Alarko ADK 200 User manual

Operation Manual
ADK 200
HEATING SYSTEM
CAST IRON BOILERS
WITH LIQUID/GAS FUEL

Kitap Revizyon Tarihi:310706 Kitap Baský Tarihi: 310706
Kitap Revizyon No: 1

ADK 200
HEATING SYSTEM
CAST IRON BOILERS
WITH LIQUID/GAS FUEL
Operation Manual

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CONTENT
05
06
07
09
10
11
12
13
14
14
15
15
16
17
18
19
20
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23
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Introduction
Guarantee Terms
General Warnings
General Characteristics of ADK 200 Boilers
ADK 200 Cast Iron Boiler - Tecnical Data
ADK 200 Cast Iron Boiler - Dimensions
Boiler Room Settings and Boiler Platform Dimensions
Plumbing Instructions
A Sample Plumbing Diagram for ADK 200 Cast Iron Boilers
The Meaning of the Symbols Used In the Diagram
Diagram of a Sample Single Boiler Heating Circuit With Water Heater
Water Circulation Principal
Instructions About Flue
Instructions for Connecting the Fuel Tank
Boiler Control Panels
Electrical Diagrams
Cast Iron Sections With High Efficiency 3 Draught Design
Operating Instructions
Loading and Unloading Boiler Water
Instructions for Product Disposal
ADK 200 Cast Iron Body - Boiler Cabin Parts List
Diagrams - Gas Side Resistance, Exit Flue Gas Resistance
Important Instructions About Boiler Room
Boiler Room Airing
Checkings and Starting the Boiler
Failure First Control
Care Instructions
Packing
Cleaning the Boiler
Burner Door and Burner Connection
Burner Connection Flange Sizes

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First of all we’d like to thank you for choosing Alarko Carrier cast iron boilers.
In this manual you will find the instructions for Alarko Carrier three pass cast iron
boilers suitable for both gas and liquid fuel. ADK 200 hot water boilers and related
informaton for installation, operation and maintanance of the boiler. For high
efficiency and proper working conditions please read this manual carefully. For
more information please check the product catalog or get in touch with Alarko
Carrier technical services.
Please do not touch or remove any parts of the boiler for starting, adjusting or
repairing the boiler except the processes written in this manual. Please call Alarko
Carrier services and technical officials for installing the boiler.
Our licensed frenchisers and services will give you instructions about working
principals, conditions and care instructions after installing and starting the boiler.
And our professionals will be glad to answer all your questions at any time.
Alarko Carrier licensed services are in your service all kind of problems and
questions. You may find the contact informations in the licensed services manual
which will be given to you with the boiler.
INTRODUCTION

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GUARENTEE TERMS
•Boiler without guarantee document.
•Boiler fixed,repaired or adjusted by unauthorized services.
•Boilers with rong type selection, wrong installing and assembling,
boilers used wrong conditions and out of aim.
•Problems occured while transportation, stocking or problems
occured under atmospheric conditions.
•The problems occured by physical or chemical effects.
•Wrong fuel selection and the problems occured by fuel conditions,
•Wrong installation or connection fo the boiler to water and other
plumbing systems.
•Weak flue (gas output) system.
•The problems occured by scratching,touching to control and safety
systems of the boiler.
•Cold water load while the boiler is hot.
•Starting the boiler without water or required water in it.
•In the terms of obeying the instructions,warnings, points in this manual
and the standards in charge (EN norms and directives must be applied if
mentioned standards are not in use) cast body is under 5 (five) and other
parts are under 2 (two) years guarantee. Alarko Carrier is responsible for
repairing or renewing if the following conditions are available.
•Guarantee Document must be filled by the franchiser that you have bought
the boiler and must be send to Alarko Carrier.
•Assembling and installing faults and problems, problems that will be
occured because of wrong upkeeping and working are not under guarantee.
Problems related to lime coating or/and any other materials coating and
corrosion on the heat transfer units of the boiler are not under guarantee
conditions.
•Minimum life of these kind of products is mentioned as 15 (fifteen) years
by the minister of industry and commerce. Manufacturer and sales
companies are to supply all spare parts and services to the clients in
this period.
The problems happened by the following mentioned issues are out of
guarantee conditions

