Astra G-50 Installation And Operation Manual Download Page 17

17

INSTALLATION AND OPERATION MANUAL

The circulation pump control thermostat SK2 (Fig. 6) is also located inside the front control panel and is not observable 

from the outside. It has two functions: 1. Turn on the circulation pump when the water temperature in the boiler reaches 
60° C, 2. Turn on the ventilator if the button 4 (Fig. 10) is in the 60-90° C position and the water temperature in the boiler is 
higher than 60° C. Consequently, this thermostat will switch off both the ventilator and the circulation pump, when the water 
temperature in the boiler drops below 60° C. To learn more about the control devices of the front control panel, please, refer 
to the chapter “Kindling procedure of the boiler”.

• ReaR conTRol Panel

The following safety devices are installed in the rear control panel: thermal fuse 1 and electric fuse 2 (Fig. 10). The purpose of 

the thermal fuse, otherwise called the maximum boiler temperature emergency thermostat, is to switch off the boiler ventilator if 
water temperature in the boiler exceeds the maximum permissible 95°C due to unforeseen reasons. The temperature sensor of the 
thermostat is installed in a dedicated sleeve 16 (Fig. 1). The burning intensity decreases when the ventilator is switched off and the 
water temperature decreases. When the emergency thermostat trips, the lamp of the ventilator switch 3 on the front panel switches 
off (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 
operating mode. For this purpose, unscrew its cover and depress the red button.

 The cause of overheating of the boiler and tripping of the emergency thermostat must be found 

and removed. If this is not done, the risk of serious damage to boiler 

equipment as well as hazard to human health and life remains. If the 

user cannot locate and remove the cause of tripping of the emergency 

thermostat, a professional servicing company must be consulted!

The electric fuse is designated to protect the elements of the electric circuit in case 

the current in the mains exceeds 2 A. If the fuse is damaged, the boiler will not switch 
on and its indicator lamps will not light. In this case, remove and replace the fuse.

The rear control panel of the boiler is grounded.

• PRePaRaTIon foR fIRInG

Before kindling the boiler, check the position of the ceramic chopper 2 in the lower combustion chamber: the edge of the 

chopper must be in contact with the rear wall of the boiler (Fig. 2). Place two ceramic segments 3 (Fig. 2) on the chopper so 
that they contact the walls of the boiler chamber.

Fill the heating system with water. The filling pressure should be 0.2 bar bigger than the hydrostatic pressure, yet it must 

not exceed the operating pressure of the boiler. After filling the system with water, perform a visual check of the tightness of 
the entire system. Perform it before kindling the boiler, then again after kindling and reaching the nominal operating mode. 
Check if the heating system is properly deaerated.

• KInDlInG PRoceDURe of THe boIleR

Before kindling the boiler, check whether all requirements indicated in the section 1 are executed.
Open the damper of the upper flue 19 by pulling the handle 3 (Fig. 1) towards yourself. Open the door of the upper 

combustion chamber, put dry smaller kindling wood pieces and paper on the ceramic bottom so that the paper protrudes into 
the lower combustion chamber through the rectangular opening of the ceramic burner 1 (Fig. 2) – this way, it will be easy 
to kindle the boiler through the lower combustion chamber. Put some of the easily flammable materials and larger pieces of 
kindling wood and firewood atop. Load the wood without any large gaps at the top of combustion chamber. Bigger pieces of 

1

2

fig. 11 Rear control panel

1. Thermal fuse ; 2. Electric fuse.

Summary of Contents for G-50

Page 1: ... 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: ...lator 12 Regulation of the Secondary Air Damper 13 Controlling the Temperature of Water Returning to the Boiler 13 Heating Output Water Temperature and Water Flow Relationship 13 Installation of the Boiler Room 14 Requirements for the Chimney 14 6 FUEL 15 7 OPERATION 16 Front Control Panel 16 Rear Control Panel 17 Preparation for Firing 17 Kindling Procedure of the Boiler 17 Fire Bed and Tips for ...

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: ...damper 10 Ventilatorand ventilatorductinspectionaperture 11 Returnwaterpipe 12 Waterdrainnipple 13 Connectionsofthecoolingserpentine 14 Fluepipe 15 Fluecleaning cap 17 Safetyventilatorshutdown95 Cthermostatsensor 18 Watertemperaturesensor 19 Uppercombustionchamberopeningtotheflue 20 Primaryairinletnozzle 21 Secondaryairinletopening 22 Ceramicburner 23 Ceramicchopper 24 Ceramicsegment 25 Openingtot...

Page 5: ...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 50 Level of electric protection of the boiler IP30 Dimensions height mm 1315 width mm 660 depth mm 1230 Weight of boiler kg 505 Threaded con...

Page 6: ...annel firstthelowerpositionisfound andafterslightly loosening the poker yet without removing it from the hole the plate is allowed to descent onto the opposite side of the heat exchanger due to the force of gravity until it touches the wall of the heat exchanger with itsuppersupports Thenthetoolcanberemovedandthenextplatecan beinstalledinasimilarway Turbulence plates decrease the temperature of th...

Page 7: ...ATION 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 istransportedinotherthanverticalposition decorativesurfacesmaybedamaged claddingbattered controlandregulation equipmentbroken built inceramicins...

