User Manual
Contents
1. Name of the boiler Boiler Ochag 2 Ochag 3 Ochag 5 Ochag 6 Geyser 9 5 Vulkan 25 characteris tics norma therm al protec tion of premis es 5 Max 9 1 137 22 7 373 13 7 227 37 5 curren t streng th of the boiler on each phase A curre nt freque ncy 50 Hz 6 N 10 16 25 32 3x16 3x25 3x40 ominal curren t streng th of the autom atics A electro mecha nical model 7 c 4 4 4 6 ross sectio 220 V n of curren tcarryi ng copper conne ction cable core sq mm 380 V 9 Max 90 operat ing temper ature of the heattransfe r agent on the Name of the boiler Boiler Ochag 2 Ochag 3 Ochag 5 Ochag 6 Geyser 9 5 Vulkan 25 characteris tics outlet of the boiler C 10 Recom 20 40 25 50 30 60 35 70 50 100 100 200 150 300 mende d volume of the heattransfe r agent in the heating system liters 11 Nomin 25 25 25 25 32 32 32 al diamet er of couplin gs for connec ting to the heating system mm 12 Class of gt protect ion against electric shock hazard 13 Constr IP X3 splash proof uction by moistu re proofin g degree 14 Length 250 275 320 335 360 410 460 mm 15 Weight 0 85 0 9 1 05 1 1 5 0 5 3 5 7 kg 16 It is recommended to use the following types of liquids as heat transfer agents for al2. OCHAG GEYSER VULKAN ELECTRODE BOILERS OPERATION MANUAL The given Operation manual contains basic information relating to the practical use of the electrode boilers for the heating systems By the aggregative technical and economic indices of effectiveness including the boiler efficiency simplicity of installation and repairing cost of heating of one square meter of the apartment specific consumption of materials per 1 kW of the boiler capacity etc the electrode boilers cannot be compared with any other type of the electric boilers The areas of application of the electrode boilers continue to extend confidently This Operation manual is intended for the electrode boiler installation specialists experts in the installation of the automatic control systems for the electrode boilers starting up and adjustment specialists experts in maintenance and repairing and owners of the boilers We thank in advance those who will send remarks and proposals to the address of the Firma GALAN Joint Stock Company All rights reserved None of the parts of the given Operation manual can be reproduced in any form without written permission of the Firma GALAN Joint Stock Company which is a copyright owner Introduction Invention of the electrode boiler is a one of the highest achievements in the area of creation of the multipurpose heating equipment A long term experience of successful operation shows that electrode b
3. Electromechanical model of the automatics Preparation and putting into operation Connect the boiler to a power network in accordance with the type and power of the boiler Diagram 1 or Diagram 2 The Inlet temperature sensor as a rule is installed on the pipeline The Outlet temperature sensor is installed on the pipeline coming from the boiler at 30 cm from the boiler outlet The sensors connecting is performed by means of the copper cable wire with cross section of 0 5 2 5 sq mm A circuit breaker is an automatic safety device which comes into action on current overload It is used for switching on and switching off the power supply of the boiler A button which is located on the automatic tripping contactor case is used for switching on and switching off the thermal relay Under normal operation of the power supply diagram of the boiler this button is always in the on pressed condition The actuating of this button signifies that consumption current exceeds the nominal current because of the malfunction of the boiler or the power supply diagram or because of the water electrical resistance is equal to 3100 Ohm cm at temperature of 4 15 C The thermal relay can be switched on by pressing the button Set up a value of the required temperature on the outlet of the boiler 65 75 C Set up a value of the required temperature on the inlet of the boiler This value depends on the size of the heated space quality of the th
4. Irrespective of the way of connecting the boiler to the heating system the boiler should be fastened to a wall in the process of the assembly Some of the key diagrams of the heating systems arrangement are depicted in Figures 1 2 3 For the easy maintenance of the heating system it is necessary to locate the shutoff valves on the pipeline right after the surge tank and before the inlet connection of the boiler see Figures 1 2 3 It is strictly forbidden to install valves and other regulating or locking mechanisms on the pipeline between the boiler outlet connection and the surge tank Electrical installation of the boilers and automatics Three phase electrode boilers are connected to the four wire three phase power network the voltage of which is equal to 380 V Industrial frequency of the current is equal to 50 Hz N is a neutral conductor and PE is a protective conductor of grounding N and PE conductors are decoupled Single phase electrode boilers are connected to the single phase power network the voltage of which is equal to 220 V N is a neutral conductor and PE is a protective conductor of grounding N and PE conductors are decoupled Connect the electrode boiler to the power network in accordance with the project documentation of your heating system and the chosen model of the automatics produced by the Firma Galan Joint Stock Company The observing of the Phase Null Ground is obligatory Cross section of all
5. There is no mud and rust in the heating system In this case a process of filling a heating system with heat transfer agent is performed without preliminary washing It is necessary to observe the following rules The heating system should be disconnected from the power network before the filling a heating system with water or low freezing liquid It is necessary to exclude unintentional connection to the power network It is necessary to check leak resistance of the heating system right after filling a system with heat transfer agent Any leakages are inadmissible It is possible to fill a heating system with the Galan Potok low freezing liquid or with water Table 1 Water as a heat transfer agent has a number of indisputable advantages such as availability cheapness and ecological compatibility Also water has good thermal properties Nevertheless water has some disadvantages such as heating system corrosion possible necessity for water specific electrical resistance correcting annual boiler repair etc Therefore we recommend you to use the Galan Potok modern low freezing liquid as a heat transfer agent for a heating system instead of water which also can be used for this purpose Galan Potok low freezing liquid A universal Galan Potok low freezing liquid the freezing temperature of which is equal to 40 C is designed with the aim of improving the reliability and economic efficiency of a heating system operatio
