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FTA Manual.pdf - Industrial Air

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YAKUT-ELMAS / YAKUT PLUS<br />

ELMAS PLUS SERIES<br />

BACK PRESSURE BOILER<br />

INSTRUCTIONS FOR INSTALLATION AND<br />

MAINTENANCE<br />

YAKUT YAKUT PLUS<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

ELMAS / ELMAS PLUS


Convenient Usage According to Conditions<br />

Table of Contents:<br />

1. About the <strong>Manual</strong>………....…….………………............................4<br />

1.1 Contents of the manual……..……………………….............4<br />

1.2 Symbols in the manual...…….……………..........................5<br />

1.3 Users………………………...……………………..................5<br />

2. Safety…..……………………………….……………………………...6<br />

2.1 Convenient Usage According to Conditions……………….6<br />

2.2 General security cautions .….….………………………......6<br />

2.3 Standarts and norms ……..………………………………... 8<br />

2.4 CE marking ........................................................................8<br />

3. Installation…………………...........................................................9<br />

3.1 Delivery Contents ......……………………………........……..9<br />

3.2 Space requirement for Yakut Elmas / Yakut Plus /<br />

Elmas Plus.......................................................................13<br />

3.3 Important Points for Mounting and Mounting Place……..14<br />

3.4 Protection against Corrosion...…………………................16<br />

3.5 Demands Related with Heating System Water….............16<br />

3.6 Gas Blown Burners…………………….......... .........……...17<br />

3.7 Related Demands for fuels that are used.........................17<br />

3.8 Turbulators………….........................................................18<br />

3.9 Before First Start-Up.........................................................19<br />

3.10 Water pressure control .....................................................21<br />

3.11 Control of the hot water tank ...........................................21<br />

3.12 Dimensions of the concrete base......................................22<br />

4. Mounting ...................................................................................23<br />

4.1 Casing mounting Yakut-Elmas/Yakut Plus/Elmas Plus....23<br />

4.2 Burner mounting.........................…………………….....….27<br />

4.3 Explosion cover mounting..……………………..............…30<br />

4.4 Control panel mounting.....…………...........................…..30<br />

5. Installation/System ...................................................................32<br />

5.1 Heating system connection...............................................32<br />

5.2 Control and filling of the system……..…...........................34<br />

5.3 Chimney connection.....................…........................…….37<br />

5.4 Installation of shunt pump.................................................39<br />

2 www.baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007


Table of Contents:<br />

CAUTION!<br />

6. Operation / Start-up....……........................................................40<br />

6.1 Operation / Start-up ………...............................................40<br />

6.2 Temperatures of installation water....................................41<br />

6.3 Emergency operation... ....................................................42<br />

6.4 Training of operator…....................................................…43<br />

7. Cleaning and maintenance…………………………....................44<br />

7.1 Cleaning.......…………………………………………...........44<br />

7.2 Maintenance…………………………………..……….........46<br />

8. Suggestions for energy saving…….........................................47<br />

8.1 Optimal heating...........................….............……..............47<br />

9. Important Cautions……………………………………….............49<br />

9.1 Important Cautions..........................................................49<br />

10. Technical Data.......................................................................... 51<br />

10.1 Technical Data................................................................51<br />

11. Certificate of Warranty....……………......………………............55<br />

Please read the guide before operating the Boiler . First start-up must be<br />

done by the authorized service.<br />

BAYMAK<br />

MAKİNE SANAYİ VE TİCARET A.Ş.<br />

Tepeören , Akdeniz Caddesi<br />

Orhanlı-Tuzla 34959 İSTANBUL<br />

Tel: (0216) 304 20 44-304 10 88 (pbx)<br />

Fax: (0216) 304 20 13<br />

http:// www.baymak.com.tr<br />

E-mail:yonetim@baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

3


About the <strong>Manual</strong><br />

1. About the <strong>Manual</strong><br />

Read the guide carefully before the boiler installation<br />

1.1 Contents of the manual<br />

This manual was prepared for Yakut – Elmas / Yakut Plus / Elmas Plus back pressure<br />

boiler series. The documentary list of the boiler series is on the below. Keep all the<br />

documents in the boiler room!<br />

Documantation Contents Users<br />

Technical Information<br />

Optional Control Panel<br />

<strong>Manual</strong><br />

Instructions for Installation<br />

and Maintenance<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

- Planning document<br />

- Technical data<br />

- Basic supplies and accessories<br />

- Applications<br />

- Parameter table<br />

- Wide processexamples and<br />

their connection plans<br />

- Electrical connection schemes<br />

- Circuit Plans<br />

- Explanation of the Functions<br />

- Programming<br />

- Error and fault tables<br />

- User settings<br />

- Explanation of the Functions<br />

- Programming<br />

- Error and breakdown tables<br />

- User settings<br />

- Convenableusage to norms<br />

- Technical data<br />

- Instructions, Norms, CE<br />

- Cautions for boiler settlement<br />

- Some examples of applications<br />

- First start up<br />

- Mounting/Installation<br />

- Operating<br />

- Cleaning/Maintenance<br />

- Operating<br />

- Cleaning/Maintenance<br />

System Designers<br />

Operaters<br />

Wiring specialists<br />

Operators<br />

Heating system<br />

specialists<br />

Operators<br />

4 www.baymak.com.tr


1.2 Symbols in the manual<br />

1.3 Users<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

About the <strong>Manual</strong><br />

Danger! Negligence of this warning creates danger for<br />

your body and life<br />

Electricshock danger! Negligence of this warning creates<br />

danger for your body and life due to electricshock.<br />

Attention! Negligence of this warning creates danger for<br />

ambient health and device.<br />

.<br />

Warning / Info : You can find special information and<br />

advices here.<br />

Reference to additional information in other documents.<br />

This installation manual is for heating expert who installs the heating system.<br />

