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Alpha Tryon MK Cast Iron Boiler
Operating & Maintenance Manual
MHS Boilers Ltd.
3 Juniper West, Fenton Way
Southfields Business Park
Basildon
ESSEX SS15 6SJ
Tel. 01268 546700 Fax 01268 888250
WWW.MHSBOILERS.COM
L334
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Contents
Product Description ..................................................................................................................................................... 2
General Regulations Application Norms And Regulations ...................................................................................... 4
General Specifications ................................................................................................................................................ 6
Technical Information .................................................................................................................................................. 7
Minimum Clearences ................................................................................................................................................... 8
Gas Resistance .......................................................................................................................................................... 10
Inside The Boiler ........................................................................................................................................................ 10
Efficiencies ................................................................................................................................................................. 10
Flue Gas ...................................................................................................................................................................... 10
Temperatures ............................................................................................................................................................. 10
Oil Supply ................................................................................................................................................................... 11
Gas Supply ................................................................................................................................................................. 11
Burner ......................................................................................................................................................................... 11
Water Side Of Boiler .................................................................................................................................................. 12
Flue Design And Chimney Installation ..................................................................................................................... 13
Preparations Before Assembly ................................................................................................................................. 14
Assembly Instructions ............................................................................................................................................... 16
Electrical Installation ................................................................................................................................................. 26
Control Panel .............................................................................................................................................................. 27
Electrical Wiring Diagram .......................................................................................................................................... 28
Maintenance And Cleaning ....................................................................................................................................... 29
End-User Instructions ................................................................................................................................................ 30
Health And Safety Information .................................................................................................................................. 32
Exploded Drawings .................................................................................................................................................... 35
Product Description
Boilers cast iron sections are available in 6 versions from 80 to 300 kW and are for use on oil and gas boilers. They
are compliant with European Directives and CE approved OPTIMAZ. The introduction and the placement of the boiler
in the boiler room are facilitated by the sections being separated. The assembly is rapid with conical steel nipples. A
rope of fiberglass between the sections, offers an absolute guarantee of sealing the flue gas, even at a pressure in
the combustion chamber and the various flues. A cylindrical combustion chamber is spacious to ensure a perfect
formation of the flame on the burner this avoids harmful emissions whether on oil or gas. The evacuation of
combustion gases takes place following the known system of "TRIPLE PASS" ensuring optimum heat transfer and
low NOx emissions. A revolving door, fully insulated with respect, guarantee easy access inside the boiler. The result
is a simple and effective maintenance.
Fig 1
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Boilers cast iron Sections of the feature of modern technology the "JETSTREAM" offers new perspectives. This
technology was developed specifically to prevent condensation of gas in the boiler. The "JETSTREAM" is based on
increasing the temperature of the hot water circulating in the boiler. This is done in the form of a jet effect, which is
caused by a tube (injector) of distribution set out in the back of the boiler return water facility is injected into the boiler
through the distributor. This injection causes a decrease in pressure at the end of the injector, which creates a
depression. This vacuum sucks the hot water in the boiler and mixes with cold water and hot water. Thus the
condensation of gas in the boiler is removed. A stream of hot water in the rear sections of the boiler protects against
excessive thermal shock. (Fig. 1)
Fig. 2
The TRYON 3 JETSTREAM Fig. 2 operates in the mode of non-condensation when the lowest temperatures of the
water that returns to the boiler, shown in table below are maintained at their thermal equilibrium and their normal heat
flow.
Fuel Type
Lowest water return temperatures (° C)
∆T= 10°C
∆T= 20°C
Natural gas and LPG
40
35
Heating oil (light oil)
30
25
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General regulations Application Norms and regulations
General regulations
This documentation contains important information, which is a base for safe and reliable installation, commissioning
and operation of the Alpha Jetstream MD and MK boilers. All activities described in this document may only be
executed by authorized companies.
Changes to this document may be effected without prior notice. We accept no obligation to adapt previously delivered
products to incorporate such changes.
Only original spare parts may be used when replacing components on the boiler, otherwise warranty will be void.
Application
The Alpha Jetstream MD and MK boiler s may be used for heating and hot water production purposes only. The
boiler should be connected to closed systems with a maximum temperature of 100ºC (high limit temperature);
maximum set point temperature is 90ºC.
