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Summary of Contents for Verner G45
- Page 1 EXPERT ON HEAT EN ISO 9001:2008 OPERATION AND INSTALLATION MANUAL FOR THE VERNER G45 and GN45 Wood burning gasification boiler Product Number Sole UK Distributor: b018.66654.250610 Ashburn Stoves Issued on: 25.06.2010 www.ashburnstoves.co.uk Translated on 13.07.2013 0845 539 0364 ...
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Page 3: Table Of Contents
CONTENTS IMPORTANT INFORMATION ...................... 3 INTRODUCTION .......................... 3 TECHNICAL DESCRIPTION ....................... 4 BOILER DETAILS .......................... 5 TECHNICAL DETAILS ........................ 6 BASIC FUNCTIONAL COMPONENTS .................... 6 ASSEMBLY AND INSTALLATION ...................... 7 Location ............................ 7 Hearth ............................ 8 Combustion air supply ......................... 8 ... -
Page 4: Important Information
Dear customer, You have become the owner of a product from our company and for that we appreciate it very much. You have joined the family of ten thousands of clients of VERNER a.s. Our designers and production teams have worked hard and believe that you will be pleased with this product. Your satisfaction can be further increased if you take the time to follow the instructions contained in this manual and take our business partners advice that are experienced with our products. We would be pleased to hear about your experiences of this product and would like to thank you in advance for any suggestions regarding the future development of our products. We wish you a lot of satisfaction VERNER a.s. IMPORTANT INFORMATION READ THESE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING, OPERATING OR SERVICING ... -
Page 5: Technical Description
Its high efficiency guarantees a very low running and environmental cost. Modern homes have superior levels of insulation and are far more energy efficient which makes homes easier to heat and retain heat much better. Verner wood burning appliances are carefully designed so that they will function correctly in modern energy efficient homes. The more energy efficient a house is, the less fuel is required to heat it, meaning less impact on the ... -
Page 6: Boiler Details
BOILER DETAILS Sectional side view Rear view Front view Side view Fuel chamber Nozzle Combustion chamber Side and rear combustion chamber insulation panels Heat exchanger Boiler body Flue connection Chimney damper Combustion fan 10. Primary air regulation 11. Secondary air regulation 12. Upper (stoking) door 13. Lower (clean out) door 14. Heating water outlet (flow) 15. Heating water inlet (return) 16. Cold feed and drain tap connection 17. Damper lever 18. Heat exchanger cleaning cover 19. Anti‐smoke plate 20. -
Page 7: Technical Details
TECHNICAL DETAILS Total rated thermal output 45 kW Efficiency 87 % Output modulation 50 – 100% Fuel consumption at rated output 13.5 kg/hour Burning duration of full fuel load at rated output 5 hours Dimension of stoking opening 240 x 430mm Fuel chamber capacity 180 litres Boiler hydraulic resistance at 70/90 C 20Pa Combustion gas temperature into chimney (at 30kW output) 200 C Minimum water return temperature C Water connections 2” BSP Total weight G45GV/GN45 630/570 kg Water capacity of boiler 92 litres Maximum operational pressure 3 bar Supply voltage (for mains adapter 12V‐1A) 230 V / 50 Hz Maximum electrical input 70W Electrical protection IP21 Maximum noise level 54dB Minimum chimney draught 15 Pa ... -
Page 8: Assembly And Installation
Turbulators (35): increase the eficiency of the heat exchanger by inducing swirl on the flue gasses. It is imperative that good quality fuel is used in conjuction with turbulators as poor quality combustion will potentially block the heat exchanger. ASSEMBLY AND INSTALLATION The boiler installation must to be carried out in compliance with this operating and installation manual. In all cases the installation must comply with current Building Regulations, Local Authority Byelaws and other specifications or regulations as they affect the installation of the stove. ... -
Page 9: Hearth
Hearth The boiler does not require a constructional hearth. However to comply with building regulations it must be located on a non‐flammable flat and level hearth of minimum 12mm thickness. The hearth temperature does not exceed 100 C. The hearth must extend a minimum of 300mm in front and 150mm to each side of the appliance. The installer must ensure that the floor on which the boiler is to be mounted has sufficient carrying capacity. Combustion air supply The boiler takes combustion air from the room in which it is installed. To perform efficiently and safely this appliance requires a combustion air ventilator fitting directly to outside air. ... - Page 10 Single wall flue connection pipes are not suitable for connection to this appliance unless connecting directly to an insulated metal flue liner. A chimney height of 5 metres should provide sufficient draught. It should have an approved termination. Masonry chimneys Masonry chimneys must be lined. The chimney should be of sound construction and swept before fitting a liner. ...
