Automatic Heating Gasogen Operating instructions
Contents
1. If the boiler s safety thermostat intervenes often do not try to relight the boiler your self Contact your nearest Unical authorized After Sales Service Centre Central heating system pressure If itis an open system design the pressure does not have to be restored as this occurs automatically via the water level regu lator inside the water tank If itis a sealed circuit system refer to local re gulations where this type of installation is per mitted the pressure will have to be restored via the mains connection cock re pressurizing the system when the boiler is cold to 1 2 1 3 bar When the correct pressure has been reached by checking the value indicated in the pressure gauge installed in the system close the filling cock If you need to re pressurize the system of ten we recommend you contact your nea rest Unical authorized After Sales Service Centre 11 12 Gasogen Operating instructions 6 3 CHECKS TO CARRY OUT BEFORE FIRING THE BOILER Before firing the boiler carry out the following checks Check that the On Off gas valve positioned upstream of the boiler is in the On position back up boiler with burner operating with gas Check that any On Off valves fitted on the flow and return pipes for servicing purposes are in the On position Check that any On Off valves fitted on the cold water inlet for servicing purposes are in the On position Check that the safet2. 12344 Cast iron bars insulation kit X 12346 13 13 Cast iron bars insulation kit 13 12348 Cast iron bars insulation kit 13 12350 Cast iron bars insulation kit 13 12352 Cast iron bars insulation kit 1 2 X X X 1 4 X X X 1 X X X 14 PUC0420 Triangular scraper X 15 37352 X 37353 Catalyst kit 15 Catalyst kit 15 37354 Catalyst kit 15 37355 Catalyst kit 15 37356 Catalyst kit X X X X X X 1 2 X X X X X X 16 11930 Inspection door kit X X 17 X X 11929 Flue chamber inspection door gt Ds Z Z Q TI O Dv O O D O mp Dv O 2 O AC O O O D o 2 2 e O lt O c O O D o z E D 2 O O D o O Dv O O Dv mi o O lt O c Q gt 0 O Q m Z Q C2 N 0 o 9 D J please always quote the following information Part number Description Quantity requested Boiler model If you need any parts not indicated in the above list please contact an authorized Unical After Sales Service J DISTRIBUTED BY N AutomaticHeating efficiency L performance solutions 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 dautomaticheating com au www automaticheating com au gt e o 3 w n c O w 3 te m e lt r e eo gt DU Z e P PR O
3. Gasogen 29 93kW Wood Fired Boiler User Operating Instructions eticiency E perrormance solutions A AutomaticHeating Gasogen Contents CONTENTS 1 SymDO used Mis man Volantini ranieri 2 2 Correct use GME appliance scscecciesoese sasa ae aia ailapoti ia a ata iara radial bea ea sido sia ani aid i ala e a 2 eub ucc o la e atei E Drd la abat lac at a SO se a ud areale ne ra aaa alla d E etil adunarea de elan 2 4 Information to be passed over to the end user by the installer servicing engineer eee 3 o SRI T aia 3 6 Operating MSMUCIONS See moo NE NP N NI IRINA A E N e nie 4 om Ste ecisteepusc r M screen 4 62 Optional contol panel sani ai N RI INI iii 7 6 3 Checks to carry out before firing the boiler retea ea email ema fe io a a e bai tal art i in ta li et 12 ox ONS Fa m 12 6O Prep sempe USILE FI Leo tome one o oom 13 6 6 Checks to carry out after first start up eee eee eee eee nana aaa 14 WUE pre Ec PREIEI ERE PORTIE PPR PI e 15 6 8 Summer operation NET adam eesti eine ai aia lalea ai 20 as lalea nido pi int 15 GEM IU e DI MM mI ae aia e a ti Rin ate ap i ea ae 16 0 0 GN e BERE EEE RER SREP EE aaa IV MPR ION e E PRE REPER NR SPER atat MERE 18 Easily replaceable Spare GUI LS castane o tunat ureei nt alai lire taina ti lia de ti a
4. with an air distributor and with primary pos P and secondary air adjusters pos S C Fan control box S Secondary air adjusting screws P Primary air adjusting screw P1 Primary air passages S1 Secondary air passages The GASOGEN G3 65 2S and GASOGEN G3 80 2S models are equipped with two fan control boxes for combustion air pos 1 the top one P for the primary air inlet and the bottom one S for the secondary air inlet air distributors and metal ring adjusters pos 1 P Primary air box S Secondary air box 1 Metal ring air adjuster During the first ignition it is necessary to adjust the primary and secondary air keeping in mind that the primary air determines the boiler s output and therefore the quantity of wood burnt whilst the secondary air completes the combustion 13 14 Gasogen Operating instructions For correct air adjustment it will be necessary to observe the flame through the sight glass placed on the lower door The flame will have to occupy about two thirds of the combustion chamber and will have to quietly lick the lower cradle without moving the ash too much and without making any noise The flame must be an orange pink white colour not too transparent and with the centre part veering to light blue The GASOGEN G3 25 40 and 50 2S models to bring the flame to optimal conditions it will therefore be necessary to regulate the primary air by screwing or unscrewing the s
