces of allthe circuit.

- It is well known that the lime, due to itsvery low thermal conductivity, reduces theheat transfer so that also a scaling of a

few millimeters produces very dangerouslocalized overheating.1 mm of lime reduces the heat transferfrom metal to water by 10%.It is suggested to make a water treatementin the following cases:

A- high hardness of the water available onsite (higher than 20°f).

B- very large C.H. systems.C- large quantities of reinstatement water

due to water leaks.D- subsequent fillings of the system due to

maintenance works.E- mixing of different metals in the C.H. circuit.For the treatment of filling water it is suggestedto address them self to specialized firms.

2.5.3 - C.H. FLOW AND RETURNCONNECTIONS

The dimensions of flow and return connectionsare shown, for each boiler model, in the tableDIMENSIONS.Before connecting the boiler to the C.H.

system, this one has to be throughly cleaned.Make sure in the system there is a sufficientnumber of air venter.When connecting flow and return pipes avoidto create mechanical stress onto the boilerflanges.

The boiler is not made to support the pipingof the C.H. system, which needs dedicatedsupports.Once the complete C.H. system is finished,check for water leaks all the connections.

2.5.4 - CONNECTION OF FILLINGAND DRAIN TAP

The same firms are able to provide for thedescaling of the boilers.Every C.H. system needs reinstatements ofwater, due to evaporation, small or large waterleaks or for maintenance works.It is, therefor, necessary to be able to evaluatethe entity of the reinstatement water to avoidinconvenients due to untreated water.For that reason it is suggested to fit, in thefeeding line to the boiler, a water meter forsmall capacities.For further informations on filling watertreatment and characteristics refer to thespecific manual supplied with the boilerin the documents envelope.

2.5.5 - CONNECTION OF THEPRESSURE RELIEF VALVE,EXPANSION PIPE AND VESSEL

An expansion vessel is necessary, tocompensate the water volume increase

due to the heating.The TERSEC boilers are suitable for fullypumped system, wich can be open ventedor sealed.In the 1st case the height of the hydrostatic

For the filling and drain of the boiler a dedicatedtap can be connected to the point T4, whichis in rear part of the boiler.

column must be, at least, 3 m above theboiler casing and the capacity of theexpansion cistern shall be able to contain,between the water surface and the overflowpipe, the volume increase of all the water

15

2.5.6 - SHUNT PUMP

The TERSEC boilers must be operated underforced water circulation and at a watertemperature higher than 30 °C, if operatedwith oil, or 35 °C, if operated with natural gas,when the boiler is used in sliding temperatureand at part load (see par. 7.2) mode.

In the C.H. systems equipped with mixingvalve it is convenient to foresee a shunt pumpPr to guarantee the necessary water circulationthrough in any possible opening condition ofthe mixing valve and to guarantee thereforethe respect of the minimum return temperatureindicated.

This pump will be sized according to thefollowing formula:

Q = P x 22

where Q = Water flow rate in liter/hP = Boiler nominal output in kW

and the manometric head 1-2 m w.c.

2.6 - FURNACE DOOR:ADJUSTMENT,OPENING & CLOSING

A special attention has been paied to thedesign of the front door, because in all thepressurised boilers a good quality of the doorsis a necessary condition for the best operationof the boiler.With the furnace working in positive pressure,in fact, every minimum fissure could cause aleakage of high temperature combustionproducts, with consequent burning of thegasket and overheating of the door up to its

permanent deformation.For these reasons the door structure of theTERSEC boilers, in addition to the fact to bevery strong, has also the possibility to beadjusted: it can be lifted, lowered and alsoslanted, getting, thus, always the perfectcentering of the sealing gasket.The special inner lining in ceramic fiberreduces, furthermore, the time to reach theboiler steady state condition and then reducesdrastically the formation of condensate at theboiler start.

An interesting particularity related to the frontdoor, is the soundness self keeping system,made with elastic steel plates whichcompensate and reposition the door exactlyonto the sealing rope, also in case the ceramicfiber sealing rope becomes hard.

2.6.1 - IMPORTANT NOTE

Before opening the furnace door it is necessaryto adopt the following precautions:- Close the fuel cock (oil or gas) to the burner.- Cool down the boiler by keeping the water

circulating through it, and only then switch

off the power.- Put on the boiler a Warning notice with

the following text: DO NOT USE, BOILERUNDER SERVICE, OUT OF ORDER.

of the C.H. system.Preference shall be given to high andnarrow cistern, to expose to the air asurface as small possible, thus reducingthe water evaporation.In the 2nd case the vessel capacity has tobe calculated taking into consideration:- The total volume of the water contained

in the system.- The maximum Working Pressure of the

system (see setting of PRV).- The maximum working pressure of the

expansion vessel.- The initial preloading of the expansion

vessel.- The maximum working temperature of the

boiler (the maximum setting of thethermostat fitted onto the panel board is90°C; under this aspect it is suggested toconsider 100°C).

The expansion pipe connects the C.H.system to the expansion vessel.This pipe which starts from the connectingpoint T3 (see table DIMENSIONS), must have

NO gate valve on it.Fit onto the point T3 or onto the supply pipe,within 0.5 m from the flow flange, a pressurerelief valve properly dimensioned for theboiler capacity and in conformity with the localrules in force.It is forbidden to put any gate valve betweenthe boiler and the pressure relief valve.For maximum working pressure of the boiler,see table DIMENSIONS.

16

L

Ø A

2.7 - BURNER

Because the TERSEC are of pressurized typeboilers, special attention has to be put in thechoice of the oil or gas burner.The burners fitted onto these boilers mustbe CE approved.Before fitting the burner it is necessary toverify the position of the turbulators insidetheir smoke pipes.In the TERSEC boilers the use of burners withlong head, according to the table beside, issuggested.The same table indicates the maximumdiameter of the burner blast tube which cango through the hole in the front door.The burner working range must be compatiblewith smoke pressure losses of the boiler: wedo not recommend burners working at thelimit of their capacities.When fitting the burner onto the boiler door,a perfect sealing between burner flange anddoor has to be granted to the combustionproducts.With each boiler, among the accessories,a piece of ceramic fiber sealing rope, tobe rolled around the burner blast tube, inorder to seal completely the free space,is delivered.No free space has to be left between theburner blast tube and the hole in the ceramicfiber insulation of the door.If a cone, having a diameter larger than thehole in the door is fitted, this cone has to beremoved from the burner head before fittingthe burner to the door, and repositioned lateron.Ascertain the flexible hoses for the fuel andthe electrical cables have a length sufficientto allow the door to rotate of at least 90° with

BURNER BLAST TUBE DIMENSIONS

BOILER TYPE øAmm

L (min.)mm

132 180TRS 65÷150

TRS 180÷350 180 200

2.8 - CONNECTION OF THESIGHTGLASS TO THEBURNER VIA ACOOLING LINE

The flame sightglass is equipped with a 1/8"threaded connection (pos. 1) on whicha pressure test nipple (9 mm dia.) is fitted.This can be used with a silicon pipe for themeasurement of the counterpressure in thecombustion chamber.At the place of this pressure test nipple, whichmust be held, a special microbore pipe (pos. 2)will connect the flame sightglass directly tothe pressure room downstream the fan of theburner.The air, blown by the fan, will cool down andclean the sightglass.If the sightglass is not cooled down it can bebrocken down.WARNING: In the proximity of the sightglassthe temperature is very high: be careful!!!

fig. 18

TRS 450÷600 210 230

the burner fitted.For gas burners it is not allowed to use flexiblesteel pipes for the rotation of the door: thegas train has to be removed for the boilerdoor rotation.

2.7.1 - MOUNTING OF THE TWO-STAGEOR MODULATING BURNERS

The boilers of the TERSEC range may beequipped with a two-stage or modulating burner,provided the following conditions, in terms ofcombustion, smoke temperature and boilertemperature are complied with:1) Combustion:- with light oil having a maximum viscosity

of 1,5°E at 20°C):CO ≅ 12 to 13%.

- with natural gas: CO ≅ 9 to 10%.2) Smoke temperature: within 140° and

180°C in any working condition.3) Boiler working temperature: max

temperature = 85°C; minimum temperaturehas to be adjusted, through the boilerthermostat, so that the return temperaturecannot go below 30°C in any workingcondition.Make sure, then, there is no condensateformation in the smoke pipes or onto the

rear tube plate when a two-stage ormodulating burner is in operation at itsminimum input.Pay attention when building the chimney:it must be perfectly sound, to avoiddamages to the walls, due to the smokecondensate, and properly insulated.