6. contain an industrial dust in quantities adversely affecting the boiler operation There are no combustible materials in the construction of the boilers therefore our boilers are fireproof Boilers meet the requirements of the Technical Specifications TS No 3468 00117289826 02 Order designations Galan XXX N electrode boiler XXX is a name of the boiler Annotation is a power of the boiler in accordance with the Table 1 Example Galan Ochag 6 electrode boiler All of the Ochag Geyser and Vulkan electrode boilers described in the Table 1 are certified Number of the certificate of conformity POCC RU ME71 H00072 dated 29 03 05 The Certification authority The Electrical Products Certification Authority of the Independent Noncommercial Organization on Certification of the Electrical Products 109052 Moscow ul Nizhegorodskaya 29 Voluntary certification Technical characteristics of the boilers produced by the Firma Galan Joint Stock Company Table 1 Name of the boiler Boiler Ochag 2 Ochag 3 Ochag 5 Ochag 6 Geyser 9 Geyseri5 Vulkan 25 characteris tics l d 8 120 175 200 340 550 850 ize of the heated space cubic meter s 2 N 2 3 5 6 9 15 25 ominal power consu mptio n kW 3 wN 220 220 220 220 380 380 380 ominal voltag e V 4 0 5 0 75 1 25 1 5 2 5 4 6 6 pproxi mate energ Y consu mptio n kW h with
7. of goods by means of the given type of transport Transportation conditions in a part of the influence of mechanical factors should meet the requirements of the C group of the All Union State Standard No 23216 78 Transportation conditions in a part of the influence of the environmental factors should meet the requirements of the 5 group of the All Union State Standard 1 transportation 2 3 No 15150 69 4 Storage conditions of the boilers should meet the requirements of the 3 group of the All Union State Standard No 15150 69 List of possible malfunctions and malfunction repair Possible malfunction Probable cause of malfunction Method of malfunction repair 1 The boiler is not switching on The automatic circuit breaker comes into action Short circuit in electric system because of incorrect boiler connection The water electric resistance is significantly lower than 3100 Ohm cm at temperature of 15 C Call the electrician Check the correspondence between assembled electric diagram and the diagram described in the given Operation manual Check the value of the starting current strength Perform the correcting procedure as may be required 2 The heating system is not heated is slightly heated High specific electric resistance of water The specified heat transfer agent temperature is lower than the required temperature Boiler connection diagrams and radiators installati
8. the boiler and outgoing out of the boiler plastic pipes with not zinc coated black pipes It is possible to increase the power of the heating system repeatedly by using parallel connection of number of the electric boilers For example the connection of 8 boilers the power of which is equal to 25 kW increases the total power of the heating system to 200 kW Fig 2 It is forbidden to use electrode boilers For the direct water heating the heating system is filled directly with water which is taken from basin well water well hole water supply line or river Our boilers are used only in the looped heating systems working without extraction of hot water The characteristics of water which is used as a heattransfer agent should meet the requirements specified in the boiler s Operation manual Non observance of these requirements results in the boiler breakage e For warm floors construction The temperatures required for the warm floors construction are considerably lower than the optimal operating temperatures of the electrode boilers For this reason a boiler is not brought to nominal power We recommend you to use highly reliable modern tubular electric heating boilers produced by the Firma Galan Joint Stock Company for warm floors construction It is not recommended to use electrode boilers in the heating systems in which large heating radiators radiators which use pipes of big diameter cast
9. the clean container Annual tasks providing electrical safety and reliability of the automatics Annually after the ending of the cold season it is necessary to perform the tasks providing electrical safety and reliability of the automatics irrespective of the kind of the heat transfer agent which is used in the heating system water or low freezing liquid It is necessary to disconnect the heating system from the power network to perform the following tasks providing electrical safety and reliability of the automatics e Checking the reliability of the grounding contacts and the automation unit e Checking the value of resistance of the heating system grounding This value should be no more than 4 Ohm e Examination of the automatic switch which includes dusting terminal connections checking terminal connections tightening electrical contacts checking e Checking of the automatic tripping contactor which includes dusting visual examination cleaning and tightening of the terminal connections electrical contacts checking installation checking and serviceability checking e Examination of the start buttons Examination of the installed automatics Istopnik 103 Istopnik 203 Navigator Galan GSM Dusting electrical contacts checking installation checking and serviceability checking The tasks specified above are performed by the electricians or control equipment and automatics specialists of the corresponding qualifica
10. the using of automatics which includes the Navigator Istopnik 103 electronic temperature regulators Istopnik 203 electronic programmable temperature regulator Galan GSM cellular monitoring system of the heating equipment and electromechanical model of the automatics Also this advance has come about through the high performance of the electrode boilers Simplicity of installation compact size and light weight For example the weight of the boiler the power of which is equal to 6 kW comprises 1 1 kg and the weight of the boiler the power of which is equal to 25 kW comprises 5 7 kg It is possible to build our electrode boilers in earlier installed heating systems also as secondary reserve boilers by using parallel connection under the condition of obligatory performance of our recommendations Fig 3 The power of the reserve boiler should correspond to the size of the heated space quality of the thermal protection and volume of the heat transfer agent in the heating system Table 1 In case of installing of the reserve boiler in running heating system it is necessary to perform the following tasks o wash the heating system carefully by means of the Galan Protektor rust inhibitor o To filter the heat transfer agent o To take measures for preventing ingress of contamination from the heating system to the boiler and to install the filters It is necessary to replace some meters of the ingoing into
11. THE COUPON No 1 For warranty repair maintenance service Date of withdrawal Executor Sold by the shop last name name surname Name of the shop Address of the shop Date of sale u n Performed tasks Executor Owner last name name and signature surname 23 Name of the company performing the warranty repair Place of the seal Post and signature of the director of the company performing the warranty repair Service department Moscow ul Marshala Novikova 2 tel 499 196 04 40 499 196 04 41 At will of the customer the acquisition and delivery of components of the heating system installation on a turn key basis warranty and after guarantee services are provided COUPON No 2 Electrode heating boiler COUNTERFOIL OF THE COUPON No 2 For warranty repair maintenance service 0 Date of withdrawal Executor Sold by the shop last name name surname Name of the shop Address of the shop Date of sale u n Performed tasks Executor Owner last name name and signature surname Name of the company performing the warranty repair Place of the seal Post and signature of the director of the company performing the warranty repair 24 Service department Moscow ul Marshala Novikova 2 tel 499 196 04 40 499 196 04 41 At will of the custom
