Unical TERNOx 2S User manual

TERNOx 2S
INSTRUCTIONS ON INSTALLATION, USE AND MAINTENANCE

2
Attention: this manual contains instructions for the exclusive use of the pro-
fessionally qualified installer and/or maintenance technician in compliance
with current legislation.
The system manager is NOT authorised to service the boiler.
The manufacturer will not be held liable in case of damage to persons, animals
or objects resulting from failure to comply with the instructions contained in
the manuals supplied with the boiler.

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1 GENERAL INFORMATION ................................................................................................................................................................................. 5
1.1 General warnings.......................................................................................................................................................................................... 5
1.2 Symbols used in the manual......................................................................................................................................................................... 6
1.3 Appropriate use of appliance ........................................................................................................................................................................ 6
1.4 Information for system manager ................................................................................................................................................................... 6
1.5 Safety warnings ............................................................................................................................................................................................ 7
1.6 Technical data plate ...................................................................................................................................................................................... 8
1.7 Water treatment ............................................................................................................................................................................................ 8
General informationTechnical featuresInstallation instructionsMaintenance instructions
4 INSPECTION AND MAINTENANCE ................................................................................................................................................................44
Routine and extraordinary maintenance............................................................................................................................................................ 44
Inspection and maintenance instructions........................................................................................................................................................... 45
Maintenance of body ......................................................................................................................................................................................... 45
Troubleshooting..................................................................................................................................................................................................46
3 INSTALLATION INSTRUCTIONS ...........................................17
3.1 General warnings ............................................................17
3.2 Installation standards.......................................................17
3.3 Installation on old or retrofittable systems .......................17
3.4 Packaging........................................................................18
3.5 Handling ..........................................................................18
3.6 Positioning in boiler room ................................................19
3.7 Hydraulic connections .....................................................20
3.8 Filling and emptying the system ......................................20
3.9 Gas connection................................................................21
3.10 Connection to the flue......................................................21
3.11 Furnace door: adjustment, opening, closing....................22
3.12 Burner..............................................................................22
3.13 Electric panel assembly...................................................24
3.14 Electrical connections ......................................................25
3.15 STANDARD panel board .................................................26
3.16 Hydraulic and electrical system connection.....................25
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................9
2.1 Technical features......................................................................................................................................................................................... 9
2.2 Operation principle........................................................................................................................................................................................ 9
2.3 Dimensions ................................................................................................................................................................................................. 10
2.4 Operating data according to UNI 10348 ..................................................................................................................................................... 13
3.17 Optional MASTER panel board .......................................29
3.18 Hydraulic and electrical system connection.....................32
3.19 Example of hydraulic and electrical system connection ..35
3.20 CASCADE panel board ...................................................37
3.21 Hydraulic and electrical system connection
with boilers in cascade ....................................................39
3.22 Commissioning............................................................. 41
3.23 Burner adjustment ...........................................................42
3.24 Checks during and after commissioning..........................43
3.25 Alkaline or “boiling” wash.................................................43
3.26 Boiler shutdown ...............................................................43

