MHS Boilers Alpha Jetstream MD User Manual

Assembly, Operating and Maintenance Instructions

Installation
and
User Guide

Alpha Jetstream MD

Cast Iron Boiler

105 - 300 kW

35 Nobel Square Basildon Essex SS13 1LT

01268 591010 / 01268 724064

01/07/04

The Alpha Jetstream MD is a cast iron sectional boiler for pressure jet oil or forced draught
gas firing. The boiler is of the horizontal 3 pass type.
The boilers are able to be utilised as low temperature boilers as described in the Boiler
Efficiency Directive 92/42 EEC

MD series are CE Marked on PIN CE-0645BO119 to

Gas Appliances Directive (90/396/EEC)
Boiler Efficiency Directive (92/42/EEC)
Electromagnetic Compatability Directive (89/336/EEC)

and conforms the requiremets of
EN 303/1: Heating boilers with forced draught burners - Terminology, general
requirements, testing and marking
EN 303/2: Heating boilers - Part 2: Heating boilers with forced draught burners - Special
requirements for boilers atomizing oil burners
EN 303/3: Heating boilers-Part 3: Gas fired heating boilers-Assembly comprising a boiler
body and a forced draught burner

MD series boilers are suitable for central heating and indirect hot water supply at
working pressures not exceeding 4 bars, and working temperatures not exceeding 100 C.
The boiler must never be used for direct water supply.

MD Jetstream Cast Iron Boiler for oil and gas firing

INTRODUCTION

TECHNICAL INFORMATION

Boiler type MD 4 MD 5 MD 6 MD 7 MD 8 MD 9

Number of sections

4 5 6 7 8 9

Product-ID number– Notified body numbe r

86/AT/572 – CE0086

Rated heat output kW

105 144 184 223 262 300

Flue gas resistance mmwg

4 9 16 20 23 33

Combustion diameter mm

370

chamber depth mm

450 580 715 845 975 1105

Length L mm

744 878 1012 1146 1280 1414

Burner mounting diameter mm

170

dimensions depth mm

115

Return/flow connections DN

65 (2 ½ “BSP M)

Flue gas temperature

o

C

185

Flue connection diameter mm

208

Weight (boiler block) kg

430 510 590 670 750 830

Weight (water content) kg

49 61 73 85 96 108

Flow temperature control

o

C

30 – 90

Natural gas* m3/h

11.98 16.5 21.04 25.57 29.97 34.36

Fuel LPG** m3/h

8.83 12.16 15.5 18.83 22.07 25.31

Consump. 35 sec oil*** kg/h

9.7 13.35 17 20.7 24.24 27.8

Heat input
to boiler

Natural gas, LPG,
35 secoil

kW

115 158 202 245 288 329

Jetstream Jetstream is a PATENTED NEW TECHNOLOGY developed particularly to prevent flue
Technology gas condensation in the boiler. It is based on increasing the temperature of cool return

water into boiler & mixing it with hot circulating water inside the boiler.
This is accomplished by a jet effect created by a distribution pipe fixed to the return
connection of the boiler
The cool return water is injected into the boiler via a distribution pipe. This injection results
in a pressure drop at the end of the pipe, creating a vacuum. This vacuum sucks hot
delivery water of the rear section/sections down to mix with the return water
thereby raising the return water temperature. Thus, the main reason
of flue gas condensation in the boiler is eliminated. Also a reverse flow of hot water
in the rear section of the boiler protects the section against excessive thermal shocks.

