Clyde Alkon 90 Datasheet

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Page 1

May 2010

Clyde Alkon 90

Floor standing condensing boilers

Natural Gas

90 kW

LP Gas

90 kW

Engineering Data Sheet 814/1

Contents Page

General information 2 & 3 Dimensions and Data 4 Installation requirements 5 & 6 Boiler wiring diagram 7 Hydraulic systems 8 to 12

Fully modulating burner and efficiency of up to 109.1% ncv Modulating integral pump Modular arrangement of floor standing boilers that simply bolt together Cascade of up to 8 boilers (2 x 4) without additional frames or manifold Aluminium/silicon/magnesium heat exchanger resists corrosion Counter flow heat exchange maximises heat transfer & thermal efficiency For internal and external installations

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Page 2

General information

Key to Figs 1 & 2

1 Non-return valve

2 Isolating valve

3 Modulating pump

4 3-way drain cock

5 Flow temperature sensor

6 Return temperature sensor

7 Low water pressure switch

8 Limit thermostat

9 Air vent

10 Heat exchanger

11 Combustion air fan and venturi

12 Condensate level sensor

13 Exhaust gas outlet (100 mm diameter)

14 Gas valve

15 Gas isolating valve

16 Low gas pressure switch

17 Condensate trap and drain

18 Ignition electrode

19 Ionisation electrode

20 Drain cock

Fig 1 Diagram of operating principles Fig 2 Component identification for Alkon 90 boiler

Operating principles

The Alkon 90 is a floor standing condensing boiler with a counter flow heat exchanger with heat exchange pins that ensure a constant rate of heat transfer through the aluminium body. It has a fully-modulating, down-firing pre-mix gas burner (refer Figs 1 and 2). When operating in condensing mode with a flow of 50°C and a return of 30°C, it will give efficiencies of up to 109.1% (ncv). The combustion air fan and venturi (11) accurately control the volumes of gas and air and mix them in a sealed chamber prior to ignition. This ensures that there is optimum combustion at any point in the modulation range of the boiler. A small flame is held on the entire surface of the plaque burner.

An integral boiler circulation pump (3) ensures an even and constant flow through the heat exchanger - refer page 8. This pump modulates to match flow rate to heat output and increases the overall operating efficiency of the Alkon 90 boiler.

System circulating pumps should be hydraulically separated from the boiler(s) by a low velocity header.

EDS814/1 page2

Gas

DN 80 flow

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Page 3

General information

Handling

Offloading, dry storing and placing of equipment in the boiler room is the responsibility of the installer.

Equipment must be dry stored and protected from frost. Cartons must not be crushed or otherwise damaged.

Commissioning

Clyde undertake commissioning of boilers. Commissioning charges do not include servicing during the guarantee period, although this may be carried out under service contract or to specific order. Boilers should be commissioned in line with CIBSE Commissioning Code B.

Servicing

The importance of regular maintenance cannot be overemphasised if maximum efficiency is to be maintained. Customers are strongly advised to place the equipment under service contract immediately commissioning is complete.

Application

Alkon 90 boilers are manufactured and tested in accordance with the Gas Appliances Directive 90/396/EEC, the Boiler Efficiency Directive 92/42/EEC, the Low Voltage Directive 2006/95/EC, the Electromagnetic Compatibility Directive 2004/108/EC, EN 483, EN 625, and EN 677 and CE marked accordingly. They are suitable for use in LTHW heating systems with a maximum operating pressure of 8.0 bar and a maximum working temperature of 90°C (see Technical data).

Alkon 90 boilers are suitable for use with Group H second family gases (eg natural gas, G20), and Group P third family gases (eg propane, G31). and Butane/Propane mix (G30).

The boiler is suitable for use in pressurised (sealed) or open vented heating systems with a minimum static head of 0.5 bar. It is not suitable for use as a direct water heater. Where potable water is required, a matching calorifier or plate heat exchanger must be provided in the system.

Statutory requirements

The installation and commissioning of the boiler must be carried out by a qualified engineer in accordance with the instructions provided.

Gas supplies and gas burners must be installed, serviced and commissioned by a qualified person, eg. a Gas Safe registered engineer.

Guarantee

Subject to correct handling, installation and operation, all equipment is guaranteed for twelve months from the date of despatch. Boiler heat exchangers are guaranteed for a period of two years from the date of manufacture.

The guarantee is not valid if the boiler is not installed in accordance with these instructions (please refer to page

5), becomes blocked with debris and/or carbonate deposits from the system water and/or there is no documented evidence of commissioning by Clyde or their appointed engineer.

Boiler Log book

A boiler log book that provides a permanent record of commissioning and servicing data and measurements is supplied with every boiler. It is recommended that the owner ensures that this log book is kept safe and brought up to date on every occasion that routine or emergency work is carried out on the boiler.

