Alarko CGS3 Series User manual

CGS 2 and CGS 3
LIQUID / GASEOUS FUEL
STEEL BOILER
USER MANUAL

Code No: A.4.1.8
Revision: 250718
Book Print Date: 250718

CGS 2 and CGS 3
LIQUID / GASEOUS FUEL
STEEL BOILER
Installation, Commissioning,
Operation and Maintenance Manual

Table of Contents
Introduction
07
Declaration of Conformity
08
Notices
09
Warranty and Service
11
Operating Conditions
12
Boiler Water Temperature and Room Temperature
13
Settings
Main Parts of the Boiler (CGS2)
16
Main Parts of the Boiler (CGS3)
17
Installation
18
Safety Systems
21
Burner Selection
26
Burner Installation
26
Suitable Fuels
28
Flue Gas System
28
Heating System Filling and Feeding Water
29
Features
Oxygen Corrosion
30
Commissioning
31
Start Up and Stop
34

Maintenance and Service
36
Boiler Control Boards
39
Appendices
40
Standard Electrical Diagram
47
Ecopanel 7/21 and 12/311 Electrical Diagram
48
Heating Control Panel SDC Easy Operation
Guide
49
Boiler Label Information
59
Technical Specifications Table
60
Burner Selection Table
62
Burner Gas Line Diagram
65
Control and Commissioning Form
66
CGS Steel Boiler Flue Information
67

7
INTRODUCTION
First of all, thank you for choosing the brand, ALARKO.
In this manual, you will find the INSTALLATION, OPERATION and
MAINTENANCE information on ALARKO's Steel Body Heater Boilers. Please
read this guide carefully for highly efficient and economic operation of your
device for a long time without any problems.
Except as described in this manual, DO NOT TOUCH any part or setting of your
device for reasons such as operation, adjustment or maintenance.
Have your device installed by ALARKO CARRIER Authorized Dealers.
Our Authorized Dealers and Services will provide you with the necessary
information about how to use and maintain the device after they have placed,
made connections of and put into operation of your device. You can ask the
issues you don't understand over and over again. Our experts will be happy to
answer your questions.
For more detailed information about your device, please contact our Customer
Services Hotline at 444 0 128 in order to reach the product brochure and
access the ALARKO CARRIER authorized dealers and services, when
necessary.

8
DECLARATION OF CONFORMITY
Our boilers with a capacity of up to 1,000 kW are manufactured in accordance
with the following rules and have the right to bear the CE marking.
•EN 303-1
•EN 303-3
•Directive 2009/142/EC on Appliances Burning Gaseous Fuels
Our boilers with a capacity of 1,000 kW and above are manufactured in
accordance with the following rules and have the right to bear the CE marking.
•EN 303-1
•EN 303-3
•EN 12953
•Directive 2009/142/EC on Appliances Burning Gaseous Fuels
The materials used in our products are designed to provide safe and proper
performance for our applications and are selected to withstand the chemical,
mechanical and thermal effects to which they may be exposed during the
expected lifetime.
•There is no soft soldering on gas bearing parts.
•The security of the changeable settings is ensured.
•Asbestos materials are not used.
•There are no parts in contact with the food and/or water used for sanitary
purposes in our boilers.
•Used parts are CE-marking approved.
•Installation and user information, nameplate and packaging information
have been written in the official language of the country where the boiler is
to be used, the national rules of the country concerned have been
considered.
•The electrical materials used are suitable for directives on low voltage.
The electrical materials used are suitable for Directives on Electromagnetic
Compatibility.

9
NOTICES
The boiler must be installed and operated in a closed space outside the living
areas, only in a well-ventilated and non-freezing risk.
The design, installation, commissioning and maintenance of the heating system
must be carried out by professional personnel trained in this field (by Alarko
Carrier Authorized Service), in accordance with this manual and the local rules
and applicable standards, regulations, or according to the EEC directives and
European norms (EN) in the absence of those specified above.
If the boiler is installed and used outside of the operating conditions specified in
this manual, it may cause accidents such as fire, explosion or the like, which
could result in loss of property or loss of life.
The boiler is designed for hot water use only (below boiling temperature). The
system operating temperature and pressure must comply with the values
specified on the boiler's nameplate and in this manual. The heat transfer medium
is water.
Boilers must only be used with gaseous or liquid fuels specified in this manual
and on the boiler's nameplate.
Boilers must only be used with EN 676 (gaseous fuel) or EN 267 (liquid fuel)
certified burners to operate in accordance with the Directive (92/42/AT) on
Efficiency Requirements for Boilers and the Directive 2009/142/EC on
Appliances Burning Gaseous Fuels.
This is a B23 type boiler, so the boiler must be connected to a flue with sufficient
draught in accordance with the regulations, and there should be no flue gas
leakage into the boiler room.
During the operating period of the boiler, a pump with suitable values must
perform circulation continuously.
The filling and feeding water must comply with the specifications given in this
manual. Lime-free, clean and non-corrosive water use is necessary in terms of
economic operation and long service life of the system.
Never close the boiler room ventilation for safe and efficient use. Fresh air is
needed for good combustion. It is necessary to be able to expel the gases that
can emerge from combustion and that may leak from fuel to the environment.
Install the boilers on a base which is at least 15 cm above the ground, parallel to
the ground, non-flammable, with sufficient strength.
Boilers should not be installed and put into operation in the environments with
flammable gases and materials. In order to prevent the boiler from being
damaged, it should be avoided to leak dense dust or halogen hydrocarbons
(solvents, spray