Norms and regulations
When installing and operating the boiler, all applicable norms (European and local) should be fulfilled:
• Local building regulations for installing combustion air and flue gas systems;
• Regulation for connecting the boiler to the electrical appliance;
• Regulations for connecting the boiler to the local gas network;
• Norms and regulations according to safety equipment for heating systems;
• Any additional local laws/regulations with regard to installing and operating heating systems.
EN 656 Gas-fired central heating boilers – Type B boilers of nominal heat input exceeding 70 kW but not exceeding
300 kW.
EN 15420 Gas-fired central heating boilers - Type C boilers of nominal heat input exceeding 70 kW, but not
exceeding 1000 kW
EN 15417 Gas-fired central heating boilers - Specific requirements for condensing boilers with a nominal heat input
greater than 70 kW but not exceeding 1000 kW
EN 13836 Gas fired central heating boilers - Type B boilers of nominal heat input exceeding 300 kW, but not
exceeding 1000 kW
EN 15502-1 Gas-fired central heating boilers - Part 1: General requirements and tests
EN 55014-1 Electromagnetic compatibility - Requirements for household appliances, electric tools and similar
apparatus Part 1: Emission
EN 55014-2 Electromagnetic compatibility - Requirements for household appliances, electric tools and similar
apparatus Part 2: Immunity - Product family standard.
EN 61000-3-2 Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions
(equipment input current 16 A per phase).
EN 61000-3-3 Electromagnetic compatibility (EMC) - Part 3-3: Limitation of voltage changes, voltage fluctuations and
flicker in public low-voltage supply systems, for equipment with rated current 16 A per phase and not subject to
conditional connection.
EN 60335-1 Household and similar electrical appliances -Safety - Part 1: General requirements
EN 50165 Household and similar electrical appliances -Safety - Part 2-102: Particular requirements for gas, oil and
solid-fuel burning appliances having electrical connections.
The following Codes of Practice are also applicable: -
BS 6644:2005 + A1 2008 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and 1.8MW
(net) (2
nd
and 3
rd
family gases).
BS 6880:1988 Code of Practice for low temperature hot water heating systems of output greater than 45kW. Parts 1,
2 & 3.
BS 6891:2005 + A2:2008 Specification for installation of low-pressure gas pipework of up to 35mm (R11/4) in
domestic premises (2
nd
family gases).
BS 7593:2006 Code of Practice for treatment of water in domestic hot water central heating systems.
BS 7671:2008 Requirements for electrical installations. IEE Wiring Regulations. Seventeenth Edition
BS EN 12828 2003 Heating systems in buildings – Design for water based heating systems.
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
IGE/UP/1 or 1A Gas Tightness Testing & Purging of Commercial Industrial Gas Installations
IGE/UP/2 Gas installation pipework, boosters and compressors on Industrial and Commercial premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises.
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IG/UP/10 edition 3 Installation of gas appliances in Industrial and Commercial premises.
Part 1: Flued appliances.
Through their unique construction, the Alpha Jetstream MD and MK range of central heating units are renowned for
their:
- Environmental-friendliness (they meet the most stringent environmental conditions)
- Durability
- Can be supplied in a wide range of models
Through active and market oriented research, MHS Boilers Ltd is in a position to offer solutions for the most
challenging heating requirements.
The supplier
MHS Boilers Ltd are proud to supply and technically support the Alpha Jetstream MD and MK range of boilers
throughout the United Kingdom. For advice or more information please contact your local sales representative or our
head office via 01268 546700 or via our website www.mhsboilers.com
This document
The present documentation has been prepared with the following target groups in mind:
- The technical consultant
-The installer
- The maintenance technician
-The user
MHS Boilers Ltd has opted to make the technical documentation as comprehensive as possible in the form of this
book, in order to ensure that these target groups have all the information they need. As the supplier we would be
happy to help you in connection with any additional information that you may require. This document covers the
following aspects relating to the boilers:
- General description
- Technical specifications
- Requirements for design and installation
-Maintenance instructions
The operating instructions for the user have been affixed to the appliance itself.
Service
For commissioning and assistance in maintenance matters, please contact the Technical Services Department
via 01268 546700.