TRS 800 270 280

TRS 1000÷1200 270 320

1

2

fig. 17

17

2.9 - CASING ASSEMBLY

N.B. It is suggested to verify that the boiler ispositioned in its final place and that all thehydraulic connections are made correctlybefore starting the casing assembly.Before opening the casing carton(s) makesure they are stamped with the right boilermodel, corresponding to the boiler to beinstalled.

N.B.: The packaging containing the panelboard is delivered inside the combustionchamber, as well as the documentsand the guarantee certificate.

Assembly of the casing for TERSEC 65 & 90should be carried out in the following steps:Refer to diagram on fig. 19 & 20 for details:

A) Fit the insulation blanket (1) onto the boilershell and secure it in to place using theelasticated straps (2) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.

B) Locate the side panels (3) and (4) withthe lower bend inside the bottom L profilesand the upper bend in the seats of frontand rear tube plates.To determine which is the left and rightpanel ensure that the cable clamp plateholes are positioned facing toward thefront edge.

C) Fit the four screws pos. 5 on the frontcounter bend.

D) Open the combustion chamber door andfit the front insulation (6), inserting thehinges in the pre-cuts.Insert the side ends of the insulation underthe bend of the two side panels (3 & 4).Note: because the front insulation is suitablefor two different boiler ranges, beforeremoving the precut insulation, follow theinstructions supplied with the insulation itself.

E) Fit the small panel (pos. 7) connecting the

two side panels 3 & 4.F) After removal of the two side screws from

the panel board rotate its cover towardsthe front and insert the cables and thecapillaries of thermometer and thermostatsthrough the slots on its base.Fit the panel board to front upper panel (8).Fit the upper panel (8), complete with thepanel board to the side panels (3 & 4).Guide the burner plug through the sidecable clamp plate (9) on the preferred sideand clamp the cable using the cable clampsupplied.Fix the side cable clamp plates (9) to thecasing side panels (3 & 4).Connect the burner cable(s) to the panelboard according to the wiring diagrams ofpage 29 and 30.The supply, pump and mixing valve cablesmust be run towards the back of the boiler.

G) Insert the thermometer and thermostatbulbs in the bulb holders as shown in fig. 20and connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.We recommend to push all the probes tothe bottom into the relevant bulb holder to

improve its contact. Fix then the capillarieswith the retaining clips (pos. 5).Close the panel board.

H) Fit the rear insulation (pos. 10), fix the rearpanel (pos. 11) with the self tappingscrews.

I) Fit the cable clamp (pos. 12) onto the rearbend of a side panel, pos. 3 or 4.Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (12).

L) Remove the protective paper film fromdata plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.

The TERSEC DUO are made of two TERSECboilers of the same model.Then, two equal casings and a kit for theconnection of the casing and for supportingthe control panel are supplied.The packagings containing the flanges, withrelevant gaskets and bolts, the cleaningaccessories, the ceramic fiber sealing ropeand the contact springs for the bulbs, arecontained in the relevant furnaces.For the composition and recognition of thecasing packagings, see the beside table.

BOILERTYPE

TRS DUO 1200

TRS DUO 900

24187 (n°2)TRS DUO 700

COMPLETECASING

24186 (n°2)TRS DUO 600

24185 (n°2)TRS DUO 480

24184 (n°2)TRS DUO 360

24133 (n°2)

CASINGimballo “A”

24131 (n°2)

CASINGimballo “B”

24134 (n°2)

24132 (n°2)

INSULATIONPACKAGING

21064 (n°2)

21065 (n°2)

CONNECTIONKIT

24140

24140

25601

25601

25600

25600

TRS 600

TRS 450

TRS 350

TRS 300

TRS 240

TRS 180

TRS 150

TRS 120

TRS 90

TRS 65

BOILERTYPE

24187

24186

24185

24184

24183

24182

24124

24133

24131

24134

24132

CASINGpackaging “C”

CASINGpackaging “B”

CASINGpackaging “A”

COMPLETECASING

24123

TRS 800 23016 27919 27920

TRS 1000 22692 22693 22694

TRS 1200 22692 22696 22697

21065

21064

INSULATIONPACKAGING

23016 (n°2) 27919 (n°2) 27920 (n°2)

22692 (n°2) 22693 (n°2) 22694 (n°2)

22692 (n°2) 22696 (n°2) 22697 (n°2)TRS DUO 2400

TRS DUO 2000

TRS DUO 1600

18

2 15

5

3

4

11

4

10

12

2

6

8

3

9

9

75

1

TERSEC 65÷90

fig. 19

fig. 20

TERSEC 65÷90

1 Thermometer bulb2 Working thermostat bulb3 Minimum thermostat bulb4 Safety thermostat bulb5 Bulb retaining clip

19

12

10

3

5

13

11

1

4

11

2

8

9

7

6

14

15

Assembly of the casing for TERSEC 120 / 350should be carried out in the following steps:Refer to diagram on fig. 21 & 22 for details:


B) Locate the side panels (3) and (4) withthe lower bend inside the bottom L profilesand the upper bend in the seats of frontand rear tube plates.To determine which is the left and rightpanel ensure that the cable clamp plateholes (11) are positioned facing toward thefront edge.

C) Open the combustion chamber door andfit the front insulation (5), inserting thehinges in the pre-cuts.Insert the side ends of the insulation underthe bend of the two side panels (3 & 4).Note: because the front insulation is suitablefor two different boiler ranges, beforeremoving the precut insulation, follow theinstructions supplied with the insulation itself.

D) Fit the rear insulation (pos. 6), fix the rearlower, intermediate and upper panels (pos.7, 15 & 8) with the self tapping screws.

Fit the plastic cable clamps (9) to theupper rear panel (8).

E) After removal of the two side screws fromthe panel board rotate its cover towardsthe front and insert the cables and thecapillaries of thermometer and thermostatsthrough the slots on its base.Fit the panel board to front upper panel (10).Fit the upper panel (10), complete with thepanel board to the side panels (3 & 4).Guide the burner plug through the sidecable clamp plate (11) on the preferredside and clamp the cable using the cableclamp supplied.Fix the side cable clamp plates (11) to thecasing side panels (3 & 4).Connect the burner cable(s) to the panelboard according to the wiring diagrams ofpage 29 and 30.The supply, pump and mixing valve cablesmust be run towards the back of the boiler.

F) Insert the thermometer and thermostatbulbs in the bulb holders as shown in fig. 22and connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.We recommend to push all the probes tothe bottom into the relevant bulb holder to

improve its contact. Fix then the capillarieswith the retaining clips (pos. 5).Close the panel board.Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (9).

G) Fit the longitudinal upper panels (pos. 12and 13) to the side panels.

H) Remove the protective paper film fromdata plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.

TERSEC 120÷350

fig. 21

20

2 15

3

5

4

fig. 22

TERSEC 120÷350



A) Fit to the front and rear tube plates thefour upper brackets (pos. 1), supportingthe side panels, using the screws, washersand nuts supplied (pos. 2, 3 and 4).

B) Fit to the front and rear tube plates thefour intermediate and lower brackets (pos.5) supporting the side panels, using thescrews, washers and nuts supplied (pos.2, 3 and 4).

C) Fit the insulation blanket (6) onto the boilershell and secure it in to place using theelasticated straps (7) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.

D) Position the side lower panels (pos. 9 and18) onto the lower and intermediatebrackets (pos. 5).To determine which one is the left or righthand side panel ensure that the cableclamp plate holes are positioned facingtoward the front edge.

E) Position the side upper panels (pos. 8 and17) onto the upper brackets (pos. 1) andfix their pivots on the lower side.

F) Fit the 8 screws (pos. 10) to the upperpart of the front and rear counter bend ofthe upper panels (pos. 8 and 17).

G) Fit the front insulation (pos. 11), insertingthe hinges in the insulation pre-cuts.WARNING: the door is standard hingedon the L.H. side.For its opening it is necessary to completelyremove the four fixing bolts.Note: because the front insulation is suitablefor two different boiler ranges, beforeremoving the precut insulation, follow theinstructions supplied with the insulation itself.