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General information
1GENERAL INFORMATION
1.1 - GENERAL WARNINGS
The instruction booklet is an integral and essential part of the
product and must be kept by the system manager.
Read the warnings contained in this instruction booklet carefully
as they provide important guidelines regarding installation, use
and maintenance safety.
Keep the booklet with care for further consultation.
Your appliance must be installed and serviced in compliance
with the standards in force according to the manufacturer
instructions, up to standard and by legally qualified and
certified personnel.
Systems for the production of domestic hot water MUST be
constructed entirely with materials that comply with M.D.
174/2004 (taps, pipes, fittings, etc.).
By professionally qualified personnel we mean: personnel
with specific technical skill in the field of heating system
components for civil use, domestic hot water production
and maintenance. Personnel must have the qualifications
provided for by current legislation.
Incorrect installation or improper maintenance can cause dam-
age to persons, animals or objects for which the manufacturer
is not responsible.
Before performing any cleaning or maintenance, disconnect the
appliance from the energy mains by acting on the switch of the
system and/or through the specific cut-off devices.
Do not obstruct the terminals of the intake/exhaust ducts.
In case of failure and/or malfunctioning of the appliance, switch
it off and do not try to repair it or intervene on it directly. Contact
only personnel qualified in compliance with law.
Any product repairs must be performed solely by personnel
authorised by Unical, using original spare parts only. Failure to
comply with the above can compromise the safety of the appli-
ance and void the warranty.
To guarantee appliance efficiency and its correct operation,
yearly maintenance must be performed by qualified personnel.
Should you decide not to use the appliance, parts entailing
potential sources of hazard must be made safe.
Before commissioning an appliance that has not been used,
wash the domestic hot water production system, making the
water flow until it has been fully replaced.
Should the appliance be sold or transferred to a new owner or
if you move and leave the appliance, always make sure that the
instruction manual accompanies it in order to be consulted by
the new owner and/or installer.
Only original accessories must be used for all appliances with
optionals or kits (including electric).
This appliance is intended solely for the use for which it was
expressly designed.
Any other use is to be considered improper and therefore dan-
gerous.
ATTENTION
Wherever the boiler operates with a pressure jet gas burner, the appliance, not belonging to any category among those considered
in Annex II of the Legislative Decree 93 of 25/02/2000 (Implementation of the Directive 97/23/EC regarding pressurised equipment),
and moreover being considered by the Directive 90/396/EEC (Gas-fired appliances - transposed in Italy with Italian Presidential De-
cree 661 of 15/11/1996) to which art. 1 comma 3 paragraph “f.5” refers, is excluded from the range of application of the decree itself.

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1.2 - SYMBOLS USED IN THE MANUAL
Pay special attention when reading this manual to the parts marked by the symbols:
NOTE!
Tips
for the user
ATTENTION!
Possible dangerous
situation for the product
and the environment
DANGER!
Serious danger for
personal safety and life
1.3 - APPROPRIATE USE OF THE APPLIANCE
The TERNOX 2S appliance has been built according to the current level of engineering and acknowledged
technical safety rules.
Nonetheless, if improperly used, dangers could arise for the safety and life of the user and other persons
or damage to the equipment or other objects.
The appliance is intended to operate in hot water circulation heating systems.
Any other use must be considered improper.
UNICAL will not be held liable for any damage resulting from improper use.
Use according to the intended purposes also includes strict compliance with the instructions in this manual.
The user must be instructed concerning the use and operation of his heating system, in particular:
• Deliver these instructions to the user, as well as other documents concerning the appliance inserted in the envelope
inside the packaging. The user must keep this documentation safe for future consultation.
• Inform the user about the importance of the air vents and the flue gas exhaust system, highlighting their essential
features and the absolute prohibition of modifying them.
• Inform the user concerning controlling the system's water pressure as well as operations to restore it.
• Inform the user concerning correct temperature control, control units/thermostats and radiators for saving energy.
• Remember that the system must receive regular maintenance at least once a year and combustion analysis must
be performed every two years (as per national law).
• Should the appliance be sold or transferred to a new owner or if you move and leave the appliance, always make
sure that the instruction manual accompanies it in order to be consulted by the new owner and/or installer.
The manufacturer will not be held liable in the event of damage to persons, animals or objects resulting from
failure to comply with the instructions contained in this manual.
1.4 - INFORMATION FOR SYSTEM MANAGER

