MHG Heating GK 4 User manual

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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010908
Installation and Operating Manual for the
GK 4 – 8 Cast Iron Sectional Floor Standing Range
Output Range 34 – 90 kW

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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Section Page #
1.0 Appliance Type 3
1.1 GK Standard 3
1.2 GK Enhanced 3
1.3 GK Combined 3
2.0 Installation Regulations and Requirements 4
2.1 Appliance Warranties 5
3.0 Dimensions GK 6
3.1 Dimensions GK Combined 7
3.2 Dimensions GK 8 Only 8
3.3 Dimensions Flue Baffle 9
3.4 Dimensions and Connections 10
3.5 Dimensions Gas Burning Option 11
3.6 Installation Clearances 12
4.0 Delivery and Mobility 13
4.1 Positioning & Leveling 13
4.2 Flue Baffle Installation 14
5.0 Technical Data 15
6.0 Pressure Relief Valve 17
7.0 Electrical Connections 18
7.1 Internal Wiring Diagrams 19
8.0 Hydraulic Configurations 20
8.1 Hydraulic Single Unit 20
8.2 Hydraulic Cascade Unit 22
9.0 Filling The System 23
9.1 Pressure Vessel 23
10.0 System Water Quality 24
11.0 Appliance Controls 25
12.0 Appliance Fault Codes 26
12.1 RVA33 Controller Setting 28
13.0 Commissioning 32
13.1 Pre-Commissioning Checks. 32
13.2 Combustion System Commissioning 32
14.0 Routine Inspection and Servicing 33
14.1 Routine Service Inspection 33
14.2 Routine Cleaning and Maintenance 33
15.0 Weather Compensation Slope Graph and Sensor Curves 36
16.0 Optional System Controls (QAA73, RVA47, RVA 63, RVA46, QAA70, QAA50, QAA10) 39
17.0 Exploded Spares Diagrams 40
18.0 Parts List 41
18.0 Installer / End Users Note 44

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1.0 Appliance Type
There are five versions within the GK range. Each unit can be supplied with or without a cascade
controller.
Please ensure you have the correct unit for the application and where required located correctly
within the cascade prior to beginning the installation.
1.1 The GK Standard unit without cascade controller appliances are designed to be applied to systems
where the cascade control is undertaken via a remote system manager or a building management
system. Either control system must be capable of providing a volt free enable per applied boiler.
1.2 The GK Enhanced unit with cascade controller appliances are designed to be applied to systems
where the cascade control is undertaken by the lead boiler. Control of the system is enhanced by the
addition of a dedicated room unit.
1.3 The GK Combined Unit with integral Calorifier appliances are designed to be applied to systems
where heating and hot water requirements are met by a single compact unit. Two storage capacities
are available 150L and 200L.
The product codes for the standard range are:
Product Name Product Code
GK – 4 Blue Flame Oil 94.10000-5034
GK – 5 Blue Flame Oil 94.10000-5042
GK – 6 Blue Flame Oil 94.10000-5051
GK – 7 Blue Flame Oil 94.10000-5061
GK – 8 Blue Flame Oil 94.10000-5069
GK – 8-90 Blue Flame Oil 94.10000-5090
Product Name Product Code
GK – 4 Gas 94.10000-5134
GK – 5 Gas 94.10000-5142
GK – 6 Gas 94.10000-5151
GK – 7 Gas 94.10000-5161
GK – 8 Gas 94.10000-5169
GK – 8-90 Gas 94.10000-5190

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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2.0 Installation Regulations and Requirements
The installation of GK boilers must be in accordance with the relevant requirements of Gas Safety
(Installation & Use) Regulations 1994, Health & Safety at Work Act, Building Regulations, IEE
Regulations, Construction (Design & Management) Regulations 1994, Local Authority Bye-Laws,
National, Fire Regulations and Insurance Company requirements.
The following Codes of Practice are also applicable:-
BS 5440-1: 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70
kW net (1st, 2nd and 3rd family gases).
Part 1: Specification for the installation of flues.
BS 5440-2: 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70
kW net (1st, 2nd and 3rd family gases).
Part 2: Specification for installation and maintenance of ventilation for gas appliances.
BS 5449: 1990 Specification for forced circulation hot water central heating systems for domestic
premises.
BS 6644: 2005 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and
1.8MW(net) (2nd and 3rd family gases).
BS 6798: 1987 Specification for installation of gas fired hot water boilers of rated input not exceeding
60 kW.
BS 6880: 1988 Code of Practice for low temperature hot water heating systems of output greater than
45kW. Parts 1, 2 & 3.
BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm (R1) in
domestic premises (2nd family gases)
BS 7593: 1992 Code of Practice for treatment of water in domestic hot water central heating systems.
BS 7671: 1992 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition.
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises
IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1: Flued
appliances.
And any addition prevailing regulation and or code of practice not detailed above.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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2.1 Appliance Warranties
All MHG appliances enjoy a full 24 month warranty as detailed in our terms and conditions.
The guarantee period shall begin on the day of commissioning, or at latest 3 months after delivery has
been made.
The customer shall only be able to claim against MHG under guarantee if the commissioning of the
object of delivery has been carried out by MHG staff or the authorised supplier, if the customer has
followed MHG's instructions relating to the treatment and maintenance of the object of delivery, and
if no replacement parts of outside origin have been fitted.
Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the guarantee.”
In addition to the above warranties, the Primary Heat Exchangers carry a 60 month guarantee against
manufacturing or material defect.

