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

07

Declaration of Conformity

08

Notices

09

Warranty and Service

11

Operating Conditions

12

Boiler Water Temperature and Room Temperature

13

Settings

Main Parts of the Boiler (CGS2)

16

Main Parts of the Boiler (CGS3)

17

Installation

18

Safety Systems

21

Burner Selection

26

Burner Installation

26

Suitable Fuels

28

Flue Gas System

28

Heating System Filling and Feeding Water

29

Features
Oxygen Corrosion

30

Commissioning

31

Start Up and Stop

34

Maintenance and Service

36
Boiler Control Boards

39

Appendices

40

Standard Electrical Diagram

47

Ecopanel 7/21 and 12/311 Electrical Diagram

48

Heating Control Panel SDC Easy Operation
Guide

49
Boiler Label Information

59

Technical Specifications Table

60

Burner Selection Table

62

Burner Gas Line Diagram

65

Control and Commissioning Form

66

CGS Steel Boiler Flue Information

67

7

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.

8

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.

9

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

10

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
[e-mail]:[e-mail]

12

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.

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.

13

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

14

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

(

o

C)

Outside temperature

Room temperature (oC)

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

Curve of 1,5 for

20 °C room

temperature

Curve of 1,5

for 15 °C room

temperature

Boiler water temperature

(

o

C)

Outside temperature

Room temperature (oC)

16

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.

18

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. 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.

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.

• 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.

21

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.

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. The pressure switches should not
have automatic reser function and should not automatically reset itself even if
the pressure drops and falls within the normal range.

The pressure limit switch 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 limit switch with manual reset with the correct
diameter and ampere value to the system. Pressure limit switch and pressure
relief valve can be connected in series to a collector to be installed on a line
from the connection point below the boiler water flow flange, without any cut-off
valve.

Protection against low water level/pressure;

Closed expansion systems must be protected against operation at low water
level. The heat transfer surfaces of the hot water boilers that continue to
operate at low water level can overheat and the boiler may become vaporous,
which is a danger that could cause boiler explosions. Low water level protection
methods include low pressure switch, water flow switch, water level switch. The
low water level controller 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.

Closed expansion tank;

In closed heating systems, the water which is in the system as the heat carrier
tries to expand and increase inherently when heated, this causes the pressure
increase due to the fact that there is no volume change in closed systems. In
closed heating systems, an expansion tank capable of meeting this increase in
volume and holding at least a certain amount of reserve water must be
connected to the system. In the system which is widely used today, the closed
expansion tanks with membrane perform this function. EN 12828 standard can
be used when selecting closed expansion tanks with membrane type, but
manufacturers' selection calculations and installation criteria of closed
expansion tanks with membrane are prioritized.

In the case of water expansion at the highest possible temperature in the
system, the expansion tank volume and the size of the connecting pipe to the
boiler should be selected so as not to increase the system pressure (without
activating the pressure limit switch and relief valve). When installing the
expansion tank, frost protection should be considered. It is recommended to
connect the expansion tanks with membrane to the connection near the boiler
return water flange. Manual shut-off equipment must not be used in the
connection line between the expansion tank and the boiler. Only for the
purpose of maintenance, repair, pre-gas pressure control of the expansion
tank, it is appropriate to use lock-type valves

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.

Water temperature controller (Boiler thermostat);

There must be a controller which controls and regulates the water temperature
required by the heating system. This temperature cannot be above the
adjustable maximum setting temperature of the controller, boiler operating
temperature. For standard CGS2 and CGS3 boilers max. 90°C. All optional
boiler control panels have a water temperature controller (Boiler thermostat). If
the optional control panel is not supplied, this controller must be supplied and
installed by the installer. The temperature control thermostat must comply with
EN 60730-2-9 and/or bear CE-marking.

Water temperature gauge (thermometer);

The boiler must be more than 20% of its maximum operating temperature. The
boiler must be installed in the flow line (the water temperature gauge in the
boiler return line is not required by the standards but is recommended by us).
All optional boiler control panels have a water temperature gauge (Boiler
thermometer). If the optional control panel is not supplied, water temperature
gauge must be supplied and installed by the installer.

Water pressure gauge (manometer);

A monometer must be connected to the boiler flow line to show 50% more
pressure than the operating pressure in the heating system. All optional boiler
control panels have a water temperature gauge (Boiler monameter 4 bar). If the
optional control panel is not supplied or when the system pressure is above 2.5
bar, water pressure gauge must be supplied and installed by the installer.

System water level and pressure regulation system;

A regulation to keep the heating system water level and pressure at operating
values must be installed in the system. According to the prEN 806-2: It is
sufficient to connect the boiler water filling line to the cold water network with 1
pressure reducer, 1 check valve,

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. It must be
ensured that this ventilation system is functional as long as the boiler is active.
Ventilation calculations must be calculated according to the local directives.

Minimum Safety Equipment Required in Systems with Open
Expansion Tank

Open expansion tanks;

Boilers used with expansion systems open to the atmosphere must be
connected to an expansion tank which is located at the highest point of the whole
heating system and open to the atmosphere with a suitable capacity.

They must be dimensioned to meet the water expansion at the highest possible
temperature in the system, and the expansion tank must comply with these
requirements when dimensioning pipe connections. When installing the
expansion tank and connecting pipes, frost protection should be considered.
Expansion tanks open to the atmosphere must be connected to the connection
located under the boiler flow and return water flange. Manual shut-off equipment
must not be used in the connection line between the expansion tank and the
boiler. There should be a ventilation outlet and overflow pipe which can not be
closed in the expansion tanks open to the atmosphere. The overflow pipe should
be dimensioned to drain the maximum flow rate of the water entering the system,
a practical selection method; The overflow pipe diameter can be provided by
selecting it as 1 DN larger than the filling pipe diameter.

Expansion tanks, safety pipes and overflow pipes must be protected against
freezing. The sample reference assembly diagram is presented in the
appendices.

Open expansion tank pipelines;

The boilers must be connected to the expansion tanks open to the atmosphere
without any valve between the pipes with sufficient diameter from both the safety
flow (expansion) and safety return (supply) lines. The expansion tank must be
open to the atmosphere. The safety flow pipe must be connected from the upper
part of the expansion tank, the safety return pipe from the lower part of the
expansion tank, and the overflow pipe at the calculated maximum expansion
level. It should not be possible to close the safety pipe or the supply and
expansion pipe.

25

The smallest internal diameter of the open safety pipe and the supply and
expansion pipes can be calculated as follows:

Safety flow (expansion) pipe: dG= 15+1.4 b 9 mm (but it cannot be smaller than
19 mm).

Safety return (supply) pipe: dD= 15+1.0 b d

m m

9 : It is the boiler's

nominal heat output in kW. (do not forget symbols)

Operational requirements of open expansion systems;

For safe and economic operation of open expansion systems, the following
controllers must be available in the system.

Water level gauge;

The hydrometer must be connected to the system to show the water level in the
heating system as a meter water column.

Water temperature gauge (thermometer);

The boiler must be more than 20% of its maximum operating temperature. The
boiler must be installed in the flow line (the water temperature gauge in the
boiler return line is not required by the standards but is recommended by us).
All optional boiler control panels have a water temperature gauge (Boiler
thermometer). If the optional control panel is not supplied, water temperature
gauge must be supplied and installed by the installer.

Water temperature controller (Boiler thermostat);

There must be a controller which controls and regulates the water temperature
required by the heating system. This temperature cannot be above the
adjustable maximum setting temperature of the controller, boiler operating
temperature. For standard CGS2 and CGS3 boilers max. 90°C. All optional
boiler control panels have a water temperature controller (Boiler thermostat). If
the optional control panel is not supplied, this controller must be supplied and
installed by the installer.