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Page 11: Optional Flue Exhauster
Optional flue exhauster The optional flue exhauster VS 5 is designed for chimney draught support during lighting and stoking of the boiler. It is situated on the boiler flue outlet and is then connected to the chimney. With the boiler at operating temperature and the flue exhauster not running the minimum flue draught of 15Pa is still required. The usage of the flue exhauster has the following advantages: Reduction of smoking during stoking Reduction of dust during deashing and boiler cleaning. The flue exhauster comprises a flue exhauster timer control box and the fan unit. They are connected together via a cable and come complete with a four‐pole plug which connects to the ... -
Page 12: Open Vented System
It is recommended to fit all radiators with thermostatic valves (other than on heat leak circuits). In this case an automatic bypass valve should also be fitted to the heating system to maintain pump circulation should the radiators all close. The boiler should be installed to allow for the inspection, service and replacement of connections and components and must have a drain tap fitted. The system can be designed and installed to dissipate heated boiler water via a gravity heat leak circuit if the electric power should fail during boiler operation. Provision for this can be through ... - Page 13 Should the appliance overheat the thermostatic safety valve will operate at temperatures above 95 C and allow cold water to flow through the cooling loop to cool the heat exchanger. Suitable thermostatic safety valves are the Honeywell T131 or Watts STS20 (not supplied). The sensor pocket for the thermostatic safety valve must be fitted into the ½”BSP connection in the heat exchanger (see diagram) and the sensor must be guarded against accidental removal. Honeywell TS131 The water connection from the thermostatic safety valve can be to either of the cooling loop heat exchanger ¾”BSP connections and the outlet to waste is connected into the other. (Either can be used for inlet or for outlet). Plastic pipes are not suitable, metal pipes should be used. We recommend that a test measurement of the flow of cooling water is made in case of it being ...
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Page 14: Electrical Connections
Electrical connections Introduction Only a registered competent electrician should connect this boiler to a power supply and external controls. Competent electricians work in accordance to BS 7671 and are members of a registration body such as the NICEIC who can be contacted here http://www.niceic.com/ ATTENTION! Isolate the mains electricity supply before starting any work and observe all safety precautiuons. ATTENTION! When connecting cables to the regulator ensure that no cable peices fall inside as they could cause a short circuit. Electrical connection The boiler is designed to be connected to a 230V/50Hz supply and must be fused at 3A. Electrical connection must be made via a fused double pole isolation switch with a minimum 3mm contact seperation of all poles. This appliance must be earthed. The connection of the circulating pumps along with time and temperature control must be in accordance with this manual. ... -
Page 15: The R4/2 Regulator Terminal Connections
The R4/2 regulator terminal connections OPERATION INSTRUCTIONS To ensure the safe and efficient use of the appliance it must be operated in accordance with the instructions set out in this operation manual. The boiler must be operated only by adults. The boiler must be tended and refuelled periodically. The boiler gets hot during operation and caution should be used when operating the damper control. A heat resistant glove is supplied and should be used when operating the stoking door and clean out door. Any materials which may give off combustible gas (solvents, glues and paint, etc.) should not be brought into the building whilst the boiler is lit as there is a risk of fire or explosion. The boiler must be extinguished before this risk develops. Burning waste in the boiler is prohibited. Only the specified fuel should be used. Liquid fuels must not be used. ... -
Page 16: Lighting The Boiler
Lighting the boiler Check before lighting: 1. Check that the system is full of water. 2. Check that the lower (13) and upper doors (12) close properly. 3. Check that the fuel chamber (1) is clear and the nozzle (2) is unobstructed. 4. Check that the combustion chamber (3) is clear and the insulation panels are in place. 5. Turn on the boiler switch, (1) page 24, ensuring the display shows the boiler temperature. Check the operation of the circulating pumps if fitted. 6. Turn the switch back off again. To light the boiler: 1. Open damper by pushing in its lever (17). 2. Set the control of the main air regulator (10) into the open position by sliding the control towards the boiler. ... -
Page 17: Combustion Control
