TERSEC TERSEC DUO /05 rev.0. INSTALLATION, USE AND SERVICING INSTRUCTION (to be kept by the user)

Transcription

1 TRS TRS DUO 886-0/0 rev.0 INSTALLATION, US AND SRVIING INSTRUTION (to be kept by the user)

2 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// (regarding pressure equipment) and beeing, furthermore, mentioned in the Directive 90/96/ (Gas Appliance Directive) to which the art., clause, paragraph 6. makes reference, it is excluded from the scope of the Directive. GNRAL INFORMATIONS Introduction This manual supplies a suary of what has to be followed during the installation, use and servicing of the UNIAL boilers, TRS range. In the course of this text the short name TRS can be used to indicate the TRS boiler. hoice of the boiler For a correct choice and application of the TRS 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, coissioned 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: urrent Building Regulations and lean Air Act. Water Authority Regulations. Local Authority Regulations and Regional Bylaws. Gas Safety Regulations. Any special regional requirements of local lectricity and Gas undertaking. Fire Service and Insurance ompany requirements. oissioning The main purpose of the coissioning is to verify the correct operation of all the safety and control devices. Before leaving the installation the coissioner 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 UNIAL boilers, TRS range, have been tested and certified for the gas operation according to the following directives: - Gas Appliances Directive (90/96 ), compulsory as per st January 996; - fficiency Directive (9/4 ), compulsory as per st January 998; - The conformity to the Low Voltage Directive (7/ ), compulsory as per st January 997 has been verified and ascertained by GAST ITALIA. The conformity to the M (lectro Magnetic ompatibility 89/6 ), compulsory as per st January 996, is not applicable to the TRS boilers because they do not have electronic components. For the time beeing there are no uropean Directives covering the oil fired boilers, except the fficiency Directive (9/4 ). 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.

3 ONSTRUTIONAL-DIMNSIONAL THNIAL HARATRISTIS... page. onstruction of the TRS boilers... page. Working principle... page. Dimensions and hydraulic connections... page INSTALLATION... page. Packaging... page. Handling... page. Positioning in the boiler house... page.4 onnection to the chimney... page 4. Water connections... page 4.. Water supply... page 4.. Feeding water quality... page 4...H. flow and return connections... page 4..4 onnection of filling and drain tap... page 4.. onnection of the pressure relief valve, expansion pipe and vessel... page 4..6 Shunt pump... page.6 Furnace door: adjustment, opening & closing... page.6. Important note... page.7 Burner... page 6.7. Mounting of the two-stage or modulating burners... page 6.8 onnection of the sightglass to the burner via a cooling line.. page 6.9 asing assembly... page 7 STANDARD PANL BOARD... page 8. Functions descriptions... page 8. lectrical supply... page 8 OPTIONAL PANL BOARD (WITH OUTR OMPNSATOR)... page 9 4. Functions description... page 9 4. Panel board with outer compensator (on request)... page 0 4. lectrical and hydraulic connections of.h.... page 4.4 lectrical and hydraulic connections of.h. and D.H.W. production circuit... page 4. Outer compensator... page STANDARD PANL BOARD FOR TRS DUO... page 4. Functions description... page 4. lectrical wiring diagram for single phase burner and pump.. page PANL BOARD FOR TRS DUO (OPTIONAL) (WITH OUTR OMPNSATOR)... page 6 6. Introduction... page 6 6. Panel board with outer compensator (optional)... page 6 6. lectrical and hydraulic connections of.h. and D.H.W. production circuit... page 8 OMMISSIONING AND OPRATION... page 9 7. Preliminary check... page 9 7. First coissioning... page 9 7. Switch OFF of the boiler... page 9 MAINTNAN... page General rules... page Ordinary maintenance... page xtraordinary maintenance... page leaning of the boiler... page 4 8. heck of the boiler operation... page heck of the burner operation... page Boiler house... page 4

4 GAS SAFTY (INSTALLATION AND US) RGULATIONS, 994 It is law that all gas appliances are installed and serviced by a ORGI 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... 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 recoendations are contained in the following British Standard odes of Practice: BS 689 Low pressure installation pipes. BS 449 Forced circulation hot water systems. BS 46 Installation of gas hot water supplies for domestic purposes (nd Family Gases). BS 6644 Ventilation (for gas appliances of rated input exceeding 60 kw). HALTH & SAFTY DOUMNT No. 6 The lectricity at Work Regulations, 989. The manufacturer's notes must NOT be taken, in any way, as overriding statutory obligations. IMPORTANT. These appliances are 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 recoended by Unical in writing. If in doubt please inquire. Notes. To obtain the gas consumption: a. For l/s divide the gross heat input (kw) by.v. of the gas (MJ/m³). b. For ft³/h divide the gross heat input (Btu/h) by.v. of the gas (Btu/ft³). Any direct connection of a control device not approved by Unical could invalidate the certification and the normal appliance warranty. 4

