INSTALLATION AND OPERATION MANUAL PRESSURISED STEEL BOILERS AR 30 AR 1000 RADIALAND - BOILER's INSTALLATION MANUAL version 1.0 / 15-02-2008
The company E. is outstanding in the field of central heating and air conditioning. For many years offers high quality products, using contemporary machinery and certified materials. Last years the company had made serious investments in establishments and equipment. The products include: Heating boiler units Steel Boiler for light oil and gas fuels Air-heating boiler Steel boiler for solid fuels The company maintains approved Quality Assurance System according to ISO 9001:2000. CONTENTS 1. Description 2. Technical Data 3. Installation Instructions 4. Operation Instructions 5. Faults 6. Control Panel 7. Declarations of Conformity NOTICE All values contained in this manual may change without notification. Page 2 of 14 RADIALAND - BOILER's INSTALLATION MANUAL
Description Hot water boilers RADIALAND represent the most advanced technology for central heating boilers. The hot-water AR boiler series are steel made with pressurized combustion chamber and flame reverse. The flue gases follow a triple travel through the boiler. The first and second travel is inside the combustion chamber and the third travel through the flue gas tubes. Hot-water boiler AR series cover the need of heating power from 35 1.163 kw (30.000 1.000.000 kcal/h). Boilers with bigger nominal power are manufactured by order. The parts consist the boiler are shown in Figure 1. 1. Water chamber 2. Combustion chamber 3. Tubes (Flue pipes) 4. Tube plates 5. Boiler door 6. Smoke chamber 7. Flue gas output connection 8. Water output connection 9. Water input connection 10. Boiler insulation 11. Boiler base 12. Burner adjustment opening 13. Flame observation hole 14. Flue gas chamber cleaning opening 15. Boiler evacuation connection 16. Baffles (gas deceleration) 17. Expansion tank connection 18. Boiler covers Figure 1. Boiler section RADIALAND - BOILER's INSTALLATION MANUAL Page 3 of 14
Technical Specification No Characteristics AR 30 AR 40 AR 50 AR 60 AR 80 AR 100 1 Output power - ΜΑΧ kw 34,32 46,50 55,80 62,6 87,20 116,20 Mcal/h 29,530 40,000 48,000 53,862 75,000 100,000 2 Output power range - ΜΙΝ kw 30,00 37,00 50,00 60,00 64,00 90,00 Mcal/h 25,800 31,850 43,000 51,650 55,100 77,450 3 Maximum input Power kw 38,09 51,58 61,73 69,16 96,14 127,69 Mcal/h 32,774 44,381 53,110 59,510 82,722 109,869 4 Fuel rate kg/h 3,22 4,36 5,21 5,84 8,12 10,78 5 Efficiency % 90,1 90,15 90,4 90,5 90,7 91 6 Temp control range C < 90 7 Max operating temperature C 90 8 Max operating pressure bar 3 9 Test pressure bar 4 10 Water capacity lt 48 77 112 107 145 165 11 Boiler weight kg 120 146 175 190 235 258 12 Draught mbar -0,25-0,25-0,27-0,27-0,28-0,30 13 Flue gas resistance and combustion chamber pressure mbar 0,5 0,5 0,6 0,7 0,8 0,9 14 Flue gas output temperature C 185 190 200 15 Flue gas connection diameter mm 114 150 170 16 Combustion chamber Type : cylindrical Length : mm 430 530 640 640 780 830 Diameter : mm 288 315 363 363 414 414 17 Fuel type light oil 18 Operational mode on-off - 1 stage 19 Electrical Power : W 250 Voltage : V / Hz 230 / 50 20 Burner fixing dimensions mm Φ100 x 115x115 Φ125 x 115x115 Φ125 x 125x125 21 IP code number IP 20 Page 4 of 14 RADIALAND - BOILER's INSTALLATION MANUAL
No Characteristics AR 120 AR 150 AR 180 AR 200 AR 250 AR 300 1 Output power - ΜΑΧ kw 137,76 174,30 209,20 232,5 290,60 348,70 Mcal/h 118,530 150,000 180,000 200,050 250,000 300,000 2 Output power range - ΜΙΝ kw 122,00 140,00 180,10 215,00 245,00 302,20 Mcal/h 105,000 120,450 155,000 185,000 210,800 260,000 3 Maximum input Power kw 150,74 190,08 227,39 251,98 314,84 377,38 Mcal/h 129,699 163,546 195,652 216,807 270,898 324,707 4 Fuel rate kg/h 12,73 16,05 19,20 21,28 26,59 31,87 5 Efficiency % 91,4 91,7 92 92,27 92,3 92,4 6 Temp control range C < 90 7 Max operating temperature C 90 8 Max operating pressure bar 3 4 9 Test pressure bar 4 5,5 10 Water capacity lt 276 267 335 325 307 583 11 Boiler weight kg 358 380 423 447 461 710 12 Draught mbar -0,30-0,35-0,40-0,40-0,45-0,50 13 Flue gas resistance and combustion chamber pressure mbar 1,25 1,75 2,25 3,25 3,8 4,2 14 Flue gas output temperature C 210 15 Flue gas connection diameter mm 190 220 16 Combustion chamber Type : cylindrical Length : mm 860 860 1080 1080 1130 1180 Diameter : mm 462 462 462 462 462 557 17 Fuel type light oil 18 Operational mode on-off - 1 stage 19 Electrical Power : W 500 750 Voltage : V / Hz 230 / 50 20 Burner fixing dimensions mm Φ140 x 125x125 by order 21 IP code number IP 20 RADIALAND - BOILER's INSTALLATION MANUAL Page 5 of 14