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GENERAL WARNINGS
•ADK 200 cast iron boilers are designed for working with hot water heating
and/or hot water plumbing and produced with the proper technology and
materials suitable to this design.This desing is restricted to use out of it’s
aim of use.
•ADK 200 boilers are delievered as sections and services assemble the
boilers in the operation area. The assembling of the boiler must be made
by Alarko Carrier technical services. Removing or re-assembling of the
boiler should also be made by licensed Alarko Carrier services, if not the
risk of damage is high.
•In the assembling of the boiler; there must be a proper and safe concrete
platform for to put the boiler on.
•In the assembling of the boiler, an empty space must be left from sides
for safety requirements and for future repairing operations.
•Starting and first operation of the boiler must be made by authorized
Alarko Carrier technicians.
•Do not add or pump water to the boiler or plumbing system as it is working
and hot. For adding water to the boiler or to the systen please wait for
water temperature to come 40ºC. Circulation pump must surely be started
while adding water to the system. If not, the sections may crack.
•If the boiler will be kept off for a long time the electric system must be
shut down from the main fuse. The electric must be cut off from the main
shelter/fuse as the boiler is in repair,service or cleaning.
•In summer months, when the boiler is off for a long term, for preventing
probable problems with circulation pumps, must be started 1 -2 times per
month for 5 minutes (The water with chalk can cause problems if the
pump is not used for long time period).
•The periodical controls of the boiler and the burner must be done. If not,
the boiler can lose efficiency and the fuel amount used can increase.
•The capacity choice of the boiler must be made according to the projects
thatprepared properly in the terms of related standards. If not the the
efficiency will be low.
•ADK 200 boilers are produced for heating only. For heating the sanitary
water another equipment such as water heater or heat exchanger is
needed. And for proper efficiency in this operation, correct water
heater or heat exchanger must be selected.

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•ADK 200 boilers are delivered without burners. For suitable burner
selection please get in touch with Alarko Carrier technicians. Suitable
burners must be selected for taking high efficiency.
•If the boiler is stopped automatically because of over heating do not add
cold water to the boiler for restarting. In this case wait for the boiler to
cool down and re-try starting. If it does not start please get in contact
with technical services.
•In cleaning, repair and other care operations the original spare parts which
approved and manufactured by Alarko Carrier must be used.
•The periodical and yearly controls of the boiler must be done properly
and on time. Natural gas is a clean fuel and doesn’t make a lot of dirt in
the boiler. But the boilers that liquid fuels are used as fuels are much
more easily get dirt. Controls and care operations of the boiler is needed
for keeping high efficiency and long life of the boiler.
•Repairing and periodical controls of ADK 200 boilers require profession.
In this manual the responsibilities and required information for users of
the boiler is declared. Besides these declared operations, boiler must
not be started by a person rather than the user or one our technicians.
Please do not try to make adjustment or do not touch any parts of the
boilers.
•The electric of the burner and the boiler is supplied by city electric network.
In this case the elecric and lighting systems of the boiler room, burner
and boiler electrical connections, grounding line of control panel and
boiler must be made by professionals under the required and related
standards.
•In this manual you will find informations only for the boilers. Please do
not forget to get the instruction manual of the burner that you purchase
from the manufacturer of it. Burner is not delivered with the boiler. In this
case we do not give any guarantee for the burner that you purchase.
Please get the quarantee certificate for the burner from your supplier.
•Please be sure that the front door (burner door) for the boiler is strictly
closed and burner connections are properly made as the boiler is working.

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GENERAL CHARACTERISTICS of ADK 200 BOILERS
ADK 200 boilers are, blowing burner, cast iron sectioned, between the capacities
163-355 kW with proper burner connection, works with gas or liquid fuel in 7
different (5-11 sections) type.
ADK 200 boilers operating pressure is 6 bar maximum, and working temperature
is 90°C maximum.
In ADK 200 boilers, heat transfer surface areas are increased by the special
wings in the burning room and chimney ways. This inceases the high heat transfer
ability of cast iron boiler to the maximum level.
ADK 200 boilers are cast iron sectioned boilers. This brings easy assembling
and easy capacity increasing by adding sections to the boiler. The transportation
and set up of the boiler is easy because boiler is assembled in boiler rooms. It is
easily to carry or shift position without breaking walls etc.
ADK 200 boilers are casted with special alloy, which is durable for heat extansions
and changes, EN GJL 200. They are long life boilers according to this special
cast iron alloy.
With the help of vertical and three pass specially designed sections burning gases
pass three times in the boiler and transmits burning energy to the water inside
the sections at high level.
ADK 200 boilers are high efficiency boilers (According to the fuel bottom heating
value % 91-93).
With this high efficiency and perfect isolation more energy is gained with less
fuel. Heat loses are minimized on ADK 200 boilers.
By appropriate burning room, heat transfer surface, turbulator, collector and
isolation high heat transfer and optimum flue gas emition results are provided.
Delivery Conditions
Boiler sections are delivered as assembled or not assembled according to the
boiler room specifications and dimensions. In not assembled deliveries, sections
and assembling aparats are delivered on a pallet, cabins,isolation and other
elements are delivered in a box. Alarko Carrier technicians make the assembling
of the boiler.

