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Table of Contents
Summary of Contents for CALOR ACK2 Series
- Page 1 Distribuitor: CALOR SRL Str. Progresului nr. 30-40, sector 5, Bucuresti tel: 021.411.44.44, fax: 021.411.36.14 www.calorserv.ro - www.calor.ro ACK2 OIL/GAS FIRED HOT WATER BOILERS ACK2-80 ..ACK2-3000 INSTALLATION, AND COMMISIONING MANUAL Rev B : Feb.2005 05 001 GB...
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Page 2: Table Of Contents
INDEX 1 INTRODUCTION ……………………………………………………… 2 WARNINGS …..……………………………….…………………….…. 3 DECLARATION OF CONFORMITY …………………………..……. 4 GUARANTEE AND SERVICE ………………………………………. 5 GENERAL SPECIFICATIONS ……………………………………… 6 OPERATING PRINCIPLES …………………………………………. 7 MAIN PARTS ………………………………………………………….. 8 INSTALLATION ……………………………………………………….. 8.1 SAFETY ARRANGEMENTS ……………………………………. 8.1.1 MINIMUM SAFETY EQUIPMENT REQUIRED FOR SEALED SYTEMS ………………….. -
Page 3: Introduction
1 INTRODUCTION This manual comprises the information concerning the Installation, operation, use and maintenance of ACK2 hot water boilers. This manual alone is not sufficient for correct installation, operation and use, installers, services and user must obey the rules specified in current EN + local norms, EC directives and local codes. This manual gives supplementary information and precautions. - Page 4 Boilers must not be installed in areas where inflammable vapors and materials are likely to e present. To avoid damage to the boilers, contamination of the combustion air by high levels of dust or halogenated hydrocarbons (e.g. Solvents, spray can propellants, cleaning agents, adhesives, etc.) must be avoided.
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Page 5: Declaration Of Conformity
3 DECLARATION OF CONFORMITY We hereby make the fallowing declaration with regard to the appliance trademark ACK2, models ACK2-80, ACK2-100, ACK2-125, ACK2-150, ACK2-200, ACK2-250, ACK2-300, ACK2-350, ACK2-400, ACK2-500, ACK2-600, ACK2-700, ACK2-800, ACK2-900, ACK2-1000, ACK2-1250, ACK2-1500, ACK2-1750, ACK2- 2000, ACK2-2500, ACK2-3000. That ... -
Page 6: General Specifications
Town gas, LPG) fuels. Please ask your seller for the details of the Local suitable fuels which can be fired in ACK2 series boiler. This boiler must be fired by a compatible burner (CE marked) certified to EN 76 (gas firing) or EN 267 (oil firing) to comply with the Boiler Efficiency Directive 92/42/EEC. -
Page 7: Main Parts
7 MAIN PARTS Combustion chamber. Second pass combustion pipes and turbulators. Main boiler body. Two way hinges. Combustion chamber door insulation. Boiler front door Flame monitoring glass. Boiler insulation. Flue box 10- Functional explosion cover. 11- Supporting feet. 12- Gas/liquid fuel burner. 13- Flue outlet 14- Boiler return 15- Boiler flow... -
Page 8: Installation
8 INSTALLATION The installation of the boilers must be performed according to the current local standards and in addition, instructions stated below; All installation, assembly and maintenance work must be carried out exclusively by fully trained, professionally qualified personnel and must conform with this manual and the local codes and requirements of the authority having jurisdiction, or in the absence of such requirements, apply to the EEC directives and European norms (EN). -
Page 9: Safety Arrangements
All electrical connections must be according to current standards and wiring diagrams are given in this manual. Please pay special attention to earth connections to all electrical items in the boiler room. Never use fuel or water pipes as an earth connection. - Page 10 Protection against exceeding the maximum operating pressure; Each boiler shall be served by at least one safety valve in order to protect the system against exceeding the maximum operating pressure. The safety valve is not a standard supply with the boiler, it must be fitted by the installer on the flow line of the boiler without any isolation valve or similar items and they must confirm prEN 1268-1 with a minimum size of DN 15.They must open at a pressure not exceeding the maximum design pressure of the system and shall be designed to prevent the...
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Page 11: Minimum Safety Equipment Required For Open Vented Sytems
Devices for controlling the operation temperature to adapt the heat supply to the heat demand. The maximum set-point of the temperature controller shall not exceed the maximum operating temperature of the boiler. Pressure maintaining control device to ensure the required minimum operating pressure of the system. -
Page 12: Burner Selection
Operational requirements of open vented systems; In order to maintain a safe and economical operation, open vented heating systems shall be equipped with: Water level indicator Temperature indicator (% 20 higher then the operating temperature and mounted in the flow pipe of the system) Devices for controlling the operation temperature to adapt the heat supply to the heat demand. -
Page 13: Flue Gas Exhaust System
8.4 FLUE GAS EXHAUST SYSTEM. ACK2 boilers are B type appliance so the flue gases must be connected to an adequate draught chimney, without any flue gas leakage to the boiler room. Chimney design must be according to local codes. Chimney inside diameter, height, material, thermal insulation, strength shall be according the flue gas specifications and shall not cause dangerous high pressures. -
Page 14: Start Up
Note :During boiler economic life, the total make up water volume can not be more then 3 times of the total system water. Guarantee will not be valid, if the boiler is out of service because of corrosion, sludge formation and deposits In order to prevent corrosion special care needed for oxygen infusion to the heating system water side. - Page 15 Before firing the burner, be sure that system is full of water and all control items are set to desired value and working properly. Check the fuel pressure, temperature and fuel line leakages before running the burner. Run the burner and adjust it to proper output according to boiler needs. Analyze the flue gas and be sure that emission levels of CO, NO , soot, CO or O...
