Unical TRISECAL 3P Series User guide

aaaaa - 07/04
TRISECAL 3P
TRISECAL 3P DUO
INSTALLATION, USE AND
SERVICING INSTRUCTION
(to be kept by the user)

2
GENERAL INFORMATIONS
Introduction
This manual supplies a summary of what has to be followed during the installation, use and
servicing of the UNICAL boilers, TRISECAL 3P range.
In the course of this text the short name TS 3P can be used to indicate the TRISECAL 3P
boiler.
Choice of the boiler
For a correct choice and application of the TRISECAL 3P 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, TRISECAL 3P range, have been tested and CE certified for the gas
operation by GASTEC (ITALIA), 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 TRISECAL 3P 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
CONSTRUCTIONAL-DIMENSIONAL
TECHNICAL CHARACTERISTICS.................... page 5
1.1 Construction of the TRISECAL 3P boilers ........................... page 5
1.2 Working principle ................................................................... page 5
1.3 Dimensions and hydraulic connections................................ page 6
INSTALLATION.................................................................. page 10
2.1 Packaging .............................................................................. page 10
2.2 Handling ................................................................................. page 10
2.3 Positioning in the boiler house.............................................. page 10
2.4 Connection to the chimney ................................................... page 11
2.5 Water connections................................................................. page 11
2.5.1 Water supply................................................................. page 11
2.5.2 Feeding water quality................................................... page 11
2.5.3 C.H. flow and return connections ................................ page 11
2.5.4 Connection of filling and drain tap............................... page 11
2.5.5 Connection of the expansion pipe and vessel............ page 12
2.5.6 Shunt pump .................................................................. page 12
2.6 Furnace door: adjustment, opening & closing ..................... page 12
2.6.1 Important note .............................................................. page 12
2.7 Burner .................................................................................... page 13
2.7.1 Mounting of the two-stage or modulating burners...... page 13
2.8 Connection of the sightglass to the burner via a cooling line.. page 13
2.9 Casing assembly ................................................................... page 14
STANDARD PANEL BOARD.................................. page 21
3.1 Electrical supply .................................................................... page 21
3.2 Functions descriptions .......................................................... page 21
OPTIONAL PANEL BOARD
(WITH OUTER COMPENSATOR .................................................. page 22
4.1 Functions description ............................................................ page 22
4.2 Panel board with outer compensator (on request) .............. page 23
4.3 Electrical and hydraulic connections of C.H. ....................... page 24
4.4 Electrical and hydraulic connections of C.H.
and D.H.W. production circuit................................................ page 25
4.5 Outer compensator................................................................ page 25
1
2
STANDARD PANEL BOARD FOR
TS/3P DUO............................................................................ page 27
5.1 Functions description ............................................................ page 27
5.2 Electrical wiring diagram for single phase burner and pump .. page 28
PANEL BOARD FORTS/3P DUO (OPTIONAL)..... page 29
6.1 Introduction ............................................................................ page 29
6.2 Panel board with outer compensator (optional) ................... page 29
6.3 Electrical and hydraulic connections of C.H.
and D.H.W. production circuit................................................ page 31
COMMISSIONING AND OPERATION ............ page 32
7.1 Preliminary check .................................................................. page 32
7.2 First commissioning .............................................................. page 32
7.3 Switch OFF of the boiler ....................................................... page 33
MAINTENANCE ................................................................ page 33
8.1 General rules ......................................................................... page 33
8.2 Ordinary maintenance........................................................... page 33
8.3 Extraordinary maintenance ................................................... page 34
8.4 Cleaning of the boiler ............................................................ page 34
8.5 Check of the boiler operation ................................................ page 34
8.6 Check of the burner operation .............................................. page 35
8.7 Boiler house ........................................................................... page 35
7
6
5
4
3
8

4
GASSAFETY(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,localbuildingregulations,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).