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. It must be
ensured that this ventilation system is functional as long as the boiler is active.
Ventilation calculations must be calculated according to the local directives.

26

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; boiler capacity, boiler gas side
counter pressure, boiler combustion chamber dimensions, burner barrel
diameter and connection flange dimensions should be taken into account (EN
303-1, EN 303-3). The material of the combustion head of the burner should be
suitable for at least 500 °C operating temperature.

The combustion chamber dimensions of and the boiler gas side counter
pressure of the CGS2 and CGS3 boilers are in compliance with the applicable
TS EN standards.

BURNER INSTALLATION

The burner must be connected to the boiler body by using the burner adapter
plate available on the front cover as standard. Actions to be made are as
follows:

1. Remove the burner adapter plate bolts and remove the adapter plate from
the boiler cover. Figure: x

Figure: x

Burner
Adapter
Plate

Burner Adapter Plate

Burner
Gasket

2. Open the barrel inlet hole in the burner adapter plate.

3. Mark the holes of the flange to be used to mount the burner to the boiler on
the adapter plate.

4. There are three options for fixing the burner flange to the adapter plate;

4.1. Fastening to the adapting plate with a bolt (Figure xx): Drill holes in
marked areas. Then fit the "burner adapter bolts" into these holes with their
ends facing outside of the burner and with their heads in between the
adapter plate and the boiler cover. After passing the holes of the flange
through these stud bolts,

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.

Burner
Adapter
Plate

Burner
Gasket

Figure: xx

4.2. Threading the adapter plate: You can weld bolts to marked areas. Then
pass the holes of the flange through these bolts and tighten them with nut.

4.3. Welding the bolt to the adapter plate: You can thread the areas you
marked with a guide. After aligning the flange holes, you can tighten them
using bolts. In this case, the outer end part of the bolt to be inserted on the
adapter plate should be maximum 8-9 mm. If it is longer, its end touches
the coiler cover and bolts cannot be tightened.

The length of the combustion head of the burner shall be at least as to reach the
front part of the boiler combustion chamber. If the length of the combustion
head is too long or too short, get approval from the boiler manufacturer for
trouble-free operation.

If the gap between the burner combustion head diameter and the refractory in
the boiler front cover is more than 10 mm, fill the remaining gap firmly with the
heat insulation material supplied with the boiler.

The burner flange connection must always be mounted so as not to cause any
gas leakage. If this cannot be achieved, there will be toxic gas leakage in the
boiler room and these hot gases will cause permanent damage to the boiler
front cover.

The burner capacity must be suitable for the boiler capacity. If a 2-stage or
modulating controlled burner is used, the 1st stage setting should be minimum
60% of the boiler capacity. However, if continuous condensation is observed in
the boiler, the 1st stage setting should be adjusted to higher levels or
anti-condensation system settings should be changed.

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.

28

SUITABLE FUELS

CGS2 and CGS3 boilers are only suitable for liquid and gaseous fuels.
Liquid fuels: Light, Medium and Heavy oils (Observe the burner manufacturer's

instructions and local government restrictions).
Gaseous fuels: Natural gas, LPG, Air gas (all gaseous fuels in accordance with

TS 11395 EN 437) (Observe the burner manufacturer's instructions and local
government restrictions).

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. Flue calculations must be carried out according to TS EN
11389 EN 13384-1. The inner diameter, height, material and heat insulation of
the flue should be based on the flue gas properties and should not cause
dangerous high and low pressures.

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%.

There must be a draught between 0 and - 0.3 mbar at the flue gas outlet of the
boiler. For reference, some tables related to this matter are given in the
appendix.

The effective flue height is the difference in height between the boiler flue outlet
and the end point of the flue.

Pre-constraint values for using the flue diagrams in the appendix; The length of
the flue gas ducts between the boiler and the flue should not exceed the % of
the effective flue height. However, it should be noted that it is not longer than

7m, and not less than 0.6m. A maximum of 2 elbows with 90° can be found in

the flue gas ducts (avoid sharp turns).
The inclination of the flue gas ducts should not be downwards. The

recommended elevation angle is 10° upwards.
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.

29

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

Boiler Supply Water

Appearance

-

Clean, stable, no

foam (*)

Clean and it should not

contain suspended

particles (*)

Conductivity (at 25 °C)

Microsienens/cm

Up to 1.500 (*)

-

Total hardness 175.000 kcal/hr

and below

French hardness

Up to 20 (**)

Up to 0,5 °Fr (*)

Total hardness 175-500.000

kcal/hr

French hardness

Up to 15 (**)

Up to 0,5 °Fr (*)

Total hardness 500.000 kcal/hr

and above

French hardness

Up to 0,2 (**)

Up to 0,5 °Fr (*)
Total hardness, Cascade system

French hardness

Up to 0,2 (**)

-

(*) TS 377-10 EN12953-10, January 2006, TSE, Cylindrical boilers requirements
for
feeding water and boiler water quality
(**) VDI 2035 – Part 1, December 2005, Association of German Engineers,
Prevention of damage in water heating installations, Scale formation in drinking
water

 If the heating system includes units made of material other than steel (e.g.

aluminum radiator - copper pipe), these units may require lower pH and
conductivity, but the protection of the boiler is a priority in the system and
the above values must be observed.

 Organic substances usually consist of various compounds. It is difficult to

predict the effect of such mixtures and each component of them on the
boiler in advance. Organic substances can be separated into components
to form carbonic acid or other acidic components and cause wear or
perforation. This can also lead to foaming and the accumulation of

substances such as limestone, which should be as little as possible.
Note: During the economic lifetime of the boiler, the total amount of feed water used
cannot be more than 3 times the water of the entire system.

30

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
d) Air entering from vacuum-forming areas

If it is not possible to remove the above factors in the heating installation, the
boiler and the installation must be separated from each other by a plate heat
exchanger.

Damages caused by the presence of oxygen in the boiler water are not covered
by the warranty.

31

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.

Before starting the first operation, please check the following matters;

• The availability of the installation, commissioning, operating,
maintenance and repair of the heating system equipment in the boiler
room.

• Compliance of the system requirements and equipment with the values
indicated on the boiler label. Fuel type and pressure, boiler - burner
capacity, electrical energy values, filling water properties, expansion
system existence and adequacy, selection of operating pressure and
temperature according to the system requirements... etc.

• Existence and adequacy of boiler room ventilation. The ventilation is
not blocked by any obstruction.

• The flue gas ducts and the flue are adequate and installed correctly.

• Ensure that all system controls and safety equipment are available,

have the correct properties, and are installed correctly and that they are
all operating in the desired range of values.

• Fuel type and burner capacity are selected correctly according to boiler
and heating system requirements.

• If gaseous fuel is used, the turbulators are present complete in the
boiler and have been placed correctly.

• If liquid fuel is used, the turbulators have been removed.

• There is no forgotten foreign material in the boiler combustion chamber.

• Boiler front cover, back cover, burner adapter plate, window box seals

are intact and installed correctly.

• The gap between the burner barrel and the cover refractory is
insulated, the suitability of the length of the burner connection bolts.

• Check that if the burner is heavy, a carrier support is placed under it,
and that flue ducts load is not carried by the boiler smoke outlet.

• In the installation criteria, the warnings specified in this manual and the
applicable standards and regulations are taken into account.

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.

Turn all valves required for filling to the open position.
Check that the properties of the filling water correspond to the specified values.
Carry out filling process very slowly. The filling rate must be performed at a flow

rate appropriate to the capacity of the air outlet elements of the system,
otherwise air may be trapped at many points in the system.

In open expansion systems, fill up to the appropriate water level (until the water
from the messaging tube) and in closed expansion systems, fill up to the
pre-calculated pressure value.