7
General information
1.5 - SAFETY WARNINGS
ATTENTION!
The appliance must be installed, adjusted and maintained by professionally qualified personnel, in com-
pliance with the standards and provisions in force. Incorrect installation can cause damage to persons,
animals and objects for which the manufacturer cannot be held responsible.
DANGER!
The boiler must be serviced or repaired by professionally qualified personnel, authorised by Unical. We
recommend stipulating a maintenance contract.
Insufficient or irregular maintenance can jeopardise the operating safety of the appliance and cause damage
to persons, animals and objects for which the manufacturer cannot be held responsible.
Modifying parts connected to appliance
Do not modify the following parts:
- the boiler
- the gas, air, water and electricity supply lines
- the flue gas pipe, the safety valve and the exhaust pipe
- the construction parts which affect the operating safety of the appliance.
Attention!
To tighten or loosen the screwed fittings, use only appropriate fixed spanners.
Incompliant use and/or inappropriate tools can cause damage (e.g. water or gas leakage).
ATTENTION!
Indications for propane gas-fired appliances
Make sure that the gas tank has been deaerated before installing the appliance.
For state-of-the-art tank venting, contact the LPG supplier or person qualified in compliance with the law requirement.
If the tank has not been professionally deaerated, ignition problems could arise.
In that case, contact the supplier of the LPG tank.
Smell of gas
Should a smell of gas be perceived, follow these safety guidelines:
- do not turn electric switches on or off
- do not smoke
- do not use the telephone
- close the gas shut-off valve
- air out the area where the gas leakage has occurred
- inform the gas supplier or a company specialised in installation and maintenance of heating systems.
Explosive and easily flammable substances
Do not use or store explosive or easily flammable materials (e.g. petrol, paints, paper) in the room where the ap-
pliance is installed.
ATTENTION!
The appliance must not be used by people with reduced physical, sensory and mental abilities, without
experience and knowledge. These people must be previously trained and supervised during manoeuvre
operations. Children must be supervised so that they do not play with the appliance.

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Mains: 230V~ 50Hz
W:
Boiler type
Serial number
Year of manufacture
*
Boiler water capacity
Max. operating pressure
l
Fuels
(only those with X)
Gas Wood
Charcoal
Diesel oil Naphtha
OUTPUTS
P.I.N. code
Furnace
Useful
kW
Capacity Max. press. Max. temp.
l °C
bar
Storage tank:
AG S.P.A.
46033 CASTELDARIO (MN) - Via Roma
tel. [phone] - fax [phone]
www.unical.ag [email protected]
Max. operating temp. °C
bar
Category
kW kW
Sup. m²
* See serial no. on boiler body
Approval
min. max. min. max.
CE marking
The CE marking certifies that the boilers meet:
- The essential requirements of the gas appliance directive
(90/396/EEC)
- The essential requirements of the electromagnetic compat-
ibility directive (89/336/EEC)
1.6 - TECHNICAL DATA PLATE
The technical data plate is inserted in the document envelope. When installation is finished, it is MANDATORY that the
appliance installer apply it at the front top part.
If lost, ask the Unical Technical Assistance Service for a duplicate.
The serial number of the boiler is on the riveted plaque on the front plate of the body (front right top side).
If the identification plate is tampered with, removed or missing, the product cannot be safely identified, making any
installation and maintenance operation difficult.
1.7 - WATER TREATMENT
The treatment of the supply water allows to
prevent inconveniences and maintain the
functionality and efficiency of the generator
over time.
The values displayed in the table can be
used as a reference.
TOTAL HARDNESS ppm 10
ALKALINITY mg/l CaCO3 750
PH 8÷9
SILICA ppm 100
CHLORIDES ppm 3500
To minimise corrosion, it is crucial to use
a corrosion inhibitor; in order for it to work
properly, the metal surfaces must be clean.
ATTENTION: These appliances are NOT suit-
able for the production of water for human
consumption according to Ministerial Decree
D.M. 174/2007.
ATTENTION!
ANY DAMAGE TO THE BOILER CAUSED BY
THE FORMATION OF FOULING OR BY COR-
ROSIVE WATER WILL NOT BE COVERED BY
THE WARRANTY.
- The essential requirements of the efficiency directive (92/42/
EEC)
- CE marking compliant to directives governing the use of
gas-fired appliances - Ts < 110°C.