5 ONSTRUTIONAL-DIMNSIONAL THNIAL HARATRISTIS. - ONSTRUTION OF TH TRS BOILRS The TRS (short name: TRS), three pass boilers, are of horizontal type (oval hape from model 6 to 0 and the model 800; eight shape from model 40 to 600 and cylindrical shape from model 000 to 00) 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 TRS boilers (three pass boiler) and the innovative exchange surfaces (pipes at controlled heat exchange) allow to use these boilers as sliding temperature and Low NOx boilers. In the models TRS 6 and TRS 90 the flow and return connections are place on back side; in the remaining models, on the contrary, they are placed on the upper part. The sheet metal parts of the pressure vessel are manufactured of certified carbon steel, type SJRG, according to N 00, with melting certificate..b, according N 004; where as the pipes are of steel ST 7.0 according to DIN 66. The welders and the WPS (Welding Procedures Specifications) have been approved according to N 87 and N 88 by TÜV (D). These boilers and production facilities have been also approved by - ISIR (RO), UDT (PL) and GOSGORTKHNAZDOR (RU). The boilers are equipped with a reversible fig. 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 80 (00 for models TRS 40 & TRS 600), protected by a textile in mineral fiber. The upper part of the outer shell is equipped with uplift hook(s).. - WORKING PRINIPL 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. UNIAL, to reduce the NOx formation on the TRS 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 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 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 . - DIMNSIONS AND HYDRAULI ONNTIONS TRS 6 90 Panel board Flame sight glass Smoke chamber cleaning door T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. fig. TRS Type Output min/max kw Input min/max kw Boiler water content l Water side pressure drop(*) m w.c. Smoke side pressure drop w.c. Maximum boiler working pressure bar Weight kg T T ISO 7/ T ISO 7/ T4 ISO 7/ T Øi Øi TRS 6 TRS , 7, 76 98,4 88 0,04 0,06 0,0 0,07 4 6, 7, 6 98 Rp½" Rp½" Rp Rp Rp¾" Rp¾" TRS Type TRS 6 TRS 90 A B D F 4 4 G DIMNSIONS H 8 8 I 0 0 L M 8 M 8 M N O P R S (*) Hydraulic resistance for delta T K. DTAIL FOR DOOR DRILLING TRS 6-90 Fiber wool eramic fiber n 4x M8 at 4 on ø 70 ø ø 0 I A F B O D n 4 "L" T T T T T I T T P H H G T T4 T T4 N R S M ONNTIONS fig. 6

7 I TRS 0 0 D A I n 4 "L" M T F N T O T B P T T T-T-T H Panel board Flame sight glass Smoke chamber cleaning door T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. fig. 4 TRS Type Output min/max kw Input min/max kw Boiler water content l Water side pressure drop(*) m w.c. Smoke side pressure drop w.c. Maximum boiler working pressure bar Weight kg T T UNI 78 PN6 T ISO 7/ T4 ISO 7/ T Øi Øi TRS 0 TRS 0 TRS 80 TRS 40 TRS 00 TRS ,6 6, , ,06 0,08 0,08 0,0 0, 0, 0,4 0, 0,4 0, 0, 0,0 6, 7 9, DN 0 DN 0 DN 6 DN 6 DN 80 DN 80 Rp¼ Rp¼" Rp½ Rp½" Rp Rp" Rp¾" Rp¾" Rp¾" Rp¾" Rp¾" Rp¾" TRS Type TRS 0 TRS 0 TRS 80 TRS 40 TRS 00 TRS 0 A B D F G DIMNSIONS H I L M 8 M 8 M 0 M 0 M 0 M 0 M N 7 7 O P R S (*) Hydraulic resistance for delta T K. DTAIL FOR DOOR DRILLING TRS 0-0 Fiber wool eramic fiber DTAIL FOR DOOR DRILLING TRS 80-0 Blind burner plate 0x0 Burner plate insulation gasket 0x0 Fiber wool eramic fiber n 4x M8 at 4 on ø 70 ø ø 0 ø 80 ø 0 G H T4 T4 R S ONNTIONS 9 fig. 9 fig. 6 7

8 TRS D A M F N T O T P B T T-T-T T T G Panel board Flame sight glass Smoke chamber cleaning door T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. fig. 7 TRS Type Output min/max kw Input min/max kw Boiler water content l Water side pressure drop(*) m w.c. Smoke side pressure drop w.c. Maximum boiler working pressure bar Weight kg T T UNI 78 PN6 T UNI 78 PN6 T4 ISO 7/ T Øi Øi TRS 40 TRS ,6 0,44 0, 0, DN 00 DN 00 DN 6 DN 6 Rp¼" Rp¼" TRS DIMNSIONS Type TRS 40 TRS 600 A B D F G H 0 0 M 7 7 N O 4 60 P R S (*) Hydraulic resistance for delta T K. DTAIL FOR DOOR DRILLING TRS Blind burner plate 80x80 Burner plate insulation gasket 80x80 Fiber wool eramic fiber ø 0 ø 00 H H T4 T4 R S ONNTIONS fig. 8 8