General restrictions
MHS Boilers Ltd products should always be used, installed and maintained in accordance with the statutory
requirements, specifications and standards applicable to these installations. All the data, information and suggestions
concerning its products provided by MHS Boilers Ltd are based on careful study. However, the use, installation and
operation of the same are outside the control of MHS Boilers Ltd and neither MHS Boilers Ltd nor any other
organisations associated with it, accept any liability for the same.
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General Specifications
Useful information
The installation and commission must be performed by a professional installer.
EXCERPT FROM OUR WARRANTY
The warranty is not covered in cases where the starting or maintaining the boiler has not been conducted according
to the O&M manual.
Warranty will not be accepted in case of damage due to a bad installation, poor adjustment, intervention of a person
not qualified to work on this type of equipment.
THERE IS NO WARRANTY FOR DAMAGE CAUSED BY OVER PRESSURE
Never install a boiler in a place where there is aggressive gases (e.g. sprays, etc.) excessive dust, in a place that is
too wet, the area should be well ventilated and insulated against frost.
MOUNTING
The boiler should be assembled according to the manual supplied. The plinth for boiler must be formed and be
horizontal and level.
The support points of the boiler must rest on metal plates with a flat surface under the feet of the boiler to allow for
expansion or movement.
TECHNICAL DATA
1. Melt composition beyond Cast iron GG20
Power Draw = 20 kg / mm ²
2. The following sections are cast
- front section
- intermediate section
- rear section
- chamber plate
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Technical information
Boiler type
MK320
MK376
MK436
MK611
MK669
MK727
MK843
MK1017
Number of section
8
9
10
13
14
15
16
17
20
Identification No.
86/AT/572 – CE0035
Rated heat input
(Natural Gas & LPG)
Kw
351
415
479
735
799
863
926
990
671
Rated heat input
(Fuel Oil)
Kw
249
315
363
555
602
650
698
749
507
Rated heat output
(Natural Gas & LPG)
Kw
320
378
436
611
669
727
785
843
1017
Mcal/h
275
325
375
525
575
625
675
725
875
Rated heat output
(Fuel Oil)
Kw
224
284
327
456
499
542
585
628
762
Mcal/h
193
244
281
392
429
466
503
540
656
Flue gas resistance
mmwg
5.7
11.1
16.3
38.8
44.0
49.0
55.0
56.0
66.0
Combustion
chamber
Diameter
mm
570
Depth
mm
953
1035
1214
1730
1859
1988
2117
2246
1601
Dimension
L
1409
1537
1665
2177
2305
2433
2561
2689
2049
Burner
mounting
Diameter
mm
180
Depth
mm
Mn 125
Flow/ Return
DN
100 (4 “)
Flue gas temperature
°C
190
192
178
175
173
170
185
200
Flue connection
diameter
mm
350 (exterior diameter)
Weight(boiler block)
Kg
1551
1710
1868
2365
2533
2702
2857
3015
3489 3489
Weight (water content)
lt
213
247
275
358
386
413
441
469
552
Weight (flue gas content)
lt
504
564
624
804
364
924
984
1044
1224
Heating surface of boiler
m2
17.5
19.8
22.1
29.0
31.3
33.6
35.9
38.2
45.1
Stand-by losses
kcal/hr
318
357
397
517
558
597
637
678
800
Watt
368
414
460
600
650
692
740
786
928
Flow temperature control
°C
30-90
Maximum boiler
temperature
°C
120
Maximum operating
pressure
Bar
4
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Minimum Clearances
The installation must be arranged in accordance with Mandatory Regulations and Codes of Practice. The following
sketch (Figure 5) shows the recommended minimum dimensions of clearance around the boiler for servicing and
maintenance.
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TECHNICAL INFORMATION
Gas resistance
inside the boiler
Efficiencies
Values given according to average boiler water temperature of 70 °C
Flue gas temperatures
Values given according to average boiler water temperature 70 °C, ambient temperature 20 °C
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Oil Supply
MK series boilers can only be fired with liquid fuels having following specifications:
Kerosene viscosity at 20 C: 1.2 cSt or viscosity at 100 F: 28 Second
Light oil (EL) viscosity at 20 C: 4- 6 max cSt or viscosity at 100 F: 35 Second
Gasoil (D) viscosity at 20 C: 4- 6 max cSt or viscosity at 100 F: 35 Second
Light/medium fuel oil viscosity at 50 C: 150 cSt max or viscosity at 100 F: 625 Second
In case of firing with fuel oils, the heat input to boiler must always be slightly reduced to required values in order to perform better at
related outputs of boiler as described in technical boiler data. Any failure due to lack of technical precautions, firing with fuels not
suitable for boilers, and operation without taking recommendations given further in this manual into consideration, will always be in
responsibility of end-user.