5


Safety<br />

2. Safety<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Danger! Please pay attention to safety rules below.<br />

Otherwise you may risk lifes both yours and others<br />

2.1 Convenient Usage According to Conditions<br />

2.2 General Safety Cautions<br />

For operations with back pressure, these boilers are<br />

equivalent to DIN EN 303 / 304, DIN 4702 section 7.<br />

Danger! Please take into considirations the cautions<br />

on the boiler. Wrong operation of the boiler causes serious<br />

damages.<br />

Applications of first start-up, setting, maintenance<br />

and cleaning must only be done by authorized service.<br />

When breakdowns occur in the heating system,<br />

system must be shut down. Damaged components must be<br />

changed by authorized service stations.<br />

The accesories in the system must be suitable to<br />

technical rules, components in question must be approved<br />

by manufacturer relating to Baymak boiler.<br />

Connections sealed with bolt paint must not be<br />

pulled out by a person who is not expert or member of<br />

service! These seals prove that bolts which is necessary<br />

for perfect and safe operation has not been changed. If<br />

seals get damage, boiler will be out of warranty!<br />

6 www.baymak.com.tr


63 9810.0156 – Rev.04 –12/01/2007<br />

Safety<br />

Alteration, structural cursory modifications and all<br />

similar works are forbidden. These kind of modifications<br />

may be dangerous for people and cause damages on<br />

boiler. In case of neglagence of these subjects, boiler will<br />

be out of warranty.<br />

Obstruction of holes of air ventilation and air relief is<br />

dangerous and forbidden.<br />

Do not place easy explosive and ignitable materials<br />

near to boiler.<br />

Danger in case of gas smell! In case of existing gas<br />

smell, do not operate switches by electricity. Ventilate the<br />

room and shut down gas prevention mechanism. If the<br />

source of the smell can not be found, gas supplier<br />

administration must be informed.<br />

Poisoning Danger! Do not drink heating system<br />

water! Water is not clean due to precipitates.<br />

Caution! Safety valve and air release line must be<br />

open everytime because of water discharge for safety.<br />

Safety valve must be checked occasionally. Safety valve<br />

must be installed onto boiler directly and there must not be<br />

any other valve or equipment. All used equipment must be<br />

in accordance with CE standards.<br />

Electricshock Danger! Before protective hat and<br />

pieces of cover are taken out, all electrical connections on<br />

boiler must be disassembled. Works that will be done when<br />

electric is on, must be carried on by authorized people after<br />

all necessary precuations are supplied.<br />

Please read this manual before using the boiler.<br />

Start-up must be done by authorized service<br />

station. Otherwise boiler will be out of warranty.<br />

7


Safety<br />

2.3 Standarts and Norms<br />

2.4 CE MARKING<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

DIN 4109 Sound insulation in buildings;<br />

requirements and testing<br />

DIN 4755 Technical<br />

installation,<br />

regulation for oil firing<br />

DIN 4756 Gas usage applications for Heating<br />

DIN EN 267 Forced draught oil burners<br />

DIN EN 676 Automatic forced draught burners for<br />

gaseous fuels,<br />

EnEV Determinants of residential space<br />

heating expenditures<br />

DIN EN 12828 Heating systems in buildings ,<br />

DIN EN 12831 Heating systems in buildings design,<br />

DIN 1986 Drainage systems on private ground ,<br />

DIN 18160 Chimneys<br />

DIN 4753 Water heaters and water heating<br />

DIN 4705<br />

installations for drinking water and<br />

service water,<br />

Chimney systems<br />

EN 50165 Electrical equipment of non-electric<br />

appliances for household and similar<br />

purposes<br />

DVGW VP 113 Systems of gas appliances and flue<br />

gas piping<br />

Arrangements of Local Energy and Gas Distrubition<br />

Companies<br />

YAKUT boiler range is certified “CE” by French<br />

Notified Body (CERTIGAZ), satisfying the requirements of<br />

the following directives :<br />

GAD/90/396 CEE, BED/92/42 CEE, LOW VOLTAGE<br />

/73/23 CEE, EMC 89/336<br />

The boilers are tested according the following standards:<br />

EN303/1 - EN303/2 - EN303/3 - EN304 -<br />

EN304/A1<br />

These boilers must be equipped either with a forced<br />

draught gas burner or with a forced draught oil burner ,<br />

recommended by BAYMAK .These burners must be in<br />

conformity with the following standards:<br />

EN267 / EN676. The gas burner must be a EC burner.<br />

BAYMAK declares the conformity of all the<br />

boilers presented in this manual by referring to those<br />

which are tested for CE marking and also to GAD and<br />

BED directives.<br />

8 www.baymak.com.tr


3. Installation<br />

3.1 Delivery Contents<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Installation<br />

- 1 unit boiler body on transpalet with outside<br />

insulation packed with stretch film<br />

- Coat group in cardboard box that is ready for<br />

mounting, joint package that is necessary for fitting<br />

coat to the boiler.<br />

- Filed user and assemble manuel in boiler package.<br />

- Connection flange, mounted to the boiler, ready for<br />

welding, 2 unit ( Flange fits to boiler easily. There is<br />

no connection flange on Yakut Plus series)<br />

- 2 unit clingrite gasket, in accordance with connection<br />

flanges, mounted to the boiler ( in accordance with<br />

the boiler, There is no clingrite gasket on Yakut Plus<br />

series )<br />

- 8 unit M16x70 bolt, mounted to the boiler, in<br />

accordance with connection flanges.<br />

- 8 unit M16 washer, in accordance with connection<br />

flanges.<br />

- Ceramic wick for insulating the surroundings of<br />

burner (Ø22mm)<br />

- Ceramic blanket for insulating the surroundings of<br />

burner where is inside of the boiler.<br />

- Explosion cover mounted to the boiler,<br />

- Burner Connection Flange mounted to the boiler,<br />

Materials mentioned above are equipments that is<br />

delivered with boiler.<br />

9


Installation<br />

- Boiler body on transport palet with outside insulation. (Boiler is delevered<br />

with its insulation and in a position that is covered by stretch film)<br />

- 2 unit connection flange mounted to the boiler and ready for welding and 8<br />

unit M16x70 bolts, flanges, nuts and washers fitting to the flanges.<br />

10 www.baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007


63 9810.0156 – Rev.04 –12/01/2007<br />

Installation<br />

- 2 unit clingrite gasket fitting to the connecton flanges mounted on the boiler.<br />

- Ceramic blanket in boiler package for insulation the surroundigs of the boiler.<br />

- Explosion cover mounted to the boiler<br />

11


Installation<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Yakut/Yakut Plus<br />

Elmas/Elmas Plus<br />

12 www.baymak.com.tr


BOILER<br />

TYPE<br />

3.2 Space Requirement for Yakut Elmas / Yakut Plus / Elmas Plus<br />

Distance between back surface of boiler and wall must be minimum 0.8 meter.<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

ELMAS SERIE<br />

YAKUT SERIE<br />

Installation<br />

YAKUT PLUS<br />

SERIE<br />

YAKUT PLUS<br />

SERIE<br />

10 12 15 18 20 22 25 28 30 35 40 50 55 60 70 80 100 125 160 200 250<br />

X mm 600 600 600 600 750 750 750 750 750 750 1000 1000 1000 1000 1000 1000 1000 1200 1200 1400 1500<br />

Y mm 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 2000 2000 2000 2000 2000 2000 2200 2300 2300 2500 3000<br />

*) 0.5 meter distance is necessary from the<br />

sides for assembling of side casing.<br />

Besides, if the boiler is settled after assembling of<br />

side casing, this distance may be reduced.<br />

If settlement of boiler is done as burner opens<br />

towards wall, distance between boiler and wall depends on<br />

the burner dimension. Burner cover must be openable at<br />

least 90° to provide the easy cleaning of the boiler and<br />

easy removing process of turbulators.<br />

If burner is opened towards right side, hinge metal bars<br />

of the boiler cover must be installed to right side.<br />

13


Installation<br />

3.3 Important Points for Mounting and Mounting Place<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Caution! Subjects refering considerations during<br />

