Unical TRIOPREX N Series User guide

26743 - 11/08
rev. 2
TRIOPREX N
INSTALLATION, USE AND
SERVICING INSTRUCTION
(to be kept by the user)

GENERAL INFORMATIONS
Introduction
This manual supplies a summary of what has to be followed during the installation, use and
servicing of the UNICAL boilers, TRIOPREX-N range.
In the course of this text the short name TX-N can be used to indicate theTRIOPREX-N boiler.
Choice of the boiler
For a correct choice and application of the TX-N boilers it is necessary to follow the instructions
given in this manual.
Installation
The installation of the boilers and the auxiliary equipments, related to the heating system,
must be in conformity with all the regulations and rules in force.
It is law that all the gas appliances are installed, commissioned and serviced by a registered
installer in accordance with the regulations below. Failure to install appliances correctly could
lead prosecution. It is in your own interest, and that of the safety, to ensure the law is complied
with.
The following must be complied with:
Current Building Regulations and Clean Air Act.
Water Authority Regulations.
Local Authority Regulations and Regional Bylaws.
Gas Safety Regulations.
Any special regional requirements of local Electricity and Gas undertaking.
Fire Service and Insurance Company requirements.
Commissioning
The main purpose of the commissioning is to verify the correct operation of all the safety and
control devices.
Before leaving the installation the commissioner has to control the operation of the boiler for,
at least, a complete working cycle.
Guarantee
The boiler guarantee is bound to the compliance of the the requirements stated in this manual,
and any non-fulfilment or modification will make it void.
Normative
It is the responsibility of the installer to fulfil all the regulations concerning the boiler house,
the safety devices, the chimney, the fuel supply lines, the electrical installations and all the
other local requirements and safety instructions.
Approvals
The UNICAL boilers, TRIOPREX-N range, have been tested and CE certified for the gas
operation by TECHNIGAS (BELGIUM), who has recognised to these boilers the conformity
certificate according to the following directives:
-Gas Appliances Directive (90/396 CE), compulsory as per 1st January 1996;
-Efficiency Directive (92/42 CE), compulsory as per 1st January 1998;
-The conformity to the Low Voltage Directive (73/23 CE), compulsory as per 1st January
1997 has been verified and ascertained by GASTEC ITALIA.
The conformity to the EMC (Electro Magnetic Compatibility 89/336 CE), compulsory as per
1st January 1996, is not applicable to the TRIOPREX-N boilers because they do not have
electronic components.
For the time beeing there are no European Directives covering the oil fired boilers, except the
Efficiency Directive (92/42 CE).
Data plate and Serial No.
The data plate, supplied in a separate enveloppe with the relevant documents, makes reference to
a serial No, embossed in an aluminium plate riveted to the front tube plate in the lower RH side
corner.
Use of the boiler
This boiler has to be used for heating the water at a temperature not higher than the
boiling temperature in the installation conditions.
WARNING
When the boiler is operated with a pressure jet gas burner, because it does not belong to any of the categories among those listed in the Annex II to
the Directive 97/23/CE (regarding pressure equipment) and beeing, furthermore, mentioned in the Directive 90/396/CE (Gas Appliance Directive)
to which the art. 1, clause 3, paragraph 6.5 makes reference, it is excluded from the scope of the Directive.

3
GAS SAFETY (INSTALLATION
AND USE) REGULATIONS,
1994
It is law that all gas appliances are installed
and serviced by a CORGI registered installer
in accordance with the above regulations.
Failure to install appliances correctly could
lead to prosecution.
It is in your own interest, and that of safety,
to ensure the law is complied with.
The installation of the boiler MUST also be
in accordance with the latest I.E.E. Wiring
Regulations, local building regulations, byelaws
of the local water authority, the building
regulations and the Building Standards
(Scotland) and any relevant requirements of
the local authority.
Detailed recommendations are contained in the
following British Standard Codes of Practice:
BS 6891 Low pressure installation pipes.
