elco Trinox 1000 Installation and operation manual

Trinox Floor Standing Shell and Tube Boiler
Operating & Maintenance Manual
Elco Heating Solutions Ltd.
3 Juniper West
Fenton Way
Basildon Essex
SS15 6SJ
Telephone [phone] Fax [phone]
www.elco.co.uk L344

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Contents
GENERAL........................................................................................................................... 3
DESCRIPTION OF THE APPLIANCE ................................................................................ 6
TECHNICAL SPECIFICATION........................................................................................... 7
IDENTIFICATION ELEMENT.............................................................................................. 8
LIST OF SPARE PART....................................................................................................... 8
INSTALLATION.................................................................................................................. 8
DISCHARGE OF COMBUSTION PRODUCT..................................................................... 8
HYDRAULIC CONNECTION .............................................................................................. 9
ELECTRICAL SYSTEM AND CONNECTIONS................................................................ 10
THE PROBLEM OF CONDENSATE ................................................................................ 11
BURNER CONNECTIONS................................................................................................ 14
PRELIMINARY OPERATIONS PRIOR TO STARTING UP.............................................. 15
FIRST START UP............................................................................................................. 16
FIRST START UP AND FURTHER CHECKS .................................................................. 16
WATER TREATMENT AND FLUSHING .......................................................................... 17
TURNING OFF THE BOILER........................................................................................... 17
MAINTENANCE................................................................................................................ 18
CHECKS AFTER BOILER CLEANING............................................................................ 18
TROUBLESHOOTING...................................................................................................... 19
Notes ................................................................................................................................ 22

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GENERAL
These instructions are intended to assist the installer; commissioning engineer, maintenance engineer
and the user with the application and usage of the Trinox Floor Standing Shell and Tube Boiler
.
Please read this manual carefully before commencing the installation, maintenance or commissioning of the
appliance. Failure to strictly observe these instructions may invalidate the warranty or prevent the appliance
from operating correctly.
The Trinox Floor Standing Shell and Tube Boiler must be installed and commissioned by persons deemed to
be competent i.e. Registered with a recognised registration body.
All installations MUST conform to the Gas Safety (Installation and Use) Regulations and Building Regulations
If you need more information relating to this appliance or its installation please do not hesitate to contact us at
Elco Heating Solutions. 3 Juniper West, Fenton Way, Southfields Business Park Basildon. Essex. SS15 6SJ.
Telephone [phone] Fax [phone] or www.elco.co.uk
The data published in this manual is based on latest information (at the date of publication) and may be
subject to revisions.
We reserve the right to continuous development in both design and manufacture, therefore any changes to the
technology employed may not be retrospective nor may we be obliged to adjust earlier supplies accordingly.
The appliance must not be left to operate with the cleaning doors open.
Instructions, data badge and warning labels on the boiler must never be removed or altered, and if damaged
or missing should be replaced as soon as possible. Generally applicable safety instructions related to accident
prevention must be consulted in addition to the information supplied in this manual.
This appliance must not be modified or non-manufactures spare parts fitted without written permission.
Failure to comply with the above may lead to prosecution.
This manual must be handed to the appliance user following completion of the installation.
1.1 Conformity Statement
Trinox Floor Standing Shell and Tube Boiler are manufactured to the highest standards of quality,
performance and safety, in accordance with EC standards and carry the CE mark.
1.2 Installation Requirements
The installation of Trinox Floor Standing Shell and Tube Boiler must be in accordance with the relevant
requirements of Gas Safety (Installation & Use) Regulations 1998, Health & Safety at Work Act, Building
Regulations, British Standards, Institution Gas Engineers, and IEE. Regulations, Construction (Design &
Management) Regulations 1994, Local Authority Bye-Laws, National, Fire Regulations and Insurance
Company requirements.
Flueing and Ventilation should be to the relevant Standards and Codes of practice, a guide to flueing
is provided in Appendix E.

