Unical Tristar 2S User guide

INSTALLER AND
MAINTENANCE
TECHNICIAN
INSTRUCTIONS
00334513 - 03/13
rev. 0
TRISTAR 2S

2
General information
TABLE OF CONTENTS
1 GENERAL INFORMATION ................................................................................................................................................................................. 3
1.1 Symbols used in the manual.........................................................................................................................................................................3
1.2 Appropriate use of appliance........................................................................................................................................................................3
1.3 Water treatment ............................................................................................................................................................................................3
1.4 Information for user or system manager.......................................................................................................................................................3
1.5 Safety warnings ............................................................................................................................................................................................4
1.6 Technical data plate......................................................................................................................................................................................5
1.7 General warnings..........................................................................................................................................................................................6
2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................7
2.1 Technical features.........................................................................................................................................................................................7
2.2 Main components .........................................................................................................................................................................................7
2.3 Smoke turbulators.........................................................................................................................................................................................8
2.4 Dimensions...................................................................................................................................................................................................9
2.5 Operating data according to UNI 10348 .....................................................................................................................................................15
3 INSTALLATION INSTRUCTIONS ..................................................................................................................................................................... 17
3.1 General warnings ......................................................................................................................................................................................17
3.2 Installation standards.................................................................................................................................................................................18
3.3 Handling ....................................................................................................................................................................................................19
3.4 Positioning in boiler room ..........................................................................................................................................................................19
3.5 Burner........................................................................................................................................................................................................19
3.5.1 Choosing the burner......................................................................................................................................................................... 19
3.5.2 Installing the burner.......................................................................................................................................................................... 20
3.6 Connecting flame control warning light to burner ...................................................................................................................................... 20
3.7 Furnace door: adjustment, opening, closing..............................................................................................................................................21
3.7.1 TST 80 2S÷TST 250 2S boilers....................................................................................................................................................... 21
3.7.2 TST 300 2S÷TST 560 2S boilers...................................................................................................................................................... 21
3.7.3 TST 680 2S÷TST 870 2S boilers...................................................................................................................................................... 22
3.7.4 TST 1000 2S÷TST 6100 2S boilers.................................................................................................................................................. 22
3.7.5 Important note .................................................................................................................................................................................22
3.8 Connecting flue exhaust pipe .................................................................................................................................................................... 23
3.9 Condensation drainage .............................................................................................................................................................................23
3.9 Connecting boiler to system ...................................................................................................................................................................... 24
3.9.1 Recirculation pump...........................................................................................................................................................................24
3.10 Filling the system.......................................................................................................................................................................................24
3.11 Gas connection..........................................................................................................................................................................................25
3.12 Packaging ..................................................................................................................................................................................................26
3.13 Assembly of casing....................................................................................................................................................................................27
3.14 Electrical connections................................................................................................................................................................................36
3.15 Panel board................................................................................................................................................................................................ 37
3.16 Hydraulic and electrical system connection...............................................................................................................................................38
3.17 Optional panel board ................................................................................................................................................................................. 40
3.18 Layout of probe connection on heating controller......................................................................................................................................41
3.19 Programming the heating controller ..........................................................................................................................................................41
3.20 Hydraulic and electric system connection with optional panel board ........................................................................................................44
3.21 Commissioning......................................................................................................................................................................................... 46
3.22 Adjustment of burner ................................................................................................................................................................................. 47
3.23 Removing flue gas turbulators................................................................................................................................................................... 47
4 INSPECTION AND MAINTENANCE ................................................................................................................................................................ 48
Inspection and maintenance instructions........................................................................................................................................................... 48
Boiler body maintenance ...................................................................................................................................................................................49
Maintenance of burner.......................................................................................................................................................................................49
Checking ignition electrode................................................................................................................................................................................ 49
Components to check during yearly inspection .................................................................................................................................................49

3
General information
1.1 - SYMBOLS USED IN THE MANUAL
Pay special attention when reading this manual to the parts marked by the symbols:
1.2 - APPROPRIATE USE OF APPLIANCE
TheTRISTAR 3G 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 air circulation heating systems. Any other use must be considered
improper.
UNICAL shall not be held liable for any damage resulting from improper use; in this case the user is fully
responsible for the risk.
Use according to the intended purposes also includes careful compliance with the instructions in this manual.
1.3 - WATER TREATMENT (see specific booklet)
• Thehardnessofthefeedwaterconditionsthefrequencyatwhichthedomestichotwaterexchangermustbe
cleaned.
• Ifthewaterhasahardnessgreaterthan15°f,werecommendusingwatersofteners,chosenaccordingtothe
characteristics of the water.
• Werecommendcheckingandcleaningthedomestichotwaterexchangerattheendoftherstyearofuseand
every two years thereafter; on this occasion, also check the state of wear of the anode.
1.4 - INFORMATION FOR SYSTEM MANAGER
1 GENERAL INFORMATION
Attention: this manual contains instructions for the exclusive use of the professionally qualified installer and/
or maintenance technician in compliance with current legislation.
The user is NOT qualified to intervene on 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.
• 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 for future consultation.
• Informtheuserabouttheimportanceoftheairventsandtheue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acombustionanalysis
must be performed in the timetable foreseen by standards in force.
• 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 booklet accompanies it in order to be consulted by the new owner and/or installer.
NOTE!
Suggestions for the
user
ATTENTION!
Possible hazardous situation
for the product and the environment
DANGER!
Serious danger for
personal safety and life

4
General information
1.5 - SAFETY WARNINGS
ATTENTION!
The appliance must be installed, adjusted and maintained by professionally qualified personnel, in
compliance with standards and provisions in force. Incorrect installation can cause damage to persons,
animals and objects for which the manufacturer cannot be held responsible.
DANGER!
NEVER attempt performing maintenance or repairs on the boiler on your own initiative.
Any work must be done by professionally qualified personnel.
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 lines
- the flue gas pipe, safety valves and heating water drain pipe
- the construction parts which affect the operating safety of the appliance.
Attention!
Totightenorloosenthescrewedttings,useonlyappropriatexed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deaerationofthetank,contacttheLPGsupplierorapersonqualiedincompliancewithlaw.
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
appliance is installed.