mountings related with operations of heating or a tank are<br />

below.<br />

To prevent from water damages that will occure due<br />

to especially water leakages in tank, convenable<br />

precuations must be taken for mounting. Drain lines and<br />

safety system must be suitable and checked periodically<br />

during first start-up and operation.<br />

Ambient where is boiler in must be dry and must not<br />

frost (between 0° and 45°).<br />

Operations about supplying required air to burn the<br />

boiler and discharging waste gas must be in accordance<br />

with CE standards and local distrubition companies that is<br />

responsible from that region.<br />

Place the boiler to a place such as rear balcony,<br />

larder, hall, boiler room. If the boier is in balcony,<br />

protect it from exterior factors. In case of settlement<br />

to bath or laundry, beware boiler not to get wet.<br />

Do not place the boiler to your bedroom!<br />

Settle the boiler onto concrete base. (See page<br />

25). Ambient where is boiler in should not be dusty and<br />

moist.<br />

Settle the boiler to a close place to chimney<br />

channel. Flue, going to chimney, must follow shortest line<br />

using minimum quantity of elbow. Do not install dump onto<br />

pipe. Chimney height must not be over 150 times of<br />

chimney hydraulic diameter.<br />

Chimney outlet must be 1 m. upper than ringe of<br />

roof. Horizontal flues must be connected to chimney with<br />

%5 slant and length must not exceed 1/4 of chimney height<br />

ever.<br />

Mount the chimney connection flue with an<br />

ascending slant towards chimney.<br />

14 www.baymak.com.tr


63 9810.0156 – Rev.04 –12/01/2007<br />

Installation<br />

Please take precuations to protect the boiler from<br />

back flow of water that occured as a result of liquifying of<br />

waste gases.<br />

It is an essential to comply with the procedures and<br />

standards about chimneys that gas distrubition companies<br />

and CE standards stated.<br />

Caution! Mount an air relief device onto outlet pipe<br />

of boiler hot water. <strong>Air</strong> relief device must be installed by<br />

installator company in accordance with installation to the<br />

points where air may be exist on installation except boiler.<br />

Carrying and transportation must be done together<br />

with original packaging material of device considering the<br />

marking on the boiler. Please protect the boiler against<br />

factors that can damage to packaging material and device.<br />

Caution! Check the slants of boiler installation<br />

connetions with a water gauge. After slants have been<br />

done There must not been air in the system. Never use a<br />

valve between expansion valve and the boiler. Set air<br />

pressure in expansion tank depending on system pressure.<br />

Device will be out of warranty in case of setting failure or<br />

undone settings.<br />

Caution! A safety relief valve in accordance with<br />

CE standards must be mounted onto the boiler which was<br />

mentioned in technical data table. There must not be any<br />

valve, armature, diameter reduction, elbow etc between<br />

boiler and safety valve. The boiler will be out of warranty in<br />

case of unconnection and/or wrong connection of safety<br />

valve. At least one unit spare safety valve must be located<br />

onto installation as close to the boiler.<br />

Caution! As the boiler works or in case of operation<br />

of the boiler without water, water must not be pumped to<br />

the boiler directly. The boiler water must be gave at low<br />

temperature when the boiler does not operate. Otherwise<br />

system may come to harm. Cold water must not be<br />

pumped into hot boiler. Otherwise the boiler will be out of<br />

warranty and manufacturer company is not responsible for<br />

physical and sipiritual damages.<br />

15


Installation<br />

3.4 Protection against corrosion<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Location of the device must be done in accordance<br />

with CE standards to ambients that air current exists.<br />

Physical life of the boiler is 10 years according to<br />

related laws. This period contains service and providing<br />

required spare part duration for executing the functions.<br />

The boiler was produced in accordance with EN<br />

303-1, EN 303-2 and EN 303-3<br />

Caution! Combustion air must not contain elements<br />

that will cause to corrosion. As an example, these gases<br />

are water steams of solution and cleaning substances or<br />

gases in spray boxes.<br />

As boiler of floor heating system which does not<br />

have oxygen insulation in accordance with DIN 4726 is<br />

mounted, exchanger must be used to separate the<br />

installation.<br />

3.5 Demands related with heating system water<br />

To prevent the damages occured as a result of<br />

corrosion in installation, quality of heating water must be as<br />

good as drinking water. Unsuitable waters containing<br />

chemical additive substances or causing to corrosion must<br />

not be used.<br />

16 www.baymak.com.tr


Installation<br />

3.6 Gas Blown Burners<br />

CAUTION! Use only fluid or gas fuel burner that<br />

is avaliable at CE norms. Burner ignition power must be<br />

set according to nominal heat efficiency of boiler.<br />

Please take care boiler mounting manual while<br />

installing boiler.<br />

Burners must be set according to nominal heat<br />

efficiency of boiler on low heat conditions. Power of 1st<br />

stage burner must be upper than 66% of boiler nominal<br />

power for two stage burner.<br />

Waste gas temperature value must not be lower<br />

than 160 °C for ordinary chimney.<br />

Height of chimney must be set properly for<br />

preventing condensation in chimney.<br />

Open the boiler cover and remove some rotarders<br />

from bottom pipes of front plate on required situation<br />

( Note : Number of removed rotarder must not<br />

exceed much more than 25% boiler pipes quantity. )<br />

Installation of suction limitation cover and<br />

additional air mechanism are recommended. Chimney<br />

must be avaliable for processof waste gas at two stage<br />

burner applications.<br />

Explosion cover setup of the boiler must not be<br />

changed and dont put any object to the front side of<br />

cover.<br />

3.7 Related demands for fuels that is used<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Fuels that is used must be convenable to<br />

