SupeRAC Installation, Operating and Service Manual
Contents
1. convenient location on the top or side of the boiler casing panels The instrument capillaries must be carefully extended and located into the thermostat pockets adjacent to the flow pipe assembly on the boiler body Flue system SupeRAC Boilers are suitable for open flue type installations B23 taking air for combustion from the room in which it is installed the boiler plant room must be suitably ventilated The flue pipe and components serving the SupeRAC boiler must be suitable for working temperatures of not less than 250 C and should be thermally insulated The route of the flue short be as short as possible and sized appropriately to ensure complete evacuation of combustion gases without causing excessive back pressure The flue should generate sufficient draught to overcome its own resistance with a minimum negative draught at the boiler flue connection in the order of 10 30Pa lf the draught generated in the flue is likely to exceed 30Pa then a suitable draught stabiliser should be installed locally to the flue connection at the boiler The flue installation should comply with the requirements of the Clean Air Act 1956 BS 6644 BS5440 and IGE UP 10 as applicable 13 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 System water Care must be taken to ensure that system pipe work is cleansed and flushed prior to filling the boiler The system water must be treated with a good quality corrosion inhibitor and the w2. 5 80 80 100 100 125 125 125 6 mm_ 350 350 350 350 400 400 450 450 500 500 600 General regulations This documentation contains important information which is a base for safe and reliable installation commissioning and operation of the SupeRac Boiler All activities described in this document may only be executed by authorized companies Changes to this document may be effected without prior notice We accept no obligation to adapt previously delivered products to incorporate such changes Only original spare parts may be used when replacing components on the boiler otherwise warranty will be void Application The SupeRac Boiler may be used for heating and hot water production purposes only The boiler should be connected to closed systems with a maximum temperature of 100 C high limit temperature maximum set point temperature is 90 C Norms and regulations When installing and operating the boiler all applicable norms European and local should be fulfilled e Local Building regulations for installing combustion air and flue gas systems e Regulation for connecting the boiler to the electrical appliance e Regulations for connecting the boiler to the local gas network e Norms and regulations according to safety equipment for heating systems e Any additional local laws regulations with regard to installing and operating heating systems 92 42 EEC Boller efficiency directiv
3. MHS BOILERS elco SupeRAC Installation Operating and Service Manual Reversed Flame 3 Pass High Efficiency Steel Shell amp Tube Type Hot Water Boiler MHS Boilers Ltd 3 Juniper West Fenton Way Basildon Essex SS15 6SJ Main Tel 01268 546700 Spares Tel 01268 546771 Service Tel 01268 546770 Technical Help 01268 545772 Fax 01268 888270 WWW MHSBOILERS COM L315 SupeRAC For Models 93 to 4070 CONTENTS General descriptiQN ocooococcccocccocnconnconnonononnnonnnonnnanons page 3 Es AA nee ene eee Senne tne eect erent page 3 Clearances ori page 5 o A de E E E E E page 6 General regulations page 7 so AOS E E E E etait eu page 10 Installation page 10 LOCO EE E EE E A AEN page 10 Combustion chamber door opening and adjustment page 10 E PIA A o AA page 11 Prevention of UN oo page 11 ai a qe page 12 Fitting the case models 93 1045 oooccccccccoconccconncconononaninnos page 12 Mounting the control panel models 1220 4070 page 13 AA page 13 Sy SCR EL A A o A page 14 Control panel schemaltiC ccccooonccnccccoccnncccnonnncncnnconnnonaronnnnnos page 15 Preliminary IAE ind page 16 AA A E E E A syecaiesueceess page 16 META o 4 We ccs tiescanconentencintawstleemealeannomsdcweinteuaeaimnavinge apt page 17 Operation Cee sch snanndnen shbtrinimmuuaunbadncaideanesuateuniensl page 17 Notes page 19 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 General Des
4. age burners The left hand thermostat is for the control of the first stage low fire and should be set to the actual final wanted flow temperature the right hand thermostat is for the control of the second stage high fireO and should be nominally set around 3 5 degrees lower than the first stage thermostat to allow the burner to reduce to it s low fire setting as the final setpoint water temperature is approached MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Care should be taken to ensure that the controls are set to avoid that the water temperature within the system remains at a level where the return water temperature is less than 60 C for gas firing or 50 C for oil firing lf a modulating burner is being used then the 4 core burner connection lead 16 18 17 should be ignored and not utilised The thermostat sensing bulb for the OM stage control thermostat should not be located in the thermostat pocket and the temperature sensor supplied with the modulating burner temperature controls can be substituted into the thermostat pocket in place of the 2 stage thermostat sensing bulb MHS Boilers 11 09 2012 Notes SupeRAC For Models 93 to 4070 MHS Boilers 11 09 2012
