SAS MI Series Operator's manual

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BOILER
Z A K Ł A D M E T A L O W O
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K O T L A R S K I
28-100 Busko-Zdrój, Owczary, ul. Przemysłowa 3
Phone: [phone], Fax: [phone]
TECHNICAL
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START
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UP DOCUME TATIO
of water boiler’s for heating installations
SAS MI type
adopted for black coal combustion of fine coal
SAS MI

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INDEX
page
Conformity declaration 3-4
1. Introduction 5
2. Use of boiler 5
3. Boiler construction description 5
4. Technical data 6
5. Fuel 6
6. Boiler’s assembly guidelines 7
6.1 Requiremends for boiler-room 7
6.2 Boiler’s arragement 7
6.3 Connecting boiler to a chimney 8
6.4 Connecting boiler to a chimney installation 8
6.5 Connecting boilers to electrical installation 9
7. Operation and installation guidelines 9
7.1 Filing with water 9
7.2 Boiler’s firing up 10
Table (technical – exploitation parameters) 11-12
Boiler’s construction scheme 13-14
7.3 Burning 15
7.4 Cleaning the boiler 15
7.5 End of heating season 15
8. Terms of safe exploitation 16
9. States of important boiler’s functioning 16
10. Protection means 18
11. Terms of delivery 18
12. Recycling 18
13. Terms of warranty 19
Service repairs 21
Warranty card 22

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Dear buyer and user of boiler of SAS MI type. This technical start-up
documentation contains all necessary information required for energy-saving, safe
and longstanding exploitation of your boiler.
We kindly ask you to get familiar with documentation content prior to
assembling and starting the exploitation of a boiler. Hereby documentation shall be
kept for future use.
Upon familiarization with this manual, the user will be able to utilize this device in
the optimum way. Careful reading of the manual will help in effective and safe
exploitation of the boiler.
Boilers of SAS MI type are designated for water installations of the central heating
systems, open type with gravitational or forced water circulation, protected
according to presently being in force, both domestic or the union detailed
regulations (e.g. PN-91/B-02413 – Boilers of SAS MI type installed in accordance to
hereby documentation recommendations are not subject to the commissioning led
by the Branch Office of Technical Inspection). Boilers are specifically
recommended for the flats heating in single-family homes, pavilions, etc., where
calculated feeding water temperature does not exceed 85°C , and working pressure
does not exceed 1,5 bar. Required gases draught pressure after a boiler is 0,30
- 0,55 mbar (depending on boiler’s power). These boilers may also work in hot
water installations utilizing a heat exchanger.
Boiler’s selection for building heating should be based on heat balance, according to
regulations in force, both domestic and the union (e.g. PN-B-02025:2001).
The heating boiler of SAS MI fine coal type, is a modern construction
heating device with upper combustion, adapted for combustion of black coal
culm type. The boiler is made of steel plates welded type
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. The front chamber (pos.
4) makes up a furnace with a water grate. Basic boiler’s elements are shown on the
drawing (p. 13). The water jacket (pos. 3) it is a cuboids shape structure with
double walls, separated by water partitions. At the upper part, the furnace is
also closed with water jacket what gives maximum use of gases heat. The
water grate (pos. 10) makes up uniform unit together with a heat exchanger,
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Internal partitions (elements having contact with fire) are mode of boilerplate 6mm thick. uter body of
water jacket is made of steel plate 4mm thick
1.
I TRODUCTIO
2. USE THE BOILER
3.BOILER CO STRUCTIO DESCRIPTIO

