Automatic Heating Gasogen Hoja de datos

Wood Fired Boiler

Gasogen 29 - 93kW

Installation and Servicing Manual

General Information

CONTENTS

1GENERAL INFORMATION ................................................................................................................................................................................. 3

1.1 Symbols used in this manual ....................................................................................................................................................................... 3

1.2 Correct use of the appliance ........................................................................................................................................................................ 3

1.3 Water treatment ............................................................................................................................................................................................. 3

1.4 Information to be passed over to the end user or the person in charge of the appliance ......................................................................... 3

1.5 Safety warnings ............................................................................................................................................................................................. 4

1.6 Data badge .................................................................................................................................................................................................... 5

1.7 General warnings .......................................................................................................................................................................................... 5

2TECHNICAL FEATURES AND DIMENSIONS ................................................................................................................................................... 6

2.1 Technical features ......................................................................................................................................................................................... 6

2.2 Dimensions and water connections ............................................................................................................................................................. 7

2.3 Main components .......................................................................................................................................................................................... 8

2.4 General information ...................................................................................................................................................................................... 8

3INSTALLATION INSTRUCTIONS ..................................................................................................................................................................... 12

3.1 General warnings ....................................................................................................................................................................................... 12

3.2 Installation Codes of Practice ................................................................................................................................................................... 13

3.3 Packaging................................................................................................................................................................................................... 14

3.4 Transportation ............................................................................................................................................................................................ 14

3.5 Installation .................................................................................................................................................................................................. 15

3.6 Boiler system connection .......................................................................................................................................................................... 15

3.7 Connection to the heat exchanger’s drainage .......................................................................................................................................... 16

3.8 Recycling pump ......................................................................................................................................................................................... 16

3.9 Installation instructions .............................................................................................................................................................................. 17

3.10 Water and electrical connection diagrams with standard control panel, without hot water storage tank .............................................. 21

3.11 Water and electrical connection diagrams with optional control panel, without hot water storage tank ............................................... 23

3.12 Water and electrical connection diagrams with optional control panel, with hot water storage tank .................................................... 27

3.13 Flue outlet connection ............................................................................................................................................................................... 40

3.14 Filling the system ....................................................................................................................................................................................... 41

4-5ELECTRICAL CONNECTIONS ........................................................................................................................................................................ 42

4.1 Standard control panel .............................................................................................................................................................................. 43

5.1 Optional control panel ............................................................................................................................................................................... 45

5.2 Functional wiring diagram (Flow chart) .................................................................................................................................................... 46

5.3 Loads and sensors connection diagram ................................................................................................................................................... 48

5.4 Functional description of optional control panel ...................................................................................................................................... 49

5.4.1 Ignition ............................................................................................................................................................................................. 49

5.4.2 Normal boiler operation ................................................................................................................................................................... 49

5.4.3 No wood ........................................................................................................................................................................................... 49

5.4.4 Oil/gas boiler operation ................................................................................................................................................................... 50

5.4.5 Domestic hot water production ....................................................................................................................................................... 50

5.5 Special functions ....................................................................................................................................................................................... 51

5.5.1 Overheating ..................................................................................................................................................................................... 51

5.5.2 Combustion gas temperature control ............................................................................................................................................. 51

5.5.3 Fan overheating protection system ................................................................................................................................................ 51

5.5.4 Temperature sensor failure alarm .................................................................................................................................................. 51

5.5.5 Fireproof thermostat ........................................................................................................................................................................ 52

5.5.6 Waiting time .................................................................................................................................................................................... 52

5.5.7 Return flow sensor installation ....................................................................................................................................................... 52

5.6 Optional control panel wiring diagram ...................................................................................................................................................... 53

6BOILER START-UP ........................................................................................................................................................................................... 54

6.1 Initial lighting ............................................................................................................................................................................................. 54

6.2 Fire wood .................................................................................................................................................................................................... 55

6.3 Wood moisture ........................................................................................................................................................................................... 55

6.4 Fire wood dimensions ................................................................................................................................................................................ 55

