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Alarko CGS3 Series User Manual

Liquid / gaseous fuel steel boiler
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CGS 2 and CGS 3
LIQUID / GASEOUS FUEL
STEEL BOILER
USER MANUAL

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  • Page 1 CGS 2 and CGS 3 LIQUID / GASEOUS FUEL STEEL BOILER USER MANUAL...
  • Page 2 Code No: A.4.1.8 Book Print Date: 250718 Revision: 250718...
  • Page 3 CGS 2 and CGS 3 LIQUID / GASEOUS FUEL STEEL BOILER Installation, Commissioning, Operation and Maintenance Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction Declaration of Conformity Notices Warranty and Service Operating Conditions Boiler Water Temperature and Room Temperature Settings Main Parts of the Boiler (CGS2) Main Parts of the Boiler (CGS3) Installation Safety Systems Burner Selection Burner Installation Suitable Fuels Flue Gas System Heating System Filling and Feeding Water Features...
  • Page 6 Maintenance and Service Boiler Control Boards Appendices Standard Electrical Diagram Ecopanel 7/21 and 12/311 Electrical Diagram Heating Control Panel SDC Easy Operation Guide Boiler Label Information Technical Specifications Table Burner Selection Table Burner Gas Line Diagram Control and Commissioning Form CGS Steel Boiler Flue Information...

  • Page 7: Introduction

    INTRODUCTION First of all, thank you for choosing the brand, ALARKO. In this manual, you will find the INSTALLATION, OPERATION and MAINTENANCE information on ALARKO's Steel Body Heater Boilers. Please read this guide carefully for highly efficient and economic operation of your device for a long time without any problems.

  • Page 8: Declaration Of Conformity

    DECLARATION OF CONFORMITY Our boilers with a capacity of up to 1,000 kW are manufactured in accordance with the following rules and have the right to bear the CE marking. • EN 303-1 • EN 303-3 • Directive 2009/142/EC on Appliances Burning Gaseous Fuels Our boilers with a capacity of 1,000 kW and above are manufactured in accordance with the following rules and have the right to bear the CE marking.

  • Page 9: Notices

    The design, installation, commissioning and maintenance of the heating system must be carried out by professional personnel trained in this field (by Alarko Carrier Authorized Service), in accordance with this manual and the local rules and applicable standards, regulations, or according to the EEC directives and European norms (EN) in the absence of those specified above.
  • Page 10 It is useful to specify it with a nameplate. When starting up a newly installed system, initial checks and commissioning must be performed by the Alarko Carrier Authorized Service. Maintenance is the responsibility of the user and must be performed by an authorized service.

  • Page 11: Warranty And Service

    If you encounter any problems, you can call the Customer Hotline at 444 0 128 with local call rate from anywhere in Turkey, and you can also reach Alarko Carrier...

  • Page 12: Operating Conditions

    OPERATING CONDITIONS Boilers are designed to produce hot water. They must be installed in a hot water heating system suitable for boiler performance. Standard operating temperature is between 55 and 90 °C (special order is required for temperatures up to 105 °C). Standard operating pressure is 3 bar (special order is required for pressure levels above this).

  • Page 13: Boiler Water Temperature And Room Temperature

    BOILER WATER TEMPERATURE AND ROOM TEMPERATURE SETTINGS Boiler can be operated with Standard Panel or Eco-panel. Temperature Settings of Boilers Operated with Standard Panel: The user cannot adjust the room temperature, can only adjust the temperature of the boiler water. He adjusts the boiler water temperature in the boiler thermostat on the panel.
  • Page 14 Heating curves are the graphs in which the boiler water temperature is determined depending on the desired room temperature and the outside temperature. Outside temperature Room temperature (...
  • Page 15 When the room temperature is changed, the curves move in parallel. In the following example, if the room temperature is desired to be 25 °C or 15 °C, the way of change of the heating curve of 1,5 is indicated by dashed lines. Curve of 1,5 for 25 °C room temperature...