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Technical features
2.1 - TECHNICAL FEATURES
One of the significant aspects taken into account when design-
ing the TERNOx 2S series boilers is the reduction of the forma-
tion of pollutants in exhaust gases.
One of these consists of nitrogen oxides (Nox). In Europe, their
emission is governed by several legislative standards and pro-
visions. Welding procedures and devices are approved and
certified according to EN Standards.
The main technical elements of the design are:
- An accurate study of geometries, to achieve an ideal ratio
between combustion volumes and exchange surfaces.
- The selection of the materials used to guarantee the long life
of the boiler.
Welding procedures and devices are approved and certified
according to EN Standards.
The boilers have pressurised combustion, with 3 flue gas pass-
es with passing flame and wet inversion chamber.
The combustion gases produced by the burner, having passed
the combustion chamber of the furnace, enter the pipes in the
second flue gas pass.
After the exhaust gases return to the front of the boiler, they
again change direction and pass through the pipes of the third
flue gas pass towards the flue duct.
This type of boilers achieves a high average yearly performance
and low content of harmful substances in the flue gas. Another
advantage of the three flue gas pass structure consists of the
fact that combustion products remain less time in high temper-
ature areas, thus limiting harmful emissions of nitrogen oxides.
The boiler body is thermally insulated by the application of a
mineral wool mattress with a high insulation level to reduce
heat dispersion to extremely low levels. It is finished by alumin-
ium sheets.
2TECHNICAL FEATURES
AND DIMENSIONS
2.2 - OPERATION PRINCIPLE
TERNOX 2S boilers have pressurised combustion, with 3 flue
gas passes with passing flame and wet inversion chamber.
The combustion gases produced by the burner, having passed
the inversion chamber of the furnace, enter the pipes in the
second flue gas pass.
After the exhaust gases return to the front of the boiler, they
again change direction and pass through the pipes of the third
flue gas pass towards the flue duct.
The combustion chamber is always pressurised while the burn-
er is operating.
For the value of this pressure, see the TECHNICAL DATA table,
in the column Flue gas pressure drop.
The flue gas duct and the fitting to the flue must be implement-
ed in compliance with Standards and Legislation in force, with
rigid ducts resistant to heat, condensation, mechanical stress
and airtight.
1 Furnace
2 Smoke pipes
3 Door with flame control warning light
4. Smoke chamber
5 Body insulation
(2nd pass) (3rd pass)

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2.3 - DIMENSIONS
TERNOX 2500 2S STD - 2200 2S Low NOx - 1800 2S Low NOx E
TERNOX 3500 2S STD - 3050 2S Low NOx - 2350 2S Low NOx E
(**) Pressure drops corresponding to a thermal variation of 15K.
T1 Heating flow
T2 Heating return
T3 Expansion vessel connection
T4 Boiler drain
T5 Chimney connection
T6 Probe holder conduit connection
T7 Probe holder conduit connection
T8 Burner connection
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame control warning light
TERNOx 2S
Model
Useful
output
kW
1800 - 2500
1800 - 2200
1800
Furnace
furnace
kW
Boiler
capacity
l
3790
Water side
pressure
drop(**)
m.w.c.
0.26 - 0.50
0.26 - 0.39
0.26
Flue gas
pressure
drop
mbar
3.77 - 7.50
3.77 - 5.73
3.77
M aximum
operating
pressure
boiler
bar
6
W eight
kg
5500
CONNECTIONS
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
DN 50DN 200
T4
ISO 7/1
Rp 1½
T5
Øi
mm
570
T6
Ø
mm
Rp 1/2
T7
Ø
mm
Rp 1/2
2500 2S STD
2200 2S Low NOx
1800 2S Low NOx E
EF
T1
T6
T8
G
HQ
D
A
L
BP
M
N
C
I
T2
T3
T5
T3
T7
T4
2
3
4
1
3500 2S STD
3050 2S Low NOx
2350 2S Low NOx E
1951 - 2753
1951 - 2406
1951
2350 - 3500
2350 - 3050
2350
4750
0.43 - 0.95
0.43 - 0.72
0.43
3.48 - 8.00
3.48 - 5.99
3.48
6 7000 DN 65DN 200 Rp 1½ 620 Rp 1/2 Rp 1/2
2537 - 3848
2537 - 3329
2537
TERNOx 2S
Model
2500 2S STD
2200 2S Low NOx
1800 2S Low NOx E
3500 2S STD
3050 2S Low NOx
2350 2S Low NOx E
DIMENSIONS
A
mm
4225
4711
B
mm
C
mm
D
mm
E
mm
F
mm
G
mm
H
mm
I
mm
L
mm
M
mm
N
mm
Q
mm
1710
1830
2010
2120
3370
3824
1940
1954
820
1140
1465
1617
420
570
1400
1480
1350
1450
800
800
1030
1080
230
250
P
mm
245
245
T8
Ø
mm
400
400