The Alpha Jetstream MD will
operate without condensation
providing the minimum return
water temperatures are
observed:

Fuels Lowest return temperatures

(°C)

Naural gas, LPG

35

Light oil 25

TECHNICAL INFORMATION

Fluegas resistance

Efficiencies

Values given according to average boiler water temperature of 70 C

Flue gas
temperatures

Values given according to average boiler water temperature 70 C, ambient temperature
20 C

TECHNICAL INFORMATION

Flue gas resistance (mbar)

1

00% load

75% load

50% load

LOAD

LOAD

Combustion

Overall

Oil Supply MD series boilers can only be fired with liquid fuels having following specifications:

Kerosene viscosity at 20 C: 1.2 cSt or viscosity at 100 F: 28 Second *
Light oil (EL) viscosity at 20 C: 4- 6 max cSt or viscosity at 100 F: 35 Second
Gasoil (D) viscosity at 20 C: 4- 6 max cSt or viscosity at 100 F: 35 Second
*Burners suitable for Kerosene have limited availability and range

Any failure due to lack of technical precautions, firing with fuels
not suitable for boilers, and operation without taking recommendations given further in
this manual into consideration, will always be the responsibility of the end-user.
A single pipe oil supply with oil at a slight positive pressure is generally required though
the burners own oil pumps can provide some lift of the oil depending on the volume flow
and the lift required. For dual fuel burners a two pipe oil supply system is generally
recommended unless the burner is fitted with an oil pump clutch. An oil filter and
isolating valve should be provided and the burner connected to the oil supply with a
flexible oil hose. The hose and filter are generally supplied with the burner.

Gas Supply The local gas supply authority should always be contacted at the design state to ensure

an adequate supply is available. An existing service pipe must not be used without prior
consultation with the local gas supply authority and the supply must be made through a
suitable meter.
The matching of burner model, burner and gas train size must be carried out in
accordance with supplied inlet gas pressure and fuel type to be fired. When sizing the
burner and gas train, all pressure losses inside the boiler, burner and gas train, and in
piping from burner inlet to main gas meter must always be taken into consideration.

Burne

r

MD boiler must be fired only with a CE APPROVED BURNER which is according to
Gas Appliance Directive and tested according to EN 676. MHS Boilers will not be
held responsible for any damage or failure due to use of a non approved burner.

It is not recommended to increase the diameter of hole in the middle of front refractory to
make the mounting of burner easier. If there is a space left between the hole in front door
refractory and burner tube after mounting, this space must be packed with rock-wool or
ceramic-fibre based insulation material to improve heat insulation. Otherwise, further heat
loss may result in damage to the front door.

Should the diameter of burner head be greater than that of the hole in front door refractory,
the diameter of the hole must be increased so that the burner passes smoothly through
the hole. Front refractory must be protected against breaking during mounting and
dismounting of burner.

TECHNICAL INFORMATION

Water side The fully watercooled sections are joined by cast iron conical nipples, and distribution
of boile

r

pipe fitted to the return ensures even the temperature distribution throughout the boiler.
The cast iron sections are to BS.1452 Grade 200 with 7 mm wall thickness. Return and
flow connections to heating system are provided by stub-pipes at the rear of the boiler.

Under no circumstances should the boiler be fired when its circulation volume is less than
a recommended minimum volume calculated according to the following formula:

The following table provides hydraulic resistances at various water volumes relativ to boiler
Dt flow/return. The difference between flow and return temperatures of the bolier should
not be greater than 20 C to provide convenient operating conditions in the boiler:

Boilers must be connected to a chimney by using the shortest possible connector which
should be insulated by mineral wool or similar material. The flue connector must rise at

Flue design

an angle from boiler to chimney of not less than 10º. Conditions creating high resistance

and chimne

y

to gas flow should be avoided in the flue connector. The flue outlet of the boiler should

installation not support the weight of chimney.

The draft generated by the chimney should be capable of overcoming the chimney
resistance.
Chimney calculations should be carried out in compliance with the standards. Conditions
of existing chimney should be checked and proper precautions should be taken against
excessive cooling and condensation. Chimneys should be lined if necessary
Positive draught conditions must be avoided
Negative draught conditions should be contained within -3 mm wg. (30Pa) for optimum
boiler performance.

The following table shows typical flue gas volumes at gross flue temperature of 190°C and
ambient air temperature of 20°C.