  • Page 16: Main Parts Of The Boiler (Cgs2)

    MAIN PARTS OF THE BOILER CGS2 SERIES BOILERS INTRODUCTION PARTS OF CSG2 BOILERS: 1. Boiler flow flange 9. Front fume cover 2. Boiler return flange 10. Rear fume cupboard 3. Flow safety connection 11. Fume transition pipes 4. Return safety connection 12.

  • Page 17: Main Parts Of The Boiler (Cgs3)

    CGS3 SERIES BOILERS FRONT VIEW SIDE VIEW INTRODUCTION PARTS OF CSG3 BOILERS: 10. Burner connection 1. Boiler flow flange cover 2. Boiler return flange 11. Front fume cover 3. Flow safety connection 12. Rear fume cupboard 4. Return safety connection 13.

  • Page 18: Installation

    EEC directives and European norms (EN) should be applicable. • The control and commissioning of the entire system must be carried out by Alarko Carrier Authorized Services. • The boiler must be installed in a closed area, except for living areas, which are well ventilated and where there is no risk of freezing in accordance with the rules.
  • Page 19 • Install the boilers on a base which is at least 10 cm above the ground, parallel to the ground, non-flammable, with sufficient strength. The base dimensions table is attached. • Boilers should not be installed and put into operation in the environments with flammable gases and materials.
  • Page 20 • After the installation of the heating system, all system equipment connections (water, fuel, flue gas lines, electricity) must be checked for leakage. • CGS2 and CGS3 boilers have a condensate outlet. This outlet must be connected to a suitable conduit via a siphon to prevent liquid gas leakage.» Condensate discharge must comply with applicable regulations.

  • Page 21: Safety Systems

    10K. The limit temperature control thermostat must comply with EN 60730-2-9 and/or bear CE-marking. All Alarko Carrier optional boiler control panels have a manual reset limit thermostat. If the optional control panel is not supplied, this controller must be supplied and installed by the installer.
  • Page 22 For boilers with a capacity more than 300kW; high pressure protection system must have at least 1 pressure limit switch (pressure switch) as well as relief valve. This switch must be tripped before the pressure relief valve and lock the burner and/or the fuel line by disabling them.
  • Page 23 (cannot be closed by anyone other than authorized persons). The closed expansion tank is not included in the equipment supplied with the boiler and the project and assembly units are responsible for the selection and installation of the equipment. Minimum Controllers Required in Systems with Closed Expansion Tank For safe and economic operation of closed expansion systems, the following controllers must be available in the system.
  • Page 24 1 filter, 1 cold water meter and 2 ball valves. There must be a ventilation system suitable for the total boiler capacity in the boiler room in order to be able to expel toxic, explosive gases that may occur in the boiler room and ensure an efficient and low emission combustion.
  • Page 25 The smallest internal diameter of the open safety pipe and the supply and expansion pipes can be calculated as follows: = 15+1.4 b 9 mm (but it cannot be smaller than Safety flow (expansion) pipe: d 19 mm). 9 : It is the boiler's Safety return (supply) pipe: d = 15+1.0 b d nominal heat output in kW.

  • Page 26: Burner Selection

    BURNER SELECTION Boilers must be put into operation with EN 676 (gaseous fuel) or EN 267 (liquid fuel) certified burners to operate in accordance with the directive (92/42/AT) on efficiency requirements for boilers and the directive 2009/142/EC on appliances burning gaseous fuels. When selecting a burner suitable for the boiler;...
  • Page 27 tighten them with nut. The gasket thickness between the adapter plate and the burner cover is 10 mm. The heads of the bolts have 8 mm or less thickness in general. Accordingly, the bolt heads between the plate and the cover will not cause an extra thickness.

  • Page 28: Suitable Fuels

    For all other fuels, contact Alarko Carrier experts. FLUE GAS SYSTEM CGS2 and CGS3 series boilers are B23 type boilers. The flue gases must be used with a flue system with sufficient draught so that there is no gas leakage to the boiler room.