5
General information
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 °Cbar
Storage tank:
AG S.P.A.
46033 CASTELDARIO (MN) - Via Roma
tel. [phone] - fax [phone]
www.unical.ag inf[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certiesthattheboilersmeet:
- Theessentialrequirementsofthe gasappliancedirective
(90/396/EEC).
- The essential requirements of the electromagnetic
compatibility directive (89/336/EEC).
- Theessentialrequirementsoftheefciencydirective(92/42/
EEC).
1.6 - TECHNICAL DATA PLATE
The technical data plate is adhesive and is included in the document case; it must be applied by the installer on the
outside of the casing.
The serial number of the boiler is on the riveted plaque on the front plate of the body (front right top side).

6
General information
1.7 - GENERAL WARNINGS
The instruction booklet is an integral and essential part of the
product and must be kept by the user or 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.
Installation and maintenance must be performed in compliance
with standards in force according to the instructions of the
manufacturer and by qualified and certified personnel in
compliance with law.
Byprofessionallyqualiedpersonnelwemean:personnelwith
specictechnicalskillintheeldofheatingsystemcomponents
for civil use, domestic hot water production and maintenance.
Personnelmusthavethequalicationsprovidedforbycurrent
legislation.
Incorrect installation or improper maintenance can cause damage
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specic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qualiedincompliancewithlaw.
Any repairs must be performed solely by personnel authorised
by Unical using original spare parts only. Failure to comply with
the above can jeopardise the safety of the appliance.
To guarantee appliance efciency and its correct operation,
yearlymaintenancemustbeperformedbyqualiedpersonnel.
Should you decide not to use the appliance, parts entailing
potential sources of hazard must be made safe.
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 booklet 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 dangerous.
ATTENTION
Wherever the boiler operates with an air-blown gas-red 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-redappliances-transposedinItalywithItalian
Presidential Decree 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.

7
Technical features and dimensions
2.1 - TECHNICAL FEATURES
TRISTAR 2S boilers are the horizontal cylindrical type with flame
inversion in furnace and third flue gas pass in tubes.
The construction fully complies with prescriptions laid down in
EN 303 part 1.
The components of the pressurised part, such as sheets and
pipes, are made in certied carbon steel, according to the
EURONORM 25 and EURONORM 28 tables.
Welding devices and procedures are approved byTÜV (D) - UDT
(PL) - SA (S) and ISPESL (I).
Up until model TST 560 2S, the furnace is bonded to the rear
tube plate.
For models TST 680 2S ÷ TST 3100 2S, the furnace is free to
expand (it is only sustained by the front tube plate).
For models from TST 3500 to TST 6100, the furnace is bonded
to the rear tube plate.
Theboilersareequippedwithanopeningdoorontherightorleft.
The outer shell is covered with a glass wool insulation mattress
60 mm thick (from model TST 80 2S to model TST 250 2S), 80
mm thick (from model TST 300 2S to model TST 560 2S), 100
mm thick (from model TST 680 2S to model TST 2350 2S), 80
mm thick (from model TST 2700 2S to model TST 3500 2S), in
turnprotectedbyamineralbrefabric.
From models from TST 3900 2S to TST 6100 2S the outer shell
is covered with a lamella mat 50 mm thick, in turn protected by
an aluminium sheet.
The top part of the shell is provided with hooks for lifting the boiler.
Note: TRISTAR 3G 2S boilers are intended to operate with ON/
OFFtypeGASburners;asanalternative,theycanbeequipped
with a dual-stage or modulating burner, as long as the minimum
heatoutputintherstameorinmodulationdoesnotdropbelow
60% the furnace load.
The boilers are provided with two ½" connections for conduits
with an inside diameter of 15 mm (suitable to house 3 bulbs
each).
The shell has holes at the sides for the cable glands of the power,
pumps, burner cables and those of any other auxiliary device.
2TECHNICAL FEATURES
AND DIMENSIONS
2.2 - MAIN COMPONENTS
TRISTAR2Sboilersareequippedwithablindcylindricalfurnace,
in which the central flame of the burner is reversed peripherally
towards the front, from whence the combustion gases enter the
smoke pipes. At the end of the pipes they are gathered in the
smoke chamber and sent to the chimney.
The combustion chamber is always pressurised while the burner
is operating, within the power range of the boiler.
For the value of this pressure, see the tables
on pages 9÷14, in the column “Flue gas pressure drop”.
The chimney must be calculated so that
no positive pressure is detected at its base.
1 Furnace
2 Smoke pipes with smoke diverters
(from model TST 300 2S)
3 Door with flame control warning light
4. Smoke chamber
5 Body insulation
6 Panel board fig. 1
M
R
1
2
4
5
3
6

8
Technical features and dimensions
2.3 - SMOKETURBULATORS
TRISTAR boilers are designed to be used
within an output range in order to improve
seasonal efciency and coupling with
each heating system.
The heat output must therefore be
adjusted upon commissioning, based
on the guidelines of the Thermotechnical
Engineer, and always within the range
provided for each boiler on pages 9 -
14 by the burner technician who will
determine the fuel flow rate.
In all cases, turbulators must be
positioned inside their respective
smoke pipes, resting on the internal
aluminium profiles.
The burner must be commissioned
under the responsibility of a qualied
burner technician authorised by the
manufacturer.
On that occasion, a complete operating
report must be drafted.
POSITIONING OF THE CORE INSIDE THE TURBULATOR (ONLY for MODELS from TST 300 2S to TST 870 2S)
fig. 2
MR
front side rear side
turbulator
core of the turbulator

