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Contents

  The given Operation manual contains basic information relating to the practical use of the electrode boilers for the heating systems. By the aggregative technical and economic indices of effectiveness, including the boiler efficiency, simplicity of installation and repairing, cost of heating of one square meter of the apartment, specific consumption of materials per 1 kW of the boiler capacity, etc. the electrode boilers cannot be compared with any other type of the electric boilers. The areas of application of the electrode boilers continue to extend confidently. This Operation manual is intended for the electrode boiler installation specialists, experts in the installation of the automatic control systems for the electrode boilers, startingup and adjustment specialists, experts in maintenance and repairing, and owners of the boilers. We thank in advance those who will send remarks and proposals to the address of the “Firma “GALAN” Joint-Stock Company. All rights reserved. None of the parts of the given Operation manual can be reproduced in any form without written permission of the “Firma “GALAN” Joint-Stock Company which is a copyright owner. 

Introduction

   Invention of the electrode boiler is a one of the highest achievements in the area of creation of the multipurpose heating equipment. A long-term experience of successful operation shows that electrode boilers are easy operating, reliable, and safety devices. The boiler efficiency reaches 98%. This is a result of application of one of the best achievements of the domestic defensive industry in peace purposes. Throughout many years the boilers of the “Firma “GALAN” Joint-Stock Company are successfully applied in almost all regions of the Russian Federation, Post-Soviet republics and other foreign countries. 

Dear customer! 

  To use a complete set of advantages of our boilers and to avoid possible annoying errors in the process of installation of the heating system and boilers and in the course of starting, further operation, and usage of the electric boilers, we convincingly ask you to familiarize yourself attentively with the given Operation manual which contains information relating to the characteristics, construction, operating principle, application, and rules of installation of the electrode boilers. Also this Operation manual contains basic requirements imposed on the safety measures, installation, operation, and repairing of the heating system, registration and maintaining of the working documentation, etc. The boilers are intended for heating of apartment houses, including country houses, cottages, multistory apartment houses, garages, baths, premises and buildings of the domestic, household, trading, public, industrial, and agricultural purpose, and also other constructions in absence or inefficiency of the centralized heating. The “Ochag”, “Geyser”, and “Vulkan” instantaneous electrode heating boilers produced by the “Firma “Galan” Joint-Stock Company (hereinafter referred to as “boilers”) are used only in the looped heating systems working without extraction of hot water for household, industrial or any other purposes. These heating systems work on the basis of the compulsory circulation of the heat-transfer agent (by means of the circulation pump). According to the recommended most economic mode the temperature on an inlet of the boiler should lie in the range +35 ÷ +45ºС, and the temperature on an outlet of the boiler should fall in the range +65 ÷ +75ºC. These boilers are made only in Russia. The specified temperature in the heated premises is supported by the automatics (by means of the temperature regulator). The boilers have a long operating mode.

  For normal operation of the boiler the following conditions are necessary:

  • Operation air temperature of the premises in which the boiler is installed should lie in the range between +10 to +35ºС; ultimate air temperature of the premises in which the boiler is installed should fall in the range between 4 +10 to +40ºC (under condition of absence of other requirements);

  • Relative humidity of an air at the temperature of +20ºС should be no more than 75%; 

  • Non-explosive environment; the environment should not contain aggressive gases and steams destroying metal and isolation; the environment should not contain an industrial dust in quantities adversely affecting the boiler operation.

  There are no combustible materials in the construction of the boilers, therefore our boilers are fireproof. Boilers meet the requirements of the Technical Specifications (TS) No. 3468- 00117289826-02. Order designations: “Galan – XXX-№” electrode boiler (“XXX” is a name of the boiler). Annotation: “№” is a power of the boiler in accordance with the Table 1. Example: “Galan – Ochag-6” electrode boiler. 

All of the “Ochag”, “Geyser”, and “Vulkan” electrode boilers described in the Table 1 are certified. Number of the certificate of conformity: РОСС RU.ME71.H00072 dated 29.03.05. The Certification authority: The Electrical Products Certification Authority of the Independent Noncommercial Organization on Certification of the Electrical Products, 109052, Moscow, ul. Nizhegorodskaya, 29. Voluntary certification. 

 It is recommended to use the following types of liquids as heat-transfer agents for all of the “Hearth”, ”Geyser”,
“Vulkan” electrode boilers of the “Firma “Galan” Joint-Stock Company which are listed in this table:
         • “Galan-Potok” low-freezing liquid with special rust prevention components and additives against formation of
scale and scum (freezing temperature: -40º C, life expectancy: no less than 5 years, warranty period: 1 year)
(hereinafter referred to as “low-freezing liquid”);
         • Potable water (defined by the Sanitary Regulations and Rules No. 2.1.4.559-96), distilled water, snow melt water,
rain water (filtered water) the specific electric resistance (hereinafter referred to as “resistance”) of which is no
less than 1300 Ohm/cm at a temperature of +15º C.
   ATTENTION!
It is strictly forbidden to use low-freezing liquids (antifreezes) such as “TOSOL”, “Arktika”, “Tvoy Dom”, etc. as heat transfer agents since they are not intended for a use by the electrode boilers.