If there is a low water level safety system in the system, check the function and
setting values of the selected low water level control system without filling the
system completely.

Deaerate all possible points of the system.
Switch on the circulation pump and check that it operates in the correct direction

and circulates the water.
Deaerate the system again. If the water level/pressure has dropped, supply

water again.
In open expansion systems, tick up the lower pressure from the water level

indicator and inform the user about the minimum water level.
In closed expansion systems, tick up the water pressure lower and upper limit

values and inform the user.
In closed expansion systems, if the water pressure relief valves are not set as

default and certified, increase the system pressure slowly and adjust the
pressure relief valve and other pressure control elements to the pre-calculated
values. Make sure that all pressure safety systems operate at the required
values.

Check that there is no water leakage from all elements in the heating system.
Check the presence and accuracy of all other control and safety devices in the
system and adjust the presets.

Before commissioning the burner, check the fuel properties (according to the
type of fuel; pressure, temperature) and the fuel lines for leakage and discharge
air from the fuel line.

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. In two-stage
and modulating burners, the minimum combustion setting should not be less
than 60% of the boiler capacity.

Check the flue gas values with the analyzer and check that the flue emissions
comply with the applicable restrictions. The values such as SCO, NOx,
sootiness, CO2 or O2, flue gas temperature must be checked.

The reference values are given below (applicable standards and regulations
are prioritized, may differ from this table).

Fuel

Sootiness
Degree
(Rinqelmann)

Heat loss %
with waste gas

% C0

2

co

(mg/kWh)

NO

x

(mg/kWh)

Gaseous

(1)

(9)

> 10

<< 100 (1070)

<? 170 (260)

LPG

(1)

(9)

> 10

<<100 (1070)

<< 230 (260)

Diesel

______ (1) ______

___ (11) ____

> 13

<<110 (110)

<< 250 (250)

Note: Flue emission values must be in accordance with applicable regulations.
The values given in parentheses are taken from the "Regulation on Control of
Air Pollution Due to Heating" of Turkish Ministry of Environment and Forestry.

After adjusting the burner, continue to burn the burner and check that the 1st
and, if any, 2nd stage thermostats are working correctly for several times.

Then heat all the water in the heating system up to 85-90 °C and deaerate the
entire system again. In the first filling process, there is melted air in the cold
water (10-25 °C) and this air can only be released by heating the system and
disposed out of the system.

Check the setting and function of all control and safety devices again. Record
the system setting parameters.

Call the person(s) who will start the heating system; Please describe all
necessary system information for a correct and safe operation and give
detailed information about the issues that need to be done in a potentially
hazardous situation.

34

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;

Before operating the system, ensure that there is no fuel leakage in the
application area. Visual inspection of liquid fuel lines may be sufficient. In
gas-fired systems, heavy gas leakage can be understood from different odors
in the environment. If a gas such as LPG which is heavier than air is used, the
odor control at the ground level must be carried out.

ACTIONS TO BE MADE IF YOU SMELL GAS OR NOTICE LEAKAGE:

• Do not activate the system.

• Do not start fire.

• Do not touch any electrical unit including plugs, light switch.

• Do not smoke.

• Do not use any phones in the building where the leak occurs.

• Close the main fuel valve entering the building.

• Warn and evacuate other people in the building.

• Contact your local authorities through your neighbor's phone

immediately.

If you have not detected any fuel leakage;

Check the water system level or pressure.
Make sure that there are no obstructions in front of the ventilation covers.
Ensure that there is no leakage in the water, flue gas lines.

Check the valve positions and ensure that all water valves are in the correct
position.
Make sure that all service, maintenance, replacement, dismantled parts are
securely closed and/or installed correctly.

Make sure that there is no flammable material in the boiler room.
If you have not used the heating system for a long time, make sure that the

water in the system is not frozen.

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.
The burner will be activated after finishing the standard automatic control functions.
If the burner does not switch on and the fault lamp on the burner is illuminated,

reset it by pressing. Call your authorized dealer if it is not activated when you try it
for 3 times.

(Visually check that there is no leakage of combustion gases from the boiler front
and rear cover area and from the flue connections after each commissioning).

Stop

Standard control panel;

a) If there is a 2nd stage thermostat in your control panel, first set the 2nd
stage thermostat to minimum (If the thermostat is operating normally, the
burner will immediately switch to 1st stage operation. This function is a
practical way to control the 2nd stage thermostat).
If the control panel is single stage, start from the section ”b“.
b) Set the boiler thermostat to minimum (If the boiler thermostat is working
normally, the burner will stop immediately. This function is a practical way to control
the boiler thermostat).
Turn off the burner control main switch.
Turn off the main fuel valve.

For long-term shutdowns: you can stop the circulation pump, but keep in mind
that the water in motion is more difficult to freeze. If you shut the system off for
a long period in winter, make sure that the heating system and other parts are
protected against frost.

If there is another type of control panel, refer to the relevant manual.

36

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.

Natural gas is a clean energy source, does not cause excessive smoke and
dust, but in order to prolong the lifetime of the system and increase its
efficiency, please call your authorized service for each burning season or at
least once a year to have them make followings;

• Cleaning of boiler heat transfer surfaces

• Control of combustion parameters, burner settings

• Control of safety and control devices

• Proper flue draught and, if necessary, flue cleaning

• Leakage control in water, fuel and flue gas lines

• Cleaning of filters in gas lines and water lines.

If the system is operating with liquid fuel, the boiler heat transfer surfaces
should be cleaned at least once a month (The cleaning frequency depends on
the operating characteristics and combustion parameters. The need for
cleaning may occur in much shorter times due to some factors such as poor
combustion setting or the use of a bad fuel, insufficient flue draught. The
occurrence of soot with a thickness of 1-2 mm on heat transfer surfaces causes
excessive drop in system efficiency, thus, keep the boiler heat transfer surfaces
clean.

Cleaning of heat surfaces;

• Stop the burner.

• Stop the circulation pump.

• Turn off the main power supply.

• Switch off the fuel line, disconnect the connection from the coupling if

necessary.

• Allow the boiler to cool down (at least 2 hours).

• Open the front cover of the boiler. First remove the clamping parts

on the opening side of the boiler cover, then loosen the clamps on the
hinge side until the cover is at least 10-15 mm away from the boiler.

• Make sure that the boiler's front cover refractory and turbulators are

cooled.

• Remove the turbulators.

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

gases.

• Reassemble and tighten cleaning cover at the rear cover with care to

the sealing element.

• Put the turbulators back. All pipes must have a turbulator.

• Close the front cover. Visually check the cover gas insulating gasket

and refractory.

• If removed, reassemble the fuel line.

• Open the fuel line.

• Carry out a fuel leakage check on the disassembled area (Never use

fire)

• Switch on the main power supply.

• You can put the system into operation again (If the fuel line is removed,

the burner may not start in the first 1-2 attempts; it will be activated
when the air in the fuel line is bled).

Call your authorized service at least once a year to have them to control

of the combustion parameters, safety and control devices.
Call your authorized service at least once a year to have them to control of the
combustion parameters, safety and control devices.

When the burner failures, please check the following before calling the authorized
service.

• Is there required power supply in boiler and burner control panels?

• Are the fuel valves open?

• Are the main power switches on the boiler and burner control panel open?

• Is the boiler water temperature below the temperature at which the

boiler thermostat is set?

• Is the fuel available within the limits given? (Min. gas pressure or fuel

level in fuel tank)

• Is the system water level or pressure within normal limits?

• Did you manually reset the limit temperature stop thermostat?

• Please do not change the setting of any safety devices.

