Table of Contents
Related Manuals for MHS Boilers AK Series
Summary of Contents for MHS Boilers AK Series
- Page 1 Installation User Guide AK Series Gas Fired Boilers with Atmospheric Burners 81 - 260 kW 3 Juniper West Fenton Way Southfields Business Park Basildon Essex SS15 6SJ Phone 01268 546700 / Fax 01268 888250 www.mhsboilers.com L285 04/09/2006...
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Page 2: Table Of Contents
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS CONTENTS Page 1. INTRODUCTION 2. TECHNICAL INFORMATION 2.1. Efficiencies 2.2. Flue gas temperatures 2.3. Section design 2.4. Safety features 2.5. Burner 2.6. Water side of boiler 3. PREPARATIONS BEFORE ASSEMBLY 3.1. Flue design and chimney installation 3.2. -
Page 3: Introduction
WITH PAGE ATMOSPHERIC BURNERS 1. INTRODUCTION The AK is a cast iron sectional boiler for gas firing with atmospherical burner. AK series are CE marked on product identification number 86/AT/574 to: Gas Appliances Directive (90/396/EEC) Boiler Efficiency Directive (92/42/EEC) Electromagnetic Compatability Directive (89/336/EEC) and conforms the requiremets of EN 656: Gas-fired central heating boilers;... -
Page 4: Technical Information
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 2. TECHNICAL INFORMATION L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION... -
Page 5: Efficiencies
Values given according to average boiler water temperature of 70 C 2.3 SECTION DESIGN The original heat surface design unique to AK series boilers in forms of water drops yield optimum heat transfer rate to boiler water with minimized resistance in flue. -
Page 6: Safety Features
* A standard service box containing ignition sequence controller and a fuse isolator otomate 2.5 BURNER The special design AK series atmospheric burners hold following techincal features: * Stainless steel body * Low CO and NOx emissions without pollutant release in environment. -
Page 7: Preparations Before Assembly
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 3. PREPARATIONS BEFORE ASSEMBLY 3.1. FLUE DESIGN AND CHIMNEY INSTALLATION Boilers must be connected to an independent chimney, using the shortest flue canal possible, starting from flue outlet of draught diverter where there is a flue ring for easy connection, which should be insulated by mineral wool or similar material. -
Page 8: Gas Supply
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 3.2. GAS SUPPLY The installation must be in accordance with relevant standards and mandatory regulasitons. The local gas supply authority should always be contacted at the design state to ensure an adequate supply is available. An existing service pipe must not be used without prior consultation with the local gas supply authority and the supply must be made through a suitable meter. -
Page 9: Boiler Room Arrangement
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 3.4. BOILER ROOM ARRANGEMENT The installation must be arranged in accordance with Mandatory Regulations and Codes of Practice. The following sketch shows the recommended minimum dimensions of clearance around the bolier for servicing and maintenance L285 # As boilers are equipped with a water distribution pipe which is installed from inlet connection through boiler lower waterways, there should be enouh space left as much as relevant boiler width, between boiler inlet and coinciding... - Page 10 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 3.5. WATER CIRCULATION SYSTEM The system design must provide water flow rates commensurate with boiler output and the temperature difference between flow and return should not exceed 20 C, or 25 C at most. Water levels should be checked regularly and any leakages corrected in order to keep system water make-up to a minimum, because excessive make-up will lead to salt deposits forming in the boiler waterways Causing local overheating and damage to the boiler sections.
