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Summary of Contents for Mark GSW+ 30
- Page 1 Technical manual...
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Page 2: Table Of Contents
Index Warranty policy General information General recommendations Description of the units Operation Technical specifications 2.1 Specifications Relationship load / performance Description of the components Dimensions Electrical overview Installation General rules Securing of the unit 3.3 Connection of the flue pipe and air supply Connection condensate pipe Gas connection Controls Comtherm Connection of the control... -
Page 3: Warranty Policy
Warranty policy CE-marking The release of the CE-marking is the official recognition of the quality of design, manufacturer and performance of this unit. The life and performance will be at the highest level when the implementation and maintenance are properly carried out and done by the regulations in force. Responsibility This unit may only be used for which MARK has designed and fabricated it. MARK cannot be held liable for damages to persons, animals or property if it is caused by error of installation, controls or maintenance or not permissible use of the unit. The unit may only be equipped with original accessories. MARK cannot be held liable for any damages resulting from use of an accessory that is not suitable for the unit. The units must be installed by qualified professionals, in compliance with the applicable regulations and in accordance with the instructions in this manual. The references to the standards, rules and guidelines mentioned in this manual are for information purposes and are only valid on the date of issue thereof. MARK is responsible for the conformity of the device to the applicable rules, guidelines and standards at the time of commercialization. The knowledge and compliance with the legal provisions, as well as the norms inherent in the design. Project planning, startup and maintenance are the responsibility of the consultant, the installer and the user. Delivery – Storage The GSW+ is delivered on a wooden pallet, protected by a cardboard box and a plastic film. Immediately after arrival, the condition of the unit delivered must be checked (even if the packaging is intact). Additionally, ensure that the device delivered corresponds with the order. With regard to the product... -
Page 4: General Information
General information General recommendations The gas-fired condensing air heater of the GSW+ series are intended for the heating of industrial and related areas. The units may only be installed inside. The units may only be used in well ventilated areas. The proper functioning of the heater depends on proper installation and commissioning. Installation and maintenance must be in accordance with the applicable regulations and be carried out by qualified personnel. With the non-compliance of these rules all responsibility of the manufacturer expires. DO NOT INSTALL GAS-FIRED CONDENSING AIR HEATERS IN: – Rooms with explosion risk; – Rooms containing chlorine fumes (or combinations thereof); – Very humid rooms (electrical hazard). It is the responsibility of the installer to ensure that during assembly the installation instructions described are fulfilled. It is expected from the installer to: 1°) inform the user that: – The user may not modify the design of the units or the implementation of the system application; – Any modification (exchange, omission) of the safety components or pieces that affect the efficiency of the unit or the combustion, automatically means the CE-marking is expired; – It is annually required to perform the prescribed maintenance and cleaning activities. 2°) hand over this manual to the user. 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. -
Page 5: Operation
Operation The gas-fired condensing air heater of the GSW+ series are intended for the heating of industrial and related areas. The GSW+ air heaters consist of a gas-fired boiler and a hot water coil, placed in the airflow. The air that is blown in by the fan will be heated by the coil. This technique provides a perfect homogeneity of the air temperature. Unlike a conventional air heater, the partial or complete restriction of air flow or an interruption of the electrical power during operation will not damage the unit. The combustion section is completely isolated from the air circuit, which makes it impossible for the system air to mix with the combustion gases. The unit is equipped with a burner with low Nox emissions. The combustion air is sucked in by a fan with a variable flow rate. The air is sucked in by a venturi system. This system makes sure that the gas and air over the entire range are in the right proportion. The air/gas mixture is fed to the burner, located in the middle of the boiler. The flame and fumes will go through the heat exchanger twice to give off maximum power. Thanks to this technology, an efficiency of at least 98% at the maximum loads and 108% at full modulation can be achieved. The optimization of the performance of a condensation system is influenced by its controls. The lower the power output of the air heater, the greater the condensation and thus the higher the efficiency. The modulation range of the GSW+ is 30% of the maximum load. 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. In versions equipped with fans with a variable flow rate, one can also vary the air supply. -
Page 6: Technical Specifications
Technical specifications Axial models The condensing gas-fired air heaters are designed with axial fans that meet the European requirements 2009/125/EC. Optionally, the unit can be provided with a fan that has a variable airflow. The device is designed as free blowing, provided with horizontal louvres. Specifications GSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70 TYPES Nominal load (higher value) 12.5 17.5 Nominal load (lower value) Nominal power 26.5 34.9 11.5 44.1 13.6 61.7 18.3 Efficiency ∆T of air flow °C 25.6 28.5 27.3 Nox Class Val. -
Page 7: Description Of The Components