defined norms. Otherwise; boiler will be out of<br />

guaranty conditions. Manufacturer company is not<br />

responsible for phisical or sipiritual damages.<br />

Coal gas , natural gas and LPG must be<br />

convenable to EN 437 norm or avaliable for local laws<br />

For fluid fues; Diesel fuel and fuel oil<br />

corresponding to DIN 51603 must be used<br />

Attention ! Fuel-oil and/or heavy oil fuels which is not<br />

in standards can not be used for boilers.<br />

Additive materials are recommended on conditions below<br />

- If they increase durability of fuel storage<br />

- If they increase termic resistance of fuel or reduce<br />

smell formation as tank is filled and provide the burning<br />

without sediment,<br />

Additive material causing sediment or ruin is<br />

forbidden<br />

Attention! It is not allowed to use fuel oil with<br />

Yakut/Elmas 6/8/10 series. Otherwise boiler will be out<br />

of warranty and manufacturer company is not<br />

responsible for physical and sipirutal damages.<br />

17


Installation<br />

3.8 Turbulators<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

All turbulators<br />

must be<br />

reclined to last<br />

point in pipes.<br />

Before installation, check position of whole<br />

turbulators in pipes on front plate. Contact points of<br />

turbulators is head surface of smoke pipe. Assembling and<br />

disassembling of turbulators must be done by operator or<br />

service member.<br />

See picure below for detailed mounting.<br />

18 www.baymak.com.tr


3.9 Before First Start -Up<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Installation<br />

- Check burner connection of burner and<br />

imperviousness of front and back covers at first.<br />

- Interpose ceramic blanket delivered in cardboard<br />

box between burner tube and door installation.<br />

- Check sittings of sensor end protections to slot they<br />

connected to, whether they are correct or not.<br />

- Be careful while choosing burner and check combustion<br />

setup<br />

- Check connection of water and electrical wiring.<br />

- Check water pressure from manometer. If water is not<br />

enough,add water into the system. Because there is closed<br />

expansion tank in the system, check whether system is<br />

filled or not. It is necessary to be released of air if water<br />

impact voice is coming from system.<br />

- Check tightness of front cover filters after first 24 hours<br />

working. If there is looseness, squeeze them.<br />

- Check the rotation of circulation pump whether it is<br />

right or not. If there is overheating or instant increase for<br />

water temperature, check pump turning direction. If the<br />

problem can not be solved, switch off toggle switch of<br />

burner and call service.<br />

- Set desired boiler thermostat value before ignition<br />

- Beware that ventilation channels are always open.<br />

19


Installation<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

If there is leakage on front cover of the boiler,<br />

tighten the bolt hinge nuts on the cover to overcome.<br />

Do not smoke and light a fire in boiler room. Comply<br />

with operation instructions related with boiler room.<br />

We recommend that make a maintenance<br />

contract with authorized service for providing<br />

regular and proper operation.<br />

Make chimney mounting rightly according to related<br />

standards.Use tape coated aluminium folio or smiliar non<br />

flammable band for providing imperviousness on chimney.<br />

Connect filling and discharging line of expansion<br />

tank. There must not be a valfe on connection pipe<br />

between boiler expansion tank and closed expansion tank.<br />

Otherwise boiler will be out of warranty.<br />

Pull and push explosion cover<br />

on back surface of boiler a few times<br />

by using your hand to check working<br />

situation. Explosion cover was<br />

controlled in factory before<br />

transportation. Explosion cover<br />

regulates operation of boiler when<br />

burner works at first time by opening<br />

towards out. Repeat the operation<br />

control before burner works. See<br />

mounting section for detailed<br />

information for explosion cover<br />

mounting.<br />

20 www.baymak.com.tr


3.10 Control of water pressure<br />

3.11 Control of the hot water tank<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Installation<br />

Check installation of heating system periodically<br />

before/after/during operation. If water pressure is low fill the<br />

water to heating system.(Maximum value of system<br />

pressure must be marked on manometer by installer<br />

expert)<br />

Installations having boiler tank to store hot water<br />

must be filled by water. Controls of installation must be<br />

done periodically, installation must be carried on by expert<br />

people, operator must get necessary traninigs. Besides,<br />

there must be cold water inlet to the system. An additinal<br />

safety valve must be installed onto heating line at<br />

connection to the boiler tank independently from existing<br />

safety valve.<br />

There must be absolutely a safety valve on the hot<br />

water line. It is adviced to be mounted an expansion valve<br />

fitting to boiler capacity. Boiler will be out of warranty<br />

because of damages stemed from wrong installation<br />

apllications of safety valves.<br />

21


Installation<br />

3.12 Dimensions of the concrete base<br />

Model<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

A<br />

Depth<br />

m<br />

Place boiler onto concreate base according to<br />

dimension<br />

Kazanı<br />

table<br />

aşağıda<br />

given below<br />

ölçüleri verilen bir<br />

beton kaide üzerine yerleştiriniz.!<br />

B<br />

Width<br />

m<br />

Yakut 6 1050 790<br />

Yakut 8 1045 900<br />

Yakut - Elmas 10 1190 920<br />

Yakut - Elmas 12 1190 920<br />

Yakut - Elmas 15 1230 940<br />

Yakut - Elmas 18 1230 940<br />

Yakut - Elmas 20 1410 1000<br />

Yakut - Elmas 22 1410 1000<br />

Yakut - Elmas 25 1410 1000<br />

Yakut - Elmas 28 1660 1050<br />

Yakut - Elmas 30 1660 1050<br />

Yakut - Elmas 35 1660 1050<br />

Yakut - Elmas 40 1687 1220<br />

Yakut - Elmas 50 1687 1325<br />

Yakut - Elmas 55 1687 1325<br />

Yakut - Elmas 60 1687 1325<br />

Yakut - Elmas 70 1925 1325<br />

Yakut - Elmas 80 1925 1325<br />

Yakut - Elmas Plus 100 2004 1650<br />

Yakut - Elmas Plus 125 2530 1950<br />

Yakut - Elmas Plus 160 2530 1950<br />

Yakut - Elmas Plus 200 2600 2100<br />

Yakut - Elmas Plus 250 2939 2600<br />

C<br />

Height<br />

m<br />

22 www.baymak.com.tr<br />

0,10


4. Mounting<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Mounting<br />

4.1 Casing mounting for Yakut – Elmas / Yakut Plus / Elmas Plus<br />

Please take into consideretion the pictures and<br />

instructions below for boiler casing mounting of Yakut –<br />

Elmas / Yakut Plus / Elmas Plus models.<br />

23


Mounting<br />

- Mount side casing onto boiler body firstly. Side casings are mounted with casette<br />

system. Be sure that channels of side casings was positioned properly.<br />

24 www.baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007


63 9810.0156 – Rev.04 –12/01/2007<br />

Mounting<br />

- Check the side casings whether<br />

they were positioned onto casette<br />

channels properly.<br />

Mount top-front casing which is<br />

seen from the picture as 1. part<br />

of top casing<br />

25


Mounting<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Mount second part of top<br />

casing to the first part of top<br />

casing.<br />

Complete casing mounting<br />

installing 3. part of top casing to 1. part<br />

of top casing. Check accordance of<br />

casings with boiler and each other after<br />

casing mounting process.<br />

26 www.baymak.com.tr


4.2 Burner mounting<br />

.<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Mounting<br />

Take into consideration directions about burner<br />

mounting!<br />

Caution : Burner that is choosen for burner must<br />

have CE Certification. Boiler and burner must be<br />

compatible eachother exactly.<br />

Burner must be choosen by authorized engineer<br />

or manufacturer firm. All parameters which may effect<br />

the accordance between burner and boiler ( boiler<br />

capacity, combustion chamber flame lenght , diameter<br />

of boiler-burner, connection flange, cover thickness)<br />

need to be calculated.<br />

Caution : If there is no CE certification of burner<br />

and if burner is not in accordance with boiler , it will be out<br />

of warranty.<br />

Caution : First start-upmust be made by an<br />

authorized service personel. Otherwise; boiler will be out<br />

of warranty conditions. Manufacturer company is not<br />

responsible for physical or sipiritual damages<br />

Please apply mounting direction defined next pages<br />

for burner mounting application. In case of incompliance of<br />

burner mounting directions, boiler will be out of warranty for<br />

damages that will occure.<br />

Boiler water temperature must be set 55 0 C at gas or<br />

fluid fuels burner mounting<br />

27


Mounting<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Space between burner tube<br />

and cover ınsulation must be<br />

insulated with ceramic wick and<br />

ceramic blanket given in boiler.<br />

Otherwise boiler will be out of<br />

warranty.<br />

- WRONG APPLICATION<br />

Boiler will be out of<br />

warranty.<br />

- RIGHT APPLICATION<br />

Space between burner<br />

tube and cover ınsulator must<br />

be insulated with seramic wick<br />

and blanket. It is not allowed to<br />

formations of heat transfer and<br />

flame .<br />

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63 9810.0156 – Rev.04 –12/01/2007<br />