9 TRS 800 A F N T O T B P T T-T-T D T T Panel board Flame sight glass Smoke chamber cleaning door T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. fig. 9 TRS Type Output min/max kw Input min/max kw Boiler water content l Water side pressure drop(*) m w.c. Smoke side pressure drop w.c. Maximum boiler working pressure bar Weight kg T T UNI 78 PN6 T UNI 78 PN6 T4 ISO 7/ T Øi Øi TRS ,7 90 0,6 0, DN 00 DN 6 Rp" 0 70 TRS Type TRS 800 A B D F DIMNSIONS G H M N O P R 00 S 04 (*) Hydraulic resistance for delta T K. DTAIL FOR DOOR DRILLING TRS 800 Blind burner plate 0x0 Burner plate insulation gasket 0x0 Refractory cement eramic fiber ø 70 ø 70 G H H M T4 T4 R S 0 ONNTIONS 0 fig. 0 9

10 TRS A F N T O B T P T T-T-T T T DTAIL FOR DOOR DRILLING TRS Blind burner plate 0x0 Burner plate insulation gasket 0x0 Refractory cement eramic fiber ø 70 ø 70 H G H M D T4 T4 R S 7 Panel board Flame sight glass Smoke chamber cleaning door T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. fig. TRS Type Output min/max kw Input min/max kw Boiler water content l Water side pressure drop(*) m w.c. Smoke side pressure drop w.c. Maximum boiler working pressure bar Weight kg T T UNI 78 PN6 T UNI 78 PN6 ONNTIONS T4 ISO 7/ T Øi Øi TRS 000 TRS ,7 80 0,6 0,4 0, 0, DN 0 DN 0 DN 80 DN 80 Rp½" Rp½" TRS Type TRS 000 TRS 00 A B D F DIMNSIONS G H 0 0 M N 6 6 O P 0 0 R S (*) Hydraulic resistance for delta T K. 80 fig. 0

11 TRS DUO A W F T T Z B T M T T4 fig. TRS DUO A W F Z B T T T M T T4 fig. 4 T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. TRS DUO Ass.y formed by Output min/max Input min/max Boiler water content Water side pressure drop(*) Smoke side pressure drop Maximum boiler working pressure A DIMNSIONS B W Z Type n kw kw l m w.c. w.c. bar 60 TRS , 0, TRS , ,4 0,, TRS ,4 0, TRS , 0, TRS ,6 0, TRS , 0, Note: For the dimensions,, F, M, see the previous tables related to the different models. (*) Hydraulic resistance for delta T K.

12 TRS DUO A W F Z B T T T T M T4 fig. T.H. flow T.H. return T xpansion vessel connection T4 Boiler drain T Flue connection Max. burner blast tube dia. TRS DUO Ass.y formed by Output min/max Input min/max Boiler water content Water side pressure drop(*) Smoke side pressure drop Maximum boiler working pressure A DIMNSIONS B W Z Type n kw kw l m w.c. w.c. bar 600 TRS ,4 80 0,6 0, TRS 000 TRS , ,6 0,4 0, 0, Note: For the dimensions,, F, M, see theprevious tables related to the different models. (*) Hydraulic resistance for delta T K.

13 INSTALLATION. - PAKAGING The TRS boilers are supplied complete with door and smoke chamber already fitted, whilst the casing with the insulation matress are contained in separate cardboard packaging(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 R & 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 7. 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 oval brush for the cleaning of the smoke pipes; - cleaning brush handle extension; - the turbulator introducer (as per model TRS 80 and on). - turbulators extractor (see page 9); - ceramic fiber rope for the insulation between the door and burner blast tube; - the contact springs for the bulbs of the protection and control devices.. - 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.. - POSITIONING IN TH BOILR HOUS The installation of the boiler must be in accordance with the relevant requirements of the Gas Safety Regulations, current I... 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 odes of Practice and building regulations. The boiler house must be ventilated through permanent openings having a total surface not lower than /0 th of the floor area of the boiler house, with a minimum of 0. m. Ventilation by grilles counicating 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 for 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 recoended. 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 R x 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. XX X x = Not shorter than the boiler body xx = Sufficient to allow accessibility to all the regulation, safety and control devices. Once the installation has been made the boiler must result perfectly horizontal and well stable (to avoid vibrations and noise). XX XX fig. 6