5
1CONSTRUCTIONAL-DIMENSIONAL
TECHNICAL CHARACTERISTICS
1.1 - CONSTRUCTION OF
THETRISECAL 3P
BOILERS
TheTRISECAL 3P (short name:TS 3P) range
of boilers are /made of an external oval shell,
to whose inside are placed: in the highest
part the cylindrical furnace completely wet,
in which the first smoke pass takes place; in
the lowest part the flame reversion pipe, used
as second smoke pass and, beside to it, the
tube bundle, used as third smoke pass.
A special manifold, positioned in
correspondence of the flow ane return pipes,
optimises the water circulation and reduces
the stratification phenomenon, facilitating a
more homogeneous distribution of the water
temperatures inside the boiler body.
The guided route of the combustion gases
allows the maximum exploitation of the thermal
exchange surfaces and the uniform balance
of the material stress.
The tube bundle is positioned in the lowest
and coldest part of the boiler, because made
of special and patented pipes with controlled
heat exchange, which are able to impede the
condensate formation.
The special geometry of the TS/3P boilers
(reversed flame furnace) and the innovative
exchange surfaces (pipes at controlled heat
exchange) allow to use these boilers as sliding
temperature and Low NOx boilers.
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; where as the pipes are of steel
ST 37.0 according to DIN 1626.
fig. 1
The welders and theWPS (Welding Procedures
Specifications) have been approved according
to EN 287 and EN 288 by TÜV (DE). These
boilers and production facilities have been
also approved by - ISCIR (RO), UDT (PL) and
GOSGORTEKHNAZDOR (RU).
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
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
TS 3P 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 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
thecombustionchambervolume hasbeen
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 9 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.
matress, thick 80 mm (100 mm for models
TS/3P 450 &TS/3P 600), protected by a textile
in mineral fiber.
The upper part of the outer shell is equipped
with uplift hook(s).

6
1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS
TRISECAL 3P 65÷90
1 Panel board
2 Smoke chamber cleaning door
3 Flame 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
TRISECAL 3P
Type
(*) Hydraulic resistance for deltaT 15K.
TS/3P 65
TS/3P 90
TRISECAL 3P
Type
TS/3P 65
TS/3P 90
130
130
T6
Øi
mm
T5
Øi
mm
150
150
T4
ISO 7/1
Rp¾"
Rp¾"
T3
ISO 7/1
Rp1”
Rp1”
T1
T2
ISO 7/1
Rp1½"
Rp1½"
Weight
with
packaging
kg
326
398
Maximum
boiler working
pressure
bar
5
5
Smoke side
pressure drop
mm w.c.
3,5÷5,5
5÷7,5
Water side
pressure
drop(*)
m w.c.
0,04÷0,06
0,05÷0,07
Boiler
water
content
l
131
187
Input
min/max
kW
53,3÷70
74,5÷97
Output
min/max
kW
50÷65
70÷90
740
740
A
mm B mm
690
950
C
mm
950
950
D
mm
190
190
E
mm
140
140
F
mm
145
145
G
mm
437
437
H
mm
585
585
I
mm
120
120
L
M 8
M 8
M
mm
190
190
N
mm
90
90
O
mm
190
190
P
mm
786
786
R
mm
660
660
S
mm
588
848
fig. 2
2
1
3
DETAIL FOR DOOR DRILLING
TS/3P 65 - 90
fig. 3
CONNECTIONS