A single pipe oil supply with oil at a slight positive pressure is generally required though the burners own oil pumps can provide some
lift of the oil depending on the volume flow and the lift required. For dual fuel burners a two pipe oil supply system is generally
recommended unless the burner is fitted with an oil pump clutch. An oil filter and isolating valve should be provided and the burner
connected to the oil supply with a flexible oil hose. The hose and filter are generally supplied with the burner.
Gas Supply
The local gas supply authority should always be contacted at the design state to ensure an adequate supply is available. An existing
service pipe must not be used without prior consultation with the local gas supply authority and the supply must be made through a
suitable meter.
The matching of burner model, burner and complete gas train size must be carried out in accordance with supplied inlet gas pressure
and fuel type to be fired. When sizing the burner and gas train, all pressure losses inside the boiler, burner and gas train and in piping
from burner inlet to main gas meter must always be taken into consideration. A reduce in boiler output due to wrong matching of any
component should be avoided before installation of whole system.
Burner
MK boiler must be fired only with a CE APPROVED BURNER. MHS Boilers Ltd will not be held responsible for any damage of failure
due to use of a non approved burner.
It is not recommended to increase the diameter of hole in the middle of front refractory to make the mounting of burner easier. If there
is a space left between the hole in front door refractory and burner tube after the mounting, this space must be fed with rock-wool or
ceramic-fibre based insulation material to improve heat insulation. Otherwise, further heat loss may result in damage on front door.
Should the diameter of burner head is greater than that of the hole in front door refractory, the diameter of the hole must be increased
so that the burner passes smoothly through the hole. Front refractory must be protected against breaking during mounting and
dismounting of burner.
Pressurized burner of 2800 rpm (blowing type) must be used with the boiler. Barrel of the burner to be mounted on the boiler should
fit the burner connection mouth depth, indicated in the technical specifications table.
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Burner and Boiler Combinations
Ceramic
Insulation
rockwool
insulation
space to seal
space has to
be sealed
burner head
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Water side of boiler
The fully water cooled sections are joined by cast iron conical nipples, and distribution pipe fitted to the return ensures even the
temperature distribution throughout the boiler. The cast iron sections are to BS.1452 Grade 200 with 7 mm wall thickness. Return and
flow connections to heating system are provided by stub-pipes at the rear of the boiler, outside the casing.
Under no circumstances should the boiler be fired when its circulation volume is less than a recommended minimum volume
calculated according to the following formula:
The following table provides hydraulic resistances at various water volumes relative to boiler Dt flow/return. The difference between
flow and return temperatures of the boiler should not be greater than 20 C to provide convenient operating conditions in the boiler:
Flue design and chimney installation
Boilers must be connected to a chimney by using the shortest flue canal possible which should be insulated by mineral wool or similar
material. Flue canal must be placed at a rising slope of 10°-45° between flue and chimney. Conditions creating higher resistance to
gas flow such as elbows should be avoided in flue canal. The flue canal outlet to the boiler should not support the weight of chimney.
At the discharge from the boiler, the flue gasses should be in a balanced state, consequently, the function of the chimney is only for
the disposal of the flue gasses to atmosphere. Chimney calculations should be carried out in compliance with the standards.
Conditions of existing chimney should be checked and proper precautions should be taken against excessive cooling and
condensation (such as applying a chimney sheet made of stainless steel grade 316 and surrounding with insulation). Positive draught
conditions must be avoided. Negative draught conditions should be contained within -3 mm wg for optimum boiler performance.
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The following table shows typical flue gas volumes at gross flue temperature of 190°C and ambient air temperature of 20°C.
PREPARATIONS BEFORE ASSEMBLY
Boiler room arrangement
Boiler room should not be used for any other applications; floor should always be kept dry and clean. Any obstacles in front of
ventilation openings must be avoided. The boiler room air openings must conform to the norms prevailing locally. Any irregular
electricity installations in boiler room should be replaced.
