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Automatic Heating Gasogen Installation And Servicing Manual

29-93kw wood fired boiler
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Gasogen
29 - 93kW
Wood Fired Boiler
Installation and Servicing Manual

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  • Page 1 Gasogen 29 - 93kW Wood Fired Boiler Installation and Servicing Manual...

  • Page 2: Table Of Contents

    Gasogen General Information CONTENTS 1 GENERAL 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 ......................................

  • Page 3: General Information

    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 1.1 - SYMBOLS USED IN THIS MANUAL...

  • Page 4: Safety Warnings

    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...

  • Page 5: Data Badge

    Please read carefully the instructions contained in this manual Any repairs must be carried out by Automatic heating authorized as they provide important indications regarding the safe technicians and using only original spare par ts. Non- installation, use and servicing of this appliance.

  • Page 6: Technical Features And Dimensions

    Technical features and dimensions 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:...

  • Page 7: Dimensions And Water Connections

    T5. Bulb holder connection for heat discharge valve T6. Bulb holder for safety thermostat T7. Bulb holder for thermometer and high limit T2-T8 and minimum working thermostat, T8. Boiler drainage fig. 1 GASOGEN GASOGEN GASOGEN GASOGEN GASOGEN MODELS G3 25 2S G3 40 2S...

  • Page 8: Main Components

    REVERSED FLAME COMBUSTION Every body knows that to make a match last it must be held The GASOGEN G3 2S boiler today has reached such a high with its head upwards. level of perfection that it can pass all the most stringent tests...
  • Page 9 To obtain this Automatic Heating has opted for an exchange surface with dry smoke passes (fig. 4), which have already been extensively tested in oil fired boilers working at low water temperature, thus permitting low smoke temperatures without danger of condensate forming.
  • Page 10 Gasogen Technical features and dimensions 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.
  • Page 11 Technical features and dimensions 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.

  • Page 12: Installation Instructions

    Gasogen Instructions for the installer INSTALLATION INSTRUCTIONS 3.1 - GENERAL WARNINGS WARNING! This boiler is to be destined only to the use for which it has expressly been designed for. Every other use is to be considered improper and therefore dangerous.

  • Page 13: Installation Codes Of Practice

    Instructions for the installer 3.2 - INSTALLATION CODES OF PRACTICE The GASOGEN G3 2S is a boiler foreseen for operation with firewood. The appliance must be installed in compliance with all applicable laws and regulations.

  • Page 14: Packaging

    Gasogen Instructions for the installer 3.3 - PACKAGING The GASOGEN G3 2S is supplied dismantled: the casing, the fan, the control panel, the handles and the cleaning accessories are delivered separately in carton boxes (fig. 8). After having unpacked everything, make sure that the consignment is intact and undamaged.

  • Page 15: Installation

    Instructions for the installer 3.5 - INSTALLATION The boiler does not differ from a normal solid fuel fired boiler; therefore there are no particular installation codes of practice other than the applicable national and local safety regulations and laws. The installation room must be properly ventilated via openings, which should have a total surface of at least 0,5 m².

  • Page 16: Connection To The Heat Exchanger's Drainage

    Solid fuel fired boilers have to be installed with the safety devices foreseen by applicable regulation and laws. For this purpose the GASOGEN G3 2S boilers are fitted with a safety heat exchanger. On this safety heat exchanger the installer must fit a heat discharge valve, whose control bulb has to be inserted in the bulb holder placed onto the rear wall of the wood fired boiler.

  • Page 17: Installation Instructions

    Instructions for the installer 3.9 - INSTALLATION INSTRUCTIONS Installation of the insulation and casing FIG. 12 A) Fit the ball grip pos. 4 onto the upper door closing handle. B) Fit the screw and nut on the upper and lower door and screw down the ball grip (pos.
  • Page 18 GASOGEN G3 40 2S GASOGEN G3 50 2S fig. 15 Ref. fig. 16 (Mod. GASOGEN G3 65 2S, GASOGEN G3 80 Models: GASOGEN G3 65 2S - Fit the air manifolds on to the intermediate door. GASOGEN G3 80 2S - Fit the gaskets and the plates to the manifolds.
  • Page 19 Instructions for the installer Wire the electrical connections as indicated on the general wiring diagram on page 44 and practical wiring diagrams on page 21 & 22). Insert the bulbs of the thermostats in their relevant bulb holders as shown in fig. 17 and secure them in place with the fixing springs.
  • Page 20 Gasogen Instructions for the installer To ensure correct operation of the GASOGEN G3 2S boilers it is necessary to fit a recirculation pump in order to avoid low temperature water returns that could jeopardize the boiler’s life span. Automatic Heating, to favour her clients, has developed a water recirculation kit that optimizes the water recirculation within the boiler.