BS 5449 Forced circulation hot water
systems.
BS 5546 Installation of gas hot water
supplies for domestic purposes
(2nd Family Gases).
BS 6644 Ventilation (for gas appliances of
rated input exceeding 60 kW).
HEALTH & SAFETY
DOCUMENT No. 635
The Electricity at Work Regulations, 1989.
The manufacturer's notes must NOT be
taken, in any way, as overriding statutory
obligations.
IMPORTANT. These appliances are CE
certificated for safety and performance.
It is, therefore, important that no external
control devices, e.g. flue dampers, economisers
etc., are directly connected to these appliances
unless covered by these Installation and
Servicing Instructions or as otherwise
recommended by Unical in writing.
If in doubt please inquire.
Any direct connection of a control device not
approved by Unical could invalidate the
certification and the normal appliance warranty.
Notes.
To obtain the gas consumption:
a. For l/s divide the gross heat input (kW) by
C.V.of the gas (MJ/m³).
b. For ft³/h divide the gross heat input (Btu/h)
by C.V.of the gas (Btu/ft³).

1
2
3
CONSTRUCTIONAL-DIMENSIONAL
TECHNICAL CHARACTERISTICS .................... page 5
1.1 Construction of the TRIOPREX-N boilers ............................ page 5
1.2 Working principle ................................................................... page 5
1.3 Dimensions and hydraulic connections ................................ page 6
INSTALLATION .................................................................. page 11
2.1 Packaging .............................................................................. page 11
2.2 Handling ................................................................................. page 11
2.3 Positioning in the boiler house .............................................. page 11
2.4 Connection to the chimney................................................... page 12
2.5 Water connections ................................................................. page 12
2.5.1 Feeding water quality ................................................... page 12
2.5.2 C.H. flow and return connections ................................ page 12
2.5.3 Connection of filling & drain tap .................................. page 12
2.5.4 Connection of the pressure relief valve...................... page 12
2.5.5 Connection of the expansion pipe and vessel ............ page 12
2.5.6 Shunt pump .................................................................. page 13
2.6 Furnace door:adjustment, opening and closing .................. page 13
2.6.1 Important note .............................................................. page 13
2.7 Burner .................................................................................... page 13
2.7.1 Conformity of the burner .............................................. page 13
2.7.2 Choice of the burner .................................................... page 13
2.7.3 Burner installation ........................................................ page 13
2.8 Connection of the sightglass to the burner via a cooling line .. page 14
2.9 Casing assembly ................................................................... page 15
STANDARD PANEL BOARD .................................. page 24
3.1 Panel board type 21056/21057 - functions description ....... page 24
3.2 Electrical wiring diagram for single phase burner & pump .. page 24
3.3 Introduction of the electronic panel board type 30688 ........ page 25
3.4 Panel board type 30688 - description of functions .............. page 25
3.5 Electrical wiring diagram for single phase burner & pump .. page 26
3.6 Outer compensator ................................................................ page 27
3.7 Electrical and hydraulic connections of C.H. ........................ page 32
3.8 Electrical and hydraulic connections for C.H. system
and D.H.W.production circuits .............................................. page 32
COMMISSIONING AND OPERATION ............ page 33
4.1 Positioning of the turbulators ................................................ page 33
4.2 Preliminary check.................................................................. page 34
4.3 First commissioning .............................................................. page 34
4.4 Operation of the boiler ........................................................... page 34
4.5 Switch Off of the boiler .......................................................... page 34
MAINTENANCE ................................................................ page 35
5.1 General rules ......................................................................... page 35
5.2 Ordinary maintenance ........................................................... page 35
5.3 Extraordinary maintenance ................................................... page 35
5.4 Cleaning of the boiler ............................................................ page 36
5.5 Check of the boiler operation ................................................ page 36
5.6 Check of the burner operation .............................................. page 36
5.7 Boiler house ........................................................................... page 36
4
5

5
1CONSTRUCTIONAL-DIMENSIONAL
TECHNICAL CHARACTERISTICS
1.1 - CONSTRUCTION
OF THE TRIOPREX-N
BOILERS
The TRIOPREX-N, three pass boilers, are
of horizontal type (oval shape from model 65
to 380 and the model 840; eight shape from
model 500 to 730 and cylindrical shape from
model 1100 to 1900), with direct flame in the
combustion chamber.