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Page 12: Safety Of Water Circulation System
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 3.6. SAFETY OF WATER CIRCULATION SYSTEM The system can be built either open vented or pressurized. In case of open vented heating system, an open type expansion tank acoording to DIN 4807 Part 2 shall be installed at the heighest level of hydraulic circuit. Delivery and return lines between expansion tank and boiler shall be constructed in aacordance with DIN 4750. -
Page 13: Assembly Instructions
ATMOSPHERIC BURNERS 4. ASSEMBLY INSTRUCTIONS 4.1. AK SERIES BOILERS DELIVERY MODE 4.1.1. Boiler block: Disassembled boiler sections are delivered attached together on a pallet. 4.1.2. Accessory box: A standard accessory box contains the materials used in the assembly of the boiler block such as nipples, fibre-glass ropes, flow and return connections, gas pipes, service panel, controy panel, retarders, gas valve and its accessories. -
Page 14: Assembly Of Boiler Group
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 4.2. ASSEMBLY OF BOILER GROUP Number in paranthesis refer to position numbers in exploded drawing: 1. Start with left or right section (6,2), clean nipple ports and nipples using cloth and parafin. Apply red lead dye onto nipples (3) (Pic.4-2) and place nipples squarely in each nipple port and, using a wooden mallet, lightly tap nipple into port to secure (Pic.4-3). - Page 15 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Picture 4-6. Picture 4-7. 5. After assembly of all sections, apply compression tools for the last time, and before loosing them, fit upper and lower staybolts (7) using M12 nuts and A13 washers (9,8). After fitting all the staybolts, leave whole free length towards to one side of the boiler (Pic 4-7).
- Page 17 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 8. Fit blank flanges (17) on right or left section other than that of water inlet and outlet connections are carried, using gaskets (16), M12 nuts and A13 washers (18 and 19). Picture 4-11.
- Page 18 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 11. Fit pilot burner (25) onto pilot burner cover (22), and fit this group on boiler gas inlet side after placing pilot burner insulation (21). Secure pilot burner cover to side section of boiler by 2 pieces of M5x15 sectscrews (24) and A5.3 washers (23) as shown in Pic 4-16.
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Page 19: Assembly Of Boiler Insulation And Casing Group
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 4.3. ASSEMBLY OF BOILER INSULATION AND CASING GROUP 1. Place M12x25 sectscrews (32) routing from fire chamber towards to left and right hand sides. Fit side casing support profiles (33) to items 32 via M12 nuts (19) and A13 washers (18) as shown in Pic 4-22. - Page 20 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 6. Place top casing front (93) and rear (90) parts on side casings as shown in Pic 4-27. Place front casing upper (98) and lower (97) parts having finished the installation of gas train. Picture 4-27.
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Page 21: Assembly Of Gas Train
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 4.4. ASSEMBLY OF GAS TRAIN Gas inlet to gas manifold can either be arranged on left on rght hand side. Here, the only regulation is to place gas inlet on the opposite side to that of the return water connection. 1. -
Page 22: Assembly Of Gas Valve Multiblock
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 4.5. ASSEMBLY OF GAS VALVE MULTIBLOCK 1. Fif gas valve multiblock (75) considering the gas flow direction so that the outlet of gas valve corresponds to flange with test nipple (74). 2. Fit a reducer nipple from G 1/4" to G 1/8" into the port signed "Pa" on gas valve. Use existing gasket of standard tapping during assembly of reducer nipple (80, 81). -
Page 23: Electrical Installation
(Diagram 4-1) is refferred. This diagram contains all electrical wiring scheme of AK series boilers. During electrical installation of boiler system, followings must be taken into consideration together with wiring scheme: 1. - Page 24 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Diagram 4-1. Electrical installation and wiring scheme of AK boiler. L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
- Page 25 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 5. Pass capillary tubes of boiler first stage, boiler second stage, safety thermostat, thermometer, and mixing water sensor (in case of P3 is used) from control panel, through spiral hose clamp in order to bring down first four to pocket on left or right hand section (whichever the water inlet and outlet side is) , and the lat one for P3 to special pocket on the same section.
- Page 26 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 11. Route ignition electrode cable with black end sleeve (dia. 7 mm), which is connected to screwed terminal of ignition transformer for producing high voltage, through a PG 11 type cable gland of service panel. Fix this cable onto M4 screw on iginition electrode by slightly pushing.
