Alarko CGS2-100, CGS2, CGS2-250, CGS2-150, CGS2-200 User Manual

...

CGS 2 and CGS 3

LIQUID / GASEOUS FUEL

STEEL BOILER

USER MANUAL

Code No: A.4.1.8 Revision: 250718

Book Print Date: 250718

CGS 2 and CGS 3

LIQUID / GASEOUS FUEL

STEEL BOILER

Installation, Commissioning,

Operation and Maintenance Manual

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 Oxygen Corrosion

Commissioning

Start Up and Stop

Maintenance and Service

36 Boiler Control Boards

Appendices

Standard Electrical Diagram

Ecopanel 7/21 and 12/311 Electrical Diagram

Heating Control Panel SDC Easy Operation Guide

49 Boiler Label Information

Technical Specifications Table

Burner Selection Table

Burner Gas Line Diagram

Control and Commissioning Form

CGS Steel Boiler Flue Information

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.

Except as described in this manual, DO NOT TOUCH any part or setting of your device for reasons such as operation, adjustment or maintenance.

Have your device installed by ALARKO CARRIER Authorized Dealers. Our Authorized Dealers and Services will provide you with the necessary

information about how to use and maintain the device after they have placed, made connections of and put into operation of your device. You can ask the issues you don't understand over and over again. Our experts will be happy to answer your questions.

For more detailed information about your device, please contact our Customer Services Hotline at 444 0 128 in order to reach the product brochure and access the ALARKO CARRIER authorized dealers and services, when necessary.

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.

• EN 303-1

• EN 303-3

• EN 12953

• Directive 2009/142/EC on Appliances Burning Gaseous Fuels

The materials used in our products are designed to provide safe and proper performance for our applications and are selected to withstand the chemical, mechanical and thermal effects to which they may be exposed during the expected lifetime.

• There is no soft soldering on gas bearing parts.

• The security of the changeable settings is ensured.

• Asbestos materials are not used.

• There are no parts in contact with the food and/or water used for sanitary

purposes in our boilers.

• Used parts are CE-marking approved.

• Installation and user information, nameplate and packaging information

have been written in the official language of the country where the boiler is to be used, the national rules of the country concerned have been considered.

• The electrical materials used are suitable for directives on low voltage. The electrical materials used are suitable for Directives on Electromagnetic

Compatibility.

NOTICES

The boiler must be installed and operated in a closed space outside the living areas, only in a well-ventilated and non-freezing risk.

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.

If the boiler is installed and used outside of the operating conditions specified in this manual, it may cause accidents such as fire, explosion or the like, which could result in loss of property or loss of life.

The boiler is designed for hot water use only (below boiling temperature). The system operating temperature and pressure must comply with the values specified on the boiler's nameplate and in this manual. The heat transfer medium is water.

Boilers must only be used with gaseous or liquid fuels specified in this manual and on the boiler's nameplate.

Boilers must only be used 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.

This is a B23 type boiler, so the boiler must be connected to a flue with sufficient draught in accordance with the regulations, and there should be no flue gas leakage into the boiler room.

During the operating period of the boiler, a pump with suitable values must perform circulation continuously.

The filling and feeding water must comply with the specifications given in this manual. Lime-free, clean and non-corrosive water use is necessary in terms of economic operation and long service life of the system.

Never close the boiler room ventilation for safe and efficient use. Fresh air is needed for good combustion. It is necessary to be able to expel the gases that can emerge from combustion and that may leak from fuel to the environment.

Install the boilers on a base which is at least 15 cm above the ground, parallel to the ground, non-flammable, with sufficient strength.

Boilers should not be installed and put into operation in the environments with flammable gases and materials. In order to prevent the boiler from being damaged, it should be avoided to leak dense dust or halogen hydrocarbons (solvents, spray

gases, adhesives, etc.) into the combustion air. The humidity of the boiler room must not be high.

In liquid or gaseous burners, ignition is automatic and there are many additional safety controls. Do not attempt to manually switch on the burners or to operate the system manually by disabling the controls. All control equipment must be kept working continuously at the specified limits. In the event of any malfunction, do not operate the system and contact your authorized service.

