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Alarko ALG 120/M, Installation Operation & Maintenance

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Alarko ALG 120/M Installation Operation & Maintenance Download Page 24

24 

COMISSIONING 

Remove the control box cover. Make the wiring connections of the power supply and boiler thermostat 
cables inserting through cable connectors and follow the wiring diagram directions. L1, L2, and L3 are 
phase and N is neutral. Connect earth cable to earth sign, boiler thermostat to BT and safety thermostat 
to  ST.  Assemble  back  the  control  box  cover.  Turn  on  the  ON/OFF  switch  to  ON  position  to  run  the 
burner.  Capacity  adjustment  of  modulating  burners  is  done  full  automatically  by  Boiler  Control  Unit 
RWF40  regarding  the  pre-set  temperature  value  after  setting  of  the  RFW40  is  done  as  indicated  in 
below titles. 

BOILER CONTROL UNIT (RWF50) 

Boiler  Control  Unit  works  as  a  boiler  thermostat  for  modulating  burners.  Air  damper 
adjustment  is  made  by  the  signal  of  the  Boiler  Control  Unit  which  has  a  pre-set 
reference  value  of  temperature  or  pressure  of  boiler.  The  pre-set  value  is  compared 
with the current values and heat demand and a signal is sent to the burner control unit. 
Modulating gas valve regulates the gas flow regarding the air flow adjusted by the air 
damper. 

The  connection  of  Siemens  RWF50  is  shown  in  the  wiring  diagram.  RWF50  user’s 
manual  must  be  referred  for  further  detailed  issues.  Some  other  compatible  boiler 
control unit can be utilized other than RWF50. 

 

Summary of Contents for ALG 120/M

Page 1: ...ALG SERIES GAS BURNERS ALG 50 2 ALG 70 2 INSTALLATION OPERATION MAINTENANCE ALG SERIES NATURAL GAS LPG BURNERS ALG 200 M ALG 120 M ALG 200 M LPG ALG 120 M LPG INSTALLATION OPERATION MAINTENANCE...

Page 2: ...Code A 6 1 5i Revision Date 071116 Print Date 071116...

Page 3: ...ALARKO Models ALG 200 M ALG120 M Natural Gas LPG Burners ASSEMBLY OPERATION MAINTENANCE...

Page 4: ...IR ADJUSTMENT in MODULATING BURNERS 19 BURNER CONTROL UNIT LFL 1 322 for MODULATING BURNERS ALG200 M 20 ERROR CODES LFL 1 322 21 IONIZATION CONTROL 21 GAS LINE ASSEMBLY 22 COMISSIONING 23 BOILER CONTR...

Page 5: ...shed time GUARANTEE AND SERVICE INTRODUCTION 5 This manual includes the information concerning the ASSEMBLY OPERATION and MAINTENANCE of ALG type gas burners produced by ALARKO Please read this manual...

Page 6: ...aintenance and seasonal start ups of your burner must be done by Alarko Carrier service people Do not keep flammable substances in any for gas liquid solid close to your burner 6 PRECAUTIONS GENERAL I...

Page 7: ...1200 VEF DN65 16 360 ANELLO FILTER 70610 F CE DUNGS MBC 1900 VEF ALG 120 M Modulating Naturalgas 2H 2 47 360 DUNGS MBC 700 VEF 2 20 6 360 DUNGS MBC 1200 VEF LPG 3B P 2 21 360 DUNGS MBC 700 VEF 2 17 36...

Page 8: ...trol Panel 19 Operation Error Reset 20 On Off Button 21 Control Unit 22 Fuse 23 Cable Connector 24 Thermal relay 25 Terminal 26 Contactor 27 Air Damper 28 RWF40 Universal Controller 29 Gas Pressure Sw...

Page 9: ...ard test tubes complying with the EN 676 standard PERFORMANCE CURVES ELECTRIC SUPPLY 3 380 415 V 50 Hz Lower Heating Value of Natrual Gas 8 250 kcal m Lower Heating Value of mix LPG 26000 kcal m The c...

Page 10: ...Pressure Switch 6 Safety Solenoid Valve 7 Gas Pressure Regulator 8 Solenoid Valve 9 Multiblock Valve 10 Valve Proving System is optional for burners having capacity of lower than 1200 kW 11 Air Pressu...

Page 11: ...ssure which is found with this method is the gas pressure to achieve the desired capacity Gas line inlet pressure should be calculated to supply the desired burner gas pressure The graphs are given un...

Page 12: ...BC 1900 VEF Gas Line DN 65 MBC 3100 VEF Gas Line DN 80 0 5 10 15 20 25 30 35 600 800 1000 1200 1400 1600 1800 2000 2200 CAPACITY kW PRESSURE LOSS mbar Lower Heating Value of NG 8250 kcal m Lower Heati...