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Page 16: Anex
10 ANEX - 15 -... - Page 17 3W V Heating system Circulation pump Anti condensate pump Membrane expansion tank 3W V Three way valve High Limit themostat Boiler thermostat Thermometer SPL2 Pressure gauge SPL1 Max. Safety pressure limiter SPL2 Min. Safety pressure limiter Safety valve Flash trap Lockable valve Pressure regulator SPL1...
- Page 18 3W V Heating system Circulation pump By pass pump Open expansion cistern 3W V Three way valve TCL TC High Limit themostat Boiler thermostat Thermometer Water level indicator Lockable valve Valve Pressure regulator BOILER One way valve ARFS Automatic refill system Drain valve ARFS TYPICAL SAFETY EQUIPMENT AND HYDROULIC ARRANGEMENT...
- Page 19 BOILER FEET LENGHT BOILER FEET WIDTH - BOILER FOUNDATION SHALL BE ENOUGH STRENGHT TO CARRY THE BOILER FULL WITH WATER AND ACCESSORIES - BOILER FOUNDATION SHALL BE FROM NON CONBUSTIBLE METERIALS - BOILER FOUNDATION SURFACE SHALL BE LEVEL AND SMOOTH - BOILER FOUNDATION...
- Page 20 L+600 A : Burner lenght. B : 600 mm minimum. W : A + 200 mm minimum. D : L/2 + 500 (min 600 mm) L : Lenght of boiler. H : Height of the boiler room must be minimum 1000 mm heigher then the boiler height.
- Page 21 FOR CIRCULAR CROSS SECTION (SCHIEDEL) 850 800 3500 3000 2500 2000 1750 1500 1250 1000 Inside diameter EFFECTIVE CHIMNEY HEIGHT (m)
- Page 23 FOR SQUARE CROSS SECTIONS (PLEWA) 55x55 50x50 60x60 70x70 3500 45x45 3000 2500 40x40 2000 35x35 1750 1500 30x30 1250 1000 27.5x27.5 25x25 22.5x22.5 20x20 18x18 Inside dimensions 16x16 14x14...
- Page 24 ACK2 OIL/GAS FIRED HOT WATER BOILERS ALARKO BURNER SELECTION CHART Blast Diameter Diameter Burner Gross Back tube (Boiler) (Burner) Boiler Net Heat Burner type exploitation Length Heat pressure Length ø ø Percentage Required. Boiler Combustion Combustion Standard Burner Combustion Thermal opening chamber chamber...
- Page 25 ACK2 OIL/GAS FIRED HOT WATER BOILERS LAMBORGHINI BURNER SELECTION CHART Burner Blast exploitati Diameter Diameter Gross Back tube Boiler Net Heat Burner type Length ø ø Heat pressure Length Percenta Required. Combust Boiler Combustion Standard Burner Combustion Thermal opening for chamber type (kw)
- Page 26 ACK2 OIL/GAS FIRED HOT WATER BOILERS ALARKO - OIL BURNER SELECTION CHART Blast Burner Diameter Diameter Gross Back tube Boiler Net Heat Burner type exploitation Length ø ø Heat pressure Length Percentage Required. Boiler Burner Combustion Combustion Standard opening Combustion Thermal blast chamber...
- Page 27 ACK2 OIL/GAS FIRED HOT WATER BOILERS CIB UNIGAZ - GAS BURNER SELECTION CHART Blast Burner tube exploitati Diameter Diameter Gross Back Lengt Boiler Net Heat Burner type Length ø ø Heat pressure Percenta Requir Boiler Combustion Combustion Standard Burner Combustion Thermal opening chamber...
- Page 28 ACK2 OIL/GAS FIRED HOT WATER BOILERS CIB UNIGAZ - OIL BURNER SELECTION CHART Blast Burner tube exploitati Diameter Gross Back Lengt Boiler Net Heat Burner type Length Length ø Heat pressure Percenta Requir Combustion Combustion Standard Extended Combustion Thermal blast tube chamber chamber type...
- Page 29 TECHNICAL SPECIFICATIONS OF ACK2 TYPE BOILERS Range of Temperature Control °C 55-90 Boiler Type Hot Water, Two Pass, Reversal Flame, Steel, B Fuel Type Oil (6 cST at 20 °C) Gaseous (Natural Gas, Town Gas, LPG) Nominal 170-190 Output °C Exit Flue Gas Temperature °C Partial 120-140...
- Page 30 BOILER CONTROL PANELS Boiler Control Panel Device Functions : 1. Main switch : Energize or shut off the panel 2. Safety limit thermostat: If boiler water temperature is out of control (boiler thermostat are not functioning, electric wire fault, etc) and reaches 100 °C (+/- 5 °C) it will stop the burner immediately.
- Page 31 BOILER CONTROL PANEL WIRING DIAGRAMS STANDART PANEL SINGLE STAGE BURNER BOILER PANEL MS : MAIN SWITCH (ON/OFF) LT : SAFETY LIMIT THERMOSTAT T1 : BOILER THERMOSTAT (STAGE 1) 1 2 L T2 : BOILER THERMOSTAT (STAGE 2) RT : ROOM THERMOSTAT OR SAFETY CONTROLS EL : POWER ON LIGHT L : PHASE...
- Page 32 WEATHER COMPANSATED SINGLE STAGE BURNER 1213 BOILER CONTROL PANEL MS : MAIN SWITCH (ON/OFF) LT : SAFETY LIMIT THERMOSTAT T : BOILER THERMOSTAT (STAGE 1) BURNER EL : POWER ON LIGHT 220/230 V (AC) 50 Hz - 16 A (max) Q2 : HEATING SYSTEM CIRCULATION PUMP B8 : FLUE GAS TEMPERATURE SENSOR B2 : BOILER TEMPERATURE SENSOR...
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