H) Fit the rear insulations (pos. 16 and 27)

and fix the rear upper panel (pos. 26).I) Position the panels 12 and 19 between

the side upper panels (pos. 8 and 17).L) After removal of the two side screws from

the panel board rotate its cover towardsthe front and insert the cables and thecapillaries of thermometer and thermostatsthrough the slots on its base.Fit the panel board to front upper panel (13).Fit the upper panel (13), complete with thepanel board to the side panels (8 & 17).Guide the burner plug through the sidecable clamp plate (14) on the preferredside and clamp the cable using the cableclamp supplied.Fix the side cable clamp plates (14) to thecasing side panels (9 & 18).Connect the burner cable(s) to the panelboard according to the wiring diagrams ofpage 29 and 30.The supply, pump and mixing valve cablesmust be run towards the back of the boiler.

M) Insert the thermometer and thermostatbulbs in the bulb holders as shown in fig. 24and connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact. Fix then the capillarieswith the retaining clips (pos. 5).Close the panel board.

N) Fit the plastic cable clamps (20) to theupper rear panel (19).Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (20).

O) Fit the longitudinal upper panels (pos. 21and 25) to the side panels.

P) Remove the protective paper film from

data plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.

21

2 15

35

4

141815

16

25

21

13

2422

23

10

11

12

9

1

5

14

4

4

3

3

5

5

5

2

2

6

71

17

21

1

34

8

19

2015

27

26

TERSEC 450÷600

fig. 23

fig. 24

TERSEC 450÷600


22

Assembly of the casing for TERSEC 800should be carried out in the following steps:Refer to diagram on fig. 25 & 26 for details:


B) Locate the side panels (pos. 3, 4, 5 and 6)hooking them to the upper and lowerprofiles.To determine which one is the left or righthand side panel ensure that the cableglands are positioned facing toward thefront edge.

C) Fit the four screws pos. 7 on the innerupper rear side panels.

D) Open the combustion chamber door andfit the front insulation (pos.8), inserting thehinges in the insulation pre-cuts.

E) After removal of the two side screws fromthe panel board rotate its cover towardsthe front and insert the cables and thecapillaries of thermometer and thermostatsthrough the slots on its base.Fit the panel board to front upper panel (9).Fit the upper panel (9), complete with thepanel board to the side panels (3 & 5).Guide the burner plug through the side

cable clamp plate (14) on the preferredside and clamp the cable using the cableclamp supplied.Fix the side cable clamp plates (14) to thecasing side panels (3 & 5).Connect the burner cable(s) to the panelboard according to the wiring diagrams ofpage 29 and 30.The supply, pump and mixing valve cablesmust be run towards the back of the boiler.

F) Insert the thermometer and thermostatbulbs in the bulb holders as shown in fig. 26and connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact. Fix then the capillarieswith the retaining clips (pos. 5).Close the panel board.


H) Fit the rear panel (pos.12).I) Fit the plastic cable clamps (13) to the

upper rear panel (12).Fit the cables, leaving the boiler from theback side, with the plastic screws of the

cable clamps (13).L) Remove the protective paper film from

data plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.

TERSEC 800

fig. 25

2

6

5

12

13

7

3

9

11

4

1

10

8

14

23

2

1

5

6

3

4

2 1

5

5 3

4


fig. 26

TERSEC 800

fig. 27

Sequence of probes introduction

Introduce the bulb into the bulb holder, in theupper part of the boiler body, in the followingsequence (Ref. to fig. 27):- (pos. 1) thermometer- (pos. 2) working thermostat- (pos. 3) high limit thermostat- (pos. 4) minimum temperature thermostat.It is recommended to introduce the bulbs upto the bottom of the bulb holder to have abetter response. Introduce then the contactspring (pos. 6) to improve the contact andsecure the capillaries in position by the clip(pos. 5).

1 Thermometer probe2 Boiler thermostat probe (with knob)3 Safety thermostat probe4 Minimum thermostat probe (screwdriver)5 Probe retaining clip6 Contact spring

24

2

5

6

3a3b

9

10

11

7

8

4a 51

4b

12

TERSEC 1000÷1200

bulbs in the bulb holders as shown in fig. 27and connect the mains, the burner, thepump(s) and any ancillary equipment tothe panel board.We recommend to push all the probes tothe bottom into the relevant bulb holder toimprove its contact. Fix then the capillarieswith the retaining clips (pos. 5).Close the panel board.Fit the cables, leaving the boiler from theback side, with the plastic screws of thecable clamps (8).


H) Remove the protective paper film fromdata plate and ventilation requirement labeland fit them at the top front corner of themost accessible side panel after removalof dust from the surface.The data plate and label are in thedocuments envelope.


A) Fit the insulation blanket (1) onto the boilershell and secure it in to place using theelasticated straps (2) provided, ensuringthat the metal clips grip in to the externalsurface of the insulation.Make a convenient cut in the upper part ofthe insulation blanket to get easy accessto the bulb holders.

B) Position the side panels (3a, 3b and 4a,4b) with the lower bend inside the bottomL profiles and hook them to the screwsfitted to the upper profiles.To determine which one of the front sidepanels is the left or the right ensure thatthe cable clamp plates (5) are positionedfacing toward the front edge.

C) Open the combustion chamber door andfit the front insulation (pos. 6), insertingthe hinges in the insulation pre-cuts.Insert the side ends of the insulation under

the bend of the two side panels (3a and 4a).D) Fit the rear panel (pos. 7).

Fit the plastic cable clamps (8) to the upperrear panel (7).

E) After removal of the two side screws fromthe panel board rotate its cover towardsthe front and insert the cables and thecapillaries of thermometer and thermostatsthrough the slots on its base.Fit the panel board to front upper panel (9).Fit the upper panel (9), complete with thepanel board to the side panels (3a & 4a).Guide the burner plug through the sidecable clamp plate (5) on the preferred sideand clamp the cable using the cable clampsupplied.Fix the side cable clamp plates (5) to thecasing side panels (3a & 4a).Connect the burner cable(s) to the panelboard according to the wiring diagrams ofpage 29 and 30.The supply, pump and mixing valve cablesmust be run towards the back of the boiler.

F) Insert the thermometer and thermostat

fig. 28

25

LOWER L BAR JUNCTIONOF BOILER BODY

120 - for models TRS DUO 360/480/600/700

140 - for models TRS DUO 900/1200

130 - for models TRS DUO 1200/2400


fig. 29

Casing mounting sequence forTERSEC DUO(Ref. figs. 29 & 30)

N.B. It is suggested to verify that the boiler ispositioned in its final place and that all thehydraulic connections are made correctlybefore starting the casing assembly.

For the composition of the casing packagingsaccording to the boiler model, see point 2.9.

For the correct positioning join the two boilerbodies using the two L bars supplied in thecardboard box of the “Connection kit”.These L bars will be fitted at both boiler bodies(joining them at the base in the front and rearside and keeping then the right distance forthe casing mounting), with the cuts upwardsto receive the casing side panels.Concerning the mounting of the casings,make reference to the instructions of fig. 21for the models TRS DUO 360, 480, 600 &700; and to the instructions of fig. 23 for themodels TRS DUO 900 & 1200, replacing onlythe two panels for the fitting of the panelboard, supplied in the two standard casingswith the two panels (1 Right, 1 Left) whichcan be found in the packaging of the“Connection Kit”.Concerning the mounting of the casings,

make reference to the instructions of fig. 25for the model TRS DUO 1600 and to theinstructions of fig. 28 for the models TRS DUO2000 & TRS DUO 2400.

Models TRS DUO 360 / TRS DUO 1200:replacing the two panels for the fitting of thepanel board, supplied in the two standardcasings with the two panels (1 Right, 1 Left)which can be found in the packaging of the“Connection Kit”.After removal of the upper panel, fit the panelboard to the two upper front panels (Rightand Left) by introducing the electrical cables(for the supply, the burners, the pumps, themixing valves) and the capillaries of thethermostats through the hole on the base ofthe panel board.Fix the upper front panels to the upper sidespanels of the casings of the two boilers.Address the cables of the burners toward theplates fixed on the side panels, in the externalsides, and stop them on the plates themselveswith a cable clamp type PG 11, fit the burnersplugs (see wiring diagram on pages 35 and 37).The supply, pumps and mixing valve cables,must indifferently be addressed toward therear part of one of the two boilers and fixed

with the dedicated cable clamps.Insert the probes of the thermostats in thebulb holders on the back sides of the boilers(above the smoke chamber) (Ref. fig. 30); theprobe of the thermometer (pos.1), of theworking thermostat (pos. 2) and the minimumtemperature thermostat (pos. 3) must beinserted in the largest bulb holder (ø = 15mm); the probe of the safety thermostat (pos.4), must be inserted in the smallest bulb holder(ø = 7 mm).Pay attention to the identification of the probes:the boiler n° 1 is the right one (seen frombehind), the boiler n° 2 is the left one (seenfrom behind).We recommend to push all the probes to thebottom into the relevant bulb holder to improveits contact. Fix then the capillaries with theretaining clips (pos. 5).Close the panel board.Fit the casing upper rear panels.Remove the protective paper film from dataplate and ventilation requirement label andfit them at the top front corner of the mostaccessible side panel after removal of dustfrom the surface.The data plate and label are in thedocuments envelope.