5. on FR OI No N C2
6. Do not use anti frost products designed for motor vehicles because they could seriou sly damage the water sealing gaskets 6 4 BOILER START UP Ensure yourself that all the checks listed in the paragraph 6 3 have been carried out Open the upper loading door and place on the main stone above the central slot some dry wood in a crosswise arrangement Use easily inflammable material avoiding big or squared logs Open the lower door Using thin paper newspapers or magazines light the fire Close the door leaving it slightly ajar Wait a few minutes until the fire starts and the some embers are produced about 5 10 minutes Close the lower door close the upper door and start the fan see point 6 1 After a few minutes looking through the sight glass on the lower door you will see that the flame is beginning to reverse downwards at this point add some bigger logs Important during boiler operation the by pass must always be perfectly closed The wood logs must be of the following size a 50 cm 1 cm 4 cm for the GASOGEN G3 25 40 2S models b 70 cm 1 cm 4 cm for the GASOGEN G3 50 60 models C 100 cm 1 cm 4 cm for the GASOGEN G3 80 2S This dimension must be stringently respected In order to have a good combustion it is essential that the wood falls down in a uniformed way Therefore it is necessary to make sure that the length of the wood logs introduced their shape and the way they
7. Unic l 11 Mains switch 12 Fan switch 13 System pump switch 18 Test key chimneysweeper mode 22 Selector switch 0 wood I gas oil 23 Back up burner switch NOTE 31 Safety thermostat 32 Boiler temperature adjustment 75 85 C 41 Main fuse 4A 42 Boiler thermometer Acoustic visual led alarm The test key in position 18 which can only be used by qualified service engineers permits you to check the correct operation of the flue evacuation fan in temporary mode without the fan s activation switch in position 12 being activa ted The boiler s control panel must be connected to the mains electricity supply via the general switch in position 11 IMPORTANT Before connecting the control panel to the mains check that all the switches are in the 0 position and that the safety thermostat is on Boiler start up wood firing mode Using this switch you can connect or disconnect the boiler from the mains electricity supply With the switch in the O position the boiler is not switched on green led light off With the switch in the I position the boiler is connected to the mains electricity supply green led light illuminated and is ready to operate The recycle pump functions Gasogen Operating instructions Mode selection keys wood firing mode With the switch nr 13 you can connect or disconnect the sy stem pump boiler load from th
8. are loaded does not prevent the wood from falling down in a regular way The wood logs must be placed in a lengthwise and a horizon tal position No logs must be placed in an oblique or slanted direction SUBSEQUENT WOOD LOADINGS Before filling the boiler with a new load of wood use up the previous one as much as possible The boiler can be filled with a new load when the bed of em bers is about 5 cm thick Slowly open the upper loading door and the inner anti smoke flap The wood logs must have the length specified in the previous paragraph and they must be placed as previously described USEFUL SUGGESTIONS and LOADING ERRORS TO BE AVOIDED Logs too long do not fall down properly and can cause ob structions Logs too short cause irregular air passages with consequent reduction in output and efficiency In case the quality of the wood causes obstructions it could become necessary to cut the wood logs in two parts in order that the total length L is as indicated in the previous para graph Always open the upper door slowly in order to avoid blow backs and smoke formation During normal boiler operation it is absolu tely forbidden to open the lower combustion door tagliare CUT Operating instructions 6 5 COMBUSTION AIR ADJUSTMENT PRIMARY AND SECONDARY AIR ADJUSTMENT The GASOGEN G3 25 and 50 2S models are equipped with a fan control box for combustion air pos 1