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The following Codes of Practice are also applicable: -
BS 5449:1990 Specification for forced circulation hot water central heating systems for domestic premises.
BS 6644:2005 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and 1.8MW(net)
(2nd and 3rd family gases).
BS 6880:1988 Code of Practice for low temperature hot water heating systems of output greater than 45kW.
Parts 1,2 & 3.
BS 6891:1988 Specification for installation of low-pressure gas pipework of up to 28mm (R1) in domestic
premises (2nd family gases).
BS 7593:2006 Code of Practice for treatment of water in domestic hot water central heating systems.
BS 7671:1992 Requirements for electrical installations. IEE Wiring Regulations. Seventeenth Edition
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
IGE/UP/1 or 1A Gas Tightness Testing & Purging of Commercial Industrial Gas Installations
IGE/UP/2 Gas installation pipework, boosters and compressors on Industrial and Commercial premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises.
IG/UP/10 edition 3 Installation of gas appliances in Industrial and Commercial premises.
Part 1: Flued appliances.
This instruction booklet is an integral and essential part of the product.
This appliance must be used for the purpose for which it was specifically intended.
All contractual or non-contractual responsibility of the manufacturer is excluded in the event of
injuries caused by errors in installation, adjustment, maintenance and improper use.
The manufacturer's responsibility is excluded for all damage to persons resulting from a clear risk
for the user which could have avoided by taking suitable safety measures.
After having removed the packaging, check the contents for breakages. If you are in doubt do not
use the appliance, contact your supplier.
Do not leave the packaging materials (wooden cage, nails, staples, plastic bags, polystyrene foam,
etc.) as they are potential sources of risk.
The installation must be performed in compliance with the regulations in force, following the
manufacturer's instructions, by professionally qualified personnel. The term "professionally
qualified personnel" means persons with specific technical skills in the sector of heating systems
and components for domestic use and domestic hot water production.
To guarantee the efficiency of the appliance and ensure correct operation, it is necessary to have
regular maintenance performed by professionally qualified personnel, following the manufacturer's
instructions.
Any repairs to the appliance must be carried out using only original spare parts.
If you decide not to use the appliance for a long period, ensure you have professionally
qualified personnel to carry out the necessary operations to preserve the boiler.

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The use of any component utilising energy power, fuels and water requires that certain
fundamental rules be respected, such as:
Do not allow unskilled people to use the appliance;
If you notice smell of gas, do not turn on electric switches, appliances, telephone or any other
objects that could cause sparks. If this is the case:
- open doors and windows immediately to clear the air in the room;
- turn off the fuel taps;
- contact professional qualified personnel.
Do not perform any maintenance and cleaning operations without having disconnected the
electrical power and turned off the fuel supply.
Do not pull, disconnect, or unwind electric cables coming from the boiler, even if they are
disconnected from the mains supply.
Do not block or reduce the ventilation openings in the room this is to prevent the formation or toxic
and explosive mixtures caused by gas leakage; it is also uneconomic and polluting because it can
cause bad combustion.
Do not expose the appliance to corrosive atmospheric agents.
The boiler has not been designed to work outdoors and is not provided with automatic anti-
freezing systems. Keep the boiler protected in freezing conditions.
Other important warnings:
- If the power cable of the appliance is damaged, have it replaced by professionally qualified
personnel;
- do not fix (and do not allow other persons to fix) electric cables on the system pipes or near
sources of heat;
- ensure that the earthing cables of the appliance are not connected to the water system;
- do not touch the hot parts of the system (in particular the manhole and the smoke box) as they
normally remain hot even for some time after the appliance has been turned off.
In the event of a water leak, turn off the system and contact a professionally qualified
personnel.