Advantages of electrode boilers
 

Boilers of ZAO "Firm "Galan" are made only in Russia (10 types, tab.1). They are not only cheaper than the similar in power boilers of all other types including foreign, but have a variety of meaningful advantages:

   The considerable power saving at the expense of extremely high efficiency of electrode boilers which reaches 98%, which is much higher than in other heating boilers. It is reached by the direct conversion of electrical energy in thermal directly in the heat coolant while current flow via the coolant, by molecules ionization, thus temperature of the coolant and its conductivity increase, the electric current which goes from an electrode to an electrode also increases, and the boiler quickly reach the nominal rating power.

Saving from 40% to 60% of input energy as a result of high-speed performance of electrode boilers, application of:

  - electronic temperature controllers "Navigator"

  - temperature controllers "Stoker"

  - cellular remote control "Galan GSM"

- electromechanical variant of automatic equipment.

   Simplicity of mounting, small sizes and light weight of electrode boilers. For example, the boiler with capacity 6 kW weighs 1,1 kg, 25 kW  - 5,7 kg weigh.

 

Possibility of imbedding our boilers in previously installed heating systems (in case of obligatory carrying out of our recommendations), also as the second reserve (parallel connection of a boiler) pic.№3. Capacity of a reserve boiler has to correspond to the size of heated space and the quality of heat insulation, the number of coolant in heating system (tab.№1).

In case the reserve boiler is set in operating heating system, it is necessary:

   • carefully, using corrosion inhibitor "Galan-Protector" wash out the system;

   • to filter the coolant;

   • to take measures to prevent the ingress of contamination from heating system in boiler, to set filters.

In case of using plastic pipes in system it is necessary to change a few meters of pipes in the input and output of a boiler to non-galvanized ("black") pipes.

   Possibility of repeated increasing of heating system power (cosequently increase of heated space capacity) by parallel connection of a large number of boilers. For example, connection of 8 boilers with capacity 25 kW each increases the capacity of heating system up to 200 kW. (pic.№2).

It is forbidden to use electrode boilers:
 

   • for "direct" heating of water, which directly goes to the boiler from a water body, an artesian well, a water well, a water supply system, the river etc. "directly" goes to a boiler. Our boilers are intended for using in heating systems. The water used as the coolant, shall correspond precisely to passport data of a boiler, as otherwise the boiler fails. Water also can't be selected from heating system for hot water-supply:

   • for installation of "heat-insulated floors" as temperatures required in this case are significantly lower than optimum working temperatures of an electrode boiler. For this reason the boiler doesn't reach a rated capacity. For this reason for "warm" floors we recommend to use high-reliable modern thermoelectric  boilers like Hearth -Turbo, Geyser-Turbo, Volcano Turbo ZAO "Firm "Galan" production.

Not recommended:

   • application of electrode boilers in heating systems in which large-size (large volume) heating radiators are installed: radiators with tubes of big diameter,       cast iron radiator, etc. In this case it is recommended to apply electric boilers like Hearth -Turbo, Geyser-Turbo, Volcano Turbo ZAO "Firm "Galan" production.

If, by force of circumstances you have no other exit except applying an electrode boiler, it is necessary to provide compliance of the coolant volume (number) which was filled in the system with boiler  capacity (tab.№1).

Besides, while using the cast iron radiators it is necessary to install extra coarse-mesh filter to the "return" line, the mood collector (sump) to prevent an event when the remains of the rod earth get from internal cavities of heating radiators with coolant to a boiler and put it out of action. With the same purpose it is necessary to wash out carefully cast iron radiators before installation in system.

 

Recommended delivery set

Boiler assembled – 1 pce.

Application and exploitation of electrode boilers in heating systems– 1 pce.

* Automation system – 1 set

** The maintenance manual of automatic equipment – no dupl.

Packing – 1 pce.

Note:

* The main actuation device, recommended by ZAO "Firm "Galan" is the two-channel temperature controller "Navigator". At will the buyer can install an electrical equipment according to the schemes below.

The guarantee don't apply to a boiler which was acquired without this automatic control system of its work.

Automatic control system cost isn't included into the cost of a boiler.

** For the Management exception for electromechanical option of automatic equipment as it is included a component into this manual. With this option of automatic equipment offered the buyer, can change.