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so it is not replaceable. Between water grate there are cast iron movable
grates (pos. 11
2
). Under a heat exchanger, on its entire section, there is an
ash pan chamber. There is an opening for combustion chamber cleaning (pos.
24)on the sidewall. At the upper part of boiler, under the cover (pos. 19),
there is a flap of combustion chamber (pos. 20), which during boiler’s work,
transfers gases into a channel placed between water partitions to the smoke
conduit (pos. 21). It also enables easy access to combustion chamber, when
cleaning operations take place. To the upper part of a heat exchanger the
hot water connector is welded (pos. 23). Blowdown connection (pos. 25) is placed
on the lateral wall.
Traditionally, fuel charge door (pos. 5), furnace door (pos. 6), and ash box door
(pos. 8), are placed on the front wall of the boiler. Use of these door enables
easy access when combustion and ash pan chambers cleaning is considered.
Fumes are carried out to a chimney through the smoke conduit (pos. 21)
placed at the back side of a boiler. The smoke conduit is equipped with
mounted smoke throttle (pos. 26), rendering draught regulation. On the smoke
conduit backside, there is a smoke conduit cleaning hole (pos. 22).
The entire heat exchanger’s construction is wrapped with insulation material (pos.
2), a mineral wool, which fill the space between the heat exchanger and boilers
casing (pos. 1).
Water temperature in a boiler may be read by use of the electronic controller (pos.
15), attached to the boiler. Due to simple and proved over many years
design, these boilers are reliable and easily operable.
Operation of boilers is based on forced air admission, what is performed by
platform fan(pos. 16, depending on size, boiler may be equipped with one or
two fans), operated by electronic controller(pos. 15) connected to mains.
Basic energetic parameters are structured in the table (p. 11-12) and on the drawing
(p. 13-14).
Basic fuel for heating boilers of SAS MI type is a black coal for energetic
applications namely fine coal (KL 27/10) with max. humidity of 25% . This
fuel is proper for obtaining the declared power. Application of fuels, other than
recommended, may lead to reduced capacity (heating capacity of boiler) and
reduced time of slow combustion.
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Does not apply to boilers of power above 36kW
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TECH ICAL DATA
5. FUEL

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Boiler’s assembling should be performed by qualified and authorized personnel
(qualified person upon adequate training and authorized for performing maintenance
and repair works).
The fitter’s obligation is to get familiar with the product, its functioning and
protection systems functionality.
Prior to boiler’s assembling it is strictly necessary to get familiarized with
the content of hereby Technical-Start-Up Documentation.
6.1REQUIREMENTS FOR BOILER-ROOM
The boiler room, where the heating boiler for central heating installation shall
be installed, must conform the requirements of detailed regulations being in
force, at the country of destination (e.g. PN-87/B-02411).
In particular, the following requirements shall be fulfilled:
the boiler rooms should be located as centrally as possible to rooms
which are covered with heating system, and the boiler itself should be
placed as close as possible to chimney (chimneys),
boiler room entrance door should be opened on the outside, and be made of
inflammable materials,
the boiler room should have air blow-in ventilation, a channel with
section no less than 50% of the chimney section, but not less than
21 x 21 cm, with the exit at the back part boiler’s room , (lack of such
ventilation or obstruction may cause: smoking, inability to get higher
temperature),
the boiler room should have air blow-out ventilation under room’s ceiling
with section no less than 25% of the chimney section, but not less than
14 x 14 cm (the purpose of this system is to carry out harmful gases).
NOTE: Employing of mechanical blow-out ventilation is unacceptable.
The boiler room should be provided with day and artificial lighting.
6.2 BOILER’S ARRANGEMENT
Special foundation for boiler is not required, however it is recommended to put it on
concrete platform 2 cm high, but it may be also practiced to put it directly on
the fire-proof floor. Boiler’s layout should ensure easy and safe operation of
such elements, as furnace, ash box and fuel loading, and do not obstruct
cleaning operations.
The front of boiler should be distant from the opposite wall no less than 2 m,
and similarly, boiler’s sidewalls no less than 0.5 m
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BOILER’S ASSEMPLY GUIDELI ES

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6.3 CONNECTING BOILER TO TE CHIMNEY
Chimney channel and connection should be performed according to the
requirements of detailed regulations being currently in force in the country of
destination (e.g. Ministry of Infrastructure Decree, as of 1 April 2002 Journal of
acts no. 75).
A boiler should be connected to a chimney with smoke conduit, which is
slightly rising towards the chimney. Smoke conduit length should not exceed 0.5
m. Area of chimney – smoke conduit connection should be precisely sealed.
The chimney’s height and section, as well as accurateness of its construction shall
ensure obtaining required chimney draught of min. 0.30 – 0.55 mbar.
Selection of the chimney’s height and section comparing to boiler power
should be based on detailed regulations being in force in the country of destination.
Assuming that it is not possible to achieve such parameters for chimney, and
chimney draught problems are experienced, resulting in improper boiler
performance, the gases blow-out fan, or chimney base together with built-in fan
may be applied, for supporting and stabilizing the draught. It is important for the
chimney to has its beginning at the level of boiler room floor, for the reason that
gases leaving the boiler are able to be repelled. It is also important, that in the
bottom part of chimney there is washout whole with tight closing.
In order to avoid the air back draught possibly appearing in the chimney, its height
should be above a crest of roof not less than 1.5 m. Chimney’s utility
(permeability) should be checked and confirmed by authorized chimney-sweeper
at least once a year.
PRIOR TO BOILER COMMISSIONING THE CHIMNEY SHOULD BE BASKED!
NOTE: It is recommended that the flue is made of stainless steel material.
Low temperatures in the boiler cause wet gases emission. This may be found as the
reason of wetting and corroding of brick chimneys.
6.4CONNECTING BOILER TO THE HEATING INSTALATION
The boiler should be connected to heat in installation with screw connectors.
Protecting measures for water heating installations of opened type should be
according to detailed regulations being in force in the country of destination (e.g.PN-
91/B-02413).
Volume of pressure vessel should be equal at least 4% volume o water in the entire
heating installation.
NOTE: Ascending and descending safety pipe as well as circulation pipe must
not be equipped with any valves. In addition, those pipes and the pressure
vessel should be protected against freezing.
Boilers of SAS MI type may work with gravitational or forced water circulation. If
installation is provided with circulation pump, than on feeding/return pipe the
differential valve should be installed. When blackout or pump malfunction occurs, this
valve will open and the system start work running by gravitation.