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DESCRIPTION OF THE APPLIANCE
The steel boiler from the TRINOx range, is a high performance hot water boiler for three-gas pass
heating systems externally-fired with wet reversal chamber.
The flame runs through the furnace and, from the bottom passing through the inversion chamber,
it is conveyed in the tube bundle for the 2nd gas passes. Gasses return to the front part for the
passage in the tube bundle (3rd gas pass). After leaving the tube bundle, gasses are collected in
the rear chamber and conveyed to the stack.
Combustion gas inversion is clearly separated from the furnace in order to reduce NOx. Smoke
stay time in the high temperature area causes NOx formation.
Burners fired with traditional liquid and gaseous fuels can be installed.
The burner is installed on a bolted burner plate, which is coated inside with insulating material.
Inspection doors on the combustion side and the hand hole on the water side (the front doors are
hinged, the rear doors are bolted) improve the access for maintenance and cleaning operations.
Models from 5000 to 9000 are supplied with a manhole on the water side.
The thermal insulation of the boiler body is a pad of highly insulating mineral wall to reduce
thermal dispersions at very low levels. Elegant pre-painted aluminium panels complete the outside
finish.
The highest admitted differential temperature of the boiler (difference between return and flow
water temperatures) is 30°C under all working conditions: should this not be the case, appropriate
solutions must be adopted such as installing a recirculation pump.
The electrical panel is located on the side of the boiler.
The electrical diagram is included in the control panel and in this manual.

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TECHNICAL SPECIFICATION

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IDENTIFICATION ELEMENT
The appliance can be identified through the DATA PLATE this contains the operating values and
identification data. The plate is applied in the front upper part, on the right.
For any servicing and spare parts the correct identification of the boiler model will facilitate
ordering of the correct parts
IMPORTANT: ensure that the boiler is provided with a data plate. If not, please request a data
plate from the suppliers.
LIST OF SPARE PART
The spare parts recommended for two years of operation are the following
n.1 working thermostat
n.1 safety thermostat
n.3 inspection doors gasket kit
n.3 hand hole gasket
n.3 manhole gasket (only models from 5000 to 9000)
n.1 flame sight glass
n.1 flame sight glass gasket
INSTALLATION
The boiler must be installed in a room that complies with the provisions and minimum distances
established by the current regulations and is provided with suitably sized air vents.
The boiler must be positioned on a flat surface capable of uniformly supporting
the base structure section bars.
The surface should be raised from the floor.
CAUTION: if the burner is powered with combustible gas with specific gravity higher than the
specific gravity of air, the electrical parts must be positioned above 0.5 metres from ground level.
The boiler must not be installed outside as it has not been designed for outdoor installation and is
not provided with automatic anti-freeze systems
DISCHARGE OF COMBUSTION PRODUCT
The use of the correct burner/boiler/flue drastically reduces consumption, optimises combustion
with low emission of contaminants and provides effective protection against condensation.
The FLUE must be resistant to heat and condensation, thermally insulated, hermetically sealed,
without bottlenecks or obstructions, as vertical as possible and sized according to current
regulations.

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The CONNECTION BETWEEN THE BOILER AND THE FLUE must comply with the current
regulations and legislation and consists of rigid hermetically sealed pipes resistant to high
temperatures, condensation and mechanical stress. For sealing the joints, use materials that can
withstand at least 250°C.
Badly sized and shaped flues and couplings between boiler and flue can amplify the combustion
noise, negatively affect the combustion parameters and cause condensation problems.
CAUTION: non-insulated outlet pipes are a potential source of injury.
HYDRAULIC CONNECTION
The choice and installation of the system components is the responsibility of the installer who must
operate in accordance with correct working practice and the current legislation.
The following recommendations should be observed:
- The boiler fittings must not be put under strain by the weight of the system connection pipes as
this can cause damage to the boiler and all pipework must be adequately supported.
- Cut-off devices must not under any circumstances be fitted between the boiler and the
expansion vessel and between the boiler and the safety valves.
- The expansion vessel must be correctly sized (there must be no leaks of water due to normal
expansion) and, if the expansion vessel is closed, the safety valves must open only in
exceptional cases in order to minimise any subsequent introduction of water and in any case
to ensure that it is introduced and controlled by one single point in the system.
- Ensure that the safety valve outlets are connected to an outlet tundish and a discharge over a
drain. If not, when the valves cut in they will flood the room and the manufacturer will accept
no liability for this.
- Ensure that the hydraulic pipes are not used as earth connections for the electrical or
telephone system. They are not suitable for this use and can rapidly deteriorate leading to
serious damage.
- Before connecting up the boiler, wash all the system pipes to remove any debris that could
affect correct operation.
- The water to fill the system must have the following technical features: hardness < 1 °F,
acidity pH > 9; otherwise a system for water treatment should be provided.
- If the mains water supply contains impurities, a suitable filter must be fitted
- Avoid any accidental contact between the heating system water and the sanitary water as the
former is not drinkable.