12. astic cover Before the installation procedure it is necessary to examine the boiler and to check the completeness of the equipment The boiler is installed only vertically into the heating system A terminal group current leads of the boiler protected from the external influence or casual touching by the protective housing should be located at the bottom of the boiler A phase terminal of the Ochag 220 V electrode boilers should be located at the bottom of the boiler It is necessary to use couplings for connecting the boiler connections to the pipelines of the heating system A nominal diameter of these couplings should meet the 10 project documentation requirements of your heating system and should be no less than the nominal diameter of the boiler connections In the course of the heating system designing it is necessary to install the boiler as low as possible in relation to the radiators This increases a pressure on the boiler outlet It is desirable to allow vertical clearance for easy removing the electrode group from the boiler and for visual examination and cleaning of the internal surfaces of the boiler The diameter of vertical standpipe above the boiler and the diameters of all of the pipelines of the heating system should meet the project documentation requirements of your heating system The height of vertical standpipe above the boiler should be no less than 2 m It is a reason for abandoning a use of the circulation pump
13. corresponding license for performing these tasks On completion of the preventive maintenance the organization firm which has performed these tasks should make an entry in the List Appendix No 2 which is assured by the person responsible for performing these tasks and by the seal of this organization The preventive maintenance is performed after termination of the cold season The periodicity and composition of the preventive maintenance is defined both by the heattransfer agent used in the system and by the defects detected during the operating and inspection of the heating system and the boiler Water as a heat transfer agent Annually right after the ending of the cold season it is necessary 6 To cool the heating system to the room temperature draw off 20 liters of water from the system to dissolve a dose of the Galan Protektor in this volume of water 1 5 liters of inhibitor per 100 liters of water to stir carefully and to fill the heating system with this mixture through the drain valve by means of the Malysh type pump Draw off 20 liters of water from the system once again and fill the hating system with water without inhibitor Perform these tasks up to the complete filling of the heating system with mixture of water and inhibitor For washing the system it is necessary to keep it working through 6 days with the temperature of the return pipe of 35 C During this period the washing of the system and the corros
14. d its further operation e Give the internal surfaces of the boiler case a mirror like polish The internal surfaces should be inspected for absence of defects such as point corrosion etc e Assemble the boiler The boiler assembling should be performed with scrupulous attention to alignment between electrodes and to alignment between electrodes and the boiler case By this is meant that equal spacing should exist between electrodes and between electrodes and the boiler case Exclude the ingress of contamination into the boiler in the course of the boiler assembling Check leak resistance of the boiler Install the boiler only vertically into the heating system Fill the heating system with heat transfer agent The surge tank should be one thirds full of the heat transfer agent On completion of the tasks listed above it is necessary to check leak resistance of the heating system tightening of the bolted and electrical connections reliability of grounding connection value of the electric resistance of grounding and reliability of automatics Perform a trial start of the heating system Correct the detected malfunctions as may be required A person responsible for performing these tasks should make an entry in the List of the performed maintenance functions assure it by his own signature and by the seal of the firm organization and to write the address and license number of the firm organization Appendix No 2 Galan Potok low freez
15. e boilers Ochag 2 Ochag 3 Ochag 5 and Ochag 6 electrode boilers e Three phase electrode boilers Geyser 9 Geyser 15 and Vulkan 25 electrode boilers Single phase electrode boilers consist of the following components e Metal case with inlet and outlet connections a case functions as the second electrode and ionization chamber Rod electrode with current lead and hermetic electric bushing insulator Two terminal groups with protective housings phase terminal is located at the bottom of the single phase electrode boiler neutral wire terminal and ground wire terminal are on the side of the single phase electrode boiler Three phase electrode boilers consist of the following components Metal case with inlet and outlet connections a case functions as ionization chamber Base on which three electrodes with current leads and hermetic electric bushing insulators are installed Terminal group with protective housing The operating principle is the same for all electrode boilers It is discussed below Advantages of the electrode boilers The electrode boilers of the Firma Galan Joint Stock Company are 2 3 times cheaper than the boilers of the same power produced by other manufacturers and have the following significant advantages Significant energy conservation is achieved by high electrode boilers efficiency which reaches 9896 By this indicator electrode boilers surpass the existing heating boilers
16. ease the water specific electrical resistance hereinafter referred to as correcting procedure for providing the electric boiler operation with nameplate rating Correcting adjustment of the water specific electrical resistance is performed after filling a heating system with water by adding sodium salt solution or water with high electrical resistance to water In this way table values of the starting current strength and maximum current strength Table 2 at specified return pipe temperatures are reached It is necessary to pay scrupulous attention to the instructions of the given Operation manual e The temperature on the inlet of the boiler Inlet sensor should lie in the range 15 20 C The boiler switching on durability should not exceed 30 seconds Correcting procedure Switch on the boiler and measure starting current strength by ammeter or splitelectromagnetic instrument after 30 seconds at the return pipe temperature of 15 20 C There are three possible situations value of the starting current strength is lower higher than the table value specified in the Table 2 or value of the starting current strength is equal to the table value specified in the Table 2 Table 2 No Boiler brand name Power Voltage Phases Starting current strength of Max current strength of of the boiler kW the boiler at the return the boiler in the pipe temperature of 15 specified mode at the C A return p