No Characteristics AR 350 AR 400 AR 500 AR 600 AR 800 AR 1000 1 Output power - ΜΑΧ kw 406,80 464,90 581,10 697,30 929,80 1162,20 Mcal/h 350,000 400,000 500,000 600,000 800,000 1000,000 2 Output power range - ΜΙΝ kw 371,90 430,00 499,80 616,00 755,40 987,90 Mcal/h 320,000 370,000 430,000 530,000 650,000 850,000 3 Maximum input Power kw 440,26 503,14 628,90 753,84 1005,19 1256,43 Mcal/h 378,809 432,911 541,116 648,618 864,886 1081,062 4 Fuel rate kg/h 37,18 42,49 53,11 63,66 84,89 106,1 5 Efficiency % 92,4 92,4 92,4 92,5 92,5 92,5 6 Temp control range C < 90 7 Max operating temperature C 90 8 Max operating pressure bar 4 9 Test pressure bar 5,5 10 Water capacity lt 565 550 630 840 1030 1180 11 Boiler weight kg 732 758 822 1110 1450 1800 12 Draught mbar -0,52-0,55-0,58-0,60-0,70-0,70 13 Flue gas resistance and combustion chamber pressure mbar 4,2 5,0 5,6 6,0 7,1 7,1 14 Flue gas output temperature C 230 240 15 Flue gas connection diameter mm 250 300 350 16 Combustion chamber Type : cylindrical Length : mm 1180 1180 1230 1230 1480 1730 Diameter : mm 557 557 557 557 557 557 17 Fuel type light oil 18 Operational mode on-off - 1 stage 19 Electrical Power : W 750 1000 Voltage : V / Hz 230 / 50 400 / 50 20 Burner fixing dimensions mm by order 21 IP code number IP 20 Page 6 of 14 RADIALAND - BOILER's INSTALLATION MANUAL
Installation Instructions In the following table the basic boiler dimensions are shown, so during the boiler installation all the required information are available (like water connections, chimney diameter required, boiler dimensions). The boiler installers should read this table in order to ensure that the required space is available at the boiler room. BOILER TYPE Water IN / OUT connection Expansion tank connection Evacuation connection Chimney diameter WIDTH HEIGHT LENGTH inch inch inch mm cm cm cm AR30 1¼" ¾" ½" 120 52 80 80 AR40 1¼" ¾" ½" 120 58 83 94 AR50 1½" ¾" ½" 150 62 94 109 AR60 1½" ¾" ½" 150 62 94 109 AR80 2" ¾" ½" 170 70 96 121 AR100 2" ¾" ½" 170 70 96 130 AR130 2" ¾" ½" 190 84 109 135 AR150 2" ¾" ½" 190 84 109 135 AR180 2½' ¾" ½" 190 84 109 169 AR200 2½' 1" ½" 190 84 109 169 AR250 3" 1" ½" 220 84 109 169 AR300 3" 1" ½" 220 104 126 181 AR350 3" 1¼" ¾" 250 104 126 181 AR400 3" 1¼" ¾" 250 104 126 185 AR500 4" 1¼" ¾" 300 104 126 210 AR600 4" 1½" 1" 300 115 147 219 AR800 4" 1½" 1" 350 125 150 245 AR1000 4" 1½" 1" 350 125 150 270 During the burner adjustment that fixed with the boiler, the maximum heat input (the fuel consumption rate) and the boiler efficiency (%) in full load should be considered (see boiler technical specification). RADIALAND - BOILER's INSTALLATION MANUAL Page 7 of 14
During the boiler installation and connections, attention should be given to the following points: The boiler should be installed in horizontal position in an appropriate place (boiler-room) and with appropriate ventilation. The installation should be carried out by approved qualified technicians. Around the installed boiler there should be enough space for repair and maintenance. The boiler installation should follow the European legislation and in agreement to the applying heating study. The installation should include, except the burner and the suitable circulating pump, automating filling valve and safety valve regulated in pressure smaller than the maximum permissible boiler operating pressure. The installation should include a thermostat to control the burner operation (ON/OFF) with maximum adjustment smaller than the maximum permissible operation temperature and a thermostat to control the water circulating pump. All electrical equipment should be connected with a separate controlled electrical circuit. Before first boiler operation, please check the following points: the water level at the heating circuit, the oil at the oil tank and the proper burner connection, the proper adjustment of burner and circulating pump thermostats, the proper connection and the power supply of the electrical circuit and the proper fixing of the baffles in the flue gas tubes. Special care should be taken to avoid liquids due to flue gas humidity to run inside boiler (corrosion danger). Page 8 of 14 RADIALAND - BOILER's INSTALLATION MANUAL