Emitter sizing (radiators)

The boiler will operate in condensing mode whenever the return water is below 50°C and will reach its full potential if the flow water temperature is also below 50°C. However, the latter condition will mainly occur when the boiler is heating an underfloor heating scheme or transiently when recharging a DHW storage tank from cold. By careful design of a traditional heating system with radiators, and with weather compensating control in operation, the return water temperature can be held below 50°C for most of the heating season, only rising above this figure when outdoor temperatures are below zero.

For optimum performance, calculate heat losses on the basis of a 20°C internal temperature and a -8°C outdoor air temperature. With no added factors, size the radiators on the basis of published EN 442 data (

T50) and size the system pump for a 20°C temperature drop. In most cases this will ensure that the boiler begins to operate in condensing mode when the outdoor air temperature rises above 1°C and becomes fully condensing when the temperature is above 5°C. For heating schemes in buildings where the occupants have special needs, different environmental conditions may apply and further advice must be sought.

Non-condensing

10 15

-5

-8 Outdoor air temperature °C

Condensing

° C

Boiler °C

eturn water temperature °C

low water temperature °C

EDS814/1 page3

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Page 4

Dimensions and technical data

EDS814/1 page4

Plan

Dimensions

Boiler model / output kW 90 Boiler flow connection HO DN 80 Boiler return connection HI DN 80 Condensate outlet Co mm 32 Gas Inlet GI DN 50 Flue connection AA mm 100

Technical data

Flow 5 0 °C / Re tu rn 3 0 °C

Heat output (ncv) Max kW 93.6 Heat output (ncv) Mi n kW 24 Heat input (ncv) Max kW 90 Effi ci e n cy (n cv) 100 % 104 Effi ci e n cy (n cv) 30 % 109.1

Flow 8 0 °C / Re tu rn 6 0 °C

Heat output (ncv) Max kW 87.5 Heat output (ncv) Mi n kW 21.1 H eat in p u t (n c v) Max kW 90 Effi ci e n cy (n cv) 100 % 97.26 Effi ci e n cy (n cv) 30 % 96.03 Flue gas tem perature rise at full load °C 38.5 Flue gas mass flow kg /s 0.039 CO

in flue gas (1) min/max % 8.8 / 9 .6

C O i n flu e g a s (0% of O2 ) min/max m g/kW h 21.5 / 104.4 Cnodensate volume at m ax rate kg /h 14.54 Natural gas consumption (gross cv) (2) m ³/h 8.36 N0x Emissions m g/kW h 35.62 Boiler seasonal efficiency (3) % 97.41 Dry weight kg 135

Water volume l 10 Maximum allowable tem perature °C

Maximum hydraulic working pressure bar 8 CE Registration number 1312BR4926 Electrical protection X5D Max electrical power consumption W 303 Notes : (1) Measured at the flue gas adaptor (2) Bas ed on GCV 38.76 MJ/m³ (3) Calculated from the non-domes tic heating and cooling compliance guide for conformance with ADL2A and ADL2 B 20 06 u si n g the fo rm u la

seasonal = 0.81

30%

+ 0 .1 9

100%

Water flow rates and hydraulic resista nce s

Wa ter flo w ra te a t 2 0 °C tem p. ri s e l/s 1.12 Hydraulic resistance at 20°C temp. rise kPa 22

Front

Left elevation

513

129

251

430

607

119

1300

149

315

448

GI Co

Right elevation

Heat output (ncv)

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Page 5

Installation requirements

Regulations governing installation

Alkon boilers should be installed in accordance with all prevailing regulations and codes of practice, including the Building Regulations, Health and Safety Regulations PM5, Water Bylaws and the current Gas Safety (Installation and Use) Regulations. Detailed relevant guidance will also be found in;

BS 6644 :2005 Installation of appliances exceeding 70 kW net input BS 5449 Forced circulation hot water central heating systems for domestic premises CIBSE AM14: 2010 Non-domestic hot water heating systems CIBSE Guides B and C and Commissioning Code B Institution of Gas Engineers Utilization Procedures 1, 1A, 2, 4, 7 and 10.

Water treatment

Alkon 90 boilers have an aluminium/silicon/magnesium alloy heat exchanger and care must be exercised to ensure that the system water and any water treatment is compatible. Whenever a new boiler is connected to an existing system, the pipework must be thoroughly cleaned and flushed. This is to remove debris, rust particles, carbonate deposits and any existing water treatment that might be incompatible with the heat exchanger. New systems must also be thoroughly flushed to remove debris and flux deposits. Clyde recommend that a permanent means of filtration be fitted into the return pipework, such as a sludge trap, hydrocyclone or full flow duplex filters. The boiler guarantee will be invalid if waterways are blocked by debris or carbonate deposits. The pH value of the system water should be measured to ensure that it is between 6.5 and 8. Temporary hardness (calcium carbonate and magnesium carbonate) can be removed by boiling and its effects limited by preventing ingress of fresh, untreated water. Permanent hardness must not exceed 15o FR (150 mg/litre calcium carbonate). The boiler guarantee will be invalidated by the use of incorrect or incompatible water treatment. Specialist advice should be obtained, eg from;

Fernox Tel. 01483 793200

For full information on cleaning, flushing and protecting hot water systems, refer to BSRIA Application Guide AG 1/2001.