26

7 65

8

5

9

2 15

3

5

4


fig. 30

1 Thermometer bulb boiler 12 Working thermostat bulb boiler 13 Minimum thermostat bulb boiler 14 Safety thermostat bulb boiler 15 Bulb retaining clip6 Thermometer bulb boiler 27 Working thermostat bulb boiler 28 Minimum thermostat bulb boiler 29 Safety thermostat bulb boiler 2

In the model TRS DUO 1600 (made of two boilers TRS 800) the panel board can be placed indifferently on the casing of the R.H.side (boiler No. 1) or L.H. side (boiler No. 2).The sensor of control and safety devices will be positioned as shown in fig. 30.

27

21

3

2

1

5

6

3

4

2

1

5

6

3

4

Electrical cables positioning

The panel board Standard or with outercompensator is equipped with a burner cable, aPG 11 gland (pos. 2) and a 7 pole plug (pos.3) - See wiring diagrams on figs. 34, 36, 41and 43.When fitting the panel board the leads of theburner cable, which has to be passed throughthe cable gland, must be connected to thepanel board terminal strip (see wiring diagramson figs. 34, 36, 41 & 43.The seven pole plug and the cable must comeout from the casing through the cable clampplate (pos. 1), onto which the cable glandemust be fixed.

fig. 32


fig. 31

1 Thermometer bulb boiler 12 Working thermostat bulb boiler 13 Minimum thermostat bulb boiler 14 Safety thermostat bulb boiler 15 Bulb retaining clip6 Thermometer bulb boiler 27 Working thermostat bulb boiler 28 Minimum thermostat bulb boiler 29 Safety thermostat bulb boiler 2

28

3 STANDARD PANEL BOARD(WIRING DIAGRAM TYPE 21058 FOR TRS 65 TO 180 AND 21059 FOR TRS 240 TO 1200)

3.1 - ELECTRICAL SUPPLY

The boiler's electrical safety is always grantedonly when the appliance is correctly andeffectively earthed, as stated in the applicablestandards in force.It is necessary to be sure about this essentialsafety requirement.In case of doubt, ask for an ispection of theelectrical installation by a competent andqualified electrician, because the manufactureris not responsible for damages due to a nonefficient earthing of the boiler.Ascertain that the electrical installation is

capable to supply the maximum electricaloutput required by the boiler and its auxiliaryequipment.It is not allowed to use, for the electrical supplyof the boiler, adaptors, multiple sockets and/orcable extensions.A double pole switch is required by thestandards.In any case refer to your local electricalrequirements.The use of any electrical appliance impliesthe observance of some foundamental rules,as:- do not touch the appliance with wet or

moist parts of the body, or barefoot;- do not pull the electrical cables;- do not expose the appliance to the

atmospheric agents (rain , sun, etc);- do not allow the use of the boiler by

untrained persons.

3.2 - FUNCTIONSDESCRIPTION

Through the main switch 11 the panel boardand the ancillary equipments connected to itare powered.The switches 12 and 13 control therespectively the burner and the heating pump.Through the thermostat 32 the boilerworking temperature is adjusted.This thermostat is provided with a DPDTcontact, for the control of a two stage burner.The differential between the switching pointsof the two double pole is 6°C (not adjustable).The minimum thermostat, accessible throughthe opening of the panel board cover, switchesOFF the C.H. pump during the reacing ofthe steady state and up to the obtention of30 °C within the boiler.On the electrical supply line to the boiler aswitch with fuses is to be foreseen.

fig. 33

11 Illuminated main switch12 Burner switch13 C.H. pump switch31 High limit thermostat

32 Working thermostat41 General fuse42 Thermometer

31

42

11 41 12 13

32

29

E

E

E E

L1 T2N S3T1 B4

IG

11 41

32

12

32 13

31

230V~ 50Hz

2

1

3

4

4-4

24 14

C

2 1

22 12

21 11

C

2

G-V

6-6

7-7

8-8

9-9

10-1

0

Ts

7 14 15 166 95 8 10

BA

20 21

24

Pi

18

1723

22

19

11

12

Ipi

Ib

(30°C)

(30°÷90°C) (24°÷84°C)

(100°C)Tm

Te1

F1 (max 4 A)

Te2

13

C

N

Ph

B5 T6 T7 T8

1 stage burner plugst 2 stage burner plug (optional)nd

In case of three phase burner and/or pump, convenient relays have to be foreseen.The terminals 22 and 23 may be used for the connection of an additional recirculating pump.

ELECTRICAL WIRING DIAGRAM FOR SINGLE PHASE BURNER AND PUMP

fig.34

Ph Phase (230V ~50Hz)N NeutralF1 General fuse (max 4A)Ib Burner switchIG Illuminated main switchIpi C.H. pump switchTe1 1st stage working thermostat (30°C÷90°C)Te2 2nd stage working thermostat (24°C÷84°C)Tm Minimum thermostat (30°C)Ts High limit thermostat (100°C)Pi C.H. pumpA Burner lockout warning lamp (eventual)B Hourmeter for 1st stage operationC Hourmeter for 2nd stage operation


The TERSEC boilers can be supplied withan electronic panel board complete with adigital outer compensator with built-inmicrocomputer and permanent memory.The TERSEC boilers, may operate in slidingtemperature between 30 to 90°C.The management of the C.H. installation ismade via the outer compensator which, inaddition to the direct control of the burnerand a loading pump of a storage tank, canalso control two different heating zones,(provided convenient flow and return manifoldsare available).The automatic operation is made on the baseof the data detected by the boiler and storagetank sensors, the flow sensor (to be fitted only

OPTIONAL PANEL BOARD (WITH OUTER COMPENSATOR)

(WIRING DIAGRAM TYPE 28734 for TRS 65 to 1200)4

when a mixing valve is there) and the outerand room sensors.The outer compensator is capable to controlseveral heating system configurations:- one direct zone C.H. system without

mixing valve: the flow sensor has not tobe fitted; the outer compensator controlsonly the pump of the C.H. system No. 1.

- C.H. installation with one heating mixedzone: a flow sensor has to be fitted(downstream the mixing valve); the outercompensator controls the C.H. pump andthe mixing valve.

- two zone C.H. system: one direct and onewith mixing valve; the outer compensatorcontrols: the C.H. pump of the unmixedzone (provided a second room sensor isfitted in this zone), the mixing valve andthe C.H. pump of the mixed zone.

The outer compensator sensors (boiler,storage tank, outer and flow) are included inthe supply; the room sensors for the C.H.systems No.1 and No. 2 are optionals.The mixing valve and the relevant motor arenot supplied by Unical.

30

4.2 - PANEL BOARD WITH OUTER COMPENSATOR (ON REQUEST)

Note: The outer compensator arrives to thecustomer with the technical data alreadyadjusted by UNICAL.As far as the wiring and the usinginstructions are concerned, please refer

fig. 35

11 Illuminated main switch12 Burner switch13 C.H. pump switch for mixed zone14 C.H. pump switch for direct zone

15 D.H.W tank loading pump switch31 High limit thermostat32 Working thermostat41 General fuse (4A)

42 Boiler thermometer

ELECTRICAL WIRING DIAGRAM PANEL BOARD WITH OUTER COMPENSATOR

Ph Phase (230V ~ 50Hz)N NeutralF1 General fuse (max 4A)Ib Burner switchIG Illuminated main switchIpi1 1st C.H. pump switch

Ipi2 2nd C.H. pump switchIpb D.H.W. tank pump switchPb D.H.W. tank loading pumpPi1C.H. pump for direct zonePi2C.H. pump for mixed zoneTe Working thermostat (30°C÷90°C)

Tm Minimum thermostat (30°C)Ts High limit thermostat (100°C)Vm2 Mixing valve for 2nd zoneA Burner lockout warning lamp (eventual)B Hourmeter (eventual)

fig. 36In case of three phase burner and/or pump, convenient relays have to be foreseen.The outer compensator is not ready to accept the connection of an additional recirculating pump.

to the instruction manual supplied withthe outer compensator itself.As far as the C.H. installation data areconcerned, please refer to the chapter 4.5of this manual.

