Alarko ACK2 User manual

Operation Manual
ACK2 - ACK3
HEATING SYSTEM BOILERS
WITH LIQUID / GAS FUEL

Code No: A.4.1.3 i Published on: 210910
Revision No: 210910

CONTENTS
05
06
08
09
10
11
12
14
17
21
21
22
22
23
24
27
29
31
33
35
36
Introduction
Warnings
Declaration of Conformity
Guarantee and Service
General Specifications
Operation Conditions
Main Parts
Installation
Safety Arrangements
Burner Selection
Burner Installation
Fuels
Flue Gas Exhaust System
Boiler Water and Make Up Water for Hot Water Boilers
Start Up
Operation and Shut Down
Maintenance and Servicing
Boiler Control Panels
Boiler Control Panel Wiring Diagrams
Boiler Records
Annexes

.

5
INTRODUCTION
This manual comprises the information concerning the Installation, operation,
use and maintenance of ACK2 and ACK3 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.

6
WARNINGS
xThis boiler must be installed in accordance with the rules in force only in
a well ventilated and frost free spaces.
xAll 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).
xIf 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.
xBoiler 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.
xBoilers must be fired by gas or oil fuels specified in this manual and
boiler plate.
xBoilers 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 andAppliances burning gaseous fuels (90/396/EEC)
directive.
xThis is a B23 appliance so the flue gases must be connected to an
adequate draught chimney, without any flue gas leakage to the boiler
room.
xIt 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.
xThe 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.
xNever 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.
xBoilers 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.
xBoilers must not be installed in areas where inflammable vapors and
materials are likely to e present. To avoid damage to the boilers,

7
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.
xThe 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.
xThe 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.
xIf 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.
xDo not use this appliance if any part has been under water. Immediately
call a qualified service to inspect.
xAn 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.
xIn 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.
xIn 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.
xIf 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.
xIf there is a fuel, flue gas or water leakage in the system, stop the burner
and call the responsible authority.
xAfter commissioning the repair, maintenance work is under responsibility
of user and must be done with a qualified person.
xBefore 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.

8
DECLARATION OF CONFORMITY
We hereby make the fallowing declaration with regard to the appliance trademark
ACK2, models ACK2-30, ACK2-40, ACK2-50, ACK2-60, ACK2-70, ACK2-80,
ACK2-100, ACK2-120, ACK2-125,ACK2-140,ACK2-150,ACK2-160,ACK2-180,
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, ACK2-2000, ACK2-2500,ACK2-3000.
ACK3, models ACK3-80, ACK3-100, ACK3-125,ACK3-150, ACK3-200,ACK3-
250, ACK3-300, ACK3-350, ACK3-400, ACK3-500, ACK3-600, ACK3-700,
ACK3-800,ACK3-900,ACK3-1000.
That
xThe 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;
xFor gas-carrying parts no soft soldered joints are applied;
xSettings that should be altered have been sealed;
xNo asbestos has been used;
xThe 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;
xThe components used in this appliance are CE approved;
xThe 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;
xThe electric equipment of the appliances consequently complies with
the requirements of the Low Voltage Directive (73/23/EEC)
xDo not light any appliance.
xDo not touch any electric item.
xDo not smoke.
xShut of the fuel valve from the main inlet to the building.
xDo not use any phone in your building.
xImmediately call your local authority from neighbor’s phone.
WHAT TO DO IF YOU SMELL GAS OR INSPECT FUEL LEAKAGE

9
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.
E
xThe electric equipment of the appliances consequently complies with
the requirements of the Electromagnetic Compatibility Directive (89/336/
EEC)

10
GENERAL SPECIFICATIONS
xACK2 boilers are reverse flame, 2 pass, wet back, cylindrical shell type,
hot water, liquid or gas fired, B23 steel boilers.
xACK3 boilers are LOW NOx, 3 pass, wet back, cylindrical shell type,
hot water, liquid or gas fired, B23 steel boilers.
xThey are manufactured and tested in accordance with TS EN 303-1, by
an ISO 9001-2000 registered company.
xThey are economical and environmentally friendly.
xCompact design ensures easy transport into boiler rooms.
xThe boilers have been specially designed and produced to perform efficient
combustion with both gas and liquid fuels.
xBoiler gas side pressure loss is well below the limited values in EN
standards.
xEconomic 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.
xACK2 boilers have 30 different capacities between 30.000-3.000.000 Kcal/
h (35 – 3488 kW) and standard working pressure is 3 bar for between
ACK2-30 / ACK2-180 capacities and 4 bar for ACK2-200 and aboves.
xACK3 boilers have 15 different capacities between 80.000-1.000.000
Kcal/h. (93 – 1163 kW) and standard working pressure is 3 bar.
xMinimum heat loss with perfect insulation.
xWide water galleries and the return water connection is from the back
bottom side provide excellent natural circulation and safe heat transfer.
xNo additional intermediate flow pieces required.All necessary connections
are already on the boiler.
xThey have low combustion chamber loading for clean combustion with
low nitrogen oxide emissions.
xBoiler front door can be opened in both directions, very useful in boiler
rooms with limited space.