  • Page 21: Water And Electrical Connection Diagrams With Standard Control Panel, Without Hot Water Storage Tank

    Domestic hot water production for a central heating system with boiler temperature control via manual mixing valve. The GASOGEN G3 2S boiler’s standard control panel automatically switches off the fan and the recirculation pump in case the boiler temperature, (once 30 minutes have passed from closing the upper loading door for firing the boiler), does not reach 65°C (minimum temperature).
  • Page 22 Domestic Hot Water (DHW) for central heating installation with boiler temperature control via a manual mixing valve. DHW production via a coiled hot water storage tank or plate heat exchanger with independent installation system and dedicated loading pump The GASOGEN G3 2S boiler’s standard control panel automatically switches off the fan and the recirculation pump in...

  • Page 23: Water And Electrical Connection Diagrams With Optional Control Panel, Without Hot Water Storage Tank

    5.2. The GASOGEN G3 2S boiler’s standard control panel The logic operation of the GASOGEN G3 2S boiler’s control automatically switches off the fan and the recirculation pump if panel, will switch off the fan and the recirculation pump once the boiler temperature, (once 30 minutes have passed from the wood finishes.
  • Page 24 Gasogen Instructions for the installer...
  • Page 25 In summer the D.H.W. production can be supplied only by the back up boiler. The two boilers are hydraulically connected in parallel and the motorized UV diverting valve, will ‘direct’ the GASOGEN G3 2S boiler in the system circuit or the auxiliary boiler alongside: in this circuit the heating circuit water will not flow through the boiler not operating, thereby reducing the heat losses.
  • Page 26 Gasogen Instructions for the installer...

  • Page 27: Water And Electrical Connection Diagrams With Optional Control Panel, With Hot Water Storage Tank

    Instructions for the installer 3.12 - WATER CONNECTIONS AND ELECTRICAL DIAGRAMS WITH OPTIONAL CONTROL PANEL AND ACCUMULATOR Dimensioning of the accumulator: The Standard EN 303-5 says that the minimum heat output for automatically fed boilers should not be higher than 30% of the nominal heat output (Qn);...
  • Page 28 27), enables you to obtain a high seasonal efficiency from the GASOGEN G3 2S boiler and a The operation logic of the GASOGEN G3 2S control panel, will better management of switch off the fan and the recirculation pump once the fire wood the heating system, as well as a longer life span of the boiler, finishes.
  • Page 29 Instructions for the installer BV AGW GM MKP TAMB MAXP NETZ 25 26 33 34 41 42 43 44 45 46 47 48 49 50 51 27 28 29 VENTILATORE 1 27 28 29 VENTILATORE 2 TT (50-55°C) PMV1 fig. 30 To permit drainage of the accumulator when the firewood is finished, position the switch 23 of the control panel in pos.
  • Page 30 The operation logic of the GASOGEN G3 2S control panel, will itself. switch off the fan and the recirculation pump once the fire wood Moreover, the accumulator, makes you save a lot on your gas finishes.
  • Page 31 Instructions for the installer BV AGW GM MKP TAMB MAXP NETZ 25 26 33 34 41 42 43 44 45 46 47 48 49 50 51 27 28 29 VENTILATORE 1 27 28 29 VENTILATORE 2 TT (50-55°C) TB (45÷60°C) PMV1 fig.
  • Page 32 Moreover, the accumulator makes you save a lot on your gas bill. The operation logic of the GASOGEN G3 2S control panel, will switch off the fan and the recirculation pump once the fire wood This type of installation is particularly effective during the “mid finishes.
  • Page 33 Instructions for the installer...
  • Page 34 The temperature of the accumulator, superior to 50-55°C, will The operation logic of the GASOGEN G3 2S control panel, will prevent the back-up boiler’s burner firing. switch off the fan and the recirculation pump once the fire wood finishes.
  • Page 35 Instructions for the installer...
  • Page 36 Gasogen Instructions for the installer...
  • Page 37 The operation logic of the GASOGEN G3 2S control panel, will switch off the fan and the recirculation pump once the fire wood The diverting valve (UV), will direct the system returns towards finishes.
  • Page 38 Gasogen Instructions for the installer...
  • Page 39 Instructions for the installer...

  • Page 40: Flue Outlet Connection

    Gasogen Instructions for the installer 3.13 - FLUE OUTLET CONNECTION The flue system must be installed in accordance with the local We recommend using only flue outlets regulation and national codes of practice. suitable to the type of fuel used.