17. er as a heattransfer agent Filter plugging The Outlet sensor comes into action only in case of emergency or malfunction of the heating system The Istopnik 103 electronic room temperature indicator and the Istopnik 203 electronic programmable room temperature indicator are used only in conjunction with the Navigator control unit Relative to the Inlet and Outlet sensors of the Navigator control unit which are installed on the pipeline the Istopnik 103 and Istopnik 203 temperature regulators are mounted directly in the heated premises This increases the effectiveness of the heating system and makes the heated premises more comfortable Set up the required temperatures in accordance with the operation manuals of these devices Contrary to the Istopnik 103 the Istopnik 203 is a programmable device by means of which it is possible to program or to specify the required room temperature changes by hours of the day or by days of the week The Galan GSM cellular monitoring system of the heating equipment makes it possible to specify and maintain the necessary temperature indoors This system makes it possible to connect four additional sensors security sensor gas leak sensor water flooding sensor etc The Galan GSM cellular monitoring system of the heating equipment is used in conjunction with the Navigator control unit Perform the installation in accordance with the Galan GSM and Navigator operation manuals
18. er the acquisition and delivery of components of the heating system installation on a turn key basis warranty and after guarantee services are provided List of the performed maintenance functions Date description maintenance functions of the License number address signature of the person responsible for performing maintenance functions Seal of the company organization which has performed the maintenance functions 25 Delivery and sale certificate The electrode boiler meets the requirements of the Technical Specifications TS No 3468 001 17289826 02 Date of issue Seal of the Quality Department Sold Date of sale Place of the seal 26 l AJIAH MUP TETUIA and GALAN WARMWORLD are registered trade marks of the Firma GALAN Joint Stock Company Central department Phone 499 196 04 40 196 04 41 123098 Moscow m Shchukinskaya ul Marshala Novikova 2 building 1 http www galan ru e mail office galan ru MAXIMUM WARMTH MINIMUM COSTS OUR COMPANY PERFORMS THE DESIGNING INSTALLATION ON A TURN KEY BASIS AND WARRANTY SERVICE OF THE HEATING SYSTEMS WATER DISTRIBUTION SYSTEMS AND SEWERAGE SYSTEMS 27
19. eration manual The contents of this offered model of the automatics can be altered Installation of the electrode boiler into the heating system The heating systems designing boilers and automatics installation tasks power network and grounding connection tasks putting into operation and repairing tasks equipment examination and testing tasks should be performed by the organization firm having the corresponding license for performing these tasks On performing the tasks listed above the provisions of the following documents should be observed e Inter branch rules for electric installations User rules for operating electrical equipment e Safety rules for operating electrical equipment User and safety rules for operating electric boilers and boiler houses The given Operation manual Also it is necessary to observe the provisions of the corresponding Construction Regulations and Rules and the Fire prevention rules of the Russian Federation It is necessary to employ the electricians or control equipment and automatics specialists of the corresponding qualification for connecting the boiler installing the automatic control systems for the heating equipment and performing the servicing and repairing tasks 9 These specialists should be certified by the electrical safety rank which is no less than a rank of 3 and should be allowed to work with electrical installations operating at the voltage up to 1000 V To perfo
20. ermal protection of the apartment etc and ranges as a rule from 35 to 45 C 14 Diagram 1 No Name of the device Wire OCHAG boilers 220 V 2 kW 3 kW 5 kW 6 kW Circuit breaker 10A 16A 25A 32A Automatic tripping contactor size 2 up to32A 2 1 Automatic tripping contactor coil 220 V 2 2 Thermal relay contacts normally closed Inlet temperature sensor Outlet temperature sensor laid on bimetallic thermostat Boiler 2 3 5 6 kW Boiler terminals Ammeter or power level indicator Cross section of the copper connecting wire sq mm 4 15 17 Diagram 2 Name of the Boilers 380 V No device 2 2 2 Wire Geyser Geyser Vulkan 9 kw 15 kw 25 kW 1 Circuit breaker 16A 25A 40A 2 Automati 6 size 2 tripping up to 25 3 contacto A NO A r 2 1 Automati 380 V 380 V C tripping contacto r coil 2 2 Thermal relay normally closed contacts 3 Inlet temperature 4 ae laid on bimetallic thermostat temperature sensor 5 Boiler bottom view 7 6 Boiler terminals Cross section of the copper connecting wire sq mm 4 4 6 Filling the heating system with heat transfer agent Your heating system is mounted The boiler and automatic control equipment are installed The heating system is connected to the power network and to the grounding
21. esh water internal surfaces of the boiler mirrorlike polish Guarantee commitments 1 The guarantee period of operation comprises 12 months from the date of sale The boiler life comprises 10 years under condition of the correct boiler operation in accordance with the given Operation manual and periodical every 3 5 years replacement of the electrodes 3 The guarantee commitments are applied to the boiler which is installed by the specialized organization which has contractual relationships with the manufacturer under condition of obligatory filling of the boiler installation coupon 4 The guarantee commitments are applied to the boiler during the course of guarantee period of operation The operation and preventive maintenance are performed in accordance with the given Operation manual 5 The manufacturer does not bear responsibility for the boilers operation in the following cases The heating and electric diagrams do not correspond to the diagrams specified in the given Operation manual The boiler is purchased without automatic control system recommended by the Firma GALAN Joint Stock Company The boiler has mechanical damages The boiler worked at the temperatures exceeding the temperatures recommended by the given Operation manual or by means of the heattransfer agents which are not recommended by the Firma Galan JointStock Company COUPON No 1 Electrode heating boiler COUNTERFOIL OF