14 .4 - ONNTION TO TH HIMNY The chimney has a foundamental importance for the good operation of the boiler. Due to the low temperature of the smokes during the intermittent operation, it is necessary that the chimney is perfectly impermeable to the condensate of the combustion products and manufactured with corrosion resistant materials. The different connections must be sealed with an approved boiler putty so that the inlet of fresh air, with consequent increase of the possibility of condensate formation, is avoided. Furthermore the possible condensate or rain water coing from the chimney must be avoided from entering the smoke chamber of the boiler. As far as the cross section and the high of the chimney is concerned, it is necessary to make reference to the local and national rules in force. In the flue pipe, between the boiler and the chimney, convenient sampling points for smoke temperature and combustion products analysis must be provided.. - WATR ONNTIONS.. - WATR SUPPLY The boiler components fed with water are normally connected to the water mains through a PRV. Ascertain that the hydraulic pressure measured downstream the PRV is not higher than the Maximum Allowed Working Pressure of the boiler (see boiler data plate). Because during the operation of the boiler the pressure of the water contained in the.h. system increases, ascertain that this value does not exceed the a.m. MAWP of the boiler. Make sure the drain of the safety valve has been connected to a discharge hopper; if not connected to a discharge hopper, the safety valve can flood the floor of the room in which the boiler is installed. The boiler manufacturer is not responsible for such a damage. Make sure the installation pipes are not used as earthing points for the electrical or telephone installations. In a short time the installation pipes, the boiler and the radiators could suffer serious damages. Once the.h. system, of closed type, has been filled, the filling valve has to be closed and kept in this position. ventual water leaks will be shown by a decrease of the water pressure at the boiler pressure gauge... - FDING WATR QUALITY - The chemical-physical characteristics of the.h. system and reinstatement water are foundamental for the good operation and safety of the boiler. - Among the inconvenients caused by the bad quality of the feeding water the most frequent and serious is the scaling of the heat exchange surfaces. - Less frequent, but also dangerous, is the corrosion of the water side surfaces of all the circuit. - It is well known that the lime, due to its very low thermal conductivity, reduces the heat transfer so that also a scaling of a few millimeters produces very dangerous localized overheating. of lime reduces the heat transfer from metal to water by 0%. It is suggested to make a water treatement in the following cases: A- high hardness of the water available on site (higher than 0 f). B- very large.h. systems. - large quantities of reinstatement water due to water leaks. D- subsequent fillings of the system due to maintenance works. - mixing of different metals in the.h. circuit. For the treatment of filling water it is suggested to address them self to specialized firms. The same firms are able to provide for the descaling of the boilers. very.h. system needs reinstatements of water, due to evaporation, small or large water leaks or for maintenance works. It is, therefor, necessary to be able to evaluate the entity of the reinstatement water to avoid inconvenients due to untreated water. For that reason it is suggested to fit, in the feeding line to the boiler, a water meter for small capacities. For further informations on filling water treatment and characteristics refer to the specific manual supplied with the boiler in the documents envelope... -.H. FLOW AND RTURN ONNTIONS The dimensions of flow and return connections are shown, for each boiler model, in the table DIMNSIONS. Before connecting the boiler to the.h. system, this one has to be throughly cleaned. Make sure in the system there is a sufficient number of air venter. When connecting flow and return pipes avoid to create mechanical stress onto the boiler flanges. The boiler is not made to support the piping of the.h. system, which needs dedicated supports. Once the complete.h. system is finished, check for water leaks all the connections ONNTION OF FILLING AND DRAIN TAP For the filling and drain of the boiler a dedicated tap can be connected to the point T4, which is in rear part of the boiler... - ONNTION OF TH PRSSUR RLIF VALV, XPANSION PIP AND VSSL An expansion vessel is necessary, to compensate the water volume increase due to the heating. The TRS boilers are suitable for fully pumped system, wich can be open vented or sealed. In the st case the height of the hydrostatic column must be, at least, m above the boiler casing and the capacity of the expansion cistern shall be able to contain, between the water surface and the overflow pipe, the volume increase of all the water 4

