Mark GS+ Manual

Introduction

Read this document before installing the heater

Incorrect installation, adjustment, alteration, repair or maintenance work may lead to material damage or injury. All work must be carried out by certified, qualified professionals. If the appliance is not positioned in accordance with the instructions, the warranty shall be rendered void. This appliance is not intended for use by children or persons with a physical, sensory or mental handicap, or who lack the required experience or expertise, unless they are supervised or have been instructed in the use of the appliance by somebody who is responsible for their safety. Children must be supervised to ensure that they do not play with the appliance.
If the manual refers to an image or table, a number will be shown between square brackets, for example [3]. The number refers to images and tables at the back of the manual with the stated number.

Installation

Positioning the appliance

After unpacking, check the appliance for damage. Check that the information relating to the type/model and the electrical voltage is correct. Place the appliance and any accessories on a sufficiently solid structure [2&3], taking into account the minimum free space required [1]. Use the M10 suspension points for this. Note in particular the space needed for cleaning the burner and fan.

Positioning the flue gas exhaust system and air supply

The GS+ and G + modules are suitable for use with flue gas ducting:
B23; C13; C33; C53 and C63 [5]. The extension pipes must be fitted in parallel. Flue gas exhaust pipes should preferably be made from stainless steel. The air supply pipes must be made of thinwalled aluminium or PP. The flue equipment must have been positively assessed for application with gas-fired appliances. This positive assessment should have been issued by an inspection body with ISO 17025 accreditation. We advise you to obtain supply equipment and flue gas equipment from the manufacturer. This ensures compliance with these requirements.
See table [4] for the correct connection size on the appliance and position details. The flue gas exhaust arrangement C63 must comply with the requirements of the Gastec QA quality label for condensing appliances with a continuous permissible flue gas temperature of 160 degrees Celsius.
Note:

• The values indicated in the flow resistance table[4] apply solely for the flue gas exhaust equipment that is supplied or recommended by the manufacturer.
• Flue equipment with a different flow resistance may affect the length of the total supply and exhaust routing.

The pH value of the condensation water is 3.4!

• C63 flue gas arrangement is not permitted in Belgium.

The roof and wall pass-throughs supplied by the manufacturer are identified by the following item numbers:

The extension pipes and bends of the gas flue exhaust system must satisfy the following requirements:

Gas connection

The installation of the gas pipeline and gas tap must comply with the relevant local and/or national regulations. The gas tap must be positioned within reach of the appliance [3]. If the connection line is subject to pressures above 60mbar, this gas tap must be closed. If there is any possibility of the presence of dirt in the gas, use a gas filter. Always blow through the gas pipe in compliance with the regulations prior to operating the appliance. If the appliance needs to be converted to a different type of gas than that indicated on the type plate, the supplier of the appliance must be contacted. The supplier can advise you which parts must be replaced in order to ensure correct operation of the appliance with the desired type of gas. Conversion to a different type of gas is not permitted in Belgium.

Electrical connection

Installation must comply with the relevant local and/or national regulations. Ensure that there is a correct connection group with a mains fuse. The electrical diagram is displayed on the appliance. A basic diagram for the GS+ appliance can be found in chapter Electrical diagram. In the case of the G+ with a centrifugal fan, please refer to the diagram on the appliance.
PLEASE NOTE:

• The appliance must be adequately earthed. The appliance must be fitted with an isolator switch which interrupts phase and zero (not earth).
• The isolator switch must be accessible at all times.
• Never, under any circumstances, allow the supply to the appliance to be interrupted by other switches. This could result in the appliance overheating.

Siphon

The boiler siphon that is included in the scope of supply must be connected to the appliance. The boiler siphon must connect to the odour trap siphon in the drainage system to the sewer via an open connection. Make sure that the siphon is protected against frost (risk of freezing).

Controls

The modulating heater can be controlled in various ways.