5. and commercial premises IG UP 10 edition 3 Installation of gas appliances in Industrial and Commercial premises Part 1 Flued appliances Through their unique construction the SupeRac Boiler range of central heating units are renowned for their High thermal output Durability Can be supplied in a wide range of models 8 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Through active and market oriented research MHS Boilers Ltd is in a position to offer solutions for the most challenging heating requirements The supplier MHS Boilers Ltd are proud to supply and technically support the SupeRac Boiler Range of boilers throughout the United Kingdom For advice or more information please contact your local sales representative or our head office via 01268 546700 or via our website www mhsboilers com This document The present documentation has been prepared with the following target groups in mind The technical consultant The installer The maintenance technician The user MHS Boilers Ltd has opted to make the technical documentation as comprehensive as possible in the form of this book in order to ensure that these target groups have all the information they need As the supplier we would be happy to help you in connection with any additional information that you may require This document covers the following aspects relating to the boilers General description Technical specifications Requireme
6. ater condition must be maintained to ensure that the following values are observed pH 8 3 9 5 Hardness lt 100mg CaCO3llitre Chlorides lt 50mg litre Oxygen lt 0 1mgllitre Phosphates lt 30 mg litre It is strongly recommended to install coarse strainers to protect the boiler pumps valves etc from the effects of solid debris or particles within the system 14 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Control panel schematic TRE J TA I 3 Tid Te Te TB CT On Off Hi Lo 2 Stage Fig Supply 230V 1ph 50Hz To Burner IG Isolator TSAH Limit thermostat TR1 1 Stage thermostat TR2 2 Stage thermostat TA External enable contacts remove link if connected F Fuse 4A 15 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Preliminary checks before first firing Check that control panel instrument bulbs are correctly positioned in the thermostat pockets Ensure that the flue tube turbulators do not protrude from the front of the tubes and that no foreign objects are within the combustion chamber Check that any gaps between the burner blast tube and the combustion chamber door have been filled using high temperature ceramic fibre material Check that the system has been filled with water and is vented and that the pressure is above 1bar and within the maximum limits of the plant Ensure that an appropriately rated safety relief valve has been fitted and where necessary a pressu
7. cription The SupeRAC series of boilers are forced draught combustion type carbon steel shell and tube appliances with reversed flame principle Suitable for use with appropriate power flame burners with Natural Gas LPG Light or Heavy Fuel Oil or Biodiesel 23 models in the range with outputs from 93kW to 4150kW Working pressure 6bar or upon request to special order either 8bar or 10bar SupeRAC Models 93 1045 SupeRAC Models 1220 4070 Technical Data Model Output Input Combustion Efficiency net chamber resistance Gross kW kW mbar 100 SupeRAC93 93 103 S SupeRAC 105 1047 1155 07 I SupeRAC 150 1512 167 t2 J SupeRAC 190 192 20 09312 o SupeRAC 230 233 57 0 015 SupeRAC 290 29 320 23 I SupeRAC 345 349 884 33 SupeRAC 405 407 49 44 S d SupeRAC 465 465 5U 33 SupeRAC 520 523 57 43 o S SupeRAC 580 581 6397 48 SupeRAC 695 700 m 45 o S SupeRAC 810 820 89 56 I SupeRAC 930 940 107 0 54 SupeRAC 1045 1060 1156 60 I SupeRAC 1220 1240 139 65 I SupeRAC 1450 1480 1606 68 I SupeRAC 1860 1890 2056 70 SupeRAC 2100 2100 2282 T72 I SupeRAC 2330 2360 2570 72 I SupeRAC 2910 2960 3213 75 SupeRAC 3490 3550 8855 78 I SupeRAC 4070 4150 4497 90 I 3 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Technical Data SupeRac Mod
