Technical manual EN

MA

RK

GSW

+06

6030

2_R

04

Index

Warranty policy 3

1 General information 4 1.1 General recommendations 4 1.2 Description of the units 4 1.3 Operation 5

2 Technicalspecifications 6 2.1 Specifications 6 2.2 Relationship load / performance 6 2.3 Description of the components 7 2.4 Dimensions 8 2.5 Electrical overview 9

3 Installation 10 3.1 General rules 10 3.2 Securing of the unit 11 3.3 Connectionofthefluepipeandairsupply 12 3.4 Connection condensate pipe 16 3.5 Gas connection 17

4 Controls 18 4.1 Comtherm 18 4.2 Connection of the control 21

5 Commissioning 22 5.1 Commissioning 22 5.2 Burner setting 23

6 Troubleshooting 24 6.1 Troubleshooting 24 6.2 Spare parts 25

7 Maintenance 26

8 Recommendations for the end user 28 8.1 Safetyrules 28 8.2 What to do in case of a problem? 28

2

Warranty policy

CE-markingThereleaseoftheCE-markingistheofficialrecognitionofthequalityofdesign,manufacturerandperformance of this unit. The life and performance will be at the highest level when the implementation andmaintenanceareproperlycarriedoutanddonebytheregulationsinforce.

ResponsibilityThisunitmayonlybeusedforwhichMARKhasdesignedandfabricatedit.MARKcannotbeheldliablefordamagestopersons,animalsorpropertyifitiscausedbyerrorofinstallation,controlsormaintenanceornotpermissibleuseoftheunit.Theunitmayonlybeequippedwithoriginalaccessories.MARKcannotbeheldliableforanydamagesresultingfromuseofanaccessorythatisnotsuitablefortheunit.

Theunitsmustbeinstalledbyqualifiedprofessionals,incompliancewiththeapplicableregulationsandinaccordancewiththeinstructionsinthismanual.Thereferencestothestandards,rulesandguidelinesmentionedinthismanualareforinformationpurposesandareonlyvalidonthedateofissuethereof.

MARKisresponsiblefortheconformityofthedevicetotheapplicablerules,guidelinesandstandardsatthetimeofcommercialization.Theknowledgeandcompliancewiththelegalprovisions,aswellasthenormsinherentinthedesign.Projectplanning,startupandmaintenancearetheresponsibilityoftheconsultant,theinstallerandtheuser.

Delivery – StorageTheGSW+isdeliveredonawoodenpallet,protectedbyacardboardboxandaplasticfilm.Immediatelyafterarrival,theconditionoftheunitdeliveredmustbechecked(evenifthepackagingisintact).Additionally,ensurethatthedevicedeliveredcorrespondswiththeorder.Withregardtotheproductwarranty:thegeneralconditionsofMARKareinforce.

3

1 General information

1.1 General recommendationsThegas-firedcondensingairheateroftheGSW+seriesareintendedfortheheatingofindustrialandrelatedareas.Theunitsmayonlybeinstalledinside.Theunitsmayonlybeusedinwellventilatedareas.The proper functioning of the heater depends on proper installation and commissioning.Installationandmaintenancemustbeinaccordancewiththeapplicableregulationsandbecarriedoutbyqualifiedpersonnel.Withthenon-complianceoftheserulesallresponsibilityofthemanufacturerexpires.

DONOTINSTALLGAS-FIREDCONDENSINGAIRHEATERSIN:–Roomswithexplosionrisk;–Roomscontainingchlorinefumes(orcombinationsthereof);–Veryhumidrooms(electricalhazard).Itistheresponsibilityoftheinstallertoensurethatduringassemblytheinstallationinstructionsdescribedarefulfilled.

Itisexpectedfromtheinstallerto:

1°)informtheuserthat:– Theusermaynotmodifythedesignoftheunitsortheimplementationofthesystemapplication;–Anymodification(exchange,omission)ofthesafetycomponentsorpiecesthataffecttheefficiencyof theunitorthecombustion,automaticallymeanstheCE-markingisexpired;– Itisannuallyrequiredtoperformtheprescribedmaintenanceandcleaningactivities.

2°)handoverthismanualtotheuser.This is an integral part of the unit and should be kept with the unit even if it is transferred to another owner or user.

Weareinvolvedwiththequalityofourproductsandwishtoimprovethempermanently.Wethereforereservetherighttochangethespecificationincludedinthisdocument.