146.9 528.9MD9 300 139.9 503.8

109.2 393.1

MD8 262 122.2 439.9 128.3 461.9

MD7 223 104 374.5

70.5 253.9

MD6 181 85.8 309 90.1 324.4

MD5 144 67.2 241.8

51.4 185.1

kW g/sec kg/h g/sec

MD4 105 49 176.3

TECHNICAL INFORMATION

Boiler type Output

Flue gas volume

Light Oil

C02=13%

Natural gas G20

C02=9.5%

kg/h

l/s

252

OutputkW

=

∆t=10oC ∆t=15oC ∆t=20oC
Type

Minimum

Circulation

Water

Flow

Hydraulic

Resistance

Water

Flow

Hydraulic

Resistance

Water

Flow

Hydraulic

Resistance

l/s l/s kPa l/s kPa l/s kPa
MD 4 0.41 2.5 8.1 1.66 3.7 1.25 2.2
MD 5 0.58 3.42 16.0 2.28 7.2 1.71 4.1
MD 6 0.75 4.38 15.5 2.92 6.8 2.19 3.9
MD 7 0.88 5.33 20.6 3.53 9.2 2.65 5.2
MD 8 1.05 6.23 29.5 4.15 13.2 3.13 7.5
MD 9 1.19 7.14 39.0 4.76 17.4 3.57 9.8

Boiler room The installation must be arranged in accordance with Mandatory Regulations and Codes
arrangement of Practice. The following sketch shows the recommended minimum dimensions of

clearance around the bolier for servicing and maintenance

Boiler room should not be used for any other applications, floor should always be kept dry
and clean. Any obstacles in front of ventillation openings must be avoided. The boiler room
air openings must conform to the requiements of BS 5410 Pt2 or BS 6644 as appropriate
Never drain the system unnecessarily.
Follow instructions for periodic cleaning and maintenance operations whose procedures
are given further in this manual.
The boilers must be installed onto a smooth level surface of non-combustible material.
A steel baseframe and a 50 mm thick mineral wool mat to insulate the underneath of the
boiler are included in the supply. A raised plinth shall be used. It is recommended that
the plinth be at 150 mm high and sized to the dimensions of casing of the boiler given as
in the following table:

PREPARATIONS BEFORE ASSEMBLY

Recommended dimensions of plinths (mm)

Type

MD4 MD5 MD6 MD7 MD8 MD9

Width 830
Length 775 905 1035 1165 1295 1425
Height 150

Water The system design must ensure a flow rate consistant with the output of the boiler at
Circulation

a temperature rise not normally exceeding 20ºC (25ºC Max).

System Due to the Jetstream technology employed in the boiler, the boiler may be operated at

continuous low return water temperatures without condensation and without the need for
back-end temperature protection measures, providing the minimum temperature limits
detailed in the technical data are observed. This allows variable flow temperatures to be
utilised (direct-on-boiler weather compensation) without the need for variable temperature
mixing valves. This simplifies the installation and ensures peak operational efficiency from
the boiler.
Should the system be operated at temperatures below than those mentioned above,
then a thermostatically controlled pumped by-pass (shunt pump) should installed
between the flow and return pipes to raise the temperature of the return water.
This is particularly important when firing with gas because of the higher dewpoint
temperature of gas products of combustion.

Water levels should be checked regularly and any leakages corrected in order to keep
system water make-up to a minimum, because excessive make-up will lead to scale
deposits forming in the boiler waterways causing local overheating and damage to the
boiler sections. Where there is doubt as to the quantity of water make-up, a water meter
should be fitted. If a system is known to lose water continuously, or be heavily
contaminated with dirt or sludge, then consideration should be given to installing a plate
type heat exchanger to separate the boiler from the damaging effects of the old system.

Boiler water systems should be thoroughly flushed and cleaned before a new boiler is
installed and system water should be treated with a scale and corrosion inhibitor
and best practise observed. The system should include strainers and consideration should
be given to fitting sludge traps if conditions warrant them.

The system can be either open vented or pressurised.The system must be fitted with
appropriately sized safety relief valve, reference to BS5410 Part2 or BS6644 will give

Safety o

f

guidance on selection.If the system is open vented then an appropriately sized open pipe

water must be installed from the flow pipe adjacent to the boiler to run by the shortest possible
circulation direct route to terminate over the feed and expansion cistern. The boiler flow and return
system pipes should be fitted with isolation valves taking care to ensure that the safety relief

valve is installed onto the flow pipe between the boiler flow connection and the flow
isolation valve.
An altitude guage should be installed onto the flow pipe at the same level as the top of
of the boiler and marked with the minimum water level/pressure following first filling
of the system.