The boiler is not recommended for domestic usage. Water level should be checked periodically with a hydrometer. Never add water
to the system when boiler is hot. Never drain the water unless it is necessary. If a gas escape is sensed in boiler room, first close the
valve before gas flow meter. Never use match and never smoke in boiler room. Never turn electricity on/off. Ventilate the room
opening doors and windows and consult authorized installer staff or Gas Company immediately.
Follow the instructions for periodic cleaning and maintenance operations whose procedures given further in this manual.
The boilers can be installed directly onto a smooth level floor of non-combustible material. A steel base frame and a 50 mm thick
mineral wool mat to insulate the underneath of the boiler are included in the supply. A raised plinth shall be used. It is recommended
that the plinth be at 200 mm high and sized to the dimensions of casing of the boiler given as in the following table:
Recommended dimensions of plinths (mm)
Type
MK 320
MK 376
MK 436
MK 494
MK 552
MK 611
MK 669
MK 727
MK 785
MK 843
MK 901
MK 959
MK 1017
Width
1130
Length
1410
1540
1665
1785
1925
2050
2180
2305
2435
2565
2690
2820
2945
Height
200
Water Circulation System
The system design must provide water flow rates commensurate with boiler output and the temperature difference between flow and
return should not exceed 20 C or 25 C at most.
The return temperatures due to oil type fired should not be lower than the degrees given in «Technical Information» to operate the
boiler in non-condensing mode. In this case, your boiler can be operated without using a by-pass pump and there will be no
condensation in the boiler. As the flow temperature of your boiler can be changeable meeting different heat requirements of the
system without any condensation, the hydraulic circuit no more needs any devices to adjust the hot water temperature such as three-
way valves.
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Should the system is operated at temperatures below than those mentioned above, a by-pass pump or a three/four-way motor vane
should be used to increase the return temperature particularly in conditions natural gas or LPG used.
A by-pass pump must be used, should the system has a three way motor vane, because of the principle of preventing condensation
in the boiler.
Water levels should be checked regularly and any leakages corrected in order to keep system water make-up to a minimum, because
excessive make-up will lead to salt deposits forming in the boiler waterways causing local overheating and damage to the boiler
sections. Where there is doubt as to the quantity of water make-up, a water meter should be fitted.
Boiler water systems should be thoroughly flushed and cleaned before a new boiler is installed and system water should be treated
by a reputable specialist and best practice observed. Consideration should be given to the fitting of sludge traps and strainers if site
conditions warrant them.
Failure to apply and maintain the correct water treatment to prevent the formation of scale
Scale and corrosion within the heating system will render all appliance warranties null and void.
Safety of water circulation system
For heating systems with maximum boiler temperature up to 100 C
The system can be built either open vented or pressurized. In case of open vented heating system an open type expansion tank
according to DIN 4807 Part 2 shall be installed at the highest level of hydraulic circuit. Delivery and return lines between expansion
tank and boiler shall be constructed in accordance with DIN 4750. No globe valves must be installed on delivery and return safety
lines. Safety lines should be attached to inlet and outlet lines of boiler at points as close as possible to boiler, using the shortest
possible vertical way between expansion tank and boiler.
A hydrometer shall be installed on delivery line from boiler at a same level with top of boiler. After filling heating system, the minimum
water level should be recorded on hydrometer in order to check water level during operation.
In case of pressurized heating system a pressure relief valve according to TRD 721 shall also be installed on heating system to
ensure safety besides closed type expansion vessel.
For heating systems with maximum boiler temperature up to 120 C
In this case, each heating circuit is constructed pressurized and shall be equipped with diaphragm or spring-tensioned pressure relief
valves according to TRD 721.
Each heating system can be equipped with up to three pressure relief valves. For boiler nominal heat outputs 350 kW and above, the
pressure relief valve shall be connected to an open relaxation pot for safety of system. If this can not be established, an additional
safety temperature and a maximum pressure limiter should be installed on the boiler.
The sizes of diaphragm pressure relief valves on inlet or outlet of boiler according to boiler nominal heat output are outlined below:
Requirements on filling with water
For heating systems with maximum boiler temperature up to 100 C, the necessary water purification shall be in accordance with VDI
2035:
Boiler capacity range Nr. Requirements at the filling and auxiliary water.
100 < Q in kW <350 1 No requirement is needed, if content of Calcium Hydrocarbonate
(CA(HC03)) is max 2 mol/m³, and if no more than the triple water filling of the plant does not take
place.