31

42

11 41 12 13

32

14 15 16 17

35

33 34

18 19 20 21 22 23

21.020

T-am

bien

te1

T-am

bien

te2

T-ec

onom

iaT-

Acqu

aSa

n.

Cur

vaR

isca

ld. 1

Cur

vaR

isca

ld. 2

Vaca

nze

Ora

Prog

. Ris

cald

.Pa

ram

etri

EE

E

L1 T2N S3T1 B4

IG

3

12 15 18

. . TERMINAL OF KROMSCHRÖDEROUTER COMPENSATOR

II9 II10

II6 II4 II7

II1

II8 IV3 IV4

II3II2

II5

4

Ts

76 95 8 10

BA

13 16

Pi2 Pb Pi1

11 14 17

26 27

30 32 31

36 35

Ipi2 Ipb Ipi1

Ib

(30°C)

(30°÷90°C)(100°C)

Tm

Te

11

12

3231

34

13 15 14

N

Ph230V~ 50Hz

(max 4A)

2

1

22 25

19

23

Vm2

20 21

3329 28 34

24

N

Ph230V~ 50Hz

(max 4A)

2

1

29

12

1

CC

2

C

Seven pole connector

41

F1 (max 4 A)

4-4

G-V

6-6

7-7

8-8

9-9

10-1

0

2nd stage

31

C

VM2

P1 P2

VFAS

Pr

FLOWSENSOR 2 (VFAS)

OUTERSENSOR (AFS)

ROOMSENSOR 2 (FBR1)

ROOMSENSOR 1 (FBR1)

BOILERSENSOR (KFS)

D.H.W. TANKSENSOR (SPFS)

KFS

23

45

67

18

910

23

45

1IV

II

1

NL1

L1'

1

11

2

2

2

MM

2T

1T

2

43

21

32

12

12

14

32

18

76

510

92

1V

III

VV

IIIIII

IX

+-

L3

Bus

H1

FB

R1

VFA

SV

FAS

AF

SK

FS/S

PFS

VFA

S3

1F

BR

1D

CF

12

3

21

VI

1

2

T3

T4

2 3 4 5 6 71 8 9 10 21VIII

1

N L1 L1'1

1 12

2

2

M

2 T1 T2

4 3 2 1 3 2 1 2 1 2 1 4 3 2 18 7 6 510 9 2 1VIIIVVIIIIIIIX

+ - L 3Bus

H 1FBR1 VFAS VFAS AFS KFS/SPFS VFAS 3 1

FBR1 DCF

1 2 3

II1

II1

II2

II2

II3

II3

II8

II8

II7

II7

II5

II5

II4

II4

II6

II6

IV4 IV3 II10

II10

II9

II9

31 35 3933 37 4132 3634 38 4240

IV4IV3

FLO

WS

EN

SO

R 2

(V

FAS

)

OU

TE

RS

EN

SO

R (

AF

S)

RO

OM

SE

NS

OR

2 (

FB

R1)

RO

OM

SE

NS

OR

1 (

FB

R1)

BO

ILE

RS

EN

SO

R (

KF

S)

D.H

.W.T

AN

KS

EN

SO

R (

SP

FS

)

1 1

2 3 4 51

M

1

2

T3 T4

IV

fig. 37

SENSOR CONNECTION ONTO THE OUTER COMPENSATOR TERMINAL STRIP

In the fig. 38 the typical connection of theboiler to C.H. system with two heating zones,of which one is with motorized mixing valve.Both, the heating zones are controled by anouter compensator.The electrical connections of the heatingpumps and the mixing valve motor must beconnected strictly according to the schemashown in fig. 36.The temperature sensors will be connectedaccording to the schema shown in fig. 37.Remember that all the TERSEC boilers arefor forced circulation.It is suggested to adopt a shunt pump "Pr" toguarantee the circulation through the boiler inany possible open condition of the mixingvalve (see fig. 38).The shunt pump “Pr”, which will have athroughput equal, at least, at 50% of the C.H.pump and a manometric of of 1 m W.G., willperform also an anticondensation function,limiting the too cold returns into the boiler.The hydraulic schemas shown in the figs. 38& 39 are principle schemas; in case ofdifferent system circuits, contact, please, ourafter sale service dept., which will supply youwith all the necessary informations.

4.3 - ELECTRICAL AND HYDRAULIC CONNECTIONS OF C.H.

fig. 38

C BoilerP1 C.H. pump for direct zoneP2 C.H. pump for mixed zonePr Shunt pumpVM2 Mixing valveKFS Boiler temperature sensorVFAS Flow temperature sensor

32

C

VM2

P1 P2

VFAS

KFS

Pr

Pb

B

SPFS

FLOWSENSOR 2 (VFAS)

OUTERSENSOR (AFS)

ROOMSENSOR 2 (FBR1)

ROOMSENSOR 1 (FBR1)

BOILERSENSOR (KFS)


23

45

67

18

910

23

45

1IV

II

1

NL1

L1'

1

11

2

2

2

MM

2T

1T

2

43

21

32

12

12

14

32

18

76

510

92

1V

III

VV

IIIIII

IX

+-

L3

Bus

H1

FB

R1

VFA

SV

FAS

AF

SK

FS/S

PFS

VFA

S3

1F

BR

1D

CF

12

3

21

VI

1

2

T3

T4

In a C.H. installation equipped with a D.H.W.storage tank, the hydraulic schema, shownin fig. 39, can be used.Note: Also in this case the remarks made inthe previous paragraph are applicable, i.e.:the adoption of a shunt pump (Pr).The electrical connections of the storage tankloading pump will follow the schema shownin fig. 36.

4.4 - ELECTRICAL AND HYDRAULIC CONNECTIONS OF C.H.AND D.H.W. PRODUCTION CIRCUIT

Pr Shunt pumpVM2 Mixing valveSPFS Storage tank temperature sensorKFS Boiler temperature sensorVFAS Flow temperature sensor

C BoilerB Storage tankP1 C.H. pump for direct zoneP2 C.H. pump for mixed zonePb Storage tank loading pump

4.5 - OUTER COMPENSATOR (code 28430)

On how to adjust or to program the outercompensator, please refer to the instructionmanual supplied with the outer compensator.In the following table we list the factory set

parameters, which are "not changeable" andthe parameters which are adjustable by theuser according to his needs.

Standard System valuesParameter Adjustment range

0203040506070809

12

131415

01 Outer temperatureTemporary operationNominal flow temperature circuit 1Actual flow temperature circuit 1Nominal flow temperature circuit 2Actual flow temperature circuit 2Nominal boiler temperatureActual boiler temperatureInfluence of room sensor above outer sensor in circuit 1

Heating optimisation according to the roomtemperature in circuit 2

Maximum anticipationTime relay with D.H.W. consensusDelay outer temperature

-----0/1 (Off/On)

------------------------------0-200-20

0/1 (Off/On)

0/1 (Off/On)

0-3 hours0/1 (Off/On)

0-3 hours

Visualization only0

Visualization onlyVisualization onlyVisualization onlyVisualization onlyVisualization only

10

1

201

Description

1011

Influence of room sensor above outer sensor in circuit 2Heating optimisation according to the roomtemperature in circuit 1

10

1

Visualization only

PARAMETERS ADJUSTABLE BY THE USER

fig. 39

33

Standard System valuesN° Adjustment range

* To adjust the pump of the solar energy panels: Set the parameter 29 at the switching off temperature (e.g. 90°C). The hysteresis (parameter 30) can be set, in thiscase, between 7 and 25 °C; the standard value is 7 °C.