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. If
the pre-filling gas pressure is lower than the specified, the system pressure will
rise abnormally and this may cause an explosion.
In closed expansion systems operated with an expansion tank with membrane,
the tank gas pressure must be checked regularly by an authorized service. If
the pre-filling gas pressure is lower than the specified, the system pressure will
rise abnormally and this may cause an explosion.
If there is a fuel, flue gas or water leakage in any part of the heating system,
stop the system immediately and contact your authorized service or the
responsible authority. If any of the flue gas gaskets have been damaged and
the flue gas leakage is present, switch off the burner and please call your
authorized service for repair or replacement.
Periodically analyze the feed water to prevent deposits (such as limestone) and
corrosion. Deposits such as limestone can lead to reduced system efficiency in
the short term and permanent damage to the boiler in the long term. Check your
safety and control devices periodically.
Wet rotor pumps not operated for long-term (summer period) may have a
locking problem due to corrosion. Operate the wet rotor pumps in the system
once a month for 5 minutes to prevent locking.
The frequent need for feed water and the frequent drop in the system water
pressure/level indicate that there is water leakage in the heating system. It must
be solved immediately.
Never drain the system if it is not necessary. In empty systems, wear is much faster.
New water filling means adding new undesirable substances and oxygen to the
system. All these reasons shorten the life of the boiler and cause loss of efficiency.
The water level and/or pressure of the system should be checked at least once a
month. After initial installation, more frequent checks may be required until the
system become stable.
The burner should be checked regularly. Observe the maintenance periods
specified in the burner manual.
It is recommended to add oil to the section where the sensor of the heat thermostat
is placed. Check oil level at least once a year and add oil if reduced. The liquid oil to
be added allows the temperature sensors to react more quickly and accurately.

Flue must be cleaned periodically according to local regulations.

39

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)

1. Control Panel Fuse (6 Av)

2. Safety Limit Thermostat (100 °C)

3. Boiler Temperature Gauge (30-120°C)

4. Main Control Switch

5. Control Panel Energy Lamp,

Pump Running Lamp

6. Limit Thermostat Fault Lamp

7. First and Second Stage Thermostats

Eco-panel (PE 7/21 or PE 12/31)

1.

Control Panel Fuse (6 A)

2.

Safety Limit Thermostat (100 °C)

3.

Boiler Temperature Gauge (0-120°C)

4.

Main Control Switch (0/1)

5.

Control Panel Energy Lamp, Pump
Running Lamp

6.

Limit Thermostat Fault Lamp

7.

Eco-panel (PE 7/21 or PE 12/31)

8.

First and Second Stage Thermostats
(30-85°C/7K)

40

APPENDICES

NOTE: IN BOILERS OF UP TO CG

S 1250,

1=FLOW AND 2=RETURN, IN BOILERS OF

UP TO CGS 1250 AND ABOVE, 1=RETURN

AND 2=FLOW.

Heating system Circulation pump By pass pump Open expansion tank 3-way valve Safety (limit) thermostat Boiler thermostat Thermometer (0

-120 C)

Manometer (6 bar) Max. pressure limiter Min. pressure limiter Relief valve Blow-off valve Lock valve Pressure regulator Check valve (non

-return valve)

Cold water meter Automatic filling system Drain valve HS

SP

ACP

MET

3WV

TC,

TC

Tl

P,

SPL1

SPL2

sv

FT

IV

PR

cv M ARFS

DV

SAFETY

EQUIPMENT AND HYDRAULIC

DIAGRAM FOR SYSTEMS WITH CLOSED EXPANSION TANK

BOILER

41

NOTE: IN BOILERS OF UP TO CGS 1250,

1=FLOW AND 2=RETURN, IN BOILERS OF

UP TO CGS 1250 AND ABOVE,

1=RETURN AND 2=FLOW.

Heating system Circulation pump By pass pump Open expansion

tank

3-way valve Safety (limit) thermostat Boiler thermostat Thermometer Hydrometer Low pressure switch Lock valve

Valve

Pressure regulator Check valve (non

-return valve)

Drain valve Safety flow pipe Safety return pipe Overflow pipe Ventilation pipe

HS

SP

BPP

OEC

3WV

TCL

TC

Tl

HM

WLI

LV v PR

CV

DV

GB

DB

TB

HB

SAFETY EQUIPMENT AND HYDRAULIC

DIAGRAM FOR SYSTEMS WITH OPEN

EXPANSION TANK

BOILER

42

BURNER INSTALLATION

NOTICE

If the gap between the burner barrel diameter and the boiler cover refractory is more than 10 mm, fill the gap tightly with 1

200 C

degree ceramic fiber supplied with the boiler.

2.Observe the size of the

burner connection bolts.

Bolt length should not exceed the total thickness of the burner connection flange,

gasket and burner adapter plate. 3. The burner barrel pipe should pass the inner alignment of the cover at a distance of 50

-

100 mm.

Burner adapter plate

Burner barrel insulatio

n

Ceramic wool

Rock wool

Rock wool

Ceramic wool

must be 50

-

100 mm

43

BOILER BASE DIMENSIONS
CGS 2 and CGS 3 100-800 BOILERS

Model

B(mm)

C(mm)

CGS2-80

660

900

CGS2-100

770

1050

CGS2-125

770

1050

CGS2-150

770

1050

CGS2-200

890

1260

CGS2-250

890

1260

CGS2-300

990

1500

CGS2-350

990

1500

CGS2-400

1090

1770

CGS2-450

1090

1770

CGS2-500

1180

1770

CGS2-600

1180

1770

CGS2-700

1310

1970

CGS2-800

1310

1970

Model

B(mm)

C(mm)

CGS3-100

680

1050

CGS3-125

680

1150

CGS3-150

680

1300

CGS3-175

750

1300

CGS3-200

750

1400

CGS3-250

750

1450

CGS3-300

750

1500

CGS3-350

880

1560

CGS3-400

880

1670

CGS3-450

880

1750

CGS3-500

960

1860

CGS3-600

1050

1900

CGS3-700

1050

2000

CGS3-800

1090

2130

CGS 3, 1000-3000 BOILERS

Model

B(mm)

C(mm)

CGS3-1000

1100

2000

CGS3-1250

1100

2000

CGS3-1500

1280

2300

CGS3-1750

1280

2500

CGS3-2000

1280

2550

CGS3-2500

1440

2600

CGS3-3000

1440

2800

44

BOILER LAYOUT

A: Burner leng

th

B: Min. 600 mm W: Min.(

A+100)mm.

D: L/2 + 500 L: Boiler length H: Boiler room height should be at least (Boiler height + 12000) mm.

Note: These dimensions are recommended reference values. They may vary according to local

standards.

45

Rated Heat Power (kW)

FOR SQUARE SECTION (PLEVVA)

Effective Flue System Height (m)

Inner Diameter

46

Rated Heat Power (kW)

CIRCULAR SECTION (SCHIEDEL)

Effective Flue System Height (m)

47

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
STAGE THERMOSTAT RUNNING LAMP F : 6.3 AMP FUSE

48

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
LT : SAFETY LIMIT THERMOSTAT
PL : PUMP LAMP (1ST MIXTURE ZONE)
AL : LIMIT FAULT LAMP
KT1 : 1ST STAGE BOILER THERMOSTAT
16-17-18 : 2ND STAGE BOILER THERMOSTAT
G : SENSOR JOINT TERMINALS
N: NEUTRAL
L: PHASE
AF : OUTDOOR AIR SENSOR

WF/KF : BOILER SENSOR
SF : BOILER SENSOR
VF1 : MIXTURE CIRCUIT SENSOR (1ST ZONE)
VF2 : MIXTURE CIRCUIT SENSOR (2ND ZONE)
P2 : 2ND ZONE MIXTURE CIRCUIT PUMP
13-14 : 2ND ZONE 3-WAY VALVE ON-OFF PHASES
P1 : 1ST ZONE MIXTURE CIRCUIT PUMP
7-8 : 1ST ZONE 3-WAY VALVE ON-OFF PHASES
BP : BOILER PUMP
DP : DIRECT CIRCUIT PUMP

49

ECO-PANEL 7/21 AND 12/31 EASY OPERATION GUIDE

Controller

1 "Manual operation" / "Emission measurement" button

(It is not included in remote controlled heating system

control panel)
2 "Operating mode" button (Basic indicator)
3 "Time Programs" / "Holiday programs button"
4 "System information" button
5 Display
6 Snap-in cover for service connector
7 "Day room temperature" button
8 "Economy temperature" button
9 "Domestic water temperature" button (KSS)
10 Entry button (push/turn)
11 Symbols of operating modes (Heating programs)

Entry button (push/turn) - General functions

Nominal values and parameters selected using the entry
button can be changed and then saved by pressing it.
Various programs can be selected by turning the entry
button.