1.2 Description of the devicesTheGSW+gas-firedcondensingairheaterisastandalonehotairgenerator,makinguseofthefuelsnaturalgasorpropane.ItisbuiltandtestedtoEuropeanstandards2009/142/CE,Gasappliancedirective,(EN1020:2009andEN1196:2011).Certificatenr.0461CN1002issued25/10/2012.

TheGSW+isagas-firedcondensingairheater.Forallunitsdescribedinthismanual,thefluegasesaredischarged to the outside. Use is made of a fan that is arranged on the discharge side of the combustion chamber.Thecombustionairmaybesuckedfromtheinsideoroutside.Theseunitscanbeconnectedtoanexhaustsystem,typeC13-C33-C53,orontoachimneyoutlet,typeB23.

4

1.3 OperationThegas-firedcondensingairheateroftheGSW+seriesareintendedfortheheatingofindustrialandrelatedareas.TheGSW+airheatersconsistofagas-firedboilerandahotwatercoil,placedintheairflow.Theairthatisblowninbythefanwillbeheatedbythecoil.Thistechniqueprovidesaperfecthomogeneityoftheairtemperature.Unlikeaconventionalairheater,thepartialorcompleterestrictionofairfloworaninterruptionoftheelectricalpowerduringoperationwillnotdamagetheunit.

Thecombustionsectioniscompletelyisolatedfromtheaircircuit,whichmakesitimpossibleforthesystemairtomixwiththecombustiongases.TheunitisequippedwithaburnerwithlowNoxemissions.Thecombustionairissuckedinbyafanwithavariableflowrate.

Theairissuckedinbyaventurisystem.Thissystemmakessurethatthegasandairovertheentirerangeareintherightproportion.Theair/gasmixtureisfedtotheburner,locatedinthemiddleoftheboiler.

Theflameandfumeswillgothroughtheheatexchangertwicetogiveoffmaximumpower.Thankstothistechnology,anefficiencyofatleast98%atthemaximumloadsand108%atfullmodulationcanbeachieved.Theoptimizationoftheperformanceofacondensationsystemisinfluencedbyitscontrols.Thelowerthepoweroutputoftheairheater,thegreaterthecondensationandthusthehighertheefficiency.ThemodulationrangeoftheGSW+is30%ofthemaximumload.

The electrical control of the air heater is connected to the room thermostat. The control device provides the continuous modulation of thermal power.

The modulating effect of the GSW+ heater guarantees perfect adaption to the real heat demand of the building.Inversionsequippedwithfanswithavariableflowrate,onecanalsovarytheairsupply.

5

2 Technicalspecifications

Axial modelsThecondensinggas-firedairheatersaredesignedwithaxialfansthatmeettheEuropeanrequirements2009/125/EC.Optionally,theunitcanbeprovidedwithafanthathasavariableairflow.

Thedeviceisdesignedasfreeblowing,providedwithhorizontal louvres.

2.1 Specifications

TYPESGSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70

max min max min max min max min

Nominalload(highervalue) kW 30 7.5 40 10 50 12.5 70 17.5

Nominalload(lowervalue) kW 27 6.5 36 9 45 11 63 16

Nominal power kW 26.5 8.2 34.9 11.5 44.1 13.6 61.7 18.3

Efficiency % 98 108 98 108 98 108 98 108

∆Tofairflow °C 25.6 8 28.5 8.8 27.3 8.5 28 8.7

NoxClass Val. 5 5 5 5

Gasconsumption(15°C)NeutralgasG20(20mbar)NeutralgasG25(25mbar)PropaneG31(37mbar)

m³/hm³/hkg/h

2.863.16 2.10

0.720.790.53

3.824.21 2.81

0.961.050.70

4.775.26 3.51

1.191.320.88

6.687.37 4.91

1.671.841.22

Airdisplacement(15°C) m³/h 3000 900* 3600 1080* 4700 1400* 6400

Motor:electricalpower/RPM W/RPM 220/1000 320/1350 500/1350 520/900

Combustion air ø mm 80 80 80 80

Gasflueø mm 80 80 80 80

Condensation connection ø mm 32 32 32 32

Gas connection ø 1/2”M 1/2”M 1/2”M 1/2”M

Electrical connection 230/240VIF~50Hz

Electrical power W 340 460 640 730

Watervolume(glycol-15°C) L 6.6 7.2 9.2 11.2

Operating temperatures °C -15/+40 -15/+40 -15/+40 -15/+40

Max.condensateamount l/h 1,8 2,4 2,9 5,2

Weight kg 88 99 110 135

* With modulating EC-fan.