Relation load / efficiency Ef. % Power (kW) The power ratings apply with an air return temperature of 16 °C. The efficiencies were determined at a water regime 54°C/80°C (maximum power) and 29°C /38°C (minimum power). The efficiency varies in function of the air return temperature. Description of the components Axial fan Line print Stainless steel boiler Burner controls Gas valve Siphon Burner door Gas mixer Combustion air fan Water flow sensor Temperature sensor Overflow valve Water pressure sensor Pump Expansion tank... -
Page 8: Dimensions
2.4 Dimensions (Air) (Gas) GSW+ 30 1079 GSW+ 40 1080 GSW+ 50 1192 GSW+ 70 1277 Dimensions in milimeters (mm) -
Page 9: Electrical Overview
Electrical overview Comtherm supply (JP18) Blue - Above Orange - Center (see photo on page 20) Water pressure sensor Water flow sensor Exhaust temperature sensor Retour water temperature sensor Inlet water temperature sensor Room temperature sensor 230V power supply ModBus PWM modulating fan Maximal thermostat (option) 230V fan power supply 230V pump power supply Ionization electrode Ignite electrode Burner control terminal Combustion air vent 230V Power supply PWM signal... -
Page 10: Installation
Installation The installation of the gas units must be done by qualified and competent practitioners. The method of installation depends on the area, volume, ventilation facilities and the possibilities that exist for flue and combustion air. This is to be determined by the installer. General rules The condensing unit can be installed directly in the to be heated room. The installation must comply with national and local regulations, particularly in the field of applied fuels. The installer must abide to the regulations in force. If in doubt, ask for information with the control- and safety regulators. Aeration Areas where a device that works on gas is placed, must have a permanent ventilation in accordance with the rules in force in the country of installation. Drainage of the condensate The air heater must be equipped with the included siphon to drain the condense water. It is a part of the safety system, each replacement by another unapproved type is strictly prohibited. The drainage of the condensate must be carried out in accordance with the applicable requirements in the country of installation. Gas connection Before connecting the unit, you must make sure that the local gas supply (type of gas, pressure) match the settings of the unit that must be installed. Note: minimum distances are essential for the maintenance and safety of the unit. 500 mm 200 mm 300 mm 2500 mm... - Page 11 3.2 Securing the unit The units that are connected using a fixed gas line must be installed rigid. To make the installation easier we recommend the use of our adjustable hanging brackets. These are adapted to the unit and will position it in compliance with the minimum distances. As for mounting: consult the manual delivered with the brackets. Before the unit is attached you should check the carrying capacity of the wall. Step 1 – Assemble the mounting bracket using the enclosed instructions. – Attach the mounting bracket to the wall. Attach this with material suitable for wall mounting. Perform a safety test, safety factor 2, to check the firmness. Step 2 – Fix the unit to the bracket using the supplied screws. Secure the screws. – Level off the appliance using the M8 adjustment screw. Step 3 – Open the louvres on the front of the device at least 45° so that the air can freely flow out. Position 1 Position 2...
- Page 12 Placement combustion gas discharge and air supply The GSW+ units are suitable for following drainage systems: C13, C33, C53, B23. The flue gas drainage system must comply with national and local regulations. The extension pipes must tolerate condensate and be suitable for a flue gas temperature of 100 °C. Flue outlets must be of polypropylene or stainless steel 316L. The drainage material must be positively accessed for the application of gas-fired units. This positive assessment must be done by an ISO 17025 accredited body. The connection of the flue gas must be placed outside. For the intake of combustion air can be chosen from: – with the intake of combustion air from the outside (type “C”); – with the intake of combustion air from the room where the heater is installed (type “B”). The used flue pipes, terminals and accessories must be tested. Use only suction and discharge terminals referenced by Mark. With the use of non-approved equipment the warranty will expire. Placement of the air inlet ring Units that receive the combustion air from the installation area (type “B”) must be fitted with a protective grate. This to prevent large parts of contamination from coming into the compartment of the unit (figures A). Installation areas wherein a type B unit is installed must have sufficient air supply. At least 100 m3/h per unit. Units where the combustion air is drawn from outside (type “C”) must be provided with the supplied mounting ring (figures B). The extensions must be provided with a lip ring. Use soapy water to easily connect them.
- Page 13 Connection of the extension pipes type C33 and C13 Closed combustion relative to the surroundings. The extension pipes of the combustion air and flue gas are horizontally or vertically placed outside the installation area. The extension pipes may only pass through the installation area. C33 vertical drainage system C13 horizontal drainage system Installation example: 1 connection ring ø 80 1 extension pipe ø 80, L=250mm 2 curves ø 80, 90° 1 transition piece: 2x ø 80 to ø 80/125 1 concentric wall or roof terminal ø 80/125 The connection pipes can be extended with for this purpose suitable materials. The pipe diameter should be at least equal to the connector on the unit. Never reduce the pipe diameter or plug the vent holes in the installation area. Don’t place the roof or wall flue: – on less than 2m from a vent or window/doorway, take the dilution factor (NEN 2757 and other national and regional regulations) into account;...