  • Page 41: Filling The System

    This could cause damage to the washers and could cause noise during normal boiler operation. Automatic Heating refuses all liability for injury to persons, animals or damage to property deriving from not having respe- cted the above mentioned recommend- ations.

  • Page 42: Electrical Connections

    The use of adaptors, multiple sockets and/or extension cords Approvals For the appliance’s general electrical supply is strictly forbidden. The Automatic Heating control panels code 36748 (standard) and code 23557 (electronic, optional) have been CE approved, according to the EN 60335-1 Standard.

  • Page 43: Standard Control Panel

    Instructions for the installer 4.1 - STANDARD CONTROL PANEL The standard control panel (code 36748) operates in a semi-automatic way and is supplied in a cardboard with the following standard items: - Microswitch which has to be fitted to the mechanism controlling the bypass rod (TKS) as shown in fig. 13 page 17. - A 3 pole cable for the fan’s electrical connection (2 fans for the models G3-65 and G3-80) The connection of the thermostat bulbs to the bulb holders must be carried out as shown in fig.
  • Page 44 Gasogen Instructions for the installer 11 Mains switch 32 Working thermostat 12 Fan switch 41 Main fuse (4A) 13 C.H.pump switch 42 Boiler thermometre 31 Safety overheat thermostat fig. 41 fig. 42 LEGEND WIRING DIAGRAM Ph Phase (230V ~ 50Hz)

  • Page 45: Optional Control Panel

    Instructions for the installer 5.1 - OPTIONAL CONTROL PANEL The optional control panel (code 23557) is supplied in a cardboard box with the following standard components: - Microswitch to be fitted integral with the opening mechanism of the loading door (TKS) (see page 17). - Flow temperature sensor (Tc): to be fitted on the boiler’s flow connection - Boiler fan supply cable, with 3 pole plug.

  • Page 46: Functional Wiring Diagram (Flow Chart)

    This jumper controls the fan’s ignition when the loading door is opened. If the fan works by pushing, as in the case of the GASOGEN G3 2S boiler, make sure that the jumper on the PINS 54 - 55 is OFF (IL=1).
  • Page 47 Instructions for the installer FLOW -Chart fig. 44...

  • Page 48: Loads And Sensors Connection Diagram

    Gasogen Instructions for the installer 5.3 - LOADS AND SENSORS CONNECTION DIAGRAM 15 = Earthing (PE) 34 = Recirculation pump N (KKP) 16 = Earthing (PE) 35 = Recirculation pump ( ) (KKP) 17 = Fire proof thermostat L1 (BS)

  • Page 49: Functional Description Of Optional Control Panel

    Instructions for the installer 5.4 - FUNCTIONAL DESCRIPTION OF OPTIONAL CONTROL PANEL (see flow-chart on page 47) 5.4.1 - IGNITION (see Step 0, Step 1 page 47) The main switch (pos. 11), the C.H. pump switch (pos. 13) and the fan switch (pos. 12) are all positioned differently to “0”; t he switch (pos.

  • Page 50: Oil/Gas Boiler Operation

    Gasogen Instructions for the installer 5.4.4 - OIL/GAS BOILER OPERATION (see Step 4, Step 6, page 47) In installations with a back up oil/gas boiler (hydraulically connected in parallel), the burner is switched ON via the potenti al free contact BV, if this has been integrated in the burner’s electrical wiring by the installer; in paragraph 3.11 an auxiliary circ uit diagram is proposed for controlling: - the C.H.

  • Page 51: Special Functions

    AGW terminals, in order to stop the burner firing in case the flue temperature of the wood fired boiler, is over 100°C. 5.5.3 - FAN OVERHEATING PROTECTION SYSTEM In this range of boilers (GASOGEN G3 2S) this system is not activated. 5.5.4 – TEMPERATURE SENSOR FAILURE ALARM (note for After Sales Service) If the flow sensor (Tc) malfunctions or is not correctly connected to the relative terminals, the microprocessor’s logical co ntrol...

  • Page 52: Fireproof Thermostat

    Gasogen Instructions for the installer 5.5.5 - FIRE PROOF THERMOSTAT A fire proof thermostat can be connected to the control panel in order to switch off the fan, connected to the terminals BS so as to arrest combustion in the wood fired boiler.

  • Page 53: Optional Control Panel Wiring Diagram

    Instructions for the installer 5.6 - WIRING DIAGRAM OPTIONAL CONTROL PANEL Control panel – rear view Mother board fig. 46 LEGEND : REL 1 Fan (GM) 1÷4 Mains supply 230 V - 50 Hz REL 2 Burner (BV) 5, 6 C.H. pump REL 3 Recirculation pump (KKP) 7, 8 Fuse 4A REL 4 C.H.