7
TRISECAL 3P 120÷350
1 Panel board
2 Smoke chamber cleaning door
3 Flame 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
TRISECAL 3P
Type
(*) Hydraulic resistance for deltaT 15K.
130
130
180
180
180
180
TS/3P 120
TS/3P 150
TS/3P 180
TS/3P 240
TS/3P 300
TS/3P 350
2
1
TRISECAL 3P
Type
T6
Øi
mm
T5
Øi
mm
T4
ISO 7/1
T3
ISO 7/1
T1
T2
UNI 2278 PN16
Weight
with
packaging
kg
Maximum
boiler working
pressure
bar
Smoke side
pressure drop
mm w.c.
Water side
pressure
drop(*)
m w.c.
Boiler
water
content
l
Input
min/max
kW
Output
min/max
kW
90÷120
120÷150
150÷180
180÷240
240÷300
300÷350
95,7÷129,3
127,8÷161,6
159,9÷194
191,7÷258,6
255,9÷323,7
320,8÷377
204
270
289
320
412
478
0,06÷0,08
0,08÷0,10
0,10÷0,18
0,17÷0,20
0,22÷0,35
0,32÷0,53
6÷8,5
7÷10
12÷17
22÷24
18÷26
18÷26
5
5
5
5
5
5
486
575
626
739
949
1118
DN 50
DN 50
DN 65
DN 65
DN 80
DN 80
Rp1¼”
Rp1¼"
Rp1½”
Rp1½"
Rp2”
Rp2"
Rp¾"
Rp¾"
Rp¾"
Rp¾"
Rp¾"
Rp¾"
180
180
180
180
225
225
820
820
860
860
890
890
A
mm 885
1145
1080
1210
1275
1470
B
mm 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
153
153
153
153
153
153
G
mm
532
532
757
757
897
897
H
mm
695
695
775
775
915
915
I
mm
120
120
200
200
200
200
L
M 8
M 8
M 10
M 10
M 10
M 10
M
mm
1215
1215
1315
1315
1470
1470
N
mm
175
175
215
215
255
255
130
390
210
340
285
480
O
mm 185
185
250
250
315
315
P
mm R mm
710
710
750
750
780
780
S
mm
786
1046
981
1111
1177
1372
TS/3P 120
TS/3P 150
TS/3P 180
TS/3P 240
TS/3P 300
TS/3P 350
fig. 4
3
DETAIL FOR DOOR DRILLING
TS/3P 120 - 150 DETAIL FOR DOOR DRILLING
TS/3P 180 - 350
CONNECTIONS
fig. 6
fig. 5

8
TRISECAL 3P 450÷600
1 Panel board
2 Smoke chamber cleaning door
3 Flame 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
TRISECAL 3P
Type 920
920 1605 1800 1645
1645 190 190 140 140 176 176 690 690 1130 1130 1735 1735 298 298 435 630 440 440
A
mm B mm C mm D mm E mm F mm G mm H mm M mm NO mm
(*) Hydraulic resistance for deltaT 15K.
210
210
TS/3P 450
TS/3P 600
TS/3P 450
TS/3P 600
2
1
TRISECAL 3P
Type
T6
Øi
mm
T5
Øi
mm
T4
ISO 7/1
T3
UNI 2278 PN16
T1
T2
UNI 2278 PN16
Weight
with
packaging
kg
Maximum
boiler working
pressure
bar
Smoke side
pressure drop
mm w.c.
Water side
pressure
drop(*)
m w.c.
Boiler
water
content
l
Input
min/max
kW
Output
min/max
kW
DN 100
DN 100 DN 65 DN 65 Rp1¼" Rp1¼" 250 250
400÷450
500÷600 427,4÷484 535,4÷644
708
794 0,26÷0,44 0,25÷0,42 20÷28 20÷30 5 51545 1755
P
mm S
mm
R
mm
790
790 1504 1699
fig. 7
3
DETAIL FOR DOOR DRILLING
TS/3P 450 - 600
CONNECTIONS
fig. 8