Right The setting value increases.
turn (+):

Left The setting value decreases.
turn (-):
Pressing: the selected and displayed

value is applied

Hold down: Switch to the programming section,

return to previous
selection

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.

Special indicators

Ice crystal symbol:
System frost protection
active

Parasol symbol: Summer
mode active (Heating system
off, KSS running as
programmed)

Error Message (Ex. KSS)
appears alternately with the
standard indicator. Contact an
authorized service!

Emission measurement

(In heating system control panels, for service only)

press the button.

Current boiler water
temperature Time elapsed
after activation

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.

Boiler water temperature:
Current actual value desired setting
value (flashes)

Set the boiler water temperature to
the desired value

Automatic recommissioning:

press the button.

Setting the day room temperature

press the button.

Changing the temperature:

Setting range: 5 to 30 °C

Application of change:

or

or

automatic depending on the duration of the set information.

Setting the economy temperature

press the button.

Changing the temperature:

Setting range: 5 to 30 °C

Application of change:

or

or

automatic depending on the duration of the set information.

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:

or

or

automatic depending on the duration of the set information.

Heating curves

The heating power through the heating curves
is adapted based on the structural properties of the building
from the relevant outside temperature.

Correction of vertical fluctuations in the heating curve

Entering the menu:

Press and hold
this button for about

3 seconds.

Selecting the heating
circuit:

DD= Direct heating circuit
KD1 = Mixture Circuit 1
KD2 = Mixture Circuit 2

Application of change:

Correction of characteristic
curve:

Room temperature too high:

Decrease the setting value

Room temperature too low:
Increase the setting value

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.

PARTY END At the specified date, the heating time is

extended to the set time.

2. Automatic programs:

Automatic heating process
according to operating hours program.

According to the working hours program,
only domestic water is active;
The heating system is disabled
for frost protection.

AUTOMATIC

SUMMER

3. Continuous programs:

HEATING

ECO HEATING

Continuous heating operation
without time limit.
Continuous heating operation in economic
operating mode without time limit.

Disabling the heating system and domestic water for
frost protection.

STANDBY

Selecting program

After pressing button <0, the last selected program appears
flashing. All other programs can be selected via the entry button
by placing the symbol (quadrangular) located on the upper part
of the operating symbols on the related symbol.

The selected program is activated by pressing the entry button.

54

Example: Press the Automatic program

button and select the option AUTOMATIC.

Application of change:

or

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.

Example: Press the Party program

button and select the option PARTY END.

Application of change:

or

Changing the time:

Application of time:

or

4. Holiday programs

Holiday programs can be selected by pressing button

HOLIDAY

Disabling the heating system for frost protection
or low power operation of the heating system
during the holiday period. The domestic water
temperature is disabled for frost protection.

Example: Press the holiday programs

button, select the option HOLIDAY and confirm by pressing

Select the holiday block E.g. HOLIDAY 01) and

confirm with it.

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:

• System temperatures (Actual values)

• Functions and values of variable inputs

• Meters and consumption data

Heating circuit information, e.g.

• Program type (HOLIDAY, OUTSIDE, RETURN HOME,
PARTY END, AUTOMATIC etc.)

• Current operating hours programs (P1 or P1-P3 depending
on activation)

• Operating Mode (Daytime operation, low power operation,
disabling operation)

• Heating circuit depending on the model of the device
(DD = Direct heating circuit, KD1= Mixture Circuit 1, KD2=
Mixture Circuit 2, KSS= Domestic Water Circuit)

• Related heating circuit pump status (OFF-ON)

• Related Valve motor status (ON-STOP-OFF)

• Boiler status (OFF-ON)

• Status and functions of variable outputs

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.
Returning to the previous selection is made by pressing the
button. By pressing the return to the standard screen button
or according to the set duration of information, it is made
automatically.

1. Selecting the circuit, Restoring and

copying of standard programs

Setting range: Direct heating circuit (DD), Mixture

circuit 1 (KD1), Mixture circuit 2 (KD2),
Domestic water circuit (KSS), standard
programs, copying of heating circuits

Continue:

2. Selecting the Time Program

Prerequisite:
It is set as Parameter 02 = P1-P3 in the "system parameters"
menu.

Setting range: P1,P2, P3
Continue:

57

3. 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.

Continue:

4. Start of heating (Activation time)

Setting range: Between 0.00 - 24.00 hours
INFORMATION: The activation time is shown in the

top clock tab via a flashing section.

Continue:

5. End of Heating (Deactivation time)

Setting range: Between 0.00 - 24.00 hours
INFORMATION: The deactivation time is shown in the

top clock tab via an additional flashing section.

Continue:

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
temperatures are changed accordingly and at
the same value!

Continue:

7. Day and heating cycle

selection, copying (Block
creation)

If necessary, select the next heating cycle or day as described
in Step 3 below and adjust accordingly.

59

BOILER LABEL INFORMATION
1ST BOILERS WITH A CAPACITY OF UP TO 1000 KW:

www.alarko-carrier.com.tr

Email: [e-mail]

İSTANBUL: GOSB-GebzeOrganize Sanayi Bölgesi Ş.Bilgisu Cad. Gebze 41480 KOCAELİ Phone: [phone] Fax: [phone] ANKARA: Sedat Simavi Sok.

No:48, Çankaya 06550 ANKARA Phone: [phone] Fax:[phone] İZMİR: Şehit Fethibey Cad. No:55 Kat:13, Pasaport 35210 İZMİR Phone: [phone] Fax:

[phone] ADANA: Ziyapaşa Bulvarı, No: 19/5-6, 01130 ADANA Phone: [phone] Fax: [phone] ANTALYA: Mehmetçik Mahallesi, Aspendos Bulvarı,

No: 79/5 ANTALYA Phone: [phone] Fax: [phone]

NAME OF THE
PRODUCT

HOT WATER BOILER

FLUE TYPE:
MODEL TYPE:

STANDARD

EN 303-1, EN 303-3

CAPACITY

kcal/h

FUEL CATEGORY

MAX. OPERATING
PRESSURE

bar

DATE OF
MANUFACTURE

MAX. OPERATING
TEMPERATURE

°C

SERIAL NO

2ND BOILERS WITH A CAPACITY OF 1000 KW AND ABOVE:

www.alarko-carrier.com.tr

Email: [e-mail]

İSTANBUL: GOSB-GebzeOrganize Sanayi Bölgesi Ş.Bilgisu Cad. Gebze 41480 KOCAELİ Phone: [phone] Fax: [phone] ANKARA: Sedat Simavi Sok.

