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.

3
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

4
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5
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.

6
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.

8
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.

9
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)

10
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

11
Technical features
TERNOX 4500 2S STD - 3800 2S Low NOx - 3000 2S Low NOx E
TERNOX 5800 2S STD - 5000 2S Low NOx - 4000 2S Low NOx E
TERNOX 7000 2S STD - 6300 2S Low NOx - 5100 2S Low NOx E
TERNOX 8500 2S STD - 7500 2S Low NOx - 5700 2S Low NOx E
TERNOX 10200 2S STD - 9500 2S Low NOx - 8400 2S Low NOx E
(**) 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
3000 - 4500
3000 - 3800
3000
Furnace
furnace
kW
Boiler
capacity
l
6400
Water side
pressure
drop(**)
m.w.c.
0.27 - 0.60
0.27 0.43
0.27
Flue gas
pressure
drop
mbar
3.64 - 8.50
3.64 - 5.96
3.64
M aximum
operating
pressure
boiler
bar
6
W eight
kg
8200
CONNECTIONS
DN 80DN 250 Rp 1½ 660 Rp 1/2 Rp 1/2
4500 2S STD
3800 2S Low NOx
3000 2S Low NOx E
EFG
HQ
D
A
L
BP
M
N
C
I
T1 T2
T3 T3
T4
T5
T6 T7
2
3
4
1
T8
5800 2S STD
5000 2S Low NOx
4000 2S Low NOx E
3239 - 4951
3239 - 4144
3239
4000 - 5800
4000 - 5000
4000
8060
0.44 - 0.93
0.44 - 0.69
0.44
4.36 - 9.50
4.36 - 6.95
4.36
6 10000 DN 80DN 250 Rp 1½ 660 Rp 1/2 Rp 1/2
4325 - 6381
4325 - 5457
4325
5100 - 7000
5100 - 6300
5100
9760
0.72 - 1.36
0.72 - 1.10
0.72
4.89 - 9.50
4.89 - 7.60
4.89
6 11500 DN 100DN 250 Rp 1½ 720 Rp 1/2 Rp 1/2
7000 2S STD
6300 2S Low NOx
5100 2S Low NOx E
8500 2S STD
7500 2S Low NOx
5700 2S Low NOx E
5529 - 7705
5529 - 6892
5529
5700 - 8500
5700 - 7500
5700
11480
0.90 - 2.00
0.90 - 1.56
0.90
4.76 - 11.0
4.76 - 8.44
4.76
6 13500 DN 100DN 250 Rp 1½ 820 Rp 1/2 Rp 1/2
6169 - 9377
6169 - 8215
6169
8400 - 10200
8400 - 9500
8400
14960
0.96 - 1.41
0.96 - 1.22
0.96
8.32 - 12.50
8.32 - 10.75
8.32
6 17300 DN 100DN 300 Rp 1½ 820 Rp 1/2 Rp 1/2
10200 2S STD
9500 2S Low NOx
8400 2S Low NOx E
9128 - 11191
9128 - 10377
9128
TERNOx 2S
Model
DIMENSIONS
A
mm
5134
5639
5875
6420
6772
B
mm
C
mm
D
mm
E
mm
F
mm
G
mm
H
mm
I
mm
L
mm
M
mm
N
mm
Q
mm
1980
2180
2320
2400
2650
2360
2580
2700
2870
3080
4174
4626
4840
5330
5632
2017
2451
2505
2035
1406
1380
1400
1510
2590
3450
1737
1788
1860
1795
1916
550
600
550
480
550
1620
1780
1870
1980
2080
1550
1710
1850
1900
2080
800
800
880
880
1000
1180
1300
1350
1460
1560
300
300
350
350
350
P
mm
250
250
250
250
250
4500 2S STD
3800 2S Low NOx
3000 2S Low NOx E
5800 2S STD
5000 2S Low NOx
4000 2S Low NOx E
7000 2S STD
6300 2S Low NOx
5100 2S Low NOx E
8500 2S STD
7500 2S Low NOx
5700 2S Low NOx E
10200 2S STD
9500 2S Low NOx
8400 2S Low NOx E
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
T4
ISO 7/1
T5
Øi
mm
T6
Ø
mm
T7
Ø
mm
T8
Ø
mm
500
500
500
500
500