10
gases, adhesives, etc.) into the combustion air. The humidity of the boiler room
must not be high.
In liquid or gaseous burners, ignition is automatic and there are many additional
safety controls. Do not attempt to manually switch on the burners or to operate
the system manually by disabling the controls. All control equipment must be
kept working continuously at the specified limits. In the event of any
malfunction, do not operate the system and contact your authorized service.
The boiler room should not be used for any other purposes and should not have
any open connection to living spaces. The door must be airtight, fire-resistant
and self-closing.
If the boiler temperature rises above 90 °C, do not feed cool water into the
system for rapid cooling. This could cause an explosion. Allow the boiler to cool
down to 40 °C naturally before the feeding water is added.
If any part of the boiler is submerged, do not put it into operation. Contact your
authorized service immediately.
Do not touch the window box, flue and fume cupboard and its surrounding
areas. These areas may be very hot and cause serious injury.
It is recommended to install an emergency stop switch in a suitable place
outside the boiler room. This switch must be able to stop the combustion
process or fuel supply. It is useful to specify it with a nameplate.
When starting up a newly installed system, initial checks and commissioning
must be performed by the Alarko Carrier Authorized Service. Maintenance is
the responsibility of the user and must be performed by an authorized service.
If you wish to change fuel in the future, please contact your authorized service.
Fuel change requires replacement of some parts and new adjustments. Do not
carry out fuel change by yourself or unauthorized persons.
This is not a condensing-type boiler, make sure that there is no long-term
condensation in the boiler.
If the system is to be put into operation with a heavy gaseous fuel (such as
LPG) and the boiler room is below ground level, additional measures should be
taken. The fuel that can be leaked into the boiler room must be able to be
expelled automatically in a safe area outside the boiler room through an
ex-proof mechanical system (ventilation) and the fuel line must be cut
automatically when the fuel leakage reaches a certain level.
If the system is to be commissioned with liquid fuel, the turbulators in the smoke
ducts must be removed. Turbulators are for use with gaseous fuel. Since the
turbulators are not used, the boiler efficiency will decrease by 2-5%.

Do not touch any part of the boiler and the
burner for the purpose of adjustment or
maintenance, except as described in this
manual.
When gaseous fuel is used, the boiler must have
an automatic cutter (solenoid valve) on the fuel
supply line and this device must be associated
with a warning system.
The condensate coupling under the Boiler Rear Fume
Cupboard must be connected to the drain with a
siphon.
Rear fume cupboard
condensate
coupling
drain
siphon
WARRANTY AND SERVICE
So long as the principles, notices and all applicable standards (EN norms,
directives and principles should be applied where those principles are not
applicable) mentioned in this manual are abided by, your device is warranted for
2(two) years from the date of sale against material and manufacturing defects.
The Product’s Warranty Certificate shall be filled in by the authorized service
from whom you purchase the products and sent to the ALARKO-CARRIER.
Please follow.
ALARKO CARRIER Authorized Services are at your service at any time, even in
the slightest problems. You can find authorized service addresses in the
Authorized Service Address Booklet supplied with your device.
Any defects arising from improper installation, maintenance or use shall not be
covered by the warranty.
Malfunctions resulting from the heat transfer parts of the boiler coated with lime
and/or similar foreign materials and the corrosion are not covered by the
warranty.
The minimum service life determined by the Ministry of Industry and Trade for
these devices is 15 (fifteen) years. Manufacturer and reseller companies
undertake to provide service and spare parts for the device within this period.
If you encounter any problems, you can call the Customer Hotline at 444 0 128
with local call rate from anywhere in Turkey, and you can also reach Alarko
Carrier Customer Services Department via e-mail at
[e-mail]:[email protected]