6

2.2 Relation load / efficiency

Thepowerratingsapplywithanairreturntemperatureof16°C.Theefficienciesweredeterminedatawaterregime54°C/80°C(maximumpower)and29°C/38°C(minimumpower).Theefficiencyvariesinfunction of the air return temperature.

2.3 Description of the components

AxialfanLineprintStainless steel boilerBurner controlsGas valveSiphonBurner doorGasmixerCombustion air fan

Waterflowsensor Temperature sensor Overflowvalve Water pressure sensor Pump Expansiontank Horizontallouvre window Air/waterheat exchanger Gas pipe complete

Ef. %

108

107

106

105

104

103 30

102 40

50101 70

100

99

98

5 10 15 20 25 30 35 40 45 50 55 60 65 70

Power (kW)

7

1

2

3

4

5

6

789101112

13

14

15

16

17

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1818

2.4 Dimensions

A B C E F G I J K L M N P(Air)

Q(Gas)

GSW+ 30 1079 574 605 120 470 280 450 625 350 400 90 165 80 80

GSW+ 40 1080 624 605 120 470 280 450 674 350 400 90 165 80 80

GSW+ 50 1192 674 605 120 470 280 450 724 350 400 90 230 80 80

GSW+ 70 1277 774 605 120 470 280 450 824 350 400 90 320 80 80

Dimensionsinmilimeters(mm)

8

C

B

A

Q

P

E

F

G

J

N

MI

L

K

9

2.5 Electrical overview

Comthermsupply(JP18)Blue-AboveOrange - Center(seephotoonpage20)

Water pressure sensor

Waterflowsensor

Exhausttemperaturesensor

Retour water temperature sensor

Inletwatertemperaturesensor

Room temperature sensor

ModBus

PWMmodulatingfan(option)

230Vpowersupply

Maximalthermostat

230Vfanpowersupply

230Vpumppowersupply

230VPowersupply

PWMsignal

Ionizationelectrode

Combustion air vent

Igniteelectrode

Burner control terminal

10

3 Installation

Theinstallationofthegasunitsmustbedonebyqualifiedandcompetentpractitioners.Themethodofinstallationdependsonthearea,volume,ventilationfacilitiesandthepossibilitiesthatexistforflueandcombustionair.Thisistobedeterminedbytheinstaller.

3.1 General rulesThecondensingunitcanbeinstalleddirectlyinthetobeheatedroom.Theinstallationmustcomplywithnationalandlocalregulations,particularlyinthefieldofappliedfuels.Theinstallermustabidetotheregulationsinforce.Ifindoubt,askforinformationwiththecontrol-andsafetyregulators.

AerationAreaswhereadevicethatworksongasisplaced,musthaveapermanentventilationinaccordancewiththerulesinforceinthecountryofinstallation.

Drainage of the condensateTheairheatermustbeequippedwiththeincludedsiphontodrainthecondensewater.Itisapartofthesafetysystem,eachreplacementbyanotherunapprovedtypeisstrictlyprohibited.Thedrainageofthecondensatemustbecarriedoutinaccordancewiththeapplicablerequirementsinthecountryofinstallation.

Gas connectionBeforeconnectingtheunit,youmustmakesurethatthelocalgassupply(typeofgas,pressure)matchthesettings of the unit that must be installed.

Note:minimumdistancesareessentialforthemaintenanceandsafetyoftheunit.

500 mm

200 mm

300 mm

2500 mm

3.2 Securing the unit

Theunitsthatareconnectedusingafixedgaslinemustbeinstalledrigid.Tomaketheinstallationeasierwe recommend the use of our adjustable hanging brackets. These are adapted to the unit and will position itincompliancewiththeminimumdistances.Asformounting:consultthemanualdeliveredwiththebrackets.

Beforetheunitisattachedyoushouldcheckthecarryingcapacityofthewall.

Step 1– Assemblethemountingbracketusingtheenclosedinstructions.–Attachthemountingbrackettothewall.Attachthiswithmaterialsuitableforwallmounting.Performasafetytest,safetyfactor2,tocheckthefirmness.

Step 2–Fixtheunittothebracketusingthesuppliedscrews.Securethescrews.– LevelofftheapplianceusingtheM8adjustmentscrew.

Step 3–Openthelouvresonthefrontofthedeviceatleast45°sothattheaircanfreelyflowout.