Deaeration

It is a condition of warranty that there is effective air separation and removal from the system. The air separator should be fitted at the hottest part of the system.

Boiler condensate

Alkon 90 boilers have a 32 mm flexible condensate drain that is compatible with standard plastic waste pipe. Do not use other materials, as they will corrode. The pipe size must not be reduced and there must be a continuous fall to drain. As a further precaution against freezing, condensate pipes should be run internally whenever possible and lagged when run externally.

Pressurisation of systems

Alkon 90 boilers should be installed as part of a pressurised (sealed) or open vented system with a minimum pressure of 0.5 bar. The maximum allowable pressure for the boilers is 8 bar. They are not to be used with a gravity circulation system.

Boiler location

Alkon 90 boilers can be installed external to a building if the optional top weather cover is fitted. The boiler must be mounted on a sound, smooth and level plinth of noncombustible material, capable of supporting its weight. The boiler location must be frost-free and adequately ventilated (see below). Contamination of the combustion air by inflammable vapours, high dust levels or halogenated hydrocarbons will constitute a safety hazard and will damage the boiler. The following minimum clearances around the boiler should be observed;

Front 500 mm Sides 500 mm

Air supply and ventilation

Adequate air for combustion and ventilation is essential to the safe operation of a boiler. The air for combustion and ventilation requirements of either BS 6644:2005 or IGEM/UP/10 must be met. Table 1 shows the requirements of BS 6644:2005 for boilers with a Type B flue. This standard requires natural ventilation at both high and low levels to the outside air, and is based on the net input of the boilers. BS 6644:2005 calls for additional ventilation if a boiler is used for more than 50% of the time during the summer or if the ambient temperature of the plant room ceiling exceeds 40°C.

Ventilation direct to outside air

Total kW input (net)

Low level 4 cm² per kW of total rated net

input

High level 2 cm² per kW of total rated net

input

Table 1 Ventilation for multiple boiler installations in a boiler room complying with BS 6644:2005

EDS814/1 page5

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Page 6

Installation requirements

Heat exchanger hydraulic resistance

The Alkon 90 boiler has a high resistance heat exchanger. The boilers should be hydraulically separated from the heating distribution system by either a low velocity header or a plate heat exchanger. With this arrangement, the boiler pump can be located in the return (where water temperature is lowest) regardless of the location of the system distribution pumps.

The boiler is supplied with an integral modulating pump that will ensure flow through the heat exchanger and low velocity header. The advantage offered by a modulating pump over a constant volume circulator is that the

T between flow and

return is maximised at all times by the control of mass flow, thus increasing heat exchanger efficiency.

Low velocity headers

Low velocity headers are used to separate hydraulically the boilers from the rest of the system. In addition to helping maintain a minimum flow through the boiler, they create a low velocity region for system dirt to be deposited and separation of air from the system water. Used in conjunction with a system filter (refer page 5), they are invaluable when connecting a new boiler to an existing system.

Low velocity headers should always be vertical and sized for a maximum water velocity of 0.5 m/s. Alkon 90 low velocity headers are designed to ensure a water velocity of 0.2 m/s or less and for

T10 / 20, so will be suitable for most

systems. Fig 3 shows dimensions for the low velocity header supplied by Clyde, and Table 3 shows dimensions for a

T10 / 20 system.

If the heating distribution system has been designed for <

T20 and a low velocity header has not been installed, the

boiler(s) will not provide heat into the system at their rated heat output.

R½

TO FILTER

Primary Circuit

Heating Distribution Circuit

R½

Fig 3 Design for a low velocity header

Number of

boilers in

cascade

D mm

T 10 / 20

Boiler Flow /

Boiler Return

T 10 / 20

Heating Flow /

Heating Return

T 10 / 20

a mm b mm c mm

1 DN 125 DN 65 (PN 16) DN 65 (PN 16) 500 1000 1740

2 DN 125 DN 65 (PN 16) DN 65 (PN 16) 500 1000 1740

3 DN 200 DN 100 (PN 16) DN 100 (PN 16) 500 1000 1740

4 DN 200 DN 100 (PN 16) DN 100 (PN 16) 500 1000 1740

Table 3 Low velocity header dimensions for T 10 / 20 system

EDS814/1 page6

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Page 7

Boiler wiring diagram

EDS814/1 page7

Key to Fig 4

1 Ignition electrode assembly 2 Ionisation electrode 3 Minimum water pressure switch 4 Modulating pump 5 Flow temperature sensor 6 Return temperature sensor 7 DHW temperature sensor (optional) 8 Limit thermostat 9 Flue gas temperature limit thermostat (optional) 10 Gas valve 11 Modulating fan speed control