6.5 Initial lighting checks ................................................................................................................................................................................. 55

6.6 Start-up ...................................................................................................................................................................................................... 56

6.7 Combustion air adjustment ....................................................................................................................................................................... 57

6.8 Checks to carry out after first start-up ...................................................................................................................................................... 58

6.9 Warnings .................................................................................................................................................................................................... 58

6.10 Thermostat adjustments ............................................................................................................................................................................ 59

6.11 Summer operation ..................................................................................................................................................................................... 59

6.12 Burner adjustment on the back up boiler ................................................................................................................................................. 59

6.13 Fault finding for boilers with standard control panel ................................................................................................................................ 60

6.14 Fault finding for boilers with optional control panel .................................................................................................................................. 61

7SERVICING AND MAINTENANCE SCHEDULE ............................................................................................................................................. 62

Gasogen

General Information

1.1 - SYMBOLS USED IN THIS MANUAL

When reading this manual particular care has to be given to the parts marked with the followings symbols:

NOTE! Suggestions for the

user

WARNING! Indicates a potentially

dangerous situation for the

product and the environment

DANGER! Indicates serious

danger for your personal safety

and for your life

1.2 - A CORRECT USE OF THE APPLIANCE

The GASOGEN G3 2S appliance has been designed utilizing today’s heating technology and in compliance

with the current safety regulations.

However, following an improper use, dangers could arise for the safety and life of the user or of other

people, or damage could be caused to the appliance or other objects.

The appliance is designed to be used in pumped hot water central heating systems.

Any other use of this appliance will be considered improper.

Automatic Heating declines any responsibility for any damages or injuries caused by an improper use;

in this case the risk is completely at the user’s responsibility.

In order to use the appliance according to the foreseen scopes it is necessary to carefully follow the

instructions indicated in this manual.

1.3 - WATER TREATMENT (refer to specific guide)

 The hardness of the mains water supply conditions the frequency with which the heat exchanger is cleaned.

 In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is recom-

mended. The choice of this device has to be made taking into consideration the characteristics of the water.

 We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the

first year and subsequently every two years; in this occasion check the state of wear of the anode.

1.4 - INFORMATION TO BE HANDED OVER TO THE USER OR PERSON IN CHARGE OFTHE

APPLIANCE

The user or the person in charge has to instructed on the use and operation of his heating system, in particular:

- Hand over these instructions to the end user or person in charge of the appliance, together with any other litera-

ture regarding this appliance placed inside the envelope contained in the packaging. The user has to keep these

documents in a safe place in order to always have them at hand for future reference.

- Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that it is absolutely

forbidden to make any alterations to the boiler.

- Inform the user how to check the system’s water pressure as well as informing him how to restore the correct

pressure.

- Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure the

greatest possible fuel economy.

- Remind the user that it is obligatory to service the appliance at least annually and to carry out a combustion

analysis in compliance with the schedule indicated in the national Codes of Practice.

- If the appliance is sold or transferred to another owner or if the present user moves home and leaves the appliance

installed, ensure yourself that the manual always follows the appliance so that it can be consulted by the new

owner and/or installer.

1GENERAL INFORMATION

Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in

accordance with the current laws.

The end user is not qualified to carry out any service work on the boiler.

Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to

persons, animals or damage to property. Automatic Heating shall not be held liable for any injury and/or damage.

General Information

1.5 - SAFETY WARNINGS

WARNING!

The installation, adjustment, and servicing of this appliance must be carried out by a competent, qualified

person and installed in accordance with the current standards and regulations. Failure to correctly install

this appliance could cause injury to persons, animals or damage to property. The manufacturer shall not

be held liable for any injury and/or damage.

DANGER!

NEVER try to carry out any repairs or service work on the boiler on your own initiative.

Servicing or repairs of the appliance must be carried out by qualified service engineers;

Automatic Heating recommends drawing up a service contract.

Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to

persons, animals or damage to property for which shall not be held liable.Automatic Heating

Modifications to parts connected to the appliance

Do not carry out any modifications to the following parts:

- the boiler

- to the gas, air, water supply pipes and electrical current

- to the flue pipe, safety relief valve and to the central heating’s drainage pipe

- to the constructive components which influence the appliance’s safe operation

WARNING!

When tightening or loosening the screw pipe connections, use only adequate fork spanners.

The improper use and/or the use of inadequate equipment can cause damages (for example water or gas leakages).

Explosive and easily inflammable substances

Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room

where the appliance has been installed.

Gasogen

General Information

1.7 - GENERAL WARNINGS

This instruction manual is an integral and indispensable part

of the product and must be retained by the person in charge of

the appliance.

Please read carefully the instructions contained in this manual

as they provide important indications regarding the safe

installation, use and servicing of this appliance.

Keep this manual in a safe place for future reference.

The installation and servicing must be carried out in accordance

with the regulations in force according to the manufacturer’s

instructions and by legally competent authorized persons.

By a competent person, we imply a person who has a specific

technical qualification in the field of components for central

heating systems for domestic use, domestic hot water

production and servicing. The person must have the

qualifications foreseen by the current laws in force.

Bad or irregular servicing could compromise the safe operation

of the appliance, and could cause injury to persons, animals

or damage to property.The manufacturer shall not be held liable

for any such injury and/or damage.

Before carrying out any cleaning or servicing turn off the

electrical supply to the boiler by means of the ON/OFF switch

and/or by means of the appropriate shutdown devices.

Do not obstruct the intake/outlet terminal ducts.

In the event of failure and/or faulty functioning of the appliance,

switch off the boiler. Do not attempt to make any repairs:contact

qualified technicians.

Any repairs must be carried out by Automatic heating authorized

technicians and using only original spare parts. Non-

observance of the above requirement may jeopardize the safety

of the appliance.

To guarantee the efficiency and correct functioning of the

appliance it is indispensable to have the boiler serviced annually

by a qualified person.

If the boiler remains unused for long periods, ensure that any

dangerous parts are rendered innocuous.

If the appliance is sold or transferred to another owner or if the

present user moves home and leaves the appliance installed,

ensure yourself that the manual always follows the appliance

so that it can be consulted by the new owner and/or installer.

Only original accessories must be used for all appliances

supplied with optional accessories or kits (including electrical

ones).

This appliance must be used only for the purposes for which it

has been expressively designed. Any other use shall be

considered incorrect and therefore dangerous

1.6 - DATA BADGE

The data badge is adhesive and placed inside the documentation envelope; it must be glued on to one side of the casing, on the

external part, by the installer.

The boiler’s serial number is indicated on the plate screwed on the boiler’s front plate (front side, upper right hand side).

Technical features and dimensions

2.1 - TECHNICAL FEATURES

The GASOGEN G3 2S boiler is a steel made wood fired unit

, with complete wood gasification combustion, inverted flame,

with a pressurised room chamber.

The following models are available:

GASOGENG3252S

GASOGENG3402S

GASOGENG3502S

GASOGENG3652S

GASOGENG3802S

The GASOGEN G3 2S boiler is equipped with all the safety

and control devices in compliance to the current standards.

DESCRIPTION OF COMPONENTS

- Steel body with a partially refractory-lined combustion

chamber;

- Refractory burner;

- Horizontal flue channels;

- Front fire box lined with refractory material;

- Intermediate door complete with combustion air regulations;

- Lower cleaning door lined with refractory material and

equipped with a flame inspection sight;

- Rear flue chamber with side inspection doors and ash

removal

-Flue evacuation via a pressure blower.

-Patented thermostatic valves system

-Safety heat exchanger

-Insulated boiler body with 60 mm thickness mineral wool

mattress

-Powder painted steel casing

-Recirculation pump kit (optional)

-Recirculation pump kit for buffer tank (optional), provided

the standard control panel is replaced by the model code

23557

-Standard control panel for electromechanical operation

-Optional control panel, code 23557, for integral control of a

buffer tank, according to the Standard EN 303-5 and with

the possibility of operating with a back up oil or gas fired

boiler.