Mounting<br />

Boiler-burner connection flange on boiler must be<br />

mounted like picture shown below before the burner<br />

mounting.Place burner insulation material to bottom of<br />

connection flange.<br />

BOILER COVER<br />

CONNECTION BOLTS<br />

BURNER INSULATION<br />

CONNECTION<br />

FLANGE<br />

29


Mounting<br />

4.3 Explosion Cover Mounting<br />

4.4 Control Panel Mounting<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Check the operating status of<br />

the explosion cover on the rear face of<br />

the boiler with your hand by pulling and<br />

pushing a few times. Exposion cover<br />

regulates the first operation of boiler at<br />

first working moment of the burner by<br />

expanding towards back. Repeat<br />

working control of the explosion cover<br />

before running the burner.<br />

Mount the electirical control panel in accordance<br />

with user manual.<br />

Electricshock Danger! Before protective hat and<br />

pieces of cover is taken out, all electrical connections on<br />

boiler must be disassembled. Works that will be done when<br />

electric is on, must be carried on by authorized people after<br />

all necessary precuations are supplied.<br />

30 www.baymak.com.tr


63 9810.0156 – Rev.04 –12/01/2007<br />

Mounting<br />

Note : In case of usage the immersed thermostate<br />

without using control panel, thermostate must be installed<br />

onto R ½” nipple. It is unsuitable to mount the thermostate<br />

nipple onto collector. This situation may cause dangerous<br />

problems.<br />

Standard thermostat case is under the outlet flange<br />

of the boiler at Yakut Plus – Elmas Plus series.<br />

31


Installation / System<br />

5. Installation/ System<br />

5.1 Heating System Connection<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Connect the heating system to inlet and outlet of the<br />

boiler.<br />

Mount the filling and discharging connection and its<br />

valve to related connection field at back side of the boiler.<br />

Move the boiler to its operation area and balance it<br />

with the balancing bolts.<br />

Mount the safety equipments connections.<br />

Maximum opening pressure can not be upper than 3<br />

bar (maximum operating pressure).<br />

Connect the safety valves (at inlet and oultet of<br />

boiler), expansion pipes and safety valve in accordance<br />

with the boiler.Ensure that expansion tank is filled by water<br />

and water level and direction of installation is correct. All<br />

pipes must be iron made. Usage of the plastic pipes are<br />

forbidden.<br />

Connect the closed expansion tank and the safety<br />

valve to the boiler properly at the closed heating<br />

installation.Be sure that the expansion tank is full with<br />

water and water pressure is suitable.<br />

Caution: Safety valve must be mounted onto<br />

boiler directly according to related standards. There<br />

must not be any valve, diameter reducer equipment,<br />

pump and these kind of equipments between boiler<br />

and safety valve. Safety valve must be unadjustable<br />

and suitable to CE standards and connection<br />

diameter. There must be a safety valve at tne nearest<br />

point to the boiler on the safety valve installation. In<br />

case of incompliance to the explanations mentioned<br />

on the top, the boiler will be out of warranty and<br />

manufacturer company is not responsible for physical<br />

and sipiritual damages.<br />

32 www.baymak.com.tr


63 9810.0156 – Rev.04 –12/01/2007<br />

Installation / System<br />

The safety valve drainage line must be arranged<br />

when there is no pressure increase and during the time<br />

when safety valve operates. This line must not be<br />

installed against an open place; the drainage end must be<br />

open and tracable. The heating system water coming out at<br />

determined circumstances must be releasing without<br />

danger.<br />

Caution: <strong>Air</strong> release equipments must be placed<br />

to convenient points to release the air that will be<br />

occured during circulation and/or first filling<br />

application.<br />

If these equipments are not mounted to suitable<br />

places or/and equipments whose CE marker is not<br />

available are used, manufacturer company is not<br />

responsible for physical and sipiritual damages.<br />

Caution: The equipments and installation must<br />

be compatible with each other for working correctly<br />

and effectively. All of safety equipments which may<br />

directly effect the operation of boiler must be<br />

covenient with CE standards. If these equipments is<br />

not choosen or placed rightly, manufacturer company<br />

is not responsible for physical and sipiritual damages.<br />

The corrosion resistance of metal materiaI,used at<br />

hot water devices, depends on oxygen that is not exist in<br />

heating water. There will not be any damage after oxygen,<br />

mixed with first or addition water into the system, reacts<br />

with other materials. Transformation of water to black<br />

colour is a sign that there is no free waste oxygen in the<br />

system. Technical rules, especially VDI-Instruction 2035-2,<br />

suggest that heating system needs to be designed and<br />

operated in a way that oxygen inlet is not possible to<br />

heating water.<br />

At the floor heating systems, to prevent intransitive<br />

diffusion of oxygen to pass trough pipe walls, it is<br />

suggested to use plastic pipe which is convenable to DIN<br />

4726. For floor heating systems which is not resistant<br />

against oxygen,system separation must be done by an<br />

exchanger.<br />

33


Installation / System<br />

5.2 Control And Filling of the System<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Ensure that deliver and flow connections on the<br />