9
TRISECAL 3P DUO 360÷700
TRISECAL 3P DUO 900÷1200
T1 C.H.flow
T2 C.H.return T3 Expansion vessel connection T4 Boiler drain T5 Flue connection T6 Max. burner blast tube dia.
(*) Hydraulic resistance for deltaT 15K.
360
480
600
700
900
1200
TS/3P DUO
Type
fig. 10
1373
1503
1568
1764
1921
2116
Z
mm
870
870
900
900
930
930
Note:For the dimensions C, E, F, M, see theprevious tables related to the different models.
W
mm
B
mm
1080
1210
1275
1470
1605
1800
A
mm
1730
1730
1790
1790
1850
1850
P ressione
max. esercizio
caldaia
bar
5
5
5
5
5
5
Smoke side
pressure
drop
mm w.c.
12÷17
22÷24
18÷26
18÷26
20÷28
20÷30
Water side
pressure
drop(*)
m w.c.
0,10÷0,18
0,17÷0,20
0,22÷0,35
0,32÷0,53
0,26÷0,44
0,25÷0,42
578
640
824
956
1416
1588
Boiler
water
content
l
Input
min/max
kW
319,8÷388
383,4÷517,2
511,8÷647,4
641,6÷754
854,8÷968
1070,8÷1288
Output
min/max
kW
300÷360
360÷480
480÷600
600÷700
800÷900
1000÷1200
Ass.y
formed by
n°2
TS/3P 180
TS/3P 240
TS/3P 300
TS/3P 350
TS/3P 450
TS/3P 600
DIMENSIONS
fig. 9

10
2INSTALLATION
2.1- PACKAGING
TheTS 3P boilers are supplied complete with
door and smoke chamber already fitted, whilst
the casing with the insulation matress are
containedinseparatecardboardpackaging(s).
The panel board and the accessories are inside
the combustion chamber.
Before starting the installation make sure that
the length and the width of the boiler body
received correspond to the dimensions M, R
e S of the ordered boiler, shown in the previous
tables and that the cartons, containing the
casing, or part of it, are marked with the
code(s) shown on pages 14.
In addition to the a. m.panel board, packaged
in its own carton, in the combustion chamber,
as accessories, there are also:
- a carton containing the flanges for flow,
return and safety connections (if applicable)
with relevant gaskets and bolts, the
triangular brush for the cleaning of the
smoke pipes.
- cleaning brush handle extension.
2.2 - HANDLING
The boiler can be moved into position by lifting,
through the upper hooks(s), or by the use of
rollers placed under the strong L profiles of
the basement.
If it necessary, due to the dimensions of the
boiler, it is possible to remove the front door
and the smoke chamber to facilitate the
introduction in the boiler house.
2.3 - POSITIONING IN THE
BOILER HOUSE
The installation of the boiler must be in
accordance with the relevant requirements
of the Gas Safety Regulations, current I.E.E.
Regulations, local water authority bye-laws
and it should also comply with any relevant
requirements of the local gas supplier, local
authority and the relevant Standard Codes
of Practice and building regulations.
The boiler house must be ventilated through
permanent openings having a total surface
not lower than 1/30th of the floor area of the
boiler house, with a minimum of 0.5 m2.
Ventilation by grilles communicating directly
with the outside air is required at both, high
and low levels.
The boiler must be positioned so that there
is enough space available for the following:
- Access around the boiler fore servicing.
- Space to open the boiler front door.
- Space to access the burner.
The installation of the boiler as close as
possible to the chimney position is highly
recommended.
To allow the cleaning of the smoke pipes, in
front of the boiler a clearance equal to the
length of the boiler, has to be available.
With the boiler door opened at 90°, the distance
between the front of the door and the adjacent
wall must be equal, at least, at the length of
the burner.
The boiler must stand on a non-combustible
floor (i.e. concrete or brick), of dimensions
Rx S(see dimensions table) which must be
flat, level and of a suitable load bearing
capacity to support the weight of the boiler
(when filled with water) and any ancillary
equipment.
x = Not shorter than the boiler body
xx = Sufficient to allow accessibility to all the regulation, safety and control devices. fig. 11
- turbulators extractor.
- ceramic fiber rope for the insulation between
the door and burner blast tube.
Once the installation has been made the
boilermustresultperfectly horizontal and well
stable (to avoid vibrations and noise).