No:48, Çankaya 06550 ANKARA Phone: [phone] Fax:[phone] İZMİR: Şehit Fethibey Cad. No:55 Kat:13, Pasaport 35210 İZMİR Phone: [phone] Fax:

[phone] ADANA: Ziyapaşa Bulvarı, No: 19/5-6, 01130 ADANA Phone: [phone] Fax: [phone] ANTALYA: Mehmetçik Mahallesi, Aspendos Bulvarı,

No: 79/5 ANTALYA Phone: [phone] Fax: [phone]

NAME OF THE
PRODUCT

HOT WATER BOILER

FLUE TYPE:

MODEL TYPE:

STANDARD

EN 303-1, EN 303-3, EN 12953

CAPACITY

kcal/h

FUEL CATEGORY

MAX. OPERATING
PRESSURE

bar

DATE OF
MANUFACTURE

MAX. OPERATING
TEMPERATURE

°C

SERIAL NO

60

CGS2

-800

800

930

863

1004

92,7 90 2,8

0,20

2025

1012 190

120 1505 903 * These values are given according to 10% CO2 in natural gas. It was calculated at the boiler water temperature of 75 °C and

the combustion air temperature of 20 °C. 30% of the rate

d power was taken

as a partial load. If there is a change in the partial load, the calculation must also be performed.

CGS2

-700

700

814

755

878

2,6

0,18

NW100 NW100

1755

794 1317 790

CGSK2

-60

0

600

698

647

753

2,8

0,16

NW100 NW100

1485

691 1130 678

CGS2

-500

500

582

539

627

2,3

0,16

NW100 NW100

1350

652 942 565

CGS2

-450

450

523

485

565

2,2

0,15

1 1/2" 1 1/2" 1250

630 847 508

CGS2

-400

400

465

431

502

2,2

0,15

1 1/2" 1 1/2" 1125

608 753 452

CGS2

-350

350

407

378

439

2,0

0,15

1 1/2" 1 1/2" 990

394 660 396

CGS2

-300

300

349

324

376

1,4

0,14

1 1/2" 1 1/2" 790

347 566 340

CGS2

-250

250

291

270

314

1,6

0,14

1 1/2" 1 1/2" 712

293 471 283

CGS2

-200

200

233

216

251

1,4

0,12

1 1/2" 1 1/2" 552

234 378 227

CGS2

-150

150

174

162

188

1,2

0,10

1 1/4" 1 1/4" 447

139 284 170

CGS2

-125

125

145

135

157

0,6

0,10

407

151 237 142

CGS2

-100

100

116

108

125

0,6

0,06

352

141 188 113

Unit

kcal/h x 1000

kcal/h x 1000

bar

mbar

mbar mSS

inch

inch

inch

inch

gr/sec

gr/sec

Pa, mbar

Efficie

ncy

Maximum operating pressure Maximum operating temperature

Recommended flow rate (At recommended flow rate) Water flow to the installation Water return from the installation Safety flow connection Safety return connection Weight of boile

r (without water)

Boiler water volume Flue gas values * Full load Partial load Full load Full load Partial load Partial load Flue gas required delivery

pressure

Flue gas

temperature

Flue gas flow

rate

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

61

CGS3-800

800

930

863

1004

92,7

5,0

0,18

NW100 NW100

1890

1290 * 185

130 1505 903 * These values are given according to 10% CO2 in natural gas. It was calculated at the boiler water temperature of 75 °C and

the combustion air temperature of 20 °C. 30% of the rated power was taken as a

partial load. If there is a change in the partial load, the calculation must also be performed.

CGS3-750

750

872

809

941

92,7

4,5

0,16

NW100 NW100

1780

1190

185

130 1411 847 CGS3-700

700

814

755

878

92,7

4,2

0,14

NW100 NW100

1700

980

185

130 1317 790 CGS3-650

650

756

701

816

92,7

4,0

0,12

NW100 NW100

1620

950

185

130 1220 732 CGS3-600

600

698

647

753

92,7

3,8

0,12

NW100 NW100

1550

920

185

130 1030 618 CGS3-550

550

640

593

690

92,7

3,0

0,10

NW100 NW100

1490

850

185

130 1035 621 CGS3-500

500

582

539

627

92,7

2,8

0,10

NW100 NW100

1350

800

185

130 942 565 CGS3-450

450

523

485

565

92,7

2,4

0,08

NW80 NW80 1 1/2" 1 1/2" 1185

740

185

130 847 508 CGS3-400

400

465

431

502

92,7

2,0

0,08

NW80 NW80 1 1/2" 1 1/2" 1108

700

185

130 753 452 CGS3-350

350

407

378

439

92,7

1,8

0,08

NW80 NW80 1 1/2" 1 1/2" 950

600

185

130 660 396 CGS3-300

300

349

324

376

92,7

1,8

0,07

NW80 NW80 1 1/2" 1 1/2" 880

525

185

130 566 340 CGS3-250

250

291

270

314

92,7

1,4

0,07

NW65 NW65 1 1/2" 1 1/2" 805

460

185

130 471 283 CGS3-200

200

233

216

251

92,7

1,2

0,06

NW65 NW65 1 1/4" 1 1/4" 650

440

185

130 378 227 CGS3-175

180

209

194

226

92,7

1,2

0,06

NW65 NW65 1 1/4" 1 1/4" 605

420

185

130 332 199 CGS3-150

150

174

162

188

92,7

1,0

0,06

NW65 NW65

500

375

185

130 284 170 CGS3-125

125

145

135

157

92,7

1,0

0,05

NW50 NW50

450

280

185

130 237 142 CGS3-100

100

116

108

125

92,7

0,9

0,05

NW50 NW50

390

250

185

130 188 113 Unit

kcal/h x 1000

kcal/h x 1000

bar

mbar

mbar mSS

inch

inch

inch

inch

gr/sec

gr/sec Pa, mbar

Efficiency Maximum operating pressure Maximum operating temperature

Recommended flow rate (At recommended flow rate) Water flow to the installation Water return from the installation Safety flow connection Safety return con

nection

Weight of boiler (without water) Boiler water volume Flue gas values * Full load Partial load Full load Full load Partial load Partial load Flue gas required delivery pressure

Flue gas

temperature

Flue gas flow

rate

62

BURNER SELECTION FOR STEEL BOILERS TABLE -260713 1.
BOILERS WITH A CAPACITY OF UP TO 1000 KW:

Natur

al

Gas

Burne

r

300

mbar

Flange

Diamet

er

(mm)

190

190

190

190

190

180

190

190

190

256

190

190

190

190

190

190

190

190

256

Note: The burner to be use

d must be checked whether it can pass through the burner hole of the boiler, if the hole is small, it should be

reported during the order to request the appropriate hole to be drilled.

Modulating

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 60/M-1 1/4" MBC 300 ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 77/M

-1 1/4" MBC 300

ALG 94/M

-1 1/4" MBC 300

ALG 94/M

-1 1/4" MBC 300

ALG 120/M

-2" MBC 700

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC

300

ALG 60/M

-1 1/4" MBC 300

ALG 77/M

-1 1/4" MBC 300

ALG 94/M

-1 1/4" MBC 300

ALG 94/M

-1 1/4" MBC 300

ALG 120/M

-2" MBC 700

Flange

Diamet

er

(mm)

115

155

155

155

155

190

190

190

115

155

155

155

155

190

190

190

Two Stage

ALG 16/2

-1/2"

ALG 27

/2-3/4"

ALG 27/2

-3/4"

ALG 36/2

-3/4"

ALG 36/2

-3/4"

ALG 60/2

-3/4"

ALG 60/2

-3/4"

ALG 60/2

-3/4"

ALG 16/2

- 1/2"

ALG 27/2

- 3/4"

ALG 27/2

- 3/4"

ALG 36/2

- 3/4"

ALG 36/2

- 3/4"

ALG 60/2

- 3/4"

ALG 60/2

- 3/4"

ALG 60/2

- 3/4"