Page 13: ...ressure Gas Line Inlet Pressure 13 ALG 120 M GAS LINE PRESSURE LOSS Burner Gas Pressure MBC 1200 VEFGas Line 2 MBC 700 VEFGas line 2 0 0 5 0 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 400 500 600 70...

Page 14: ...ner Gas Pressure Gas Line Inlet Pressure 14 ALG 120 M GAS LINE PRESSURE LOSS LPG Burner Gas Pressure MBC 700 VEF Gas Line 2 MBC 1200 VEF Gas Line 2 0 0 5 0 10 0 15 0 20 0 25 0 400 500 600 700 800 900...

Page 15: ...n capacity of 1579 9kW as the boiler inlet capacity 3 Boiler flue losses are given as 3 1mbar in the same document It is seen in the below graph ALG 200 M Gas Line Pressure Graph that the burner press...

Page 16: ...16 DIMENSIONS mm ALG 200 M ALG 200 M LPG ALG 200 M ALG 200 M LPG ALG 120 M ALG 120 M LPG...

Page 17: ...nd is stabilized with the hinge rod 2 and bolt 1 17 There are 3 electrodes 2 for ignition and 1 for ionization Dimensions are in mm Make sure the spaces between the electrodes and the turbulator compl...

Page 18: ...ect position can be found by utilizing the below graphs 18 COMBUSTION HEAD TURBULATOR ADJUSTMENT Somun Namlu Ayar Kapa Stroke length Nut Head Adjustment Cover ALG 200 M 0 5 1 1 5 2 2 5 3 800 1000 1200...

Page 19: ...ven on this page These graphs are derived in laboratory conditions and are for avarage values The positioning values may vary according to different boiler conditions Therefore the final adjustment mu...

Page 20: ...sed when II cam indicates 0 Stage Switching cam from 1st to 2nd stage Must be adjusted 10 15 smaller than the 2nd stage point 0 point cam Min Capacity 1st adjustment cam Max Capacity 2nd adjustment ca...

Page 21: ...RWF50 Z Ignition transformer R Boiler thermostate or pressure switch BV1 Gas Solenoid Valve LK Damper motor RV Modulating Gas Solenoid Valve M Burner motor FS Flame signal Working diagram is given ab...

Page 22: ...ic cover by unscrewing the 3 screws Determine the below defined error types from the indicator on LFL 1 322 2 Press once on the indicator placed on the control unit This will reset the control unit Be...

Page 23: ...tion to the burner must be done via placing the gasket 1 between the gas line 3 and the flange using the washers 6 and bolts 7 which are supplied along with the burner as shown in the relevant figure...

Page 24: ...temperature value after setting of the RFW40 is done as indicated in below titles BOILER CONTROL UNIT RWF50 Boiler Control Unit works as a boiler thermostat for modulating burners Air damper adjustmen...

Page 25: ...system has three Levels beyond the Basic display The User Level The Parameter Level The Configuration Level The setting principle is shown below It will be referred in further pages RWF50 MENU SYSTEM...

Page 26: ...26...

Page 27: ...mply wait 30 180 seconds and the controller will return to the basic display automatically Shown at the right is the User level display This level started from the basic display Setpoint SP1 and SP2 d...

Page 28: ...en Press Enter once and SP1 starts blinking The value can be set by using and and be confirmed by pressing The timeout period is 180 seconds and RWF 50 will accept the last confirmed value to be valid...

Page 29: ...y used and neccesary items are summarized in the below chart For further information please refer to the RWF 50 user s manual SELF TUNING FUNCTION FOR PARAMETER SETTING RWF50 parameter setting also ca...

Page 30: ...1 sensor usage For the selection of sensor analog input ConF InP1 4 should be followed i e the set value should be 4 SCL SCH Measured value limits SPL and SPH Setpoint value limits Configuration Param...

Page 31: ...control panel mustbe connected to the gas pressure switch as shown in the below table NO 2 GP Red COM 3 GP Red GAS PRES SW TIPS CONNECTI ON TIPS CABLE COLOR Key Functions Rising pressure 1 NC opens 2...

Page 32: ...der a certain value The adjustment value can be made as 3mbar or as 20 lower of the gas line inlet pressure corresponding to the min capacity of the burner Gas Pressure Switch Types DUNGS GW50A6 Setti...

Page 33: ...ly of Valve proving system VPS 504 SO2 are as follows Installation and Assembly 1 Turn off gas supply 2 Switch off power supply 3 Remove screw plugs 1 2 Fig 1 4 Insert sealing rings 10 5x2 25 into VPS...

Page 34: ...2 34 VALVE PROVING SYSTEM VPS 504 SO2 Dimensions Lockout Run...

Page 35: ...g the test Screw plug in the test socket p2 during the test time pumping time Replacing Filter Replace the filter Fitter replacement set art no 243 801 2 O Ring 2 Microfilter mats 4 screw Replace the...