In the case of a sealed and pressurised heating system, an appropriately sized and
charged expansion vessel should be installed in conjunction with an automatic
water make up unit (pressurisation unit).

Filling the System . Non Domestic (other than in-house) fluid category 4

For category 4 systems, the approved method of filling must comprise the following
components arranged as shown: Control valve on the mains cold water pipework,
Strainer,Verifiable backflow prevention device with Reduced Pressure Zone (RPZ valve)
incorporating a type BA air gap, Tundish, Control valve on heating system.

PREPARATIONS BEFORE ASSEMBLY

Requirements
on filling The quality of the filling and any refilling water is important and must be of
water sufficient quality to maintain the following requirements:

pH 8 - 9.5
Maximum hardness between 8 and 12 grammes of calcium carbonate per 100
litres of water.

We strongly recommend that the system is chemically cleaned and then
dosed with a good quality corrosion and scale inhibitor before the boiler is
first fired. The boiler is guaranteed against material and manufacturing defects
however, failures or problems brought about by inadequate water quality are
expressly excluded from any guarantee or warranty and will render the
guarantee on the product void.

PREPARATIONS BEFORE ASSEMBLY

MD Jetstream MD boilers are delivered unassembled and consists of the following parts:
Delivery Consignement

1. Boiler block: A block of sections, smokehood and front door is delivered on a pallet for

easy shipping. The sections must be assembled in the boiler room. Refractories for
combustion chamber insulation are mounted on the rear section at the factory. Smokehood
is fixed to rear section. Boiler block contains the materials used in the assembly of the
block such as nipples, fiberglass ropes, flow and return connections...

2. Casing/insulation box: This box contains all casings and baseframes (if required)
together with the insulation blankets. Retarder sets and control panel are also
supplied in this box.

Delivery method of Alpha Jetstream MD boilers.

ASSEMBLY INSTRUCTIONS

Assembly o

f

Numbers in the brackets refer to position numbers in the exploded drawing.

Boiler Body

1. Place steel profiles (19) which are used
as baseframes of the boiler parallel to each
other as shown in the figure at the l/h side.
The distance from the baseframes vary
from 320 mm to 970 mm as the number of
sections vary from 4 to 9.

2. Start assembly with rear section (1), clean all rope grooves on the section using a wire
brush. Clean nipple ports and nipples using cloth and paraffin. Apply adhesive to the rope
grooves on the front side of the section. Fix continuous lengths of 10 mm rope (5) in each
groove starting with the outer groove as shown in following picture. Tape each end of rope.
Apply jointing compound onto nipples, and place nipples (4) squarely in each nipple port
and, using a wooden mallet, lightly tap nipple into the port to secure.

3. Take an intermediate section (2) and prepare the section as described above. Place
rear section at the end of baseframes. With its unroped side facing towards the rear, fit
the intermediate section squarely onto nipples of the rear section and secure by using
a wooden mallet. Ensure that the rope on the rear section remains in correct position

NOTE: Do not fix rope into the grooves of the side of the intermediate section facing the
rear section. Likewise, apply the same procedure for the following sections applying one
rope between two sections.

4. Continue boiler assembly repeating the same procedures with the other sections.
Apply "Compression Tools" passing them through bottom and top nipples as shown in
following figure, and accordance with the table headed "Usage of Compression Tools",
until the rope between each section is firm. The gap between each section should be
3-4 mm.

ASSEMBLY INSTRUCTIONS

320/450/580/

710/840/970

Rear section

Intermediate section

Upper staybolt

Front section

Nipple

Copression tools

Usage of compression tools

Model First

application

(Number of

sections)

Second

application

(Numbe r o f

sections)
MD4 4
MD5 3 5
MD6 3 6
MD7 4 7
MD8 4 8
MD9 5 9

After assembly of all sections, apply compression tools for the block. Before loosening
fit upper and lower staybolts (7,8) using M12 nuts (9) and washers (10).

