Cast Iron Boiler Selection & Purchase for Engine Rooms

The cast iron boiler is a vital piece of equipment in the engine rooms, and with the burner, it provides hot water for the heating system and consumption. We provide you with specifications, capacity estimates, replacement methods, selection guides, and unbeatable prices for all cast iron boilers.

Review, Selection, and Purchase Guide for Cast Iron Boilers

In general, all types of boilers (either cast iron or steel) that are installed in the engine room give the building the ability to provide hot water for heating equipment such as radiators, fan coils, swimming pool, and other hot water consumptions, using the thermal energy of the boiler burner.

Even though the working pressure and thermal energy absorption efficiency in cast iron heating boilers are lower than steel boilers, what makes a cast iron boiler a better option in some cases is the ability to separate its fins for easy transportation. As well as its affordable price and easy replacement of the parts during its operation period.

Features & Benefits of the Cast Iron Boilers

Here are some of the cast iron benefits and features yet not all of them:

• Easy transportation of cast iron (fin) heating boilers due to the ability to separate the sections from each other.
• Resistant to rust and wear.
• The price of cast iron boilers is more reasonable than steel boilers (standardized) in the same capacity and working pressure.
• Increasing or decreasing the heating capacity of the boiler by increasing or decreasing the number of sections of the cast iron heating boiler in the engine room.
• The ability to repair and replace sections and replace them with new sections if any of the blades of the cast iron boiler are punctured.

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How to Calculate the Required Capacity of a Cast Iron Boiler

To calculate the approximate capacity of the cast iron boiler in weather conditions like Tehran, first, multiply the infrastructure of the building by 100 (kilocalories), and then, for each residential unit, add an extra 6000 (kilocalories) for their water consumption.

For Example, For a building with a useful infrastructure of 2500 square meters and 18 apartment units, the required heating power of the cast iron boiler is 358,000 kilocalories = (18x6000) + (100x2500). Usually, after this calculation, up to 20% as a safety factor is added to the calculated capacity.

Approximate capacity of cast iron boiler (kcal/hr) = (100 kilocalories * useful infrastructure area of the building) + (6000 kilocalories * number of residential units) + (necessary heating for swimming pool)

To calculate the capacity of the cast iron hot water boiler required based on the number of units, the size, and type of building, the presence or absence of a hot water pool, etc., you can consult with the experts of DamaTajhiz HVAC.

Factors to Consider When Choosing and Installing a Cast Iron Boiler

Here are the most important factors you should keep in mind when choosing and installing a Cast Iron Boiler:

The Possibility of Defects and/or Failures

Considering the importance of the boiler and burner as the heart of the central heating system of any building and the need to consider the possibility of defects and failures in their operation (in the long term) as well as the possibility of saving as much fuel as possible.

So if the number of residential units in the building is 8 or more, or the total area of the useful substructure of the building is more than 1000 square meters, it is recommended to install two cast iron boilers (according to the installation standards), so each one can provide 60% of the heating capacity required for the entire building.

Cast Iron Boilers for Public Service Buildings

In public service buildings such as hospitals, hotels, etc., regardless of the type of boiler selected (cast iron or steel boiler), for the central heating system, according to the recommendation of international engineering standards, 3 boilers are required, each with the power to provide 75% of the building's heating power needs should be installed. So that even if one of the burners or boilers is damaged or causes any problems, other boilers can provide a major part of the work.

The Location of the Engine Room

Considering the importance of the engine room of the buildings as a power center for providing cooling and heating, it is recommended that the location of the engine room should be considered. In such a way that, in addition to the possibility of easy movement and a large entrance door to carry required equipment, it should have a large area, as well as having sufficient light and proper ventilation.

Also, Considering that the installation of all the main equipment of the engine room, including the central boiler, is done on the pre-made concrete foundation with suitable dimensions according to the placement plan and exactly where the equipment is located. Therefore, before installing the main equipment of the engine room, including the cast iron boiler.

Cast Iron Boiler Cover

After installing and sealing the cast iron boiler in the engine room, installing the boiler cover prevents heat loss and overheating (due to the layers of glass wool or stone wool inside the boiler cover), in addition to finishing and beautifying it.

Thermostat & Thermometer

Installing a manometer thermometer to display the temperature of the hot water and the pressure of the device is mandatory on every hot water boiler.

It is also necessary to install a submerged programmable thermostat (Augusta smart thermometer) with a temperature range of 30°C to 90°C (or 30°F to 110°F) to adjust the boiler temperature as well as the ON/OFF command to the burner relay on every cast iron boiler. So when ordering a cast iron boiler, you can order the Augusta smart thermometer (IMIT, Honeywell, or other brands), as well as a thermometer and manometer (Fimet or any other brand) from the sales experts of DamaTajhiz HVAC.

Note: Cast iron hot water boilers are usually used in the engine room of apartments and houses that, firstly, have a smaller engine room, and secondly, it is not possible to easily pass a large and integrated steel boiler in them.