Boilers arrangement
 

Depending on the efficiency ZAO "Firm "Galan" produce two groups of boilers – single-phase and three-phase:

   • the single-phase: - " Hearth -2", " Hearth-3", " Hearth -5" and " Hearth -6";

   • the three-phase: - "Geyser-6" "Geyser-9", "Geyser-15", "Volcano-25", "Volcano-36", "Volcano-50"

Single-phase boilers consist of:

   • the metal case with branch pipes of an coolant inlet. The case also fulfills functions of the second electrode and the ionization chamber;

   • rod electrode with a current lead and a with a tight isolating feedthrough;

   • 2-terminal groups with protection covers. In single-phase boilers there is the terminal  – a phase, sideways below settles down: the jumper – a zero wire, the jumper – an earth wire.

Three-phase boilers consist from:

   • the metal case with branch pipes of an coolant inlet. The case also fulfills functions of the ionization chamber;

   • the bases on which 3 electrodes with current leads and hermetic flow electrical insulators are set;

   • terminal group with the protection cover.

The operating principle of boilers is identical and is considered below.

Electrode boiler installation (mounting) in heating system

Heating systems projects, boiler installation works, automatic equipment, electrical grid connection (including electrical grounding), placing in service, repairing, witness point of a condition, testing works must be performed by the organization (firm) which have the corresponding license for it's carrying out.

In performance of the listed above works, execution of heating systems documentation, and also while operation have to be observed:

   • "Intersectoral electric installation code" (EIC);

   • "Rules for Operation of Customers' Electrical Installations";

   • "Power system safety standards";

   • "Procedure for Design and Safe Operation of electric boilers and electric boiler house";

   • Present manual.

Also it is necessary to observe "Regulation of fire safety of Russian Federation", which correspond to the Building code.

For boiler connection, installation of heating systems automatic control, their service, including repairing, it is necessary to have electricians or specialists in instrumentation and control systems of the corresponding qualification, certified and allowed to work with electro installations to 1000B, with a group of electrical safety not lower than 3. For installation, operation and repairing of heating systems heating engineers are necessary.

The experts mentioned above have to know "Procedure for Design and Safe Operation of electric boilers and electric boiler house", the present manual. During the works with corrosion inhibitor, low-freeze liquid, washing and cleaning means for surfaces, need to know and comply with the rules of the safe application.

   Upon completion of the listed above works, the organization (firm), which performed these works makes entry in Sheets (Appendix No. 2) which is certified by the contractor and by the press of this organization.

   Attention! Warranty liability extends on the copper, installed according to the above mentioned requirements, with appropriate execution of the performed works. The guaranty does not extend on the boilers, which were not established according to the project or by the unauthorized organization, or not certified experts.

The boiler work can be monitored only by the person, not younger than 18 years, passed the corresponding instructing, who knows the present manual, the boiler design and the rules of safe monitoring of its work.

Boiler connection to electric grid of the energy provider.

In case the allocated power is not enough, boiler connection is performed according to established procedure.

It should be noted that this order of connection to the energy provider to electric boilers of all other types and is not only an electrode boilers feature.

Grounding.

By the time of boiler installation the grounding in heating system has to be completely executed and tested.

Resistance value of the grounding. Grounding resistance value of a boiler and a heating system has to be no more than 4 Ohms. As the grounding conductor it is used a copper wire with a section of 4-6 mm2 (tab №1). Safe execution of the grounding has to correspond to EIC. "Procedure for Design and Safe Operation of electric boilers and electric boiler house"

All open electro-conductive parts of a boiler and heating system, including metal conduits of the cold (return water) and the hot coolant have to be grounded.

Input of the grounding conductors in the building or construction has to be marked by the identification sign.

Ground leads

Ground leads have to conform to EIC requirements. The design and execution of the ground lead have to provide demanded resistance value of the boiler and heating system grounding at most 4 Ohms.

Term of periodic inspection of the grounding condition is 12 years.

Corrosive wealth should not exceed 50%.

It is forbidden to color the body of ground lead to protect it from corrosion by removable or constant dielectric coverings. For example, plastic or rubber boots.

Adjustment of the conductivity of water.


Switch on the boiler and after 30 seconds at the temperature of "the return heat carrier" of 15 °C ÷ 20 °C, measure starting current using an ammeter or current clamp. Switch off boiler. Three cases are possible: starting current is greater or less than specified in tab.№4 for your boiler or equal to tabular

Filling of the heating system with the coolant

Your system is installed. A boiler and automatic control system are mounted, also connection to the grounding power supply network is made. The heating system is without dirt and corrosion.