boiler are correct.<br />

Check the leakproof of the system.<br />

Recommended water pressure must be as much as<br />

boiler operation pressure (maximum water pressure can<br />

not be much more than boiler test pressure). For the<br />

control of safety valve and its equipments after checking<br />

the system leakproofness, increase the system pressure<br />

0,5 bar over boiler maximum operation pressure<br />

temporarily. Operation control of the safety valves must be<br />

done under this pressure. The equipment which is inactive<br />

and/or response lately must be changed with a new one<br />

and the tests must be repeated.<br />

Tests must be done absolutely under management<br />

of an expert installer. Otherwise boiler will be out of<br />

warranty and manufacturer will not be responsable for the<br />

damages.<br />

Check the connection line of boiler expansion tank,<br />

ensure that there is no any valve between boiler and<br />

expansion tank.<br />

Pump the water to the central heating unit. This<br />

process must be slowly as much as possible.So, the air in<br />

the installation can be released by the air releasing devices<br />

regularly.<br />

Caution: There must be a standardized CE mark<br />

water filter on the filling line. Otherwise particles or pieces<br />

in the water may be harmful for the system directly or<br />

indirectly.Under these circumstances, boiler will be out of<br />

warranty.<br />

Discharging line and drainage of the safety valve<br />

must be connected to a convenient drainage line and must<br />

be noticable and viewable.<br />

34 www.baymak.com.tr


63 9810.0156 – Rev.04 –12/01/2007<br />

Installation / System<br />

Filling process must be<br />

finished providing convenient<br />

water pressure to the<br />

installation. ( For the convenient<br />

water pressure value, please get<br />

information from authorized<br />

service and installer company’s<br />

authority ).<br />

Water pressure must not<br />

exceed upper than 3 bar<br />

(maximum operation pressure).<br />

Fillling process must be done by<br />

an expert and relief of the air in<br />

installation must be done<br />

correctly.<br />

After the installation is<br />

filled completely, air relief<br />

process must be done and the<br />

air on the pumps must be<br />

released by activating the<br />

pumps at temporary times.<br />

To release the air on the<br />

pump, opening the wet rotor<br />

sleeve as shown, both turning<br />

direction of pump is checked or<br />

air in the pump is relased<br />

Electricshock Danger! Before protective hat and<br />

pieces of cover is taken out, all electrical connections on<br />

boiler must be disassembled. Works that will be done when<br />

electric is on, must be carried on by authorized people after<br />

all necessary precuations are supplied.<br />

35


Installation / System<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

It is suggested that after installation filling and air<br />

ventilation processes are completed, installation pumps<br />

must circulate the water in the system about one hour. It is<br />

neccesary to release last air molecules and activate the<br />

system completely. During the test circulation, pump<br />

and/or pumps must be in use.<br />

Caution: Boiler must not be operated certainly<br />

without providing the water pressure completely and<br />

releasing the air in the installation.<br />

Boiler must be observed for a while after it is<br />

activated, boiler water level must be controlled and<br />

observed constantly by the suitable manometer which<br />

is mounted to a convenable and traceable place in the<br />

installation.<br />

In case of a different pump mounting onto boiler to<br />

provide hot water, circulation lines must be checked<br />

carefully. In case of 4 way valve usage, water heating<br />

installation should be done through another exchanger to<br />

prevent wrong circulation.<br />

Discharging of the Condense Water<br />

Caution! Condense water occured during heating process<br />

must be transferred via an convenable neutralizer<br />

installation(accessory). pH value is between 3 and 4 for<br />

gas fuels and between 2 and 3 for liquid fuels. Therefore<br />

suitable neutralizer must be used.<br />

Condense water line must be installed as slanting.<br />

The line going to channel connection must be seen clearly.<br />

Bottom drainage line must be under the chimney hood<br />

level.<br />

Neutralizer installation is not required for the liquid<br />

fuel which has low rate sulfur (In accordance with ATV note<br />

page A251). Generally , there is no need to neutralizer<br />

installation in the boiler having 200 kW nominal heating<br />

power.<br />

For the neutralization of the boiler outlet water,<br />

local waste water specifications and\or local specifications<br />

must be taken into consideration.<br />

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5.3 Chimney Connection<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Installation / System<br />

Caution! Waste gas way must be as short as<br />

possible. Waste gas pipes must be installed as in slanting<br />

direction towards chimney and connections must have full<br />

imperviousness.<br />

The chimney must be designed considering<br />

technical specifications determined in DIN 4705 and built<br />

according to DIN 18160.<br />

Both boiler back pressures and boiler pressures<br />

must be in consideration at chimney calculations.<br />

If the waste gas heat is under 160°C in continuous<br />

operating, it is forbidden to use an ordinary chimney.<br />

Warning! ! To change the burner power may effect<br />

waste gas temperature. It is advised to attach an<br />

absorbtion restrictive for high rating exhaust chimneys.<br />

37


Installation / System<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Interior diameters, heights, heat conduction<br />

resistances and interior faces of chimney systems must be<br />

in the dimensions , fitting to aim of waste gases, which<br />

enables to throw out the chimney gases in every kind of<br />

operation conditions and high pressures in dangerous<br />

levels according to living places must not occur.<br />

There must be at least 20 cm distance between<br />

chimney gas lines and windows in the building.<br />

It is recommended to be consulted to an authorized<br />

establishment about chimney cleaning.<br />

Total resistance value is equal to ∑ζ = 2,2 (sehiedel<br />

diagram) or to 2,5 (plewa diagrams) for direction alteration,<br />

entrance, shape and speed alterations.<br />

∑ζ=2,2 total resistance value is equal to loses of flue<br />

with 2 unit 90º elbow, fixing to chimney with 10º slant, and<br />

an excessive large boiler smoke outlet causing velocity<br />

increase.<br />

45° slant is recommended for inlet of the chimney<br />

gases into the chimney system.<br />

Boiler back pressure and boiler draught<br />

necessity vaules (Pw) must be taken into<br />

consideration at chimney calculations. In case of<br />

usage of wrong calculated chimneys according to<br />

these values or in case of usage of chimneys that has<br />

unsuitable materials, inner boiler and cover insualation<br />

damages (because of wrong burner settings,<br />

overloading, temperature) the device will be out of<br />

warranty<br />

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5.4 Installation of Shunt Pump<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Installation / System<br />

In case of the drop of the<br />

return water temperature under<br />

55 °C, shunt pump must be<br />

used to supply the return water<br />

at 55°C<br />

In case of usage of the<br />

shunt pump, temperatures of<br />

boiler water was specified at<br />

section of “Temperatures of<br />

Radiator Water” which was<br />

explained on chapter 6.2<br />

Attention In case of drop of the return water<br />

temperature under 55 °C because of installation, shunt<br />

pump must be used to supply return water at 55°C. It is an<br />

essential to use a shunt pump which was calculated at<br />

proper flow quantity and pressure height. Unusage of this<br />

pump or/and usage of a pump that is not suitable, wrong<br />

assembly, falty connections and placement of the pump<br />

may damage to the boiler in long or short term. In case of<br />

these circumstances pump will be out of warranty.<br />

Attention: It is important that installation which<br />

pump connected to must be designed and applied in<br />

accordance with projects and standards. Engineering<br />

calculations must be in accordance with EN installation<br />

design standards.<br />

Attention: As long as device works with shunt<br />

pump, connections of electrical panel and mechanical<br />

installation must be installed by experienced people,<br />

process of first start-up of the device must be done by<br />

authorized technical service. Otherwise the device will be<br />

out of warranty.<br />

Electricshock Danger! Before protective hat and<br />

pieces of cover is taken out, all electrical connections on<br />

boiler must be disassembled. Works that will be done when<br />

electric is on, must be carried on by authorized people after<br />

all necessary precuations are supplied.<br />

39


Operating/Start Up<br />

6. Operation/Start-up<br />

6.1 Operation/Start-up<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Danger! First start-up must be done by only<br />

authorized service. Before all these applications, expert or<br />

installer of heating system installing and controlling the<br />

installation must check the imperviousness of line, and<br />

declerates the sufficiency of installation to authorized<br />

service. Authorized service checks all parameters that is<br />

necessary for working of the boiler and all substances<br />

mentioned at the top, measures burning values of the<br />

boiler and operates the boiler.<br />

At the unsuitable appications, there is danger risk to<br />

damage to people, envoirement and objects! Devices<br />

which is not started up by authorized services will be out of<br />

warranty and manufacturer company is not responsible for<br />

possible damages.<br />

Attention! It is not allowed heating boiler to be<br />

worked in cicumstances such as building works having<br />

intense dust. Devices may break down.<br />

Injury danger due to hot water! Boiling water may<br />

release from relief valve or drain line for short time when<br />

device is started up.<br />

- Switch on raidator switch.<br />

- Switch on Fuel oil/gas locking mechanism.<br />

- Switch on the switch of boiler line and operating<br />

switch where is on control panel of boiler.<br />

- Arrange essential settings on setup-operating unit<br />

for desired temperature of ambient turning the button.<br />

40 www.baymak.com.tr


6.2 Temperatures of Installation Water<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Operating/First Start Up<br />