Page 8: ...the flow of cold water from the public water supply network through the coolingserpentine whereitabsorbstheexcessiveheatenergyand flowsoutintothesewage Thesensorofthevalvewiththeexternal thread isscrewedontothesocketontherearwalloftheboiler Technical data of the thermostatic safety valve are the following Opening temperature 95 C Maximum operating temperature 110 C Operating pressure 10 bar Bulb o...

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: ...e boiler as possible at a location easy to reach by hand pressure relief valves and control devices must conform to the following technical characteristics Instrument Technical characteristics Type of boiler Pressure relief valve Connectiondiam doesnotexceed setopeningpressure3bar Astra G 50 Thermometer manometer Range of temperature 0 120 C pressure 0 4 0 bar All boilers There must be no ball val...

Page 11: ...ion pump of the heating system U water temperature sensors Inordertoguaranteenaturalwatercirculationofwaterintheboiler thepipeworkbetweentheboiler and the mixing valve in the line boiler mixing valve boiler is to be of the same diameter and correspond to the diameter of the connection pipes of the boiler Circuit Diagram of the Boiler 1 2 3 4 5 6 7 8 9 10 11 12 N L N1 L15 N1 L12 M P N L P N 220V P ...

Page 12: ...e tee 1 Fig 8 present in the supply set on the boiler flow pipe 6 Fig 1 Then install the draught regulator 2 Fig 8 into the lateral pipe of the tee Connect the lever of the draught regulator with the ventilator lid When the temperature of the water in the boiler rises the lever descends and the main air supply damper 4 cloaks the opening of the air duct thus restricting the air supply to the combu...

Page 13: ... device opens completely However the actual temperature of the water returning from the system and getting into the boiler after mixing is 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...

Page 14: ...r foritsservicingandcleaning Thefloorundertheboiler withinthedistanceof50cminfrontofitand withinthedistanceof30cmaroundtheboilershouldbemadeofinflammablematerials Screwsupportinglegsontothebaseof theboilerandleveltheboilerwithscrewnutsusingalevel thenconnecttheheatingsystemcirculationpumptotheboiler The smoke exhaust pipe of the boiler should be connected to the chimney through a metal duct The in...

Page 15: ... be damaged if they are removed every day when cleaning thustheirlifetimewillbeshorter Therefore werecommendusageoffuelpeatbriquettesonlyinrare exceptionalcases Itisrecommendedtofiredryfirewoodwithamoisturecontentof12 20 Thedrierthefirewood thelargeritscalorificcapacity When the moisture content of the firewood is 20 the heat potential of 1 kg is approximately 4 kWh when the moisture content is 50...

Page 16: ...definedinthenextway first turn thethermostatknobtomaximum Then setthedraughtregulator2 Fig 8 tothetargetedtemperature forexampleto75 C Start the boiler and allow it to reach a 75 C temperature Then turn the thermostat knob in the direction of the lower temperature until you hear a click sound Turn the knob a little bit further and mark this position on the knob case with a pencil Now you have foun...

Page 17: ...o boiler equipment as well as hazard to human health and life remains If the user cannot locate and remove the cause of tripping of the emergency thermostat a professional servicing company must be consulted Theelectricfuseisdesignatedtoprotecttheelementsoftheelectriccircuitincase thecurrentinthemainsexceeds2A Ifthefuseisdamaged theboilerwillnotswitch onanditsindicatorlampswillnotlight Inthiscase ...

Page 18: ...screwing the hinge and lock screws of the door Fire Bed and Tips for Effective Boiler Stoking The hot embers and charcoal in the boiler are called the fire bed Combustible gases emerge from there and are further burnedinthelowerchamberoftheboiler Theoptimalfirebedheightduringboileroperationisapproximately4 5cmabove the bottom of the fuel chamber The output of the boiler ventilator is deliberately ...

Page 19: ... the thermometer 2 Fig 10 The firing is active if the temperature of water in the boiler exceeds approximately 60 C The flame in the boiler can be checked by opening the door of the lower combustion chamber when the ventilator is on The visible tongue of flame has to be yellow or yellow red and reach the ceramic element this means the firing is proceeding in an optimal manner Donotkeepthelowerdoor...

Page 20: ...rn 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 No draught in the chimney due to accumulated impurities Clean The ceramic burner is congested Clean Ventilator damper is stuck Move or clean 2 Smoke escapes through the ...

Page 21: ...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 connectedtotheheatingsystemandoperatedfollowingtherequirements of this manual The warranty does not apply in the f...

Page 22: ...ate of sale Signature BOILER INSTALLATION PROTOCOL Boiler was installed by Company technician Address Telephone Installation date Installation data Height of the chimney Diameter of the flue Draught of the chimney Otherinformationconcerninginstallation The boiler was tested on site the control and safety elements were checked and found to be operating properly Person responsible for installation a...

Page 23: ...AIR CARD Boiler repaired by Company technician Address Telephone Repair date Informationonfault worksperformed Signature of the technician Boiler repaired by Company technician Address Telephone Repair date Informationonfault worksperformed Signature of the technician ...

Page 24: ...onformtotherequirementsofdirectives97 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 60529 ProcedureofconformityevaluationinaccordancewithArticle2 3of97 23 EECwasperformedby Inspecta www inspecta com Certification No 2 4 2 1 619 2012 Alytus 201 date Gražvydas Eimanavičius project manager LT ...

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