11

Position 1 Position 2

12

3.3 Placement combustion gas discharge and air supply

TheGSW+unitsaresuitableforfollowingdrainagesystems:C13,C33,C53,B23.Thefluegasdrainagesystemmustcomplywithnationalandlocalregulations.Theextensionpipesmusttoleratecondensateandbesuitableforafluegastemperatureof100°C.Flueoutletsmustbeofpolypropyleneorstainlesssteel316L.Thedrainagematerialmustbepositivelyaccessedfortheapplicationofgas-firedunits.ThispositiveassessmentmustbedonebyanISO17025accreditedbody.

Theconnectionofthefluegasmustbeplacedoutside.Fortheintakeofcombustionaircanbechosenfrom:– withtheintakeofcombustionairfromtheoutside(type“C”);– withtheintakeofcombustionairfromtheroomwheretheheaterisinstalled(type“B”).

Theusedfluepipes,terminalsandaccessoriesmustbetested.UseonlysuctionanddischargeterminalsreferencedbyMark.Withtheuseofnon-approvedequipmentthewarrantywillexpire.

Placement of the air inlet ringUnitsthatreceivethecombustionairfromtheinstallationarea(type“B”)mustbefittedwithaprotectivegrate.Thistopreventlargepartsofcontaminationfromcomingintothecompartmentoftheunit(figuresA).InstallationareaswhereinatypeBunitisinstalledmusthavesufficientairsupply.Atleast100m3/hperunit.

Unitswherethecombustionairisdrawnfromoutside(type“C”)mustbeprovidedwiththesuppliedmountingring(figuresB).

Theextensionsmustbeprovidedwithalipring.Usesoapywatertoeasilyconnectthem.

A1 A2 A2

B1 B2 B3

13

Connection of the extension pipes type C33 and C13

Closedcombustionrelativetothesurroundings.Theextensionpipesofthecombustionairandfluegasarehorizontallyorverticallyplacedoutsidetheinstallationarea.Theextensionpipesmayonlypassthroughtheinstallation area.

C33verticaldrainagesystem C13horizontaldrainagesystem

Installationexample: 1 connection ring ø 80 1extensionpipeø80,L=250mm 2curvesø80,90° 1transitionpiece:2xø80toø80/125 1 concentric wall or roof terminal ø 80/125

Theconnectionpipescanbeextendedwithforthispurposesuitablematerials.Thepipediametershouldbeatleastequaltotheconnectorontheunit.Neverreducethepipediameterorplugtheventholesinthe installation area.

Don’tplacetherooforwallflue:– onlessthan2mfromaventorwindow/doorway,takethedilutionfactor(NEN2757andother nationalandregionalregulations)intoaccount;– inatransitzone;– atlessthan2mfromthegroundordirectlyaccessible(riskofobstructionand/orcombustion).

NOTE

Thesealsbetweentheextensionmustbecloseandtight,makesurethelipringsarepresent.Thetotallengthshouldnotexceed8m,assumingthat:1angleof90°of45°=1mpipe.Inahorizontalsection,ensurethattheextensionpipelieswithaslopetotheunit,toavoidoutflowofthecondensation.

5

3

2

4

1

1

2

3

4

5

5

1

3

4

2

14

Connection of the extension tubes type B23

Non-closedcombustionrelativetothesurroundings.Thecombustionairisdrawndirectlyfromtheinstallationareaandthefluegasgoesthroughaverticalpipethroughtherooforahorizontalpipethroughthewall.Theextensionpipesmayonlypassthroughtheinstallationarea.

B23Horizontal B23 Vertical

3

1

2

1

2

NOTE

Thesealsbetweentheextensionmustbecloseandtight,makesurethelipringsarepresent.Thetotallengthshouldnotexceed8m,assumingthat:1angleof90°of45°=1mpipe.Inahorizontalsection,ensurethattheextensionpipelieswithaslopetotheunit,toavoidoutflowofthecondensation.

Installationexample: Extensionpipeø80,L=250mm Protection louvre Bendø80,90° Wall duct ø 80

Thewalloutletcanbeextendedwithapprovedpipes and elbows. The pipe diameter should be at leastequaltotheconnectorontheunit.Neverreduce the pipe diameter or plug the vent holes in theinstallationarea.Itisrecommendedtouse45°bends. Do not place a wall duct on less than 2m from the ventilation,doororwindow,ofthegroundorinatransit zone.

Installationexample: Extensionpipeø80,L=250mm Protection louvre Adhesiveplate(optional) Roof duct ø 80

Thewalloutletcanbeextendedwithapprovedpipes and elbows. The pipe diameter should be at leastequaltotheconnectorontheunit.Neverreduce the pipe diameter or plug the vent holes in theinstallationarea.Itisrecommendedtouse45°bends.

