Astra G-120E Installation And Operation Manual Download Page 5

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INSTALLATION AND OPERATION MANUAL

• TECHNICAL DATA OF THE BOILER

Name of indicator

Indicator value

Astra G-120E

Nominal heat output, kW

120

Class of boiler according to EN 303-5

Class of protection against electric impact

Efficiency rate,%

81-89

Power of emergency cooling system, kW

Water volume in the boiler, l

241

Setting range of the temperature regulator, °C

65-90

Recommended draught, Pa

Working pressure of water in the system, bar, max.

3,0

Testing pressure of the boiler, bar

4,5

Max. allowable water temperature in the boiler, °C

108

Max. allowable operating water temperature in the boiler, °C

Electric characteristics:

voltage, V / frequency, Hz

220/50

average power used, W

150

Level of electric protection of the boiler

IP30

Dimensions:

height, mm

1490

width, mm

662

depth, mm

1730

Weight of boiler, kg,

868

Threaded connection diameter

1½"

Volume of fuel chamber, l

425

Dimensions of the loading aperture, mm

434x348

Flue gas duct diameter, mm

220

Length of wood pieces, mm

1000

Average temperature of the flue gases at the nominal heat output, °C

230

Summary of Contents for G-120E

Page 1: ...A MACHINERY PLANT AB ANNO 1929 CONTACT INFORMATION OFTHE FACTORY MACHINERY PLANT ASTRA AB ULONŲ G 33 LT 62161 ALYTUS LITHUANIA TEL 370 315 75449 FAX 370 315 52265 E MAIL INFO ASTRA LT WWW ASTRA GAS LT INSTALLATION AND OPERATION MANUAL ...

Page 2: ... Water Returning to the Boiler 12 Heating Output Water Temperature and Water Flow Relationship 12 Installation of the Boiler Room 13 Requirements for the Chimney 13 6 FUEL 14 7 OPERATION 15 Front Control Panel 15 Rear Control Panel 15 Electronic Boiler Regulator KR 4 4 16 Preparation for Firing 17 Kindling Procedure of the Boiler 17 Fire Bed and Tips for Effective Boiler Stoking 18 Regulation of t...

Page 3: ...sin from the boiler flues as instructed in this manual 1 7 The room where the boiler is installed should have fire extinguishing tools fire extinguishers sand box shovel and other tools 1 8 Do not place flammable materials on or near the boiler 1 9 Connect the boiler to the electric system only via a three pole plug plugged into an adequate three pole socket with earthing Protect connection cable ...

Page 4: ...gulation damper 15 Lid of the air supply duct 16 Return water pipe 17 Water drain nipple 18 Connections of the cooling serpentine 19 Flue pipe 20 Bleed valve 21 Flue cleaning cap 22 Decorative cover 23 Smoke temperature sensor 24 Sensor immersion pocket of the safety temperature limiter 95 C valve 25 Safety ventilator shutdown 95 C thermostat sensor 26 Smoke exhaust compartment 27 Smoke exhaust fa...

Page 5: ...f water in the system bar max 3 0 Testing pressure of the boiler bar 4 5 Max allowable water temperature in the boiler C 108 Max allowable operating water temperature in the boiler C 95 Electric characteristics voltage V frequency Hz 220 50 average power used W 150 Level of electric protection of the boiler IP30 Dimensions height mm 1490 width mm 662 depth mm 1730 Weight of boiler kg 868 Threaded ...

Page 6: ...ingtheturbulenceplates alwaysliftthemthetriangle part upside Theturbulenceplates2 showninFig 3 maintaintheirpositionintheflueduetotheir forceofgravityalone Theyareinsertedintothefluechannelorremovedusingapoker 3 whichisprovidedwiththeboiler Poker3 Fig 3 isbentatanangleofapproximately 80 tothehandle sothatthehookedplatedoesnotslideoff Inordertobeabletohook theturbulenceplate2withapoker aholehasbeen...

Page 7: ...duce the temperature of the smoke in the chimney it is sufficient to remove the ashes 1 2 times per week 4 TRANSPORTATION STORAGE UNPACKING Theheatingboileristobetransportedandpackagedinaccordancewiththedocumentationofthemanufacturer protected from precipitation and dust It can be transported only in vertical position fastened to avoid sliding and falling If the boiler istransportedinotherthanvert...

Page 8: ... boiler exceeds95 C thevalveautomaticallyopenstheflowofcoldwaterfrom thepublicwatersupplynetworkthroughthecoolingserpentine where it absorbs the excessive heat energy and flows out into the sewage Thesensorofthevalvewiththeexternalthread isscrewedontothe socketontherearwalloftheboiler Technical data of the thermostatic safety valve are the following Opening temperature 95 C Maximum operating tempe...

Page 9: ...h Membrane Expansion Vessel Thermostatic Mixing Valve Domestic Water Preparation From Water Supply Hot Water Air Outlet Other Notations Automatic Water Addition Valve Accumulation Tank Thermometer 3 Way Servo Drive Mixing Valve Return Overflow Valve Filter Heating System Supply Heating System Return Automatic Air Outlet Return Valve Valve Pressure Relief Valve Pump Thermometer Manometer Manometer ...

Page 10: ...snotexceed setopeningpressure3bar Thermometer manometer Range of temperature 0 120 C pressure 0 4 0 bar There must be no ball valves installed between the boiler and the pressure relief valve Water from the pressure relief valve should be conducted via an offtake pipe It should be conducted in a way that will allow the water passing through the pressure relief valve to flow safely avoiding exposur...