In this case filling of the system with the coolant is made without preliminary washing. It is necessary to meet the following conditions:

* the heating system has to be surely disconnected from the power supply network at any filling of the system with water or low-freezing liquids. It is necessary to exclude the case of connection to the power supply network.

* Right after filling system with a coolant needs to check the system integrity. Any leakages are inadmissible.

Filling with low-freezing "Argus-Galan" liquid or water (tab.№1) is possible.

Water as the coolant, possesses a number of undoubted advantages, such as availability, low price, environmental friendliness, high heat physical qualities. At the same time such disadvantages, as corrosion of heating system, possible necessity of water resistivity adjustment during the heating season, carrying out of a boiler annual repairing, etc. Therefore, without denying use water as the coolant, we recommend you to apply a modern low-freezing "Argus-Galan" liquid as the coolant.

Using of water as the coolant

It is necessary to increase or decrease a water resistivity (further - adjustment) to maintain boiler operation with a passport capacity. Adjustment ("control") of resistance is carried out after the system is filled with water, by addition in water of solution of table salt or water with a high resistance and achievements thus tabular values of starting (starting) and maximum current (tab.№4) at certain temperatures of a return water (further – "Entrance"). It is necessary to carry out instructions of our Management pronouncedly:

  • the temperature of the boiler input ("input" detector) has to be 15-20ºC;

  • boiler on-time is no more than 30 sec.

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Boiler installation (mounting) in the heating system

Before installation it is needed to examine a boiler and to check its completeness.

The boiler is installed in heating system strictly vertically. Thus the terminal group (current leads of a boiler) for connection to the power supply network has to be situated from below, protected from external influence and accidental contact with the protection cover (cap). For boilers of the "Hearth" series (220V) the terminal – phase also has to settle down from below.

Connection of branch pipes of a boiler with piping of heating system is performed with the use of sanitary sleeves with DU not less than DU of branch pipes of a boiler and according to the project. In the design of heating system it must be provided:

   • the copper needs to be installed as low as possible towards heating radiators as it raises output pressure of a boiler.  Thus it is advisable to provide a vertical spacing, which will be enough for free removing of electrode group from a boiler, inspection and cleaning of its internal surfaces.  Diameter of a riser board over  the boiler, as diameters of all heating system piping are strictly according to the design of your heating system. The height of a riser board over the boiler need to be not less than 2 m.  It is one of conditions for not using of the circulating pump.

While installation, the boiler has to be attached to a wall apart from the way of its connection with heating system.

On the pic.№1, 2, 3 there are provided some schematic diagrams of execution of heating systems. For convenience of heating system service it os advisable to install pipe stops right after a expansion tank and before an inlet branch a boiler (look pic.№1, 2, 3).

Strictly forbidden

Installation of any cranes, any isolation or control valves on a pipeline section between an outlet fitting of a boiler and an expansion tank.

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The name of the equipment

1, Electrode boilers

2. Radiator

3. Balancing tank

4. Backup electrode boiler

5. Basic boiler working on hard or gas fuel

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Attachable thermostat

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Valve

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Filter (setting, mud collector mechanical)

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A valve for discharging of a heat carrier from the system

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A valve of air discharge

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Circulation pump, capacity is 70-100 W

A    

A vertical riser over the boiler, not less than 2 m high. DN-40, DN-32

On application of: remote cellular control system and control of the equipment "Galan — GSM", electronic temperature control "Navigator", "Stoker"; electromechanical option – strictly follow the connection schemes, specified in the Maintenance manual. Precisely fulfill requirements for operation, installation, safety. The temperature detector "Entrance" is installed on the pipeline, "return pipe". The sensor "Exit" - on the pipeline, an exit from the boiler (a riser board) at distance of 30 cm from a boiler exit (from a boiler branch pipe).

Recommended optimum working temperatures of the heat conductor on an entrance and an exit from the boiler, verified by long-term experience, are noted above.  These modes guarantee reaching of the maximum effect.

Regulation band of a heat controller "Navigator" at the exit from a boiler ("Exit" sensor) is 10+85ºC, on an entrance to the boiler ("Entrance" sensor) is 10+80ºC.

In heat controllers "Stoker", "Galan GSM" the temperature is measured directly in the heated room which significantly increases efficiency of the heating system and comfort in heated rooms.

For installation of automatic heating system control it is advisable to use a cooper wire with a section of 0,5-2,5 mm2. (Copper) A brand of a wire has to be specified in the project of your heating system and in the Managements of automatic equipment.  If you use   a multicore copper wire, apply a cable shoe, but do not tin the wire end as it can cause a poor contact.

Electrical schematics of connection via the two channel electronic regulating temperature indicator "Navigator" are given in the maintenance manual for the "Navigator."