3

1

2

3

1

3

15

Connection extension pipes type C53

Closed combustion relative to the surroundings. The combustion air will be drawn from outside. The pipe shallbeplacedhorizontal.Thefluegasshallbebroughtoutvertically.Theextensionpipesmayonlypassthrough the installation area.

C53 Vertical

NOTE

Thesealsbetweentheextensionmustbecloseandtight,makesurethelipringsarepresent.Thetotallengthshouldnotexceed8m,assumingthat:1angleof90°of45°=1mpipe.Inahorizontalsection,ensurethattheextensionpipelieswithaslopetotheunit,toavoidoutflowofthecondensation.

Installationexample: Connection ring ø 80 Bendø80,90° Wall duct ø 80 Extensionpipeø80,L=250mm Roof duct ø 80 Adhesiveplate(optional)

Theinletandfluegasmaybeextendedwithapprovedpipesandelbows.Neverreducethepipediametertoadiametersmallerthantheconnectiontothedevice.Neverclosetheairinletopenings.Itisrecommendedtousebendsof45°insteadof90°.If90°bendsareunavoidable,donotapplymorethantwopieces.

1

2

3

4

5

1

53

24

6

16

3.4 Connection condensate pipe

Thegas-firedcondensingairheatermustbefittedwithasiphontodrainthecondensatewater.Thesuppliedsiphonmustbefittedduringinstallation.NotethatthedischargeofthecondensatemustbecarriedoutwithmaterialwhichisresistanttoacidwaterwithapHof3.Neverusecopperorgalvanizedironpipes.ForthedisposalofcondensedwateryoumustusePVCpipeswithadiameterthatisequaltothisoftheunit(PVCØ32).Makesurethepipingisplacedonsufficientslope.Checkthetightnessoftheplumbingofthecondensate.Beforeusingtheunit,fillthesiphonwithwaterthroughthefillercap.Thisavoids that combustion gas will get into the sewer during the start-up.

Anti-freeze protectionThecondensatedrain,includingthesiphon,mustbeprotectedagainstfrost.Itispreferredtokeepthedrainsfrost-freeasbestaspossible.Incasetheyfalloutsidethebuilding,thepipepartbehindthesiphonshouldbeopentoavoidtheformationoficewhichwillblockthedischarge.Takethenecessaryprecautionstoavoidsuchanincident,asthismaycauseirreversibledamagetotheheater.

Neutralization of the condensateTheacidityofthecondensatefromthecombustionofnaturalgasis3,5-3,8pH.Incertainregionsitisrequiredthatthecondensatemustbetreatedbeforeitcanbedischarged.Inthesecasesyoushouldtakeon a neutralization kit in the condensate circuit.

Included in delivery

No delivery

FillerAcidwater

Neutralization kit

Neutralized condensate

17

3.5 Gas connection

Foremostyoushouldcheckwhetherthedeliveredunitismadeforthegasthatunitwillbeconnectedto.Thisdataofthedeviceismentionedonthetypeplateontheinsideofthedoor.Thegassupplymustbesuitablefortheloadofthedeviceandmustbeequippedwithallthesafetyandcontroldevicesrequiredbytheregulationsinforce.Thediameterofthepipemustbeaccuratelydetermined.Importantfactorsforthisare,amongothers,thegasflowandthelengthandrouteofthepipes.

Themaximumallowablelinelossesmaynotbegreaterthan5%ofthenominalsupplypressure.Thegasconnections must be installed in accordance with national and regional regulations and must be performed byauthorizedpersonnel.Beforecommissioningtheunitmustbepressuretestedinaccordancewiththeapplicableregulationsandbecleaned.Themaximumallowablepressureofthegasis60mbar.

Note,beforeopeningthegasyoumustcheckthesealonthethrottle.

Gas connection:

Connectionpressurenaturalgashigherthan50mbar;

connectionpressurenaturalgaslowerthan50mbar;

LPGsupply.

Gas connection set: Gasket(supplied); Suitableconnection(supplied); Gaspressureregulator; Filter; Gas tap.

A

B

C1

23

4

5

A

B

C

1

2

3

4

5

18

4 Controls

4.1 Comtherm

The Comtherm is a modulating temperature controller. The room temperature sensor is integrated in the housingofthecontroller.TheComthermisequippedwithaclockfunction,day-nightcontrol,continuousrunningfanandcontinuesdaytime.Basedontheprevailingroomtemperatureandthedesiredtemperature,thecapacityisdetermined.Thecontrollerstandardlycomeswitha9metercable.Maximumcablelengthis100m. The cable must be shielded.