The boiler room should not be used for any other purposes and should not have any open connection to living spaces. The door must be airtight, fire-resistant and self-closing.

If the boiler temperature rises above 90 °C, do not feed cool water into the

system for rapid cooling. This could cause an explosion. Allow the boiler to cool down to 40 °C naturally before the feeding water is added.

If any part of the boiler is submerged, do not put it into operation. Contact your authorized service immediately.

Do not touch the window box, flue and fume cupboard and its surrounding areas. These areas may be very hot and cause serious injury.

It is recommended to install an emergency stop switch in a suitable place outside the boiler room. This switch must be able to stop the combustion process or fuel supply. 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.

If you wish to change fuel in the future, please contact your authorized service. Fuel change requires replacement of some parts and new adjustments. Do not carry out fuel change by yourself or unauthorized persons.

This is not a condensing-type boiler, make sure that there is no long-term condensation in the boiler.

If the system is to be put into operation with a heavy gaseous fuel (such as LPG) and the boiler room is below ground level, additional measures should be taken. The fuel that can be leaked into the boiler room must be able to be expelled automatically in a safe area outside the boiler room through an ex-proof mechanical system (ventilation) and the fuel line must be cut automatically when the fuel leakage reaches a certain level.

If the system is to be commissioned with liquid fuel, the turbulators in the smoke ducts must be removed. Turbulators are for use with gaseous fuel. Since the turbulators are not used, the boiler efficiency will decrease by 2-5%.

Do not touch any part of the boiler and the burner for the purpose of adjustment or maintenance, except as described in this manual.

When gaseous fuel is used, the boiler must have an automatic cutter (solenoid valve) on the fuel supply line and this device must be associated with a warning system.

The condensate coupling under the Boiler Rear Fume Cupboard must be connected to the drain with a siphon.

Rear fume cupboard

condensate coupling

drain

siphon

WARRANTY AND SERVICE

So long as the principles, notices and all applicable standards (EN norms, directives and principles should be applied where those principles are not applicable) mentioned in this manual are abided by, your device is warranted for 2 (two) years from the date of sale against material and manufacturing defects.

The Product’s Warranty Certificate shall be filled in by the authorized service from whom you purchase the products and sent to the ALARKO-CARRIER. Please follow.

ALARKO CARRIER Authorized Services are at your service at any time, even in the slightest problems. You can find authorized service addresses in the Authorized Service Address Booklet supplied with your device.

Any defects arising from improper installation, maintenance or use shall not be covered by the warranty.

Malfunctions resulting from the heat transfer parts of the boiler coated with lime and/or similar foreign materials and the corrosion are not covered by the warranty.

The minimum service life determined by the Ministry of Industry and Trade for these devices is 15 (fifteen) years. Manufacturer and reseller companies undertake to provide service and spare parts for the device within this period.

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 Customer Services Department via e-mail at info@alarko-carrier.com.tr.mailto:info@alarko-carrier.com.tr

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). These boilers are not suitable for use as a direct water heater. In case of

potable or clean hot water needs, a closed circuit heat exchanger suitable for the system must be installed.

These boilers are suitable for operating with liquid and gaseous fuels. Consult our authorized dealers for the fuels you can use. If you want to change the fuel that has been commissioned for the first time, contact our authorized services.

The boiler can be used in both open and closed expansion systems. A suitable expansion system in the system should work actively at all times.

In the 2nd transition pipe in CGS2 boilers and 3rd transition pipe in CGS3 boilers, there are turbulators to increase the heat transfer to the water. Never remove these turbulators, this will cause loss of efficiency in the boiler and may damage the boiler.

This is not a condensing-type boiler, so make sure that there is no condensation in the boiler.

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. As the outside temperature changes, he must also change the thermostat setting.

Temperature Settings of Boilers Operated with Eco-panel: The user determines the desired room temperatures and time program and saves them to the eco-panel. The boiler then operates automatically depending on the outside temperature. With the tests to be carried out in 1 or 2 weeks, it should be determined whether the values determined at the beginning are suitable for the conditions of the building and suitable values for building should be found.