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NOTE: It is recommended to connect the boiler to heating system provided
with three- or four-pass valve. The main advantage of such connection is boiler
protection function against low temperature corrosion, preventing it from
premature wear.
If not satisfactory to comply with manufacturer’s recommendations in reference
to maintaining given heating water temperature ranges occurs (table TECHNICAL
– EXPLOATATION PARAMETERS p. 11-12, point 12, 13 it concerns in particular
long-lasting return water temperature below 55°C), then the boiler should be
connected to the heating installation equipped with three- or four-pass valve protecting
it against low temperature corrosion.
6.5. CONNECTING BOILER TO ELECTRICAL INSTALLATION
Boiler room should be equipped with electrical installation 230V/50Hz should
be according to detailed regulations being in force in the country of destination.
Electric socked should be earthed. Grounding functionality should be checked.
Cable extensions are forbidden. Faulty installation may cause the controller to be
destroyed or be unsafe for the user. Controller and other cooperating devices are
powered with 230 V, therefore all connections shell be made by qualified
personnel (certified electrician).
NOTE: Electrical cables of powered devices should be placed away from
boiler’s parts, which tend to be hot during exploitation of boiler ( cover
of the upper washout hole, smoke conduit, door).
7.1. FILING WITH WATER
Boiler and the entire installation water filling is to be performed using blowdown
connection.
This activity should be performed slowly allowing the air residing in the
installation to be removed. It is accomplished when water is going out of
overflow pipe. When filling the heating system installation with water it is
recommended to loose screw connection at the place of boiler – installation
assembly (on the hot water connector). Once water is flowing out, tight the
connection.
NOTE: Filling installation with water when boiler is in use, especially if it is
very hot is strictly forbidden, as boiler’s damage or fracture may be caused.
Once heating season is over do not get rid of water from heating installation and
boiler. When required, water may be let of through blowdown connection to a drain
once it is cooled down.
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OPERATIO A D EXPLOITATIO GUIDELI ES

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7.2. FIRING UP A BOILER
Firing up a fuel in boiler should be started when checked if heating installation is filled
with water, and water is not frozen. It should also be checked, if water is not leaking
through thread fittings on boiler. Do not forget to heat the chimney prior to the firs
startup.
Before firing up a boiler it is necessary to close furnace and ash box door, than on
the surface of the fine coal already placed in the furnace (filled up to the edge of the
chute) put pieces of crumpled paper, and then pieces of wood on top of it. Fire it
up, close chute door, switch on the controller and set the required temperature.
NOTE: Person operating the boiler should know that some of boiler’s
areas are hot, therefore protective gloves should be worn! The same applies
to protective goggles.
Fuel combustion process is regulated by controller, as well as the process of
forced air delivery into combustion chamber. Next fuel application takes place
provided previously introduced fuel is completely burned out and furnace is
cleaned.
During fire up process the boiler should be monitored until it gets
feeding water temperature of 45°C. It is import ant, as varying fuel quality
may cause the boiler to go out.
In case of fire in boiler went out during fire up operation a furnace must be
cleaned, boiler’s should be ventilated and fire up should start again.
During the process a smoking or sweating of boiler may occur. Once boiler and
chimney duct get hot, those adverse phenomena should go away.