ForfurtherinformationabouttheComtherm,pleaserefertothemanualofthiscontroller.AComthermcan control one GSW+.

19

Connection diagram

Condensing air heater Maintenanceswitch230Vac Comtherm Room sensor

C

A

B

D

A

B

C

D

20

Supply Comtherm (Connector JP 18)

RS 485 Bus connector

21

4.2 Control connection

Figure2a

Cablecolor Function ConnectionOrange 24v(supply) ConnectorJP18Blue 0v(supply) ConnectorJP18Green 0v(rs485) ClampGNDBrown AandB(rs485) White-brownclampA Brown clamp B

Figure2b

D G

Cable 1

22

5 Commissioning

5.1 Commissioning

1 Beforecommissioningtheheaterandputtingitundervoltage,ensurethattheconnectorsarewell performedasdescribedinthefollowingchapters: – Connectingthecondensate,page16; – Connectingtheflue,page12-15; – Electricalconnection,page18-21; – Gasconnection,page 17.

2 Alsoensurethat: – Theprotectivefilmonthepanelshasbeenremoved; – Thedistancearoundtheunithasbeenmet; – Allelectricalconnectionsareperformed; – That the ground connection is performed.

3 Checkthepowersupplyoftheheater.Thisshouldbebetween210Vand230VAC.Notethepolarity NeutralandPhase.Incaseofatwo-stagenetworkanisolatingtransformershouldbeapplied.Formore information please ask the manufacturer.

4 Ensurethatthetypeofgasandthegaspressurematchtheinformationonthetypeplate.

5 Ensure that the Comtherm or the communication with the heater operates.

6 Taketheairheaterintooperation: – Openthegasvalveandpurgeit; – Switchontheelectricalsupply; – Ensurethattheexhaustvanesareopenataminimumof45°; – Createheatdemandbysettingtheroomtemperaturecontrol(Comtherm)toavalueatleast 1°Chigherthantheactualroomtemperature.SettheComthermto<auto>(seethemanualofthe Comtherm); – The heater starts.

Note:Theunitsarepre-calibratedatthefactory,thoughitmaybenecessarytocorrecttheinitialadjustmentvalues.Thisisparticularlythecasewhentheunitsareinstalledataheighthigherthan500m.Duetothelowerairpressure,thecombustionvaluesmaybeaffected.Inaddition,correctionmaybenecessaryincaseofdifferentqualitiesofthelocalgas.Forinstruction,seepage25.

7 Set the Comtherm according to the manual.

Incaseofafanwithvariablespeedtheminimumandmaximumspeedsshouldalsobeenterednexttotheswitchingtimesandtemperaturesettings.Fortheminimumspeedaminimumvalueof30shouldbeenteredandforthemaximumspeedaminimumvalueof70shouldbeentered.

23

5.2 Adjustment of the combustion

Thecommissioningofthegasvalvemustbedonebyaqualifiedprofessionalequippedwithafluegasanalyzer.Beforeanyinterventionyoumustturnthegasandelectricalsuppliesoff.Stateonthetypeplate(insideofthedoor)thegastypebeingtunediniftheunitwastunedintoanothergastype.Check the tightness of the gas circuit after each intervention.

Requiredtools: – Hexkey2.5mmbalancingair-gasratiofullload(throttle); – Hexkey4balancingair-gasratiominimumload(offset); – Gasanalyzer(CO₂/CO-gastemperature); – Gasgaugemaximumpressure50mBar.

Controllingandregulatingprocedureoftheburnerwithpremix:1 Placeyourfluegasanalyzerintheflue;2 Checkthepressureofthegassupplybeforestarting,whenstoppingandrunning(seetable);3 Turntheheateron: – Starttheunitinmaximumpowermode(seedescription“servicemenu”oftheComtherm); – Check that the O2 valuecorrespondswiththetablebelow,aftertheunithasbeeninoperationforat least2minutes; – Ifnecessary,correctthevaluewithscrewA.TurnclockwisetoincreasetheO2 value and counter clockwisetodecreaseit; – Continuewiththeminimumload(seedescription“servicemenu”oftheComtherm); – Ifnecessary,correctthemeasuredvaluewithscrewBaccordingtothetablebelow.Ifnecessary, correctthevaluewithscrewA.TurnclockwisetodecreasetheO2 value and counter clockwise to increaseit; – Checkthemaximumandminimumloadagain.Iftherearenoabnormalities,settheComtherminthe desired mode.