5. Fit studs M12x45 (20) to return and flow connections of the rear section.

Do not use excessive force to tighten the nuts up on the staybolts, from 48 to 54 Nm
(35 - 40 lbf/ft) torque is recommended.

Hydraulic test Fit plugs (147) to top and bottom of front section. Fit 1/8" plug (109) supplied in boiler

block into 1/8" hole on top of the rear section (with control panel this hole is not used).
For 1/2" and 3/8" instrument tappings on top of the rear section, use
1/2" and 3/8" pockets for bulbs supplied with standard control panel or suitable plugs.
Use hydraulic test apparatus for the boiler. Fit bottom test flange with two globe valves
and test gasket to return connection. Fit blank flange and the other test gasket to flow
connection as shown for MD boiler in the following figure.

Connect a hydraulic test set to one of the globe valves on test flange fitted to return
connection. Fill the boiler with water by connecting the other valve on test flange to the
water circuit. Meanwhile, release the air left in the boiler via bulb pocket holes on top of
the rear section. When water comes out of the holes, refit the bulb pockets . Turn the
valve connected to circuit off and turn the other valve connected to the hydraulic test set
on. Pressurise the boiler via the pump on the test set until the pressure gauge
reaches the test pressure.

Hydrostatic test should be carried out at a pressure of 1.5 x P; where, P is the
maximum operating pressure of boiler. Duration of test should be at least 30 minutes.

The hydrostatic test must always be carried out before boiler being jacketed or heat
insulated, and connected to the heating circuit.

After hydrostatic test, "Boiler Assembly Certificate" should be filled in and signed by the
erector/installer. In order for warranty terms of boiler to be valid, make sure
that this certificate is completed, signed, and sent to MHS. We recommend that you
ask for a copy of assembly certificate from erector/installer.

ASSEMBLY INSTRUCTIONS

6. Fit distribution pipe (22) with gasket (25) to return connection. Fit flanged stubpipes
(21) and their gaskets (25) to flow and return connections. Fit nuts and washers to the
35 mm threaded end of M10x105 studs (145), screw and lock the studs into the corner
positions of rear section.

When placing the distribution pipe into the return connection, ensure that the white arrow
on the flange of the pipe points upwards (The axis of the pipe should be off -centre towards
the bottom of the square flange). Wrong position of the distribution pipe will result in
incorrect temperature gradient and higher condensation rate in the boiler.

ASSEMBLY INSTRUCTIONS

Jacket assembl

y

1. Fit cast iron hinges(143) used for carrying front door onto front
section using 2 M8x30 setscrews (142) for each hinge.
Before assembly of front door (131), first decide the side of hinging
(for LH or RH opening). Screw hinge pins (141) into threaded holes.
Screw a M16 nut (49) onto each hinge pin as shown in figure below
left.

Hang the front door on M16 nuts. Position the front door up or
downwards by losening or tightening the M16 nuts.

2. There are two types of retarders. One is the second pass retarder (95) or (99) and the
other is the third pass retarder (for 4,5,6,7 sections) (97). Second pass retarders consist
of two stainless steel bladed modules (95 and 99). The modules are combined together
according to following table for preparing second pass retarders. Retarders are placed into
second and third flue gas passages of boiler as shown in following pictures:

In case of light or medium fuel-oil firing, the second pass retarders should not be used,
and input to boiler should be slightly reduced to values given in technical informations.

3. Fix front door to front section using four x M10x30
setscrews(136) and 10.5 washers(137).

4. Loosen the nuts on the front end of the upper staybolts(8) and
fit upper casing support (155) with its bend facing towards the rear
section. After mounting the front support sheet, ensure it to be
aligned parallel to the floor.