0-10 volt DC
A 0-10 volt DC controller passes a signal to the air heater. If the signal is greater than 2 volts DC, the air heater will start to operate. If the signal remains below 1 volt DC, the air heater switches off. The speed of the combustion air fan and consequently the burner load are controlled linearly between 2 and 10 volts DC. When the signal lies between 1 and 2 volts DC, the combustion air fan speed is continually set to minimum. A link must be placed across terminals A and B (230 VAC) for continuous ventilation. A 0-10 volt DC signal must be connected using two-core shielded mains cable for low-power use. Make sure polarity is correct.

OpenTherm
An OpenTherm thermostat measures the prevailing room temperature, the target room temperature and the current air discharge temperature. This data is used to determine the target air discharge temperature. The microprocessor built into the air heater adjusts the burner capacity until the target air discharge temperature is achieved. An OpenTherm thermostat must be connected using a shielded 'twisted-pair' two-core cable for low power use. The polarity is unimportant. The OpenTherm thermostat provided by the manufacturer allows the burner controls to be unlocked at the thermostat. This thermostat also displays operating and fault codes, see chapter Faults. Switching on continuous ventilation is possible with this thermostat.

230 volt AC thermostat
The heater can be switched on and off via a 230 volt AC thermostat. The thermostat must be connected to terminals 1 and 2 and a jumper must placed across terminals A and C; refer also to the electrical diagram. When heat is demanded, the appliance will ramp up to maximum load in stages.

On/off control
If a conventional on/off control arrangement is used, the room thermostat operates independently. The thermostat measures the room temperature via a built-in sensor and compares the reading to the set temperature. In this on/off control arrangement, communication only takes place in one direction: i.e. from the thermostat to the air heater.

Start-up/shutdown

General

Before being packed, each appliance is fully tested for safety and correct operation. Among other checks, the gas pressure and CO2 are set. You must however always check the gas pre-pressure. Never turn the adjusment screws without good cause. Do not forget to instruct the user on the proper use and operation of the appliance and peripherals.

Checks

• Switch off the electricity supply at the main switch.
• Set the room thermostat to the minimum temperature.
• Open the gas stop cock, then carefully purge the gas pipes of air and check for leaks. Under no circumstances use a naked flame!
• Close the gas stop cock.
  Check whether the siphon has been correctly mounted and is protected against frost. Fill it with water before starting up the appliance for the first time.
• In the case of the GS+, check whether the vanes in the air discharge port are set to the open position (open to a min. of 45º).
• In the case of appliances with a centrifugal fan, check the external static system pressure, direction of rotation of the fan, current draw and check the belt tension after 20 to 40 operating hours. Adjust the tension regularly during the first year of operation[19].
• Switch on the electrical supply at the main switch and set the room thermostat to maximum temperature. After the purge time has elapsed, the automatic ignition control will generate an electric spark and the safety valve on the gas control unit will open. Because the gas stop cock is closed, no flame will appear. The automatic ignition control will lock out after 4 attempts at ignition, each lasting about 5 seconds. After waiting for approximately 30 seconds, the automatic controller can be reset and the same cycle can be repeated.
• Open the gas stop cock, the appliance will now start up.
• Check the flame pattern at the main burner (clearly defined inner core, even combustion).
• In the case of appliances with an external fan, check that the maximum temperature increase of 30K is not exceeded.

Check that the room thermostat is functioning correctly

If the setting is lower than the ambient temperature, the burner will extinguish. At a setting higher than the ambient temperature, the burner should ignite. When there is no more heat demand, the anti-cycling time starts. The air heater cannot be started up (again) during this period of time (1 minute).

Check the pre-pressure

The gas pre-pressure must be measured at the gas unit when the appliance is in operation. The pre-pressure is indicated on the appliance's type plate. To check, the volume of gas consumed [3] can be measured via the gas meter (temporarily switch off all other appliances that consume gas).

Check appliance operation

Finally, check that the operation of the appliance cannot be influenced by other appliances close to it, localised air flows or corrosive or explosive vapours, etc.