Attention; In this section, essential temperature of<br />

installation is explained for exact and suitable working of<br />

your device. It is very important to match to these<br />

temperatures. Problems occured at the cicumstances<br />

steaming from improper apllications such as liquefying,<br />

chimney, corrosion is out of warranty. Manufacturer<br />

company is not responsible for problems that may occure.<br />

IMPORTANT WARNING ! FOR GAS FUELS<br />

Attention; Minimum boiler inlet water<br />

temperature for gas fuels is limited as 55 °C,<br />

maximum boiler outlet water temperature is limited as<br />

85 °C. Boilers can not be operated out of limits<br />

mentioned. Mentioned inlet water temperatures are<br />

valid in case of shunt pump usage.<br />

IMPORTANT WARNING ! FOR FLUID FUELS;<br />

Minimum boiler inlet water temperature for flue<br />

fuels is limited as 55 °C, maximum boiler outlet water<br />

temperature is limited as 85 °C. Boilers can not be<br />

operated out of limits mentioned. Mentioned inlet water<br />

temperatures are valid in case of shunt pump usage.<br />

FLUID FUEL<br />

USAGE<br />

GAS FUEL<br />

USAGE<br />

Min. Boiler Inlet<br />

Water Temp. o C 55 o C 55 o C<br />

Min. Boiler Outlet<br />

Water Temp. o C 85 o C 85 o C<br />

Attention: Temperature of Boiler inlet must not go down<br />

under 55 o C (Section 5.4.) Otherwise boiler is out of<br />

warranty.<br />

41


Operating/First Start Up<br />

6.3 Emergency Operation<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

When the pressure goes under 0,5 bar or goes<br />

up 1,5 times over opening limit of relief valve (4,5 bar),<br />

boiler must be shut down by applying emergency<br />

operation immediately. Ensure that burner is shut<br />

down and leave boiler for getting cold by itself.<br />

Do not load water to boiler absolutely, open the<br />

door of boiler room and get away from boiler. Call<br />

authorized service immediately.<br />

IMPORTANT WARNING !<br />

Do not load cold water to boiler in any condition.<br />

This situation may cause to important damages and<br />

vital dangers.<br />

Electricshock Danger! Before protective hat and<br />

pieces of cover is taken out, all electrical connections on<br />

boiler must be disassembled. Works that will be done when<br />

electric is on, must be carried on by authorized people after<br />

all necessary precuations are supplied.<br />

As boiler works, in case of circumstances such as<br />

limit exceeding of temperature or/and pressure,<br />

overworking, steam overloading etc., boiler thermostat<br />

must be shut down, pump must go on circulating certainly,<br />

all gas and fuel valves must be shut down, boiler must be<br />

left to get cold by itself. Uncapable and unlicenced people<br />

must not barge to boiler. Opposite conditions may cause<br />

serious life and property losses. The boiler will be out of<br />

warranty in these conditions.<br />

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6.4 Training of Operator<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Training;<br />

Operating/First Start up<br />

The person who will operate the heating system<br />

must have training in detail about operating of system and<br />

operating forms of safe tools and especially informations<br />

that;<br />

- Not to close or cover of air inlet side;<br />

- Functionality control of explosition cover which is<br />

necessary for good combustion ( See, Explosition cover );<br />

- Not to store ignitable substances and fluids near to<br />

boiler;<br />

- Precuations of control that operator must have;<br />

- Control of water pressure of manometer;<br />

- Control of relief valve drain line;<br />

- Release of installation air;<br />

- To be given the information that “applications made<br />

in regular time periods such as maintenance and cleaning<br />

must be gone on by capable heating system experts” .<br />

Documents;<br />

- Instruction including short information about<br />

operation of boiler must be placed to a close area to boiler.<br />

- As documents related with heating system is<br />

delivered, a warning about necessity of location of these<br />

documents where boiler placed must be declared. (DIN<br />

4756).<br />

43


Cleaning and Maintenance<br />

7. Cleaning and Maintenance<br />

7.1 Cleaning<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Electricshock Danger! Before protective hat and<br />

pieces of cover is taken out, all electrical connections on<br />

boiler must be disassembled. Works that will be done when<br />

electric is on, must be carried on by authorized people after<br />

all necessary precuations are supplied.<br />

Cleaning consists of items below;<br />

- Cleaning of the boiler from outside,<br />

- Cleaning of combustion chamber and pipes of the<br />

boiler ( this may change depending on operation).<br />

It is strongly advised that cleaning and<br />

maintenance of boiler must be done once in a year by<br />

authorized services.<br />

Attention: Insulation of front cover was made by<br />

a material that is not required to be cleaned. Therefore,<br />

do not clean with any shape or corrosive tool, do not<br />

apply force or pressurized air, do not clean with fluids<br />

like water, etc. In case of damage on cover insulation,<br />

boiler will be out of warranty.<br />

For cleaning of combustion chamber in boiler room,<br />

open boiler cover, pull and take out turbulators with tools<br />

which was delivered with the boiler. After turbulators are<br />

taken out, clean them with a brush and brush holder, clean<br />

smut and dirts accumulating to the side of flume hood<br />

taking out the explotion hoot then repeating all the works<br />

from reverse, assemble explosition hoot and turbulators,<br />

close boiler cover and after bolts are tighten check if there<br />

is gas leakage from connections.<br />

See figure of turbulator assemble for process of<br />

connection and disconnection of turbulators.<br />

Burner must be checked for impurity, cleaned and<br />

processed to maintenance if it is necessary.<br />

In case of necessity, clean boilers from outside.<br />

Use only soft cleaning materials which will not damage to<br />

surface. Cleaning of surfaces, heating the inside of the<br />

boiler and burner, must be only done by authorized<br />

service.<br />

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Assemble of Turbulators :<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Cleaning and Maintenance<br />

All turbulators must be located into pipe (see figure<br />

below) after related applications are done using related<br />

tools.<br />

All turbulators<br />

must be pushed<br />

till last point<br />

they can go<br />

45


Cleaning and Maintenance<br />

7.2 Maintenance<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Maintenance applications consist of items below;<br />

- Cleaning and control of insulation points and<br />

connections that water passes through,<br />

- Control of regular operation of safety valves and<br />

cleaning from outside.<br />

- Control of operation pressure and water addition if it<br />

is necessary.<br />

- Releasing of the air in installation<br />

Electricshock Danger! For the purpose of<br />

preventing the electricshock in case of touch, all<br />

pieces on boiler which is necessary to be assembled<br />

(especially plating pieces) must be screwed correctly<br />

after operation is completed.<br />

Danger! Maintenance applications must be made by<br />

an authorized installation expert. Please do not try to make<br />

these applications by yourself. Otherwise you may face off<br />

with dangerous situations.<br />

Maintanence Agreement<br />

Maintananence of Heating system installation<br />

should be done properly according to local standards. It is<br />

suggested heating system installation to have complete<br />

maintanence process once in a year. If an agrement is<br />

done with authorized service for maintenance, boiler life<br />

extends and this provides heating system to be operated<br />

for long years economically and safely.<br />

46 www.baymak.com.tr


Suggestions for Energy Saving<br />

8. Suggestions for Energy Saving<br />

8.1 Optimal Heating<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

BAYMAK Boilers proved themselves with their<br />

specialities of economical consumption and perfect energy<br />

savings as long as their regular maintenance goes on.<br />

You can be effective at the factors of energy saving.<br />

For this purpose, we would like to suggest some useful<br />

information to provide much more saving.<br />

Ambient Temperature<br />

• Do not set room (ambient) temperature higher than it<br />

has to be. Each one degree will increase energy<br />

consumption %6.<br />

• Beware ambient temperature to be in accordance with<br />

process type. You can set each raditor in the room by<br />

their termostat valves independently.<br />

Suggestions about temperature of various ambients are;<br />

Bath………………………………………..22 0 C – 24 0 C<br />

Sitting rooms……………………………... ……… 20 0 C<br />

Bed rooms ……………………………….16 0 C - 18 0 C<br />

Kitchen …………………………………...18 0 C - 20 0 C<br />

Hallway/Other rooms …………………...16 0 C - 18 0 C<br />

• Reduce room temperature 4 – 5 °C during night and when<br />

you are not in the home.<br />

• When you cook something, kitchen warms up nearly by<br />

itself. To save energy, take the advantage of heat coming<br />

from oven and dish washer machine.<br />

• Do not set thermostate repeatly! If you do not heat a room<br />

because it is not used, the room spread the heat from cell,<br />

wall and doors to other rooms. Because radiator capacity is<br />

not enough to supply this additional heat, they do not work<br />

economically.<br />

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Suggestions for Energy Saving<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