9
Technical features and dimensions
2.4 - DIMENSIONS - TRISTAR 80÷250 2S
DETAIL FOR DOOR DRILLING
TST 80 2S
DETAIL FOR DOOR DRILLING
TST 120 2S÷TST 250 2S
Useful
output
kW
60÷80
90÷120
120÷160
150÷200
187.5÷250
CONNECTIONS
T1
T2
UNI 228
UNI 2278 PN16
T3
Øe
mm
T4
Øi
mm
T5
UNI 228
T6
Øe
mm
G 1½
G 2
G 2
DN 65
DN 65
200
200
200
250
250
130
180
180
180
180
G ¾
G ¾
G ¾
G ¾
G ¾
40
40
40
40
40
TST 80 2S
TST 120 2S
TST 160 2S
TST 200 2S
TST 250 2S
TRISTAR 2S
Model
Furnace
output
kW
63.3÷85.2
94.6÷127.4
125.8÷169.4
157÷211.3
195.8÷263.6
Boiler
capacity
l
86
126
151
203
247
Water side
pressure
drop (**)
m.w.c.
0.08÷0.15
0.06÷0.11
0.11÷0.20
0.10÷0.17
0.12÷0.22
3.8÷6.8
6.1÷10.8
8.9÷15.8
11.1÷19.7
13.3÷23.6
Flue gas
pressure
drop
mm.w.c.
M aximum
operating
pressure
boiler
bar
5
5
5
5
5
W eight
kg
221
325
366
505
583
TRISTAR 2S
Model
TST 80 2S
TST 120 2S
TST 160 2S
TST 200 2S
TST 250 2S
DIMENSIONS
A
mm
690
760
760
860
860
B
mm
722
812
812
937
937
995
1210
1390
1442
1692
C
mm
190
190
190
190
190
D
mm
305
350
350
421
421
E
mm F mm
480
500
500
580
580
G
mm
115
130
130
165
165
H
mm
--
--
--
1487
1737
I
mm
147
157
157
258
258
(*) In the TRISTAR 200 2S and TRISTAR 250 2S models, connections T1 and T2 are flanged.
(**) Pressure drops corresponding to a thermal variation of 15K.
fig. 4
fig. 3
fig. 5
E
B D
A
4
2
1
T3
T6
F
G
T2-T5
121
I
T1
T4
C
H
3
Lana di roccia
Fibra ceramica
P ias tra porta-bruc iatore ciec a 200x200
Guarnizione pias tra porta-bruciatore 200x200
ø 130 ø 130
75
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame control warning light
T1 Heating flow
T2 Heating return
T3 Chimney connection
T4 Burner connection
T5 Boiler drain
T6 Condensation drain
Lana di roccia
Fibra ceramica
P ias tra por ta-bruciatore c iec a 250x250
Guarnizione pias tra porta-bruciatore 250x250
ø 180
ø 150
75
ø 180
TS T 120÷160 2S TS T 200÷250 2S
Blind burner plate 200x200
Burner plate insulation gasket 200x200
Mineral wool
Ceramicbre
Blind burner plate 250x250
Burner plate insulation gasket 250x250
Mineral wool
Ceramicbre

10
Technical features and dimensions
TRISTAR 300÷560 2S
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame control warning light
T1 Heating flow
T2 Heating return
T3 Expansion vessel connection
T4 Boiler drain
T5 Chimney connection
T6 Burner connection
T7 Condensation drain
DETAIL FOR DOOR DRILLING
TST 300 2S÷TST 560 2S
Useful
output
kW
225÷300
277.5÷370
337.5÷450
420÷560
CONNECTIONS
T1
T2
UNI 2278 PN16
T3
UNI 228
T4
UNI 228
T5
Øi
mm
T6
Ø
mm
DN 80
DN 100
DN 100
DN 100
G 2
G 2
G 2
G 2
G ¾
G ¾
G ¾
G ¾
250
250
250
300
220
220
220
220
TST 300 2S
TST 370 2S
TST 450 2S
TST 560 2S
TRISTAR 2S
Model
Furnace
output
kW
234.6÷315.8
288.8÷388.7
351÷472.4
436.8÷587.9
Boiler
capacity
l
298
398
462
565
Water side
pressure
drop (**)
m.w.c.
0.12÷0.22
0.08÷0.14
0.11÷0.20
0.17÷0.30
15.9÷28.4
18.1÷32.2
20.2÷35.8
23.7÷42.1
Flue gas
pressure
drop
mm.w.c.
M aximum
operating
pressure
boiler
bar
6
6
6
6
W eight
kg
665
845
986
1119
TRISTAR 2S
Model
DIMENSIONS
A
mm
860
890
890
890
B
mm
1210
1275
1470
1780
1182
1352
1352
1352
C
mm
190
190
190
190
D
mm
140
140
140
141
E
mm F mm
191
191
191
192
G
mm
708
748
748
748
H
mm
400
440
440
440
I
mm
1541
1606
1801
2113
L
mm
130
125
125
125
1310
1485
1485
1485
M*
mm
215
255
255
255
N
mm
340
285
480
790
O
mm
250
315
315
315
P
mm
750
780
780
780
Q*
mm
1112
1177
1372
1684
R*
mm
(*) Minimum dimensions for boiler room access.
(**) Pressure drops corresponding to a thermal variation of 15K.
fig. 6
fig. 7
Lana di roccia
Fibra ceramica
Piastra porta-bruciatore cieca 280x280
Guarnizione piastra porta-bruciatore 280x280
ø 220 ø 220
95
TST 300 2S
TST 370 2S
TST 450 2S
TST 560 2S
T7
Øe
mm
40
40
40
40
CD
Q
H
A
1
R
G
T4
T7 T7
T5
M
FBE
T2
N O P
T3 T1
H
T6
T4
T5
T2-T3-T1
L
100
I
2
4
3
Blind burner plate 280x280
Burner plate insulation gasket 280x280
Mineral wool
Ceramicbre