STANDARD CONTROL PANEL COMPONENTS:

- Power On light indicator

- Boiler thermometer

- Safety thermostat in case of boiler overheating

- Boiler temperature adjustment thermostat

OPTIONAL CONTROL PANEL COMPONENTS:

- Power On light indicator

- Boiler thermometer

- Safety thermostat in case of boiler overheating

- Boiler temperature adjustment thermostat

2TECHNICAL FEATURES

AND DIMENSIONS

Gasogen

Technical features and dimensions

BT1

T2-T8

2.2 - DIMENSIONS AND

WATER CONNECTIONS

fig. 1

1. Control panel

2. Primary air adjustment

3. Secondary air adjustment

4. Flame sight control

5. Cleaning door

6. Rear smoke chamber

7. Loading door

8. Fan

9. Bottom inspection and cleaning door

T1. Central Heating flow

T2. Central Heating return

T3. Chimney connection

T4. Safety heat exchanger connections

T5. Bulb holder connection for heat discharge

valve

T6. Bulb holder for safety thermostat

T7. Bulb holder for thermometer and high limit

and minimum working thermostat,

T8. Boiler drainage

* Output obtained with good quality wood with a 15% .moisture content.

** Pressure losses for a flow rate corresponding to 15 K Delta T.

MODELS

GASOGEN

G3 25 2S

GASOGEN

G3 40 2S

GASOGEN

G3 50 2S

(kW) 15 23 29

AVERAGE OUTPUT

MINIMUM OUTPUT

MAXIMUM USEFUL OUTPUT*

(kW) 26 37 47

(kW) 29 47 58

MAXIMUM OUPUT (kW) 34 55 69

DIMENSIONS:

560

700

655

700

655

900

1225 1355

190

315

190

315

245

1030

1355

190

315

245245

1140 1140

(mm)

CONNECTIONS T1 - T2

T5 - T6 - T7 - T8

UNI ISO 7/1

(Ø mm)

UNI ISO 7/1

Rp 1¼

150

R½

Rp ½

Rp 1½

200

R½

Rp ½

Rp 1½

200

R½

Rp ½

BOILER WATER CONTENT

WATER SIDE PRESSURE DROP**

SMOKE SIDE PRESSURE DROP

MAX. WORKING PRESSURE

FIRE BOX STORAGE VOLUME

FIRE BOX DIMENSIONS

WEIGHT

WOOD LOGS LENGTH

(m c.a.)

(l) 90

0,10

110

0,08

140

0,12

0,60,40,3

(mm c.a.)

(bar)

(l)

(mm)

(kg)

290x340

386

135

350x440

475

185

350x440

593

(cm) 50 50 70

GASOGEN

G3 65 2S

755

955

1405

190

315

245

1180

Rp 2

220

R¾

Rp ½

170

0,06

0,3

235

340x520

630

GASOGEN

G3 80 2S

109

755

1255

1405

190

315

245

1180

Rp 2

220

R¾

Rp ½

220

0,10

0,5

325

340x520

850

100

UNI ISO 7/1

Technical features and dimensions

121413

2.3 - MAIN COMPONENTS

1. Control panel

2. Upper casing panel

3. N° 2 side casing panels

4. Smoke proof hinged door

5. Refractory-lined loading door with sealing gasket

6. Central door with gasket and primary and secondary

air adjustment screws

7. Fan

8. Refractory-lined combustion chamber door, sealing

gasket and flame sight

9. Thick steel plated combustion chamber

10. Heat exchange baffle

11. Boiler drainage

12. Safety heat exchanger

13. By-pass with command rod

14. Boiler body mineral wool insulation

15. Steel boiler body

16. Refractory burner with fire bars and grate

17. Flue chamber

19. Thermostatic valve

MC.H.flow

R C.H. return

fig. 2

N.B.:

The fire bars and the refractory steel grate are subject to wear; it is therefore advisable

to carry out an annual inspection to prevent bad boiler operation.