The construction completely satisfies the
requirements of the EN 303- part 1.
The sheet metal parts of the pressure vessel
are manufactured of certified carbon steel,
type S235JRG2, according to EN 10025, with
melting certificate 3.1.B, according EN
10024; whereas the pipes are of steel ST 37.0
according to DIN 1626.
The welders and the WPS (Welding
Procedures Specifications) have been
approved according to EN 287 and EN 288
by TUEV (DE).These boilers have been also
approved by - ISCIR (RO).
Up to the model TX-N 380 the furnace is
linked to the rear tube plate.
For larger models (TX-N 500 to TX-N 3500)
the furnace is free to dilatate (it is supported
only by the double welding seam (inner and
outer) to the front tube plate.
The boilers are equipped with a reversible
hinged door, which can be opened, for this
reason, from L.H. or R.H. side.
The outer shell is insulated with a glass wool
matress, thick 100 mm (80 mm for models
TX-N65 & TX-N 85), protected by a textile
in mineral fiber.
The upper part of the outer shell is equipped
with uplift hook(s).
fig. 1
Note: The TRIOPREX-N boilers are to be
equipped with ON/OFF burner;alternatively
they can be equipped with a two stage or
modulating burner, provided the minimum
reachable heat input is not lower than the figure
shown on the data plate for the fuel used on
site.
For two stage or modulating burner see
paragraph 2.7.1.
1.2 - WORKING PRINCIPLE
The NOx formation process is strongly
affected by:
-the flame temperature;
-the time during which the combustion gases
stay in a high temperature zone.
-oxygen partial pressure and its
concentration.
The provisions to be adopted for the NOx
reduction are then:
-reduction of combustion temperature;
-reduction of the specific thermal input;
-permanence time reduction of the gases
in the combustion chamber;
-reduction of oxygen concentration.
UNICAL, to reduce the NOx formation on the
TRIOPREX-N range of boilers, has adopted
the following construction solutions:
-three pass
the furnace is of direct flame type and not
of reversal type any more; the burner flame
results more compact and shorter, thus
The boilers are provided with two 1/2" bulb
holders with inner diameter of 15 mm (for 3
bulbs each), suitable to locate the thermostats
and thermometer bulbs.
The casing side panels are provided with
holes for the cables of the electrical supply,
of the pumps, of the burner and any other
auxiliary equipment.
reducing the permanence time at high
temperature;
the direct pass allows a quicker flame
cooling down by the water cooled furnace
surfaces;
-specific thermal input reduction
the combustion chamber volume has been
increased if compared with standard boilers
of the same capacity.
With the adoption of the modern Low NOx
burners a further reduction of the NOx
emissions can be obtained with:
-reburning
a part of the combustion gases is taken
and sent again to the combustion chamber
with the combustion air.
In this way the partial oxygen pressure is
reduced and the flame temperature is
reduced too.
-reduction of the partial oxygen pressure
thanks to an air excess reduction
During the operation of the burner within the
output range of the boiler, the combustion
chamber is always under positive pressure.
For the value of this pressure see tables on
pages 6 to 10 under the column "Smoke side
pressure losses".
The chimney has to be calculated in such a
way that at its base there is no positive
pressure.