9. aximum Reset the safety thermostat pos 31 Problem The fan starts but after 30 minutes it stops by switching OFF and ON the main switch pos 11 it re starts Remedy Increase the temporized relay s intervention time this has to be done by the After Sales Service or by authorized trained personnel after switching OFF the mains supply Problem When opening the loading door there are blowbacks and flue formation Remedy Open the door slowly Use wood with a higher moisture content make sure the boi ler does not remain unused for long periods see paragraph 6 7 Use thicker wood logs Use up all the wood before loading a new batch Problem The boiler does not reach the requested temperature The flame is small and there is too much air When the fire box is checked a formation of log bridges is found Remedy Check the length of the wood logs see paragraph 6 4 Check how the wood logs are loaded in the fire box see paragraph 6 4 Cut the logs in two parts see paragraph 6 4 Use smaller logs round or square 5 to 7 cm diam Mix medium large sized logs 15 20 cm diam with small si zed logs see previous point Problem The boiler does not reach the requested temperature The flame is too small Remedy Check if the by pass is closed Check the fan Check if the doors are properly closed If you cannot solve the problem do no attempt any other
10. crew pos P the same operation must be carried out for the secondary air with the screws placed in position S The GASOGEN G3 65 2S and GASOGEN G3 80 2S models to bring the flame to optimal conditions it will therefore be necessary to regulate the primary air by screwing or unscrewing the metal ring nut pos 1 on the air distributor the same operation must be carried out for the secondary air on the second air distributor Example n 1 Thick wet wood logs difficult combustion S Very closed try to get the maximum dimension of the flame but not a reddish colour P Reasonably open in order to obtain a sufficient gasification Example n 2 Very inflammable wood logs S Completely open P Slightly closed to reduce the gasification but sufficiently open to evacuate the ash that can close the combustion head GENERAL SUGGESTIONS Better performances are obtained after two three days of ope ration The refractory cement in fact needs to be baked and the tar has to cover the upper part of the fire box The flame has to have good dimensions and reasonably fill up the combustion chamber The flame must not be too red lack of secondary air S The flame must not be too blue excess of secondary air S The flame must not be too noisy excess of primary air P The flame must not be too small lack of primary air P f the ash does not falls down properly increase the pri mary air P f too
11. d by a bad use of the boiler wet wood excessive loadings etc CORROSION IN THE FLUE CIRCUIT The flue is rich in water steam due to combustion and the use of wood which always retains water If the flue comes into contact with relatively cold surfaces with a minimum temperature of about 60 70 C the steam water condensates and in combination with other combustion pro ducts originates corrosion phenomena of the metallic parts Every day check if there are signs of smoke condensation black liquid on the floor behind the boiler In this case you must use a wood with a lower moisture content check that the recircula tion pump is working correctly the flue temperature at part load and increase the working temperature To control the room temperature it is therefore necessary to install a mixing valve The corrosion caused by flue condensation is not cove red by the guarantee because it is caused by the wood s moisture content and the way the boiler is used PRECAUTIONS TO TAKE DURING BOILER OPERA TION After every air adjustment wait 5 to 10 minutes before making a new adjustment Once the best adjustment has been esta blished at the end of the day check that the surfaces of the combustion chamber and the door insulation are of a white colour In the ash deposited in the cradle there must be only a few unburnt embers If the primary air is in excess in the ash there will be embers and small pieces of coal the flame w