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3.0 Dimensions. GK 4- 8 Boilers
Legend
~ Description Units
GK4 GK5 GK6 GK7 GK8
L Overall Length mm 817 917 1017 1117 1217
LA Flue Baffle Length mm 350 460 460 460 460
LK Boiler Excluding Burner Length mm 506 606 706 806 906
A Flue Spigot Diameter mm 130 180 180 180 180

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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3.1 Dimensions.GK 4-8 Combined
Legend
~ Description Units
GK4 GK5 GK6 GK7 GK8
L Overall Length mm 817 917 1017 1117 1217
LA Flue Baffle Length mm 350 460 460 460 460
LK Boiler Excluding
Burner Length mm 506 606 706 806 906
A Flue Spigot
Diameter mm 130 180 180 180 180
H Height to Optional
Pump Group mm 1760 1800 1800 1800 1800
LS Length of Calorifier
(150/200) mm 970/1250
970/1250 970/1250 970/1250 970/1250

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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010908
3.2 Dimensions. GK 8 Only
Legend
~ Description Units
GK8
LA Flue Baffle Length mm 460

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3.3 Flue Baffle Dimensions
Legend
~ Description Units
GK2-4 GK5-8
L1 Socket Length mm 60 132
L2 Overall Length mm 320 436
HA Height From Base to Centre Line mm 320 350
D Body Diameter mm 200 250
A Exit Spigot Diameter mm 130 180

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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010908
3.4 Dimension and Connection Dimension

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3.5 Dimension Gas Burner Option
Legend
~ Description Units
GK4 GK5 GK6 GK7 GK8
L Overall Length mm 826 926 1026 1126 1226
LA Flue Baffle Length mm 350 460 460 460 460
LK Boiler Excluding
Burner Length mm 506 606 706 806 906
A Flue Spigot
Diameter mm 130 180 180 180 180
H Height to Optional
Pump Group mm 1760 1800 1800 1800 1800
LS Length of Calorifier
(150/200) mm 970/1250
970/1250 970/1250 970/1250 970/1250

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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3.6 Installation and Service Clearances
Legend
~ Minimum Clearance Location
A 50mm. (If alternate access to the rear of the unit is available.) To either side of single boiler
B 100mm Above the optional pump kit
C 50mm. (If alternate access to the rear of the unit is available.) Between two or more boilers
D 50mm. (If alternate access to the rear of the unit is available.) To either side of two or more boilers
E 500mm Above the top case of the boiler
F 1000mm To the front on the boiler case
G 1000mm To the front of the burner
H 500mm To either side of the burner in front of unit

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4.0 Delivery and Mobility
All GKs are supplied fully tested and therefore may contain residual test water.
The test water utilised contains additives that will help prevent associated pumps from sticking and
other metals from oxidising.
To maintain the structural integrity of the appliance the internal components should not be used
during the lifting and positioning of the unit.
Please utilise the supplied handles when manoeuvring the unit.
All packaging materials should be disposed of in an environmentally way.
4.1 Positioning and Levelling
Following the final positioning of the unit the supplied levelling feet must be adjusted to ensure that
the unit is secure and level.
A specially designed boiler base can be supplied if a prepared base is not available.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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4.2 Flue Baffle Installation.
All GK models are supplied with a flue system baffle. This must be connected to the appliances spigot
as indicate below prior to installing the flue system.
If excessive draughts are present within the flue system and suitable stabiliser and volume control
damper must be installed.
Due to the high efficiency of the GK range condensate within the flue is a possibility.
Condensate collection, disposal, reduction device should be considered when designing the flue
system.