Page 11: ...n water pipe behind the mixing valve The electronic controller of the boiler controls the pump The circulation pump is connected to 1 2 N 3 L 4 L1 5 L1 6 L14 7 8 9 N 10 L3 11 N 12 L4 L1 N L2 L3 L4 M2 P N L P N L P N L X4 X2 X1 P L N L2 L14 L1 L U1 U3 U2 KR 4 4 S1 S2 SK F 220 V 2 N L 2A 2B 3 1 2 X3 1 1A 1B 3 1 2 1 C J M1 P L N L5 Fig 6 Circuit diagram of the boiler S1 power supply switch S2 fan swi...

Page 12: ... 5 6 C lower The higher the temperature of the return water is the better it is for the boiler Thermoregulation devices of other manufacturers could be used for maintaining the temperature of the returning water as well HEATING OUTPUT WATER TEMPERATURE AND WATER FLOW RELATIONSHIP The heating output supplied to a heating system depends directly upon the difference of flow and return water temperatu...

Page 13: ...pe of the boiler should be connected to the chimney through a metal duct The internal diameter of the metal connecting duct should be at least the same as the external diameter of the smoke exhaust pipe of the boiler To improve the draught the connecting duct between the boiler and the chimney should be installed at an inclination towards the boiler All junctions should be carefully tightened usin...

Page 14: ...100 200mm Thickerpiecesoffirewoodshouldbesplitatleastonce Upto 15 ofthefuelloadcanconsistoffinewoodensplintersandsawdust However theymustbeloadedinsuchawaysoasnot to block the opening of the ceramic burner 22 Fig 1 connecting the upper and lower chambers of the boiler Do not fire freshly prepared and excessively damp pieces of firewood The operation of the boiler becomes inefficient deposits of re...

Page 15: ...e decreases When the emergency thermostat trips thelampoftheventilatorswitch3onthefrontpanelswitchesoff Fig 9 and the lighting indicator bulb 4 Firing off on the electronic regulator lights up Fig 11 In this case it is necessary to find out the causes of tripping and to remove them After the boiler cools down the emergency thermostat can be returned to its normal operatingmode Forthispurpose unscr...

Page 16: ...ithin the range of 65 90 C Lamp3 Firingon indicatestheactivestatusoftheboiler Thislamplightsupwhentheventilatorisswitchedonusingthe button 3 Fig 9 on the front control panel and regulation of the ventilator speed starts The ventilator can be in operation mode only when the signal lamp 3 Fig 11 lights Lamp 4 lights up when the boiler turns to the mode Firing off This boiler operation mode is establ...

Page 17: ...deaerated KINDLING PROCEDURE OF THE BOILER Before kindling the boiler check whether all requirements indicated in the section 1 are executed Pull the handle 4 Fig 1 of the damper 11 Fig 1 towards yourself until it halts Turn the handle counterclockwise and release until it halts Fig 13 Open the upper boilerdoor Putsmallerpiecesofwoodandkindlingpaperontotheceramicinserton a bottom of a fuel chamber...

Page 18: ...ombustion of wood gases takes place Avoid a situation when the volume of the fire bed expands several times This situation can occur if very dry and thinly cut wood gets loaded into the fuel chamber Consequently the volume of the fire bed increases rapidly during the burning process and soon a lack of air occurs allowing the combustible gases to escape unburned through the chimney into the atmosph...

Page 19: ...a display and signals loading of fuel The air supply ventilator stops while the smoke exhaust ventilator turns on 2 Pull out the handle 4 Fig 1 of the dampers 11 Fig 1 in the way described in Fig 13 Open a door for loading 3 Load firewood into the boiler and close the door and the dampers 11 Fig 1 4 Resume the running boiler program by pressing shortly the ventilator button into the START position...

Page 20: ...he smoke temperature sensor will help to turn off the ventilator of the boiler and the circulation pump When the temperature of the flue gases drops bellow 75 C the rotational speed of the ventilator is minimized and after some more time the ventilator and circulation pump are turned off Ifyouthinkthatthatthesmoketemperaturesensorisunnecessaryforyourboiler youcaneasilyshutitoff Forthatpurpose take...

Page 21: ...set temperature cannot be reached Not enough water in the heating system Fill up Too low temperature of the return water Raise the return water temperature Thermoregulator or ventilator is defective Repair or replace Poor quality fuel high moisture content too large pieces of firewood Use dry fuel split firewood Heating surfaces of the boiler are very dirty Clean Nodraughtinthechimneyduetoaccumula...

Page 22: ...djustment works are not covered by the warranty the damage caused to the premises and the property in the premises due to the boiler fault will not be compensated the warranty repair works and replacement of parts during the warranty period are free the warranty period starts from the boiler purchase date thewarrantyisvalidonlyiftheboilerisinstalled connectedtotheheatingsystemandoperatedfollowingt...

Page 23: ...ephone Date of sale Signature BOILER INSTALLATION PROTOCOL Boiler was installed by Company technician Address Telephone Installation date Installation data Heightofthechimney Diameteroftheflue Draughtofthechimney Other information concerning installation The boiler was tested on site the control and safety elements were checked and found to be operating properly Person responsible for installation...

Page 24: ...he technician DECLARATION OF CONFORMITY Manufacturer Machinery plant Astra AB Address Ulonu g 33 62161 Alytus Lithuania Product designation heating boilers Astra G 120E Wedeclarethattheabove mentionedproductsconformtotherequirementsofdirectives97 23 EECArticle2 3and2006 95 EEC The following standards were applied for the above mentioned products LST EN 303 5 LST EN 12828 LST EN 60335 1 LST EN 6052...

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