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After connection to the hydraulic system, ensure that the latter is completely de-aerated.
You are advised to insulate the heating system pipes to avoid heat dispersion resulting in increased
fuel consumption and environmental pollution.
ELECTRICAL SYSTEM AND CONNECTIONS
The electrical system must comply with the current regulations and be installed by professionally
qualified personnel.
Electrical safety of the equipment is ensured only when it is correctly connected to an efficient earth
system in compliance with the current safety regulations.
The manufacturer will not be liable for any damage caused by failure to earth the system.
Call professionally qualified personnel to check that the electrical system is suitable for the
maximum power absorbed by the equipment, ensuring in particular that the system cable sections
are suitable for the power absorbed by the equipment.
Adapters, multiple sockets and extension leads must not be used for general power supply of the
equipment from the mains.
For connection to the mains, a twin-pole switch must be provided in compliance with the current
regulations.
The control panel is already installed on the boiler.
Power supply: 220 V - 50 Hz.
By unscrewing the self-tapping screws, open the instrument panel and connect the boiler
electrically.
All the instruments capillary probes of the panel are located in the bulb on the heating system flow
connection.
Electric connections must be performed following the attached electrical diagram.
Never fix the electric cables to the front part of the boiler, to the doors or the smokebox.
Finally, close the panel.

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Wiring Diagram for BMS relays.

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THE PROBLEM OF CONDENSATE
The water vapour contained in the fumes discharged from the boiler condenses when the
temperature of the water returning to the boiler is below 50°C. Condensation occurs in particular
when the boiler comes on in the morning after being switched off during the night.
The condensation is acid and corrosive and will gradually attack the boiler sheet metal panels.
To limit the formation of condensate as far as possible an anti-condensate pump must be fitted
following the diagram illustrated below.
When the burner starts, a thermostat positioned on the water return to the boiler and set to 55°C
with exchange contact will start up the anti-condensate pump which will continue to operate until
the set temperature is reached; the thermostat will then simultaneously switch off the anti-
condensate pump and switch on the system pumps.
In order to totally eliminate the problem, the above circuit must be correctly adjusted in order to
maintain the boiler constantly at 55°C even at night and a further temperature-limiting thermostat
must be added to prevent the system mixing valve from sending water below 55°C to the boiler.
This will ensure long life of the boiler.
The flow rate of the anti-condensate pump is normally 25%-30% of the system pump flow rate
whereas the head required is not particularly high as it only has to overcome the resistance of the
boiler and the valves.
The smokebox of the TRINOx is provided with a fitting for discharge of any condensation that forms
during the start-up phase.
Do not connect the fitting directly to the mains drainage system but to a collecting basin in order to
monitor condensation.

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For accurate monitoring, check that the condensate forming in the flue does not also end up in the
basin.
The condensation is acid and corrosive and will therefore contaminate if discharged into the mains
drainage system.
Before emptying the basin into the mains drainage system, the acid level must therefore be restored
to between pH 6.5 and 9 using neutralising products.
The fuel supply line must comply with current regulations and be installed by professionally
qualified personnel.
Before installation, you are advised to thoroughly clean the inside of all the fuel supply pipes in
order to remove any debris that may affect correct operation of the boiler.
Check the fuel supply system internal and external seal.
If using gas, the connections must be perfectly sealed.
Check that the fuel supply system is provided with the safety and control devices prescribed b y the
current regulations.
Do not use the fuel system pipes to earth electrical or telephone systems. Check that the
boiler is pre-set for operation with the type of fuel available.
BURNER CONNECTIONS
For installation of the burner, the electrical connections and the necessary settings, consult the
burner instruction manual.
Ascertain that the correct type of burner has been chosen for the boiler, checking the technical
specifications of both.