22. g Geyser and Vulkan instantaneous electrode heating boilers produced by the Firma Galan Joint Stock Company hereinafter referred to as boilers are used only in the looped heating systems working without extraction of hot water for household industrial or any other purposes These heating systems work on the basis of the compulsory circulation of the heat transfer agent by means of the circulation pump According to the recommended most economic mode the temperature on an inlet of the boiler should lie in the range 35 45 C and the temperature on an outlet of the boiler should fall in the range 65 475 C These boilers are made only in Russia The specified temperature in the heated premises is supported by the automatics by means of the temperature regulator The boilers have a long operating mode For normal operation of the boiler the following conditions are necessary Operation air temperature of the premises in which the boiler is installed should lie in the range between 10 to 35 C ultimate air temperature of the premises in which the boiler is installed should fall in the range between 10 to 40 C under condition of absence of other requirements Relative humidity of an air at the temperature of 20 C should be no more than 75 Non explosive environment the environment should not contain aggressive gases and steams destroying metal and isolation the environment should not
23. ing liquid as a heat transfer agent In this case the preventive maintenance of the boiler is performed one in every three years between the cold seasons The examination and checking of the tightening of the bolted and electrical connections and the reliability of grounding connection are performed yearly A procedure of performing the preventive maintenance is similar to the procedure described above which is performed in case of using water as a heat transfer agent with the exception of washing the system that is not performed and with observance of the safety measures The washing of the system is not performed because the Galan Potok low freezing liquid contains rust prevention additives and components against formation of scum and scale It is necessary to clean the boiler and its components of low freezing liquid carefully by flushing with water before performing the boiler repair Visual examination of the boiler operation This task can be performed by the instructed persons no younger than 18 years old These specialists should be acquainted with the given Operation manual and the boiler construction It is necessary to monitor the volume of the heat transfer agent in the heating system by its level in the surge tank during visual examination of the boiler operation The surge tank should be one thirds full of heat transfer agent under normal conditions If level of the heat transfer agent in the surge tank is lower than the specified v
24. ion protection inhibition of the external surfaces of the system take place At this time it is necessary to clear the filter periodically After six days of operating the heating system it is necessary s To disconnect the heating system from the power network To cool the heating system to the room temperature To draw off water from the heating system completely This water cannot be reused If required the procedure can be repeated It is necessary to examine and check the tightening of the bolted and electrical connections and the reliability of grounding connection 19 Boiler repair Remove the boiler from the heating system Remove the electrode group electrode from the boiler case Decontaminate the internal surfaces of the boiler Be convinced of absence of any defects It is necessary to perform the following tasks in the course of the boiler repair Remove an electrode of the single phase electrode boiler or electrode group of the three phase electrode boiler from the boiler case Electrode or electrode group should be inspected for absence of defects cracks of the bushing insulators etc and for evaluation of electrodes wear In case of a wear comprises more than 40 the electrode electrodes should be replaced Traditionally this happens every 3 5 years e Clean the mating surfaces carefully for providing leak resistance which is achieved by applying sealing materials in the course of the boiler assembly an
25. ipe temperature of 60 C A 1 Ochag 2 2 220 1 4 9 1 2 Ochag 3 3 220 1 5 13 7 3 Ochag 5 5 220 1 10 12 23 4 Ochag 6 6 220 1 15 18 27 5 Geyser 9 9 380 3 6 8 per phase 13 7 per phase 6 Geyser 15 15 380 3 8 10 per phase 23 per phase 7 Vulkan 25 25 380 3 12 15 per phase 37 per phase Value of the starting current strength is lower than the table value specified in the Table 2 17 The correcting procedure of the starting current is performed in the following way e Clear sodium salt solution is prepared 1 teaspoon of sodium salt is dissolved in 200 grams of hot water This is an approximate volume of the solution per 100 liters of water filled in the heating system Single dose of the salt solution which is filled in 20 liters of water drawn off from the heating system is defined depending on the difference between measured value of the starting current strength and it s table value Table 2 for your boiler power of your boiler and the volume of water filled in the heating system Stir the dose of the salt solution and the water drawn off from the heating system carefully e This mixture is filled in the heating system through the drain valve by means of the Malysh type pump Draw off 20 liters of water from the system once again and fill the heating system with water without salt solution e Switch on the circulation pump for 20 30 minutes Running time of the circulation pump depends on the
26. iron radiators etc are installed In this case we also recommend you to use tubular electric heating boilers produced by the Firma Galan Joint Stock Company If you need to use electrode boiler by force of circumstances it is necessary to provide the conformity of volume of the heat transfer agent filled in the heating system to the boiler power Table 1 Besides in case of using cast iron radiators it is necessary to install a strainer or mud settler in the return pipe to prevent the situation in which the remaining volume of the core sand with the heat transfer agent is brought into the boiler from the cast iron radiators resulting in the boiler breakage With that end in view it is necessary to wash cast iron radiators carefully before installing them into the heating system Recommended complete set of delivery Boiler as an assembly 1 item The electrode boiler operation manual and reference guide 1 item e Automatics 1 complement e Automatics operation manual 1 item e Package 1 item Note One of the models of the automatic control units produced by the Firma Galan Joint Stock Company is chosen The warranty is not applied to the boiler which is purchased without this automatic control system The electrode boiler cost does not include a cost of the automatic control unit With the exception of the operation manual for electromechanical model of the automatics which is a part of this Op
27. l of the Ochag Geyser Vulkan electrode boilers of the Firma Galan Joint Stock Company which are listed in this table e Galan Potok low freezing liquid with special rust prevention components and additives against formation of scale and scum freezing temperature 40 C life expectancy no less than 5 years warranty period 1 year hereinafter referred to as low freezing liquid e Potable water defined by the Sanitary Regulations and Rules No 2 1 4 559 96 distilled water snow melt water rain water filtered water the specific electric resistance hereinafter referred to as resistance of which is no less than 1300 Ohm cm at a temperature of 15 C ATTENTION It is strictly forbidden to use low freezing liquids antifreezes such as TOSOL Arktika Tvoy Dom etc as heat Name of the boiler Boiler Ochag 2 Ochag 3 Ochag 5 Ochag 6 Geyser 9 Geyseri5 Vulkan 25 characteris tics transfer agents since they are not intended for a use by the electrode boilers The Firma Galan Joint Stock Company regularly performs technological improvements of electric boilers therefore their technical characteristics can slightly differ from characteristics resulted in the table above Boilers construction Depending on the boiler power the electrode boilers produced by the Firma Galan Joint Stock Company fall into the following categories e Single phase electrod