12. d on With the switch in the II position the system pump is connected to the mains electricity supply dun 32 Operating instructions With the switch nr 12 you can connect or disconnect the fan from the mains electrical system With the switch in the 0 position the fan is not switched on With the switch in the l position the fan is connected to the mains electricity supply but it will not run It will start run ning only after the upper loading door has been closed Note The upper door is open in order to load the wood and the fan is off Proceed with igniting the wood as described in paragraph 6 4 The opening of the loading door activates a control timer by means of a microswitch whose default value is of 30 minutes which can be increased by another 30 this can only be car ried out by qualified personnel If the boiler does not reach the minimum temperature about 65 C within the foreseen time control timer the fan and re cycling pump will be turned off Panel connected to the mains electricity supply but the boiler is not running Therefore repeat the lighting procedure Central heating temperature adjustment The adjustment of the system water s temperature in the GA SOGEN G3 2S boiler is obtained by rotating the knob position 32 in a clockwise direction to increase the temperature and in an antic clockwise direction to lower it The temperature can be adj
13. e mains electrical system With the switch in the 0 position the system pump is not switched on With the switch in the Il position the system pump is connected to the mains electricity supply With the switch nr 12 you can connect or disconnect the fan from the mains electrical system With the switch in the 0 position the fan is not switched on With the switch in the T position the fan is connected to the mains electricity supply but it will not run It will start run ning only after the upper loading door has been closed With the switch 22 it is possible to select the operation mode wood or the back up gas or oil fired boiler Place the switch into the 0 position wood firing mode Note The upper door is open in order to load the wood and the fan is off Proceed with igniting the wood as described in paragraph 6 4 The opening of the loading door activates a control timer via a microswitch with a 30 minutes default value which can be increased by another 30 this can only be carried out by qua lified personnel If the boiler does not reach the minimum temperature about 65 C within the foreseen time control timer the fan and re cycling pump will be turned off Panel connected to the mains electricity supply but the boiler is not running Therefore repeat the lighting procedure Operating instructions Back up boiler start up gas oil firing mode Usin
14. emove carefully all the residues of combustion accumula ted in the fire box Clean with the brush supplied the triangular passes of the combustion chamber Remove the ashes from the flue chamber via the side doors using the scraper Make sure the grate s slots are not obstructed if so free the passages using the poker f the boiler continues to operate badly even after having cleaned it as described above it could be caused by bad di stribution of the secondary air In this case 1 Check the adjustment of the air setting according to the instructions given in the paragraph Combustion air adjust ment 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 if they are pass a soft brush in both the holes as shown in the following figure Check that the fire bars and the steel grate are positioned correctly in their housing and that the side wool insulation is in place Main stone Side fire bars insulation Front rear fire bars insulation Iron fire bars Stainless steel grate PI Deu et The iron fire bars and the steel grate are subject to wear we therefore recommend you to service the boiler at least once a year in order to avoid bad boiler operation Note the above figure is generic the quantity of the iron bars and the steel grates can vary according to the boiler model E
15. ength Check the normal operation of the working thermostat Te 32 at full until it arrests the fan Check there are no water leaks from the water connections After the first start up with the boiler OFF open the lower door and inspect the internal walls and the door insulation which has to be of a white colour indication of a correct air adjust ment On the contrary if the walls are blackened it means that the secondary air is not working properly paragraph 6 5 6 7 WARNINGS HOW TO AVOID CORROSION IN THE FIRE WOOD BOX The use of wood with a high moisture content higher than about 25 and or loadings not proportioned to the sy stem s heat request long OFF periods with the wood sto rage full can cause considerable condensate formation in the fire box s internal wall Check once a week the internal steel walls of the fire box They must be covered by a slight layer of opaque coloured dry tar with bubbles inclined to break and fall off On the contrary if the tar is bright runny and if removed with the fire stoke some liquid appears it is necessary to use wood with a lower moisture content and or reduce the quantity of the wood when loading the boiler If in despite of these interventions the tar does not dry you must inform the local After Sales Service of this The condensate inside the fire box causes the corrosion of the steel plates Corrosion is not covered by the guarantee because it is Cau se