5. Close the upper door. 6. Turn on the regulator (unless fitted with optional flue exhauster). 7. Close the damper. If excessive smoking occurs during stoking, we advise you to check if there is enough air supplied to the room and that any air vents are not obstructed. Try opening a window or door whilst stoking and if this helps the problem then you may need extra combustion ventilation. ATTENTION: Initial lighting may cause paint and oils used in manufacture to emit fumes. Combustion control During operation it is necessary to make sure that combustion is running optimally. Efficiency is reduced by imperfect combustion and as a result high amounts of harmful substances (hydrocarbons, ... -
Page 18: Output Control
maximum open position. When the maximum boiler power output is required, it is necessary to open it at maximum. ATTENTION: During combustion fan operation the bottom door can only be opened if strictly necessary and then for the shortest possible time. Hot gasses will be exhausted and can cause damage. Output control The regulator controls the combustion fan speed during operation to control the outgoing water temperature corresponding to heat value set on the regulator (65 ‐ 90°C). If the output required by the heating system is less than the boiler output during continuous operation the regulator shuts the combustion fan off and the boiler switches to the stand‐by mode. In standby ... -
Page 19: Boiler Shut Down
It is required to empty the ash also from the areas beside the combustion chamber and under the heat exchanger. The ash is removed from the area under the tubular exchanger by using the ash scraper. There is a hole in the rear wall of the combustion chamber for this purpose accessed by removing the chamot brick (30). After cleaning replace this brick at the rear wall of the combustion chamber. Boiler shut down During boiler shut down for longer periods, it is necessary to remove the ash from the boiler and to ventilate the boiler properly so any condensation moisture doesn’t collect on the internal boilers walls. At boiler shut down during summer do not unplug boiler mains supply. It is sufficient to switch off the boiler using the control switch on the regulator. In case of long term mains supply interruption the backup batteries in the switching clock can be damaged. ... - Page 20 Source: Forestry Commision. Average densities of wood (in kg/m of dry wood). Sycamore 500 Hornbeam Alder 520 Fir 500 Ash Spruce 450 Birch 630 Maple Poplar 450 Beech 670 Chestnut Willow 440 Oak 690 Larch 570 The specific weight of stacked wood per cubic metre is 0.6 to 0.8 times less than the specific weight of solid wood. Source: Forestry Commision. 19 | P a g e ...
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Page 21: The R4/2 Regulator
THE R4/2 REGULATOR The R4/2 regulator :‐ controls the combustion process and boiler output protects the boiler from accidental overheating controls the heat of the building in conjunction with the room thermostat and time clock It reads and monitors:‐ water temperature in the boiler outlet flue gas temperature room temperature via the room thermostat (not the part of the boiler supply) It controls:‐ the boiler combustion fan the primary (shunt) pump the secondary (system) pump Front panel 1. Control switch – switching off and on of the whole 2. Manual control switches – manual control of the appliance combustion fan (right) and the shunt pump (left) 3. Main fuse – type F 2A 4. Pump fuse – type F 1A 5. Pump switch – manual control of the system pump 6. Indicator light – overheat thermostat ... -
Page 22: Regulator Description
Regulator description The regulator is specifically made for VERNER lump wood boiler control. The boiler is turned on by the control switch (1) and when the time clock and room thermostat are calling for heat. During operation the regulator measures flue gas and outgoing water temperatures which in turn control the air supply based on the output temperature required. When the time clock and room thermostat are not calling for heat the boiler will shut down and when the boiler temperature drops low enough the circulating pumps are also turned off. The regulator can be set up that when the time clock and room thermostat are satisfied the regulator turns off only the system pump and the boiler including shunt pump keep running ... - Page 23 “System pump switching off“ mode; if the time clock and room thermostat are turned on and the water temperature in the boiler is higher than 65°C then the boiler and secondary pump runs. If the time clock and room thermostat are turned off the system pump is switched off but the boiler and the shunt pump run on according to the water temperature in the boiler. In this mode the external input shuts off only the system pump. Fuel burnout This sensing of this occurs based on the low flue gas temperature or based on the water temperature falling. The specific operating mode determines the way the boiler shuts down into the fuel burnout position, it can be either with or without flue gas temperature measuring. ...