28. means of the Malysh type pump after each addition of salt solution or water with high specific electric resistance to the heating system Switching on the boiler Switch on the boiler and establish the most careful control over the boiler s automatic switching on and switching off It is inadmissible to switch on the boiler at presence of the frozen heat transfer agent in the system or in danger of freezing the heat transfer agent The temperature of the premise in which the heating system is installed should lie in the range 15 20 C In case of the heating system and the electrical connection diagram for the equipment including automatics are mounted correctly the system will start to get warm In case of gradual power decreasing of the boiler at the initial period of work fresh water as a heat transfer agent it is necessary to perform the following steps e Remove the boiler from the heating system e Disassemble the boiler and decontaminate the surfaces of electrodes and internal surfaces of the boiler e Assemble the boiler and install it into the heating system Preventive maintenance Washing of the heating system The purpose of this task consists in providing the reliable effective and long term work of the heating system The task is performed by the qualified personnel The heating system should be disconnected from the power network The preventive maintenance is performed by the firm organization having the
29. mplished and tested grounding The value of resistance of the boiler grounding and the value of resistance of the heating system grounding should be no more than 4 Ohm The copper wire with the cross section of 4 6 sq mm is used as the conductor for the grounding Table 1 The arrangement of the protective grounding should meet the requirements of the Inter branch rules for electric installations and the User and safety rules for operating electric boilers and boiler houses All of the open current conducting parts of the boiler and heating system including metal pipelines for the cold return pipe and hot heat transfer agent should be grounded The place of entering of the conductors into the building or construction should be marked by the identification sign Grounding electrodes The construction of the grounding electrodes should meet the requirements of the Inter branch rules for electric installations The construction and arrangement of the grounding electrode should provide the required value of resistance of the boiler grounding and the value of resistance of the heating system grounding which is no more than 4 Ohm The periodical review period of grounding electrode state comprises 12 years The rusting wear should not exceed 50 It is forbidden to paint the grounding electrode and to safeguard the grounding electrode against rust by means of the removable or permanent dielectric coating for example rubber or pl
30. n Low freezing liquid has special additives against formation of scum and scale on the walls of the heating system Also the Galan Potok low freezing liquid includes the additives used for inhibition of corrosion and for scale dissolving The application of low freezing liquid saves from danger of unfreezing the heating system in the event of sudden power supply disconnection Also the usage of low freezing liquid significantly simplifies a heating system servicing because the parameters and properties of low freezing liquid completely meet the requirements of the heating system with electrode boiler The application of low freezing liquid significantly improves the economic and performance indicators of the heating system In particular the usage of low freezing liquid simplifies the execution of starting up and adjustment reduces the time intervals for performing these tasks provides the stable operation of the heating system and reduces the expenses for the heating system servicing Filling a heating system with low freezing liquid There is no mud and rust in the heating system The heating system is filled with a measured volume of low freezing liquid through a drain valve by means of the pump for example by means of the Malysh pump After performing of exhaustion of an air from the heating system the filling of 1 3 of surge tank volume is accepted as normal Water as a heat transfer agent It is necessary to reduce or to incr
31. of other types This advance has come about through the direct transformation of electric energy to thermal energy in the heat transfer agent during the passage of electric current through the heat transfer agent Under these conditions the ionization of the heat transfer agent takes place The temperature and electrical conductance of the heat transfer agent grow The strength of electric current passing from one electrode to another grows too The electrode boiler is brought to nominal power quickly The pressure of the heat transfer agent on the boiler outlet comprises up to 1 atm without usage of the circulation pump This advance has come about through the using of ionization chamber of small size which provides a sharp heating of the heat transfer agent and through the using of a standpipe which is installed at a height of no less than 2 m above the boiler The dy value of the standpipe depends on the power of the boiler For example for the boiler the power of which is equal to 25 kW the dy value of the standpipe should be no less than 40 mm A possibility of working without circulation pump depends on the floor on which the heated space is located and on the configuration of the heating system Therefore our electrode boiler is at once a heating device and a circulation pump This results in considerable savings of customer expenses The saving of power consumption ranges from 40 to 60 This advance has come about through
32. oiler is equal to the value specified in the Table 2 Value of the starting current strength is higher than the table value specified in the Table 2 In this case it is necessary to add water the specific electric resistance of which is significantly higher than a value specified in the operation manual This may be distilled water clear uncontaminated filtered rain water snow melt water Potable water with high specific electric resistance Table 1 can be also used A volume of water which is added to the heating system depends on the volume of water filled in the heating system A procedure of adding water with high specific electric resistance to the heating system is similar to a method of adding salt solution in the event that the starting current strength and the maximum current strength are lower than the value specified in the Table 2 A volume of water with high specific electric resistance which is added to the heating system should be equal to a volume of water drawn off from the system If the heating system works without circulation pump a value of the specific electric resistance can be changed by the following ways Increase the number of single additions of salt solution or water with high specific electric resistance to the heating system 18 Decrease the salt solution doses or volume of water with high specific electric resistance added to the heating system Increase the volume of water pumped to the surge tank by