- Page 14 Connection of the extension tubes type B23 Non-closed combustion relative to the surroundings. The combustion air is drawn directly from the installation area and the flue gas goes through a vertical pipe through the roof or a horizontal pipe through the wall. The extension pipes may only pass through the installation area. B23 Horizontal B23 Vertical Installation example: Installation example: Extension pipe ø 80, L=250mm Extension pipe ø 80, L=250mm Protection louvre Protection louvre Bend ø 80, 90° Adhesive plate (optional) Wall duct ø 80 Roof duct ø 80 The wall outlet can be extended with approved The wall outlet can be extended with approved pipes and elbows. The pipe diameter should be at pipes and elbows.
- Page 15 Connection extension pipes type C53 Closed combustion relative to the surroundings. The combustion air will be drawn from outside. The pipe shall be placed horizontal. The flue gas shall be brought out vertically. The extension pipes may only pass through the installation area. C53 Vertical Installation example: Connection ring ø 80 Bend ø 80, 90° Wall duct ø 80 Extension pipe ø 80, L=250mm Roof duct ø 80 Adhesive plate (optional) The inlet and flue gas may be extended with approved pipes and elbows. Never reduce the pipe diameter to a diameter smaller than the connection to the device. Never close the air inlet openings. It is...
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Page 16: Connection Condensate Pipe
Connection condensate pipe The gas-fired condensing air heater must be fitted with a siphon to drain the condensate water. The supplied siphon must be fitted during installation. Note that the discharge of the condensate must be carried out with material which is resistant to acid water with a pH of 3. Never use copper or galvanized iron pipes. For the disposal of condensed water you must use PVC pipes with a diameter that is equal to this of the unit (PVC 32). Make sure the piping is placed on sufficient slope. Check the tightness of the Ø plumbing of the condensate. Before using the unit, fill the siphon with water through the filler cap. This avoids that combustion gas will get into the sewer during the start-up. Anti-freeze protection The condensate drain, including the siphon, must be protected against frost. It is preferred to keep the drains frost-free as best as possible. In case they fall outside the building, the pipe part behind the siphon should be open to avoid the formation of ice which will block the discharge. Take the necessary precautions to avoid such an incident, as this may cause irreversible damage to the heater. Neutralization of the condensate The acidity of the condensate from the combustion of natural gas is 3,5-3,8 pH. In certain regions it is required that the condensate must be treated before it can be discharged. In these cases you should take on a neutralization kit in the condensate circuit. Filler Acid water Neutralization kit... -
Page 17: Gas Connection
Gas connection Foremost you should check whether the delivered unit is made for the gas that unit will be connected to. This data of the device is mentioned on the type plate on the inside of the door. The gas supply must be suitable for the load of the device and must be equipped with all the safety and control devices required by the regulations in force. The diameter of the pipe must be accurately determined. Important factors for this are, among others, the gas flow and the length and route of the pipes. The maximum allowable line losses may not be greater than 5% of the nominal supply pressure. The gas connections must be installed in accordance with national and regional regulations and must be performed by authorized personnel. Before commissioning the unit must be pressure tested in accordance with the applicable regulations and be cleaned. The maximum allowable pressure of the gas is 60mbar. Note, before opening the gas you must check the seal on the throttle. Gas connection: Connection pressure natural gas higher than 50mbar; connection pressure natural gas lower than 50mbar; LPG supply. Gas connection set: Gasket (supplied); Suitable connection (supplied); Gas pressure regulator; Filter; Gas tap. -
Page 18: Controls
Controls Comtherm The Comtherm is a modulating temperature controller. The room temperature sensor is integrated in the housing of the controller. The Comtherm is equipped with a clock function, day-night control, continuous running fan and continues daytime. Based on the prevailing room temperature and the desired temperature, the capacity is determined. The controller standardly comes with a 9 meter cable. Maximum cable length is 100m. The cable must be shielded. For further information about the Comtherm, please refer to the manual of this controller. A Comtherm can control one GSW+. - Page 19 Connection diagram Condensing air heater Maintenance switch 230Vac Comtherm Room sensor...
- Page 20 Supply Comtherm (Connector JP 18) RS 485 Bus connector...
- Page 21 Control connection Figure 2a Cable 1 Cable color Function Connection Orange 24v (supply) Connector JP 18 Blue 0v (supply) Connector JP 18 Green 0v (rs485) Clamp GND Brown A and B (rs485) White-brown clamp A Brown clamp B Figure 2b...