  • Page 29: Heating System Filling And Feeding Water

    BOILER WATER PROPERTIES The properties that should be in boiler water are below. Other parameters not specified in the table must comply with "TS 377-10 EN12953-10, January 2006, TSE, Cylindrical boilers requirements for feeding water and boiler water quality" standard. Parameter Unit Boiler Water...

  • Page 30: Oxygen Corrosion

    OXYGEN CORROSION The presence of oxygen in the boiler water causes corrosion. The oxygen from the first filling water or the next two fillings of water to the boiler generally does not cause much damage. The main damaging factors are below; a) Continuous supply of fresh water to the system b) Using plastic pipes without oxygen barrier c) Using an open expansion tank...

  • Page 31: Commissioning

    COMMISSIONING Installation control and first operation must be carried out by Alarko Carrier Authorized Services and necessary documents must be recorded. Otherwise, the manufacturer and/or the dealer shall not accept any liability for any matter and the product is deemed to be out of warranty.
  • Page 32 Before the boiler is not put into first operation, all heating system components (water and fuel side) must be cleaned from foreign materials and the system should be blown (filled and quickly drained) several times. Make sure that there are no foreign materials . Before starting to fill the system with water, in closed expansion systems, check the closed expansion pre-pressure and make sure it is in accordance with the system requirements.
  • Page 33 Adjust the burner presets. Before starting the burner, make sure that all heating system is filled with water, valve positions, water and fuel side are completely deaerated, and all control and safety element elements in the heating system are correctly pre-adjusted. Start the burner, make the capacity and combustion adjustments.

  • Page 34: Start Up And Stop

    START UP AND STOP For economic and safe use, please read this installation, commissioning, operation and maintenance manual before starting. Improper installation, commissioning, operation and maintenance may result in accidents, fire, or explosion, which could result in injury, loss of property or life. Preliminary checks to be made before operation;...
  • Page 35 Start Up Standard control panel; Turn on the main burner switch (if equipped and in the closed position). Turn on the control panel switch. Adjust the boiler thermostats to the desired level. (If there is a 2nd stage thermostat, set it to 7 °C below the degree of the 1st stage thermostat). Switch on the circulation pump.

  • Page 36: Maintenance And Service

    MAINTENANCE AND SERVICE Do not interfere with any part of the heating system while the system is running. Before starting maintenance, servicing, cleaning, please stop the burner, close the fuel valves, switch off the system's electrical power supply at the main switch and wait until all parts of the boiler cool down.
  • Page 37 Clean the combustion chamber and 2nd transition pipes with a pipe brush. • Open the cleaning cover on the back cover and remove any sooting • from the fume cupboard. Check the front cover refractory. • Check the sealing elements of the front and rear cover combustion •...
  • Page 38 Refer to the burner manual for additional checks. • Reset the burner fault switch up to 3 times and call the authorized service if • there is still no ignition. In closed expansion systems operated with an expansion tank with membrane, the tank gas pressure must be checked regularly by an authorized service.

  • Page 39: Boiler Control Boards

    If the system shuts down for a long time in winter, necessary precautions should be taken against frost. Fuel and water filters must be cleaned periodically according to system requirements. BOILER CONTROL PANELS Standard Panel (PS) Control Panel Fuse (6 Av) Safety Limit Thermostat (100 °C) Boiler Temperature Gauge (30-120°C) Main Control Switch...