Set the gas control unit

Before being packed, each appliance is fully tested for safety and correct operation. The correct combustion values are set during this procedure. Further setting is generally not required; the appliance need only be checked for correct operation. However, if checks indicate that the CO2 value is different from that in table [3], adjustments may be made (difference of more than 0.2%). Never adjust set screws without the correct measuring equipment.

1. Set the appliance to run at full operational load by adjusting the room temperature control to maximum. If the appliance will not fire up, you can try sealing the air opening in the gas mixer during ignition using your thumb and index finger. This makes the mixture richer and easier to ignite. Check the CO2 when the appliance is operating at high output. If the CO2 is too high, turn the throttle adjuster to the right (less gas). If the CO2 is too low, turn the screw to the left (more gas). The correct CO2 value is shown in table [3].
2. Set the appliance to minimum load by setting the target temperature on the room controller to a value close to the prevailing temperature, or by applying 2 VDC to the 0 – 10 VDC input. Check the CO2 against the value in table [3]. If different, correct by turning the offset adjuster under the cap. To the left for lower CO2, to the right for higher CO2.

Legend [6]

1. Measuring point for gas pre-pressure
2. Measuring point for offset
3. offset adjustment screw
4. Throttle adjustment screw

Shutting down the heater

For short periods of time:

• Set the room thermostat to the minimum temperature.
• Do not switch off the electricity supply at the main switch as this may damage the maximum temperature and safety thermostat.

For longer periods of time:

• Set the room thermostat to the minimum temperature.
• After ± 5 minutes, the electrical power may be switched off.

Maintenance

General

The appliance must be subjected to maintenance at least once a year, more often if necessary. If applicable, ask a qualified installer for maintenance advice. When carrying out maintenance, the appliance must have been shut down for an extended period. Make sure that you comply with all safety rules.

Cleaning

All gas-fired appliances require periodical maintenance. This maintenance work must be performed by qualified maintenance technicians.

• Before starting maintenance work, the gas and electrical supplies must be shut off.
• Check all gaskets and replace if required.
• The gas transport section is located on the side of the appliance in the electrical compartment. The gas transport section can be removed from the appliance as a single assembly. To do so, six M6 nuts must be removed and the electrical wiring disconnected.
• Removal of the gas transport section provides access to the burner and the ignition/ionisation electrode. Any oxidation on the electrode tips must be removed.
• Check the burner surface for irregularities. Never use a steel brush!
• Clean the gas mixer using a soft brush. Make sure that no dust gets into the burner and the gas suction tube. Refit the gas transport section, reconnect the wiring and the gas and electrical supplies.
• The flue collector chamber is located under the flue gas pipe. Remove the clamping strip to gain access to the heat exchanger.
• The condensation drain nozzle is located in the base-plate of the flue gas collection chamber.
  This opening and the siphon should be checked regularly for dirt build-up.
• A water level sensor is fitted in the flue gas collection chamber. This switches the appliance off if a blockage forms in the condensation water pipe or the siphon in order to avoid an unacceptable build-up of water in the flue gas collection chamber.
  Check the fan pulley(s) and belt tension, clean the pulley(s) if required.
• If a G+ with a centrifugal fan is fitted with filters, the flow resistance through the filters increases as dirt accumulates. This flow resistance may not exceed the value shown on the type plate. Only replacement filters of the same class may be used. Refer to the sticker on the filter housing for more information about the filter set(s).

Description of parts

The parts are:

• Fan[7].
• Combustion air fan[8].
• Ignition set[9].
• Water level sensor[10].
• Burner[11].
• Gas control unit[12].
• Sensor[13].
• Safety thermostat[14].
• Gasket set[15].
• Microprocessor[16].
• Gas mixer[17].
• Siphon[18]

Faults

Appliance will not operate (Does absolutely nothing)

1. Check:
   • the setting at the room thermostat
   • for a voltage between terminals L and N (230 VAC)
   • that the room thermostat is connected correctly.
   • check the glass fuse on the terminal strip (refer also to the electrical diagram)
2. The burner controls are locked out. Reset the appliance using the reset button.
3. The maximum thermostat(s) are locked out. Reset the thermostat(s).