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Page 24: Description Of Controls
Description of controls Control switch (1) Turn to position 1 to start the boiler. Turn to position 0 to turn the boiler off after the boiler has shut down completely or if it is necessary to reset the regulator after refuelling or relighting. Manual control switches (2) Turn to position 1 to manually override: Right hand side switch turns the fan on at full speed ATTENTION the regulator interupts this function if the overheat thermostat operates. Left hand side hand turns the shunt pump on for the circulation of the primary (boiler) circuit. Turning either of these swithes to the 0 position returns them to automatic operation. Main fuse (3) This provides the electrical protection for the fan and regulator and has a value of F 2A – breaking capacity of 1500A. Pump fuse (4) This provides the electrical protection of the system pump and has a value of F 1A ‐ breaking capacity of 1500A. Manual control of the system pump (5) Turn to position 1 to manually override the system pump to on. Turning the switch to the 0 position returns the pump to automatic operation. The pump is automatically controlled from the regulator electronics and by the safety pump thermostat. The pump is not a part of the standard supply. Overheat thermostat indicator light (6) ... -
Page 25: Regulator Set
Indicator light fan reduced output (8) Indicates the reduced output of the fan: Flashing ‐ fan at 1/2 output. Flashing quickly – fan at 1/3 output. Shunt pump indicator light (9) Indicates the status of the shunt pump: Light on – pump is in running. Light off – pump is not running. STOP indicator light (10) Indicates the overheating or extinguishing of the boiler: Light on – boiler extinguished. Light flashing – boiler overheating. light off – boiler in operation. Up‐arrow button (11) Pressing the button: Increases values in some set up menus. Display the actual flue gas temperature in tens of °C (e.g. 19 = 190C). Setting the maximum flue gas temperature, along with the middle button for 3 seconds. Temperature set up button (12) Pressing the button: Adjusts the required water temperature by pressing the button then using the up or down arrow buttons. Sets the maximum flue gas temperature, along with the upper button for 3 seconds. Adjusts the operation type by pressing the button for 7 sec. Sets the value for 1/3 output of the fan by pressing simultaneously with the down arrow button for 3 seconds. Down arrow button (13) Pressing the button: ... - Page 26 The operating mode can be changed by the Up‐arrow (11) or Down arrow (13) buttons to values 01 or 00. Pressing the middle button (12) after changing the operation type stores the new reading into the regulators memory. If the setting isn‘t stored then the actual outgoing water boiler temperature is shown on the display automatically afer several seconds. Required boiler flow water temperature set up Briefly press the set button (12) and the actual target temperature of the required flow water will flash on the display. The required boiler temperature can be changed by pressing the Up‐arrow (11) or Down‐arrow (13) buttons. Pressing the middle button (12) after changing the value stores the new reading into the regulators ...
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Page 27: Description Of The Regulators Sensors And Their Functions
Description of the regulators sensors and their functions Boiler temperature sensor The round stainless steel sensor is situated in the reservoir in the upper part of the boiler body. It measures the flow water temperature from the boiler. Flue gas temperature sensor The sensor is fitted inside the metal tube that is situated in the flue outlet. It measures the outgoing flue gas temperature based on which the regulator adjusts the boiler output and regulates the boiler efficiency. Pump thermostatic control (dependant on boiler type) The boiler includes a safety thermostat for the system pump control. When the boiler water temperature reaches 85C the system pump is turned on automatically by the thermostat. This ... -
Page 28: Internal Electrical Schematic Of The R4/2 Regulator
Internal electrical schematic of the R4/2 regulator 27 | P a g e ... -
Page 29: Commissioning
COMMISSIONING Commisioning procedure The following checks should be made before lighting the boiler: Check for correct electrical 230V / 50Hz polarity. Check the hydronic system is correctly installed and full of water. Check that the flue and chimney system are correctly installed and sound. Check ventilation is present and correctly sized. Switch the control switch (1) to position 1, the actual temperature in the boiler shows on the display and the appropriate indicating lights illuminate on the panel. Press the up‐arrow (11) button to check the function of the flue gas temperature sensor. The actual flue gas temperature is displayed and in case of a cold boiler the display will show 00. Press the set (12) button to show the required water temperature in the boiler display. Adjust as required. Set the external controls and ensure they are calling for heat. Check the correct connection and operation of the circulating pumps. Check the operation of external controls. The boiler can now be lit. Observe the boiler and system until the boiler and chimney reache operating temperature. Ensure the boiler regulates the water temperature by modulating the speed of the fan. Check the external controls are functioning correctly. Set the lower 1/3rd output of the boiler according to the fuel supply available. Check for sufficient chimney draught with the appliance and chimney hot. Flush the hydronic system according to BS 7593. Instruct the customer how to use the boiler and external controls. Leave these instructions with the end user. Complete the commisioning report, detatch and send to the UK distributor to activate the extended gaurantee. ... -
Page 30: Maintenance
Examles of display information IMPORTANT NOTICE The boiler regulator is sealed by a protective seal bearing the company logo. Should the seal become damaged by opening the regulator the guarantee becomes invalid. MAINTENANCE Routine maintenance is necessary to ensure safe and efficient boiler operation. Some maintenance can be undertaken by the end user and some only by a qualified engineer. User maintenance The user should regularly visually inspect the appliance and ensure all other necessary maintenance is carried out according to the manufacturer's instructions. During the hand over ... -
Page 31: Engineer Maintenance
Due to the influence of temperature cycle cracks can occur in the ceramic chamber insulation panels during normal boiler operation. The replacement of these panels are only required if their condition deteriorates enough to affect the boilers function. Correct boiler output depends on the air supply into the fuel chamber where the wood is gasifying. It is supplied through the slot under the upper door. The following picture shows the direction of the air inlet and the 10 mm slot which must be checked weekly and if obstructed must be cleaned. ... - Page 32 Cleaning of heat transfer surfaces When used as recommended the boilers heat transfer surfaces are only lightly coated with deposits. Nevertheless it is still recommended that once a month to check the following. 1. Heat exchanger (5). The heat exchanger tubes are accessed and cleaned by removing the top cover (28), the two nuts securing the heat exchanger cleaning cover (18) followed by the turbulators (if fitted) and sweeping the tubes with a wire brush. Clean ...