11
Technical features and dimensions
(*) Minimum dimensions for boiler room access.
(**) Pressure drops corresponding to a thermal variation of 15K.
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame control warning light
T1 Heating flow
T2 Heating return
T3 Expansion vessel connection
T4 Boiler drain
T5 Chimney connection
T6 Burner connection
T7 Condensation drain
DETAIL FOR DOOR DRILLING
TST 680 2S÷TST 870 2S
TRISTAR 2S
Model
DIMENSIONS
A
mm
1122
1122
1122
B
mm
1605
1800
1995
1432
1432
1432
C
mm
190
190
190
D
mm
195
195
195
E
mm F mm
190
190
190
G
mm
765
765
765
H
mm
480
480
480
I
mm
1989
2184
2379
L
mm
125
125
125
1540
1540
1540
M*
mm
298
298
298
N
mm
435
630
825
O
mm
440
440
440
P
mm
1020
1020
1020
Q*
mm
1504
1699
1894
R*
mm
Furnace
output
kW
510÷680
585÷780
652.5÷870
CONNECTIONS
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
T4
UNI 228
T5
Øi
mm
T6
Ø
mm
DN 125
DN 125
DN 125
DN 65
DN 65
DN 65
G 1¼
G 1¼
G 1¼
350
350
350
270
270
270
TST 680 2S
TST 780 2S
TST 870 2S
TRISTAR 2S
Model
Furnace
output
kW
530.4÷713.9
608.4÷818.9
678.6÷913.4
Boiler
capacity
l
671
753
836
Flue gas
pressure
drop(**)
m.w.c.
0.12÷0.21
0.15÷0.27
0.19÷0.33
27.8÷49.4
30.7÷54.5
33÷58.6
Flue gas
pressure
drop
mm.w.c.
M aximum
operating
pressure
boiler
bar
6
6
6
W eight
kg
1435
1557
1656
TRISTAR 680÷870 2S
fig. 8
fig. 9
C em ento r efra ttar io
Fibra ceramica
Piastra porta-bruciatore cieca 330x330
Guarnizione pias tra porta-bruciatore 330x330
ø 270 ø 270
150
TST 680 2S
TST 780 2S
TST 870 2S
T7
Øe
mm
40
40
40
CD
A
Q
H
R
200
G
T4
L
T5
M
FBE
T2
N O P
T3 T1
I
H
T6
T4
T5
T2-T3-T 1
1
2
3
4
T7 T7
Blind burner plate 330x330
Burner plate insulation gasket 330x330
Refractory cement
Ceramicbre

12
Technical features and dimensions
T1 Heating flow
T2 Heating return
T3 Expansion vessel connection
T4 Boiler drain
T5 Chimney connection
T6 Burner connection
T7 Boiler air bleed
T8 Inspection door
(*) Minimum dimensions for boiler room access.
(**) Pressure drops corresponding to a thermal variation of 15K.
TRISTAR 1000÷2350 2S
TST 1000 2S
TST 1180 2S
TST 1400 2S
TST 1650 2S
TST 2000 2S
TST 2350 2S
TRISTAR 2S
Model
TRISTAR 2S
Model
TST 1000 2S
TST 1180 2S
TST 1400 2S
TST 1650 2S
TST 2000 2S
TST 2350 2S
DIMENSIONS
A
mm
1352
1352
1462
1462
1622
1622
B
mm
1952
2292
2282
2652
2692
3014
1432
1432
1542
1542
1702
1702
C
mm
190
190
190
190
190
190
D
mm
207
207
227
227
259
258
E
mm F mm
187
187
272
272
274
273
G
mm
810
810
880
880
950
950
H
mm
595
595
640
640
690
690
I
mm
2346
2686
2781
3151
3225
3545
L
mm
180
180
75
75
75
75
1540
1540
1650
1650
1810
1810
M*
mm
461
461
561
561
661
662
N
mm
330
670
510
880
670
990
O
mm
500
500
550
550
700
700
P
mm
1250
1250
1360
1360
1520
1520
Q*
mm
1846
2186
2176
2546
2590
2910
R*
mm
DETAIL FOR DOOR DRILLING
TST 1000 2S÷TST 1180 2S
DETAIL FOR DOOR DRILLING
TST 2000 2S÷TST 2350 2S
DETAIL FOR DOOR DRILLING
TST 1400 2S÷TST 1650 2S
Useful
output
kW
750÷1000
885÷1180
1050÷1400
1237.5÷1650
1500÷2000
1762.5÷2350
Furnace
output
kW
780÷1049.8
920.4÷1238.8
1092÷1469.8
1287÷1732.3
1560÷2099.7
1833÷2467.1
Boiler
capacity
l
1040
1242
1418
1617
2086
2324
Water side
pressure
drop(**)
m.w.c.
0.11÷0.19
0.15÷0.26
0.15÷0.26
0.20÷0.36
0.16÷0.28
0.21÷0.38
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame sight glass
Flue gas
pressure
drop
mm.w.c.
35.9÷63.9
38.6÷68.6
42.1÷74.9
45.5÷80.9
40.5÷72
43.2÷76.9
M aximum
operating
pressure
boiler
bar
6
6
6
6
6
6
W eight
kg
1970
2175
2975
3465
4390
4700
CONNECTIONS
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
DN 80
DN 80
DN 100
DN 100
DN 125
DN 125
DN 150
DN 150
DN 175
DN 175
DN 200
DN 200
T4
UNI 228
G 1½
G 1½
G 1½
G 1½
G 1½
G 1½
T5
Øi
mm
400
400
450
450
520
520
T6
Ø
mm
320
320
320
320
380
380
fig. 10
C em ento r efra ttar io
Piastra porta-bruciatore cieca 380x380
Guarnizione pias tra porta-bruciatore 380x380
ø 320 ø 320
160
C em ento r efra ttar io
Piastra porta-bruciatore cieca 380x380
Guarnizione pias tra porta-bruciatore 380x380
ø 320 ø 320
180
C em ento r efr atta rio
Piastra porta-bruciatore cieca 450x450
Guarnizione pias tra porta-bruc iatore 450x450
ø 380 ø 380
190
fig. 11 fig. 12 fig. 13
T9 Condensation drain
200
T4
T9
T9
L
G
T5
M
FB E
T3
N O P
T2 T1
I
R
H
T6
T3-T 2-T1
T4
T5
Q
A
H
CD
1
4
2
3
T8
T7
T9
Øe
mm
40
40
40
40
40
40
Blind burner plate 380x380
Burner plate insulation gasket 380x380
Refractory cement
Blind burner plate 380x380
Burner plate insulation gasket 380x380
Refractory cement
Blind burner plate 380x380
Burner plate insulation gasket 380x380
Refractory cement

