HydroTherm OM 06, OM 08, OM 07, OM 09, OM 11 Installation, Operation And Maintanance Manual
...
Oil / Gas Fired Boiler
Cast iron
Triple -Pass Design
378 kW to 930 kW
CONTENTS Page
INTRODUCTION 3
GUARANTEE TERMS 4
GENERAL WARNINGS 5
GENERAL CHARACTERISTICS OF OM SERIES BOILERS 7
OM SERIES CAST IRON BOILER - TECNICAL DATA 8
OM SERIES CAST IRON BOILER - DIMENSIONS 10
BOILER ROOM SETTINGS AND BOILER PLATFORM DIMENSIONS 12
PLUMBING INSTRUCTIONS 13
A SAMPLE PLUMBING DIAGRAM FOR OM SERIES CAST IRON BOILERS 14
THE MEANING OF THE SYMBOLS USED IN THE DIAGRAM 15
DIAGRAM OF A SAMPLE SINGLE BOILER HEATING CIRCUIT WITH WATER HEATER 16
WATER CIRCULATION PRINCIPAL 17
INSTRUCTIONS ABOUT FLUE 18
INSTRUCTIONS FOR CONNECTING THE FUEL TANK 19
BOILER CONTROL PANELS 20
ELECTRICAL DIAGRAMS 21
CAST IRON SECTIONS WITH HIGH EFFICIENCY 3 DRAUGHT DESIGN 22
OPERATING INSTRUCTIONS 23
LOADING AND UNLOADING BOILER WATER,INSTRUCTIONS FOR PRODUCT DISPOSAL 24
OM SERIE CAST IRON BODY -BOILER CABIN PARTS LIST 25
DIAGRAMS - GAS SIDE RESISTANCE , EXIT FLUE GAS RESISTANCE 26
IMPORTANT INSTRUCTIONS ABOUT BOILER ROOM 28
BOILER ROOM AIRING 29
CHECKINGS AND STARTING THE BOILER 31
FAILURE FIRST CONTROL 32
CARE INSTRUCTIONS , PACKING 34
CLEANING THE BOILER 35
BURNER DOOR AND BURNER CONNECTION 36
BURNER CONNECTION FLANGE SIZES 37
INTRODUCTION
In this manual you will find the instructions for three pass cast iron boilers suitable for both gas
and liquid fuel.OM series hot water boilers and related informaton for installation,operation and maintanance of the boiler. For high efficiency and proper working conditions please read this manual carefully.
For more information please check the product catalog or get in touch with technical services.
Please do not touch or remove any parts of the boiler for starting,adjusting or repairing the boiler except
the processes written in this manual
Please call services and technical officials for installing the boiler.
Our licensed frenchisers and services will
g
ive you instructions about working principals,conditions and
care instructions after installing and starting the boiler.
And our professionals will be glad to answer all your questions at any time.
licensed services are in your service all kind of problems and questions. You may find the contact
informations in the licensed services manual which will be given to you with the boiler.
First of all we'd like to thank you for choosing our cast iron boilers.
GUARENTEE TERMS
*In the terms of obeying the instructions,warnings, points in this manual and the standards in charge
(EN norms and directives must be applied if mentioned standards are not in use.) cast body is under
5 (five) and other parts are under 2 (two) years guarantee.
Our company is responsible for repairing or renewing if the following conditions are available.
*Guarantee Document must be filled by the franchiser that you have bought the boiler and must be
send to
*Assembling and installing faults and problems, problems that will be occured because of wrong upkee
ping
and working are not under guarantee.Problems related to lime coating or/and any other ma-
terials coatin
g
and corrosion on the heat transfer units of the boiler are not under guarantee conditions.
*Minimum life of these kind of
p
roducts is mentioned as 15 (fifteen) years by the minister of industry
and commerce. Manufacturer and sales companies are to suplly all spare parts and services to the
clients in this period.
! The problems happened by the following mentioned issues are out of guarantee conditions
! Boiler without guarantee document
! Boiler fixed,repaired or adjusted by unauthorized services
! Boilers with rong type selection, wrong installing and assembling, boilers used wrong conditions and
out of aim.