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Page 33: Boiler Repairs
If the fuses blow repeatedly then investigations must be made as to the cause. BOILER REPAIRS To maintain the quality, function and safe operation of this appliance it is necessary that only authorized VERNER trained service technicians commision and repair this appliance both during and after the guarantee period. Boilers commissioning and repairs can be provided by VERNER through their service centres. Sensor malfunction If the water temperature sensor is faulty the display shows ‐ P2 If the water temperature sensor is short‐circuited the display shows ‐ P3 If the flue gas temperature sensor is faulty the display shows ‐ P4 If any other error message is shown on the display (P0 – P8), a VERNER qualified service technician should investigate the fault. 32 | P a g e ... -
Page 34: Accompanying Documentation And Accessories
ACCOMPANYING DOCUMENTATION AND ACCESSORIES List of accompanying documentation and accessories supplied with the product: Operation and installation manual. Guarantee certificate. Commisioning report (completed copy to be sent to UK distributor). Catalogue of spare parts. Set of cleaning equipment. o sweeping bar complete. o Scrape. o Hook. Drain tap Fuses o 1 x F 2A o 1 x F 1A DISPOSAL OF PACKAGING Recycle the polythene bags if possible Recycle the cardboard Dismantle the wooden packaging and burn it BOILER DISPOSAL AT THE END OF ITS LIFE Clean the boiler and dismantle into individual parts Take the metal parts to a metal waste collection centre Ceramic parts can be disposed of as domestic waste Insulation can be disposed of as domestic waste SAFETY INFORMATION Special care must be taken when installing the appliance such that the requirements of the Health and Safety at Work Act are met. Industrial safety guidelines should be followed whilst ... -
Page 35: Boiler Connection Examples
vacated. The boiler, flue and chimney should not be put back into service until they have been inspected by a suitably qualified person. Do not allow children to operate the boiler. Unattended children should not be left with the boiler. In circumstances leading to the danger of temporary combustible gas build up that could cause fire or expolosion such as working with linoleum, PVC glueing and work involving painting materials etc. the boiler must be turned off well before this danger develops. If the appliance is used in a property in the presence of elderly/infirm people or children then a fireguard conforming to BS 8423:2002 should be used. Use the accessories supplied to prevent burns through contact with hot surfaces. Skin contact with un‐insulated parts of the boiler will result in injury. It is mandatory to fit a carbon monoxide detector conforming to BS EN 50292:2002 within the room that this appliance is installed. ... -
Page 36: Heat Store With Back-Up Electric Heating
Heat store with back‐up electric heating. This system must be fitted with a cooling loop Heat store with partial gravity system This system does not require a cooling loop 35 | P a g e ... -
Page 37: Guarantee Conditions
GUARANTEE CONDITIONS It is a requirement under the VERNER a.s. warranty system that the installation of the boiler is undertaken and/or certified by a Competent Person registered with a Government approved Competent Persons Scheme. HETAS Ltd operate such a Scheme and a listing of their Registered Competent Persons can be found on their website at www.hetas.co.uk The manufacturer guarantees this product free from defective parts, material and workmanship. The guarantee is provided on the following conditions: On receipt of a valid claim we will repair or replace the appliance at our discretion. The standard guarantee period is 12 months from the delivery date. On receipt of a completed commissioning report (please detach from the back of this manual) the guarantee period will be extended, free of charge, to 24 months from the delivery date. The guarantee for the ... - Page 38 37 | P a g e ...
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Page 39: Service Record
SERVICE RECORD It is recommended that your heating system is serviced regularly and that this service record is completed. Service provider Before completing the appropriate service record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing components. SERVICE 1 Date . SERVICE 2 Date . Engineer Name . Engineer Name . Company Name . Company Name . Telephone Number . Telephone Number . Registration Number . Registration Number . Comments . Comments . Signature . Signature . SERVICE 3 Date . ...
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