33. oilers are easy operating reliable and safety devices The boiler efficiency reaches 98 This is a result of application of one of the best achievements of the domestic defensive industry in peace purposes Throughout many years the boilers of the Firma GALAN Joint Stock Company are successfully applied in almost all regions of the Russian Federation Post Soviet republics and other foreign countries Dear customer To use a complete set of advantages of our boilers and to avoid possible annoying errors in the process of installation of the heating system and boilers and in the course of starting further operation and usage of the electric boilers we convincingly ask you to familiarize yourself attentively with the given Operation manual which contains information relating to the characteristics construction operating principle application and rules of installation of the electrode boilers Also this Operation manual contains basic requirements imposed on the safety measures installation operation and repairing of the heating system registration and maintaining of the working documentation etc The boilers are intended for heating of apartment houses including country houses cottages multistory apartment houses garages baths premises and buildings of the domestic household trading public industrial and agricultural purpose and also other constructions in absence or inefficiency of the centralized heating The Ocha
34. olume a specialist of the firm organization serving a system should perform one of the following procedures depending on a kind of the heat transfer agent 20 a Water as a heat transfer agent Add distilled water clear uncontaminated filtered rain water or snow melt water water the specific electric resistance of which significantly exceeds 3100 Ohm cm to the surge tank until a normal level will not be reached b Low freezing liquid as a heat transfer agent Add distilled water clear uncontaminated filtered rain water or snow melt water water the specific electric resistance of which significantly exceeds 3100 Ohm cm and lowfreezing liquid in the 3 1 ratio to the surge tank until a normal level will not be reached It is necessary to disconnect the heating system from the power network to perform this task The boiler should be switched off immediately in the following situations e Voltage absence e Heat transfer agent leak e Presence of the frozen heat transfer agent e Grounding malfunction e Appearance of moisture on a boiler shell or on the automatic equipment Circulation pump malfunction In case of heating system malfunction you should call the specialists of the firm organization serving your heating system Before their arrival you should act according to the given instructions In case of threat of unfreezing of the heating system you should draw off the heattransfer agent water from the heating system to
35. on diagrams do not correspond to the diagrams described in the given Operation manual Pay scrupulous attention to the recommendations of the given Operation manual for the heattransfer agent Increase the specified temperature of the heat transfer agent Put the connection and installation diagrams into correspondence with the diagrams described in the given Operation manual Presence of air locks in the heating system because of incorrect installation Power of the boiler does not correspond to the power of the connected heating devices radiators convectors etc Correct the mistakes in the boiler installation Fill the heating system with heat transfer agent through the drain valve under pressure Put the power of the boiler into correspondence with the power of the connected heating devices 3 The boiler consumes nominal power but only the standpipe is heated Disruption of the heat transfer agent circulation Presence of air locks in the heating system Clean the heating system Wash it carefully by means of the GalanProtektor rust inhibitor Usage of the strainer is mandatory It is necessary to clean the strainer periodically Remove the air locks 22 4 In due course the boiler wastes Presence of contamination rust and Give the electrodes and the internal its power gradually under condition scale on the electrodes and on the surfaces of the boiler case a of using fr
36. rature range of the adjustable hysteresis of the Navigator temperature regulator This temperature range stretches from 1 to 9 C A hysteresis setting for the Outlet sensor as a rule is equal to 9 C A hysteresis setting for the Inlet sensor is strictly individual for every heating system It is defined both by the objective factors for example match between the heat losses of the heated premises and the power of the heating system and by the subjective factors for example requirements on the comfort of the heated premises requirements on the operating economy of the heating system With the exception of particular cases in the course of the cold season the hysteresis settings as a rule are not changed The boiler is switching off as a rule by the command of the Inlet sensor 13 In case of emergency or malfunction of the heating system in consequence of deterioration of the heat transfer agent circulation or increase of temperature on the outlet of the boiler the boiler is switched off by the command of the Outlet sensor The boiler is switching off by the command of the Outlet sensor in the following cases Circulation pump stop by reason of power network connecting wire break or rotor clogging Presence of the air locks in the heating system e Leakage of portion of heat transfer agent by reason of the heating system depressurization e Freezing of part of the heating system because of using wat
37. rm the installation operation and repairing of the heating systems it is necessary to employ the heating engineers The specialists listed above should be acquainted with the User and safety rules for operating electric boilers and boilerhouses and the given Operation manual In the process of working with rust inhibitor lowfreezing liquid washing and clearing agents it is necessary to follow the safety rules for using these substances On completion of the tasks listed above the organization firm which has performed these tasks should make an entry in the List Appendix No 2 which is assured by the person responsible for performing these tasks and by the seal of this organization Visual examination of the boiler operation can be made by the instructed persons no younger than 18 years old These specialists should be acquainted with the given Operation manual the boiler construction and safety rules for visual examination of the boiler operation Connecting the boilers to the power networks of the supply authority In case of the lack of the allocated power the boiler connecting is performed in accordance with the established procedure It is necessary to note that this procedure of connecting the electric boilers to power networks is applied to the electric boilers of other types and is not the distinctive feature of the electrode boilers Grounding By the time of boiler installation the heating system should have the completely acco