12
TERNOX 12500 2S STD
TERNOX 15000 2S STD
(**) 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
Model
Useful
output
kW
12500
Furnace
furnace
kW
Boiler
capacity
l
24100
Water side
pressure
drop(**)
m.w.c.
1.31 - 2.00
Flue gas
pressure
drop
mbar
8.93 - 14.0
M aximum
operating
pressure
boiler
bar
6
W eight
kg
25500
CONNECTIONS
DN 125DN 300 DN 60 820 Rp 1/2 Rp 1/2
12500 2S STD
EFG
HQ
D
A
L
BP
M
N
C
I
2
3
4
1
T1 T2
T3 T3
T5
T4
T6 T7
T8
15000 2S STD
13789
15000 27300 1.46 - 2.20 9.72 - 15.0 6 30000 DN 125DN 350 DN 60 1000 Rp 1/2 Rp 1/2
16458
TERNOx
Model
12500 2S STD
15000 2S STD
DIMENSIONS
A
mm
7211
7761
B
mm
C
mm
D
mm
E
mm
F
mm
G
mm
H
mm
I
mm
L
mm
M
mm
N
mm
Q
mm
3210
3320
3715
3910
6236
6736
1643
1693
3500
4000
2068
2068
650
650
2700
2750
2400
2500
1470
1470
1480
1583
400
400
P
mm
230
230
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
T4
ISO 7/1
T5
Øi
mm
T6
Ø
mm
T7
Ø
mm
T8
Ø
mm
650
650

13
Technical features
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
2.4 - OPERATING DATA ACCORDING TO UNI 10348
kW
kW
%
%
%
%
%
%
°C
%
kg/h
TERNOX 2500
2S STD
1800 - 2500
1951 - 2753
92.25 - 90.80
91.40
92.9 - 91.5
0.60 - 0.71
7.15 - 8.49
0.10
146.46 - 174
9.80
2932.8 - 4138.6
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED TERNOX 2500
2S STD
1800 - 2500
1951 - 2753
92.25 - 90.80
91.40
92.9 - 91.5
0.60 - 0.71
7.15 - 8.49
0.10
156.73 - 186.20
12.80
2987.9 - 4216.3
TERNOX 2200
2S LOW NOx
1800 - 2200
1951 - 2406
92.25 - 91.45
91.40
92.9 - 92.1
0.60 - 0.65
7.15 - 7.90
0.10
146.46 - 161.92
9.80
2932.8 - 3616.1
TERNOX 2200
2S LOW NOx
1800 - 2200
1951 - 2406
92.25 - 91.45
91.40
92.9 - 92.1
0.60 - 0.65
7.15 - 7.90
0.10
156.73 - 173.27
12.80
2987.9 - 3684.0
TERNOX 1800
2S LOW NOx E
1800
1951
92.25
91.40
92.9
0.60
7.15
0.10
146.46
9.80
2932.8
TERNOX 1800
2S LOW NOx E
1800
1951
92.25
91.40
92.9
0.60
7.15
0.10
156.73
12.80
2987.9
TERNOX 3500
2S STD
2350 - 3500
2537 - 3848
92.64 - 90.95
91.40
93.2 - 91.7
0.58 - 071
6.78 - 8.34
0.10
139.00 - 171.00
9.80
3813.1 - 5784.7
TERNOX 3500
2S STD
2350 - 3500
2537 - 3848
92.64 - 90.95
91.40
93.2 - 91.7
0.58 - 071
6.78 - 8.34
0.10
148.67 - 182.90
12.80
3884.6 - 5893.1
TERNOX 3050
2S LOW NOx
2350 - 3050
2537 - 3329
92.64 - 91.62
91.40
93.2 - 92.3
0.58 - 0.65
6.78 - 7.73
0.10
139.0 - 158.35
9.80
3913.1 - 5003.7
TERNOX 3050
2S LOW NOx
2350 - 3050
2537 - 3329
92.64 - 91.62
91.40
93.2 - 92.3
0.58 - 0.65
6.78 - 7.73
0.10
148.67 - 169.37
12.80
3884.6 - 5097.5
TERNOX 2350
2S LOW NOx E
2350
2537
92.64
91.40
93.2
0.58
6.78
0.10
139
9.80
3813.1
TERNOX 2350
2S LOW NOx E
2350
2537
92.64
91.40
93.2
0.58
6.78
0.10
148.67
12.80
3884.6
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED

14
TERNOX 4500
2S STD
3000 - 4500
3239 - 4951
92.62 - 90.90
91.40
93.2 - 91.6
0.58 - 0.71
6.80 - 8.39
0.10
139.31 - 172.00
9.80
4868.5 - 7441.4
TERNOX 4500
2S STD
3000 - 4500
3239 - 4951
92.62 - 90.90
91.40
93.2 - 91.6
0.58 - 0.71
6.80 - 8.39
0.10
149.03 - 184.00
12.80
4959.9 - 7581.0
TERNOX 3800
2S LOW NOx
3000 - 3800
3239 - 4144
92.62 - 91.70
91.40
93.2 - 92.4
0.58 - 0.65
6.80 - 7.65
0.10
139.31 - 156.79
9.80
4868.5 - 6228.9
TERNOX 3800
2S LOW NOx
3000 - 3800
3239 - 4144
92.62 - 91.70
91.40
93.2 - 92.3 0.58 -
0.65
6.80 - 7.65
0.10
149.03 - 167.73
12.80
4959.9 - 6345.8
TERNOX 3000
2S LOW NOx E
3000
3239
92.62
91.40
93.2
0.58
6.80
0.10
139.31
9.80
4868.5
TERNOX 3000
2S LOW NOx E
3000
3239
92.62
91.40
93.2
0.58
6.80
0.10
149.03
12.80
4959.9
TERNOX 5800
2S STD
4000 - 5800
4324 - 6381
92.50 - 90.90
91.40
93.1 - 91.6
0.59 - 0.71
6.91 - 8.39
0.10
141.70 - 172.00
9.80
6500.2 - 9591.1
TERNOX 5800
2S STD
4000 - 5800
4324 - 6381
92.50 - 90.90
91.40
93.1 - 91.6
0.59 - 0.71
6.91 - 8.39
0.10
151.58 - 184.00
12.80
6622.2 - 9771.1
TERNOX 5000
2S LOW NOx
4000 - 5000
4324 - 5457
92.50 - 91.62
91.40
93.1 - 92.3
0.59 - 0.65
6.91 - 7.73
0.10
141.70 - 158.42
9.80
6500.2 - 8203.0
TERNOX 5000
2S LOW NOx
4000 - 5000
4325 - 5457
92.50 - 91.62
91.40
93.1 - 92.3
0.59 - 0.65
6.91 - 7.73
0.10
151.58 - 169.47
12.80
6622.2 - 8356.9
TERNOX 4000
2S LOW NOx E
4000
4324
92.50
91.40
93.1
0.59
6.91
0.10
141.70
9.80
6500.2
TERNOX 4000
2S LOW NOx E
4000
4324
92.50
91.40
93.1
0.59
6.91
0.10
151.58
12.80
6622.2
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED

15
Technical features
TERNOX 7000
2S STD
5100 - 7000
5529 - 7705
92.25 - 90.85
91.40
92.9 - 91.6
0.61 - 0.71
7.15 - 8.44
0.10
146.49 - 173.00
9.80
8310.3 - 11581.7
TERNOX 7000
2S STD
5100 - 7000
5529 - 7705
92.25 - 90.85
91.40
92.9 - 91.6
0.61 - 0.71
7.15 - 8.44
0.10
156.65 - 185.00
12.80
8465.9 - 11798.7
TERNOX 6300
2S LOW NOx
5100 - 6300
5529 - 6892
92.25 - 91.41
91.40
92.9 - 92.1
0.61 - 0.65
7.15 - 7.94
0.10
146.49 - 162.81
9.80
8310.3 - 10360.0
TERNOX 6300
2S LOW NOx
5100 - 6300
5529 - 6892
92.25 - 91.41
91.40
92.9 - 92.1
0.61 - 0.65
7.15 - 7.94
0.10
156.65 - 174.10
12.80
8465.9 - 10554.1
TERNOX 5100
2S LOW NOx E
5100
5529
92.25
91.40
92.9
0.61
7.15
0.10
146.48
9.80
8310.3
TERNOX 5100
2S LOW NOx E
5100
5529
92.25
91.40
92.9
0.61
7.15
0.10
156.65
12.80
8465.9
TERNOX 8500
2S STD
5700 - 8500
6169 - 9376
92.40 - 90.65
91.40
93.0 - 91.4
0.58 - 0.71
7.01 - 8.64
0.10
143.78 - 177.00
9.80
9272.2 - 14093.8
TERNOX 8500
2S STD
5700 - 8500
6169 - 9377
92.40 - 90.65
91.40
93.0 - 91.4
0.58 - 0.71
7.02 - 8.64
0.10
153.94 - 189.50
12.80
9446.8 - 14359.4
TERNOX 7500
2S LOW NOx
5700 - 7500
6169 - 8214
92,40 - 91,30
91.40
93.0 - 92.0
0.58 - 0.65
7.01 - 8.04
0.10
143.78 - 164.93
9.80
9272.2 - 12347.4
TERNOX 7500
2S LOW NOx
5700 - 7500
6169 - 8215
92.40 - 91.29
91.40
93.0 - 91.9
0.58 - 0.65
7.02 - 8.06
0.10
153.94 - 176.58
12.80
9446.8 - 12579.9
TERNOX 5700
2S LOW NOx E
5700
6169
92.40
91.40
93.0
0.58
7.01
0.10
143.78
9.80
9272.2
TERNOX 5700
2S LOW NOx E
5700
6169
92.40
91.40
93.0
0.58
7.02
0.10
153.94
12.80
9446.8
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED

16
TERNOX 10200
2S STD
8400 - 10200
9128 - 11191
92.02 - 91.14
91.40
92.7 - 91.9
0.64 - 0.71
7.33 - 8.15
0.10
150.34 - 167.00
9.80
13721.2 - 16822.0
TERNOX 9500
2S LOW NOx
8400 - 9500
9128 - 10377
92.02 - 91.55
91.40
92.7 - 92.2
0.64 - 0.65
7.33 - 7.80
0.10
150.34 - 159.88
9.80
13721.2 - 15579.9
TERNOX 8400
2S LOW NOx E
8400
9128
92.03
91.40
92.7
0.64
7.33
0.10
150.34
9.80
13720.5
TERNOX 12500
2S STD
10100 - 12500
11012 - 13789
91.72 - 90.65
91.40
92.3 - 91.4
0.58 - 0.71
7.70 - 8.64
0.10
157.83 - 177.00
9.80
16552,5 - 20726,2
TERNOX 12500
2S STD
10100 - 12500
11012 - 13789
91.71 - 90.65
91.40
92.3 - 91.4
0.58 - 0.71
7.70 - 8.64
0.10
168.89 - 189.40
12.80
16863.5 - 21115.7
TERNOX 15000
2S STD
12200 - 15000
13251 - 16458
92.07 - 91.14
91.40
92.7 - 91.9
0.64 - 0.71
7.29 - 8.15
0.10
149.40 - 167.00
9.80
19918.5 - 24738.3
TERNOX 15000
2S STD
12200 - 15000
13251 - 16458
92.07 - 91.14
91.40
92.7 - 91.9
0.64 - 0.71
7.29 - 8.15
0.10
159.78 - 178.60
12.80
20291.8 - 25201.8
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
GAS-FIRED
Nominal heat output
Thermal output of furnace
Heat efficiency at nominal load (100%)
Heat efficiency at 30% load
Combustion efficiency at nominal load (100%)
Heat loss at casing (min.-max.)
Heat loss at chimney with burner on (min.-max.)
Heat loss at chimney with burner off (min.-max.)
Flue gas temperature tf-ta (min.-max.)
CO2content
Flue gas mass flow rate (min.-max)
kW
kW
%
%
%
%
%
%
°C
%
kg/h
DIESEL OIL-FIRED
TERNOX 10200
2S STD
8400 - 10200
9128 - 11191
92.02 - 91.14
91.40
92.7 - 91.9
0.64 - 0.71
7.33 - 8.15
0.10
160.78 - 178.60
12.80
13978.3 - 17137.3
TERNOX 9500
2S LOW NOx
8400 - 9500
9128 - 10377
92.02 - 91.55
91.40
92.7 - 92.2
0.64 - 0.65
7.33 - 7.80
0.10
160.78 - 170.98
12.80
13978.3 - 15890.1
TERNOX 8400
2S LOW NOx E
8400
9128
92.03
91.40
92.7
0.64
7.33
0.10
160.78
12.80
13977.6