• Beware that there is no curtain, cupboad etc. infront of<br />

radiators. This situation effects heat transfer to room badly.<br />

Convenable Setting According to <strong>Air</strong> Conditions<br />

In case of operation position with a panel combined<br />

with sensor sensing outside temperature, your heating system<br />

is adjusted according to outer air conditions.<br />

Ventilation<br />

For purpose of providing a comfort climate ambient and<br />

preventing from formatin of fungus on walls, regular ventilation<br />

of the heated rooms is very improtant. Barely, right ventilation<br />

is important to prevent cost loss steming from undesired<br />

energy loss.<br />

• Open window completely but do not wait much more than<br />

10 minutes. So, you can provide enough air ventialation<br />

without cooling the room.<br />

• Ventilation: Open the window a few times in a day between<br />

4 and 10 minutes.<br />

• <strong>Air</strong> current: Open all windows and doors in the room 2 or 4<br />

times in a day.<br />

Maintenance<br />

Before winter term starts, get maintenance of boiler<br />

done ! If maintenance and cleaning of the device is done at<br />

autumn term, this is in optimum situation as heating term.<br />

48 www.baymak.com.tr


9. Important Cautions<br />

9.1 Important Cautions<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Important Cautions<br />

Subjects related with product warranty<br />

conditions that consumer must consider:<br />

Product warranty document that was given by<br />

Baymak A.S. does not contain breakdowns and damages<br />

which occur because of usage in conditions that is not<br />

normal.<br />

By depending on this matter, items below including<br />

warranty conditions is presented to your attention. You can<br />

find the conditions that warranty is not valid in these items:<br />

1. Get your warranty, belonging to your product ,<br />

aprroved to your authorized dealer<br />

2. If there is no approvals of authorized seller and<br />

dealer that has to be on warranty document or if<br />

original serial number on waranty document is<br />

erased by scraping-damaging,<br />

3. Breakdowns and damages that usage faults caused,<br />

(Please use your device applying applications<br />

described on your manual)<br />

4. Occured damages during transport to customer<br />

after delivery date.<br />

5. Breakdowns occuring because of insufficient<br />

antifreeze (freezing etc.)<br />

6. Except authorized service experts, other people<br />

must not intervene to device for any reason.<br />

7. Problems that will occur because of<br />

unaccomplished maintenance and control that is<br />

neccesary to be done,<br />

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Important Cautions<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

8. Responsibles for delivery of warranty documents are<br />

seller, agent, dealer or represantative that was<br />

purchased from.<br />

9. Wrong location, wrong piping fitings, wrong capacity<br />

choice, installation pressure over 4 atu, insufficient<br />

chimney system, low or high voltage, safety<br />

thermostate, thermometer, altered burner settings,<br />

wrong heating system installation, external physical<br />

or chemical factors, breakdowns because of<br />

tranportation or storage conditions, usage of<br />

unsuitable fuel.<br />

10. Repair or alterations that is not done by authorized<br />

service team.<br />

11. Customer is responsible in case of excesive<br />

installation pressure or water leakage from<br />

installation fittings.<br />

12. Problems because of insufficient soot cleaning,<br />

plugged nozzle, materials damaged from fuel are out<br />

of warranty.<br />

13. Boiler will be out of warranty because of breakdowns<br />

and damages occured because there is no water in<br />

boiler, unconnected equipment that has to be<br />

mounted to the installation, missing or wrong<br />

mounting, usage of equipment which is<br />

unconvenient (i.e. safety valve), leaving the boiler to<br />

have steam, pumping the limy water<br />

14. A safety valve which is suitable according to<br />

standards must be mounted onto boiler. Boiler will<br />

be out of warranty if safety valve is not mounted or<br />

there is valve, pipe, elbow between safety valve and<br />

boiler.<br />

15. Damages related with liquifying point corrosion<br />

occured because boiler or return water temperature<br />

is very low and damages that operation with<br />

uconvenient filling and addition water caused are out<br />

of warranty.<br />

50 www.baymak.com.tr


10. Technical Data<br />

10.1 Technical Data<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Technical Data<br />

51


Technical Data<br />

INSTALLATON SCHEMA OF CENTRAL HEATING SYSTEM<br />

Attention! Schema is for guidence. Location of installation and equipments may vary<br />

according to condition of installation.<br />

At Yakut-Elmas boiler series, expansion tank connection must be done from nearest point,<br />

an convenable safety valve must be connected onto safety flange on boiler.<br />

52 www.baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007<br />

Expansion tank return


63 9810.0156 – Rev.04 –12/01/2007<br />

Technical Data<br />

INSTALLATION DEFINITION OF CENTRAL HEATIG SYSTEM SCHEMA<br />

1 BOILER<br />

2 BURNER<br />

3 BOILER WATER OUTLET PIPE<br />

4 BOILER WATER INLET PIPE<br />

5 INSTALLATION OUTLET COLLECTOR<br />

6 CIRCULATION PUMP<br />

7 GATE VALVE<br />

8 MANOMETER<br />

9 AIR RELIEF NIPPLE<br />

10 HEATING GROUPS<br />

11 INSTALLATION INLET COLLECTOR<br />

12 OPEN EXPANSION TANK<br />

13 OPEN EXPANSION TANK OUTLET PIPE<br />

14 BOILER OUTLET PIPE TO OPEN EXPANSION VALVE<br />

15 FILLING-DISCHARGING PIPE OF BOILER WATER<br />

16 CONDENSE PIPE<br />

17 BOILER THERMOSTATE CASE<br />

18 CLEANING COVER<br />

19 EXPLOSION COVER<br />

20 FLUE<br />

CLOSED EXPANSION VALVE (AVAILABLE WITH ELMAS SERIES)BOILERS<br />

21<br />

22<br />

SAFETY VALVE (SAFETY VALVE IS MOUNTED BY INSTALLER IN ACCORDANCE<br />

WITH INSTALLATION)<br />

53


Technical Data<br />

54 www.baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007


63 9810.0156 – Rev.04 –12/01/2007<br />

Warranty Document<br />

55


Warranty Document<br />

56 www.baymak.com.tr<br />

63 9810.0156 – Rev.04 –12/01/2007

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