Operation Instructions For boiler protection and its effective operation, appropriate maintenance should be carried out by professionally qualified technicians. This maintenance should include operational check and cleaning for both boiler body and burner. The maintenance is very important because ensures the long life of the boiler and the high efficiency rate (savings in fuel consumption). The regulation of the boiler s operational parameters and especially the burner fuel consumption should always be in the effective area of the power range. Very important for boiler efficiency is the flue gas temperature. In any case the baffles should not be taken off the flue gas tubes, because they directly affect the flue gas temperature and boiler efficiency. Inspections (every month) For leakages, electrical connections, oil filter, etc. At the beginning of the operation period (September) Boiler cleaning (combustion chamber, tubes, flue gas baffles, smoke chamber), Burner cleaning, Oil filter cleaning, Burner operation adjustment (choice of right operation parameters like oil pump pressure and air adjustment), Safety valve, ventilation, thermostats and insulation check, Flue gas concentration and temperature measurement. RADIALAND - BOILER's INSTALLATION MANUAL Page 9 of 14
Faults During boiler operation, faults may occur that effect its proper operation (either directly block of operation or indirectly). Examples of faults are given below. Fault Actions to do Burner block Check the oil level at the tank Clean the flame detection sensor of the burner (read the burner instructions manual) Press the burner RESET button for restart (max 4 times) Boiler overheating Check the air trapping through the heating circuit. Press the top valve to release the air trapped. Check if the circulating pump operates normally. In case that it does not operate, check the activation circuit (sensors, power) or read manufacturer instructions Press the overheating sensor RESET button in control panel. High temperature in chimney or in flue-gas chimney output Stop the boiler operation. Check if baffles installed inside the flue gas tubes. Replace the baffles that are damaged. Measure the flue gas temperature in chimney with appropriate thermometer. The temperature should be relevant with the value given in the boiler specifications. In any case the temperature should not exceed 250 C. Flue-gas leakage Check the cause of flue gas leakage (boiler door, flue gas chamber and chimney). In case that the leakage cannot be restricted, replace the damaged materials (glass made cord, silicon, etc). Take measures to avoid carbon oxide concentration (ensure appropriate ventilation). ATTENTION: In case that after yours actions appropriate for the existing fault, the operation of the boiler is not normal, please ask for help from approved qualified technicians. Page 10 of 14 RADIALAND - BOILER's INSTALLATION MANUAL
Control Panel The control panel includes all the necessary equipment for the proper control of the boiler operation. The control panel is fixed at the top of the boiler. It has a metallic shell, which includes all the required equipment that are necessary for proper boiler operation. The following figure shows the control panel and its equipment. 1. Power Switch ON / OFF with led 2. Boiler water thermometer 3. Burner thermostat 4. Circulation pump thermostat 5. Overheating fuse Figure 2. Boiler control panel RADIALAND - BOILER's INSTALLATION MANUAL Page 11 of 14
Control Panel connections During boiler installation the control panel connection terminals should be connected as follows: to electric power supply 230V / 50 Hz to air thermostat to burner to circulation pump L N GND T 1 T 2 N L N GND L N GND Special attention should be given in ground connection. No one part should be connected in power without prior connection to ground (GND). In other case there is serious danger for electric shock. Page 12 of 14 RADIALAND - BOILER's INSTALLATION MANUAL
Declaration of Conformity This is to declare and assure that hot-water boiler RADIALAND AR series (pressurized steel oil-fired boilers with flame reverse) of are made according to the type described in EC Type Examination certificate and satisfies the relevant requirements of 92/42/EC directive relevant with "efficiency requirements for new hot water boilers fired with liquid or gaseous fuels". The results of testing conducted are: Characteristic Data AR 30 AR 60 AR 120 AR 200 Nominal Output Power kw 34,32 62,61 137,76 232,50 kcal/h 29.530 53.871 118.535 200.048 Efficiency in full load % 90,10 90,515 91,40 92,27 Efficiency in part load (30%) % 88,80 89,26 91,72 90,13 Efficiency Marking For Manufacturer Elias Kostopoulos 15/02/2008 Manufacturer Data ELIAS RADIALAND SA 40 ο km Thessaloniki Athens Aiginio GR 60300 Tel. +30-23530-22016, +30-23530-23800 Fax +30-23530-24291 RADIALAND - BOILER's INSTALLATION MANUAL Page 13 of 14
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