ASSEMBLY INSTRUCTIONS

Second pass retarder

modules

MD4 MD5 MD6 MD7 MD8 MD9

2 bladed module 2 1
3 bladed module 1 2 2 2 2

5. Place boiler body insulation (117) squarely on top of boiler block. After placing the
insulation, secure both ends of the insulation blanket to lower staybolts by using four
retaining springs(156).

6. Fit left and right rear insulation panels(157) to smokehood (11) and secure by pushing
onto the M10x105 studs (145). Fit base insulation panel (93) underneath the boiler block.

7. Fit side casings (148,149) passing M10x105 studs (145) through the holes on the return
folds of the casing, hanging the front edges of casing onto the upper casing support (155)
and fixing the front lower end of the casing to the free end of the lower staybolt (7). Fit side
casings by M10 nuts (153) and washers (152) to the M10x105 studs (145), by M6 set
screws to the front upper casing support and by M12 nuts and washers to the lower
staybolts.

8. Fit the top casings (163,164) onto the side casings by special pins (162,161).

9. Fit the rear panel by self tapping screws (160) to the return folds of the side casings.
The rear panel is in two parts - upper (158) and lower rear (159) panels.

ASSEMBLY INSTRUCTIONS

M10x105 studs

Insulation
springs

Electrical 1. Before assembly of control panel on top casing front piece (163), pass the capillary
Installation tubes of the panel through the large hole on the top casing. Fix control panel (110) onto

the top casing using 4 self tapping screws S 4.8x9.5

2. Place the bulbs of the control and safety thermostats into 1/2" pocket and the bulb of
boiler thermometer into 3/8" pocket fitted on the rear section routing all the capillary
tubes underneath top casings but on the top side of the insulation blanket. Secure the
bulbs of the instruments into the pockets with the clips supplied.

3. Fit top casing front panel mounted with the control panel onto the boiler.

4. Pass electrical wiring through prepared hole in rear of side casing and route cables into
control panel making sure that cables are on the top side of the insulation. Make
electrical connections in accordance with Mandatory Regulations and Codes of Practice,
and follow burner manufacturers instructions.

The main electrical supply should be taken from a local fused isolator having a minimum
contact separation between the poles of 3 mm, and taken to the phase, neutral and earth
connection in the boiler control panel.
The burner connection cables from the boiler control panel should be routed through the
top and side panels, then shall pass under side panel to the burner, ensuring that the
cables are placed on the outside of the boiler insulation blankets.

All cables should be suitable for a service temperature of 100 C and a load of 10 Amp, and
have a minimum cross sectional area of 1,5 mm2.

This appliance must be earthed.

Control panel

Detail of the P3 climatic control panel can be found in the separate literature for this item.

ASSEMBLY INSTRUCTIONS

ASSEMBLY INSTRUCTIONS

Electrical safet

y

Carry out the following electrical safety checks using a multimeter.

checks

Earth continuity check

1. Appliance must be electrically disconnected from the mains

2. Set the meter to Ohmsx1 scale and zero if necessary

3. Measure resistance between the earth connection point in the boiler control panel and
the earth connection point in the supply junction box or the earth pin on the 3 way plug if
this is being used.

4. If the resistance is greater than 0.1 Ohm, check all earth wires and connections for
continuity and that they are clean and tight and rectify as necessary.

Short circuit check

1. Appliance must be electrically disconnected from the mains and all appliance switches
set to "ON" including the thermostats.

2. Set the meter to Ohmsx1 scale and measure the resistance between the neutral and
phase terminals in the boiler control panel. If the meter monitors zero then there is a
direct short cricuit and a fault that should be rectified.

3. Set the meter to the Ohmsx100 scale, and measure the resistance between the phase
and earth block in the boiler control panel. If the meter monitors less than infinity then
there is a fault that requires rectifying.

Resistance to earth check

1. The appliance must be disconnected from the manis supply and all switches including
the thermostats set to "ON".

2. Set the meter to the Ohmsx100 scale

3. Measure the resistance between the phase and the earth block. The reading should be
infinity and if there is any other reading then there is a fault which should be traced and
rectified.

