Alarko ACK2 Operation Manual
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Alarko ACK2 Operation Manual

Heating system boilers with liquid / gas fuel
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ACK2 - ACK3
HEATING SYSTEM BOILERS
WITH LIQUID / GAS FUEL

Operation Manual

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  • Page 1: Operation Manual

    ACK2 - ACK3 HEATING SYSTEM BOILERS WITH LIQUID / GAS FUEL Operation Manual...
  • Page 2 Code No: A.4.1.3 i Published on: 210910 Revision No: 210910...

  • Page 3: Table Of Contents

    CONTENTS Introduction Warnings Declaration of Conformity Guarantee and Service General Specifications Operation Conditions Main Parts Installation Safety Arrangements Burner Selection Burner Installation Fuels Flue Gas Exhaust System Boiler Water and Make Up Water for Hot Water Boilers Start Up Operation and Shut Down Maintenance and Servicing Boiler Control Panels Boiler Control Panel Wiring Diagrams...

  • Page 5: Introduction

    INTRODUCTION This manual comprises the information concerning the Installation, operation, use and maintenance of ACK2 and ACK3 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.

  • Page 6: Warnings

    WARNINGS This boiler must be installed in accordance with the rules in force only in a well ventilated and frost free spaces. 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 7 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. The humidity level must not be high in boiler rooms. The boiler room must not be used for other purposes and must not have an open connection to the other closed living areas.

  • Page 8: Declaration Of Conformity

    Immediately call your local authority from neighbor’s phone. DECLARATION OF CONFORMITY We hereby make the fallowing declaration with regard to the appliance trademark ACK2, models ACK2-30, ACK2-40, ACK2-50, ACK2-60, ACK2-70, ACK2-80, ACK2-100, ACK2-120, ACK2-125, ACK2-140, ACK2-150, ACK2-160, ACK2-180, 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.

  • Page 9: Guarantee And Service

    The electric equipment of the appliances consequently complies with the requirements of the Electromagnetic Compatibility Directive (89/336/ EEC) GUARANTEE AND SERVICE Provided that the principles, warnings and standards set out in the operation in this manual and taking into account the national installation regulation of the country (in the absence of such requirements, they shall be referred to EN norms, directives and codes) are complied with, your boiler shall be under the warranty for a period of 3 (three) years starting from the date of dispatch (from manufacturer)

  • Page 10: General Specifications

    GENERAL SPECIFICATIONS ACK2 boilers are reverse flame, 2 pass, wet back, cylindrical shell type, hot water, liquid or gas fired, B steel boilers. ACK3 boilers are LOW NO , 3 pass, wet back, cylindrical shell type, hot water, liquid or gas fired, B steel boilers.

  • Page 11: Operation Conditions

    These boilers are suitable for Liquid (6 cSt at 20ÚC oil) and gaseous (Natural gas, 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 12: Main Parts

    MAIN PARTS - ACK 2 (TWO PASS) BOILERS Combustion chamber. 11- Supporting feet. Second pass combustion pipes 12- Gas/liquid fuel burner. and turbulators. 13- Flue outlet Main boiler body. 14- Boiler return Two way hinges. 15- Boiler flow Combustion chamber door 16- Drain and fill insulation.
  • Page 13 MAIN PARTS - ACK 3 (THREE PASS) BOILERS Combustion chamber. 11- Supporting feet. Third pass combustion pipes 12- Gas/liquid fuel burner. and turbulators. 13- Flue outlet Main boiler body. 14- Boiler return Two way hinges. 15- Boiler flow Combustion chamber door 16- Drain and fill insulation.

  • Page 14: Installation

    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 15 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.
  • Page 16 For ACK2 and ACK3 type boilers, it is advisable to have a three-way valve between flow and return line in order to keep the water return line over 55 °C in order to overcome condensation problem.

  • Page 17: Safety Arrangements

    SAFETY ARRANGEMENTS Heating system shall be equipped with safety arrangements against, exceeding the maximum operating temperature and exceeding the maximum operating pressure. Safety arrangements shall be designed in accordance with the type of heating system, energy source, and the way which the heat supply is provided to the heating system, i.e.
  • Page 18 Safeguard against lack of water: Sealed (closed expansion tank systems) shall be equipped with a water level limiter or other device, e.g. minimum pressure limiter or flow controller, thus providing interlock protection against excess temperature rise on the heat emitting surface of the boiler. Expansion vessels: When the heating system’s heat carrying medium water is heated it expands and it cause pressure rise in sealed systems so expansion vessels shall be designed to accommodate at least the maximum expansion...
  • Page 19 MINIMUM SAFETY EQUIPMENT REQUIRED FOR OPEN VENTED SYTEMS Expansion cisterns: Boilers in an open vented system shall be connected to an expansion cistern, which, is installed at the highest point of the heating system. They shall be dimensioned so that changes in water volume due to heating up and cooling down can be accommodated.
  • Page 20 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 21: Burner Selection

    BURNER SELECTION Boilers must be fired by a compatible burner certified to EN 676 (gas firing) or EN 267 (oil firing) to comply with the boiler efficiency requirement (92/42/EEC) directive and Appliances burning gaseous fuels (90/396/EEC) directive. The burner must be suitable for the respective rated output and the resistance on the flue gas side of the boiler.