16. esent 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 5 SAFETY WARNINGS WARNING The installation adjustment and servicing of this appliance must be carried out by a competent quali fied 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 UNICAL 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 UNICAL shall not be held liable 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 Smell of gas If you smell gas follow these safety indications e Do not turn on or off electrical sw
17. g this switch you can connect or disconnect the back up boiler linked to the GASOGEN G3 2S from the control panel With the switch in the 0 position the back up boiler is not switched on green led light off With the switch in the I position the back up boiler is connected to the mains electricity supply green led light illu minated and is ready to fire wood or gas oil refer to fol lowing points The recycle pump functions Mode selection keys gas oil firing mode With the switch nr 13 you can connect or disconnect the sy stem pump boiler load from the mains electrical system With the switch in the O position the system pump is not switched on With the switch in the Il position the system pump is connected to the mains electricity supply Note The upper loading door must be closed With the switch 22 it is possible to select the operation mode wood or the back up gas or oil fired boiler Place the switch into the I position gas oil firing mode With the switch nr 23 you can connect or disconnect the bur ner gas or oil from the mains electrical system With the switch in the 0 position the burner is not fired With the switch in the Il position the burner is connected to the mains electricity supply The recycle pump is not running 10 Gasogen Operating instructions Boiler start up wood firing mode with automa tic sw
18. ggered when the wood fired boiler s temperature falls below 65 C due to the fact that there is no wood left in the fire box and therefore the back up gas or oil boiler is activated and the recycle pump is arrested Reinstatement of the initial operating conditions will occur when the boiler s loading door is opened or by removing and then re establishing the power supply to the control panel Cu SE Operating instructions Central heating temperature adjustment The adjustment of the system water s temperature in the GASOGEN G3 2S boiler is obtained by rotating the knob in position 32 in a clockwise direction to increase the temperatu re and in an antic clockwise direction to lower it The temperature can be adjusted between 75 C minimum and 85 C maximum You can adjust the system water s temperature in the back up oil gas boiler via the knobs on the boiler s control pa nel Activation of the safety thermostat IMPORTANT The GASOGEN G3 2S safety thermostat s re set is positioned on the front of the control panel The thermostat in position 31 reactivates the wood fired boi lers operation To gain access to it in case the boiler goes into lock out un screw the plastic cap with the help of a screwdriver after ha ving reset it replace the plastic cap The safety thermostat can intervene in case of boiler tempera ture overheating You can avoid this happening by lowering the working thermostat see above
19. ill burn fast be dry have a cold colour and be noisier and the output will be excessive paragraph 6 5 If the primary air is insufficient the flame burn slowly be small it will not touch the lower cradle and it will drag little ash the output will be insufficient If the flame is a dark orange colour the secondary air is insuf ficient and the surfaces of the combustion chamber will not be a white colour if itis small and blue there is too much secon dary air Operating instructions Always open the upper loading door and the internal antismo ke flap slowly If in despite of these precautions some blow back will occur it will be necessary to use bigger pieces of wood with a higher moisture content and to check that the boiler does not remain unused for a long time reduce the primary air paragraph 6 5 and make sure that the possible distortion of the cast iron fire bars or the modification of the stainless steel grates or that the presence of extraneous bodies nails metallic pieces has not obstructed the refractory burner s slot 6 8 SUMMER OPERATION Use of the boiler in summer for the production of only dome stic hot water is not advised unless you follow these rules meticulously 1 Use very dry wood 2 Do not load the boiler with too much wood load the boiler partially 2 or 3 times per day according to need Important It is absolutely wrong to load the boiler completely so as to gain very long work