8. e 90 396 EEC Gas appliance directive 73 23 EEC Low voltage directive 89 336 EEC EMC directive EN 656 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 70 kW but not exceeding 300 kW EN 15420 Gas fired central heating boilers Type C boilers of nominal heat input exceeding 70 kW but not exceeding 1000 kW EN 15417 Gas fired central heating boilers Specific requirements for condensing boilers with a nominal heat input greater than 70 kW but not exceeding 1000 kW EN 13836 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 300 kW but not exceeding 1000 kW EN 15502 1 Gas fired central heating boilers Part 1 General requirements and tests 7 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 EN 55014 1 Electromagnetic compatibility Requirements for household appliances electric tools and similar apparatus Part 1 Emission EN 55014 2 Electromagnetic compatibility Requirements for household appliances electric tools and similar apparatus Part 2 Immunity Product family standard EN 61000 3 2 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions equipment input current 16 A per phase EN 61000 3 3 Electromagnetic compatibility EMC Part 3 3 Limitation of voltage changes voltage fluctuations and flicker in public low voltage supply systems for equipment with rated curren
9. ector hood clean out port A minimum of 450mm must be allowed at either side of the boiler s with attention being paid to the space required to fully open the combustion chamber door with the burner mounted upon it Clearance at the front of the boiler must allow for cleaning of the flue tubes which run horizontally for the entire length of the boiler minus the thickness of the combustion chamber door and the depth of the flue collector hood The clearance required at the front measured from the front of the boiler body excluding the door must not be less than dimension B1 in the following tables 5 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Dimensions A Ur SS mo Al A r Return connection Boiler shell Combustion chamber door a Fonccion Burner mounting plate Combustion chamber viewing port v Connection for safety valve Flue collector hood Flue collector hood cleaning access Condense drain Data plate 0 Control panel oO MO NOOR OND Model 93 105 150 190 230 290 345 405 465 520 580_ H mm 880 880 880 990 990 990 990 990 1150 1150 1150_ Ai mm 750 750 750 900 900 900 900 900 1000 1000 1000_ 65 80 80 80 1412 2 z 68 R Aw Hn R 6 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Model 695 810 930 1045 1220 1450 1860 2330 2910 3490 4070 v DN 65 65 65 6
10. el eo o Y litres poon o oo bar aena hal C 2 21 Weight empty 250 kg Nominal design flow rate At 10 C cd 2 l s Hydraulic resistance At 10 C 10 1 12 6 mbar Nominal design flow rate At 15 C i l s Hydraulic resistance At 15 C 4 mbar Nominal design flow rate At 20 C dl Ed l s 105 119 5 270 SupeRac Model litres epa e ep e e bar Minimum return water temperature C Weight empty 1310 1380 1440 1620 2200 Kg Nominal design flow rate At 11 07 cu o laa 16 66 19 52 22 38 25 23 29 52 10 Is A we eels fer fer lel ee fell ia 6 Nominal design flow rate At mbar Sal ll ad he i ae 157 ls acia il Ea Rel id al Hl mbar OO We 583 622 e91 833 976 1149 1261 1478 20 C l s Hydraulic resistance At 20 C 10 1 Md 10 1 mbar 3 83 28 91 15 7 4 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 SupeRac Model da MARA litres gnomes e B bar rame fe fae fel e le 6 ini AA ko Nominal design flow rate At 10 C 56 19 70 47 84 52 l s A AAA mbar Nominal design flow rate At 15 C 33 33 37 46 46 98 56 34 65 87 l s A an Ba ha Hydraulic resistance At 15 C ey 120 mbar Nominal design flow rate At 20 C 28 09 35 23 42 26 49 4 l s A ojej e mbar Clearances 121 3 49 54 17 6 30 2 Sufficient space must be allowed as necessary at the rear of the boiler for connection of the flue components and access to the flue coll
11. ered suitable The oil supply pipe should terminate adjacent to the burner with an isolating valve and should include metal bowl type filter Fitting the case Models 93 1045 See Fig 1 It is advised to complete the installation of the boiler before fitting the casing and control panel assembly Wrap the insulating blanket 1 around the drum of the boiler body making cuts apertures for the flow and return pipes as necessary Retain the insulation in place using the securing bands Next fit the left hand side casing panel 3 by locating the lower retaining bracket of the panel inside the lower lateral rail of the boiler body assembly and then hook the top part of the panel on to the upper structural rail of the boiler body Repeat for the right hand side panel 2 Temporarily position the top cover panels 4 amp 5 on to the top of the boiler unpack the control panel 6 and carefully extend the capillary tubes of the thermostats etc and pass them through the hole in the top cover panel 4 Insert the sensing bulbs of the instrument capillaries into the thermostat pockets adjacent to the flow pipe tube on the top of the boiler Secure the control panel to the top cover panel 4 and then finally locate the top casing panels 12 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Mounting the control panel Models 1220 4070 Mount the control panel using the supplied bracket on to the casing at a suitable and