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The burner draught tube must be sized as shown below:
Secure the burner to the door by means of the fixing plate so that the flame is parallel and centred
in the furnace; if not, combustion problems can occur with the risk of seriously damaging the boiler.
IMPORTANT: after installing the burner, fill any space between the draught tube and the hole of the
door with the material provided, resistant to 1000°C (ceramic fibre mat).
This operation prevents overheating of the door which would otherwise be permanently deformed.
If the burner is provided with an air intake, connect it by means of a rubber tube to the intake
located on the flame inspection window: in this way the glass will remain clear.
If the burner is not provided with air intake, remove the intake on the flame inspection window and
close the hole with a 1/8" BSP plug.
The fuel connections to the burner must be positioned in order to permit complete opening of the
boiler door with the burner fitted.
PRELIMINARY OPERATIONS PRIOR TO STARTING UP
Before starting up:
- ensure that the regulation and control instrument probes are positioned correctly in their pockets;
- check that the system is filled with water, de-aerated and at a correct pressure for the boiler;
(minimum 1.5 bar);
- check that all the control and safety devices are in efficient working order and correctly set;
- check that the furnace is free from foreign bodies;
CERAMIC FIBRE

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- check that the refractory lining of the door has not been damaged;
- check that the burner draught tube has been correctly sealed
- check that the discharge valves are closet and the system cut-off valves are completely open;
- ensure that the fuel is available and that fuel controls are open;
- Ensure that the electric motors of the burner fan and circulation pumps are running in the
correct rotation;
- Check that the water treatment system (if any) works properly;
- Start the circulation pumps and ensure that the water runs homogeneously (the plant must be
de-aerated).
FIRST START UP
After performing the preliminary checks, perform the following operations to start the boiler:
- set the boiler thermostat(s) on the control panel; 60 to 90°C, according to the type of plant;
- set the master switch to "on";
- press the main control panel switch (the button light will come on).
The boiler will perform an ignition phase and, once started, will remain on until the set temperatures
have been reached.
Operation will be automatic from now on.
FIRST START UP AND FURTHER CHECKS
Once the boiler has been started, check that it stops and then starts again by:
- altering the boiler thermostat setting;
- operating the main switch on the main control panel.
Check the seal on all the gaskets on the water and fume side; they must be further tightened while
hot in order to guarantee a perfect seal.
This operation is of fundamental importance for the gaskets of the door, of the burner plate and of
the smokebox to prevent leakage of toxic and therefore hazardous combustion fumes into the boiler
room.

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It is also very important to check the boiler/flue coupling seal for the above reasons.
It is also very important to tight progressively the generator hand hole and manhole gasket as long
as the pressure increases to guarantee a perfect seal. If not, at the first leakage, the gasket must
be replaced.
Use the main switch to turn off totally the appliance.
After all the conditions have been satisfied, the burner must be set at the max. output allowed by
the boiler. Smokes must be analysed to reach the correct combustion and the less possible
polluting emissions.
The pressure of the water contained in the system increases during operation and you should
therefore check that its maximum value does not exceed the boiler pressure.
WATER TREATMENT AND FLUSHING
This treatment must be carried out by qualified companies on new boilers. After the boiler has been
prepared and installed, all deposits are removed such as residues of oil, grease, metal oxides.
If these substances are not removed, they will help the onset of corrosive phenomena caused by
the formation of a passivating film on water-exposed surfaces.
The boiler should be flushed and cleansed to the current standards before operation of the boiler.
TURNING OFF THE BOILER
In the event of a long period of inactivity, turn off the boiler as follows:
- Water side preservation procedure that can be "wet" or "dry";
- Turn off the main switch from the electrical panel and power off;
- Turn off the fuel cut-off valve;
- Smoke side preservation procedure;
- Protect from dust and humidity all control, regulation and safety devices.
With "Wet preservation" the boiler must be completely filled with water which is later added with
preservatives or neutralising products. The plant is subsequently sealed and all cut-off valves
locked. This type of preservation procedure should not be followed in case of freezing conditions.
With "Dry preservation" the boiler is emptied. Open the manhole, dry completely the boiler inside
with air and ad highly hygroscopic substance (ex. caustic lime). Close all cut-off valves and the
manhole sealing the boiler.