12
OPERATING CONDITIONS
Boilers are designed to produce hot water. They must be installed in a hot
water heating system suitable for boiler performance.
Standard operating temperature is between 55 and 90 °C (special order is
required for temperatures up to 105 °C). Standard operating pressure is 3 bar
(special order is required for pressure levels above this).
These boilers are not suitable for use as a direct water heater. In case of
potable or clean hot water needs, a closed circuit heat exchanger suitable for
the system must be installed.
These boilers are suitable for operating with liquid and gaseous fuels. Consult
our authorized dealers for the fuels you can use. If you want to change the fuel
that has been commissioned for the first time, contact our authorized services.
The boiler can be used in both open and closed expansion systems. A suitable
expansion system in the system should work actively at all times.
In the 2nd transition pipe in CGS2 boilers and 3rd transition pipe in CGS3
boilers, there are turbulators to increase the heat transfer to the water. Never
remove these turbulators, this will cause loss of efficiency in the boiler and may
damage the boiler.
This is not a condensing-type boiler, so make sure that there is no
condensation in the boiler.
These boilers are suitable for operating with liquid and gaseous fuels. Consult
our authorized dealers for the fuels you can use. If you want to change the fuel
that has been commissioned for the first time, contact our authorized services.

13
BOILER WATER TEMPERATURE AND ROOM TEMPERATURE
SETTINGS
Boiler can be operated with Standard Panel or Eco-panel.
Temperature Settings of Boilers Operated with Standard Panel:
The user cannot adjust the room temperature, can only adjust the temperature of
the boiler water.
He adjusts the boiler water temperature in the boiler thermostat on the panel. As the
outside temperature changes, he must also change the thermostat setting.
Temperature Settings of Boilers Operated with Eco-panel:
The user determines the desired room temperatures and time program and saves
them to the eco-panel. The boiler then operates automatically depending on the
outside temperature. With the tests to be carried out in 1 or 2 weeks, it should be
determined whether the values determined at the beginning are suitable for the
conditions of the building and suitable values for building should be found.
As long as it is not changed by the user, the eco-panel works according to the
factory settings. The factory settings are as follows;
Factory Settings
User Setting
Comfort room temperature
20 °C
Economy room temperature
16 °C
Working hours at comfort temperature
06:00 - 22:00
Working hours at economy temperature
22:00 - 06:00
Heating curve (if building with radiator)
1,5
Heating curve (if building with underfloor
heating)
1,0

14
Heating curves are the graphs in which the boiler water temperature is
determined depending on the desired room temperature and the outside
temperature.
Boiler water temperature (oC)
Outside temperature
(oC)
Room temperature (oC)

15
When the room temperature is changed, the curves move in parallel. In the
following example, if the room temperature is desired to be 25 °C or 15 °C, the
way of change of the heating curve of 1,5 is indicated by dashed lines.
Curve of 1,5 for
25 °C room
temperature
Curve of 1,5 for
20 °C room
temperature
Curve of 1,5
for 15 °C room
temperature
Boiler water temperature (oC)
Outside temperature
(oC)
Room temperature (oC)

16
MAIN PARTS OF THE BOILER
CGS2 SERIES BOILERS
INTRODUCTION PARTS OF CSG2 BOILERS:
1. Boiler flow flange
9. Front fume cover
2. Boiler return flange
10. Rear fume cupboard
3. Flow safety connection
11. Fume transition pipes
4. Return safety connection
12. Flue connection outlet
5. Hydrometer connection
13. Cleaning cover
6. Thermometer connection
14. Blowout cover
7. Condensate drain connection
15. Carrier frame
8. Burner connection cover
16. Boiler feet

17.
CGS3 SERIES BOILERS
FRONT VIEW
SIDE VIEW
INTRODUCTION PARTS OF CSG3 BOILERS:
1. Boiler flow flange
10. Burner connection
cover
2. Boiler return flange
11. Front fume cover
3. Flow safety connection
12. Rear fume cupboard
4. Return safety connection
13. Flue connection outlet
5. Hydrometer connection
14. Cleaning cover
6. Thermometer connection
15. Blowout cover
7. Condensate drain connection
16. Carrier frame
8. III. Fume Extractor Pipes
17. Boiler feet
9. II. Fume Extractor Pipes