Combustion air fan Restriction ring Gasmixer Gas pipe Burner controls Throttle Gauge

Gastype Gas pressure Minimumpressure O2 full load(screwA)

O2 minimum load (screwB)

COmaxPPMG20/G25 G31

G20(naturalgas) 20-50 mbar Min.18mbar 5% 6% 160 200G25(naturalgas) 25-50 mbar Min.20mbar 5% 6% 160 200G31(propane) 28-50 mbar Min.25mbar 5% 6% 160 200

Venture restriction ring colorModel GSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70Ring color / ø White / 6mm White / 6mm Red / - - / -

1

2

3

4

5

6

7

1 32 4 5 6 7

A-Fullloadsetting

B-Minimumloadsetting

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6 Malfunctions

6.1 Malfunctions

Whenamalfunctionappears,makesureallabovementionedconditions/procedureshavebeenperformed.

Note:allelectricalormechanicalworkhastobedoneafterinterruptingthepowersupplyandclosingthegassupply.

Malfunction Cause SolutionThe unit doesn’t start -ThemainswitchissettoOFF

-BlueLEDonthecontrolboardisturnedoff=nopower-LEDonthecontrolboardflashesblue communication error-LEDonthecontrolboardisblue/red sensor error-LEDonthecontrolboardflashes blue/red overpressure or overheat-LEDonthecontrolboardisblue/yellow burner error-LEDonthecontrolboardflashesblue/yellow water circuit error- Burner fan is not functioning- No heat demand

- Turn the switch ON-Checkthepowersupply

- Check the communication cable

- Check the sensor and replace

- Check the pump and the water circuit for blockages.- Reset the burner control

- Check the water level and the pump

- Replace these-ConfiguretheComtherm

The burner fan starts several times withoutaflameandthecontrolboxgoesintomalfunction(burnererror)

- No gas-Airinthepipes- Poor control air/gas- Defective gas valve-Igniterispoorlyadjustedordefective- Control panel is defective

- Check the pressure- Vent the pipes-Adjusttheratioair/gas(page25)- Replace-Adjustorreplace-Adjustorreplace

Theburnerfanisatmaximumspeedbutthecapacitydoesnotreachthemaximum

-Toolongfluepipe-Theairintakepipeorchimneypipeis blocked-Incorrectburnercontrol-Toohightemperatureoftheexhaust air

-Limitoradaptthelength- Unclog the pipes

-Adjustthecombustion(page3)- Room temperature too high

The burner is not modulating and the speed of the burner fan is set at maximum

-IncorrectlysetComtherm-TheCableofthePWM-steeringis disconnected- The ventilation motor is defective- The control board is defective

-Tunethisin(seemanualComtherm)- Check the connection

- Replace- Replace

Theburnerstarts,theflameisformedand the burner control goes to malfunction

- Phase-Neutral swaps

-Powersupplytwophasesnetwork- Defective ionization electrode

-Applythephaseandneutraltotheelectricalsupply- Use a isolation transformer- Replace

(forunitswithavariableairflow)Thefanis not modulating

- Variable speed is not set to the Comtherm- The cable for speed variation is disconnected- Defective motor

- Set to Comtherm

- Check the cable

- Replace these

Note:onlytheoriginalpartsfromthemanufacturercanensurethesafetyoftheproductandthepersons.Whenpartsofadifferentoriginareused,theproductliabilityofthemanufacturerexpires.

25

6.2 Spare parts

N° Description CodesGSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70

1 Water/airheatexchanger 0699303 0699304 0699305 06993072 Pump 06993103 Return pipe 0699313 06993144 Water pressure sensor 06993165 Return water temperature sensor 06993186 Overflowvalve(3bar) 06993207 Supplypipe 0699323 0699324 0699325 06993278 Supplywatertemperaturesensor 06993189 Waterflowmeter 069931710 Combustion air fan 0699331 069933211 Gasmixerwithrestriction 0699333 069933412 Gas pipe -13 Siphon 069933914 Throttle 069934115 Automaticburner 069934316 Burnersupplypipe -17 Igniteelectrode 069934718 Control board 310167019 Axialfan(on/off) 0699365 0699366 0699367 069936820 Maximumfuse -21 Combustionboiler(body) -22 Ionisationelectrode 069934923 Expansiontank 069938024 Capexpansiontank 0699381

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7 Maintenance

Correctandregularmaintenanceofatleastonceayearwillincreasethesafety,reliabilityandefficiency.Additionally,itwillextendthelifeoftheunit.