  • Page 22: Fuels

    Natural gas, LPG and Town gas (according to EN 437 and/or to local limitations). FLUE GAS EXHAUST SYSTEM ACK2 and ACK3 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.

  • Page 23: Boiler Water And Make Up Water For Hot Water Boilers

    BOILER WATER and MAKE UP WATER FOR HOT WATER BOILERS According to EN 12953-10:2003 (Shell boilers: Requirements for feed water and boiler water quality. If non-ferrous materials are present in the system, e.g aluminum, they may require lower pH value and direct conductivity, however, the protection of the boiler has priority.

  • Page 24: Start Up

    START UP First start up work shall be carried out exclusively by fully trained, professionally qualified personnel. Before first start up check that; There is a copy of the boiler and burner instructions in the boiler room. The boiler name plate and manual specifications and power supply network and other system need specifications correspond.
  • Page 25 In starting a new installation all the fuel and water pipes, boiler and all the other heating system items must be flushed and free from deposits. Before filling the system with water control the expansion tank pre charge pressure in sealed systems. Open all the necessary valves for filling.
  • Page 26 Analyze the flue gas and be sure that emission levels of CO, NO , soot, CO or O are according to current regulations. For reference (current and local regulations has priority) Note: Emission values shall be according to current and local limitations. In absence of local limitations refer to current EN 677 for gas firing and current EN 300-2 for oil firing.

  • Page 27: Operation And Shut Down

    OPERATION and SHUT DOWN Please read operation, use and maintenance manuals before start up for economic and safe use. Wrong operation can cause a fire or explosion which may result property damage, personnel injury, or loss of life. Preliminary Checks Before Operating Before operating, smell all around the appliance area for gas.
  • Page 28 OPERATION Standard Control Panel Activate the burner main switch if it is off position. Activate the boiler control panel switch. Set the boiler thermostat (s) to desired level (if 2 stage thermostat is present set it 6 to 10 °C below the 1 stage thermostat).

  • Page 29: Maintenance And Servicing

    MAINTENANCE and SERVICING Do not open any part on the boiler or burner when the system is running. Please stop the burner, isolate fuel supply, disconnect the power supply and always wait until all the parts are cooled down before cleaning and servicing operations. Natural gas is a clean source, does not cause excessive smoke and dust but in order to extend the lifetime and increase efficiency at every heating season or once a year please call your authorized service to;...
  • Page 30 Again once a year call your authorized service for checking the combustion parameters, security and operational devices. When the burner lock-out for any reason please check the following; Main power Fuel valves open Boiler and burner control panel main switch position Circulation pump is running Boiler water temperature is lower then boiler thermostat set value.
  • Page 31 System water never fully drained if it is not necessary. Corrosion is very rapid in empty systems. New water filling means adding new scale and oxygen to the system. Both reasons cause to shorten the boiler service life and cause loss of efficiency.

  • Page 32: 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 33: Boiler Control Panel Wiring Diagrams

    BOILER CONTROL PANEL WIRING DIAGRAMS...
  • Page 34 ECO PANEL 7/21 AND 12/31 ELECTRÝCAL DÝAGRAMS...

  • Page 35: Boiler Records

    BOILER RECORDS MODEL : ……………… TYPE : …………….. HEAT OUTPUT : …………… KCAL/H OPERATING PRESSURE : ……. BAR (MAX) OPERATING TEMPERATURE : ………. (MAX) MANUFACTURING DATE : …… / …… / …… SERýAL NUMBER : ………………….. FUEL : …………………….. COMMISIONING DATE : …… / ……. / ……… COMMýSIONED BY : NAME : TEL :...

  • Page 36: Annexes

    ANNEXES...
  • Page 42 ÝSTANBUL : GOSB - Gebze Org. San. Bölgesi, Þ. Bilgisu Cad. 41480 Gebze-KOCAELÝ Tel: (0262) 648 60 00 - Fax: (0262) 648 60 08 ANKARA : Sedat Simavi Sok. No: 48, 06550 Çankaya - ANKARA Tel: (0312) 409 52 00 - Fax: (0312) 440 79 30 ÝZMÝR...

This manual is also suitable for:

Ack3

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