2.4 - GENERAL INFORMATION:

REVERSED FLAME COMBUSTION

Every body knows that to make a match last it must be held

with its head upwards.

This is because it is necessary that the flame, in its convective

motion, does not meet another fuel in addition to the one which

it has generated it. As in residential heating the fuel is in form

of wood logs which are loaded from the top, the flame has to

go in the opposite way, i.e. downwards.

Natural draught is a very variable source of depression,

according to the type of chimney, on the weather conditions,

onthetypeoffuel,etc.

Therefore it is necessary to integrate it with forced ventilation

in order to stabilize it.

By fitting a fan it is possible to considerably reduce the section

of the gas passages on the grate and furthermore there are no

problems with cold starts.

The small grate permits a more controlled passage of

combustion air, contrarily to what happens with the large

traditional grates.

The air can be perfectly dosed because the grate covered with

fired wood has the same crossing resistance and thus the

combustion will be always optimal.

Automatic Heating has already used this principal for many

years with the GASOGEN G3 2S boiler.

The GASOGEN G3 2S boiler today has reached such a high

level of perfection that it can pass all the most stringent tests

foreseen by the European Standards in force concerning the

environment.

Gasogen

Technical features and dimensions

fig. 3

GASOGEN G3 2S - BOILER CONSTRUCTION

The boiler body is made of two oval elements, one placed inside

the other, so as to form a water cavity (fig.3).

The large fire box , in its rear wall, has a refractory insulation,

which is particularly resistant to heat and mechanical stresses,

in order to keep the by-pass zone dry in every working

condition.

We can distinguish the following parts (fig.3):

1. Fire box, drying area

2. Gasification zone

3. Embers zone

4. Refractory burner

5. Combustion chamber

6. Heat exchange surface

7. Refractory steel cradle

8. Boiler water

9. Thermostatic system

10. Safety heat exchanger

M C.H. system flow

R C.H. system return

GASIFICATION ZONE (2)

The gasification takes place In the lower part of the fire box .

It is very important that the gasification is as regular as possible,

so as not to overburden the burner with gas. The gasification

speed depends on the quantity of the wood and the dimensions

of the drying area. Generally, it is better to use large logs if

they are dry and small logs if the wood is wet . The quantity of

primary air, proportional to the delivered output, is regulated

via the adjustment system.

EXCHANGE SURFACE (6)

As the boiler operates on wood, and because the sulphur

concentrations are not very high , it is important to obtain very

low smoke temperatures in order to increase the water

efficiency.

To obtain this Automatic Heating has opted for an exchange

surface with dry smoke passes (fig. 4), which have already

been extensivelytested in oil fired boilers working at low water

temperature, thus permitting low smoke temperatures without

danger of condensate forming.

The surfaces of the dry passages “A” (fig. 4) have had incisions

made on them in order to avoid dilatation problems.

The solid residues of combustion (ashes), which lie on the

high temperature refractory-lined cradle (fig. 3, pos. 7,) will

become with time always lighter until they will be dragged by

the gas speed and will deposit themselves in the lowest area

of the rear smoke chamber, from which they will be removed

during the cleaning operation.

REFRACTORY BURNER (4)

The burner is made up of refractory stone (fig. 3, pos. 4).

This stone has an oval central opening through which the flame

passes.

The embers lie directly on the main stone which divides the

fire box from the lower combustion chamber.

Furthermore the main refractory stone has a rectangular seat

in which the opportunely grooved cast iron fire bars are placed

(fig. 5, pos. 2), which receive the secondary air from a front

distributor.

The embers are prevented from falling by cylindrical pieces of

refractory steel. The combustion gases, poor in oxygen and

fig. 4

fig. 5

1. Metallic grate

2. Cast iron fire bars

Technical features and dimensions

SSS

P-S

M=C.H.flow

R=C.H.return

P = Primary air

S = Secondary air

F = Flue

fig. 7

still rich in carbon not yet combined, travel across the embers

and enter the opening in the centre of the main stone.