17
Technical features and dimensions
ATTENTION!
In rooms with the presence of aggressive
vapours or dust, the appliance must operate
independently from the air inside the instal-
lation room!
ATTENTION!
The appliance must be installed by a qualified
technician with the technical-professional
requirements according to law 46/90 which,
under his own responsibility, guarantees
compliance with standards according to
good practice rules.
ATTENTION!
Mount the appliance respecting the minimum
distances required for installation and main-
tenance.
The boiler must be connected to a heating
system compatible with its performance and
output.
3.2 - INSTALLATION STANDARDS
It must be installed by a professionally qualified technician, who
shall take the responsibility of observing all local and/or
national laws published in the official journal, as well as
applicable technical standards.
3.3 - INSTALLATION ON
OLD OR RETROFITTABLE SYSTEMS
Before installing this appliance on old systems, check that:
- The flue is able to withstand the temperature generated by
the combustion products, has been measured and designed
according to the regulations in force, is airtight and insulated,
and does not feature obstructions or constrictions.
- The flue has a device for releasing condensation.
- The electrical system has been set up by a qualified techni-
cian in compliance with the rules in force.
- The rate, head and direction of the flow of the circulation
pumps are appropriate.
- The expansion vessel(s) can fully absorb dilation of the flu-
id in the system.
- The fuel adduction line and the tank, if any, are made ac-
cording to relevant standards in force.
- The expansion vessels can fully absorb dilation of the fluid
in the system.
- The system has been cleaned and cleared of all sludge
and scale, has been vented, and all its seals have been
checked.
- There is a treatment system for feed/recirculation water
(see reference values).
3INSTRUCTIONS FOR
INSTALLATION
3.1 - GENERAL WARNINGS
ATTENTION!
This boiler is intended solely for the use for
which it was expressly designed. Any other
use is to be considered improper and there-
fore dangerous.
This boiler heats water at a temperature
lower than the atmospheric pressure boiling
temperature.
Before connecting the boiler, have professionally
qualified personnel:
a) Thoroughly wash all the piping of the system
to remove any residues or impurities which
could jeopardise proper operation of the
boiler, even from a hygienic point of view.
b) Check that boiler is set up to operate with the
available type of fuel.
The type of fuel can be seen written on the
package and on the technical feature plate.
c) Check that the chimney/flue has an appropri-
ate draught, without any bottlenecks, and that
no exhausts from other appliances are insert-
ed, unless the flue has been implemented to
accommodate several utilities according to
specific standards and prescriptions in force.
Only after this check can the fitting between
the boiler and chimney/flue be mounted.

18
3.4 - PACKAGING
TERNOX 2S boilers are supplied with casing and with the door
and smoke chamber assembled.
The panel and accessories are inside the combustion chamber.
Upon reception, make sure that the supply is complete and
undamaged.
The document envelope, besides the appliance, contains:
3.5 - HANDLING
TERNOX 2S boilers are equipped with lifting eyebolts.
Pay attention when handling the boiler and use equipment suit-
able for its weight.
- Hydraulic test certificate
- Heating system booklet
- System manager operating instructions
- Installation and maintenance instruction booklet
- Warranty
- Local ventilation requirements label.