2122232425262728

293031323334

20 Introduction of the numeric codeNumeric codeBus code for heating circuit 1 (HK1)Bus code for heating circuit 2 (HK2)Anti frost temperatureMax. flow temperature for flow heating circuit 1Max. flow temperature for flow heating circuit 1Heating curves distanceTime relay function

Relay activation temperature (see 28)Hysteresis for supplementary relay (see 28)Loading pump stopPumps in parallel operationAnti legionella programZone outer compensators communication address

(if in the 0, 1 or 3 setting position no sensor isconnected, the relay is activated with the temporisedprogram for the circulating pump)

0000-99990000-9999

0-150-15

(-5)°C - (+5)°C30°C - 110°C30°C - 110°C

5 - 50°C0-3

0: Increase of the return water temperature

1: Solid fuel fired boiler2: Manifold pump3: Solar panel

10°C - 90°C2°C - 20°C*0/1 (Off/On)0/1 (Off/On)0/1 (Off/On)0/1 (Off/On)

Parameter

-----

-----1-380455

0

51011

-----

10

FACTORY SET PARAMETERS(protected by a secret code)

51 Boiler maximum temperature 50°C - 110°C52 Boiler minimum temperature 10°C - 60°C53 Temperature increase for D.H.W. 0°C - 50°C54 Simplified start 10°C - 50°C55 Activation of minimum temperature limit 0/1 (Off/On)56 Boiler temperature hysteresis (dynamic) 5°C - 20°C57 Boiler time hysteresis (dynamic) 1 - 30 min58 Stop time for 2nd burner 0 - 30 min59 Fixed hysteresis for 2nd boiler 2°C - 20°C60 Hours to the next boiler sequence change 0 - 250 hours

8035203005101020

61 Number of starts burner 162 Operation time burner 163 Number of starts burner 264 Operation time burner 2

Mixing valve parameters71 Operation time of mixing valve 1 (see motor data plate 1)72 Operation time of mixing valve 2 (see motor data plate 2)

Service81 Burner relay control82 Outer sensor control85 Software version E6

Boiler parameters

30 - 240 s30 - 240 s

According to configurationAccording to configuration

120120

Visualization onlyVisualization onlyVisualization onlyVisualization only

Start with burner relayStart with outer temperature sensor

Visualization only

**

** For TRS-DUO the pre-adjusted value is 250.

In case of the modulating electronicoperation of the two stage burner isrequested, the outer compensator,code 28430, will be replaced by the outercompensator code 20313.

34

STANDARD PANEL BOARD FOR TRS-DUO(code nr. 21076 - for TRS DUO 360 to 2400)

5


Through the main switch 11 the panel boardand all the equipments connected to it willbe under power.The switches 12 & 14 switch On and OFFthe power to the burners.The switch 13 switch ON and OFF the powerto the C.H. pump.With the thermostats 32 & 33 the workingtemperature of the boilers can be adjusted.These thermostats are provided with a DPDTcontact, for the control of a two stage burner.

The differential between the switching pointsof the two double pole is 6°C (not adjustable).The minimum thermostats, accessible throughthe opening of the panel board cover, switchesOFF the C.H. pump during the reacing ofthe steady state and up to the obtention of30 °C within the boilers.In case of three phase burner and/or C.H.pump with a current higher than 3A, convenientrelays have to be foreseen between theseones and the panel board.

11 Illuminated main switch12 Burner switch 1st boiler13 C.H. pump switch14 Burner switch 2nd boiler

15 Free switch - not used31 High limit thermostat 1st boiler32 Working thermostat 1st boiler33 Working thermostat 2nd boiler

35 High limit thermostat 2nd boiler41 General fuse (4A)42 Thermometer 1st boiler43 Thermometer 2nd boiler fig. 40

31

42

11 41 12 13

32

14 15 16 17

35

33 34

18 19 20 21 22 2343

On the electrical supply line to the boiler aswitch with fuses is to be foreseen.

35

5.2 - ELECTRICAL WIRING DIAGRAM FOR SINGLE PHASE BURNER AND PUMP

fig. 41

Ph Phase (230V ~ 50Hz)N NeutralF1 General fuse (max 4A)Ib1 Burner switch 1st boilerIb2 Burner switch 2nd boilerIG Illuminated main switchIpi C.H. pump switchPi C.H. pump

Te1(1) 1st stage working thermostat (1st boiler)(30°C÷90°C)

Te1(2) 2nd stage working thermostat (1st boiler )(24°C÷84°C)

Te2(1) 1st stage working thermostat (2nd boiler)(30°C÷90°C)

Te2(2) 2nd stage working thermostat (2nd boiler )(24°C÷84°C)

Tm1 Minimum thermostat 1st boiler (30°C)Tm2 Minimum thermostat 2nd boiler (30°C)Ts1 High limit thermostat 1st boiler (100°C)Ts2 High limit thermostat 2nd boiler (100°C)A1,A2 Additional repetition of lockout for burners 1 & 2B1, B2 Additional repetition of working hour

meter for 1st stage for burners 1 & 2C1, C2 Additional repetition of working hour

meter for 2nd stage for burners 1 & 2

In case of three phase burner and/or pump, convenient relays have to be foreseen.The terminals 35 - 36 - 38 - 39 may be used for the connection of additional recirculating pumps.

E

EE

33

34

4038

39Pi

32

Ipi

(30°C)Tm134

13

3333

E

E

L1 T2N S3T1 B4

15

Ts2

1817 2016 19 21

B2 C2A2

Ib2

(24°÷84°C)(30°÷90°C)

(100°C)

Te2 (2)Te2 (1)

35

(30°C)Tm2

IG

3

11

N

Ph230V~ 50Hz(max 4A)

2

1

C

21

C

F1 (max 4 A)

41

2

22

29

2

12

2

1

14

1

C

11

3735

30

36

31

B5 T7 T8T6

22 23 24 25

4-4

G-V

6-6

7-7

8-8

9-9

10-1

0

28

E

3232

E

E

L1 T2N S3T1 B4

4

Ts1

76 95 8 10

B1 C1A1

Ib1

(24°÷84°C)(30°÷90°C)

(100°C)

Te1 (2)Te1 (1)

31

12C

21

2

22

27

12 14

11

B5 T7 T8T6

11 12 13 14

2 stage burner plug (boiler 1)(optional)

nd

4-4

G-V

6-6

7-7

8-8

9-9

10-1

0

26

14

1 stage burner plug (boiler 1)st 2 stage burner plug (boiler 2)(optional)

nd1 stage burner plug (boiler 2)st

36

35 High limit thermostat 2nd boiler (100°C)41 General fuse (4A)42 Thermometer 1st boiler43 Thermometer 2nd boiler

6.1 - INTRODUCTION

The TRS-DUO boilers can be supplied withan electronic panel board complete with adigital outer compensator with built-inmicrocomputer and permanent memory.The room temperature will be kept constantby modulation of the flow temperature viathe motorised mixing valve according to the

PANEL BOARD FOR TRS-DUO (OPTIONAL)(code nr. 21110 - for TRS DUO 360 to 2400)

6

external temperature.The outer compensator, then, will act ontothe burner and/or onto the mixing valve andonto the C.H. pump.The outer compensator sensors (boiler,storage tank, outer and flow) are included inthe supply; the room sensors for the C.H.systems No.1 and No. 2 are optionals.The mixing valve and the relevant motor are

6.2 - PANEL BOARD WITH OUTER COMPENSATOR (optional)

Note: The outer compensator arrives tothe customer with the manufacturer tech-nical data already adjusted.As far as the connection instructions and useof the outer compensator are concerned,please refer to the instruction manualsupplied with the outer compensator.As far as the programming by the installeror use is concerned, see chapter 4.5.

not supplied by Unical.

11 Illuminated main switch12 Burner switch 1st boiler13 C.H. pump switch14 Burner switch 2nd boiler

15 D.H.W. tank loading pump switch31 High limit thermostat 1st boiler (100°C)32 Working thermostat 1st boiler33 Working thermostat 2nd boiler fig. 42

31

42

11 41 12 13

32

14 15 16 17

35

33 34

18 19 20 21 22 2343

21.020

T-am

bien

te1

T-am

bien

te2

T-ec

onom

iaT-

Acqu

aSa

n.