20. ing periods for example 24 hours Doing so the boiler when the fan is OFF will produce a lot of acid condensate and corrode the fire box 15 Gasogen Operating instructions 6 9 SERVICING Danger Before servicing the boiler make sure the boiler and its components has cooled down Warnings Do not drain any water from the boiler even only partially un less absolutely necessary Periodically check that the chim ney is working correctly and that it is in good condition Do not clean the boiler and or its parts with easily inflammable products gasoline alcohol etc Do not leave inflammable products in the room where the boi ler is installed Do not clean the boiler room when the boiler is firing IMPORTANT For cleaning the boiler use brushes and a vacuum cleaner If pieces of cloths are used make sure they are all recovered Always keep the screws and nuts protected with grease CLEANING AND ORDINARY MAINTENANCE OF THE WOOD FIRED BOILER Every day Remove the ash from the lower cradle Remove with the help of the scraper supplied with the boiler the embers so that the ashes accumulated in the fire bed will fall down through the holes in the grate This operation will help to avoid the grate becoming obstructed and the subsequent bad operation of the boiler This operation has to be carried out when there is not much flame and in any case before wood loading Every week R
21. interventions and contact an autho rized UNICAL After Sales Service WOOD FIRED BOILER WITH OPTIONAL CON TROL PANEL Problem The fan does not start Remedy Adjust the working thermostat pos 32 turning the knob ina clockwise direction to maximum Reset the safety thermostat pos 31 Problem The fan starts but after 30 minutes it stops by switching OFF and ON the main switch pos 11 it re starts Remedy Increase the TIMER 1 intervention time this operation has to be carried out by the After Sales Service or by authorized trai ned personnel after switching OFF the mains supply Problem When opening the loading door there are blowbacks and flue formation Remedy Open the door slowly Use wood with a higher moisture content make sure the boi ler does not remain unused for long periods see paragraph 6 7 Use bigger logs Use up all the wood before loading a new batch Problem The boiler does not reach the requested temperature The flame is small and there is too much air When the fire box is checked a formation of log bridges is found Remedy Check the length of the wood logs see paragraph 6 4 Check how the wood logs are loaded in the fire box see paragraph 6 4 Cut the logs in two parts see paragraph 6 4 Use smaller logs round or square 5 to 7 cm diam Mix medium large sized logs 15 20 cm diam with small si zed logs see previous poin
22. ion the characteristics of the water e 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 Generali Informations 4 INFORMATION TO BE HANDED OVER TO THE USER BY THE INSTALLER SERVICE EN GINEER 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 together with any other literature 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 pr
23. itches e Do not smoke e Do not use the telephone e Close the On Off gas cock e Open all windows and doors where the gas leakage has occurred e Inform the gas society or a company specialized in installing and servicing heating systems 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 Operating instructions 6 OPERATING INSTRUCTIONS 6 1 STANDARD CONTROL PANEL Unical 11 Mains switch 32 Working thermostat 12 Fan switch 41 Main fuse 4A 13 System pump switch 42 Boiler thermometer 31 Safety thermostat IMPORTANT Before connecting the control panel to the mains check that all the switches are in the 0 position and that the safety thermostat is on Boiler start up Using this switch you can connect or disconnect the boiler from the mains electricity supply With the switch in the O position the boiler is not switched on green led light off With the switch in the l position the boiler is connected to the mains electricity supply green led light illuminated and is ready to operate The recycle pump functions Mode selection keys With the switch nr 13 you can connect or disconnect the sy stem pump boiler load from the mains electrical system With the switch in the O position the system pump is not switche