350 < Q in kW <1000 2 Like 1, however content of Calcium Hydrocarbonate is1,5 mol/m³ max.
1000 < Q in kW 3 In this case, quantity of water, which can be fed without softening, is to
be determined after VDI 2035 equation If the system needs more filling and auxiliary water, this
must be demineralised.
Boiler output in kW
50
100
200
350
600
900
Connection to outlet
G 1/2"
G 3/4"
G 1"
G 1 1/4"
G 1 1/2"
G 2"
Connection to inlet
G 3/4"
G 1"
G 1 1/4"
G 1 1/2"
G 2"
G 2 1/2"
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The maximum quantity of water Vmax, which can be re-fed without softening as filling and auxiliary water, is determinable after
equation (9) the VDI 2035 sheet 1: Vmax in m³ = 0,0313 x Q in kW / Concentration of (CA(HC03)) in mol/m³. The quality of water is
important. The recommended hardness of water: 1-3 mol/m3 (1 mol/m3=5.6 dH), PH:8-9.5.
For heating systems with maximum boiler temperature above 100 C, the following
Salt-free
Salty
Electrical conductivity
at 25 C (µS/cm)
≤30
≤30-100
>100-1500
pH degree at 25 C
9-10,4
9-10,5
9-10,5
Oxygen (O2) (mg/lt)
<1,0
<0,05
<0,02
MK Jetstream Delivery Mode
An MK boiler delivered unassembled consists of following parts:
1. Boiler block: A block of sections, smoke hood and front door is delivered on a pallet for an easy shipping. The sections
are assembled in the boiler room. Refractory for combustion chamber insulation are mounted on the rear
section at the factory. Smoke hood is fixed to rear section and, front door refractory is placed in factory.
Each MK boiler block is shipped in two pieces:
1.1. Standard palette of intermediate/rear sections + smoke hood. From MK 8 to MK 14, four pieces of intermediate
sections, rear section, and smoke hood is delivered on one palette. From MK 15 to MK 20, nine pieces of
intermediate sections, rear section and smoke hood is delivered on one palette. Smoke hood
is fixed to rear section; rear cleaning covers and refractory of combustion
chamber on rear section are fitted to their correspondent places before shipment from factory.
Intermediate sections are shipped disassembled.
1.2. The remaining palette of intermediate sections + front section. The rest of intermediate sections, front section and front
door of boiler are shipped on one palette. Intermediate sections are delivered disassembled. Front door refractory
and insulations are placed and fixed before shipment. Front door is fixed temporarily onto front section for a secure
shipment. Before assembly of boiler in site, front door should be detached from front section. The materials
used in the assembly of the boiler block such as nipples, fibreglass ropes, flow and return connections; retarders
are delivered with in remaining palette of intermediate sections+ front section group.
2. Casing/insulation box: This box contains all casings and base frames (if required) together with all insulations of an MK
boiler. Auxiliary piping system for series MK 12 and above, and retarders set of boiler, and
control panel are also supplied in this box.
ASSEMBLY INSTRUCTIONS
Assembly of Boiler Group
Numbers in the parenthesis refer to position numbers in the exploded drawing.
1. Place steel profiles (174) which are used as base frames of the boiler parallel to each other as shown in Fig. 1. There are four base
frames for MK 8-10, six for MK 11-15, and eight for MK 16-20.
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2. Start with the rear section (1), clean all rope grooves on the section using a wire brush. Clean nipple ports using cloth and paraffin.
Apply adhesive to the rope grooves on the front side of the section Fit continuous lengths of 12 mm diameter. Rope (5) in each
groove of the section starting with the outer grove. Tape the ends of each rope to avoid unravelling. Apply jointing compound onto
nipples and place nipples (4) squarely in each nipple port, and using a wooden mallet, lightly tap nipple into the port to secure.
3. Take an intermediate section (3) and prepare the section as described above. Do not fit rope into the grooves on the side of
intermediate section facing towards the rear section. Likewise, fit ropes only to one side of the other intermediate sections which are
to be assembled later. Place the rear section at the end of the base frames.
With its un-roped side facing towards the rear, fit the intermediate section squarely onto nipples of the rear section and secure by
using a wooden mallet. Ensure that rope on rear section remains in correct position.