The Alpha Jetstream MD Boiler must only be commissioned and serviced by competant

Pre-firing checks persons of approved classes, qualified and certified to undertake the works involved.

i.e. Corgi/Oftec Registered.
The following points must be checked before the operation of the boiler and system.

1. Boiler seals, including front door, burner plate, rear cleaning cover, and flue / chimney
connections.

2. Electric supply, fuel and water system connections,water level, water quality and
soundness of fuel supplies and correct purging of fuel supply pipework.

3. Burner to ensure correct model and setting.

4. Boiler controls, including thermostats.

5. Sizing and settings of safety relief valves.

6. Ventilation/air supply provision.

The burner is started by adjusting the first stage thermostat to desired water temperature.

Firing With two stage, the first stage thermostat should be adjusted to a setting slightly higher

than that of the second stage thermostat. The adjustment of the fuel consumption of the
burner and flue gas analysis should be carried out simultaneously to prevent the influences
of the adjustments on each other. The flue gas analyser should sense from a distance at
least four times the diameter of the flue to the flue outlet of the boiler to make a reliable
analysis. Adjust the burner in accordance with the burner manufacturers instructions.
The return temperatures to boiler due to fuel type fired should not be lower than the
limits given in the following table to operate the boiler in non-condensing mode. These
temperatures may decrease to lower points temporarily during the operation particularly
during the initial starting period.

OPERATION

Fuel type

Lowest return

temperatures

(

o

C)

Natural gas, LPG 35
Light oil 25

Before carrying out any maintenance operations on the boiler, first of all turn off/isolate
electricity and oil or gas fuel supply valves.

Periodic 1. Cleaning of heat transfer surfaces of the boiler heat exchanger at a frequency determined
inspections by the usage patterns of the boiler but not exceeding 6 months for oil and 12 months for gas.

2. Controls settings

3. Ventilation provision

4. Noise (excessive or unusual)

5. Flue gas leakage (soot deposits / marks)

6. Vibration (excessive or unusual)

7. Fuel or water leakage

8. Burner settings - check using flue gas analyser.
9 .Effectiveness of the flue.

10.Water quality/water treatment dosage

Cleaning Before starting to clean the boiler:

1. Isolate by switching off electrical supplies at the mains, and valve-off fuel supplies.

2. Cover control panel and burner to protect from any damage.

To clean the boiler:

1. Disconnect fuel supplies from burner as necessary and open the front door (131)

2. Remove all retarders inside the flue gas passages. Prepare the cleaning brush,
combining items 101, and 102. Remove any deposits from combustion chamber and flue
gas passages using cleaning brush.

3. Clean the retarders and check their condition, replacing any that are damaged.

4. Check the condition of the fiberglass braided rope (6) between front door and front
section and replace if necessary

5. Re-fit all the retarders with their original positions, close the front door and check that
it compresses squarely onto front section.

6. Clean/remove any accumulated deposits from the smoke hood via the cleaning ports.
For that operation, undo the rear cleaning cover (27) on the smokehood. Remove all
deposits and check the condition of rear cleaning cover seals (28) and replace the seal if
necessary. Re-fit cleaning cover.

7. Check the condition of the fiberglass rope around the burner mounting plate and replace if
necessary.

8. Uncover the control panel and the burner. Clean/service the burner as necessary.

9. Re-connect the boiler/burner to external supplies and check for soundness.

10. Start the boiler and check for performance.

11. It is recommended that a flue gas analysis be carried out to check the combustion.

MAINTENANCE AND CLEANING

To shut down Switch off the electrical supply and decrease the control thermostats on boiler control
the boiler panel to the minimum set point. If switching off for an extended period e.g. Holidays, turn

off the gas or oil supplies at the service and isolating gas or oil valves on the burner.

Care of the 1. Do not shut down the boiler if freezing conditions are expected unless a frost protection
boile

r

thermostat has been incorporated into the control system.

2. Do not obstruct the airvents, grilles or other air openings in the boiler room, and ensure
a clear path of combustion and ventillation air to the burner.