24. itching over to gas or oil firing mode when the wood load has been consumed Using this switch you can connect or disconnect the back up boiler linked to the GASOGEN G3 2S from the control panel With the switch in the 0 position the back up boiler is not switched on green led light off With the switch in the I position the back up boiler is connected to the mains electricity supply green led light illu minated and is ready to fire wood or gas oil refer to fol lowing points The recycle pump functions Mode selection keys wood gas oil firing mode With the switch nr 13 you can connect or disconnect the sy stem pump boiler load from the mains electrical system Set the switch in the Il position the system pump is powered electrically With the switch nr 12 you can connect or disconnect the fan from the mains electrical system Set the switch in the T position the fan is powered electrically but it will not run It will start running only after the upper loading door has been closed With the switch 22 it is possible to select the operation mode wood or the back up gas or oil fired boiler Set the switch into the 0 position wood firing mode With the switch nr 23 you can connect or disconnect the bur ner gas or oil from the mains electrical system Set the switch in the Il position the burner will be auto matically powered Automatic switching over is tri
25. much ash falls down reduce the primary air P If the chimney smokes open the secondary air S comple tely If the chimney continues smoking adjust the secondary air S to maximum and reduce the primary air P AIR ADJUSTMENT FAULTS 1 If the primary air is excessive a lot of ash and small pie ces of coal will fall through the slot into the combustion cham ber The flame is too fast dry a cold colour and makes a noi se The boiler is consuming a lot of wood and the door s refractory insulation is white 2 If the primary air is insufficient the flame will be slow indecisive influenced by air currents and by the chimney drau ght very small incapable of touching the lower cradle with low ash production and the door s refractory insulation will be of a dark colour 3 If the secondary air is excessive the flame will be small a blueish colour and very transparent 4 If the secondary air is insufficient the flame will be big it will touch the lower cradle it will completely fill the combustion chamber and above all it will be a red colour and not transpa rent 6 6 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 If you notice air suctions through the door s seals close the door handle with greater str
26. ret O a ra a re 20 1 SYMBOLS USED IN THIS MANUAL When reading this manual particular care has to be given to the parts marked with the followings symbols DANGER Indicates se WARNING Indicates a potentially NOTE Suggestions for the rious danger for your dangerous situation for the product user personal safety and for and the environment your life 2 A CORRECT USE OF THE APPLIANCE The GASOGEN G3 28 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 UNICAL 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 3 WATER TREATMENT e The hardness of the mains water supply conditions the frequency with which the heat exchanger is cleaned e n 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 considerat
27. t Problem The boiler does not reach the requested temperature The flame is too small Remedy Check if the by pass is closed Check the fan Check if the doors are properly closed Operating instructions If you cannot solve the problem do no attempt any other interventions and contact an autho rized UNICAL After Sales Service Spare parts GASOGEN G3 25 2S GASOGEN G3 40 2S GASOGEN G3 50 2S GASOGEN G3 65 2S GASOGEN G3 80 2S GASOGEN G3 25 2S GASOGEN G3 40 2S GASOGEN G3 50 2S GASOGEN G3 65 2S GASOGEN G3 80 2S 21 22 Gasogen BOILER MODEL GASOGEN GASOGEN GASOGEN GASOGEN G3 40 2S G3 50 2S G3 65 2S G3 80 2S COMPONENT DESCRIPTION 1 20446 Fibre glass gasket 16x21 m IMP0010 Grip M8 MANOO10 Handle grip x lt VOL0010 Handle 20446 m 3 co Fibre glass gasket 16x21 GAMO010 Gasket diam 24 5x10x3 N GRP2021 Fan fixing kit VNTOOO2 Fan 20446 Fibre glass gasket 16x21 m 3 h o O 3 10 16649 Tempered glass diam 29 5x4 11 11546 Steel fire bars kit 11 11547 Steel fire bars kit 11 11548 Steel fire bars kit 11 KIT0467 Steel fire bars kit 11 KIT0482 Steel fire bars kit 26952 Stone cast iron bars insulation kit 26953 12 12 Stone cast iron bars insulation kit 12 26954 Stone cast iron bars insulation kit 12 26955 Stone cast iron bars insulation kit 12 26956 Stone cast iron bars insulation kit