Flange

Diamet

er

(mm)

115

115

Single

Stage with

Damper

Motor

ALG 16DM

-1/2"

ALG 16DM

-1/2"

21

mbar

Flange

Diamete

r (mm)

190

190

190

190

190

190

190

190

256

190

190

190

190

190

190

190

190

256

Modulating

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-2" MBC 700

ALG 60/M

-2" MBC 700

ALG 77/M

-2" MBC 700

ALG 94/M

-2" MBC 1200

ALG 94/M

-2" MBC 1200

ALG 120/M

-2" MBC 1200

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MBC 300

ALG 60/M

-1 1/4" MB

C 300

ALG 60/M

-2" MBC 700

ALG 60/M

-2" MBC 700

ALG 77/M

-2" MBC 1200

ALG 94/M

-2" MBC 1200

ALG 94/M

-2" MBC 1200

ALG 120/M

-2" MBC 1200

Flange

Diamet

er

(mm)

115

155

155

155

155

190

190

190

115

155

155

155

155

190

190

190

Two Stage

ALG 16/2

-3/4"

ALG 27/2

-3/4"

ALG 27/2

-1"

ALG 36/2

-1 1/2"

ALG 36/2

-1 1/2"

ALG 60/2

-1 1/2"

ALG 60/2

-1 1/2"

ALG 60/2

-2"

ALG 16/2

-3/4"

ALG 27/2

-3/4"

ALG 27/2

-1"

ALG 36/2

-1 1/2"

ALG 36/2

-1 1/2"

ALG 60/2

-1 1/2"

ALG 60/2

-1 1/2"

ALG 60/2

-2"

Flange

Diamet

er

(mm)

115

115

Single

Stage with

Damper

Motor

ALG 16DM

-1"

ALG 16DM 1"

Boiler

Outp

ut

Pow

er

(kW)

116

145

174

232

290

349

407

465

581

698

814

930

116

145

174

232

290

349

407

465

581

698

814

930

Type

CGS2

-100
CGS2-125

CGS2

-150

CGS2

-200

CGS2

-250

CGS2

-300

CGS2

-350

CGS2

-400

CGS2

-500

CGS2

-600

CGS2

-700

CGS2

-800

CGS3

-100

CGS3

-125

CGD3

-150

CGS3

-200

CGS3

-250

CGS3

-300

CGS3

-350

CGS3

-400

CGS3

-500

CGS3

-600

CGS3

-700

CGS3

-800

63

BURNER SELECTION TABLE FOR STEEL BOILERS-260713

Flange

Diamete

r (mm)

Modulating

Flange

Diamet

er (mm)

132

132

132

132

162

162

162

162

162

185

185

230

132

132

132

132

162

162

162

162

162

185

185

230

Fuel Oil Burner

Two Stage

ALF 24/2

-T

ALF 24/2

-T

ALF 24/2

-T

ALF 24/2

-T

ALF 42/2 ALF 42/2 ALF 42/2 ALF 65/2 ALF 65/2 ALF 80/2 ALF 80/2 ALF 130/2 ALF 24/2

-T

ALF 24/2

-T

ALF 24/2

-T

ALF 24/2

-T

ALF 42/2 ALF 42/2 ALF 42/2 ALF 65/2 ALF 65/2 ALF 80/2 ALF 80/2 ALF 130/2

Flange

Diamet

er (mm)

132

Note: The burner to be used must be checked whether it can pass through the burner hole of

the boiler, if the hole is small, it should be reported during the order to request the appropriate

hole to be drilled.

Single

Stage with

Damper Motor

ALF 12DM

-T

Flange

Diamet

er (mm)

132

132

132

132

162

162

162

185

185

132

132

132

132

162

162

162

185

185

Single Stage

ALF 12 ALF 24 ALF 24 ALF 24 ALF 42 ALF 42 ALF 42 ALF 65 ALF 65

ALF 12 ALF 24 ALF 24 ALF 24 ALF 42 ALF 42 ALF 42 ALF 65 ALF 65

Flange

Diamet

er (mm)

145

160

165

165

165

165

184

184

230

145

160

162

162

162

162

184

184

230

Diesel Burner

Two Stage

ALM 30/2 ALM 40/2 ALM 60/2 ALM 60/2 ALM 60/2 ALM 60/2 ALM 76/2 ALM 76/2 ALM 125/2

ALM 30/2 ALM 40/2 ALM 60/2 ALM 60/2 ALM 60/2 ALM 60/2 ALM 76/2 ALM 76/2 ALM 125/2 Flange

Diamet

er (mm)

110

135

135

145

162

162

162

162

184

110

135

135

145

162

162

162

162

184

Single

Stage

ALM 14 ALM 22 ALM 22 ALM 30 ALM 50 ALM 50 ALM 50 ALM 50

ALM 59

ALM 14 ALM 22 ALM 22 ALM 30 ALM 50 ALM 50 ALM 50 ALM 50 ALM 59

Outp

ut

Pow

er

(kW)

116

145

174

232

290

349

407

465

581

698

814

930

116

145

174

232

290

349

407

465

581

698

814

930

Boiler

Type

CGS2

-100

CGS2

-125

CGS2

-150

CGS2

-200

CGS2

-250

CGS2

-300

CGS2

-350

CGS2

-400

CGS2

-500

CGS2

-600

CGS2

-700

CGS2

-800

CGS3

-100

CGS3

-125

CGD3

-150

CGS3

-200

CGS3

-250

CGS3

-300

CGS3

-350

CGS3

-400

CGS3

-500

CGS3

-600

CGS3

-700

CGS3

-800

64

1ST BOILERS WITH A CAPACITY OF 1000 KW OR ABOVE:

Boiler

Natural Gas Burner

Diesel

Burner

Fuel Oil Burner

Type

Output
Power
(kW)

21 mbar

300 mbar

Modulating

Flange

Diamet

er

Modulating

Flange

Diame

ter

Two

Stage

Flange

Diame

ter

Two

Stage

Flange

Diame

ter

Modulating

Flange

Diame

ter

CGS3-1000

1.163

ALG 200/M MBC 1900

256

ALG 200/M-M BC 700

256

240

ALM 125/2

230

ALF 130/2

230

CGS3-1250

1.453

ALG 200/M MBC 3100

256

ALG 200/M-M BC 700

256

240

ALM 174/2

230

ALF 180/2

230

RMS9 VMDU

278

CGS3-1500

1.744

ALM 174/2

230

ALF 180/2

230

RMS9 VMDU

278

CGS3-1750

2.034

L9 VZDU

278

MS9 VZDU

278

RMS9 VMDU

278

CGS3-2000

2.325

L9 VZDU

278

MS9 VZDU

278

RMS9 VMDU

278

CGS3-2500

2.907

L9 VZDU

278

MS10 VZDU

278

RMS10 VMDU

278

CGS3-3000

3.488

L10 VZDU

278

MS10 VZDU

278

RMS10 VMDU

278

Note: The burner to be used must be checked whether it can pass through the burner hole of the boiler, if the hole is small, it should be reported during the order

to request the appropriate hole to be drilled.