Fig 4 Schematic wiring diagram

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Page 8

Hydraulic system design and control

Mains connection

Each Alkon 90 boiler requires a permanent mains supply of 230V 50Hz, protected by a 3 Amp fuse. The electrical supply to the boiler must be installed in accordance with current IEE (BS 7671) Regulations. A separate supply and isolating switch is required for each boiler, with at least 3 mm separation for both the phase and neutral poles.

Individual boiler operation

Alkon 90 boilers can operate independently of external controls, controlled by their internal flow and return thermostats. To control boiler operation with a basic room thermostat, programmable room thermostat or time clock, remove the link between terminals 1 and 2 on the boiler Y1 terminal board and connect to these - see fig 4.

Cascade control, weather compensation and DHW control

The addition of an E8 heating controller, connected to terminals 3 and 4 of the Y1 terminal board, will provide the following functions;

Cascade control of up to 8 boilers DHW generation via a calorifier with loading pump, giving DHW priority Temperature control of one or two heating circuits. The options are one directly controlled index circuit with a mixer

for a secondary circuit, or direct control of the DHW circuit as the index, with two mixers for the two heating circuits Weather compensation Integration of a solar thermal system

The E8 controller can be built into a plant room control panel, mounted on the wall, or supplied with an optional wall mounting box that also serves as a boiler controls wiring centre. An E8 controller is supplied as part of the cascade kit for 2, 3 and 4 boilers, and as an optional extra for single-boiler configurations if DHW control, temperature control of more than one heating zone or weather compensation is required.

Outside air sensor, DHW temperature sensor and heating circuit sensors are supplied with the E8 controller. A DHW complete wiring kit is also available. Refer to the Alkon 90 installation manual for full details and schematics.

Building and Energy Management Systems

A single E8 controller will be required if one or more boilers are to be controlled by a 0 - 10V signal from a BMS or EMS. If the overall control is by a Modbus Network, the E8 controller should be replaced with a single Boiler Communications Module (BCM) as the controlling interface. Refer to Alkon 90 installation manual for full details and schematics.

Key to figs 5 to 8

Items supplied as part of standard boiler frame and pipework kits

1 Alkon 90 master boiler with side panels and flanges 2 Alkon 90 slave boiler 7 Low velocity header connection pipework 8 Y-filter section 9 Low velocity header 10 E8 controller (not shown) is standard for 2, 3 and 4 boiler cascades, and optional for single boiler installations (see above)

Items supplied as optional extras to standard boiler frame and pipework kits

3 Safety device pipework manifold 4 Safety device housing 5 Safety device kit comprising limit temperature thermostat, maximum pressure switch, manometer, thermometer, common gas and water safety valves and boiler expansion vessel 6 Top cover for exterior use 11 BCM (Boiler Communications Module - not shown) 12 CGCPU Pressurisation unit (not shown) 13 DHW control wiring kit (not shown)

EDS814/1 page8

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Page 9

Hydraulic system design and control

EDS814/1 page9

Notes;

(1) Overall length of the standard frame and pipework kit, which does not include items 3, 4 and 5.

(2) This is the overall length including items 3, 4 and 5. These items are a safety device kit including housing, manifold, controls and boiler expansion vessel. These are optional items only and must be specifically ordered if required.

Fig 5 1-boiler frame and pipework

32 (1)

2313 (2)

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Page 10

Hydraulic system design and control

EDS814/1 page10

Notes;

(1) Overall length of the standard frame and pipework kit, which does not include items 3, 4 and 5.

Fig 6 2-boiler frame and pipework

14 (1)

2795 (2)

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Page 11

Hydraulic system design and control

EDS814/1 page11

Notes;

(1) Overall length of the standard frame and pipework kit, which does not include items 3, 4 and 5.

Fig 7 3-boiler frame and pipework

34 (1)

3415 (2)

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Page 12

Hydraulic system design and control

Notes;

(1) Overall length of the standard frame and pipework kit, which does not include items 3, 4 and 5.

Fig 8 4-boiler frame and pipework

17 (1)

3898 (2)

Units 13 - 14 Charlwoods Rd East Grinstead West Sussex RH19 2HU

e : info@clyde4heat.co.uk w : clyde4heat.co.uk

Clyde Energy Solutions Ltd

This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company's current terms and conditions of sale, a copy of which is available on request.

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Clyde Alkon 90 Datasheet

Specifications and Main Features

Frequently Asked Questions

User Manual