- Page 27 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Diagram 4-2. Wiring scheme between AK boiler service panel and P2 control panel L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
- Page 28 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Diagram 4-3. Wiring scheme between AK boiler service panel and P3 control panel L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
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Page 29: Operation
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 5. OPERATION Before operation and adjustments of boiler gas train accessories, ensure that all mechanical, electrical, and hydraulic installations are completed and checked, and comply with relevant standards, mandatory regulations and instructions provided with this manual. Check that chimney conditions and sealing is appropriate and comply with local regulations. -
Page 30: Minimum Pressure Switch Setting
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Following should be taken into consideration prior to setting of gas valve multiblock: 1. Pilot burner ventile shall be connected to port 14 on the right side of valve or equivalent port on opposite side. 2. -
Page 31: Rapid Stroke Adjustment
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Turn the main gas supply valve on, and ensure thet the minimum required gas pressure at the inlet of gas train is reached. Set the button on V-otomate on boiler service panel, and power the boiler system. Power the circulation pump of heating circuit, and ensure water is circulating within the delivery system. - Page 32 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 4.7. CONTROL PANELS P2 is the standard panel of the boiler and suitable for two stage burners. Boiler thermostats can be adjusted between 30 and 90 °C, safety thermostat is set to 110 °C. In the case of P3 economy panel usage, refer to "P3 operating manual".
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Page 33: Pressure Drop Diagram Of Gas Valve Multiblocks
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS We recommend a smooth start without explosion in combustion room. That is why, having completed 1st and 2nd stage pressure settings of burner, turn the 2nd stage thermostat knob on control panel down to operate the boiler in 1st stage. Adjust rapid stroke, and, ensure that a smooth initial is established, by starting and stopping burner continuously on 1st stage thermostat of control panel. - Page 34 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS L285 The correction factors for other gas types used, refer to following information: × used where; Gas type density (kg/m3) Natural gas 1.24 0.81 0.65 City gas 1.45 0.58 0.47 0.77 2.08 1.67 1.00 1.24...
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Page 35: Gas Valve Multiblock Operational Sequence
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 5.6. GAS VALVE MULTIBLOCK OPERATIONAL SEQUENCE Heat demand, start signal Inlet pressure is reached, chinmey sensor is off, and no failure in system Safety and pilot burner valve swithced on, regulation will start Ignition transformer Flame on pilot burner sparks... -
Page 36: Maintenance And Cleaning
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 6. MAINTENANCE AND CLEANING 6.1. PERIODIC INSPECTIONS The periodic inspections throughout boiler operating life should be provided for better and high efficient performance of boiler. Following inspections must be carried out: 1. Inspection of control accesories (thermostats etc..) 2. -
Page 37: Troubleshooting
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 7. TROUBLESHOOTING Pilot burner does not ignite L285 Main burner does not ignite PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION... - Page 38 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS Main burner occasionally stops Small flame length Yellow flames detected L285 # Boiling at low temperatures High flue gas temperature Low outlet temperatures PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
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Page 39: Exploded Drawings
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 8. EXPLODED DRAWINGS - GENERAL L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION... - Page 40 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 8.1. EXPLODED DRAWINGS - BOILER GROUP DETAIL L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
- Page 41 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 8.2. EXPLODED DRAWINGS - PILOT AND MULTIBLOCK DETAIL L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
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Page 42: Spare Parts List
UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS 9. SPARE PARTS LIST L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION... - Page 43 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
- Page 44 UGM-AK-03/04 GAS FIRED BOILERS WITH PAGE ATMOSPHERIC BURNERS L285 PREPARED BY DOCUMENT TYPE VALIDITY DATE END OF VALIDITY REVISION Murat GEDİK TECHNICAL INFORMATION...
- Page 45 Form Nr. : 2.009 F 14 R2 BOILER ASSEMBLY CERTIFICATE MODEL BOILER GROUP NR.1 RATED OUTPUT BOILER GROUP NR.2 FUEL TYPE DATE OF MANUFACTURE SERIAL NR. CONTACT PERSON : ADDRESS TELEPHONE COMPANY NAME ADDRESS TELEPHONE COMPANY NAME ADDRESS TELEPHONE L285 Assembled ....
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