65

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. Gas Sealing Unit (optional for small capacity burners

3. Gas Line Inlet Pressure Measuring Point

of less than 1200 kW)

4. Gas Filter

11. Air Pressure Switch

5. Minimum Gas Pressure Switch

12. Burner Gas Pressure Measuring Point

6. Safety Solenoid Valve

13. Burner

7. Gas Pressure Regulator

14. Regulator Output Pressure Measuring Point

8. Operating Solenoid Valve

15. Gas Line Output Pressure Measuring Point

66

LIQUID OR GASEOUS FUEL BOILER CONTROL AND COMMISSIONING FORM

Customer name, address

Phone and fax number
Authorized dealer name

Authorized dealer

Installer company

Installer company phone

Authorized service

Authorized service

Product model and type

Product serial no

Invoice date

Invoice no

Warranty certificate no

Suitable for gas, certificate

Burner model

Burner serial no

INSTALLATION CONTROL

Yes

No

Yes

No

BOILER ROOM

Boiler room layout is adequate

Water system connections are adequate

Electrical installation is

Ventilation is adequate

BOILER

Electrical control board suitable is adequate

Boiler sections installation is adequate (if casting)

Boiler safety thermostat is adequate

Expansion tank connection is adequate

Boiler relief valve is adequate

Operation of pumps is adequate

Boiler base is adequate

System is watered, deaerated

WATER SYSTEM

A drain valve at the bottom of the installation is available

A bleed valve on radiators is available

An air purge valve at the top of the installation is available

BURNER SYSTEM

Burner installation is adequate

The entrance of the barrel into the boiler is adequate

A carrier support under the burner is available, adequate

..................... cm

CLOSED EXPANSION TANK

Connection diameter is adequate ................ finger

No valve in the connection line to the boiler

Tank volume is adequate, ................ liter

Gas pressure was measured when the tank was

FLUE SYSTEM

Boiler flue connection is adequate

Number of elbows and angles are adequate

Flue cross section is

Insulated, adequate

COMMISSIONING

Burner authorized service operated the burner

Radiator temperatures checked

On / Off switch checked

Flue draught checked

Burner thermostats working

2

Circulation pumps operated

Heated radiator is adequate, .............. meter

IMPORTANT NOTICES

Have your authorized service checked your equipment at least once a year. Faults that may occur due to misuse, faults in the electrical system, voltage imbalance,

unauthorized persons intervention, lack of maintenance, frost and usage error are not covered by the warranty.

CONCLUSION

The equipment has been put into operation, the operating manual and warranty certificate have been delivered

and the instructions for use has been given.

□ Yes

□

No

Authorized service (Name, signature, date)

........./........... / ...................

Customer (Name, signature, date)

........ / .......... / ...................

EXPLANATION

67

CGS STEEL BOILER FLUE INFORMATION

Rated Thermal

Power / Rated

Capacity (kW)

Ignition Thermal
Power / Rated
Thermal Load

(kW)

CO2 Amount

(%)

Waste Gas Flow

(g/sec)

Waste Gas

Temperature

(°C)

Pressure

Required

to be in

Flue

(mbar)

Flue Outlet

Diameter (mm)

Full

Load

Partial

Load

Full

Load

Partial

Load

Full

Load

Partial

Load

Full

Load

Partial

Load

Full

Load

Partial

Load

Full

Load

Partial

Load

Full

Load

Partial

Load

CGS 2-100

116

35

125

38

10

10

47

28

190

120

-0,1; 0

-0,1; 0

200

200

CGS 2-125

145

44

157

47

10

10

60

35

190

120

-0,1; 0

-0,1; 0

200

200

CGS 2-150

174

52

188

56

10

10

71

42

190

120

-0,1; 0

-0,1; 0

200

200

CGS 2-200

233

70

251

75

10

10

95

57

190

120

-0,1; 0

-0,1; 0

200

200

CGS 2-250

291

87

314

94

10

10

117

71

190

120

-0,1; 0

-0,1; 0

200

200

CGS 2-300

349

105

376

113

10

10

141

85

190

120

-0,1; 0

-0,1; 0

250

250

CGS 2-350

407

122

439

132

10

10

165

99

190

120

-0,1; 0

-0,1; 0

250

250

CGS 2-400

465

140

502

151

10

10

188

113

190

120

-0,1; 0

-0,1; 0

250

250

CGS 2-450

523

157

565

170

10

10

212

127

190

120

-0,1; 0

-0,1; 0

250

250

CGS 2-500

582

175

627

188

10

10

235

141

190

120

-0,1; 0

-0,1; 0

300

300

CGS 2-600

698

209

753

226

10

10

282

170

190

120

-0,1; 0

-0,1; 0

350

350

CGS 2-700

814

244

878

263

10

10

330

198

190

120

-0,1; 0

-0,1; 0

350

350

CGS 2-800

930

279

1004

301

10

10

376

226

190

120

-0,1; 0

-0,1; 0

350

350

CGS 3-100

116

35

125

38

10

10

47

28

190

120

-0,1; 0

-0,1; 0

150

150

CGS 3-125

145

44

157

47

10

10

60

35

190

120

-0,1; 0

-0,1; 0

150

150

CGS 3-150

174

52

188

56

10

10

71

42

190

120

-0,1; 0

-0,1; 0

150

150

CGS 3-200

233

70

251

75

10

10

95

57

190

120

-0,1; 0

-0,1; 0

200

200

CGS 3-250

291

87

314

94

10

10

117

71

190

120

-0,1; 0

-0,1; 0

200

200

CGS 3-300

349

105

376

113

10

10

141

85

190

120

-0,1; 0

-0,1; 0

250

250

CGS 3-350

407

122

439

132

10

10

165

99

190

120

-0,1; 0

-0,1; 0

250

250

CGS 3-400

465

140

502

151

10

10

188

113

190

120

-0,1; 0

-0,1; 0

250

250

CGS 3-450

523

157

565

170

10

10

212

127

190

120

-0,1; 0

-0,1; 0

250

250

CGS 3-500

582

175

627

188

10

10

235

141

190

120

-0,1; 0

-0,1; 0

300

300

CGS 3-600

698

209

753

226

10

10

282

170

190

120

-0,1; 0

-0,1; 0

300

300

CGS 3-700

814

244

878

263

10

10

330

198

190

120

-0,1; 0

-0,1; 0

350

350

CGS 3-800

930

279

1004

301

10

10

376

226

190

120

-0,1; 0

-0,1; 0

350

350

CGS 3-1000

1163

349

1255

377

10

10

465

280

190

120

-0,1; 0

-0,1; 0

400

400

CGS 3-1250

1454

436

1568

470

10

10

582

349

190

120

-0,1; 0

-0,1; 0

400

400

CGS 3-1500

1745

524

1882

565

10

10

698

418

190

120

-0,1; 0

-0,1; 0

450

450

CGS 3-1750

2035

611

2196

659

10

10

814

488

190

120

-0,1; 0

-0,1; 0

450

450

CGS 3-2000

2326

698

2509

753

10

10

930

558

190

120

-0,1; 0

-0,1; 0

500

500

CGS 3-2500

2908

872

3137

941

10

10

1163

698

190

120

-0,1; 0

-0,1; 0

600

600

CGS 3-3000

3489

1047

3764

1129

10

10

1395

838

190

120

-0,1; 0

-0,1; 0

600

600

Note: The partial load is considered to be 30% of the full load capacity.

İSTANBUL : GOSB - Gebze Org. S an. Bölgesi, Ş. Bilgisu Cad. 41480 Gebze-KOCAELİ

Phone: [phone] - Fax: [phone]

ANKARA : Sedat Simavi Sok. N o: 48, 06550 Çankaya - ANKARA Phone: [phone]

00 - Fax: [phone]

İZMİR : Şehit Fethibey Cad. No:55, Kat:13, 35210 Pasaport - İZMİR Phone: (0232)

483 25 60 - Fax: [phone]

ADANA : Ziyapaşa Bulvarı Çelik Ap. No : 25/5-6, 01130 ADANA Phone: [phone]

23 - Fax: [phone]

ANTALYA : Mehmetçik M ahallesi Aspendos Bulvarı No: 79/5 - ANTALYA Phone: (0242)

322 00 29 - Fax: [phone] MDH : 444 0 128

web: www.alarko-carrier.com.tr
e-mail: [e-mail]