! Problems occured while transportation,stocking or problems occured under atmospheric conditions.
! The problems occured by physical or chemical effects.
! Wrong fuel selection and the problems occured by fuel conditions,
! Wrong installation or connection fo the boiler to water and other plumbing systems.
! Weak flue (gas output) system
! The problems occured by scratching,touching to control and safety systems of the boiler.
! Cold water load while the boiler is hot
! Starting the boiler without water or required water in it.
GENERAL WARNINGS
!
ted to use out of it's aim of use.
!
!
on.
!
future repairing operations.
! Starting and first operation of the boiler must be made by authorized technicians.
!
!
!
! The periodical controls of the boiler and the burner must be done. If not, the boiler can lose efficiency
and the fuel amount used can increase.
! The ca
p
acity choice of the boiler must be made according to the projects that prepared properly in the
terms of related standards. If not the the efficiency will be low.
! OM series boilers are produced for heating only. For heating the sanitary water another equipment
such as water heater or heat exchanger is needed.And for proper efficiency in this operation,correct water heater or heat exchanger must be selected.
culation pumps, must be started 1 -2 times per month for 5 minutes. (The water with chalk can cause
problems if the pump is not used for long time period.)
In summer months, when the boiler is off for a long term, for preventing probable problems with cir-
In the assembling of the boiler; there must be a proper and safe concrete platform for to put the boiler
surely be started while adding water to the system.If not,the sections may crack.
The electric must be cut off from the main shelter/fuse as the boiler is in repair,service or cleaning.
If the boiler will be kept off for a long time the electric system must be shut down from the main fuse.
OM series cast iron boilers are designed for working with hot water heating and/or hot water plumbing
Do not add or pump water to the boiler or plumbing system as it is working and hot.For adding water to
the boiler or to the systen please wait for water temperature to come 40ºC. Circulation pump must
of the boiler should also be made by licensed services, if not the risk of damage is high.
and produced with the proper technology and materials suitable to this design.This desing is restric-
OM series boilers are delievered as sections and services assemble the boilers in the operation
area. The assembling of the boiler must be made by technical services. Removing or re-assembling
In the assembling of the boiler,an empty space must be left from sides for safety requirements and for
! OM series boilers are delivered without burners. For suitable burner selection
p
lease get in touch with
technicians. Suitable burners must be selected for takin
g
high efficiency.
! If the boiler is sto
pp
ed automatically because of over heating do not add cold water to the boiler for
restartin
g
. In this case wait for the boiler to cool down and re- try starting.If it does not start please
g
et in contact with technical services.
! In cleanin
g
, repair and other care operations the original spare parts which approved and manufactured
b
y
manufacturer must be used.
! The
p
eriodical and yearly controls of the boiler must be done properly and on time.Natural gas is a clean
fuel and doesn't make a lot of dirt in the boiler.But the boilers that li
q
uid fuels are used as fuels are much
more easil
y g
et dirt. Controls and care operations of the boiler is needed for keeping high efficiency and
lon
g
life of the boiler.
! Re
p
airing and periodical controls of OM series boilers require profession.In this manual the responsibilities
and re
q
uired information for users of the boiler is declared. Besides these declared operations, boiler
must not be started b
y
a person rather than the user or one our technicians.Please do not try to make
ad
j
ustment or do not touch any parts of the boilers.
! The electric of the burner and the boiler is su
pp
lied by city electric network.In this case the elecric and
li
g
hting systems of the boiler room, burner and boiler electrical connections, grounding line of control
p
anel and boiler must be made by professionals under the required and related standards.
! In this manual
y
ou will find informations only for the boilers. Please do not forget to get the instruction
manual of the burner that
y
ou purchase from the manufacturer of it. Burner is not delivered with the
boiler. In this case we do not give any guarantee for the burner that you purchase. Please get th
e
q
uarantee certificate for the burner from your supplier.
! Please be sure that the front door
(
burner door) for the boiler is strictly closed and burner connections
are
prop
erly made as the boiler is working.
GENERAL CHARACTERISTICS OF RS SERIES BOILERS
OM series boilers are, blowing burner, cast iron sectioned, between the capacities 378 – 930 kW with
proper burner connection, works with gas or liquid fuel in 11 different ( 6 – 16 sections) type.