13
Technical features and dimensions
Q
4
C
AD
H
2
145
T4
T9
L
3
G
M
T3T2 T1
N O P
FB
I
E
T8
T7
T6
H
R
T5
1
T1 Heating flow
T2 Heating return
T3 Expansion vessel connection
T4 Boiler drain
T5 Chimney connection
T6 Burner connection
T7 Boiler air bleed
T8 Inspection door
(*) Minimum dimensions for boiler room access.
(**) Pressure drops corresponding to a thermal variation of 15K.
TRISTAR 2700÷3500 2S
TST 2700 2S
TST 3100 2S
TST 3500 2S
TRISTAR 2S
Model
TRISTAR 2S
Model
DIMENSIONS
A
mm
1720
1970
1970
B
mm
3230
3194
3594
1830
2090
2090
C
mm
190
190
190
D
mm
295
325
325
E
mm F mm
310
360
360
G
mm
1315
1535
1535
H
mm
772
915
915
I
mm
3835
3879
4279
L
mm
115
144
144
1990
2271
2271
M*
mm
325
377
777
N
mm
1100
1060
1060
O
mm
1470
1420
1420
P
mm
1620
1870
1870
Q*
mm
3200
3164
3564
R*
mm
Useful
output
kW
2025÷2700
2325÷3100
2625÷3500
Furnace
output
kW
2106÷2834.6
2418.1÷3254.5
2730.1÷3674.5
Boiler
capacity
l
2667
4142
4455
Water side
pressure
drop(**)
m.w.c.
0.28÷0.50
0.37÷0.66
0.37÷0.65
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame sight glass
Flue gas
pressure
drop
mm.w.c.
45.6÷81
43.3÷76.9
50.4÷89.5
M aximum
operating
pressure
boiler
bar
6
6
6
W eight
kg
5370
6990
7790
CONNECTIONS
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
DN 125
DN 125
DN 125
DN 200
DN 200
DN 250
T4
UNI 228
G 1½
G 1½
G 1½
T5
Øi
mm
570
620
620
T6
Ø
mm
380
400
400
DETAIL FOR DOOR DRILLING
TST 2700 2S
DETAIL FOR DOOR DRILLING
TST 3100 2S÷TST 3500 2S
C eme nto r efr atta rio
Piastra porta-bruciatore cieca 450x450
Guarnizione pias tra porta-bruciatore 450x450
ø 400 ø 400
210
fig. 14
fig. 15 fig. 16
C eme nto r efr atta rio
Piastra porta-bruciatore cieca 450x450
Guarnizione pias tra porta-bruciatore 450x450
ø 380 ø 380
210
TST 2700 2S
TST 3100 2S
TST 3500 2S
T9 Condensation drain
Blind burner plate 450x450
Burner plate insulation gasket 450x450
Refractory cement
Blind burner plate 450x450
Burner plate insulation gasket 450x450
Refractory cement