12. es rods e Carefully offer up the door assembly and remount onto the tie rods and retain using previously removed nuts Release and remove any lifting alds equipment 10 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 To adjust and tighten the door e Slightly slacken back the jam nuts e Tighten the door evenly onto the front of the boiler body using the door retaining nuts capstans to form a gas tight seal e Re tighten as necessary the jam nuts back against the bush seating on the door assembly e Proceed to mount the burner following which check and adjust as necessary the fitting of the combustion chamber door against the boiler body Burner mounting Follow carefully the instructions supplied with burner The burner mounting plate must be cut and drilled as appropriate to the dimensions of the burner to be utilised It is extremely important that any space around the burner blast tube is packed with the ceramic fibre material supplied with the boiler Ceramic fibre material packed in to seal any gaps between the burner blast tube and the insulation pad on the combustion chamber door Boiler It is most important to ensure that the return water temperature entering the boiler is maintained above the dew point temperature of the flue gases An acceptable method of creating of this facility is to install a link pipe between the main flow and return pipes serving the boiler with a pump and a non return valve i
13. ncluded as shown above The pump needs only to be of a very low head and the flow rate should be in the order of 25 30 of the mass flow of the main boiler pump The anti condensation pump should be controlled by a thermostat mounted onto the return pipe adjacent to the return pipe connection of the boiler and the temperature setting should be nominally 60 C for gas firing and 50 C for oil firing 11 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Fuel supply Gas supply pipework must be in accordance with BS 6891 or IGE UP 2 The gas installation must be soundness tested to and purged in accordance with BS 6891 or IGE UP A IGE UP 1A Gas connections to the burner shall not be smaller than the connection size on the burner If a gas pressure booster is required refer to the manual supplied with the burner then the controls must include a low gas pressure cut off device at the inlet to the booster It may be necessary to install a governor between the booster and the burner gas train should the inlet pressure to the gas train exceed 50mbar The oil storage and supply system should be designed and installed in accordance with BS 5410 Part 2 If liquid bio fuel is being used ensure all components are suitable for such use Liquid bio fuel must be in accordance with BS EN 1423 The oil supply pipe between storage tank and burner should be installed using copper steel or aluminium pipe and fittings Galvanised pipes are not consid
14. nts for design and installation Maintenance instructions The operating instructions for the user have been affixed to the appliance itself Service For commissioning and assistance in maintenance matters please contact the Technical Services Department via 01268 546700 General restrictions MHS Boilers Ltd products should always be used installed and maintained in accordance with the statutory requirements specifications and standards applicable to these installations All the data information and suggestions concerning its products provided by MHS Boilers Ltd are based on careful study However the use installation and operation of the same are outside the control of MHS Boilers Ltd and neither MHS Boilers Ltd nor any other organisations associated with it accept any liability for the same 9 MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Handling Scope of Supply Models up to and including 1045 are supplied with the control panel insulating blankets ceramic fibre packing material for sealing around the burner blast tube and documentation packed inside the combustion chamber The casing and burner assembly are supplied in separate cartons Models 1220 to 4070 are factory pre insulated and have their casing panels fitted the control panel documentation and ceramic fibre packing material for sealing around the burner blast tube is packed inside the combustion chamber SupeRAC boiler models 1220 to 4070 are eq
15. re limiter Check that combustion chamber door has been closed correctly Check that pumps rotate freely and in the correct direction Check fuel supplies have been appropriately tested for soundness have been purged vented and the fuel control valve is closed Ask to view certificates Gas supplies should be tested and purged in accordance IGE UP 1 or IGE UP 1A as appropriate Check that the ventilation provision meets with the appropriate standards Check that the power supply is of the appropriate rating and adequately fused and that an isolator is positioned adjacent to the boiler Ensure a heat load is available Check that flue pipe is securely connected sealed onto appliance First start up Refer to the instructions supplied with the burner Check that appropriate sized nozzles have been fitted oil fired burner Check security and condition of flexible fuel lines oil fired burner Check electrode condition positioning and gaps as specified in the burner manufacturer s instructions Make burner pre settings for head positioning and air settings Attach oil pressure gauge to burner oil pump oil fired burner Ensure temperature controls are calling for heat Turn on fuel supply at isolating valve MHS Boilers 11 09 2012 SupeRAC For Models 93 to 4070 Turn on boiler at isolator and on off on boiler control panel the burner should start its start up and ignition process Check gas train gas burner and any pipe