  • Page 54: Boiler Start-Up

    Failure to do so could cause injury to persons, animals or damage Explain and demonstrate to the user the correct function to property. Automatic Heating shall not be and adjustment of the temperature, thermostats and held liable for any injury and/or damage radiators for the economic use of the system.

  • Page 55: Fire Wood

    3.250 0,93 content of the wood used. The heat output of the 3.010 0,86 GASOGEN G3 2S boiler is calculated for wood with a 15% moisture content. 2.780 0,79 As an example wood which has been dried for 2 2.540...

  • Page 56: Start-Up

    GASOGEN G3 40 2S models - Logs too short cause irregular air passages, with consequent b) 70 cm (+ 1 cm, - 4 cm) for the GASOGEN G3 50 2S and reduction in output and efficiency. GASOGEN G3 65 2S models - In case the quality of the wood causes “obstructions”...

  • Page 57: Combustion Air Adjustment

    (pos. S). insulation is white. For the GASOGEN G3 65 2S and GASOGEN G3 80 2S boilers the primary air adjustment is achieved by acting on the upper 2) If the primary air is insufficient the flame will be slow, fan’s external ring nut;...

  • Page 58: Checks To Carry Out After First Start-Up

    Gasogen Instructions for the installer 6.8 - CHECKS TO CARRY OUT AFTER THE FIRST START-UP SOUNDNESS CHECK During the first start-up check the soundness of the seals of the flue circuit and the chimney connection. If you notice smoke leakages inform the installer or the After Sale Service.

  • Page 59: Thermostat Adjustments

    Instructions for the installer 6.10 - THERMOSTAT ADJUSTMENT WOOD FIRED BOILER The boiler’s adjustment thermostat must be set to the desired temperature (the adjustment range, limited by stoppers that must not be removed, varies from 75° to 85°C). To adjust the boiler’s flow temperature to the heating system it is necessary to foresee the installation of a 3 or 4 way mixing valve.

  • Page 60: Fault Finding For Boilers With Standard Control Panel

    - The fan starts, but after 30 minutes it stops; any other inter ventions and contact an by switching OFF and ON the main switch (pos. 11) it re-starts. authorized Automatic Heating After Sales Service. Remedy: - Increase the temporized relay’s intervention time...

  • Page 61: Fault Finding For Boilers With Optional Control Panel

    - The fan starts, but after 30 minutes it stops; any other inter ventions and contact an by switching OFF and ON the main switch (pos. 11) it re-starts. authorized Automatic Heating After Sales Remedy: Service. - Increase the TIMER 1 intervention time...

  • Page 62: Servicing And Maintenance Schedule

    Once all the necessary maintenance work has been completed always follow these steps: For this reason Automatic Heating recommends that a servicing contract should be made with one of our authorized After Sales - Open the CH flow and return valves as well as the cold Service Assistance Centre.
  • Page 63 Servicing schedule Servicing of the boiler body In this case: 1) Check the adjustment of the air setting, according to the Danger ! instr uctions given in the paragraph “Combustion air Before servicing the boiler body, make sure adjustment”. the boiler has cooled down. 2) Check that the two holes for the secondary air, placed in the front part of the main stone, just in front of the two adjustment screws, are not obstructed;...
  • Page 64 Gasogen Servicing schedule If the incrustations are more resistant, due to the formation of condensate or tar tears , clean very carefully in order not to bend or deform the blades. This could make the fan noisy during operation and could reduce the fan’s performances.
  • Page 65 Servicing schedule Components to check during annual servicing Component Soluzione inconveniente Cast iron fire bars If necessary replace Stainless steel grate If necessary replace Fire bars mineral wool insulation If necessary replace If necessary clean them Primary and secondary air inlets If necessary adjust it Soundness of the bypass disk If necessary repair it using the refractory kit (see spare...
  • Page 66 Gasogen notes...
  • Page 67 notes...
  • Page 68 DISTRIBUTED BY 51 Assembly Tullamarine Vic 3043 Australia PO Box 356 Tullamarine Vic 3043 Australia Telephone +61 3 9330 3300 Facsimile +61 3 9310 5655 Email sales@automaticheating.com.au www.automaticheating.com.au...

This manual is also suitable for:

Gasogen g3 25 2sGasogen g3 40 2sGasogen g3 50 2sGasogen g3 65 2sGasogen g3 80 2s

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