As long as it is not changed by the user, the eco-panel works according to the factory settings. The factory settings are as follows;

Factory Settings

User Setting

Comfort room temperature

20 °C

Economy room temperature

16 °C

Working hours at comfort temperature

06:00 - 22:00

Working hours at economy temperature

22:00 - 06:00

Heating curve (if building with radiator)

1,5

Heating curve (if building with underfloor heating)

1,0

Heating curves are the graphs in which the boiler water temperature is determined depending on the desired room temperature and the outside temperature.

Boiler water temperature

(

Outside temperature

Room temperature (oC)

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

Curve of 1,5 for

20 °C room

temperature

Curve of 1,5

for 15 °C room

temperature

Boiler water temperature

(

Outside temperature

Room temperature (oC)

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. Flue connection outlet

5. Hydrometer connection

13. Cleaning cover

6. Thermometer connection

14. Blowout cover

7. Condensate drain connection

15. Carrier frame

8. Burner connection cover

16. Boiler feet

17.

CGS3 SERIES BOILERS

FRONT VIEW

SIDE VIEW

INTRODUCTION PARTS OF CSG3 BOILERS:

1. Boiler flow flange

10. Burner connection

2. Boiler return flange

11. Front fume cover

3. Flow safety connection

12. Rear fume cupboard

4. Return safety connection

13. Flue connection outlet

5. Hydrometer connection

14. Cleaning cover

6. Thermometer connection

15. Blowout cover

7. Condensate drain connection

16. Carrier frame

8. III. Fume Extractor Pipes

17. Boiler feet

9. II. Fume Extractor Pipes

INSTALLATION

The design, installation and commissioning of the heating system must be carried

out

in accordance with the applicable standards, regulations and the warnings in this

manual.

In cases where there are no local standards, regulations or inadequate standards

and regulations,

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. Top and bottom ventilation systems must comply with local regulations.

• Boilers must only be used 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.

• This is a B23 type boiler, so the boiler must be connected to a flue with sufficient draught in accordance with the regulations, and there should be no flue gas leakage into the boiler room.

• All equipment and control system of the heating system should be able to provide the specified heating loads according to the external climatic conditions and the desired internal temperature. It should be able to protect the heating system against freezing and humidity when normal operating conditions (comfort temperature level) are not required.

• The equipment for the control and safety systems of the heating system must comply with the applicable TS standards, and, where insufficient, the instructions in EN 12828 and this manual must be observed.

• The heating system must also have at least one circulation pump complying with the system requirements and this pump must be kept in operation as long as the burner is operating.

• An effective installation circuit must be installed to protect the boiler from flue gas condensation. The condensation return water temperature should be kept above the condensation value by a system such as condensation by pass pump, 3-way valve system.

• The first filling water and then the feeding water should have the properties specified in this manual. The use of water with proper properties is necessary for the longevity of the system and its economic operation. Extremely soft water causes corrosion, extremely hard water causes limestone, so water with proper values should be used.

• 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. In order to prevent the boiler from being damaged, it should be avoided to leak dense dust or halogen hydrocarbons (solvents, spray gases, adhesives, etc.) into the combustion air. The humidity of the boiler room must not be high.

• The boiler room should not be used for any other purposes and should not

have any open connection to living spaces. The door must be airtight, fire-resistant and self-closing.

• It is recommended to install an emergency stop switch in a suitable place

outside the boiler room. This switch must be able to stop the combustion process and fuel supply. It is useful to specify it with a nameplate.

• If the system is to be put into operation with a heavy gaseous fuel (such as

LPG) and the boiler room is below ground level, additional measures should be taken. The fuel that can be leaked into the boiler room must be able to be expelled automatically in a safe area outside the boiler room through an ex-proof mechanical system (ventilation) and the fuel line must be cut automatically when the fuel leakage reaches a certain level.