15 of the.h. system. Preference shall be given to high and narrow cistern, to expose to the air a surface as small possible, thus reducing the water evaporation. In the nd case the vessel capacity has to be calculated taking into consideration: - The total volume of the water contained in the system. - The maximum Working Pressure of the system (see setting of PRV). - The maximum working pressure of the expansion vessel. - The initial preloading of the expansion vessel. - The maximum working temperature of the boiler (the maximum setting of the thermostat fitted onto the panel board is 90 ; under this aspect it is suggested to consider 00 ). The expansion pipe connects the.h. system to the expansion vessel. This pipe which starts from the connecting point T (see table DIMNSIONS), must have NO gate valve on it. Fit onto the point T or onto the supply pipe, within 0. m from the flow flange, a pressure relief valve properly dimensioned for the boiler capacity and in conformity with the local rules in force. It is forbidden to put any gate valve between the boiler and the pressure relief valve. For maximum working pressure of the boiler, see table DIMNSIONS SHUNT PUMP The TRS boilers must be operated under forced water circulation and at a water temperature higher than 0, if operated with oil, or, if operated with natural gas, when the boiler is used in sliding temperature and at part load (see par. 7.) mode. In the.h. systems equipped with mixing valve it is convenient to foresee a shunt pump Pr to guarantee the necessary water circulation through in any possible opening condition of the mixing valve and to guarantee therefore the respect of the minimum return temperature indicated. This pump will be sized according to the following formula: Q = P x where Q = Water flow rate in liter/h P = Boiler nominal output in kw and the manometric head - m w.c..6 - FURNA DOOR: ADJUSTMNT, OPNING & LOSING A special attention has been paied to the design of the front door, because in all the pressurised boilers a good quality of the doors is a necessary condition for the best operation of the boiler. With the furnace working in positive pressure, in fact, every minimum fissure could cause a leakage of high temperature combustion products, with consequent burning of the gasket and overheating of the door up to its permanent deformation. For these reasons the door structure of the TRS boilers, in addition to the fact to be very strong, has also the possibility to be adjusted: it can be lifted, lowered and also slanted, getting, thus, always the perfect centering of the sealing gasket. The special inner lining in ceramic fiber reduces, furthermore, the time to reach the boiler steady state condition and then reduces drastically the formation of condensate at the boiler start. An interesting particularity related to the front door, is the soundness self keeping system, made with elastic steel plates which compensate and reposition the door exactly onto the sealing rope, also in case the ceramic fiber sealing rope becomes hard IMPORTANT NOT Before opening the furnace door it is necessary to adopt the following precautions: - lose the fuel cock (oil or gas) to the burner. - ool down the boiler by keeping the water circulating through it, and only then switch off the power. - Put on the boiler a Warning notice with the following text: DO NOT US, BOILR UNDR SRVI, OUT OF ORDR.

16 .7 - BURNR Because the TRS are of pressurized type boilers, special attention has to be put in the choice of the oil or gas burner. The burners fitted onto these boilers must be approved. Before fitting the burner it is necessary to verify the position of the turbulators inside their smoke pipes. In the TRS boilers the use of burners with long head, according to the table beside, is suggested. The same table indicates the maximum diameter of the burner blast tube which can go through the hole in the front door. The burner working range must be compatible with smoke pressure losses of the boiler: we do not recoend burners working at the limit of their capacities. When fitting the burner onto the boiler door, a perfect sealing between burner flange and door has to be granted to the combustion products. With each boiler, among the accessories, a piece of ceramic fiber sealing rope, to be rolled around the burner blast tube, in order to seal completely the free space, is delivered. No free space has to be left between the burner blast tube and the hole in the ceramic fiber insulation of the door. If a cone, having a diameter larger than the hole in the door is fitted, this cone has to be removed from the burner head before fitting the burner to the door, and repositioned later on. Ascertain the flexible hoses for the fuel and the electrical cables have a length sufficient to allow the door to rotate of at least 90 with BOILR TYP TRS 6 0 øa L (min.) 80 TRS TRS TRS TRS the burner fitted. For gas burners it is not allowed to use flexible steel pipes for the rotation of the door: the gas train has to be removed for the boiler door rotation MOUNTING OF TH TWO-STAG OR MODULATING BURNRS The boilers of the TRS range may be equipped with a two-stage or modulating burner, provided the following conditions, in terms of combustion, smoke temperature and boiler temperature are complied with: ) ombustion: - with light oil having a maximum viscosity of, at 0 ): O to %. - with natural gas: O 9 to 0%. ) Smoke temperature: within 40 and 80 in any working condition. ) Boiler working temperature: max temperature = 8 ; minimum temperature has to be adjusted, through the boiler thermostat, so that the return temperature cannot go below 0 in any working condition. Make sure, then, there is no condensate formation in the smoke pipes or onto the L Ø A fig. 7 BURNR BLAST TUB DIMNSIONS rear tube plate when a two-stage or modulating burner is in operation at its minimum input. Pay attention when building the chimney: it must be perfectly sound, to avoid damages to the walls, due to the smoke condensate, and properly insulated..8 - ONNTION OF TH SIGHTGLASS TO TH BURNR VIA A OOLING LIN The flame sightglass is equipped with a /8" threaded connection (pos. ) on which a pressure test nipple (9 dia.) is fitted. This can be used with a silicon pipe for the measurement of the counterpressure in the combustion chamber. At the place of this pressure test nipple, which must be held, a special microbore pipe (pos. ) will connect the flame sightglass directly to the pressure room downstream the fan of the burner. The air, blown by the fan, will cool down and clean the sightglass. If the sightglass is not cooled down it can be brocken down. WARNING: In the proximity of the sightglass the temperature is very high: be careful!!! fig. 8 6

17 .9 - ASING ASSMBLY N.B. It is suggested to verify that the boiler is positioned in its final place and that all the hydraulic connections are made correctly before starting the casing assembly. Before opening the casing carton(s) make sure they are stamped with the right boiler model, corresponding to the boiler to be installed. N.B.: The packaging containing the panel board is delivered inside the combustion chamber, as well as the documents and the guarantee certificate. The TRS DUO are made of two TRS boilers of the same model. Then, two equal casings and a kit for the connection of the casing and for supporting the control panel are supplied. The packagings containing the flanges, with relevant gaskets and bolts, the cleaning accessories, the ceramic fiber sealing rope and the contact springs for the bulbs, are contained in the relevant furnaces. For the composition and recognition of the casing packagings, see the beside table. BOILR TYP TRS 6 TRS 90 TRS 0 TRS 0 TRS 80 TRS 40 TRS 00 TRS 0 TRS 40 TRS 600 BOILR TYP TRS DUO 60 TRS DUO 480 TRS DUO 600 TRS DUO 700 TRS DUO 900 TRS DUO 00 OMPLT ASING OMPLT ASING 484 (n ) 48 (n ) 486 (n ) 487 (n ) ASING packaging A 4 4 ASING imballo A 4 (n ) 4 (n ) ASING packaging B 4 44 ASING imballo B 4 (n ) 44 (n ) ASING packaging TRS TRS TRS TRS DUO 600 TRS DUO 000 TRS DUO 400 INSULATION PAKAGING 064 (n ) 06 (n ) 06 (n ) 799 (n ) 790 (n ) 69 (n ) 69 (n ) 694 (n ) 69 (n ) 696 (n ) 697 (n ) INSULATION PAKAGING ONNTION KIT Assembly of the casing for TRS 6 & 90 should be carried out in the following steps: Refer to diagram on fig. 9 & 0 for details: A) Fit the insulation blanket () onto the boiler shell and secure it in to place using the elasticated straps () provided, ensuring that the metal clips grip in to the external surface of the insulation. B) Locate the side panels () and (4) with the lower bend inside the bottom L profiles and the upper bend in the seats of front and rear tube plates. To determine which is the left and right panel ensure that the cable clamp plate holes are positioned facing toward the front edge. ) Fit the four screws pos. on the front counter bend. D) Open the combustion chamber door and fit the front insulation (6), inserting the hinges in the pre-cuts. Insert the side ends of the insulation under the bend of the two side panels ( & 4). Note: because the front insulation is suitable for two different boiler ranges, before removing the precut insulation, follow the instructions supplied with the insulation it self. ) Fit the small panel (pos. 7) connecting the two side panels & 4. F) After removal of the two side screws from the panel board rotate its cover towards the front and insert the cables and the capillaries of thermometer and thermostats through the slots on its base. Fit the panel board to front upper panel (8). Fit the upper panel (8), complete with the panel board to the side panels ( & 4). Guide the burner plug through the side cable clamp plate (9) on the preferred side and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates (9) to the casing side panels ( & 4). onnect the burner cable(s) to the panel board according to the wiring diagrams of page 9 and 0. The supply, pump and mixing valve cables must be run towards the back of the boiler. G) Insert the thermometer and thermostat bulbs in the bulb holders as shown in fig. 0 and connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. We recoend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. ). lose the panel board. H) Fit the rear insulation (pos. 0), fix the rear panel (pos. ) with the self tapping screws. I) Fit the cable clamp (pos. ) onto the rear bend of a side panel, pos. or 4. Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (). L) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope. 7

18 TRS fig. 9 TRS Thermometer bulb Working thermostat bulb Minimum thermostat bulb 4 Safety thermostat bulb Bulb retaining clip fig. 0 8

19 Assembly of the casing for TRS 0 / 0 should be carried out in the following steps: Refer to diagram on fig. & for details: A) Fit the insulation blanket () onto the boiler shell and secure it in to place using the elasticated straps () provided, ensuring that the metal clips grip in to the external surface of the insulation. B) Locate the side panels () and (4) with the lower bend inside the bottom L profiles and the upper bend in the seats of front and rear tube plates. To determine which is the left and right panel ensure that the cable clamp plate holes () are positioned facing toward the front edge. ) Open the combustion chamber door and fit the front insulation (), inserting the hinges in the pre-cuts. Insert the side ends of the insulation under the bend of the two side panels ( & 4). Note: because the front insulation is suitable for two different boiler ranges, before removing the precut insulation, follow the instructions supplied with the insulation it self. D) Fit the rear insulation (pos. 6), fix the rear lower, intermediate and upper panels (pos. 7, & 8) with the self tapping screws. Fit the plastic cable clamps (9) to the upper rear panel (8). ) After removal of the two side screws from the panel board rotate its cover towards the front and insert the cables and the capillaries of thermometer and thermostats through the slots on its base. Fit the panel board to front upper panel (0). Fit the upper panel (0), complete with the panel board to the side panels ( & 4). Guide the burner plug through the side cable clamp plate () on the preferred side and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates () to the casing side panels ( & 4). onnect the burner cable(s) to the panel board according to the wiring diagrams of page 9 and 0. The supply, pump and mixing valve cables must be run towards the back of the boiler. F) Insert the thermometer and thermostat bulbs in the bulb holders as shown in fig. and connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. We recoend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. ). lose the panel board. Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (9). G) Fit the longitudinal upper panels (pos. and ) to the side panels. H) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope. TRS fig. 9

20 TRS Thermometer bulb Working thermostat bulb Minimum thermostat bulb 4 Safety thermostat bulb Bulb retaining clip fig. 0 Assembly of the casing for TRS 40 & 600 should be carried out in the following steps: Refer to diagram on fig. & 4 for details: A) Fit to the front and rear tube plates the four upper brackets (pos. ), supporting the side panels, using the screws, washers and nuts supplied (pos., and 4). B) Fit to the front and rear tube plates the four intermediate and lower brackets (pos. ) supporting the side panels, using the screws, washers and nuts supplied (pos., and 4). ) Fit the insulation blanket (6) onto the boiler shell and secure it in to place using the elasticated straps (7) provided, ensuring that the metal clips grip in to the external surface of the insulation. D) Position the side lower panels (pos. 9 and 8) onto the lower and intermediate brackets (pos. ). To determine which one is the left or right hand side panel ensure that the cable clamp plate holes are positioned facing toward the front edge. ) Position the side upper panels (pos. 8 and 7) onto the upper brackets (pos. ) and fix their pivots on the lower side. F) Fit the 8 screws (pos. 0) to the upper part of the front and rear counter bend of the upper panels (pos. 8 and 7). G) Fit the front insulation (pos. ), inserting the hinges in the insulation pre-cuts. WARNING: the door is standard hinged on the L.H. side. For its opening it is necessary to completely remove the four fixing bolts. Note: because the front insulation is suitable for two different boiler ranges, before removing the precut insulation, follow the instructions supplied with the insulation it self. H) Fit the rear insulations (pos. 6 and 7) and fix the rear upper panel (pos. 6). I) Position the panels and 9 between the side upper panels (pos. 8 and 7). L) After removal of the two side screws from the panel board rotate its cover towards the front and insert the cables and the capillaries of thermometer and thermostats through the slots on its base. Fit the panel board to front upper panel (). Fit the upper panel (), complete with the panel board to the side panels (8 & 7). Guide the burner plug through the side cable clamp plate (4) on the preferred side and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates (4) to the casing side panels (9 & 8). onnect the burner cable(s) to the panel board according to the wiring diagrams of page 9 and 0. The supply, pump and mixing valve cables must be run towards the back of the boiler. M) Insert the thermometer and thermostat bulbs in the bulb holders as shown in fig. 4 and connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. We recoend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. ). lose the panel board. N) Fit the plastic cable clamps (0) to the upper rear panel (9). Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (0). O) Fit the longitudinal upper panels (pos. and ) to the side panels. P) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope.

21 TRS fig. TRS Thermometer bulb Working thermostat bulb Minimum thermostat bulb 4 Safety thermostat bulb Bulb retaining clip fig. 4

22 Assembly of the casing for TRS 800 should be carried out in the following steps: Refer to diagram on fig. & 6 for details: A) Fit the insulation blanket () onto the boiler shell and secure it in to place using the elasticated straps () provided, ensuring that the metal clips grip in to the external surface of the insulation. B) Locate the side panels (pos., 4, and 6) hooking them to the upper and lower profiles. To determine which one is the left or right hand side panel ensure that the cable glands are positioned facing toward the front edge. ) Fit the four screws pos. 7 on the inner upper rear side panels. D) Open the combustion chamber door and fit the front insulation (pos.8), inserting the hinges in the insulation pre-cuts. ) After removal of the two side screws from the panel board rotate its cover towards the front and insert the cables and the capillaries of thermometer and thermostats through the slots on its base. Fit the panel board to front upper panel (9). Fit the upper panel (9), complete with the panel board to the side panels ( & ). Guide the burner plug through the side cable clamp plate (4) on the preferred side and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates (4) to the casing side panels ( & ). onnect the burner cable(s) to the panel board according to the wiring diagrams of page 9 and 0. The supply, pump and mixing valve cables must be run towards the back of the boiler. F) Insert the thermometer and thermostat bulbs in the bulb holders as shown in fig. 6 and connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. We recoend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. ). lose the panel board. G) Fit the longitudinal upper panels (pos. 0 and ) to the side panels. H) Fit the rear panel (pos.). I) Fit the plastic cable clamps () to the upper rear panel (). Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (). L) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope. TRS fig.