16. t 16 A per phase and not subject to conditional connection EN 60335 1 Household and similar electrical appliances Safety Part 1 General re quirements EN 50165 Household and similar electrical appliances Safety Part 2 102 Particular requirements for gas oil and solid fuel burning appliances having electrical connections The following Codes of Practice are also applicable BS 6644 2011 Specification for gas fired hot water boilers of rated inputs between 70kW net and 1 8MW net 2 and 3 family gases BS 6880 1988 Code of Practice for low temperature hot water heating systems of output greater than 45kW Parts 1 2 4 3 BS 6891 2005 A2 2008 Specification for installation of low pressure gas pipework of up to 35mm R1 1 4 in domestic premises 2 family gases BS 7593 2006 Code of Practice for treatment of water in domestic hot water central heating systems BS 7671 2008 Requirements for electrical installations IEE Wiring Regulations Seventeenth Edition BS EN 12828 2003 Heating systems in buildings Design for water based heating systems CISBE Guide reference sections B7 B11 and B13 CP342 Part 2 1974 Code of Practice for centralized hot water supply IGE UP 1 or 1A Gas Tightness Testing Purging of Commercial Industrial Gas Installations IGE UP 2 Gas installation pipework boosters and compressors on Industrial and Commercial premises IGE UP 4 Commissioning of gas fired plant on industrial
17. uipped with lifting eyes to assist with the moving and handling of the boiler body Installation Location The location chosen for the installation of the boiler s must be flat and level to facilitate correct alignment of connections and must be capable of supporting the units when full of water The floor or plinth must be fireproof in accordance with BS 6644 The plant room must have sufficient space for the installation of the boilers associated pipework pumps controls flues ventilation and with due allowance to access and servicing of other pieces of equipment Adequate space must be provided around the boiler to allow the removal of the burner and opening of the combustion chamber door Combustion chamber door opening and adjustment The boiler is supplied with the door opening front left to right on models 93 to 2330 inclusive it is possible to reverse the opening To open the door remove the fixing nuts from the left hand side To reverse the direction of opening of the combustion chamber door it will be necessary due to the size and weight of door to utilise lifting gear e Attach lifting gear via the two holes in the upper part of the door assembly e Remove the 4 door retaining nuts e Carefully remove the door assembly and set to one side e Remove the jam nuts from the tie rods on the left hand side and transfer them to the rods at the right hand side positioning them approximately the same as when on the left hand ti
18. work between isolating valve and burner connection for leakage Check oil lines oil connections for soundness oil burner Adjust burner in accordance with the burner manufacturer s instructions and allow the burner to stabilise for approximately 10 15 minutes following which take measurements of combustion gases fuel throughput gas burner and making any further adjustments as necessary Record measurements Switch off boiler remove any gauges and refit test points Restart stop boiler several times to check integrity of ignition system Check combustion chamber door for correct sealing Check flue joints for integrity Check water connections for soundness For gas fired burner only with burner firing turn off gas supply and ensure burner goes to lockout Wait 45 seconds turn on gas supply and press reset button on burner ensure burner restarts normally Set controls to normal operational settings Instruct user on the operation of the boiler and its controls and safety functions User Instructions Following the successful installation and commissioning procedures the user must be made aware of the lighting and operating instructions including a practical demonstration This installation guide plus the burner instructions must handed over for safe keeping and future reference Operation Controls The control panel includes two control thermostats which allows for the operation of high low firing 2 st
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