3. Do not store objects on or near the burner, boiler, and flue.

4. Do not use propellant sprays or chemicals particularly chlorine based chemicals in the
vinicity of the boiler.

5. The boiler must be serviced at regular intervals by competant persons.

To re-start 1. Check that the gas supply or oil isolating valve is open.
the boiler 2. Switch on the electrical supply, set the control thermostats to the desired setting and

ensure any external controls (time/temperature controls) are turned on and calling for heat.

3. The burner should now start pre-ventillation and then fire.

1. If there is fuel leakage from your boiler, first stop the system and shut down the oil
valve at the outlet of the fuel tank. If a gas leak is suspected (e.g. Odour in the boiler room)

Fuel leakage do not use a naked flame to locate the leak, or turn on or off any electrical switches.

Immediately contact your gas supplier, details should be on the notice at the gas meter.

2. If there is leakage from an oil tank, it must be removed and replaced.

Electrical The boiler will not work, if the electricity is cut off. The boiler should start automatically
failure when the electircity is restored.

Boiler If the burner does not operate; check that there is enough fuel in the tank, and the gate
operational valve at the outlet of the tank is opened (oil fired installations).
failures Ensure that any controls are calling for heat. Check/reset the burner lockout reset button.

Ensure that the system pumps are running and that the boiler overheat safety thermostat
is not tripped (see "safety thermostat fault" below.
If burner still fails to operate, seek expert assistance from your service company.

If the raditaors can not be heated; refer to followings:

System 1. There may be air in the circuit; it must be removed.
heating problem 2. There may be pressure drop in the circuit. If the pressure gauge on the manometer of

the heating system is below the minimum safe value, water must be added to the circuit.

3. The thermostat setpoint may be rather low; the setpoint degree must be increased.

4. The room unit or programmable timer on the control panel may be in service. The
adjustments of these devices must be checked again.

Safety In the case of safety thermostat lock-out; first check to make sure that the water level is
thermostat correct. If there is any water loss from the system investigate and remedy, adding more
fault water treatment as necessary. Reset the overheat safety themostat by pressing the reset

button under the removable cap. If the boiler should go to overheat safety lockout again
or the thermostat fails to reset, then seek expert assistance from your service company.

Flue gas leakage 1. The leakage may be due to damaged/ineffective seals on the cleaning covers.
from boiler 2. Check the condition of the fibreglass ropes between each section, also check the
body seals between the front door and front section.

3. Check the effectiveness of the chimney and ensure no restrictions.

END-USER INSTRUCTIONS

EXPLODED DRAWINGS

MD JETSTREAM EXPLODED DRAWING
(BOILER GROUP)

EXPLODED DRAWINGS

A

LPHA JETSTREAM MD EXPLODED DRAWIN

G

(INSULATION AND OUTER CASINGS)

Form Nr. : MDT01

MODEL : BOILER GROUP NR.1 :
RATED OUTPUT : BOILER GROUP NR.2 :
FUEL TYPE : DATE OF MANUFACTURE :
SERIAL NR. :

CONTACT PERSON :
ADDRESS :

TELEPHONE :

COMPANY NAME :
ADDRESS :

TELEPHONE :

COMPANY NAME :
ADDRESS :

TELEPHONE :

Assembled ............ Boiler group tested at

Ps = 1. 5 x Pmax = 1.5 x ....... = .......... Bars

where Pmax is the maximum operating pressure of heating system;

for a duration of ……. minutes, and

No leakage detected

Leakages detected and corrected on following points:

1.

2.

3.

4.

5.

OTHER FAULTS OR DEFICIENCIES DETECTED

TESTED BY: (Print Name)

DATE and SIGNATURE

ERECTO

R

HYDROSTATIC TEST DATACOMMENTS

A COPY OF THIS TEST CERTIFICATE MUST BE RETURNED TO MHS BOILERS LTD

BOILER ASSEMBLY

CERTIFICATE

BOILER

DATA

END USER

INSTAL

LER

A member of the Modular Heating Group Plc

35 Nobel Square, Burnt Mills Industrial Estate, Basildon, Essex, SS13 1LT. Tel: [phone]. Fax: [phone]

www.mhsboilers.co.uk