19
Technical features and dimensions
3.6 - POSITIONING IN BOILER ROOM
TERNOX 2S boilers must be installed in rooms for exclusive
use complying with Technical Standards and Legislation in
force and with sufficiently sized air vents.
The ventilation openings must be permanent, communicating
directly with the outside and must be positioned high or low
according to standards in force.
The location of the ventilation openings, the fuel supply trains,
electric energy supply and lighting must comply with current
legal provisions in relation to the type of fuel used.
To make it easier to clean the smoke circuit, a free space must
be left in front of the boiler no less than the length of the boiler
body and, in any case, never less than 1300 mm. It must be
checked that with the door/s open 90°, the distance between
the door and the adjacent wall X is at least equal to the length
of the burner.
The boiler must rest on a perfectly level surface.
It is advisable to provide a flat, level cement basement capable
of bearing the weight of the boiler full of water. For the dimen-
sions of the basement, see the dimensions R x B (dimensions
table).
If the burner is fed with fuel gas weighing more than air, the
electrical parts must be placed higher than 500 mm above the
ground.
The appliance cannot be installed outdoors as it was not so
designed and does not have automatic antifreeze systems.

20
The connection pipes of the expansion vessel will start from the
T3 attachment (see DIMENSIONS TABLES) and must have no
shut-off valve.
Safety valve drain
Install a safety pressure valve on the flow pipe within 0.5 m of
the starting flange, sized according to the capacity of the boiler
and in compliance with local standards in force.
It is prohibited to place any type of shut-off valve between the
boiler and expansion vessel or between the boiler and safety
pressure valves. The valves used must be adjusted to trigger
not beyond the maximum allowed operating pressure.
3.9.1 - RECIRCULATION PUMP
TERNOX 2S boilers must always operate with forced water
circulation and a minimum return temperature of 55°C.
It is therefore recommended to use a recirculation pump, which
also has an anti-condensation function, installed between the
flow and return connections upstream the mixing valve.
This pump is dimensioned according to the formula:
Q = P x 22
where Q= Flow rate in l/hr
P= Nominal output of boiler in kW
and head 1÷2 m H2O
3.7 - HYDRAULIC CONNECTIONS
ATTENTION!
Before connecting the boiler to the heating
system, thoroughly clean the piping with an
appropriate product compliant with UNI-CTI
8065, in order to eliminate metallic residue
from processing and welding, oil and grease
which could be present and which, reaching
the boiler, could alter its functioning.
Attention!
The fittings of the boiler must not take the
weight of the connecting pipes of the sys-
tem; suitable supporting devices should be
installed to do this.
The dimensions of the supply and return pipes for each boiler
model are given in the DIMENSIONS table.
Check that the system is fitted with a sufficient number of air
release valves.
Connection of expansion vessel
TERNOX 2S boilers are suitable for operating with forced water
circulation both with the expansion vessel opened or closed.
An expansion vessel is always necessary to compensate the
increase in water volume due to heating.
In the first case, the hydrostatic column must be
at least 3 m above the casing of the boiler and
sufficient to contain the volume increase of all
the water of the system between the exposed
surface of the water in the tank and the overflow
pipe.
ATTENTION!
ANY DAMAGE TO THE BOILER CAUSED BY
THE FORMATION OF FOULING OR BY COR-
ROSIVE WATER WILL NOT BE COVERED BY
THE WARRANTY.
TOTAL HARDNESS ppm 10
ALKALINITY mg/l CaCO3 750
PH 8÷9
SILICA ppm 100
CHLORIDES ppm 3500
A specific tap can be connected to the T4 attach-
ment at the rear of the boiler for filling and draining.
The values displayed in the table can be used
as a reference.
3.8 - FILLING AND EMPTYING
THE SYSTEM
Attention!
Do not mix the heating water with incorrect
concentrations of antifreeze or anti-corrosion
substances! This could damage the gaskets
and cause noise during operation.
Unical will not be held liable for damage to
persons, animals or objects due to failure to
comply with the above instruction.
When all system connections have been completed, the circuit
can be filled.