6
n°4x M8 at 45°
on ø 170
ø 132
Fiber wool
Ceramic fiber
ø 130
95
132
132
TX N 65
TX N 85
1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS FOR TRIOPREX-N
TRIOPREX-N 65÷85
Output
min/max
kW
T1
T2
ISO 7/1
T3
ISO 7/1
T4
ISO 7/1
T5
Ø
mm
Rp 1½
Rp 1½
Rp 1
Rp 1
Rp ¾
Rp ¾
150
150
TRIOPREX N
Type
Input
min/max
kW
59,8÷71
78,3÷93
Boiler
water
content
l
131
187
Water side
pressure
drop (*)
mw.c.
0,04÷0,06
0,05÷0,07
3÷4
4,5÷6
Smoke side
pressure
drop
mm w.c.
Maximum
boiler working
pressure
bar
5
5
Weight
with
packaging
kg
307
348
55÷65
72÷85
TX N 65
TX N 85
1Panel board
2Smoke chamber cleaning door
3Flame sight glass
T1 C.H. flow
T2 C.H. return
T3 Expansion vessel connection
T4 Boiler drain
T5 Flue connection
T6 Max. burner blast tube dia.
DIMENSIONS
TRIOPREX N
Type
T6
Ø
mm
fig. 2
A
mm
740
740
B
mm
690
950
C
mm
950
950
D
mm
190
190
E
mm
140
140
F
mm
145
145
G
mm
660
660
H
mm
345
345
I
mm
120
120
L
M 8
M 8
M
mm
470
470
N
mm
310
310
O
mm
190
190
P
mm
846
846
R
mm
(*) Hydraulic resistance for delta T 15K.
Q
mm
660
660
590
850
DETAIL FOR DOOR DRILLING
TX N 65 - 85
CONNECTIONS
fig. 3
A
I
n°4 "L"
M
I
H
G
CD
T6 T2
T4
T1
T3
BF E
H
T1
T3
T5
T2
T4
N
P
T1
O
T2
T5
QR
120
3
1
2

7
Fiber wool
Ceramic fiber
Blind burner plate 250x250
Burner plate insulation gasket 250x250
ø 180 ø 150
95
n°4x M8 at 45°
on ø 170
ø 132
Fiber wool
Ceramic fiber
ø 130
95
Fiber wool
Ceramic fiber
Blind burner plate 250x250
Burner plate insulation gasket 250x250
ø 180 ø 165
95
3
1
2
A
I
I
H
G
CD
T6
T4
T5
T1
BF
N
E
H
T4
T6
OP
T5
T1-T3-T2
M
T3 T2
n°4 "L"
Q R
S
TRIOPREX-N 110÷380
1Panel board
2Smoke chamber cleaning door
3Flame sight glass
T1 C.H. flow
T2 C.H. return
T3 Expansion vessel connection
T4 Boiler drain
T5 Flue connection
T6 Max. burner blast tube dia.
Output
min/max
kW
T1
T2
UNI 2278 PN 16
T3
ISO 7/1
T4
ISO 7/1
T5
Ø
mm
T6
Ø
mm
DN 50
DN 50
DN 65
DN 65
DN 80
DN 80
Rp 1¼
Rp 1¼
Rp 1½
Rp 1½
Rp 2
Rp 2
Rp ¾
Rp ¾
Rp ¾
Rp ¾
Rp ¾
Rp ¾
180
180
180
180
225
225
132
132
180
180
180
180
TRIOPREX N
Type
Input
min/max
kW
101÷120
137,7÷163
170÷202
207÷245
276÷327
350÷414
Boiler
water
content
l
204
270
285
322
408
475
Water side
pressure
drop (*)
mw.c.
0,06÷0,08
0,08÷0,10
0,10÷0,18
0,17÷0,20
0,22÷0,35
0,32÷0,53
5,5÷7,5
12÷16
9÷12
12,5÷17,5
9÷12
15÷21
Smoke side
pressure
drop
mm w.c.