Page 36: ...s wise Mount tension free Do not allow any direct contact between the VPS 504 and hardened masonry concrete walls or floors Always use new seals after dismounting and mounting parts Pipeline leakage t...

Page 37: ...F SETTINGS 37 Mounting Position Electric and Hydrolic Connections OPERATION AND ASSEMBLY GUIDELINES The important issues about the operation and assembly of Multiblock Servo pressure regulator MBC VEF...

Page 38: ...sure Page 9 PL Air pressure Page 9 PB Burner gas pressure Page 9 Effective burner pressure PB PB PF Effective fan pressure PL PL PF PL max 100 mbar PL min 0 4 mbar V PB PL Vmax 3 1 Vmin 0 4 1 Zero poi...

Page 39: ...stream of V1 possible on both sides 8 pa Test point connecion G1 8 downstream of V2 possible on both sides 9 Setting screw Zero point adjustment N 10 Setting screw Ratio V 11 Vent nozzle G 1 8 12 Pres...

Page 40: ...repeat settings 4 and 5 Check intermediate values 7 Seal setting screws with lead Warning Ensure optimum combustion and ignition reliability Screwing back After setting the required pressure point 1 C...

Page 41: ...on 1 Interrupt gas supply close ball valve 2 Remove screws 1 2 Figure 1 2 Change filter insert 3 3 Screw in screws 1 2 without using any force and fasten 4 Perform leakage and function test Pmax 360 m...

Page 42: ...e 3 5 Unplug the earth connection and conductive plate conneciton Figure 4 6 Change the solenoid Figure 5 Always check solenoid No And voltage 7 Make the power connections Make the mounting in reverse...

Page 43: ...sues about the operation and assembly of Double Solenoid Valve Gas Air Ratio Control MBC VEF are as follows MBC 1900 DN 65 MBC 3100 DN 80 GAS MULTIBLOCK MBC 1900 VEF MBC 3100 VEF SETTINGS 43 Installat...

Page 44: ...PL PF PL max 100 mbar PL min 0 4 mbar V PB PL Vmax 3 1 Vmin 0 75 1 Zero point correction 1mbar PB max 100 mbar PB min 0 5 mbar PF max 50 mbar PF min 20 mbar PL max 100 mbar PL Air PB min 0 5 mbar PB G...

Page 45: ...a lever MOUNTING 1 Insert setscrews A 2 Insert seals 3 Insert setscres B 4 Tighten screws A B Ensure correct sealing of the seal 5 Option externer impuls Attach pulse lines PBr PL PF 6 After installa...

Page 46: ...900 VEF MBC 3100 VEF SETTINGS 46 Allen Key No 2 5 MBC VEF SETTING THE PRESSURE CONTROLLER Pressure controller is provosionally set at the factory The setting value must be locally adapted to the machi...

Page 47: ...asonry concrete walls or floors Ensure that no condensate flows back from the pulse line to the MBC Always use new seals after dismounting and mounting parts Pipeline leakage test close ball valve ups...

Page 48: ...s such as NG or LPG The following points are followed for turbulator change Dismount the Multiblock 1 Unscrew the bolts 2 between the burner body 12 and connection body 13 Burner is rotated via its hi...

Page 49: ...upwards to unmount it from the connection body Take the turbulator gas supply pipe 3 out as seen in Figure 3 Unscrew the electrode bolts 6 and loosen the electrodes 5 Figure 4 Unscrew the 2 bolts 8 an...

Page 50: ...he modulating gas line 2 from the connection body Remove the gasket 1 between the connection body and gas line Mount the new gasket 1 comes with the new gas line between the connection body and gas li...

Page 51: ...rol box are checked The electrical box can opened via unscrewing the 3 M5 bolts on the protective cover Figure 1 51 WARNING Disconnect the power supply before starting the maintenanace Burners and rel...

Page 52: ...by the below RFI filter models in accordance with the related issues of 2004 108 EC EMC Directive The appropriate filter should be mounted to the entrance of the RWF 50 or the main supply line used bu...

Page 53: ...53 WIRING DIAGRAMS RWF50 ALG 200 M and ALG 200 M LPG...

Page 54: ...54 WIRING DIAGRAMS RWF50 ALG 120 M and ALG 120 M LPG...

Page 55: ...WIRING DIAGRAMS SDC 12 31 ALG 200 M and ALG 200 M LPG...

Page 56: ...56 WIRING DIAGRAMS SDC 12 31 ALG 120 M and ALG 120 M LPG...

Page 57: ...id valves Check the min 200V of power supply c 1 Set the main solenoid valve regulated and the safety valve fully open c 2 Clean c 3 Check the min 200V power supply d Check the ignition transformer e...

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