4. Continue boiler assembly repeating the same procedures with other intermediate sections. Apply "Compression Tools" passing
them through bottom and top nipples as shown in following scheme and accordance with the table headed "Usage order of
compression tools", until the rope between each section is firm. The gap between each section should be 4-5 mm (check the gap
using a screwdriver blade).
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After each application of compression tools, fit stay bolts (to secure group of sections to each other) (8,9) with M16 nuts (11) and
washers (10).
Do not use excessive force to tighten the nuts up on the stay bolts, from 48 to 54 Nm (35 - 40 lbf/ft) torque is recommended.
5. Prepare the front section (2) for the assembly. Apply special adhesive called fiberfrax supplied in accessory box into grooves of
front section facing towards the front door. Fit fibreglass rope braided 16x16 mm (29) in the grooves of the front section. Fit the front
section and make final usage of Boiler Compression Tools and correctly align the sections. Fit stay bolts (8,9) with M16 nuts (11) and
washers (10).
Fit two 2" plugs (22) into the ports of front section. For MK 8 and 9, fit plug 1 1/2" (181) on top of the front section. For MK 10 and
above, fit elbow 1 1/2" (182) on top of the front section, and auxiliary pipe (184) to the elbow. For MK 12 and above, there are two
auxiliary pipes. In that case, bring them together using pipe union (183). Piping from the elbow should be raised slightly and
connected into the main rear flow outside the boiler without fouling the top and rear casing. Fit studs M16x65 (20) to return and flow
connections of the rear section.
Hydraulic test
Fit 1/8" plug (155) supplied in accessory box into 1/8" hole on top of the rear section (with P2-A standard control panel, this hole is
not used). For 1/2" and 3/8" instrument tapings on top of the rear section, use 1/2" and 3/8" pockets for bulbs supplied within the
standard control panel or any suitable plugs. Fit a 3/4" plug into drain connection of the rear section. Use hydraulic test apparatus of
MK boiler. Fit bottom test flange with two globe valves and test gasket to return connection. Fit blank flange and the other gasket to
flow connection as shown in following scheme.
Alpha Tryon MK Floor Standing Cast Iron Boiler L334
19 17/08/2011 ©MHS Boilers
Fit closing piece with a gate valve to the end of the auxiliary pipe.
Connect a hydraulic press to one of the globe valves on test flange fitted to return connection. Fill the boiler with water by connecting
the other valve on test flange to the water circuit. Meanwhile, release the air left in the boiler via pocket bulbs holes on top of the rear
section. When the water comes out of the holes, fix the pocket bulbs again. Turn the valve connected to circuit off and turn the other
valve connected to the hydraulic press on. Pressurize the system via the pump on hydraulic press until the pressure gauge reaches
the test pressure.
Hydrostatic test shall be carried out at a pressure gauge of 1.43 x P; where, P is the maximum operating pressure of boiler. Duration
of test should be at least 30 minutes.
The hydrostatic test must always be carried out before boiler being jacketed or heat insulated, and connected to heating circuit.
After hydrostatic test, "Boiler Assembly Certificate" shall be filled in and signed by the erector/installer. In order to warranty terms of
boiler to be put into operation, make sure that this certificate is completed, signed, and sent to manufacturer. We recommend you to
ask for a copy of assembly certificate from erector/installer.
We recommend you to ask your erector/installer to record the data of boiler group such as boiler shipment group serial numbers,
production date etc. which will help both installer and manufacturer use for optimum customer care and technical feedback.
Alpha Tryon MK Floor Standing Cast Iron Boiler L334
20 17/08/2011 ©MHS Boilers
6. Fit distribution pipe (271/272) with gasket (12) squarely into the return connection in any position as shown in following pictures. Fit
flanged stub-pipes (13) with their gaskets (12) to the flow and return connections on the rear section. Fix the stub-pipes using M16
nuts(11) and washers (10).
7. Fit second pass retarders (67,70,72) in each of the four inner passages. Fit third pass retarders (76,79,83) in each of the four
corner passages with the ends of the tubes facing towards the front section. After placing all the retarders, pull them towards the
front section side as much as possible.
Jacket assembly MK 320-494
1. Fit cast iron hinges (229) used for carrying front door onto front section using two pieces of M12x50 Allen screws (32) for each
hinge. When fitting hinges to front door, place front support sheets (247) between front door and hinges.
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