14
Technical features and dimensions
(*) Minimum dimensions for boiler room access.
(**) Pressure drops corresponding to a thermal variation of 15K.
TRISTAR 3900÷6100 2S
fig. 17
T1 Heating flow
T2 Heating return
T3 Expansion vessel connection
T4 Boiler drain
T5 Chimney connection
T6 Burner connection
T7 Inspection door
T8 Condensation drain
1 Panel board
2 Burner connection flange
3 Smoke chamber cleaning door
4 Flame sight glass
TRISTAR 2S
Model
TRISTAR 2S
Model
DIMENSIONS
A
mm
2088
2088
2214
2214
2380
2380
B
mm
226
226
240
240
240
240
2533
2533
2653
2653
2860
2860
C*
mm
417
417
437
437
509
509
D
mm
485
485
515
515
595
595
E
mm F mm
1437
1437
1550
1550
1650
1650
G
mm
987
987
1007
1007
1100
1100
H
mm
170
170
167
167
224
224
I
mm
4738
4738
4928
4928
5484
5484
L
mm
323
323
323
323
325
325
1475
1475
1475
1475
2920
2920
M
mm
1665
1665
1815
1815
670
670
N
mm
363
363
363
363
465
465
O
mm
1700
1700
1700
1700
1850
1850
Q*
mm R* mm
Useful
output
kW
2925÷3900
3300÷4400
3600÷4800
3900÷5200
4275÷5700
4575÷6100
Furnace
output
kW
3042.1÷4094.4
3432.1÷4619.3
3744.1÷5039.3
4056.1÷5459.2
4446.1÷5984.1
4758.1÷6404.1
Boiler
capacity
l
6012
6012
7058
7058
7909
7909
Water side
pressure
drop(**)
m.w.c.
0.28÷0.50
0.35÷0.63
0.42÷0.75
0.50÷0.88
0.59÷1.05
0.68÷1.21
Flue gas
pressure
drop
mm.w.c.
44.4÷78.6
56.6÷100.5
50.5÷92.2
59.3÷105.4
49.5÷90.5
56.7÷100.7
M aximum
operating
pressure
boiler
bar
6
6
6
6
6
6
W eight
kg
8630
8630
9675
9675
13060
13060
CONNECTIONS
T1
T2
UNI 2278 PN16
T3
UNI 2278 PN16
DN 125
DN 125
DN 125
DN 125
DN 125
DN 125
DN 250
DN 250
DN 250
DN 250
DN 250
DN 250
T4
ISO 7/1
Rp 1½
Rp 1½
Rp 1½
Rp 1½
Rp 1½
Rp 1½
T5
Øi
mm
660
660
660
660
720
720
T6
Ø
mm
500
500
500
500
500
500
T7
Ø
mm
133
133
133
133
133
133
3826
3826
3976
3976
4380
4380
fig. 18
C emento refrattario
Piastra porta-bruciatore cieca 700x700
Guarnizione pias tra porta-bruciatore 700x700
ø 500 ø 500
240
DETAIL FOR DOOR DRILLING
TST 3900 2S÷TST 5200 2S
TST 3900 2S
TST 4400 2S
TST 4800 2S
TST 5200 2S
TST 5700 2S
TST 6100 2S
DETAIL FOR DOOR DRILLING
TST 5700 2S÷TST 6100 2S
C emento refrattario
Piastra porta-bruciatore cieca 700x700
Guarnizione pias tra porta-bruciatore 700x700
ø 500 ø 500
282
fig. 19
TST 3900 2S
TST 4400 2S
TST 4800 2S
TST 5200 2S
TST 5700 2S
TST 6100 2S
T8
Øe
mm
40
40
40
40
40
40
B
A
QR
ONML
I
D E
G G
C
F
T4
T8
H
T2
T5
T6
T1-T3-T2
T3T1
T6
T7
4
2
3
1
Blind burner plate 700x700
Burner plate insulation gasket 700x700
Refractory cement
Blind burner plate 700x700
Burner plate insulation gasket 700x700
Refractory cement

15
Technical features and dimensions
TST 250 2S
187.5÷250
195.8÷263.6
95.7÷94.8
95.9÷95
96.2÷95.4
0.5÷0.6 3.7÷4.6 0.1÷0.1
77.2÷94.3
9.8÷9.8
294÷396
TST 300 2S
225÷300
234.6÷315.8
95.9÷95
96.1÷95.2 96.4÷95.5
0.5÷0.5 3.6÷4.5 0.1÷0.1
74.5÷91.9
9.8÷9.8
353÷475
TST 370 2S
277.5÷370
288.8÷388.7
96.1÷95.2 96.3÷95.4 96.3÷95.4
0.2÷0.2 3.7÷4.6 0.1÷0.1
76.6÷94.9
9.8÷9.8
434÷584
TST 450 2S
337.5÷450 351÷472.4
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
528÷710
TST 560 2S
420÷560
436.8÷587.9
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
657÷884
TST 1180 2S
885÷1180
920.4÷1238.8
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
1383÷1862
TST 1400 2S
1050÷1400
1092÷1469.8
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
1641÷22095
TST 1650 2S
1237.5÷1650 1287÷1732.3
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
1935÷2609
TST 2000 2S
1500÷2000
1560÷2099.7
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
2345÷3156
TST 2350 2S
1762.5÷2350 1833÷2467.1
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
2755÷3708
Nominal heat output Thermal output of furnace
Heatefciencyatnominalload(100%) Heatefciencyat30%load Combustionefciency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) Nominal heat output Thermal output of furnace
Heatefciencyatnominalload(100%) Heatefciencyat30%load Combustionefciency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
TST 80 2S
60÷80
63.3÷85.2 94.7÷93.8 94.9÷94.0 95.4÷94.6
0.6÷0.7 4.6÷5.4 0.1÷0.1
94.9÷111.7
9.8÷9.8 95÷128
GAS-FIRED TST 120 2S
90÷120
94.6÷127.4
95.1÷94.2 95.3÷94.4 95.7÷94.9
0.6÷0.6 4.3÷5.1 0.1÷0.1
88.6÷105.7
9.8÷9.8
142÷191
TST 160 2S
120÷160
125.8÷169.4
95.4÷94.5 95.6÷94.7 95.9÷95.1
0.5÷0.6 4.1÷4.9 0.1÷0.1
84.4÷101.5
9.8÷9.8
189÷255
TST 200 2S
150÷200
157÷211.3
95.5÷94.6 95.7÷94.8 96.1÷95.2
0.5÷0.6 3.9÷4.8 0.1÷0.1
80.8÷97.9
9.8÷9.8
236÷318
2.5 - OPERATING DATA ACCORDING TO UNI 10348
kW kW % % % % % % °C % kg/h
TST 680 2S
510÷680
530.4÷713.9
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
797÷1073
TST 780 2S
585÷780
608.4÷818.9
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
914÷1231
TST 870 2S
652.5÷870
678.6÷913.4
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
1020.1÷1372.9
TST 1000 2S
750÷1000
780÷1049.8
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
1172÷1578
GAS-FIRED