  • Page 40: Appendices

    APPENDICES...
  • Page 43 BOILER BASE DIMENSIONS CGS 2 and CGS 3 100-800 BOILERS Model B(mm) C(mm) Model B(mm) C(mm) CGS2-80 CGS3-100 1050 CGS2-100 1050 CGS3-125 1150 CGS2-125 1050 CGS3-150 1300 CGS2-150 1050 CGS3-175 1300 CGS2-200 CGS3-200 1400 1260 CGS2-250 CGS3-250 1450 1260 CGS2-300 1500 CGS3-300 1500...
  • Page 45 Rated Heat Power (kW)
  • Page 46 Rated Heat Power (kW)

  • Page 47: Standard Electrical Diagram

    STANDARD PANEL ELECTRICAL DIAGRAM PHASE ENERGY NEUTRAL ENERGY GROUNDING ENERGY 1ST STAGE THERMOSTAT OUTLET 2ND STAGE THERMOSTAT INLET 2ND STAGE THERMOSTAT OUTLET NEUTRAL RESET INLET RESET OUTLET IL : ON-OFF SWITCH TS : SAFETY THERMOSTAT TC-1 : 1ST STAGE THERMOSTAT TC-2 : 2ND STAGE THERMOSTAT L1 : FAULT LAMP L2 : 1ST STAGE THERMOSTAT RUNNING LAMP L3 : 2ND...

  • Page 48: Ecopanel 7/21 And 12/311 Electrical Diagram

    ECO-PANEL 7/21 AND 12/31 ELECTRICAL DIAGRAM ECO-PANEL EXTERNAL AIR COMPENSATION WITH FIRST AND SECOND STAGE BOILER CONTROL PANEL BURNER AA : ON-OFF SWITCH WF/KF : BOILER SENSOR LT : SAFETY LIMIT THERMOSTAT SF : BOILER SENSOR PL : PUMP LAMP (1ST MIXTURE ZONE) VF1 : MIXTURE CIRCUIT SENSOR (1ST ZONE) AL : LIMIT FAULT LAMP VF2 : MIXTURE CIRCUIT SENSOR (2ND ZONE)

  • Page 49: Guide

    ECO-PANEL 7/21 AND 12/31 EASY OPERATION GUIDE Controller "Manual operation" / "Emission measurement" button (It is not included in remote controlled heating system control panel) "Operating mode" button (Basic indicator) "Time Programs" / "Holiday programs button" "System information" button Display Snap-in cover for service connector "Day room temperature"...
  • Page 50 Flashing indicators on the display In this manual, flashing indicators on the display are shown as follows: Standard Display View Day, date, time, boiler water temperature The cursor on the operating modes indicates the active operating mode which is active at that moment.
  • Page 51 After pressing the button, the boiler tries to reach the maximum temperature value set. The emission measurement time is limited to 20 minutes and must be reactivated if necessary. Cancel: Press the button or wait for the countdown to end. Manual operation press and hold the button for approximately 5 seconds.
  • Page 52 INFORMATION: In operating mode 2, first select the corresponding heating circuit and confirm it by pressing the enter button before setting the day and night room temperatures. Setting the domestic water temperature press the button. Changing the temperature: Setting range: 5 °C to maximum domestic water temperature Application of change:...
  • Page 53 ATTENTION Make corrections only after long evaluation periods and in small steps. Termination (Return to standard screen): press the button. Operating Modes After pressing this button, the following operating modes can be selected with the entry button: 1. Short term program: OUTSIDE Heating when not at home RETURN HOME Stopping the operation for short time.
  • Page 54 Example: Press the Automatic program button and select the option AUTOMATIC. Application of change: When selecting a time adjusted program, the time information such as the return date (HOLIDAY), the return time (OUTSIDE, RETURN HOME) or extended heating operation (PARTY END) can be entered.
  • Page 55 Changing year and date: Application of time: Entering Date: Application of time: System information After pressing this button, all system temperatures and operating states of all system components can be queried respectively using the entry button. Pressing: • System temperatures (Set values) Turning: •...
  • Page 56 INFORMATION: System information appears suitable according to the device model used. Changing Time Programs Entering to the "Time programs" menu press this button. (For more information, see. SDC/DHC User Manual, TR2H-0220) Each setting value flashing on the screen is corrected with the entry button and applied by pressing the entry button.
  • Page 57 Day and heating cycle selection, copying (Block creation) Ayar sırası: Monday 1st Cycle - Monday 2nd Cycle, Tuesday 1st Cycle - Tuesday 2nd Cycle ... Sunday 2nd Cycle, copy to each days (Monday, Sunday), weekday block (1-5), weekend block (6-7), entire week (1—7). INFORMATION: When the second cycle is also completed, a third cycle is available for use.
  • Page 58 6. Cycle temperature for selected heating cycle on selected day Setting range: For heating circuits (DD, KD1, KD2): 5 to 30 °C For domestic water temperature (KSS): 10 to 80 °C (or maximum domestic water temperature) . ATTENTION When the desired daytime room temperature or domestic water temperature is changed using the buttons or all the relevant cycle...

  • Page 59: Boiler Label Information

    BOILER LABEL INFORMATION 1ST BOILERS WITH A CAPACITY OF UP TO 1000 KW: www.alarko-carrier.com.tr Email: info@alarko-carrier.com.tr İSTANBUL: GOSB-GebzeOrganize Sanayi Bölgesi Ş.Bilgisu Cad. Gebze 41480 KOCAELİ Phone: (0262) 648 6000 Fax: (0262) 648 6101 ANKARA: Sedat Simavi Sok. İZMİR: No:48, Çankaya 06550 ANKARA Phone: (0312) 409 5200 Fax:(0312) 440 7930 Şehit Fethibey Cad.

  • Page 60: Technical Specifications Table

    TECHNICAL TABLES-1. BOILERS WITH A CAPACITY OF UP TO 1000...

  • Page 62: Burner Selection Table

    BURNER SELECTION FOR STEEL BOILERS TABLE -260713 1. BOILERS WITH A CAPACITY OF UP TO 1000 KW:...
  • Page 63 BURNER SELECTION TABLE FOR STEEL BOILERS-260713...
  • Page 64 1ST BOILERS WITH A CAPACITY OF 1000 KW OR ABOVE: Boiler Natural Gas Burner Diesel Fuel Oil Burner Burner 21 mbar 300 mbar Output Flange Flange Flange Flange Flange Type Power Stage Stage Modulating Modulating Modulating Diamet Diame Diame Diame Diame (kW) (mm)

  • Page 65: Burner Gas Line Diagram

    GAS LINE The required and optional elements for the use of the gas line in the burners are shown below. Sectional Gas Line (2-Stage) Multi-block Gas Line (2-Stage) MB - ZRDLE or MBC1200 VEF 1ST Ball Valve 9. Multi-block Valve 2ND Flexible Coupling (Optional) 10.

  • Page 66: Control And Commissioning Form

    LIQUID OR GASEOUS FUEL BOILER CONTROL AND COMMISSIONING FORM Customer name, address Phone and fax number Authorized dealer Authorized dealer name phone/fax Installer company Installer company phone Authorized service Authorized service phone/fax Product model and type Product serial no Invoice date Invoice no Suitable for gas, certificate Warranty certificate no...

  • Page 67: Cgs Steel Boiler Flue Information

    CGS STEEL BOILER FLUE INFORMATION CO2 Amount Rated Thermal Pressure Ignition Thermal Waste Gas Flow Waste Gas Flue Outlet Power / Rated Required Power / Rated (g/sec) Temperature Diameter (mm) (°C) Capacity (kW) to be in Thermal Load Flue (kW) (mbar) Full Partial...
  • Page 68 : Ziyapaşa Bulvarı Çelik Ap. No : 25/5-6, 01130 ADANA Phone: (0322) 457 62 ADANA 23 - Fax: (0322) 453 05 84 : Mehmetçik Mahallesi Aspendos Bulvarı No: 79/5 - ANTALYA Phone: (0242) ANTALYA web: www.alarko-carrier.com.tr 322 00 29 - Fax: (0242) 322 87 66 MDH : 444 0 128 e-mail: info@alarko-carrier.com.tr...

This manual is also suitable for:

Cgs2 seriesCgs2-125Cgs2-80Cgs2-100Cgs2-250Cgs2-150 ... Show all

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