28. usted between 75 C minimum and 85 C maximum Activation of the safety thermostat IMPORTANT The GASOGEN G3 2S safety thermostat s activation command is positioned on the front of the con trol panel The thermostat in position 31 reactivates the wood fired boi lers operation To gain access to it in case the boiler goes into lock out un screw the plastic cap with the help of a screwdriver after ha ving reset it replace the plastic cap Gasogen Operating instructions The safety thermostat may intervene in case of boiler overheating You can avoid this by lowe ring the working thermostat see previous point If the boilers safety thermostat intervenes often do not try to relight the boiler yourself Contact your nearest Unical authori zed After Sales Service Centre Central heating system pressure If it is an open circuit system the pressure does not have to be restored as this occurs automatically via the water level regu lator inside the water tank If itis a sealed circuit system refer to local regulations where this type of installation is permitted the pressure will have to be restored via the mains connection cock re pressurizing the system when the boiler is cold to 1 2 1 3 bar When the correct pressure has been reached by checking the value indicated in the pressure gauge installed in the system close the filling cock 6 2 OPTIONAL CONTROL PANEL Operating instructions
29. very month Check that the by pass is working correctly The by pass is a direct passage between the fire box and the chimney It is normally closed by a mobile shutter The by pass is automatically opened or closed via a pushing rod when the loading door is opened In this way the smoke accumulated in the firebox is aspirated and sent to the chimney directly The bypass in conclusion allows the smoke to be discharged at the chimney without letting it escape from the upper loading door when loading the wood or during lighting EXTRAORDINARY MAINTENANCE OF THE WOOD FIRED BOILER At the end of each heating season perform a general cleaning of the boiler taking care to remove all the ashes from the fire box During the summer season the boiler doors must be clo sed Cleaning the fan WARNING This operation must be carried out only by a competent qualified technician as bad maintenance will compromise good boiler operation Operating instructions CLEANING AND ORDINARY MAINTENACE OF THE BACK UP GAS OIL BOILER At the beginning of every heating season Call a service engineer to check and clean the boiler Burner control The burner must be checked solely by persons authorized by the burner manufacturer 17 18 Gasogen Operating instructions 6 10 FAULT FINDING WOOD FIRED BOILER WITH STANDARD CON TROL PANEL Problem The fan does not start Remedy Adjust the working thermostat pos 32 to m
30. y relief valves are connected to the sewage system Check that the boiler is connected to the electrical supply the main switch in position 11 on the control panel must be illuminated when set to f Checkthe heating system pressure indicated by the pres sure gauge refer to Central heating system pressure For correct operation the pressure should be between 1 and 1 2 bar with the pump not running If the pressure falls below 1 bar when the system is cold re pressurise the system by regulating the filling valve Check that the by pass is open when the door is opened and or the correct operation via a pushing rod which can be found on the right hand side of boiler body and controls the microswitch which in turn consents fan operation Check fan operation with the loading door closed Shutting down the boiler If the boiler is completely shut down the DHW mode will be completely disenabled To completely shut down the boiler remove the power supply by opening the contact on the bi polar switch upstream of the boiler and setting the switch 11 in the 0 position the led will be unlighted Place the On Off gas cock into the Off position eventual back up boiler with gas operating burner and turn the cold water supply cock into the Off position WARNING The heating system can be effectively pro tected from frost by using specific antifree ze products suitable for multi metal heating systems
Download Pdf Manuals
Related Search