INSTALLATION
The design, installation and commissioning of the heating system must be carried
out
in accordance with the applicable standards, regulations and the warnings in this
manual.
In cases where there are no local standards, regulations or inadequate standards
and regulations,
EEC directives and European norms (EN) should be applicable.
•The control and commissioning of the entire system must be carried out by
Alarko Carrier Authorized Services.
•The boiler must be installed in a closed area, except for living areas, which
are well ventilated and where there is no risk of freezing in accordance with
the rules. Top and bottom ventilation systems must comply with local
regulations.
•Boilers must only be used with EN 676 (gaseous fuel) or EN 267 (liquid fuel)
certified burners to operate in accordance with the Directive (92/42/AT) on
Efficiency Requirements for Boilers and the Directive 2009/142/EC on
Appliances Burning Gaseous Fuels.
•This is a B23 type boiler, so the boiler must be connected to a flue with
sufficient draught in accordance with the regulations, and there should be no
flue gas leakage into the boiler room.
•All equipment and control system of the heating system should be able to
provide the specified heating loads according to the external climatic
conditions and the desired internal temperature. It should be able to protect
the heating system against freezing and humidity when normal operating
conditions (comfort temperature level) are not required.
•The equipment for the control and safety systems of the heating system must
comply with the applicable TS standards, and, where insufficient, the
instructions in EN 12828 and this manual must be observed.
•The heating system must also have at least one circulation pump complying
with the system requirements and this pump must be kept in operation as
long as the burner is operating.
•An effective installation circuit must be installed to protect the boiler from flue
gas condensation. The condensation return water temperature should be
kept above the condensation value by a system such as condensation by
pass pump, 3-way valve system.
•The first filling water and then the feeding water should have the properties
specified in this manual. The use of water with proper properties is necessary
for the longevity of the system and its economic operation. Extremely soft
water causes corrosion, extremely hard water causes limestone, so water
with proper values should be used.
18

19
•Install the boilers on a base which is at least 10 cm above the ground, parallel
to the ground, non-flammable, with sufficient strength. The base dimensions
table is attached.
•Boilers should not be installed and put into operation in the environments with
flammable gases and materials. In order to prevent the boiler from being
damaged, it should be avoided to leak dense dust or halogen hydrocarbons
(solvents, spray gases, adhesives, etc.) into the combustion air. The humidity
of the boiler room must not be high.
•The boiler room should not be used for any other purposes and should not
have any open connection to living spaces. The door must be airtight,
fire-resistant and self-closing.
•It is recommended to install an emergency stop switch in a suitable place
outside the boiler room. This switch must be able to stop the combustion
process and fuel supply. It is useful to specify it with a nameplate.
•If the system is to be put into operation with a heavy gaseous fuel (such as
LPG) and the boiler room is below ground level, additional measures should
be taken. The fuel that can be leaked into the boiler room must be able to be
expelled automatically in a safe area outside the boiler room through an
ex-proof mechanical system (ventilation) and the fuel line must be cut
automatically when the fuel leakage reaches a certain level.
•If the system is to be commissioned with liquid fuel, the turbulators in the
smoke ducts must be removed. Turbulators are for use with gaseous fuel.
Since the turbulators are not used, the boiler efficiency will decrease by
2-5%.
•All electrical connections must be made according to current standards and
according to the diagrams given in this manual. Please pay special attention
to the grounding of all electrical appliances in the boiler room. Never use fuel
or water pipes as ground connections.
•Boiler flue connections should be made according to standards. The boiler
position should be selected so that the distance between the boiler and flue
and the number of elbows is minimum. Flue ducts should not be directed
downwards and vertical elbow turns should be avoided. Smoke ducts and
flue should be heat insulated. Tables for the selection of flue height and
diameter are given in the appendix. These tables can be used under certain
conditions, in systems other than these conditions, a flue calculation must be
made according to the norms (TS 2165).
•There should be no manual shut-off systems (such as valves) between the
boiler and the safety and control systems. A lock valve can only be fitted to
the connection of the closed expansion tank for maintenance and
pre-pressure checks. Accidental closure of this valve should be strictly
prevented.

20
•After the installation of the heating system, all system equipment connections
(water, fuel, flue gas lines, electricity) must be checked for leakage.
•CGS2 and CGS3 boilers have a condensate outlet. This outlet must be
connected to a suitable conduit via a siphon to prevent liquid gas leakage.»
Condensate discharge must comply with applicable regulations.
•The weight of the flue gas ducts must not get carried by the boiler's flue gas
connection point and a flanged or leak-tight connection must be used for easy
maintenance.
•The total weight of the large and heavy burners should not get carried by the
boiler front cover, and the weight of the burner should get carried by the
ground with the help of a suitable adjustable support.
•The length of the burner connection bolts should not exceed the total thickness
of the burner flange, gasket and adapter plate.
•If the gap between the burner barrel and the boiler refractory is more than 10
mm, this area must be filled tightly with 1200 °C resistant ceramic fiber
material.
•The responsibility for the installation and commissioning of the control and
safety system of the heating system in compliance with the applicable
standards and regulations is in the units that implement the system project,
installation and operation. The minimum information is given as a preliminary
reference in accordance with the standards in force at the date of the
preparation of the installation part of this manual.
•For the types with 800.000 kcal/hr and under, they have a prismatic cabinet for
closing the thermal insulation. Cabin steel plates are delivered separately and
our authorized service department assembles them.
•For the types with 1.000.000 kcal/hr and above, insulation closure sheet
plates are rolled and packed and put in the combustion chamber. Our
authorized service assembles them as shown in the following pictures
1-2-3-4.