38. size of the heating system and the volume of water filled in the heating system The switching on of the circulation pump is required for equalization of the water parameters in the heating system e Switch on the boiler and measure starting current strength after 30 seconds at the return pipe temperature of 15 20 C e Switch off the boiler and compare the measured value of the starting current strength with the table value for your boiler Table 2 It is necessary to repeat the correcting procedure in the event that the measured value of the starting current strength is different from the table value During the execution of the correcting procedure the temperature on the inlet of the boiler should lie in the range 15 20 C It is necessary to switch on the heating system after equalization of the measured value of the starting current strength and the table value Once the temperature on the Inlet sensor has reached the value of 60 C measure the maximum current strength and compare it with the value specified in the Table 2 Perform the correcting procedure once again as the need arose It is necessary to note that the value of the starting current strength is a testing value which simplifies the process of performing the correcting procedure The correcting procedure is finished when the value of maximum current strength of the boiler at the temperature of 60 C on the inlet of the boiler on the Inlet sensor of the b
39. tion These specialists should be certified by the electrical safety rank which is no less than a rank of 3 and should be allowed to work with electrical installations working at the voltage up to 1000 V After the completion of these works the trial start of the boiler is performed On completion of these tasks the person responsible for performing these tasks should make an entry in the List of the performed maintenance functions assure it by his own signature and by the seal of the firm organization and to write the address and license number of the firm organization Appendix No 2 21 Fire safety In the course of performing the installation tasks starting up and adjustment and operating the electrode boilers it is necessary to follow the Fire prevention rules of the Russian Federation It is inadmissible To store bottles containing condensed or pressure gas inflammable liquids and materials fuels and lubricating oils gasoline acetone turpentine bitumen roll roofing kerosene oils in the premises where the boiler is installed To dry clothing on the electric boiler shell Transportation and storing of the electrode boilers The boiler should not be damaged and should be in operable state after the influence of the mechanical and environmental factors during the The boilers transportation can be performed by means of any type of the transport in the covered vehicles in accordance with the rules concerning the carriage
40. tion manual In case of applying copper stranded wire use a thimble but do not tin an end of the wire because it may bring into existence a bad contact Automatic control units of the heating systems produced by the Firma Galan Joint Stock Company In the course of starting up and adjustment tasks and on the basis of the specific situation the following temperatures are set on the Navigator temperature regulator Temperature on the outlet of the boiler a value belonging to the recommended optimal operating temperatures range which stretches from 65 to 75 C at which the boiler is switching off obligatory in any condition temperature which is set on the boiler outlet As a rule this temperature is equal to 470 C Temperature on the inlet of the boiler a value belonging to the recommended optimal operating temperatures range which stretches from 35 to 45 C at which the boiler is switching off obligatory in any condition temperature which is set on the boiler inlet A hysteresis setting specific number of Celsius degrees by which the temperatures on the inlet and outlet of the boiler should be decreased in comparison with the specified temperatures in order that the temperature sensors on the inlet and outlet of the boiler Inlet sensor and Outlet sensor should send commands for switching off the boiler is also set on the Navigator temperature regulator A value of the hysteresis setting belongs to the tempe
41. ulators Follow exactly the instructions of operation installation and safety control The Inlet temperature sensor is installed on the pipeline return pipe The Outlet temperature sensor is installed on the pipeline coming from the boiler vertical standpipe at 30 cm from the boiler outlet boiler connection The recommended optimal operating temperatures of the heat transfer agent on the inlet and outlet of the boiler are specified in the Introduction section of the given Operation manual The observation of these temperature modes assures the greatest effect of using the electrode boiler The range of thermoregulation of the Navigator temperature regulator on an outlet of the boiler stretches from 10 to 90 C Outlet indicator The range of thermoregulation of the Navigator temperature regulator on an inlet of the boiler stretches from 10 to 60 C Inlet indicator When employing the Istopnik 103 Istopnik 203 and Galan GSM temperature regulators the temperature is measured directly in the heated premises The usage of these devices increases the effectiveness of the heating system and makes the heated premises more comfortable Use a copper wire with a value of cross section lying in the range between 0 5 to 2 5 sq mm for installation of the automatic control unit of the heating system A wire make up should be specified in the project documentation of your heating system and in the automatic control unit opera
42. wires should be similar and no less than a value specified in the Table 1 electromechanical model of the automatics of the given Operation manual or no less than a value specified in the operation manual of the chosen electronic model of the automatic control unit of the heating system 11 Fig 1 Heating system with top pouring Fig 2 Parallel connection Electromechanical model of the automatics Label number Name of the equipment 1 Electrode boiler Radiator Surge tank Reserve electrode boiler 9r nce Main boiler running solid liquid or gas fuel Legend Laid on thermostat sensor Valve Filter mechanical mud settler Heat transfer agent drain valve Air drain valve Circulation pump power 70 or 100 W A Vertical settler of height which is no less than 2 m located above the boiler The diameter should meet the project documentation requirements of the heating system without circulation pump depending on the floor and the size of the heated premises B Difference in height no less than 1 5 m Fig 3 Reserve electrode boiler connection diagram 12 It is necessary to use the connection diagrams specified in the Operation manual to connect the Galan GSM cellular monitoring system of the heating equipment Navigator Istopnik 103 and Istopnik 203 electronic temperature reg
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