Appliance (combustion air fan) purges, but the burner does not ignite.
Check:

• The gas supply
• Whether the gas pipe has been adequately deaerated
• The siphon for blockages
• Adjustment of the ignition electrode

Appliance operates but the burner load modulates back continuously even though maximum load is required.
Check:

• the system fan(s) for damage
• if multiple fans are fitted to a single appliance, check for damage and correct connection
• the fans(s) and heat exchanger for dirt build-up

OpenTherm thermostat fault codes (item number 06 29 072)

Electrical diagram

For G+: see inside the appliance.

General

Application

Appliance type GS+ is solely suitable for the free and direct intake of the air to be heated and the free discharge of heated air into the room. Appliance type G+ with a centrifugal fan is suitable both for the free and direct intake of the air to be heated and the free discharge of heated air into the room, and for connection to a duct system.
If areas are to be heated in which corrosive vapours are present (chlorinated hydrocarbons in particular), which are either produced directly in the area, or which may be drawn in from the outside by the heater via a duct or an open connection, wall air heaters cannot be used because of the risk of corrosion to the heat exchanger.

Subject to change
The manufacturer is committed to constantly improving its products and reserves the right to make changes in the specifications without prior notice. The technical details are considered correct but do not form the basis for a contract or warranty. All orders are accepted according to the standard terms of our general sales and delivery conditions (available upon request).

Type indication

All the types of appliance are listed in table [3]. The various types are shown in the rows, and technical information relating to the appliances is shown in the columns. See the key below. Key to table [3]

1. Nominal load (upper value)
2. Nominal load (lower value)
3. Efficiency at 100% full load
4. Efficiency at 30% partial load
5. Gas consumption for a specified gas type (15°) max/min
   E1 CO2 for a specified gas type: max. load %
   E2 CO2 for a specified gas type: min. load % E3 Gas pre-pressure for a specified gas type
6. Burner turndown ratio
7. Flue gas temperature (+/- 10°C)
8. NOx emission 3% O2
9. Burner fan start-max.-min.
10. Admissible flue gas flow resistance
11. Diameter of the flue gas duct/air supply duct
12. Electrical supply
13. Electrical power
14. Appliance fuse rating
15. Protection class

17. Air displacement (20°C)
18. Air temperature rise GS+
19. Throw GS+

Information for Belgium

1. Nominal load (lower value) H gas / L gas
2. Power H gas / L gas

General warnings

Incorrect installation, adjustment, alteration, maintenance or repair may lead to material or environmental damage and/or injuries. The appliance should therefore be installed, adapted or converted by a skilled and qualified installer, taking into account national and international regulations. Faulty installation, adjustment, alteration, maintenance activity or repair shall render the warranty void.

Appliance
When installing wall air heaters, you must comply with the relevant national and, if applicable, regional and local regulations (e.g. gas company regulations, building regulations etc.). The wall air heater may be installed only in an area and position suitable for the purpose, see Installation. In Belgium, the wall air heater must be installed in accordance with Belgian standard NBN D51-003.

Gas supply and connection
Before installation, check that the local distribution conditions, gas type and pressure and the current adjustment of the appliance all match. An approved gas stop cock must be fitted to the inner pipeline.

Flue gas route
Combustion air supply pipelines and combustion gas exhaust ducts should have as few bends as possible; in general, flow resistance should be kept to a minimum and in all cases, the diameter should be constant along the entire length. The exhaust duct may not rest on the heater, but should be suspended efficiently! If the flue gas exhaust duct passes along or through combustible walls or floors, the duct must be sufficiently far away from the combustible material to prevent fire.

Think of your safety

If you smell gas, you must not under any circumstances:

• Ignite an appliance
• Touch electrical switches or telephone from the area in question Take the following action:
• Switch off the gas and electricity
• Activate the operational emergency plan
• Evacuate the building if necessary