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ADK 200 CAST IRON BOILER - TECNICAL DATA

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ADK 200 CAST IRON BOILER - DIMENSIONS

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BOILER ROOM SETTINGS and BOILER PLATFORM DIMENSIONS
The measurements of the boiler room and the empty spaces must be arranged
properly for future assembling repairing, re-assembling, burner connecting issues.
• In ADK 200 boilers burner doors
can be opened to both sides.
According to this the required
empty spaces for the both sides
are given equal (min. 700 mm). This
will bring advantages for
operations. If the boiler room area
is not enough for this you can
choose one side and leve the big
empty space there. Half of this
empty space will be enough for the
other side in these conditions.
• There must be space left for the
tools that will be used in boiler
room.
• The concret platform must be in the mentioned dimensions.
• Concrete platfrom must not be coated with slipper materials such as
ceramics etc.
• If sound izolaton will be made,first do the sound izolation than make
the concrete for platform.
• Platfroms must be made of BS 25 concrete and scales.

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Fresh water must be added periodically to the plumbing. The chalk and other
chemicals will connect with the system and become solid. For avoiding this
closed expansion tank must be used in the system. In the systems that closed
expansion tanks are used, water will flow in closed system so it will not evaporate
and lost. So in this kind of systems the water level wiill stay same and fresh
water addition will not be necessary. This will prevent chalk and dust and the life
of the ssytem will be long.
PLUMBING INSTRUCTIONS
•The water in the radiator or heating system is not healthy. Do not use this
water as drinking or cleaning water. Do not take water from the system. If
the water level is low water addition is needed.
•For avoiding chalk and other chemical dust problems soft water must be
used in the system. Plumbing system water quality: Ph > 7,2 Th < 25 °Fr.
•If the city sanitary water is not in requested quality water addition from
wells or other sources must be made after testing it. For reaching the
requested quality additional processes must be applied to the water if
needed.
•For avoiding the chalk and other dust to get in to the boiler, or from boiler
to plumbing system dust holders must be placed in and out line of the
system.
•Circulation pump must be connected to the water output of the boiler and
the capacity of the pump must be suitable to the boiler capacity. If not,
problems may occur in flowing of the water and heating efficiency of the
boiler.
•For working the system properly 4 way mixture valve or thermostatic control
by-pass pump must be used for increasing return water temperature.
•By connecting a three way motor valve between the forward and return
line of heating system, the water that flows to the system can be controlled
in ratios.
•There must be water inside of the boiler every time. If not corrosion can
occur in the boiler and the plumbing system. If the boiler will not be used
in winter season, for avoid freezing anti-freeze solution must be used.

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A SAMPLE PLUMBING DIAGRAM for ADK 200 CAST IRON BOILERS
This diagram is a sample diagram and does not include all of the safety
requirements. Every system has its own characteristics and requirs a special
project according to these specifications. The types and the quantities of heat
cells in the dagram are examples. Maximum quantity of controlled heat cells,
specifications and the additional for controlling are related with the control panel
type of the boiler. In the diagram the water heating process is mentioned as it is
made by water heter with serpantine. Instead of this exchanger with plate+hot
water acumulator can be used. In that case the diagram will be different.
* This diagram does not cancel the related standards requirements.
NOT :
It is better to choose the check valves and valves in pipe dimension rather than
pump dimension.
Filter’s dimension must be chosen 1 level bigger that the pipes dimension and
must be connected in horizontal way.
The output of safety ventiles must be connected to water collecting path with a
pipe.
In the systems which thermostatic valve is used, in wet places normal radiator
valve must be used.
The Meanings of the
Shortenings In Diagram
The Meaning of the
Symbols Used In The
Diagram

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DIAGRAM of a SAMPLE SINGLE BOILER HEATING CIRCUIT WITH WATER HEATER
WATER CIRCULATION PRINCIPAL
IMPORTANT:
Alarko Carrier ADK 200 boiler is designed, forced circulation hot water heating
systems only.
For healthy working conditions of the boiler, temperature difference between water
forward and water return must not be more than 20°C and boiler must not be
started or work under the water volumes which is mentioned in the above table.

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INSTRUCTIONS ABOUT FLUE

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The platform of the fuel tank must be strong to carry the tank. If the fuel tank is
outside tank and connection pipes must be isolated. Fuel tank must be positioned
in higher level than the burner. The height difference between the burner and fuel
tank (H) must be more than 4 m. In the seasons that the boiler is not used,fuel
tank must be empty for avoiding corrosion.
INSTRUCTIONS for CONNECTING the FUEL TANK
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Fuel Tank
Air Pipe
Filling Pipe
Unloading Valve Pipe
Unloading Valve
Level Sign
Heater
Fuel Suction Pipe
Off Valve
Heater Filter

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BOILER CONTROL PANELS