OM series boilers operating pressure is 6 bar maximum, and working temperature is 90 °C maximum.
In OM series boilers,heat transfer surface areas are increased by the special wings in the burning room
and chimney ways.This inceases the high heat transfer ability of cast iron boiler to the maximum level.
OM series boilers are cast iron sectioned boilers.This brings easy assembling and easy capacity increasing
by adding sections to the boiler. The transportation and set up of the boiler is easy because boiler is
assembled in boiler rooms It is easily to carry or shift position without breaking walls etc.
OM series boilers are casted with special alloy, which is durable for heat extansions and changes, EN GJ
L
200. They are long life boilers according to this special cast iron alloy.
With the help of horizontal and three pass specially designed sections burning gases pass three times in
the boiler and transmits burning energy to the water inside the sections at high level.
OM series boilers are high efficiency boilers. ( According to the fuel bottom heating value % 91 – 93 ).
With this high efficiency and perfect isolation more energy is gained with less fuel. Heat loses are
minimized on OM series boilers.
By appropriate burning room, heat transfer surface, turbulator, collector and isolation high heat transfer
and optimum flue gas emition results are provided.
Boiler sections are delivered as assembled or not assembled according to the boiler room specifications
and dimensions.In not assembled deliveries, sections and assembling aparats are delivered on a pallet,
cabins,isolation and other elements are delivered in a box. technicians make the assembling of the
boiler.
Delivery Conditions
OM SERIES CAST IRON BOILER - TECNICAL DATA . I
OM SERIES CAST IRON BOILER - TECNICAL DATA . II
OM SERIES CAST IRON BOILER DIMENSIONS
BOILER ROOM SETTINGS AND BOILER PLATFORM DIMENSIONS
W
B
C
D
E
The measurements of the boiler room and the empty spaces must be arranged properly for future
assembling repairing, re-assembling, burner connecting issues.
* The concret platform must be in the mentioned dimensions.
* Concrete platfrom must not be coated with slipper materials such as ceramics etc.
* If sound izolaton will be made,first do the sound izolation than make the concrete for platform.
* Platfroms must be made of BS 25 concrete and scales.
* In OM series boilers burner doors can be opened to
both sides. According to this the required empty
spaces for the both sides are given equal.
(min. 700 mm).
This will bring advantages for operations.
If the boiler room area is not enough for thi
s
you can choose one side and leve the big empty
space there. Half of this empty space will be enough
for the other side in these conditions.
* There must be space left for the tools that will be
used in boiler room.
PLUMBING INSTRUCTIONS
Fresh water must be added periodically to the plumbing. The chalk and other chemicals will connect
with the system and become solid . For avoiding this closed expansion tank must be used in the system.
In the systems that closed expansion tanks are used, water will flow in closed system so it will not
evaporate and lost.So in this kind of systems the water level wiill stay same and fresh water addition will
not be necessary. This will prevent chalk and dust and the life of the ssytem will be long.
The water in the radiator or heatin
g
system is not healthy.Do not use this water as drinking or cleanin
g
water.Do not take water from the system.If the water level is low water addition is needed.
For avoiding chalk and other chemical dust problems soft water must be used in the system.
Plumbing system water quality : Ph 7,2 Th 25 °Fr
If the city sanitary water is not in requested quality water addition from wells or other sources must
be made after testing it.For reaching the requested quality additional processes must be applied to the
water if needed.
For avoiding the chalk and other dust to get in to the boiler, or from boiler to plumbing system dust
holders must be placed in and out line of the system.
Circulation pump must be connected to the water output of the boiler and the capacity of the pump must
be suitable to the boiler capacity. If not,problems may occur in flowing of the water and heating efficiency
of the boiler.
For working the system properly 4 way mixture valve or thermostatic control by-pass pump must be
used for increasing return water temperature.
By connecting a three way motor valve between the forward and return line of heating system,the water
that flows to the system can be controlled in ratios.
There must be water inside of the boiler every time. If not corrosion can occur in the boiler and the
plumbing system.If the boiler will not be used in winter season,for avoid freezing anti-freeze solution must
be used.
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