The Minimum Equipment Required for a Simple Engine Room

Here are the 14 most essential pieces of equipment every simple engine room should have:

1. A central boiler (either cast iron or steel)
2. A submerged Augusta smart programmable thermostat for the boiler
3. A Manometer thermometer for the boiler
4. A Burner (desired fuel type)
5. A gas hose and filter with the right size (or diesel nozzle and filter for diesel burners)
6. A Hot Water Tank (coiled or double wall tank)
7. A temperature and pressure valve
8. A linear circulator pump (usually 2 inches HV, 2 inches AA, 2 inches A6 or 2 inches A7, etc., based on the infrastructure size)
9. A septal Augusta (to operate circulator pump command)
10. A water return pump (usually a linear pump)
11. A one-inch hot water return flange
12. An expansion tank (either galvanized or aluminum)
13. An expansion tank float valve (metal or plastic)
14. An engine room electrical panel with at least 5 cells

Estimating the Boiler Heating Capacity Required for Pool & Hot Tubs

In order to approximately calculate the required heating power for a pool and/or hot tub and add it to the heat capacity of a boiler (cast iron or steel), use the following formula:

In the above formula, the pool water volume is in (liters), and the temperature difference is in (Celsius). Usually, the temperature difference between the water entering the pools is about 20°C. The temperature difference between the water entering the hot tub is about 30°C (due to the 10-12 °C of the water in the pipes), and these numbers should be included in the above formula as "ΔT".

However, the swimming pool water heating time is not subject to specific rules and is included in the above formula according to the type of pool usage. However, on average, the heating time in private pools is between 18 and 24 hours, in public pools between 48 and 72 hours, and hot tubs between 4 and 8 hours.

Notes:

1. The amount of heating obtained from the above formula is suitable for indoor swimming pools and hot tubs, and for outdoor pools, this number should be doubled!
2. In general, the numbers obtained from the formula above are approximated, so it is recommended to add about 10% to the obtained capacity when choosing a boiler (either cast iron or steel boilers).

The Main Components of the Cast Iron Boiler

Cast iron boilers are made up of different components, each of which has its tasks in the operation. The components of a cast iron pot are as follows:

• Cast Iron Fins: After these fins are connected by bushing and boiler paste, the incoming water flows inside them, and after being heated by the flame of the burner, it leaves the boiler.
• Inlet and Outlet Water Flanges: The inlet and outlet water pipes of the boiler are connected to the flanges.
• Flame Inspection Valve: This valve is installed on the body of the boiler to observe the burner flame and combustion performance.
• Four Restraining Rods: Restraining rods are used to keep the cast iron blades of the boiler stable relative to each other.
• The Chimney Connection: By connecting to the chimney, it is responsible for removing the gases from combustion.
• Boiler Cover and Insulation: Boiler cover and insulation (body sheets) are installed to prevent heat loss and the beauty of the boiler.
• Burner: The burner is responsible for creating the required flame at the moment of ignition of the cast iron pot.

The Most Important Factors that Can Increase the Lifespan of a Cast Iron Boiler

These 8 rules of thumb will help you increase the life of your cast iron and let you benefit from its performance for years to come:

1. Choosing the appropriate capacity of the boiler so that even on the coldest days of the year, the boiler does not have to work continuously and without interruption.
2. Choosing the right burner (maximum 20% more than the boiler capacity).
3. Use a proper resin water softener based on the water volume, as well as a scale remover on the engine room pipes in a sufficient number and size.
4. Adjust the burner flame (blue flame and direct longitudinal to the boiler).
5. If a diesel burner is used, the type and angle of diesel injection from the burner nozzle are determined based on the diameter and length of the combustion chamber of the boiler and according to the suggestion of the boiler manufacturer.
6. The appropriate length of the combustion chamber of the boiler and the non-permanent impact of the flame on the rear or middle fins of the boiler.
7. The continuous thickness in all parts of the cast iron boiler body.
8. Proper sealing of the fins during installation, leakage check, and controlled pressure of the water circulation inside the boiler.

Buying a Cast Iron Boiler for the Engine Room

According to the capacity, cast iron boilers consist of a number of middle fins, the front fin, and the rear fin, which are connected by bushings. The front and rear fins are different, while all the middle fins are the same.

In order to be able to buy the best cast-iron boiler that suits your needs, you must first determine the capacity, dimensions, and working pressure of the device. On the site of DamaTajhiz HVAC, the technical information of dozens of cast iron boilers from reputed brands with their main guarantee has been provided for you to enjoy the good feeling of optimal and smart shopping.

The Price of Cast Iron Boilers of the Engine Room

Choose and examine all types of cast iron heating boilers at the best price on the DamaTajhiz HVAC website. The price of cast iron boilers varies based on model, capacity, working pressure, and brand.
It should be noted that the cast iron boilers prices presented on DamaTajhiz HVAC are all up-to-date with a discount on them.

Dear Users

If, after reading the above material, you have more questions about deciding to buy different types of cast iron boilers, diatomaceous, and cartridge cast iron boilers, you can contact the heating equipment sales experts at extension numbers 107 - 108 - 121 - 122. Get cast iron boiler advice and ask your questions.
Because the specialized group of DamaTajhiz HVAC Group provides all kinds of cast iron boilers in the Middle East region, if you need a cast iron boiler for any of the countries in the region, you can place your purchase order with confidence, product guarantee, and reasonable price. Please leave it to our sales experts.

"Buy with confidence and peace of mind from DamaTajhiz."

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