16
Technical features and dimensions
Nominal heat output Thermal output of furnace Heatefciencyatnominalload(100%) Heatefciencyat30%load Combustionefciency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
TST 3100 2S
2325÷3100
2418.1÷3254.5
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
3635÷4892
GAS-FIRED TST 3500 2S
2625÷3500
2730.1÷3674.5
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
4104÷5523
TST 3900 2S
2925÷3900
3042.1÷4094.4
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
4573÷6154
OPERATING DATA ACCORDING TO UNI 10348
TST 4400 2S
3300÷4400
3432.1÷4619.3
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
5159÷6943
TST 4800 2S
3600÷4800
3744.1÷5039.3
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
5628÷7575
TST 5200 2S
3900÷5200
4056.1÷5459.2
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
6097÷8206
Nominal heat output Thermal output of furnace
Heatefciencyatnominalload(100%) Heatefciencyat30%load Combustionefciency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
TST 5700 2S
4275÷5700
4446,1÷5984,1
96,1÷95,2 96,3÷95,4 96,3÷95,5
0,2÷0,2 3,7÷4,5 0,1÷0,1
75,4÷93,4
9,8÷9,8
6683÷8995
TST 6100 2S
4575÷6100
4758.1÷6404.1
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
7152÷9626
GAS-FIRED
TST 2700 2S
2025÷2700
2106÷2834.6
96.1÷95.2 96.3÷95.4 96.3÷95.5
0.2÷0.2 3.7÷4.5 0.1÷0.1
75.4÷93.4
9.8÷9.8
3166÷4261

17
Installation instructions
3INSTALLATION
INSTRUCTIONS
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
therefore dangerous.
This boiler heats water at a temperature
lower than the atmospheric pressure boiling
temperature.
ATTENTION!
The appliances are designed to be installed
inside suitable rooms or technical spaces
only. The appliances cannot be installed or
operate outdoors. Outdoor installation can
cause malfunctioning and be dangerous.
Choose specifically designed appliances for
outdoor installation.
Before connecting the boiler, have professionally
qualiedpersonnel:
a) Thoroughly wash all the piping of the system
to remove any residue or impurities which
could jeopardise proper operation of the
boiler.
b) Check that boiler is set up to operate with the
available type of fuel.
This can be seen written on the package and
on the technical feature plate.
c) Check that the chimney/flue has an appropriate
draught, without any bottlenecks, and that no
exhausts from other appliances are inserted,
unless the flue has been implemented to
accommodate several utilities according to
specicstandardsandprescriptionsinforce.
Onlyafterthischeckcanthettingbetween
the boiler and chimney/flue be mounted.
ATTENTION!
In rooms with the presence of aggressive
vapours or dust, the appliance must operate
independently from the air inside the
installation 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.
The boiler must be connected to a central heating
system and/or domestic hot water supply network
compatiblewithitsefciencyandoutput.

18
Installation instructions
3.2 - INSTALLATION STANDARDS
The appliance must be installed in compliance with the
instructions provided in this manual.
Itmustbeinstalledbyaprofessionallyqualiedtechnician, who
shall assume the responsibility of respecting all local and/
or national laws published in the official journal, as well as
applicable technical standards.
TRISTAR 2S is a steel boiler which can be combined with air-
blownburnersredbygasofcategoryII2H3+.
Contact the gas supplying company before installing the
appliance.
The following standards, rules and prescriptions must be
observed to perform installation. This list is indicative and not
complete, needing to follow the progress of the "state-of-the-art".
Standard UNI 7129
Design, installation and maintenance of gas systems for
household use supplied by distribution network (NATURAL GAS).
Standard UNI 11137-1
Guidelines for inspection and restoration of the sealing of indoor
systems in operation
Standard UNI 7131
Design,installationandmaintenanceofliqueedpetroleumgas
(LPG) systems for household use not supplied by distribution
network.
Standard UNI 10412 of December 1994.
Hot water heating systems. Safety prescriptions.
FIELD OF APPLICATION: thermal potentials greater than 35
kW (30,000 kcal/h).
LAW March 5,1990 N° 46 and relative applicative regulation
by Italian Presidential Decree 447 of December 6, 1991 (and
subsequentamendments).
Safety standards for systems
FIELD OF APPLICATION: without thermal potential limits.
STANDARD UNI EN 676, November 1998.
Air-blowngas-redburners.
Safety prescriptions.
LAWJanuary9,1990N°10andrelativeapplicativeregulation
by Italian Presidential Decree. 412 of 26 August 1993 (and
subsequent modications), Italian Presidential Decree n°551
of 21.12.1999.
RegulationwithamendmentstoItalianPresidentialDecree.n°
412 concerning design, installation, operation and maintenance
of thermal systems in buildings, in order to reduce energy
consumption.
FIELD OF APPLICATION: without thermal potential limits.
Lawn°186of01.03.1968
Installation standard IEC 64-8 / II ed.
Electric systems using rated voltage no greater than 1000 V AC
and 1500 V DC.
Installation standard IEC 64-8 / II ed.
Electric systems in buildings intended for residential and similar
use.
Approvalart.44CommunityLawof2001''INSTALLATIONOF
HEAT GENERATORS'' suppression of last period comma 10
DPR551/99, (0.4 m² ventilation).
Directives concerning boiler rooms, building regulations and
combustion heating provisions in the country of installation must
also be respected.
The appliance must be installed, commissioned and undergo
maintenance according to the current "state-of-the-art".
This also holds for the hydraulic system, the flue exhaust system
and the installation room.