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Page 22: Commissioning
Commissioning Commissioning 1 Before commissioning the heater and putting it under voltage, ensure that the connectors are well performed as described in the following chapters: – Connecting the condensate, page 16; – Connecting the flue, page 12-15; – Electrical connection, page 18-21; – Gas connection, page 17. 2 Also ensure that: – The protective film on the panels has been removed; – The distance around the unit has been met; – All electrical connections are performed; – That the ground connection is performed. 3 Check the power supply of the heater. This should be between 210V and 230V AC. Note the polarity Neutral and Phase. In case of a two-stage network an isolating transformer should be applied. For more information please ask the manufacturer. 4 Ensure that the type of gas and the gas pressure match the information on the type plate. 5 Ensure that the Comtherm or the communication with the heater operates. 6 Take the air heater into operation: –... - Page 23 20-50 mbar Min. 18 mbar G25 (natural gas) 25-50 mbar Min. 20 mbar G31 (propane) 28-50 mbar Min. 25 mbar Venture restriction ring color Model GSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70 Ring color / ø White / 6mm White / 6mm Red / - - / -...
- Page 24 Malfunctions Malfunctions When a malfunction appears, make sure all above mentioned conditions / procedures have been performed. Note: all electrical or mechanical work has to be done after interrupting the power supply and closing the gas supply. Malfunction Cause Solution The unit doesn’t start - The main switch is set to OFF - Turn the switch ON - Blue LED on the control board is - Check the power supply turned off = no power - LED on the control board flashes blue - Check the communication cable communication error - LED on the control board is blue/red - Check the sensor and replace sensor error - LED on the control board flashes - Check the pump and the water blue/red ...
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Page 25: Spare Parts
Spare parts N° Description Codes GSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70 Water/air heat exchanger 0699303 0699304 0699305 0699307 Pump 0699310 Return pipe 0699313 0699314 Water pressure sensor 0699316 Return water temperature sensor 0699318 Overflow valve (3bar) 0699320 Supply pipe 0699323 0699324 0699325 0699327... -
Page 26: Maintenance
Maintenance Correct and regular maintenance of at least once a year will increase the safety, reliability and efficiency. Additionally, it will extend the life of the unit. SERVICE MUST BE PERFORMED WHEN THE UNIT IS COLD. GAS AND ELECTRICAL SUPPLY MUST BE DISABLED. MAINTENANCE SHOULD ONLY BE DONE BY CERTIFIED PROFESSIONALS. Part Work to be carried out Heater Check that the device is functioning correctly for all safeties. Make sure all the screws are tightened. Flue gas system Check the combustion air and flue gas pipe trace. Check the seals and check for corrosion. Condensate drain Check the siphon for contamination and clean it. Burner Disconnect the electrodes, the electrical connections of the combustion air fan and the gas pipe at the gas valve. - Page 27 Part Work to be carried out Boiler body Check the sealing of the front plate. Inspect the heat exchanger tubes. Inspect the isolation on the front and back plate of the heat exchanger. Damaged or hardened seals must be replaced. Clean the inside of the heat exchanger with a stiff brush. Heat exchanger Remove the exhaust vane window and clean it with a vacuum cleaner of air syringe. Check the heat exchanger for leaks. Expansion tank Do not open the filler cap when the unit is still hot. Risk of severe burns! Check the level when the unit is off and cold. The level must touch the filler neck. If necessary, fill it with a monoethylene-glycol solution (-15 °C) provided with corrosion inhibitors. Pump Check that the pump is functioning.
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Page 28: Recommendations For The End User
Recommendations for the end user Safety rules – It is prohibited to seal the ventilation openings of the room where the unit is installed or that of the unit. – Never block the smoke evacuation and the combustion air intake. – Do not make any changes to the controls that have been installed by qualified professionals. – Do not spray water on the heater or touch the unit with wet hands. – Do not touch any hot or moving parts of the air heater. – Do not place objects on the unit or hook objects onto the unit. –... - Page 32 MARK DEUTSCHLAND GmbH BENEDEN VERLAAT 87-89 MAX-PLANCK-STRASSE 16 VEENDAM (NEDERLAND) 46446 EMMERICH AM RHEIN POSTBUS 13, 9640 AA VEENDAM (DEUTSCHLAND) TELEFOON +31(0)598 656600 TELEFON +49 (0)2822 97728-0 FAX +31 (0)598 624584 TELEFAX +49 (0)2822 97728-10 info@mark.nl info@mark.de www.mark.nl www.mark.de MARK EIRE BV MARK POLSKA Sp. z o.o COOLEA, MACROOM UL. KAWIA 4/16 CO. CORK (IRELAND) 42-200 CZE ˛STOCHOWA (POLSKA) PHONE +353 (0)26 45334 PHONE +48 34 3683443 FAX +353 (0)26 45383 FAX +48 34 3683553 sales@markeire.com info@markpolska.pl www.markeire.com www.markpolska.pl MARK BELGIUM b.v.b.a.
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