SERVICEMUSTBEPERFORMEDWHENTHEUNITISCOLD.GASANDELECTRICALSUPPLYMUSTBEDISABLED.MAINTENANCESHOULDONLYBEDONEBYCERTIFIEDPROFESSIONALS.

Part WorktobecarriedoutHeater Checkthatthedeviceisfunctioningcorrectlyforall

safeties.Makesureallthescrewsaretightened.

Fluegassystem Checkthecombustionairandfluegaspipetrace.Check the seals and check for corrosion.

Condensate drain Check the siphon for contamination and clean it.

Burner Disconnecttheelectrodes,theelectricalconnections of the combustion air fan and the gas pipe at the gas valve. Remove the burner / fan / gas mixercomposition.Cleantheburnerwithabrush,vacuumcleaneroranairsyringe.Checktheburnerfordamagesandcracksinthesurface.Incaseofdamages,replaceit.Note:whenre-insertingthegaspipe,checkthegasketfordamage.

Ignite/Ionizationelectrode

Checktheconditionandcleanifnecessary.Checkthe distance between the ignition electrodes (4+/-0.5mm)andthedistancebetweentheelectrodeandtheburner(8+/-1mm).Checktheseal,replaceifnecessary.Checktheheightoftheionizationcurrent.Ifthisislowerthan3μA,checkthe adjustment and the condition of the ionization electrode and the connection to the ground.

4 ±0,5

8 ±1

8 ±1

Part WorktobecarriedoutBoilerbody Checkthesealingofthefrontplate.Inspecttheheat

exchangertubes.Inspecttheisolationonthefrontandbackplateoftheheatexchanger.Damagedorhardened seals must be replaced. Clean the inside of theheatexchangerwithastiffbrush.

Heatexchanger Removetheexhaustvanewindowandcleanitwithavacuumcleanerofairsyringe.Checktheheatexchangerforleaks.

Expansiontank Donotopenthefillercapwhentheunitisstillhot.Risk of severe burns!

Check the level when the unit is off and cold. The levelmusttouchthefillerneck.Ifnecessary,fillitwithamonoethylene-glycolsolution(-15°C)provided with corrosion inhibitors.

Pump Check that the pump is functioning. Pump failure isdetectedbythewaterpressuresensor.Inanexceptionalcase,thepumpmaybestuck.Thiscanbesolvedbytakingthecaponthefrontofpumpoffandthengettingthepumpstartedbyturningaflatscrewdriver clockwise. Then attach the protective cap again.

Combustion MeasuretheO2/CO2amountandthefluegastemperature.Verifythatthemeasuredvaluesofthedatamatchthedatathatispresentedonpage23.Ifnecessary,adjustthesettinginaccordancewiththeinstructionsonpage23.Checktheflamestatuevisuallythroughthesightglass.Theflameshouldbestable,blueincolorwithorangedots(maximumload).Duringtheexhaustgasanalysistheendoftheprobemustbelocatedinthemiddleofthefluegaspipe.

Condensate pump Whenusingacondensatepump(3100587)withcondensationneutralizationkit(3100586)thecartridgeneedstobereplacedannually.

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8 Recommendations for the end user

8.1 Safety rules

– Itisprohibitedtosealtheventilationopeningsoftheroomwheretheunitisinstalledorthatofthe unit.– Never block the smoke evacuation and the combustion air intake.– Donotmakeanychangestothecontrolsthathavebeeninstalledbyqualifiedprofessionals.– Donotspraywaterontheheaterortouchtheunitwithwethands.– Donottouchanyhotormovingpartsoftheairheater.– Do not place objects on the unit or hook objects onto the unit.– Turnoffthegasandelectricitybeforeworkisperformedontheunit.– Donotchangethetypeofgasused,unitregulationsorsafety-andcontrolsystems.Thiscanleadto dangerous situations.

Whentheunitistakenoutofoperationforaconsiderabletime,disconnecttheelectricalsupply.Itisrecommendedtoappealtoanexpertwhenre-commissioningtheunit.Atleastonceayeartheunitshouldbeservicedbyauthorizedqualifiedprofessionals.Consultyourinstallerforthis.

Takingoutamaintenancecontractishighlyrecommended.

8.2 What to do in case of a problem?

Problem SolutionThe smell of unburned gas Closethevalveandswitchoftheelectricity.

Contactyourinstaller.

Burner in fault Resettheburnercontrolbypushingtheresetbutton or using the Comtherm. See the manual of the Comtherm for this.Ifthisdoesnotresolvetheproblem,contactyourinstaller.

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