Alarko | ACK2 | Specifications | Alarko ACK2 Specifications

Alarko ACK2 Specifications
Distribuitor: CALOR SRL
Str. Progresului nr. 30-40, sector 5, Bucuresti
tel: 021.411.44.44, fax: 021.411.36.14
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ACK2
OIL/GAS FIRED HOT WATER BOILERS
ACK2-80 ....... ACK2-3000
INSTALLATION, AND COMMISIONING MANUAL
Rev B : Feb.2005
05 001 GB
INDEX
1 INTRODUCTION ………………………………………………………
2
2 WARNINGS …..……………………………….…………………….….
2
3 DECLARATION OF CONFORMITY …………………………..…….
4
4 GUARANTEE AND SERVICE ……………………………………….
4
5 GENERAL SPECIFICATIONS ………………………………………
5
6 OPERATING PRINCIPLES ………………………………………….
5
7 MAIN PARTS …………………………………………………………..
6
8 INSTALLATION ………………………………………………………..
7
8.1 SAFETY ARRANGEMENTS …………………………………….
8
8.1.1 MINIMUM SAFETY EQUIPMENT
REQUIRED FOR SEALED SYTEMS …………………..
8
8.1.2 MINIMUM SAFETY EQUIPMENT
REQUIRED FOR OPEN VENTED SYTEMS …………
10
8.2 BURNER SELECTION ………………………………………
11
8.3 FUELS
………………………………………………………..
11
8.4 FLUE GAS EXHAUST SYSTEM …………………………..
12
8.5 BOILER WATER AND MAKE UP WATER FOR ………
HOT WATER BOILERS
12
9 START UP ………………………………………………………………….
13
10 ANEX
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1 INTRODUCTION
This manual comprises the information concerning the Installation, operation, use
and maintenance of ACK2 hot water boilers. This manual alone is not sufficient for
correct installation, operation and use, installers, services and user must obey the
rules specified in current EN + local norms, EC directives and local codes. This
manual gives supplementary information and precautions.
Keep this booklet near the appliance in a safe place in the boiler room for future
reference.
Please read the manual very carefully in order to be able to operate your boiler
safely and with high efficiency for a long period.
2 WARNINGS
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This boiler must be installed in accordance with the rules in force only in a
well ventilated and frost free spaces.
All installation, assembly and maintenance work must be carried out
exclusively by fully trained, professionally qualified personnel and must
conform with this manual and the local codes and requirements of the
authority having jurisdiction, or in the absence of such requirements, apply to
the EEC directives and European norms (EN).
If the boiler is not used for the purposes other then specified in this booklet
and incorrect installation, commissioning and use can cause a fire or
explosion which may result property damage, personnel injury, or loss of life.
Boiler is designed for hot water operation only (less then the boiling
temperature) and the system pressure must be according to the limited
operating pressure specified on the boiler name plate and in this booklet.
Heat transfer medium is water.
Boilers must be fired by gas or oil fuels specified in this manual and boiler
plate.
Boilers must be fired by a compatible burner certified to EN 676 (gas firing) or
EN 267 (oil firing) to comply with the boiler efficiency requirement
(92/42/EEC) directive and Appliances burning gaseous fuels (90/396/EEC)
directive
This is a B 23 appliance so the flue gases must be connected to an adequate
draught chimney, without any flue gas leakage to the boiler room.
It is essential that an appropriate pump is fitted in the circulation system
which must be kept in automatic operation at all the times when the boiler in
use.
The filling and make up water must be according to the specifications given in
this manual. Long term water treatment is essential to the economic
operation and life of both new and refurbished heating systems.
Never obstruct the ventilation openings to the boiler room for a safe and
efficient operation. An adequate air supply for combustion and ventilation
must be provided at all times.
Boilers should be installed on a non-combustible, smooth and level foundation
which is at least 150 mm high and according to these manual and local codes.
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Boilers must not be installed in areas where inflammable vapors and materials
are likely to e present. To avoid damage to the boilers, contamination of the
combustion air by high levels of dust or halogenated hydrocarbons (e.g.
Solvents, spray can propellants, cleaning agents, adhesives, etc.) must be
avoided. The humidity level must not be high in boiler rooms.
The boiler room must not be used for other purposes and must not have an
open connection to the other closed living areas. Connection door must be air
tight, fire resistant and self closing.
The oil or gas burners are equipped with an ignition device which
automatically lights the pilot, and some more additional automated safety
controls. Do not try to light the burner or operate the system manually. All
the control devices must be functional and operating with in the limits
specified at all the time. If any of them is null functioning do not operate the
system and call a qualified service.
If the boiler is heated above 90 °C, do not supply cold water to the system for
rapid cool down. It can cause an explosion. Wait the boiler cool down
naturally up to 40 °C before adding make up water.
Do not use this appliance if any part has been under water. Immediately call
a qualified service to inspect.
An emergency shut down switch must be placed in a proper place outside the
boiler room. This switch must cut off the fuel line and must be identified by a
name plate.
In starting a new installation or if fuel lines have been disconnected after
servicing, air must be purged from the fuel lines by a qualified person.
In closed expansion systems with a membrane type expansion tank, tank gas
pressure must be controlled regularly by a qualified service. If the pre-charge
gas pressure is less then specified; then the system pressure will rise
enormously and can cause an explosion.
If the system is running with a fuel heavier then air and the boiler room is
under ground level, then the firing system must have a flame control device
and the possible leakage from fuel lines must be ventilated to a safe place by
ex-proof mechanical means.
If there is a fuel, flue gas or water leakage in the system, stop the burner and
call the responsible authority.
After commissioning the repair, maintenance work is under responsibility of
user and must be done with a qualified person.
Before operating, smell all around the appliance area for gas. Be sure to smell
next to the floor because some gas is heavier then the air and will settle on
the floor.
WHAT TO DO IF YOU SMELL GAS OR INSPECT FUEL LEAKAGE.
• Do not light any appliance
• Do not touch any electric item.
• Do not smoke
• Shut of the fuel valve from the main inlet to the building.
• Do not use any phone in your building
• Immediately call your local authority from neighbor’s phone.
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3 DECLARATION OF CONFORMITY
We hereby make the fallowing declaration with regard to the appliance
trademark ACK2, models ACK2-80, ACK2-100, ACK2-125, ACK2-150, ACK2-200,
ACK2-250, ACK2-300, ACK2-350, ACK2-400, ACK2-500, ACK2-600, ACK2-700,
ACK2-800, ACK2-900, ACK2-1000, ACK2-1250, ACK2-1500, ACK2-1750, ACK22000, ACK2-2500, ACK2-3000.
That
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The material used in this appliances have been selected that safety and
proper performance of these appliances are ensured and that the materials
are resistant to chemical, mechanical and thermal influences to which the
appliances will be exposed during their expected service life;
For gas-carrying parts no soft soldered joints are applied;
Settings that should be altered have been sealed;
No asbestos has been used;
The components of the appliance which come into contact with food and/or
water used for sanitary purposes do not impair the quality of this food and/or
water;
The components used in this appliance are CE approved;
The installation and user’s instructions, type plate and packaging inscriptions
are translated into the official language of the country of destination, taking
into account the national installation regulation of the country concerned;
The electric equipment of the appliances consequently complies with the
requirements of the Low Voltage Directive (73/23/EEC)
The electric equipment of the appliances consequently complies with the
requirements of the Electromagnetic Compatibility Directive (89/336/EEC)
4 GUARANTEE AND SERVICE
Provided that the principles, warnings and standards set out in the operation in this
manual and taking into account the national installation regulation of the country (in
the absence of such requirements, they shall be referred to EN norms, directives and
codes) are complied with, your boiler shall be under the warranty for a period of 3
(three) years starting from the date of dispatch (from manufacturer) against any
faults of material and workmanship.
The certificate of guarantee shall be filled out by seller and the verification of
installation by a qualified (by the seller) service must be filled out and forwarded to
seller for warranty purposes.
Wrong installation, maintenance and use will not be covered by guarantee.
The boiler guarantee will be invalid if the boiler waterways and system water pipes
are covered with debris and/or carbonate deposits from the system water and/or
boiler heat exchanger parts fails because of corrosion caused by the system water.
The minimum service life for these boilers are 15 (fifteen) years. The producer and
the suppliers undertake to provide service and spare parts to the boilers during said
period.
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5 GENERAL SPECIFICATIONS
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ACK2 boilers are reverse flame, 2 pass, wet back, cylindrical shell type, hot
water, liquid or gas fired, B 23 steel boilers.
They are manufactured and tested in accordance with TS EN 303-1, by an
ISO 9001-2000 registered company.
They are economical and environmentally friendly.
Compact design ensures easy transport into boiler rooms.
The boilers have been specially designed and produced to perform efficient
combustion with both gas and liquid fuels.
Boiler gas side pressure loss is well below the limited values in EN standards.
Economic ad safe heating system operation through optional boiler control
panels. Control Panel in Three Different Models: a) Standard Single stage
boiler control panel b) Standard Two stage boiler control panel c) Weather
Compensated Economy Panel.
ACK2 boilers have 21 different capacities between 80.000-3.000.000 Kcal/h.
(93 – 3488 kW) and standard working pressure is 4 bar.
Minimum heat loss with perfect insulation.
Wide water galleries and the return water connection is from the back bottom
side provide excellent natural circulation and safe heat transfer.
No additional intermediate flow pieces required. All necessary connections are
already on the boiler.
They have low combustion chamber loading for clean combustion with low
nitrogen oxide emissions.
Boiler front door can be opened in both directions, very useful in boiler rooms
with limited space.
6 OPERATING PRINCIPLES
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These boilers have been designed to heat hot water and must be connected
to a heating plant and/or a domestic hot water plant within the limits of its
performance and output.
ACK2 boilers are hot water boilers with a maximum outlet temperature of 90
°C (up to 105 optional) and a maximum allowable operation pressure of 4 bar
gauge (up to 8 bar gauge optional). Return water temperatures must not be
lower then 55 °C on oil and 60°C on gas firing .
These boilers are not suitable for use as a direct water heater. Where potable
or sanitary hot water is required, a matching indirect heat exchanger must be
provided in the system.
These boilers are suitable for Liquid (6 cSt at 20˚C oil) and gaseous (Natural
gas, Town gas, LPG) fuels. Please ask your seller for the details of the Local
suitable fuels which can be fired in ACK2 series boiler.
This boiler must be fired by a compatible burner (CE marked) certified to EN
76 (gas firing) or EN 267 (oil firing) to comply with the Boiler Efficiency
Directive 92/42/EEC.
This boiler is suitable for use in either open vented or pressurized expansion
vessel heating systems. The system must have a matching expansion system.
Second pass heat transfer combustion gas pipes have turbulators in order to
maximize heat transfer to water.
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7 MAIN PARTS
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Combustion chamber.
Second pass combustion pipes and turbulators.
Main boiler body.
Two way hinges.
Combustion chamber door insulation.
Boiler front door
Flame monitoring glass.
Boiler insulation.
Flue box
Functional explosion cover.
Supporting feet.
Gas/liquid fuel burner.
Flue outlet
Boiler return
Boiler flow
Drain and fill
Condense outlet
Pressure sensing coupling
Temperature sensor coupling
Safety connections
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8 INSTALLATION
The installation of the boilers must be performed according to the current local
standards
and in addition, instructions stated below;
 All installation, assembly and maintenance work must be carried out exclusively
by fully trained, professionally qualified personnel and must conform with this
manual and the local codes and requirements of the authority having jurisdiction, or
in the absence of such requirements, apply to the EEC directives and European
norms (EN).
 This boiler must be installed in accordance with the rules in force and only in a
well ventilated and frost free spaces. Top and bottom ventilation openings must be
according to local codes.
 Boilers must be fired by a compatible burner certified to EN 676 (gas firing) or EN
267 (oil firing) to comply with the boiler efficiency requirement (92/42/EEC) directive
and Appliances burning gaseous fuels (90/396/EEC) directive.
 This is a B 23 appliance so the flue gases must be connected to an adequate
draught chimney, without any flue gas leakage to the boiler room.
 Control of the heating system shall enable the specified designed indoor
temperatures to be achieved under the specified variation of internal loads and
external climate and, protect building and equipment against frost and moisture
damage when normal comfort temperature level is not required.
 Heating system shall be equipped with automatic and/or manual control devices
according to current EN 12828.
 It is essential that an appropriate pump is fitted in the circulation system which
must be kept in automatic operation at all the times when the boiler in use.
 It is essential that a shunt pump (anti condensate pump) and/or 3 way valve
systems shall be fitted to the system in order to keep the return line temperature
above the condensation values.
 The filling and make up water must be according to the specifications given in
this manual. Long term water treatment is essential to the economic operation and
life of both new and refurbished heating systems.
 Boilers should be installed on a non-combustible, smooth and level foundation
which is at least 150 mm high and according to these manual and local codes.
 Boilers must not be installed in areas where inflammable vapors and materials
are likely to e present. To avoid damage to the boilers, contamination of the
combustion air by high levels of dust or halogenated hydrocarbons (e.g. Solvents,
spray can propellants, cleaning agents, adhesives, etc.) must be avoided. The
humidity level must not be high in boiler rooms.
 The boiler room must not be used for other purposes and must not have an open
connection to the other closed living areas. Connection door must be air tight, fire
resistant and self closing.
 An emergency shut down switch must be placed in a proper place outside the
boiler room. This switch must cut off the fuel line and must be identified by a name
plate.
 If the system is running with a fuel heavier then air and the boiler room is under
ground level, then the firing system must have a flame control device and the
possible leakage from fuel lines must be ventilated to a safe place by ex-proof
mechanical means.
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 All electrical connections must be according to current standards and wiring
diagrams are given in this manual. Please pay special attention to earth connections
to all electrical items in the boiler room. Never use fuel or water pipes as an earth
connection.
 The boiler chimney connections should be designed according to the norms
and the distance between boiler and the chimney must be minimum. The
chimney connection must be executed according to the required technique;
the ducts must be easily dismountable with no counter slopes, fissures, elbow
curves, etc. For quick guide a Stack dimension chart is given in this manual.
 There must not be any valves between the boiler and the safety items such as
high pressure safety valve, safeguard against lack of water, pressure limiter, and
expansion tank. Only you can have an engineer’s lockable isolating valve can be
placed before the closed expansion tank for maintenance purposes.
 After the installation of the boiler all the water and fuel connections and valves
must be controlled for leakage.
 For ACK2 type boilers, it is advisable to have a three-way valve between flow
and return line in order to keep the water return line over 55 °C in order to
overcome condensation problem.
 ACK2 boilers have condensation outlet which is on the boiler flue gas side,
this outlet shall be drained with a siphon in order to prevent flue gas leakage
from boiler. Condensation drain shall be according to local codes.
 ACK2 boilers, it is advisable to have the circulation pump on the flow direction at
closed expansion systems and on the return line on open vented expansion systems.
 For ACK2 boilers, it is advisable to have the safety valve on flow line to the
connection present on the boiler outlet pipe without any valve.
 For connection of the closed expansion tank it is advice to have on return line and
a lockable valve + drain valve is advised only for servicing.
 If necessary, national regulations regarding the condensate waste disposal rules
shall be applied.
8.1
SAFETY ARRANGEMENTS
Heating system shall be equipped with safety arrangements against, exceeding
the maximum operating temperature and exceeding the maximum operating
pressure. Safety arrangements shall be designed in accordance with the type of
heating system, energy source, and the way which the heat supply is provided to the
heating system, i.e. automatically controlled or manually operated. Minimum
required safety arrangement is under the responsibility of the installer and must be
according to local codes and/or EN 12828.
8.1.1 MINIMUM SAFETY EQUIPMENT REQUIRED FOR SEALED SYTEMS
Protection against exceeding the maximum operating temperature;
Each boiler shall be served by a safety temperature limiter (manual reset
thermostat) including a specific sensor and the boiler temperature shall not rise by
more then 10 K after switching off the heating or fuel supply line. The temperature
limiter shall confirm current EN 60730-2-9 or have CE mark. If one of the boiler
control panel is purchased (optional) then this item is present on all kinds of boiler
control panels.
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Protection against exceeding the maximum operating pressure;
Each boiler shall be served by at least one safety valve in order to protect the
system against exceeding the maximum operating pressure. The safety valve is not
a standard supply with the boiler, it must be fitted by the installer on the flow line of
the boiler without any isolation valve or similar items and they must confirm prEN
1268-1 with a minimum size of DN 15.They must open at a pressure not exceeding
the maximum design pressure of the system and shall be designed to prevent the
maximum operating pressure from being exceeded by more then 10 %. Safety
valves shall be installed so that the pressure drop on the inlet pipe does not exceed 3
% and the pressure drop of the discharge pipe does not exceed 10 % of the safety
valve set pressure.
Safety valves shall discharge safely and boilers greater then 300 kW nominal
heat output have special requirements, please refer to EN 12828.
Each boiler greater then 300 kW nominal heat output shall be served by a
pressure limiter. This is not a standard supply with the boiler; it must be fitted by
the installer on the flow line of the boiler without any isolation valve or similar items.
If the operating pressure of the heating system exceeds the given pressure limit, the
pressure limiter shall shut-off the heating or fuel supply and interlock it against
automatic restoring. Pressure limiter shall be adjusted so that it responds before the
safety valve(s) operate.
Safeguard against lack of water;
Sealed (closed expansion tank systems) shall be equipped with a water level
limiter or other device, e.g. minimum pressure limiter or flow controller, thus
providing interlock protection against excess temperature rise on the heat emitting
surface of the boiler.
Expansion vessels;
When the heating system’s heat carrying medium water is heated it expands
and it cause pressure rise in sealed systems so expansion vessels shall be designed
to accommodate at least the maximum expansion volume of the heating water of the
system including a minimal water reserve volume. The expansion vessel shall
confirm to prEN 13831. For guidance on dimensioning refer to EN 12828 but the
expansion vessel manufacturer’s installation instructions shall be paramount.
The expansion vessel and the connection pipe to the heating system shall be
dimensioned so that the temperature rise up to the maximum operating temperature
does not cause a pressure rise in the system at which the pressure limiting device
and safety valves respond and shall be installed in frost protected rooms or protected
against freezing. Diaphragm-type expansion vessels shall be positioned to the return
pipe of the boiler and shall be no shut-off device positioned between the expansion
vessel and the boiler. Consideration may be given to an engineer’s lockable isolating
valve for maintenance purposes.
Operational requirements of sealed systems;
In order to maintain a safe and economical operation, open vented heating systems
shall be equipped with:
Temperature measuring device (20 % higher then the operating temperature
and mounted in the flow pipe of the system)
Pressure gauge (50 % higher then the operating pressure and mounted in the
flow pipe of the system
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Devices for controlling the operation temperature to adapt the heat supply to
the heat demand. The maximum set-point of the temperature controller shall not
exceed the maximum operating temperature of the boiler.
Pressure maintaining control device to ensure the required minimum
operating pressure of the system. This can be achieved for example by an automatic
refill-set or expansion vessel linked to a low pressure limiter.
Heating system shall be equipped with devices to fill the system and provide
adjustment of the water level. Connections to a drinking water supply system shall
comply with prEN 806-2, e.g. back flow prevention.
An adequate supply of combustion air is important for safe and clean
combustion. For open flue heating systems with a total rated output higher than
50 kW, the rule regarding the supply of combustion air is treated as satisfied, if the
cross-section of the aperture leading into the open air is at least 150 cm2 and is 2
cm2 larger for each kW of rated output above 50 kW.
8.1.2 MINIMUM SAFETY EQUIPMENT REQUIRED FOR OPEN VENTED
SYTEMS
Expansion cisterns;
Boilers in an open vented system shall be connected to an expansion cistern,
which, is installed at the highest point of the heating system. They shall be
dimensioned so that changes in water volume due to heating up and cooling down
can be accommodated. Open vented system expansion cisterns shall be provided
with a cistern vent and overflow pipe that cannot be blocked. The overflow pipe shall
be dimensioned so that it can safely drain off the maximum mass flow rate entering
the system, which can be achieved by selecting the overflow pipe to be one DN-size
larger then the filling pipe.
Expansion cisterns, safety pipes, open vent and overflow pipes shall be
designed and arranged to protect against freezing.
Installation example is given in figure ….
Safety pipes, feed and expansion pipes;
Boilers shall be connected to an expansion cistern and served by an open vent pipe.
The expansion cistern shall be vented to the atmosphere. The feed and expansion
pipe shall be connected to the lower part of the expansion cistern. Shutting off the
safety pipe or the feed and expansion pipes shall not be possible.
The minimum internal diameter of the open vent safety pipe and feed and
expansion pipe shall be:
Safety pipe:
d s = 15 + 1.4 √Ф
mm
(but not less then 19 mm internal diameter)
Feed and expansion pipe: d fe = 15+ 1.0 √Ф mm
Where Ф is the nominal heat output of the boiler in kW.
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Operational requirements of open vented systems;
In order to maintain a safe and economical operation, open vented heating systems
shall be equipped with:
Water level indicator
Temperature indicator (% 20 higher then the operating temperature and
mounted in the flow pipe of the system)
Devices for controlling the operation temperature to adapt the heat supply to
the heat demand. The maximum set-point of the temperature controller shall not
exceed the maximum operating temperature of the boiler.
Heating system shall be equipped with devices to fill the system and provide
adjustment of the water level. Connections to a drinking water supply system shall
comply with prEN 806-2, e.g. back flow prevention
An adequate supply of combustion air is important for safe and clean
combustion. For open flue heating systems with a total rated output higher than
50 kW, the rule regarding the supply of combustion air is treated as satisfied, if the
cross-section of the aperture leading into the open air is at least 150 cm2 and is 2
cm2 larger for each kW of rated output above 50 kW.
8.2 BURNER SELECTION
Boilers must be fired by a compatible burner certified to EN 676 (gas firing) or
EN 267 (oil firing) to comply with the boiler efficiency requirement (92/42/EEC)
directive and Appliances burning gaseous fuels (90/396/EEC) directive
The burner must be suitable for the respective rated output and the resistance
on the flue gas side of the boiler. The material of the burner head must be suitable
for operating temperatures of at least 500 C.
Boiler combustion chamber dimensions and flue gas side resistances are
according to the current regulations.
BURNER INSTALLATION
The burner should be installed to the hinged boiler front door by the help of
burner plate, which is the standard delivery.
The ballast tube of the burner must protrude from the thermal insulation on the
boiler door. If the burner ballast tube to be used is short or very long then verify
perfect functioning by burner and boiler manufacturer.
If the burner ballast tube diameter is less then the boiler door please fill the
gap with thermal insulation material supplied by the boiler.
Flange connections shall be air tight always. If there will be combustion hot gas
leakage from the flanges to the boiler room it can be poisonous and hot gases will
overheat the boiler front door.
Burner shall be adjusted according to the boiler output. In two stage or
modulating burners low fire output adjustment be sure that flue gas temperature is
not lower then the condensation point of flue gas.
8.3 FUELS
ACK2 boilers can be fired with the fuels;
Oil (according to DIN 51 603 and/or to local limitations)
Natural gas, LPG and Town gas (according to EN 437 and/or to local limitations)
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8.4 FLUE GAS EXHAUST SYSTEM.
ACK2 boilers are B 23 type appliance so the flue gases must be connected to an
adequate draught chimney, without any flue gas leakage to the boiler room.
Chimney design must be according to local codes. Chimney inside diameter, height,
material, thermal insulation, strength shall be according the flue gas specifications
and shall not cause dangerous high pressures.
0 to -0.3 mbar vacuum shall be observed at the flue gas exit of boiler.
Some informative diagrams are given for quick reference in annex
Effective chimney height is the height difference between boiler flue gas exit and
chimney end.
Flue gas ducts between boiler and chimney shall not be longer then ¼ of the
effective height but anyhow it shall not be longer then 7 m and shall not be shorter
then 0.6 m. There can be maximum two 90° elbow (avoid sharp turns)
Flue gas ducts shall not have any downward slope. It is advised to have 10° slope
upwards and enter the chimney with an angle of 45°.
8.5 BOILER WATER AND MAKE UP WATER FOR HOT WATER BOILERS
According to EN 12953-10:2003 (Shell boilers: Requirements for feed water and
boiler water quality.
Parameter
Unit
Operating pressure
Appearance
Direct conductivity at 25 °C
pH value at 25 °C
Total hardness (Ca + Mg)
Iron concentration
Composite alkalinity
Oil/grease concentration
Organic substances
(as TOC)
Bar
μS/cm
mmol/l
mg/l
mmol/l
mg/l
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Make up Boiler Water
Boiler water
Total range
Clear, free from suspended solids, no stable foam
< 1500
>7.0
9.0 to 11,5 a
< 0,05
< 0,2
<5
<1
See footnote
b
a
If non-ferrous materials are present in the system, e.g. aluminum, they may require
lower pH value and direct conductivity, however, the protection of the boiler has
priority.
b
Organic substances are generally a mixture of several different compounds. The
composition of such mixtures and the behavior of their individual components under the
conditions of boiler operation are difficult to predict. Organic substances may be
decomposed to form carbonic acid or other acidic decomposition products which increase
the acid conductivity and cause corrosion or deposits. They also may lead to foaming
and/or priming which shall be kept as low as possible.
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Note :During boiler economic life, the total make up water volume can not be more then
3 times of the total system water.
Guarantee will not be valid, if the boiler is out of service because of corrosion, sludge
formation and deposits
In order to prevent corrosion special care needed for oxygen infusion to the heating
system water side. Possible points for oxygen infusion are from open vented cisterns,
negative pressure points on the system and some gas permeable system items like
plastic pipes.
9 START UP
First start up work shall be carried out exclusively by fully trained, professionally
qualified personnel.
Before first start up check that;
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There is a copy of the boiler and burner instructions in the boiler room.
The boiler name plate and manual specifications and power supply network and
other system need specifications correspond. (electric supply, fuel, water, boiler
and burner output, system pressure, circulating pipes …)
The air inlet and outlet supply openings are correctly sized and free from
obstacles.
The flue gas exhaust system is correctly fitted and sized.
All the system control and security devices are present and installed according to
the current regulations and working properly.
The burner output and fuel type is compatible with the boiler and system
specifications.
The flue gas turbulators are present in all the second pass pipes and properly
placed.
Control the boiler gas side seals are not damaged and fixed properly. (boiler front
door, burner mounting plates, smoke box, flame monitoring glass)
In starting a new installation all the fuel and water pipes, boiler and all the other
heating system items must be flushed and free from deposits.
Before filling the system with water control the expansion tank pre charge pressure
in sealed systems.
Open all the necessary valves for filling
Fill the heating system with water (water specifications shall be according to boiler
manuals) very slowly according to the air bleeding capacity of the components.
In open vented systems fill the system up expansion cistern’s proper level. In sealed
systems fill the system up to predefined pressure.
Bleed all the air in the water side. Any air pockets have been eliminated.
Run the circulating pumps and control that they are working properly.
Control all the possible water leakage points.
Check all security and operation items are working properly and set to system needs.
If the safety valve is not factory adjusted, set it according to system need and be sure
that it is working properly.
Control the fuel system installation
Bleed all the air in fuel system.
- 13 -
Before firing the burner, be sure that system is full of water and all control items are
set to desired value and working properly.
Check the fuel pressure, temperature and fuel line leakages before running the
burner.
Run the burner and adjust it to proper output according to boiler needs.
Analyze the flue gas and be sure that emission levels of CO, NO x , soot, CO 2 or O 2
are according to current regulations.
For reference (current and local regulations has priority)
Gas
LPG
Oil
FUEL
≥ 10
≥ 10
≥ 13
% C0 2
CO (mg/kWh)
≤ 100
≤100
≤110
NO x (mg/kWh)
≤ 170
≤ 230
≤ 250
Note: Emission values shall be according to current and local limitations. In absence of
local limitations refer to current EN 677 for gas firing and current EN 300-2 for oil firing.
In correct adjustments can cause damage to people, animals, nature and also loss of
energy.
After running the burner heat the system up to 85 °C and again bleed the air in the
water side. After first heating most of the dissolved air in the system water will be free
for bleeding.
Control all the security and operation devices for proper operation and set values are
according to system needs again.
Call the owner or operator of the boiler house and give the necessary information for
proper operation of the system and warn them about the possible dangers and
limitations and what will they do in case of emergency.
- 14 -
10 ANEX
- 15 -
HS
HS
V
V
V
SP
V
3W V
SP
V
V
V
TC
TI
PI
LV
HS
SP
ACP
MET
3W V
TCL
TC
TI
PI
SPL1
SPL2
SV
FT
LV
PR
CV
ARFS
DV
ACP
PI
V
TCL
V
SPL2
PI
SV
FT
SPL1
V
LV
MET
Heating system
Circulation pump
Anti condensate pump
Membrane expansion tank
Three way valve
High Limit themostat
Boiler thermostat
Thermometer
Pressure gauge
Max. Safety pressure limiter
Min. Safety pressure limiter
Safety valve
Flash trap
Lockable valve
Pressure regulator
One way valve
Automatic refill system
Drain valve
LV
TI
DV
V
PR
V
V
DV
CV
V
ARFS
TYPICAL SAFETY EQUIPMENT AND HYDRAULIC ARRANGEMENT
FOR SEALED (CLOSED EXPANSION) SYSTEMS
16
OEC
V
HS
HS
V
V
V
SP
V
3W V
SP
V
V
V
TCL TC
TI
V
BPP
V
BOILER
WLI
LV
TI
HS
Heating system
SP
Circulation pump
BPP
OEC
By pass pump
Open expansion cistern
3W V
Three way valve
TCL
High Limit themostat
TC
TI
Boiler thermostat
Thermometer
WLI
Water level indicator
LV
Lockable valve
V
Valve
PR
Pressure regulator
CV
One way valve
ARFS
Automatic refill system
DV
Drain valve
V
V
DV
V
PR
CV
V
ARFS
TYPICAL SAFETY EQUIPMENT AND HYDROULIC ARRANGEMENT
FOR OPEN VENTED (OPEN EXPANSION CISTERN) SYSTEMS
17
150
100
BOILER FEET WIDTH
100
80
BOILER FEET LENGHT
80
- BOILER FOUNDATION SHALL BE ENOUGH STRENGHT TO CARRY THE BOILER FULL WITH WATER AND ACCESSORIES
- BOILER FOUNDATION SHALL BE FROM NON CONBUSTIBLE METERIALS
- BOILER FOUNDATION SURFACE SHALL BE LEVEL AND SMOOTH
- BOILER FOUNDATION
18
D
B
W
W
W
L
A
500
A
L+600
A : Burner lenght.
B : 600 mm minimum.
W : A + 200 mm minimum.
D : L/2 + 500 (min 600 mm)
L : Lenght of boiler.
H : Height of the boiler room must be minimum 1000 mm
heigher then the boiler height.
Note : These dimensions are recomendations only.
They can be changed according to local standarts.
BOILER ROOM LAYOUT
19
FOR CIRCULAR CROSS SECTION (SCHIEDEL)
3500
3000
850 800
700
750
600
650
550
2500
500
NOMINAL OUTPUT (kW)
2000
1750
1500
450
400
1250
1000
900
800
700
600
500
450
400
350
300
350
300
250
250
225
200
175
150
220
200
Inside diameter
180
125
100
90
80
70
60
50
40
160
20
10
0
5
10
15
20
25
30
35
40
45
50
55
60
EFFECTIVE CHIMNEY HEIGHT (m)
20
21
FOR SQUARE CROSS SECTIONS (PLEWA)
55x55
70x70 60x60
3500
3000
2500
50x50
45x45
40x40
2000
1750
1500
35x35
30x30
NOMINAL OUTPUT (kW)
1250
1000
900
800
700
600
500
450
400
350
300
250
225
200
175
150
125
100
90
80
70
60
50
40
30
20
10
27.5x27.5
25x25
22.5x22.5
20x20
18x18
Inside dimensions
16x16
14x14
0
5
10
15
20
25
30
35
40
45
50
55
60
22
ACK2 OIL/GAS FIRED HOT WATER BOILERS
ALARKO - GAS BURNER SELECTION CHART
Boiler
Net Heat
Gross
Heat
Back
pressure
Burner type
Burner
exploitation
Percentage
Blast
tube
Length
Required.
Length
Diameter
(Boiler)
Diameter
(Burner)
ø
ø
mm
Standard
(S) blast
tube (mm)
Boiler
opening
for burner
(mm)
Burner
blast tube
(mm)
Combustion
chamber
diameter
mm
Combustion
chamber
length mm
Combustion
chamber
Volume
(m3)
Thermal
load
(kW/m3)
130
108
339
950
0,0857
1.190
130
108
339
950
0,0857
1.493
160
140
450
950
0,1511
1.059
type
(kw)
(kw)
(mbar)
type
model
%
ACK2-80
93
102
0,5
ALG
16
69
150
60..143
ACK2-100
116
128
0,6
ALG
16
87
150
60..143
ACK2-125
145
160
0,7
ALG
27 or 27/2
83 or 81
150
100..265
ACK2-150
175
193
1,2
ALG
27/2
97
150
100..265
160
140
450
950
0,1511
1.277
ACK2-200
232
255
1,5
ALG
36 or 36/2
81 or 75
150
110..350
160
140
548
1040
0,2453
1.040
ACK2-250
290
319
1,6
ALG
36/2
93
150
110..350
180
140
548
1040
0,2453
1.300
ACK2-300
349
384
1,4
ALG
60/2
68
150
357..391
180
163
634
1270
0,4009
958
ACK2-350
407
448
2,0
ALG
60/2
81
150
357..391
180
163
634
1270
0,4009
1.117
ACK2-400
465
512
2,2
ALG
60/2
93
150
357..391
180
163
634
1500
0,4735
1.081
ACK2-500
581
639
2,1
ALG
77/2
89
150
357..391
205
172
700
1453
0,5592
1.143
ACK2-600
698
768
2,8
N/A
N/A
700
1453
0,5592
1.373
ACK2-700
814
895
2,6
N/A
N/A
860
1730
1,0049
891
ACK2-800
930
1023
2,8
N/A
N/A
860
1730
1,0049
1.018
ACK2-900
1046
1151
2,9
N/A
N/A
860
1730
1,0049
1.145
ACK2-1000
1163
1279
3,0
N/A
N/A
860
1730
1,0049
1.273
ACK2-1250
1453
1598
3,1
N/A
N/A
880
2145
1,3046
1.225
ACK2-1500
1744
1918
3,6
N/A
N/A
880
2490
1,5144
1.266
ACK2-1750
2034
2237
4,2
N/A
N/A
1000
2400
1,8850
1.187
ACK2-2000
2325
2558
4,7
N/A
N/A
1000
2650
2,0813
1.229
ACK2-2500
2907
3198
5,2
N/A
N/A
1050
2640
2,2860
1.399
ACK2-3000
3488
3837
5,5
N/A
N/A
339
950
0,0857
1.190
23
ACK2 OIL/GAS FIRED HOT WATER BOILERS
LAMBORGHINI - GAS BURNER SELECTION CHART
Boiler
type
Net Heat
Gross
Heat
Back
pressure
Burner type
Burner
exploitati
on
Percenta
ge
Blast
tube
Length
Required.
Length
(kw)
(kw)
(mbar)
type
model
%
mm
Minimum
Diameter
Diameter
ø
ø
Standard
(S) blast
tube (mm)
Boiler
opening for
burner
(mm)
Burner
blast tube
(mm)
Combust
ion
chamber
diameter
mm
Combustion
chamber
length mm
Combustion
chamber
Volume
(m3)
Thermal
load
(kW/m3)
130
108
339
950
0,0857
1.190
130
108
339
950
0,0857
1.493
160
140
450
950
0,1511
1.059
160
140
450
950
0,1511
1.277
ACK2-80
93
102
0,5
EM
16-E or 16/2-E
62 or 71
150
60..150
ACK2-100
116
128
0,6
EM
16-E or 16/2-E
88 or 90
150
60..150
ACK2-125
145
160
0,7
EM
26-E or 26/2-E
70 or 73
150
100..265
ACK2-150
175
193
1,2
EM
26-E or 26/2-E
87 or 90
150
100..265
ACK2-200
232
255
1,5
EM
35-E or 40/2-E
89 or 90
150
120..310
160
140
548
1040
0,2453
1.040
ACK2-250
290
319
1,6
EM
50/2-E
63
150
140..400
180
170
548
1040
0,2453
1.300
ACK2-300
349
384
1,4
EM
74 or 52
150
140..400
180
170
634
1270
0,4009
958
ACK2-350
407
448
2,0
EM
50/2-E or 70/2-E
90 or 63
150
140..400
180
170
634
1270
0,4009
1.117
ACK2-400
465
512
2,2
PM
70/2-E
73
150
140..400
180
170
634
1500
0,4735
1.081
ACK2-500
581
639
2,1
PM
70/2-E
90
150
140..400
205
170
700
1453
0,5592
1.143
ACK2-600
698
768
2,8
PM
140/2-E
66
200
200..460
205
197
700
1453
0,5592
1.373
ACK2-700
814
895
2,6
PM
140/2-E
66
200
200..460
250
197
860
1730
1,0049
891
ACK2-800
930
1023
2,8
PM
140/2-E
88
200
200..460
250
197
860
1730
1,0049
1.018
ACK2-900
1046
1151
2,9
PM
140/2-E or 210/2-E
99 or 70
200
200..460
250
197 or 228
860
1730
1,0049
1.145
ACK2-1000
1163
1279
3,0
PM
210/2-E
77
200
200..460
250
228
860
1730
1,0049
1.273
ACK2-1250
1453
1598
3,1
PM
210/2-E
97
200
200..460
250
228
880
2145
1,3046
1.225
ACK2-1500
1744
1918
3,6
PM
310/2-E
71
200
250..550
280
256
880
2490
1,5144
1.266
ACK2-1750
2034
2237
4,2
PM
310/2-E
84
200
250..550
280
256
1000
2400
1,8850
1.187
ACK2-2000
2325
2558
4,7
PM
310/2-E or 430/2-E
97 or 61
200
250..550
350
256 or 303
1000
2650
2,0813
1.229
ACK2-2500
2907
3198
5,2
PM
430/2-E
77
200
250..600
350
303
1050
2640
2,2860
1.399
ACK2-3000
3488
3837
5,5
PM
430/2-E
92
200
250..600
350
303
339
950
0,0857
1.190
50/2-E or 70/2-E
24
ACK2 OIL/GAS FIRED HOT WATER BOILERS
ALARKO - OIL BURNER SELECTION CHART
Boiler
Net Heat
Gross
Heat
Back
pressure
Burner type
Burner
exploitation
Percentage
Blast
tube
Length
Required.
Length
Standard
(S) blast
tube (mm)
Diameter
Diameter
ø
ø
Boiler
opening
for
burner
(mm)
Burner
blast
tube
(mm)
Combustion
chamber
diameter
mm
Combustion
chamber
length mm
Combustion
chamber
Volume
(m3)
Thermal
load
(kW/m3)
130
339
950
0,0857
1.190
type
(kW)
(kW)
(mbar)
Type
model
%
mm
ACK2-80
93
102
0,5
ALM
14
64
150
120..235
130
ACK2-100
116
128
0,6
ALM
14
82
150
120..235
130
130
339
950
0,0857
1.493
ACK2-125
145
160
0,7
ALM
22
65
150
60..200
160
120
450
950
0,1511
1.059
ACK2-150
175
193
1,2
ALM
22
83
150
60..200
160
120
450
950
0,1511
1.277
ACK2-200
232
255
1,5
ALM
30 or 30/2
78 or 75
150
70..290
160
133
548
1040
0,2453
1.040
ACK2-250
290
319
1,6
ALM
30/2
94
150
70..290
180
133
548
1040
0,2453
1.300
ACK2-300
349
384
1,4
ALM
40/2
87
150
120..310
180
147
634
1270
0,4009
958
ACK2-350
407
448
2,0
ALM
50 or 60/2
77 or 67
150
181..203
180
159
634
1270
0,4009
1.117
ACK2-400
465
512
2,2
ALM
50 or 60/2
89 or 75
150
181..203
180
159
634
1500
0,4735
1.081
ACK2-500
581
639
2,1
ALM
59 OR60/2
91 or 94
150
181..203
205
159
700
1453
0,5592
1.143
ACK2-600
698
768
2,8
ALM
76/2
84
200
181..211
205
181
700
1453
0,5592
1.373
ACK2-700
814
895
2,6
ALM
76/2
99
200
181.211
250
181
860
1730
1,0049
891
ACK2-800
930
1023
2,8
MS
7-1VZDU
74
200
223
250
200
860
1730
1,0049
1.018
ACK2-900
1046
1151
2,9
MS
7-1VZDU
84
200
223
250
200
860
1730
1,0049
1.145
ACK2-1000
1163
1279
3,0
MS
7-1VZDU or
8-1VZDU
93 or 50
200
223 or 242
250
200 or
240
860
1730
1,0049
1.273
ACK2-1250
1453
1598
3,1
MS
8-1VZDU
65
200
242
250
240
880
2145
1,3046
1.225
ACK2-1500
1744
1918
3,6
MS
8-1VZDU
79
200
242
280
240
880
2490
1,5144
1.266
ACK2-1750
2034
2237
4,2
MS
8-1VZDU
93
200
242
280
240
1000
2400
1,8850
1.187
ACK2-2000
2325
2558
4,7
MS
9-VZDU
88
200
225
350
265
1000
2650
2,0813
1.229
ACK2-2500
2907
3198
5,2
MS
10-VZDU
89
200
235
350
265
1050
2640
2,2860
1.399
ACK2-3000
3488
3837
5,5
RMS
10 VDMU
100
200
235
350
265
339
950
0,0857
1.190
25
ACK2 OIL/GAS FIRED HOT WATER BOILERS
CIB UNIGAZ - GAS BURNER SELECTION CHART
Burner
exploitati
on
Percenta
ge
Blast
tube
Lengt
h
Requir
ed.
Length
Diameter
Diameter
ø
ø
Standard
(S) blast
tube (mm)
Boiler
opening
for burner
(mm)
Burner
blast tube
(mm)
Combustion
chamber
diameter
mm
Combustion
chamber
length mm
Combustion
chamber
Volume
(m3)
Thermal
load
(kW/m3)
150
180
130
108(113)
339
950
0,0857
1.190
99
150
180
130
108(113)
339
950
0,0857
1.493
M-.AB.S.IT.A.0.25
100
150
205
160
126
450
950
0,1511
1.059
NG350
M-.PR.M.IT.A.0.xx
63
150
177
160
125 (157)
450
950
0,1511
1.277
1,5
NG350
M-.PR.M.IT.A.0.xx
82
150
177
160
125 (157)
548
1040
0,2453
1.040
1,6
NG400
M-.PR.M.IT.A.0.xx
87
150
195
180
144 (157)
548
1040
0,2453
1.300
384
1,4
NG550
M-.PR.S.IT.A.0.xx
73
150
252
180
155(168)
634
1270
0,4009
958
407
448
2,0
NG550
M-.PR.S.IT.A.0.xx
87
150
252
180
155(168)
634
1270
0,4009
1.117
ACK2-400
465
512
2,2
NG550
M-.PR.S.IT.A.0.xx
98
150
252
180
155(168)
634
1500
0,4735
1.081
ACK2-500
581
639
2,1
P60
M-.AB.S.IT.A.0.xx
83
150
345
205
184
700
1453
0,5592
1.143
ACK2-600
698
768
2,8
P65
M-.AB.S.IT.A.0.xx
92
200
325
205
184(198)
700
1453
0,5592
1.373
ACK2-700
814
895
2,6
P72
M-.AB.S.IT.A.0.xx
76
200
385
250
234
860
1730
1,0049
891
ACK2-800
930
1023
2,8
P72
M-.AB.S.IT.A.0.xx
87
200
385
250
234
860
1730
1,0049
1.018
ACK2-900
1046
1151
2,9
P72
M-.AB.S.IT.A.0.xx
97
200
385
250
234
860
1730
1,0049
1.145
ACK2-1000
1163
1279
3,0
P72
M-.AB.S.IT.A.1.xx
86
200
385
250
234
860
1730
1,0049
1.273
ACK2-1250
1453
1598
3,1
P72
M-.AB.S.IT.A.1.xx
99
200
385
250
234
880
2145
1,3046
1.225
ACK2-1500
1744
1918
3,6
P91
M-.PR.S.IT.A.1.xx
85
200
490
280
265
880
2490
1,5144
1.266
ACK2-1750
2034
2237
4,2
P91
M-.PR.S.IT.A.1.xx
100
200
490
280
265
1000
2400
1,8850
1.187
ACK2-2000
2325
2558
4,7
P510
M-.PR.S.IT.A.1.xx
61
200
520
350
340
1000
2650
2,0813
1.229
ACK2-2500
2907
3198
5,2
P510
M-.PR.S.IT.A.1.xx
76
200
520
350
340
1050
2640
2,2860
1.399
ACK2-3000
3488
3837
5,5
P510
M-.PR.S.IT.A.1.xx
94
200
520
350
340
339
950
0,0857
1.190
Boiler
Net Heat
Gross
Heat
Back
pressure
type
(kw)
(kw)
(mbar)
type
model
%
mm
Minim
um
ACK2-80
93
102
0,5
S10
M-.AB.S.IT.A.0.20
74
ACK2-100
116
128
0,6
S10
M-.AB.S.IT.A.0.20
ACK2-125
145
160
0,7
S18
ACK2-150
175
193
1,2
ACK2-200
232
255
ACK2-250
290
319
ACK2-300
349
ACK2-350
Burner type
26
ACK2 OIL/GAS FIRED HOT WATER BOILERS
CIB UNIGAZ - OIL BURNER SELECTION CHART
Burner
exploitati
on
Percenta
ge
Blast
tube
Lengt
h
Requir
ed.
Length
Length
Diameter
Boiler
Net Heat
Gross
Heat
Back
pressure
type
(kw)
(kw)
(mbar)
type
model
%
mm
Minim
um
Standard
(S) blast
tube (mm)
Extended
(L) blast
tube (mm)
blast tube
(mm)
Combustion
chamber
diameter
mm
Combustion
chamber
length mm
Combustion
chamber
Volume
(m3)
Thermal
load
(kW/m3)
ACK2-80
93
102
0,5
G10
G.TN.L.IT.A
87
150
80
200
114
339
950
0,0857
1.190
ACK2-100
116
128
0,6
G18
G.SP.L.IT.A
68
150
-
200
114
339
950
0,0857
1.493
ACK2-125
145
160
0,7
G18
G.SP.L.IT.A
84
150
-
200
114
450
950
0,1511
1.059
ACK2-150
175
193
1,2
G18
G.SP.L.IT.A
100
150
-
200
114
450
950
0,1511
1.277
ACK2-200
232
255
1,5
LO400
G-.AB.M.IT.A
65
150
194
324
133 (143)
548
1040
0,2453
1.040
ACK2-250
290
319
1,6
LO400
G-.AB.M.IT.A
85
150
194
324
133 (143)
548
1040
0,2453
1.300
ACK2-300
349
384
1,4
LO400
G-.AB.M.IT.A
100
150
194
324
133 (143)
634
1270
0,4009
958
ACK2-350
407
448
2,0
LO550
G-.AB.S.IT.A
88
150
252
352
144(155)
634
1270
0,4009
1.117
ACK2-400
465
512
2,2
LO550
G-.AB.S.IT.A
99
150
252
352
144(155)
634
1500
0,4735
1.081
ACK2-500
581
639
2,1
PG60
G-.AB.S.IT.A
100
150
310
460
198
700
1453
0,5592
1.143
ACK2-600
698
768
2,8
PG70
G-.AB.S.IT.A
75
200
310
460
198
700
1453
0,5592
1.373
ACK2-700
814
895
2,6
PG70
G-.AB.S.IT.A
87
200
310
460
198
860
1730
1,0049
891
ACK2-800
930
1023
2,8
PG70
G-.AB.S.IT.A
99
200
310
460
198
860
1730
1,0049
1.018
ACK2-900
1046
1151
2,9
PG80
G-.AB.S.IT.A
78
200
340
490
218
860
1730
1,0049
1.145
ACK2-1000
1163
1279
3,0
PG80
G-.AB.S.IT.A
87
200
340
490
218
860
1730
1,0049
1.273
ACK2-1250
1453
1598
3,1
PG91
G-.AB.S.IT.A
78
200
300
475
238
880
2145
1,3046
1.225
ACK2-1500
1744
1918
3,6
PG91
G-.AB.S.IT.A
93
200
300
475
238
880
2490
1,5144
1.266
ACK2-1750
2034
2237
4,2
PG92
G-.AB.S.IT.A
89
200
295
465
266
1000
2400
1,8850
1.187
ACK2-2000
2325
2558
4,7
PG510
G-.PR.S.IT.A
66
200
300
520
329
1000
2650
2,0813
1.229
ACK2-2500
2907
3198
5,2
PG510
G-.PR.S.IT.A
82
200
300
520
329
1050
2640
2,2860
1.399
ACK2-3000
3488
3837
5,5
PG510
G-.PR.S.IT.A
98
200
300
520
329
339
950
0,0857
1.190
Burner type
ø
27
TECHNICAL SPECIFICATIONS OF ACK2 TYPE BOILERS
Range of Temperature Control
°C
55-90
Boiler Type
Hot Water, Two Pass, Reversal Flame, Steel, B
Fuel Type
Oil (6 cST at 20 °C)
23
Gaseous (Natural Gas, Town Gas, LPG)
Nominal
Output °C
170-190
Partial
Output °C
120-140
mbar
-0,3~0
Exit Flue Gas Temperature °C
Required Draught
Specifications
Unit
BOILER TYPE
ACK2-250
ACK2-300
ACK2-350
ACK2-400
Combustion Chamber Pressure
mbar
0,5
0,6
0,8
1,2
1,5
1,6
1,4
2
2,2
2,1
Exit Flue Gas Mass Flow Rate
kg/h
155
195
242
293
387
484
582
679
775
968
Water Resistance
mbar
4
6
10
10
12
14
14
15
15
16
kW
102
128
160
193
255
319
384
448
512
639
kcal/h
88.000
110.000
137.500
165.000
220.000
275.000
330.000
385.000
440.000
550.000
kW
93
116
145
175
232
290
349
407
465
581
kcal/h
80.000
100.000
125.000
150.000
200.000
250.000
300.000
350.000
400.000
500.000
Heat Input
Nominal Heat Output
ACK2-80
ACK2-100
ACK2-125
ACK2-150
ACK2-200
ACK2-500
Standby Loss
%
0,42
0,42
0,33
0,33
0,32
0,28
0,27
0,25
0,24
0,17
Gas Volume
m³
0,126
0,137
0,219
0,234
0,330
0,350
0,525
0,545
0,639
0,811
Combustion Chamber Inner Dia.
mm
339
339
450
450
548
548
634
634
634
700
Combustion Chamber Length
mm
950
950
950
950
1040
1040
1270
1270
1500
1453
Combustion Chamber Volume
m³
0,086
890
0,151
0,245
0,245
0,401
0,401
0,474
0,559
mm
0,086
890
0,151
Boiler Height
1029
1029
1104
1104
1305
1305
1305
1511
Boiler Width
mm
700
700
840
840
923
923
1040
1040
1040
1240
Boiler Length
mm
1350
1350
1329
1329
1425
1425
1734
1734
1734
2005
Exit Flue Gas Connection Dia.
mm
200
200
200
200
250
250
300
300
300
400
Exit Flue Gas Connection Height
mm
555
555
625
625
744
744
821
821
821
956
-
2"
2"
NW 65
NW 65
NW 65
NW 65
NW 80
NW 80
NW 80
NW 100
Inlet Flange
Exit Flange
-
2"
2"
NW 65
NW 65
NW 65
NW 65
NW 80
NW 80
NW 80
NW 100
Filling and Drain Pipes
inch
¾"
¾"
¾"
¾"
¾"
¾"
¾"
¾"
¾"
¾"
Expansion Tank Outlet
inch
1¼ "
1 ¼"
1¼ "
1¼ "
1¼ "
1½ "
1½"
2"
2"
2"
Expansion Tank Inlet
inch
1"
1"
1"
1"
1¼ "
1¼ "
1¼"
1¼ "
1¼ "
1½"
Weight
kg
304
330
426
445
534
561
865
899
993
1323
Water Content
lt
132
119
175
157
193
169
290
266
311
623
ACK2-600
ACK2-700
ACK2-800
ACK2-900
Specifications
Unit
BOILER TYPE
ACK2-1000 ACK2-1250 ACK2-1500 ACK2-1750 ACK2-2000 ACK2-2500 ACK2-3000
Combustion Chamber Pressure
mbar
2,8
2,6
2,8
2,9
3
3,1
3,6
4,2
4,7
5,2
5,5
Exit Flue Gas Mass Flow Rate
kg/h
1168
1368
1558
1752
1942
2429
2900
3400
3886
4859
5830
Water Resistance
mbar
16
18
20
22
22
28
31
35
46
48
50
kW
768
895
1023
1151
1279
1598
1918
2237
2558
3198
3837
kcal/h
660.000
770.000
880.000
990.000
1.100.000
1.375.000
1.650.000
1.925.000
2.200.000
2.750.000
3.300.000
kW
698
814
930
1046
1163
1453
1744
2034
2325
2907
3488
kcal/h
600.000
700.000
800.000
900.000
1.000.000
1.250.000
1.500.000
1.750.000
2.000.000
2.500.000
3.000.000
Max Heat Input
Nominal Heat Output
Standby Loss
%
0,17
0,16
0,16
0,16
0,16
0,15
0,15
0,15
0,15
0,15
0,15
Gas Volume
m³
0,857
1,341
1,376
1,410
1,465
1,926
2,221
2,647
2,912
3,575
4,839
Combustion Chamber Inner Dia.
mm
700
860
860
860
860
880
880
1000
1000
1050
1180
Combustion Chamber Length
mm
1453
1730
1730
1730
1730
2145
2490
2400
2650
2640
3000
Combustion Chamber Volume
m³
0,559
1,005
1,005
1,005
1,005
1,305
1,514
1,885
2,081
2,286
3,281
Boiler Height
mm
1511
1400
1400
1400
1400
1810
1810
1918
1918
2171
2325
Boiler Width
mm
1240
1450
1450
1450
1450
1550
1550
1650
1650
1890
2050
Boiler Length
mm
2005
2400
2400
2400
2400
2800
3100
3000
3268
3300
3670
Exit Flue Gas Connection Dia.
mm
400
450
450
450
450
500
500
500
500
600
600
Exit Flue Gas Connection Height
mm
956
1045
1045
1045
1045
1123
1123
1277
1277
1406
1480
Inlet Flange
-
NW 100
NW 125
NW 125
NW 125
NW 125
NW 150
NW 150
NW 150
NW 150
NW 200
NW 200
Exit Flange
-
NW 100
NW 125
NW 125
NW 125
NW 125
NW 150
NW 150
NW 150
NW 150
NW 200
NW 200
Filling and Drain Pipes
inch
¾"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
Expansion Tank Outlet
inch
2"
2 ½"
2½ "
2½ "
2½ "
2½ "
3"
3"
4"
4"
4"
Expansion Tank Inlet
inch
1½ "
2"
2"
2"
2"
2½ "
2½"
2½ "
2½ "
2½"
3"
Weight
kg
1397
1888
1945
2002
2093
2791
3125
3558
3854
4991
6074
Water Content
lt
569
1019
979
938
874
1371
1583
1653
1818
2560
3370
BOILER CONTROL PANELS
1
2
3
5
1
2
1
2
3
5
4
3
5
4
6
Boiler Control Panel Device Functions :
1. Main switch : Energize or shut off the panel
2. Safety limit thermostat: If boiler water temperature is out of control (boiler
thermostat are not functioning, electric wire fault, etc) and reaches 100 °C (+/- 5 °C)
it will stop the burner immediately. It is manual reset type high temperature safety
device. It will not reset automatically before reset it find the reason for high
temperature.
3. Boiler thermostat : It regulates the desired boiler water temperature. Set it to
system need temperature.
4. 2nd Stage thermostat : It regulates the burner stages. Set it 6 to 10 C below the
boiler thermostat value. When the boiler water temperature reached to set value it
turns down the burner to 1st stage.
5. Temperature indicator and pressure gauge: They indicate the boiler water
temperature and pressure.
6. Weather compensated control device : It is a multifunctional device but the
main aim is regulating the desired boiler water temperature automatically according
to atmospheric conditions with the help of motorized 3 way valve. (setting must be
performed by a qualified service at commissioning)
- 29 -
BOILER CONTROL PANEL WIRING DIAGRAMS
G
EL
LT
T1
MS
L N
1 2 L N
C 3 4 5
RT
F
L N
220/230 V (AC)
50 Hz - 16 A (max)
BURNER
LT
EARTHING
T1
2
1
T2
G
MS
L N
1 2 L N
RT
F
L N
220/230 V (AC)
50 Hz - 16 A (max)
MS : MAIN SWITCH (ON/OFF)
LT : SAFETY LIMIT THERMOSTAT
T1 : BOILER THERMOSTAT (STAGE 1)
T2 : BOILER THERMOSTAT (STAGE 2)
RT : ROOM THERMOSTAT OR
SAFETY CONTROLS
EL : POWER ON LIGHT
L : PHASE
N : NEUTRAL
G : PANEL EARTHING
F : FUSE
C : COMMON 1 : NC
C
EL
STANDART PANEL
SINGLE STAGE BURNER
BOILER PANEL
BURNER
C 3 4 5
2 : NO
STANDART PANEL
TWO STAGE BURNER
BOILER PANEL
MS : MAIN SWITCH (ON/OFF)
LT : SAFETY LIMIT THERMOSTAT
T1 : BOILER THERMOSTAT (STAGE 1)
T2 : BOILER THERMOSTAT (STAGE 2)
RT : ROOM THERMOSTAT OR
SAFETY CONTROLS
EL : POWER ON LIGHT
L : PHASE
N : NEUTRAL
EARTHING
G : PANEL EARTHING
F : FUSE
C : COMMON 1 : NC
2 : NO
- 30 -
G
EL
LT
T
Q2
B8
B2
B9
A6
M
M
M
M
B
B
B
PPS
MS
L N
1 2 L N
C 3 4 5 6 7 8 9 10 11 1213 14
WEATHER COMPANSATED
SINGLE STAGE BURNER
BOILER CONTROL PANEL
F
MS : MAIN SWITCH (ON/OFF)
LT : SAFETY LIMIT THERMOSTAT
T : BOILER THERMOSTAT (STAGE 1)
EL : POWER ON LIGHT
Q2 : HEATING SYSTEM CIRCULATION PUMP
B8 : FLUE GAS TEMPERATURE SENSOR
B2 : BOILER TEMPERATURE SENSOR
B9 : OUTSIDE TEMPERATURE SENSOR
A6 : ROOM THERMOSTAT (HC1)
L : PHASE
N : NEUTRAL
L N
BURNER
220/230 V (AC)
50 Hz - 16 A (max)
EARTHING
G : PANEL EARTHING
F : FUSE
G
C
EL
LT
T1
2
1
T2
Q2
B8
B2
B9
A6
M
M
M
M
B
B
B
PPS
MS
L N
1 2 L N
F
L N
BURNER
220/230 V (AC)
50 Hz - 16 A (max)
C 3 4 5 6 7 8 9 10 11 12 13 14
WEATHER COMPANSATED
TWO STAGE BURNER
BOILER CONTROL PANEL
MS : MAIN SWITCH (ON/OFF)
LT : SAFETY LIMIT THERMOSTAT
T1 : BOILER THERMOSTAT (STAGE 1)
T2 : BOILER THERMOSTAT (STAGE 2)
EL : POWER ON LIGHT
Q2 : HEATING SYSTEM CIRCULATION PUMP
B8 : FLUE GAS TEMPERATURE SENSOR
B2 : BOILER TEMPERATURE SENSOR
B9 : OUTSIDE TEMPERATURE SENSOR
A6 : ROOM THERMOSTAT (HC1)
L : PHASE
N : NEUTRAL
EARTHING
G : PANEL EARTHING
F : FUSE
C : COMMON
1 : NC
1 : NO
- 31 -
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