19
Installation instructions
x = not less than the length of the boiler body
(dimensions in mm); in any case, never less than 1300 mm.
xx = see instructions to the side.
3.4 - POSITIONING IN BOILER ROOM
The boiler must be installed in compliance with standards and
prescriptions in force.
The room must be well ventilated by openings with a total
surface no less than 1/30 the surface of the boiler room, with a
minimum of 0.5 m².
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 circuits,
electric energy supply and lighting must comply with current legal
provisions in relation to the type of fuel used.
It is recommended to install the boiler as close to the chimney
connection as possible.
To make it easier to clean the smoke circuit, in front of the boiler,
there must be a free space no less than the length of the boiler
body and, in any case, never less than 1300 mm. Check that
withthedooropened90°,thedistancebetweenthedoorand
the adjacent wall is at least the length of the burner.
Theboilercanbeplaceddirectlyontheoorasitisequipped
with a base.
However it is useful to provide a flat, level cement plinth capable
of bearing the weight of the boiler full of water.
When positioned on the plinth, the dimensions must be at least
Q x R (see dimensions table).
When installation has been performed, the boiler must be
perfectly horizontal and stable (to reduce vibrations and noise). fig. 20
3.3 - HANDLING
The boiler can be handled easily, lifting it by means
of upper hook/s or shifting it on rollers underneath
the sturdy base longerons.
1000
X
XX
XX
600
600
3.5 - BURNER
The burners operating with the TRISTAR 3G 2S boilers must
havetheECcerticationandcomplywith:
- Gas appliance directive (90/396/EEC);
- EMC Directive - Electromagnetic Compatibility (89/336/EEC).
Theymustalsobeapprovedaccordingtothespecications:
- UNI EN 676 - air-blown burners for gaseous fuel.
- EfciencyDirective(92/42EEC).
3.5.1 - Choosing the burner
The correct choice and adjustment of the burner are fundamental
for optimal operation of the boiler and therefore must be done
carefully and not underestimated.
The burner must be chosen verifying that its ring rate (fuel
capacity - combustion chamber pressure) is compatible with the
same features declared for the boiler.
Remember that pressure drops on the flue side of the boiler,
namely combustion chamber backpressure, refer to zero
pressure at the base of the chimney.
It is also recommended that the burner blast tube be no shorter
than the minimum dimension shown in the following table and
that the flame which must be implemented be suitable for the
characteristics of the combustion chamber.
In order to take advantage of the whole heat exchange surface
of the blind bottom furnaces, use burners capable of providing
a "long and narrow" flame in any operating condition, namely
even at the minimum output when controlling two or more stages
or modulating.
Flames which are too short cause overheating in the front of
thefurnaceandcombustionproducts,notsufciently cooled,
entering the smoke pipes at too high temperatures can seriously
damage the generator.
If necessary for clearance purposes, the door and the smoke
chamber can be removed to make it easier to enter the boiler
room.

20
Installation instructions
The manufacturing companies of the burners can supply the
dimensions of the flames which their appliances develop,
especially those approved based on the standards indicated
above.
Further information is provided in the chapter “Commissioning”.
BOILER TYPE øA
mm
L
mm
fig. 21
TST 2000÷2350 2S 380 350
TST 1400÷1650 2S 320 320
TST 1000÷1180 2S 320 300
TST 680÷870 2S 270 270
TST 300÷560 2S 220 250
TST 80 2S 130 150
DIMENSIONS OF BURNER BLAST TUBE
TST 2700 2S 380 400
TST 3100÷3500 2S 400 400
3.6 - CONNECTING FLAME CONTROL
WARNING LIGHT TO BURNER
The flame control warning light is provided with a 1/8" threaded
connection (pos. 1) upon which a 9 mm pressure test nipple
is mounted. It can be used with a silicon tube to measure the
counter pressure in the combustion chamber.
In place of this test nipple, which must be kept, an appropriate
ttingwillbemountedtoconnecttheamecontrolwarninglight
directly to the pressure chamber downstream the burner fan by
means of a copper tube.
The air blown by the fan will conveniently cool the warning light
glass and keep it from blackening.
If the cooling tube is not connected to the warning light, it could
break.
ATTENTION: the flame control warning light can be very
hot; therefore pay the utmost attention.
fig. 22
3.5.2 - INSTALLING THE BURNER
Before assembling the burner it is necessary to check the position
of the turbulators inside the pipes: each tube must be provided
with its own turbulator and this must be positioned as shown in
the table at page 8.
The burner must be mounted to the door of the boiler
guaranteeing perfect sealing of the combustion products.
The burner is supplied with a piece of ceramic fibre cord which
must be placed on the blast tube of the burner to fully seal
the space between the blast tube and the slot in the door.
Make sure that no gaps remain between the blast tube and the
slot on the refractory material inside the door.
Should a cone larger than the diameter of the blast tube be
mounted, it must be removed before mounting the burner on
the support plate and put back afterwards.
With the burner mounted, check that the flexible hoses of the
liquidfuelandtheelectriccablesarelongenoughtoallowthe
doortoopen90°.
For gas-fired burners, flexible hoses cannot be used for
connections.Therefore it must be equipped with a threaded
or anged joint for disconnecting the nal section of the gas
adduction tube.
2
1
L
Ø A
TST 3900÷5200 2S 500 520
TST 5700÷6100 2S 500 630
TST 120÷250 2S 180 170