Inside this pre-combustion chamber, the gases combine with

the pre-heated secondary air coming through the grooves of

the two cast iron fire bars.

The resulting flame will be highly oxygenated and have a light

blue colour. This flame comes out from the oval opening and

invades the combustion chamber.

Due to the high temperatures the refractory burner will become

a bright red colour.

THERMOSTATIC VALVE (9)

As well known, wood normally has a high moisture content

when compared with other types of fuels. The first operation

which occurs inside the fire box is therefore the drying phase.

The high moisture content can then cause condensation

phenomena within the boiler and also in the chimney.

To limit the inconvenience in the boiler it is necessary to

maintain high working temperatures.

For this reason the boiler is equipped with a patented

thermostatic system (fig. 6) which permits the boiler

temperature to be kept constantly high and in particular, in the

fire box, where

the condensation phenomena is more likely to occur.

In order to reduce the consequences of condensate formation

(formation of layers of tar, corrosion, etc.) it is advantageous

to dimension, time by time, the wood load to the actual needs,

so as to prevent long stop overs with the wood storage

completely full of humid wood.

Nevertheless all these expedients do not impede the formation

of condensate in the chimney. Therefore we suggest, when

building the chimney, to use air-tight components, to avoid the

condensate damaging the building structure.

COMBUSTION CHAMBER (5)

The combustion is optimised by increasing the flame

temperature and producing a strong turbulence in the bottom

chamber.

For this reason the flame, in addition to not to touching cold

walls irrigated by the water, rebounds and is divided on a

semicircular cradle which rests on the lower exchange surfaces

(baffles), which, as well delimiting the smoke passages, also

has the task of collecting the ashes and possible embers.

The flames, after having bounced off the walls of the bottom

area and the refractory ones, direct themselves with a whirling

motion towards the front part of the combustion chamber and

enter the flue ducts.The combustion will be complete and clean

and the dominant colour will be that of the ashes: white.

Firewood, as is well known, normally has a high moisture

content when compared to other types of fuels. The first

operation which occurs inside the fire box is therefore the

drying phase.

The high moisture content can cause condensate

phenomenons inside the boiler and also in the chimney.

In order to limit this problem it is necessary to maintain the

boiler at a high working temperature.

Therefore, in order to adjust the flow temperature it is necessary

toinstalla3or4waymixingvalve.

If the mixing valve is not installed it will make the guarantee

void.

Always in order to reduce the consequences of condensate

formation (tar formation , corrosion, etc.) it is advantageous to

dimension, time by time, the wood load to the actual needs, so

fig. 6

Gasogen

Este manual sirve para los siguientes modelos

Tabla de contenidos

Otros manuales de Caldera de Automatic Heating

Automatic Heating

Automatic Heating Modulex EXT 440 Guía del usuario

Manuales populares de Caldera de otras marcas

Vaillant

Vaillant uniSTOR VIH SW GB 500 BES Manual de usuario

Radijator

Radijator BIO max 23.1 Manual de usuario

Brunner

Brunner BSV 20 Manual de usuario

Buderus

Buderus Logamax GB062-24 KDE H V2 Manual de usuario

Potterton

Potterton 50e Hoja de datos

UTICA BOILERS

UTICA BOILERS TriFire Manual de usuario

Joannes

Joannes LADY Series Manual

ECR International

ECR International UB90-125 Manual de instrucciones

Froling

Froling FHG Turbo 3000 Manual de usuario

Froling

Froling P4 Pellet 8 - 105 Manual de usuario

U.S. Boiler Company

U.S. Boiler Company K2 Manual de usuario

Henrad

Henrad C95 FF Manual de usuario

NeOvo

NeOvo EcoNox EF 36 Manual de usuario

Potterton

Potterton PROMAX SL 12 Manual de usuario

Eco Hometec

Eco Hometec EC 25 COMPACT Manual de usuario

Viessmann

Viessmann VITODENS 200 Guía

Baxi

Baxi Prime 1.24 Manual de usuario

REXNOVA

REXNOVA ISA 20 BITHERMAL Manual de usuario