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5.0 Technical Data
Technical Data Units GK 4 GK 5 GK 6 GK7 GK8
Number of Sections 4 5 6 7 8
Nominal Heat Input Net Min/Max kW 36.8-46.6 45.0-52.7 53.7-66.7 62.3-80.6 69.8-96.8
Nominal Heat Output Min/Max kW 34-43 42-49 50-62 58-75 65-90
Flow and Return Connections 1.5” 1.5” 1.5” 1.5” 1.5”
Combustion Chamber Volume l 25.64 32.7 39.76 46.82 53.88
Standby Losses % 0.78-0.57 0.75-0.52 0.71-0.47 0.67-0.41 0.65-0.37
Maximum Flue Gas Volume Kg/s 0.0151-0.0190 0.0185-0.0010 0.0220-0.0274 0.0256-0.0331 0.0286-0.0397
Flue Gas Temperature OC 160-200 160-185 160-190 150-195 160-211
Minimum Water Pressure bar 0.5 0.5 0.5 0.5 0.5
Flue Gas Resistance mbar 0.08-0.14 0.10-0.15 0.09-0.17 0.10-0.16 0.08-0.20
Required Fan Pressure Pa 8-14 10-15 9-17 10-16 8-20
Power Supply (230 V / 50 Hz) Amps Burner
Dependant
Burner
Dependant
Burner
Dependant
Burner
Dependant
Burner
Dependant
Hydraulic Resistance mbar 10 12 13 15 17
Max Power Consumption Watts Burner
Dependant
Burner
Dependant
Burner
Dependant
Burner
Dependant
Burner
Dependant
Limit Temperature OC 110 110 110 110 110
Maximum Flow Temperature OC 90 90 90 90 90
Maximum Working Pressure bar 4 4 4 4 4
Water Content Ltrs 19.5 23.0 26.5 30.0 33.5
Minimum Flow Rate Kg/S 0.55 0.63 0.79 0.96 0.83/1.15*
Lift Weight (Dry) kg 140 170 195 220 250
*GK8-69/GK8-90
Units supplied with a Blue Flame Oil Rocket Burner.
Technical Data U GK 4-34 GK 5-42 GK 6-51 GK7-61 GK8-69 GK8-90
Burner Type RE 34 HU RE 42 HU RE 51 HU RE 61 HU RE 69 HU RZ 2.7 U
Nominal Heat Output kW 34 42 51 61 69 90
Flue Gas CO2 Percentage kW 13.5 13.5 13.5 13.5 13.5 13.5
Nominal Input kW 36.8 45 54.8 65.7 74.5 96.8
Residual Fan Pressure Pa 0 0 0 0 0 0
Flue Gas Volume Kg/s 0.0151 0.0185 0.0225 0.0270 0.0306 0.0397
Flue Gas Temperature 0C 160 160 160 160 170 211
Burner Weight Kg 12 12 12 12 12 22
Units supplied with a Gas Burner.
Technical Data U GK 4- GK 5- GK 6- GK7- GK8- GK8-
Burner Type GE 40 HUN GE 40 HUN GE 65 HUN GE 65 HUN GE 1.20 GE 1.40
Nominal Heat Output kW 34 42 51 61 69 90
Flue Gas CO2 Percentage kW 10.0 10.0 10.0 10.0 10.0 10.0
Nominal Input kW 36.4 45 54.5 65.3 73.8 96.3
Residual Fan Pressure Pa 0 0 0 0 0 0
Flue Gas Volume Kg/s 0.0155 0.0192 0.0232 0.0278 0.0314 0.0410
Flue Gas Temperature 0C 170 170 170 170 170 205
Burner Weight Kg 13 13 13 13 18 19

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6.0 Pressure (Safety) Relief Valve
In accordance with the prevailing British Standard 5440/6644, the installer shall install as suitably sized
Pressure (Safety) Relief Valve.
The location of this valve is important with respect to the applied pressure of the boiler circulation
pump, it is therefore recommended to locate the Pressure (Safety) Relief Valve on the flow pipe
immediately adjacent to the boiler; furthermore, there must not be any means of isolation between
the boiler and the Pressure (Safety) Relief Valve.
To assist with the correct positioning of the pressure relief valve hydraulic connector kits are available
as an optional extra.
General Kits
GK 4 Kit GK 5-7 Kit

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Hydraulic kits are also available for the combined units.
The installation of the hydraulic kit will facilitate that installation of the system pump groups that are
also available as an optional extra.
Legend
1 Boiler Drain Valve
2 Hot Water Outlet
3 Secondary Return
4 Cold Feed
5 Primary Flow Valve
6 Primary Drain Valve
7 Primary Return Valve
8 Primary Circulating Pump
9 Primary Return
10 Primary Flow Isolating Valve
11 Primary Flow
12 Heating Return
13 Flue Spigot
14 Heating Flow
15 Heating Pump Group
16 Boiler Pressure Relief Valve and Gauge
1 6 5

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7.0 Electrical Connections
Basic electrical connection for all types of GKs
Legend
High Voltage Output and Input Terminals 230 Volts
Y1 230 Volt Output For Mixing Valve Opening (Max 1Amp)
Y2 230 Volt Output For Mixing Valve Opening (Max 1Amp)
B5 230 Volt Burner Output 2nd Stage Operating Signal
T6 230 Volt Burner Output for 2nd Stage Enabling
T7 230 Volt Burner Input From Volt Free Disable for Burner 2nd Stage (Not Used)
T8 230 Volt Burner Input From Volt Free Enable for Burner 2nd Stage
B4 230 Volt Burner Output 1st Stage Operating Signal
S3 230 Volt Output Fault/Lockout Signal
T2 230 Volt Burner Input From Volt Free Enable For Burner 1st Stage
L 230 Volt Output Pumps (Max 1Amp)

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Internal Wiring Diagram

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8.0 Hydraulic Configurations
The GK range has been designed to suit a vast number of installation hydraulic configurations. In all
cases the minimum flow rate detailed in the appliance data table must be achieved through the units
when during operational periods.
8. 1 Single Boiler Installation Boiler Without Integral RVA Controller
8. 12 Single Boiler Installation Boiler Without Integral RVA Controller With Low Loss Header