Maximum
boiler working
pressure
bar
5
5
5
5
5
5
Weight
with
packaging
kg
426
503
564
621
812
906
93÷110
127÷150
157÷185
191÷225
255÷300
323÷380
TX N 110
TX N 150
TX N 185
TX N 225
TX N 300
TX N 380
DIMENSIONS
TRIOPREX N
Type
TX N 110
TX N 150
TX N 185
TX N 225
TX N 300
TX N 380
fig. 4
A
mm
820
820
860
860
890
890
B
mm
885
1145
1080
1210
1275
1470
C
mm
1082
1082
1182
1182
1352
1352
D
mm
190
190
190
190
190
190
E
mm
140
140
140
140
140
140
F
mm
145
145
145
145
145
145
G
mm
748
748
828
828
928
928
H
mm
380
380
400
400
440
440
I
mm
120
120
--
--
--
--
L
M 8
M 8
--
--
--
--
M
mm
1210
1210
1310
1310
1485
1485
N
mm
175
175
215
215
255
255
O
mm
130
390
210
340
285
480
P
mm
185
185
250
250
315
315
Q
mm
710
710
750
750
780
780
R
mm
786
1046
981
1111
1177
1372
DETAIL FOR DOOR DRILLING
TX N 110 - 150
DETAIL FOR DOOR DRILLING
TX N 185 - 225
(*) Hydraulic resistance for delta T 15K.
fig. 5 fig. 6
CONNECTIONS
DETAIL FOR DOOR DRILLING
TX N 300 - 380
fig. 7

8
TRIOPREX-N 500÷730
Output
min/max
kW
T1
T2
UNI 2278 PN 16
T3
UNI 2278 PN 16
T4
ISO 7/1
T5
Øi
mm
T6
Ø
mm
DN 100
DN 100
DN 100
DN 65
DN 65
DN 65
Rp 1
Rp 1
Rp 1
250
250
250
220
220
220
TRIOPREX N
Type
Input
min/max
kW
460÷545
579÷686
671÷795
Boiler
water
content
l
656
737
807
Water side
pressure
drop (*)
mw.c.
0,10÷0,15
0,16÷0,23
0,23÷0,33
25÷35
32÷45
35÷49
Smoke side
pressure
drop
mm w.c.
Maximum
boiler working
pressure
bar
5
5
5
Weight
with
packaging
kg
1198
1304
1431
425÷500
535÷630
620÷730
TX N 500
TX N 630
TX N 730
DIMENSIONS
TRIOPREX N
Type
TX N 500
TX N 630
TX N 730
(*) Hydraulic resistance for delta T 15K.
fig. 8
1Panel board
2Smoke chamber cleaning door
3Flame sight glass
T1 C.H. flow
T2 C.H. return
T3 Expansion vessel connection
T4 Boiler drain
T5 Flue connection
T6 Max. burner blast tube dia.
CONNECTIONS
A
mm
920
920
920
B
mm
1605
1800
1995
C
mm
1645
1645
1645
D
mm
190
190
190
E
mm
135
135
135
F
mm
195
195
195
G
mm
1110
1110
1110
H
mm
480
480
480
1735
1735
1735
N
mm
298
298
298
O
mm
435
630
825
P
mm
440
440
440
Q
mm
790
790
790
R
mm
1505
1790
1895
DETAIL FOR DOOR DRILLING
TX N 500 - 730
M
mm
fig. 9
1
3
2
S
mm
860
860
860

9
Refractory cement
Ceramic fiber
Blind burner plate 330x330
Burner plate insulation gasket 330x330
ø 270 ø 270
150
TRIOPREX-N 840
Output
min/max
kW
T1
T2
UNI 2278 PN 16
T3
UNI 2278 PN 16
T4
ISO 7/1
T5
Øi
mm
T6
Ø
mm
DN 100 DN 65 Rp 1¼ 250 270
TRIOPREX N
Type
Input
min/max
kW
772÷915
Boiler
water
content
l
932
Water side
pressure
drop (*)
mw.c.