11
xThese 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.
xACK2 and ACK3 boilers are hot water boilers with a maximum outlet
temperature of 90 °C (up to 105 optional) . Return water temperatures
must not be lower then 55 °C on oil and 60°C on gas firing .
xThese 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.
xThese boilers are suitable for Liquid (6 cSt at 20ÚC 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.
xThis 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.
xThis boiler is suitable for use in either open vented or pressurized expansion
vessel heating systems. The system must have a matching expansion
system.
xSecond pass heat transfer combustion gas pipes have turbulators in
order to maximize heat transfer to water.
OPERATION CONDITIONS

1- Combustion chamber.
2- Second pass combustion pipes
and turbulators.
3- Main boiler body.
4- Two way hinges.
5- Combustion chamber door
insulation.
6- Boiler front door
7- Flame monitoring glass.
8- Boiler insulation.
9- Flue box
10- Functional explosion cover.
12
MAIN PARTS - ACK 2 (TWO PASS) BOILERS
11- Supporting feet.
12- Gas/liquid fuel burner.
13- Flue outlet
14- Boiler return
15- Boiler flow
16- Drain and fill
17- Condense outlet
18- Pressure sensing coupling
19- Temperature sensor coupling
20- Safety connections

13
1- Combustion chamber.
2- Third pass combustion pipes
and turbulators.
3- Main boiler body.
4- Two way hinges.
5- Combustion chamber door
insulation.
6- Boiler front door
7- Flame monitoring glass.
8- Boiler insulation.
9- Flue box
10- Functional explosion cover.
1
2
3
4
5
6
7
8
9
10
11
12
13
15
14
16
17
19
18
20
20
11- Supporting feet.
12- Gas/liquid fuel burner.
13- Flue outlet
14- Boiler return
15- Boiler flow
16- Drain and fill
17- Condense outlet
18- Pressure sensing coupling
19- Temperature sensor coupling
20- Safety connections
MAIN PARTS - ACK 3 (THREE PASS) BOILERS

INSTALLATION
The installation of the boilers must be performed according to the current local
standards
and in addition, instructions stated below;
xAll 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).
xThis 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.
xBoilers 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.
xThis is a B23 appliance so the flue gases must be connected to an adequate
draught chimney, without any flue gas leakage to the boiler room.
xControl 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.
xHeating system shall be equipped with automatic and/or manual control
devices according to current EN 12828.
xIt 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.
xIt 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.
xThe 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.
xBoilers 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.
14

15
xBoilers 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.
xThe 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.
xAn 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.
xIf 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.
xAll 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.
xThe 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.
xThere 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.

16
1
2
3
4
5
xAfter the installation of the boiler all the water and fuel connections and
valves must be controlled for leakage.
xForACK2 and ACK3 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.
xACK2 andACK3 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.
xACK2 and ACK3 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.
xForACK2 and ACK3 boilers, it is advisable to have the safety valve on flow
line to the connection present on the boiler outlet pipe without any valve.
xFor 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.
xIf necessary, national regulations regarding the condensate waste disposal
rules shall be applied.

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.
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.
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.
17
SAFETY ARRANGEMENTS

18
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
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.

19
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: ds= 15 + 1.4 mm (but not less then 19 mm internal diameter)
Feed and expansion pipe: dfe = 15+ 1.0 mm
Where is the nominal heat output of the boiler in kW.
MINIMUM SAFETY EQUIPMENT REQUIRED FOR OPEN VENTED
SYTEMS

Operational requirements of open vented systems: In order to maintain a
safe and economical operation, open vented heating systems shall be equipped
with:
20
xWater level indicator
xTemperature indicator (% 20 higher then the operating temperature and
mounted in the flow pipe of the system)
xDevices 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.
xHeating 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
xAn adequate supply of combustion air is important for safe and clean
combustion. For open flue heating systems with a total rated output
higher than50 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 .