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To preserve the combustion side open the door and the smoke box doors, clean thoroughly all
surfaces removing all the soot (which may contain sulphur which turn into sulphuric acid when wet)
and add highly hygroscopic substances (ex. caustic lime) in the furnace and smoke box.
Close and seal the door and the cleaning doors.
MAINTENANCE
Periodical maintenance is essential for the safety, efficiency and long life of the equipment.
It is also required by law and must be carried out by professionally qualified personnel.
Before carrying out any work, you are advised to perform a combustion analysis to ascertain the
operating conditions and obtain any other useful information.
After performing the combustion analysis and before any other operation:
- Wait until the plant is cold;
- disconnect the electricity supply by switching off the master switch;;
- close the fuel on-off controls.
Clean the smoke side every 3 months if heavy oil is used, every 6 months with light oil, every year
with gas fuels.
To clean the smoke side open the inspection doors, remove the burner, the plug. With a tube-brush,
clean thoroughly all surfaces and the tube bundle to remove soot. Remove all soot from the furnace
and the cleaning doors.
If you believe that the boiler is scaled inside, empty it and open the hand-hole/manhole; scales
must never be thicker than 0.5 mm. If not, have a chemical washing carried out by qualified
companies and check the softener system.
Warning: replace the hand-hole/manhole gasket each time you open it and tight gradually in hot and
cold conditions.
CHECKS AFTER BOILER CLEANING
After performing the maintenance and cleaning operations, repeat the preliminary operations prior
to switching on for the first time (see page 15), check the burner setting and perform a fume
analysis.
Check the fuel supply system seal: this check is particularly important when using gaseous fuels.
Check that the fume circuit is perfectly sealed and replace any worn gaskets.
Check the system hydraulic seal to avoid unnecessary exchange of water and topping up which will
increase the risk of scaling.

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Check the efficiency of safety and control instruments.
Never leave highly inflammable substance containers in the premises where the boiler has been
installed.
TROUBLESHOOTING
Below is the description of the most common faults and their remedy:
FAULT: the burner does not turn on.
REMEDY:
- check electric connections;
- check the regular fuel supply
- check the integrity and the cleanness of the fuel supply system and that no air is present;
- check that ignition sparks form regularly and the burner appliance works correctly;
- check the boiler safety thermostat intervention with manual reset;
- check the calibration of the environment thermostat.
FAULT: the burner turns on well but turns off immediately after.
REMEDY:
check the pilot flame, the air calibration and that the burner appliance works correctly.
FAULT: the burner is difficult to be adjusted and/or no output.
REMEDY:
- check for the cleanness of burner, boiler, boiler/flue pipes and flue;
- check the hermetic seal of the smoke circuit (door, burner plate, smoke box, boiler/flue
connection);
- check that the fuel supply is flowing regularly and verify the effective power of the burner;
- check for the presence of scale and carry out a chemical washing.
FAULT: the boiler gets easily covered with soot.
REMEDY:
- check the burner regulation (smoke analysis);
- check the fuel quality;
- check the flue for clogging and the cleanness of the burner air intake (dust).
FAULT: smell of gas and/or unburnt products.
REMEDY:
- check the seal of the fuel supply system (if gas fuel);

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- check the hermetic seal of the smoke circuit (inspection doors, burner plate, smoke box,
boiler/flue connection);
- check that the rubber holder on the flame warning light is connected to the burner air inlet or
clogged.
FAULT: the boiler does not reach set pressure.
REMEDY:
- check that the smoke side and water side of the boiler are clean;
- check the combination, regulation and performance of the burner;
- check the regulation of the pressure switches and that they work correctly;
- check the position of the thermostat gauges;
- ensure that the boiler capacity is appropriate for the plant
FAULT: the boiler reaches the appropriate temperature but the heating system
is cold.
REMEDY:
- check that no air is in the system;
- check that circulation pumps are working well;
FAULT: the safety pressure switch intervenes.
REMEDY:
- check electric wires
- check the position of the thermostat probes;
- check the thermostat setting and ensure they work well
FAULT: the safety valve of the boiler intervenes often.
REMEDY:
- check the system loading pressure;
- check the efficiency of the expansion vessel;
- check the calibration of the safety valves.
FAULT: membranes overheating due to lack of water in the boiler.