Cur

vaR

isca

ld. 1

Cur

vaR

isca

ld. 2

Vaca

nze

Ora

Prog

. Ris

cald

.Pa

ram

etri

37

Ph Phase (230V ~ 50Hz)N NeutralF1 General fuse (max 4A)b1 Burner switch 1st boilerIb2 Burner switch 2nd boilerIG Illuminated main switchIpb D.H.W. tank pump switch

Ipr Recirculating pump switchPb D.H.W. tank loading pumpPr Shunt pumpP1 C.H. pump for direct zoneP2 C.H. pump for mixed zoneTe1 Working thermostat 1st boiler (30°C÷90°C)Te2 Working thermostat 2nd boiler (30°C÷90°C)

Tm1 Minimum thermostat 1st boiler (30°C)Tm2 Minimum thermostat 2nd boiler (30°C)Ts1 High limit thermostat 1st boiler (100°C)Ts2 High limit thermostat 2nd boiler (100°C)Vm2 Mixing valve for 2nd zoneA1/A2 Additional repetition of lockout for burners 1 & 2B1/B2 Additional repetition of working hour

meter for boiler 1 & 2

WIRING DIAGRAM OF A PANEL BOARD WITH OUTER COMPENSATOR

In case of three phase burner and/or pump, convenient relays have to be foreseen.

fig. 44

SENSOR CONNECTION ONTO THE OUTER COMPENSATOR TERMINAL STRIP

fig. 43

EE

EE

E

L1 T2N S3T1 B4

19 22

Ts1

76 95 8 10

B1A1

20

Pr

18

32

41 42

Ipr

Ib1

(30°C)

(30°÷90°C)(100°C)

Tm1

Te131

32 33

12

13

34

E

L1 T2N S3T1 B4

11

Ts2

1413 1612 15 17

B2A2

Ib2

(30°÷90°C)(100°C)Te2

35

14

(30°C)Tm2

39 40

IG

3

4

21

38 35

Ipb

11

15

N

Ph230V~ 50Hz

(max 4A)

2

1

28 31

3027

34 37 36II10 II9 IV4 IV3

II2

- -

II6

Pb

25

26

Vm2

23 24

II7 II8 II4 II5 II1

P1 P2

29

TERMINAL OF KROMSCHÖDEROUTER COMPENSATOR

33II3

C CC

C

C

4-4

G-V

6-6

7-7

8-8

9-9

10-1

0

F1 (max 4 A)

41


2 21

1

2

2

1

1

C

4-4

G-V

6-6

7-7

8-8

9-9

10-1

0


2 3 4 5 6 71 8 9 10 21VIII

1

N L1 L1'1

1 12

2

2

M

2 T1 T2

4 3 2 1 3 2 1 2 1 2 1 4 3 2 18 7 6 510 9 2 1VIIIVVIIIIIIIX

+ - L 3Bus

H 1FBR1 VFAS VFAS AFS KFS/SPFS VFAS 3 1

FBR1 DCF

1 2 3

II1

II1

II2

II2

II3

II3

II8

II8

II7

II7

II5

II5

II4

II4

II6

II6

IV4 IV3 II10

II10

II9

II9

31 35 3933 37 4132 3634 38 4240

IV4IV3

FLO

WS

EN

SO

R 2

(V

FAS

)

OU

TE

RS

EN

SO

R (

AF

S)

RO

OM

SE

NS

OR

2 (

FB

R1)

RO

OM

SE

NS

OR

1 (

FB

R1)

BO

ILE

RS

EN

SO

R (

KF

S)

D.H

.W.T

AN

KS

EN

SO

R (

SP

FS

)

1 1

2 3 4 51

M

1

2

T3 T4

IV

38

FLOWSENSOR 2 (VFAS)

OUTERSENSOR (AFS)

ROOMSENSOR 2 (FBR1)

ROOMSENSOR 1 (FBR1)

BOILERSENSOR (KFS)


VM2

P1 P2

VFAS

Pr

Pb

B

SPFSKFS

BOILER 1 BOILER 2

23

45

67

18

910

21

VI

II

1

NL1

L1'

1

11

2

2

2

M 2T

1T

2

43

21

32

12

12

14

32

18

76

510

92

1V

III

VV

IIIIII

IX

+-

L3

Bus

H1

FB

R1

VFA

SV

FAS

AF

SK

FS/S

PFS

VFA

S3

1F

BR

1D

CF

12

31

1

23

45

1

M

1

2

T3

T4

IV

6.3 - ELECTRICAL AND HYDRAULIC CONNECTIONS OF C.H.AND D.H.W. PRODUCTION CIRCUITS

In the fig. 45 the typical connection of theboiler to C.H. system with two heating zones,of which one is with motorized mixing valve.Both, the heating zones are controled by anouter compensator.The electrical connections of the heatingpumps and the mixing valve motor must beconnected strictly according to the schemasshown in the figs. 41 & 43.The temperature sensors will be connectedaccording to the schema shown in fig. 44.

Remember that all the TERSEC boilers arefor forced circulation.It is suggested to adopt a shunt pump "Pr" toguarantee the circulation through the boiler inany possible open condition of the mixingvalve (see fig. 45).The shunt pump “Pr”, which will have athroughput equal, at least, at 50% of the C.H.pump and a manometric of of 1 m W.G., willperform also an anticondensation function,limiting the too cold returns into the boiler.

fig. 45

B Storage tankC1/C2 BoilersP1 C.H. pump for direct zoneP2 C.H. pump for mixed zone

As far as the outer compensator adjustment and programming are concerned, refer to the instruction manual supplied with outercompensator. The parameters which can be modified by the user, according to his needs, are shown on the clause 4.5.

Pb Storage tank loading pumpPr Shunt pumpVM2 Mixing valveKFS Boiler temperature sensor

SPFS Storage tank temperature sensorVFAS Flow temperature sensor

The hydraulic schema shown in fig. 35 areprinciple schema; in case of different systemcircuits, contact, please, our after sale servicedept., which will supply you with all thenecessary informations.

39

COMMISSIONING AND OPERATION

The TERSEC boilers have been designed tobe used in sliding temperature to improve theseasonal efficiency in all type of C.H. systems.When using the boiler at minimum output,the smoke temperature can be extremalylow, also below 160°C.The turbulators will be pushed to the bottom

of the pipes, against the rear wall of the smokechamber.Do not use automatic filling valves.The commissioning of the burner must beperformed under the responsibility of aspecialized and well trained burner technician,authorised by the burner manufacturer.

7.1 - PRELIMINARY CHECK

Once all the hydraulic, electrical and fuelconnections have been made, before startingthe boiler we suggest to ascertain that:- The expansion vessel and the pressure

relief valve are correctly connected andare in no way interceptable.

- The bulb of thermometer, working, highlimit and minimum thermostats are wellsecured into their proper bulb holder.

- The turbulators are correctly fitted in allthe smoke pipes.

- The C.H. circuit has been washed andrinsed and is free from solid impurities.

- The C.H. circuit is filled with water and

has been completely purged.- The pumps operate properly.- The flow switch, the pressure relief valve,

and the overheating discharge valve, ifany, are adjusted at the right value.

- The fuel, hydraulic, electricaI and safetyconnections are executed in conformitywith national and local requirements inforce.

- There are no water leaks.- The burner has been fitted according to

the instructions of the burner manufacturer.- The mains voltage and frequency are

compatible with the burner and the electricalequipment of the boiler.

- The burner is adjusted for the fuel type,

among those listed in the burner data plate,available on the installation site, and theburner output range is compatible with theboiler output.

- In the boiler house there are also the burnerinstructions.

- The C.H. pipes are properly insulated.- The C.H. system is capable to absorb the

heat quantity produced at the first start ofthe burner, during the test period.

- The shunt pump is installed asprescribed in the paragraph 2.5.6.

7.2 - FIRST COMMISSIONING

At the commissioning stage of the boiler aqualified technician has to perform the followingchecks:- Internal and external sound test of burner

and fuel feeding pipe.- Adjustment of the fuel throughput according

to the nominal input of the boiler (it isconvenient to remember that the nominalinput can be adjusted between the minimumand the maximum shown in the table ofpages 6 to 9), by sharing the outputbetween the 1st and the 2nd stage,knowing that the 1st stage flame can godown to the 60% of the nominal output(which at its turn can vary between theminimum and the maximum depending onthe output requested by the C.H. system).

Proceed, then, in the following way:- Open the fuel feeding cock and check that

there are no leaks in the feeding line.- Ascertain that all the switches of the

panel board are in OFF position and adjustthe working thermostat to the minimumposition.

- Switch ON the panel board through themain switch.

- Switch ON the C.H. pump: it will start to

rotate as soon as the minimum watertemperature thermostat detects 50°C.

- Switch the burner ON.- Position the working thermostats of 1st

and 2nd stages to the maximum settingto create a heat request.

During this phase check that:- There are no smoke leaks from the front

door, the burner plate and the chimneyconnection.

- There is a draught at the chimney basebetween 2 and 4 mm w.g.

- There are no water leaks.- The different thermostats and the other

installation safety devices work properly.- The shunt pump operates correctly.- The burner ignition is good.- The burner characteristics (main

adjustments and nozzle type) correspondto the boiler data plate.

With a burner properly adjusted it must bepossible to reach easily, from a smoke sampletaken at the chimney base, the values givenbelow:1) With light oil having a maximum viscosity

of 1.5 °E at 20 °C: - CO = 12 to 13 % - Smoke index < 1 - Smoke temperature = 180 to 200 °C

7

In that occasion a commissioning report hasto be filled out.