23 TRS Thermometer bulb Working thermostat bulb Minimum thermostat bulb 4 Safety thermostat bulb Bulb retaining clip fig. 6 Sequence of probes introduction 6 Introduce the bulb into the bulb holder, in the upper part of the boiler body, in the following sequence (Ref. to fig. 7): - (pos. ) thermometer - (pos. ) working thermostat - (pos. ) high limit thermostat - (pos. 4) minimum temperature thermostat. It is recoended to introduce the bulbs up to the bottom of the bulb holder to have a better response. Introduce then the contact spring (pos. 6) to improve the contact and secure the capillaries in position by the clip (pos. ). 4 Thermometer probe Boiler thermostat probe (with knob) Safety thermostat probe 4 Minimum thermostat probe (screwdriver) Probe retaining clip 6 ontact spring fig. 7

24 TRS a b b 4a fig. 8 4 Assembly of the casing for TRS 000 & 00 should be carried out in the following steps: Refer to diagram on fig. 7 & 8 for details: A) Fit the insulation blanket () onto the boiler shell and secure it in to place using the elasticated straps () provided, ensuring that the metal clips grip in to the external surface of the insulation. Make a convenient cut in the upper part of the insulation blanket to get easy access to the bulb holders. B) Position the side panels (a, b and 4a, 4b) with the lower bend inside the bottom L profiles and hook them to the screws fitted to the upper profiles. To determine which one of the front side panels is the left or the right ensure that the cable clamp plates () are positioned facing toward the front edge. ) Open the combustion chamber door and fit the front insulation (pos. 6), inserting the hinges in the insulation pre-cuts. Insert the side ends of the insulation under the bend of the two side panels (a and 4a). D) Fit the rear panel (pos. 7). Fit the plastic cable clamps (8) to the upper rear panel (7). ) After removal of the two side screws from the panel board rotate its cover towards the front and insert the cables and the capillaries of thermometer and thermostats through the slots on its base. Fit the panel board to front upper panel (9). Fit the upper panel (9), complete with the panel board to the side panels (a & 4a). Guide the burner plug through the side cable clamp plate () on the preferred side and clamp the cable using the cable clamp supplied. Fix the side cable clamp plates () to the casing side panels (a & 4a). onnect the burner cable(s) to the panel board according to the wiring diagrams of page 9 and 0. The supply, pump and mixing valve cables must be run towards the back of the boiler. F) Insert the thermometer and thermostat bulbs in the bulb holders as shown in fig. 7 and connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. We recoend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. ). lose the panel board. Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (8). G) Fit the longitudinal upper panels (pos. 0 and ) to the side panels. H) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope.

25 asing mounting sequence for TRS DUO (Ref. figs. 9 & 0) N.B. It is suggested to verify that the boiler is positioned in its final place and that all the hydraulic connections are made correctly before starting the casing assembly. For the composition of the casing packagings according to the boiler model, see point.9. For the correct positioning join the two boiler bodies using the two L bars supplied in the cardboard box of the onnection kit. These L bars will be fitted at both boiler bodies (joining them at the base in the front and rear side and keeping then the right distance for the casing mounting), with the cuts upwards to receive the casing side panels. oncerning the mounting of the casings, make reference to the instructions of fig. for the models TRS DUO 60, 480, 600 & 700; and to the instructions of fig. for the models TRS DUO 900 & 00, replacing only the two panels for the fitting of the panel board, supplied in the two standard casings with the two panels ( Right, Left) which can be found in the packaging of the onnection Kit. oncerning the mounting of the casings, make reference to the instructions of fig. for the model TRS DUO 600 and to the instructions of fig. 8 for the models TRS DUO 000 & TRS DUO 400. Models TRS DUO 60 / TRS DUO 00: replacing the two panels for the fitting of the panel board, supplied in the two standard casings with the two panels ( Right, Left) which can be found in the packaging of the onnection Kit. After removal of the upper panel, fit the panel board to the two upper front panels (Right and Left) by introducing the electrical cables (for the supply, the burners, the pumps, the mixing valves) and the capillaries of the thermostats through the hole on the base of the panel board. Fix the upper front panels to the upper sides panels of the casings of the two boilers. Address the cables of the burners toward the plates fixed on the side panels, in the external sides, and stop them on the plates themselves with a cable clamp type PG, fit the burners plugs (see wiring diagram on pages and 7). The supply, pumps and mixing valve cables, must indifferently be addressed toward the rear part of one of the two boilers and fixed with the dedicated cable clamps. Insert the probes of the thermostats in the bulb holders on the back sides of the boilers (above the smoke chamber) (Ref. fig. 0); the probe of the thermometer (pos.), of the working thermostat (pos. ) and the minimum temperature thermostat (pos. ) must be inserted in the largest bulb holder (ø = ); the probe of the safety thermostat (pos. 4), must be inserted in the smallest bulb holder (ø = 7 ). Pay attention to the identification of the probes: the boiler n is the right one (seen from behind), the boiler n is the left one (seen from behind). We recoend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. ). lose the panel board. Fit the casing upper rear panels. Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope. TRS DUO for models TRS DUO 60/480/600/ for models TRS DUO 900/ for models TRS DUO 00/400 LOWR L BAR JUNTION OF BOILR BODY fig. 9