0,35÷0,52 42÷58
Smoke side
pressure
drop
mm w.c.
Maximum
boiler working
pressure
bar
5
Weight
with
packaging
kg
1581714÷840
DIMENSIONS
TRIOPREX N
Type
(*) Hydraulic resistance for delta T 15K.
fig. 10
1Panel board
2Smoke chamber cleaning door
3Flame sight glass
T1 C.H. flow
T2 C.H. return
T3 Expansion vessel connection
T4 Boiler drain
T5 Flue connection
T6 Max. burner blast tube dia.
CONNECTIONS
A
mm
1122
B
mm
2115
C
mm
1432
D
mm
190
E
mm
195
F
mm
195
G
mm
1025
H
mm
480
M
mm
1540
N
mm
298
O
mm
945
P
mm
440
Q
mm
1020
R
mm
2014
DETAIL FOR DOOR DRILLING
TX N 840
TX N 840
TX N 840
fig. 11
1
3
2
H
T6
A
D
C
Q
G
T4
T5
T1
BF
N
E
H
T6
O P
M
T3 T2
R
T4
T5
T1-T3-T2
125

10
Refractory cement
Ceramic fiber
Blind burner plate 330x330
Burner plate insulation gasket 330x330
ø 270 ø 270
180
Refractory cement
Ceramic fiber
Blind burner plate 380x380
Burner plate insulation gasket 380x380
ø 285 ø 285
200
TRIOPREX-N 1100÷1900
Output
min/max
kW
T1
T2
UNI 2278 PN 16
T3
UNI 2278 PN 16
T4
ISO 7/1
T5
Øi
mm
T6
Ø
mm
DN 150
DN 150
DN 175
DN 175
DN 80
DN 80
DN 100
DN 100
Rp 1½
Rp 1½
Rp 1½
Rp 1½
350
350
400
400
TRIOPREX N
Type
Input
min/max
kW
1012÷1198
1214÷1438
1470÷1743
1745÷2070
1580
1791
2297
2496
0,15÷0,21
0,21÷0,30
0,20÷0,28
0,27÷0,39
45÷62
61÷85
40÷55
52÷73
Smoke side
pressure
drop
mm w.c.
Maximum
boiler working
pressure
bar
6
6
6
6
Weight
with
packaging
kg
2444
2965
3685
4089
935÷1100
1122÷1320
1360÷1600
1615÷1900
DIMENSIONS
TRIOPREX N
Type
(*) Hydraulic resistance for delta T 15K.
fig. 12
1Panel board
2Smoke chamber cleaning door
3Flame sight glass
T1 C.H. flow
T2 C.H. return
T3 Expansion vessel connection
T4 Boiler drain
T5 Flue connection
T6 Max. burner blast tube dia.
CONNECTIONS
A
mm
1462
1462
1622
1622
B
mm
2282
2652
2692
3014
C
mm
1542
1542
1702
1702
D
mm
190
190
190
190
E
mm
230
230
260
260
F
mm
290
290
290
290
G
mm
1120
1120
1245
1245
H
mm
565
565
605
605
M
mm
1650
1650
1810
1810
N
mm
561
561
661
662
O
mm
510
880
670
990
P
mm
550
550
700
700
Q
mm
1360
1360
1520
1520
R
mm
2176
2546
2590
2910
DETAIL FOR DOOR DRILLING
TX N 1100 - 1320
DETAIL FOR DOOR DRILLING
TX N 1600 - 1900
TX N 1100
TX N 1320
TX N 1600
TX N 1900
TX N 1100
TX N 1320
TX N 1600
TX N 1900
270
270
285
285
fig. 13 fig. 14
32
1
G
T4
T5
T3
BF
N
E
H
T6
O P
M
T1 T2
R
A
Q
T4
T5
D
C
T3-T1-T2
185
H
T6
Boiler
water
content
l
Water side
pressure
drop (*)
mw.c.