2) With Natural Gas: - CO = 9 to 10 % - Smoke temperature = 170 to 190 °C(values related to a clean boiler, with waterat 70 °C).It is suggested to adjust the fuel throughputto the actual needs of the C.H. installationwithout exceeding the a.m. smoketemperatures and without going below 160 °Cwith the boiler at maximum output.The return temperature of this boiler hasnever to be below 25°C (for oil) or 30°C(for gas) when the boiler works at nominalload (100%), and never below 30°C (for oil)or 35°C (for gas) when it works at part load(30%).The installation of a shunt pump between flowand return is necessary only when there isthe possibility to have a return temperaturebelow the a.m. figures.The corrosion caused by acid condensationof the combustion products is nevercovered by the guarante, because itdepends only on the management of theC.H. system.

7.3 - SWITCH OFF OF THEBOILER

- Switch OFF the burner (switch No.12 to 0position).

- Leave the pumps working up to when they

are not stopped by the minimumthermostat.

- Switch Off the power to the boiler panel board.- If it is decided not to use the boiler for a

long period close also the gate valves ofthe fuel.

40

8.2 - ORDINARYMAINTENANCE

The boiler operating condition are very differentfrom one case to the other and depend onthe fuel used, on the adjustment of the burner,on the number of starting, on the C.H. systemcharacteristics, etc. and for that reason it isnot possible to esthablish, in advance, thefrequence of the maintenances.It is, then, necessary that the technician,who performs the first cleaning, esthablishthe cleaning frequency on the base of theboiler status.Generally, we suggest the following frequency,according to the fuel used:- Gas fired boilers: once a year.- Oil fired boilers: twice a year or more often

if there is reason to doubte of theiradjustment.

In any case the local rules in force have tocomplied with.We suggest to shake the turbulators -positioned in the rear part of the smokepipes - at least every 15-20 days of boileroperation, to avoid that the combustionresidues can block them so that their removalbecomes extremely difficult.This operation is made from the front, usingthe on purpose extractor (see fig. 47).To facilitate the turbulators introduction, aspecial guide is foreseen (fig. 46). Once allthe pipes have been cleaned through the brushsupplied with the boiler, all the turbulatorshave to be re-introduced and pushed againstthe rear wall of the smoke chamber.During the operations of ordinary maintenanceit will be necessary to brush the tube bundle- after the removal of the turbulators - andthe furnace and collect the soots through thecleaning doors on the smoke chamber.Besides it will be necessary to verify the goodoperation of the protection and controldevices (thermostats, thermometers) of theboiler and of the plant (manometers, flowand pressure switches, expansion vessels)and all the safety devices.In this occasion it will be necessary to noticethe quantity of reinstatement water used anddecide, also in base to its hardness, an

intervention of preventive descaling.It must be considered that the calcium andmagnesium salts dissolved in the raw water,with repeated reinstatements, can causedeposits in the boiler that hinder the innercirculation and subsequent overheating ofthe wall plates with possible serious damagesthat cannot be attributed to the constructivegeometry and/or to the materials used and/to the constructive technique and, therefore,they are not covered by guarantee.On the occasion of the ordinary maintenanceit is useful to perform a small discharge fromthe boiler to verify if sludges escape.In affirmative case, it will be necessary toprolong the discharge up to get clear water.At the end of the drainage it will be necessaryto reestablish the level of the water in thesystem.At the end of the smoke circuit cleaning, tothe next restart check around the burner plate

fig. 46

MAINTENANCE8

8.1 - GENERAL RULES

Before effecting any operation of cleaning ormaintenance, disconnect the boiler from theelectrical supply acting on the main switchonto the panel board.In case of failure or bad operation of the boiler,switch it off, abstaining your self from anyattempt of reparation or direct intervention.Exclusively address to professionally qualifiedpersonnel.The possible reparation of the boiler must beeffected by an authorized service centerusing only original spare parts.

The non respect of the above can jeopardizethe safety of the boiler.To guarantee the efficiency of the boiler andfor its correct operation it is essential to submitthe boiler to an annual maintenance, througha professionally qualified technician, accordingto the indications of the manufacturer.When it is decided not to use the boileranymore, the parts which can be potentialsources of danger shall be made harmless.After a month of boiler operation, open thefront door and ascertain the smoke pipes areclean.In case of a heavy dirtiness:

- Remove the turbulators from smoke pipes.- Clean all the smoke pipes using the brush

delivered with the boiler.- Open the cleaning door on the rear of the

smoke chamber and remove, with avacuum cleaner all the soot.

- Relocate the cleaning door and theturbulators; then close the boiler front doorand check for soundness all around thesealing rope.

- Then adjust the burner.Note: With a burner properly adjusted only acleanup at the season end is necessary.

and the smoke chamber for smoke leaks. Inthe case some smoke leaks were noticed,first of all tighten the screws fitting the smokeand, not getting result, it will be necessary toreplace the sealing gasket.Similarly it will be necessary to act on thefront door, increasing at first the tighteningof the nuts (after having loosened the innercounternuts) and then, if necessary, byreplacing the whole gasket.If it was necessary to center the sealinggaskets on the sealing ring of the door it ispossible to adjust the door position by actingas suggested on the paragraph 2.6.At the end check and, if necessary, restorethe sealing of the connection of the chimneyand of the burner with the door.The performed operations must be recor-ded on the log book of C.H. system.

41

Detail 1:Fit the brush handle extensiononto the turbulator remover.

Detail 2:Screw the turbulator remover ontothe turbulator.

Detail 3:Turn up to unblock the turbulator.Turn the remover counterclockwiseto release the turbulator.

The procedure has to be repeated for all the turbulators.

Turbulators removal

fig. 47

8.3 - EXTRAORDINARYMAINTENANCE

Extraordinary maintenance of end seasonor for long periods of inactivity.It will be necessary to perform all the operationsdescribed in the preceding chapter andbesides:- Check the state of consumption of the

turbulators to replace them in time.- After the cleaning of the smoke circuit it

is convenient to pass in the smoke pipes

and in the furnace with a rag soaked ofdiluted solution of caustic soda.After having let to dry cross again all thesurfaces with a rag soaked of oil.Perfectly close the the burner air intaketo avoid a continuous passage of damp airthrough the boiler recalled by the chimneyit self.It is advisable to put inside the furnacesome alive mortar that has an hygroscopicaction.

- Do not empty the C.H. system and theboiler.

- Protect the screws with graphitized fat,nuts and pivots of the door.

- Show all the operations that must beperform to the following put into operationparticularly the operation of the shuntpump must be checked.

8.4 - CLEANING OF THEBOILER

Follow the next sequence:- Close the feeding of the oil.- Cooldown the boiler to the ambient

temperature.- Switch Off the electrical supply to the

boiler and the burner.- Open the front door.- Remove the cleaning doors from the smoke

chamber.- Shake and remove the turbulators (fig. 48).- Clean the turbulators and the smoke pipes

by brushing them with the brush (fig. 49)fitted to the brush handle (fig. 50) andrelevant extension (fig. 51) supplied.

- Reposition the turbulators.- Remove all the soot from the smoke

chamber.- Re-fit the cleaning doors.- Verify the state of the refractory insula-

tion of the combustion chamber door.- Verify the state of the door sealing rope.- Close the door of the furnace.

fig. 50

fig. 51

Brush handle

Brush handle extension(if applicable)

fig. 49Oval brushfig. 48Turbulator

42

8.5 - CHECK OF THEBOILER OPERATION

For a safe operation of the boiler it is necessaryto check:- The good operation of the working

thermostat.

8.6 - CHECK OF THEBURNER OPERATION

- See the burner instruction manual.- Follow all the local requirement in terms

of burner maintenance .

- The good operation of the high limitthermostat.

- The adjustment and the good operationof the minimum thermostat.

- The good operation of the shunt system.- The good operation of the outer

compensator (if fitted).

- The good operation of all the other safetyand control devices imposed by localrequirements.

8.7 - BOILER HOUSE

For the combustion of oil or gas the burnerneeds air.Accordingly wide openings are foreseen for

the entry of the air in the boiler house.These openings never have to be obstructed.Maintain the boiler house clean and dust free.The boiler is not a closet: avoid to store anykind of materials.

Maintain the entry of the boiler free and easyto reach in any moment.Ascertain that the boiler house is endowedwith efficient emergency lamp.

43

46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - telefax 0376/660556www.unical.ag [email protected]

This catalogue is purely indicative.The manufacturers reserve the right to modify technical data and any other parts of the contents.

AG S.P.A.

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