• If the system is to be commissioned with liquid fuel, the turbulators in the

smoke ducts must be removed. Turbulators are for use with gaseous fuel. Since the turbulators are not used, the boiler efficiency will decrease by 2-5%.

• All electrical connections must be made according to current standards and

according to the diagrams given in this manual. Please pay special attention to the grounding of all electrical appliances in the boiler room. Never use fuel or water pipes as ground connections.

• Boiler flue connections should be made according to standards. The boiler

position should be selected so that the distance between the boiler and flue and the number of elbows is minimum. Flue ducts should not be directed downwards and vertical elbow turns should be avoided. Smoke ducts and flue should be heat insulated. Tables for the selection of flue height and diameter are given in the appendix. These tables can be used under certain conditions, in systems other than these conditions, a flue calculation must be made according to the norms (TS 2165).

• There should be no manual shut-off systems (such as valves) between the

boiler and the safety and control systems. A lock valve can only be fitted to the connection of the closed expansion tank for maintenance and pre-pressure checks. Accidental closure of this valve should be strictly prevented.

• 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.

• The weight of the flue gas ducts must not get carried by the boiler's flue gas connection point and a flanged or leak-tight connection must be used for easy maintenance.

• The total weight of the large and heavy burners should not get carried by the boiler front cover, and the weight of the burner should get carried by the ground with the help of a suitable adjustable support.

• The length of the burner connection bolts should not exceed the total thickness of the burner flange, gasket and adapter plate.

• If the gap between the burner barrel and the boiler refractory is more than 10 mm, this area must be filled tightly with 1200 °C resistant ceramic fiber

material.

• The responsibility for the installation and commissioning of the control and safety system of the heating system in compliance with the applicable standards and regulations is in the units that implement the system project, installation and operation. The minimum information is given as a preliminary reference in accordance with the standards in force at the date of the preparation of the installation part of this manual.

• For the types with 800.000 kcal/hr and under, they have a prismatic cabinet for closing the thermal insulation. Cabin steel plates are delivered separately and our authorized service department assembles them.

• For the types with 1.000.000 kcal/hr and above, insulation closure sheet plates are rolled and packed and put in the combustion chamber. Our

authorized service assembles them as shown in the following pictures 1-2-3-4.

SAFETY SYSTEMS

In the heating system, safety precautions must be taken against exceeding the maximum operating temperature and the maximum operating pressure. The safety precautions must be taken based on the power, type, energy source and controller of the heat transfer system (e.g. automatic control or manual operation) of the heating system. It is the responsibility of the designer, the installer and the units putting it into operation to take the necessary safety precautions, select, install and adjust the safety and operating equipment correctly. If they are inadequate for the applicable standards and regulations, they must comply with EN 12828.

Minimum Safety Equipment Required in Systems with Closed Expansion Tank

Protection against exceeding the maximum operating temperature;

Each boiler control circuit must have at least one manual reset limit thermostat. After stopping the limit thermostat burner and/or fuel supply, the boiler water

temperature should not increase by more than 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.

Protection against exceeding the maximum operating pressure;

Each boiler control circuit must have at least one pressure relief valve. The pressure relief valve must protect the system from high pressure by opening before the boiler exceeds its operating pressure and the system pressure should never exceed 10% of the operating pressure when it is opened. The pressure relief valve assembly should be done so that the pressure drop on the inlet pipe side should not be more than 3% and the pressure drop on the outlet pipe side should not be more than 10%.

The pressure relief valve is not included in the standard equipment supplied with the boiler. It is the responsibility of the project and assembly units to properly connect the pressure relief valve with the correct diameter and pressure value to the system. The relief valve must be connected to the connection point below the water flow flange without any cut-off valve, and water discharge should be done in a safe area. Boilers with a capacity above 300 kW must have a suitable size blow-off valve at the relief valve outlet line (see EN 12828). Safety valves must comply with prEN 1268-1 standard. The relief valve diameters should be selected according to the boiler capacity, but the selection diameter may not be less than DN 15.

+ 47 hidden pages

Alarko CGS2-100, CGS2, CGS2-250, CGS2-150, CGS2-200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual