MHS Boilers MK8 Manual de usuario

L MK

Assembly, Operating and Maintenance Instructions

Installation

and

User Guide

MK Jetstream

Cast Iron Boiler

320 - 1017 kW

35 Nobel Square Basildon Essex SS13 1LT

01268 591010 / 01268 724064

01/02/06

INTRODUCTION

The MK is a cast iron sectional boiler for pressure jet oil firing or forced draught gas firing

which is constructed in three pass horizontal flue gas circulation principle. MK series are

CE Marked on PIN CE-0645 BO118 to

Gas Appliances Directive (90/396/EEC)

Boiler Efficiency Directive (92/42/EEC)

Electromagnetic Compatability Directive (89/336/EEC)

Pressure Equipment Directive (97/23/EC)

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

TRD 702: Steam boiler plants with hot water generators of group II

MK series boilers are suitable for central heating and indirect hot water supply at

working pressures not exceeding 6 bars, and working temperatures not exceeding 120 C.

The boiler must never be used for direct water supply.

MK Jetstream Cast Iron Boiler for oil and gas firing

TECHNICAL INFORMATION

(1): In series MK 8-12, flue connection diameter could be reduced minimum to 250 mm by using

a flue spigot adaptor.

Filling/draining tapping size 3/4"

35.0 44.038.0 49.0 55.0 56.0 57.0 60.0 66.0

192 180 178 175 173 170 185 190 195 200

TECHNICAL INFORMATION

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 cold return

water to boiler, mixing it with hot circulating water inside boiler. This is accomplished

by a jet effect created by a distribution pipe fixed to the return connection of the boiler.

The cold return water is injected into 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 rear section/sections down to the cold water side, and a mixture of

cold and hot water makes the cold water temperature increase. Thus, the main reason

of flue gas condensation in the boiler is eliminated. A reverse flow of hot delivery water

in the rear section of the boiler protects the section against excessive thermal shocks.

MK Jetstream is operated in non-

condensing mode if the lowest return

water temperatures to boiler given

in the following table are maintained

at thermal equilibrium at nominal

heat output:

Fuels Lowest return temperatures

(

Natural gas, LPG 40

Diesel-oil, Fuel-oil 30

TECHNICAL INFORMATION

Gas resistance

inside the boiler

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

Oil Supply MK 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

Light/medium fuel oil viscosity at 50 C: 150 cSt max or viscosity at 100 F: 625 Second

In case of firing with fuel oils, the heat input to boiler must alwals be slightly reduced to

required values in order to perform better at related outputs of boiler as described in

technical boiler data. 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 in responsibility of 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 compele 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. A

reduce in boiler output due to wrong matching of any component should be avoided before

installation of whole system.

Burne

MK boiler must be fired only with a CE APPROVED BURNER. DemirDöküm will not be

held responsible for any damage of 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 the mounting, this space must be fed with rock-wool or

ceramic-fibre based insulation material to improve heat insulation. Otherwise, further heat

loss may result in damage on front door.

Should the diameter of burner head is 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.

Pressurized burner of 2800 rpm (blowing type) must be used with the boiler. Barrel of the

burner to be mounted on the boiler should fit the burner connection mouth depth, indicated

in the technical specifications table.

TECHNICAL INFORMATION

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

of boiler 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,

outboard the casing

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:

Flue design Boilers must be connected to a chimney by using the shortest flue canal possible which

and chimney should be insulated by mineral wool or similar material. Flue canal must be placed at a

installation rising slope of 10°-45° between flue and chimney. Conditions creating higher resistance

to gas flow such as elbows should be avoided in flue canal. The flue canal outlet to the

boiler should not support the weight of chimney.

At discharge from the boiler, the flue gasses should be in a balanced state, consequently,

the function of the chimney is only for the disposal of the flue gasses to atmosphere.

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 (such as applying a chimney sheet made of stainless

steel grade 316 and surrounding with insulation). Positive draught conditions must be

avoided. Negative draught conditions should be contained within -3 mm wg. 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.

kWOutput /

t=10oC

t=15oC!t=20oC

Type

Minimum

Circulation

Water

volume

Hydraulic

Resistance

Water

volume

Hydraulic

Resistance

Water

volume

Hydraulic

Resistance

m3/h m3/h mbar m3/h mbar m3/h mbar

MK8 4.6 27.5 57.7 18.3 25.6 13.8 14.7

MK9 5.4 32.5 83.5 21.7 37.2 16.3 21.0

MK10 6.3 37.5 113.1 25.0 50.2 18.8 28.6

MK11 7.1 42.5 145.6 28.3 64.5 21.3 38.5

MK12 7.9 47.5 185.3 31.7 82.5 23.8 51.7

MK13 8.8 52.5 249.0 35.0 110.7 26.3 62.5

MK14 9.6 57.5 305.4 38.3 135.5 28.8 76.5

MK15 10.4 62.5 368.1 41.7 163.7 31.3 92.2

MK16 11.3 67.5 309.5 45.0 137.5 33.6 77.0

MK17 12.1 75.5 384.4 48.3 163.1 36.3 92.0

MK18 12.9 77.5 431.1 51.7 183.2 38.8 107.9

MK19 13.8 82.5 501.4 55.0 211.6 41.3 125.5

MK20 14.6 87.5 578.7 58.3 244.7 43.8 144.8

PREPARATIONS BEFORE ASSEMBLY

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 norms prevailing locally.

Any irregular electricity installations in boiler room should be replaced.

The circulating water in boiler and heating system must never be taken out for any

domestic usage.

Water level should be checked periodically with a hydrometer.Nnever add water to the

system when boiler is hot. Never drain the water unless it is necessary.

Should odour is sensed in boiler room, first close the valve before gas flow meter. Never

use match and never smoke in boiler room. Never turn electricity on/off. Ventilate the room

opening doors and windows and consult authorized installer staff or Gas Dealer Company

immediately.

Follow instructions for periodic cleaning and maintenance operations whose procedures

given further in this manual.

PREPARATIONS BEFORE ASSEMBLY

The boilers can be installed directly onto a smooth level floor 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 200 mm high and sized to the dimensions of casing of the boiler given as

in the following table:

Water The system design must provide water flow rates commensurate with boiler output and the

Circulation temperature difference between flow and return should not exceed 20 C, or 25 C at most.

System

The return temperatures due to oil type fired should not be lower than the degrees given in

«Technical Informations» to operate the boiler in non-condensing mode. In this case, your

boiler can be operated without using a by-pass pump and there will be no condensation in

the boiler. As the flow temperature of your boiler can be changeable meeting different heat

requirements of the system without any condensation, the hydraulic circuit no more needs

any devices to adjust the hot water temperature such as three-way valves.

Should the system is operated at temperatures below than those mentioned above, a

by-pass pump or a three/four-way motor vane should be used to increase the return

temperature particularly in conditions natural gas or LPG used.

A by-pass pump must be used, should the system has a three way motor vane, because

of the principle of preventing condensation in the boiler.

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 salt

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.

Boiler water systems should be thoroughly flushed and cleaned before a new boiler is

installed and system water should be treated by a reputable specialist and best practice

observed. Consideration should be given to the fitting of sludge traps and strainers if site

conditions warrant them.

Failure to apply and maintain the correct water treatment to prevent the formation of scale

scale and corrosion within the heating system will render all appliance warranties null and

and void.

Recommended dimensions of plinths (mm)

Type

MK8 MK9 MK10 MK11 MK12 MK13 MK14 MK15 MK16 MK17 MK18 MK19 MK20

Width 1130

Lenght

1410 1540 1665 1785 1925 2050 2180 2305 2435 2565 2690 2820 2945

Height 200

PREPARATIONS BEFORE ASSEMBLY

Safety o

For heating systems with maximum boiler temperature up to 100 C:

water

circulation The system can be built either open vented or pressurized. In case of open vented heating

system system an open type expansion tank acoording to DIN 4807 Part 2 shall be installed at

the heighest level of hydraulic circuit. Delivery and return lines between expansion tank

and boiler shall be constructed in aacordance with DIN 4750. No globe valves must be

installed on delivery and return safety lines. Safety lines should be attached to inlet and

outlet lines of boiler at points as close as possible to boiler, using the shortest possible

vertical way between expansion tank and boiler.

A hydrometer shall be installed on delivery line from boiler at a same level with top of boiler.

After filling heating system, the minimum water level should be recorded on hydrometer

in order to check water level during operation.

In case of pressurized heating system a pressure relief valve according to TRD 721 shall

also be installed on heating system to ensure safety besides closed type expansion

vessel.

For heating systems with maximum boiler temperature up to 120 C:

In this case, each heating circuit is constructed pressurized and shall be equipped with

diaphragm or spring-tensioned pressure relief valves according to TRD 721.

Each heating system can be equipped with up to three pressure relief valves. For boiler

nominal heat outputs 350 kW and above, the pressure relief valve shall be connected to

an open relaxation pot for safety of system. If this can not be established, an additional

safety temperature and a maximum pressure limiter should be installed on the boiler.

The sizes of diaphragm pressure relief valves on inlet or outlet of boiler according to

boiler nominal heat output are outlined below:

Boiler output in kW 50 100 200 350 600 900

Connection to outlet G 1/2" G 3/4" G 1" G 1 1/4" G 1 1/2" G 2"

Connection to inlet G 3/4" G 1" G 1 1/4" G 1 1/2" G 2" G 2 1/2"

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