gassero Alubox Series Guide de dépannage
1015-14
Alubox 540
Alubox 700
Alubox 1100
Table of Contents
Table of Contents
IMPORTANT , you are highly recommended to perform the following checks:
When carrying out commissioning of the boiler
–
Make sure that there are no liquids or inflammable materials in the immediate vicinity of the boiler.
– Make sure that the electrical connections have been made correctly and the earth wire is connected to a
weel done earthing system.
– Open the gas tap and check the soundness of the connections, including the burner.
– Make sure that the boiler is set for operation for the type of gas supplied.
– Check that the flue pipe for the outlet of the products of the combustion is unobstructed and has been properly
installed.
– Make sure that any shutoff valves are open.
– Make sure that the system is charged with water and is thoroughly vented.
– Check that the circulation pump is not locked.
– Purge the system, bleeding off the air present in the gas pipe by operating the pressure relief valve on the gas
valve inlet.
–
The installer must provide the user with instruction in operation of the boiler and safety devices and hand over the
instruction booklet to the user.
–
The images shown in this manual are a simplified representation of the product. In this representation there may be
slight, unimportant differences with the supplied product.
1 Meaning of the symbols and safety instructions . . 3
1.1 Meaning of symbols
1.2 General warnings
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Designated use . . . . . . . . . . . . . . . . . . . . . 5
2.3 Boiler room & ventilation. . . . . . . . . .. . . . . 5
2.2 Description of the appliance . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 3
1.3 Safety instructions
. . . . . . . . . . . . . . . . . . . 4
1.4 Regulations and standarts
. . . . . . . . . . . . 4
2.4 Packaging label . . . . . . . . . . . . . . . . . . . . . 6
2.5 Warning label . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Data label . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.1
Alubox 540-700 dimensions . . . . . . . . . . . 7
3.2 Alubox main components . . . . . . . . . . . . . . . 8
3 Technical features . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Instructions for the installer . . . . . . . . . . . . . . . . . . . 10
4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1.2 Transport . . . . . . . . . . . . . . . . . . . . . . 10
4.1.3 Clearances . . . . . . . . . . . . . . . . . . . . . 11
4.1.5 Water side connections . . . . . . . . . . . . 12
4.1.4 Water quality and treatment . . . . . . . . . 11
4.1.6 Expansion vessel . . . . . . . . . . . . . . . . . 12
4.1.7 Safety valve . . . . . . . . . . . . . . . . . . . . 12
4.1.8 Condansate drain . . . . . . . . . . . . . . . . 12
4.1.9 Frost protection . . . . . . . . . . . . . . . . . 12
4.1.10 Dirt seperation . . . . . . . . . . . . . . . . . . 12
4.1.12 Pump . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.11 Automatic air vent . . . . . . . . . . . . . . . . 12
4.2 Installation examples . . . . . . . . . . . . . . . . 13
4.2.1 Single boiler installations . . . . . . . . . . . 13
4.3 Adjustment of the gas rate . . . . . . . . . . . 14
4.3.1 Alubox 540-700 adjustment points . . . 14
4.3.3 Description of the gas valve . . . 15
4.3.4 Maximum output adjustment . . . . . . . . . 16
4.3.5 Minimum output adjustment . . . . . . . . . 16
4.4 Gas conversion instructions . . . . . . . . . . . 16
4.5 Flue installation instructions . . . . . . . . . . . 17
4.5.1 Flue appliance types . . . . . . . . . . . . . . . 17
4.5.2 Flue installation types . . . . . . . . . . . . . . 17
4.6 Electrical installation . . . . . . . . . . . . . . . . 18
4.6.1 Wiring diagram . . . . . . . . . . . . . . . . . . . . 18
4.6.2 External probe installation . . . . . . . . . . 19
4.6.3 Outdoor temperature control . . . . . . . . 20
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Programming . . . . . . . . . . . . . . . . . . . . . 23
5.3 Error codes . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Maintenance codes . . . . . . . . . . . . . . . . 25
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Comissioning checklist . . . . . . . . . . . . . . . . . . 30
6.2 Maintenance procedure . . . . . . . . . . . . . 26
Service interval record . . . . . . . . . . . . . . . . . . 32
6.3 Troubleshooting . . . . . . . . . . . . . . . . . . . 28
3.1.2 Alubox 1100 dimensions . . . . . . . . . . . . . . . . . . 7
4.3.2 Alubox 700 adjustment points . . . 14
1 MEANING OF THE SYMBOLS AND SAFETY INSTRUCTIONS
1.1 MEANING OF THE SYMBOLS
WARNINGS
Keywords indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
• NOTE indicates that material damage may occur.
• CAUTION indicates that injuries may occur.
• WARNING indicates that serious injury may occur.
• DANGER indicates potentially risk to life.
IMPORTANT INFORMATION
Warnings in this document are framed and
identified with a warning icon which is
shown on the left figure.
Electrical hazards are identified by a
lightning icon surrounded by a warning
triangle.
Important information in cases where there
is no risk of injury material losses is
identified by the symbol shown on the left.
It is bordered by horizontal lines above and
below the text.
After having removed the packaging, check that the
material supplied is intact and complete; if this is
not the case, contact with GASSERO or dealers.
The Alubox Series boilers must be installed by
authorized person as detailed under any current
standards and law applicable and with the instruc-
tions provided by Gassero in the manual given
with the appliance.
The boiler must be used for the purposes it has
been expressly manufactured. Gassero declines
all contractual and extra-contractual liability for
damage caused to persons, animals or things, due
to errors in installation, control, servicing or impro-
per use.
In case of the water leakage, disconnect the boiler
from the mains power supply, close the water sup -
ply and promptly notify Gassero or other authorized
qualified personnel.
Periodically check that the condensate drain is free
of blockages.
Periodically check that the operating pressure of
the water circuit when cold is 1.5 barand less than
the maximum limit specified for the appliance. If this
is not the case, contact with Gassero or other aut -
horized qualified personnel.
If the boiler is not used for an extended period, the
following operations must be completed:
- move the main system switch to "off"
- close the fuel cock and the water cocks on the cen -
tral heating system
- empty the central heating system if there is the risk
of frost.
Maintenance and servicing must be done once a year.
This manual is an integral part of the boiler and as a
consequence must be kept with care. If the manual
is damaged or lost, contact with Gassero to supply
a new copy.
PLEASE READ THESE INSTRUCTIONS CAREFULLY
BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE
GASSERO BOILER MODELS WRITTEN ON THE
FRONT COVER OF MANUAL ONLY AND MUST NOT
BE USED WITH ANY OTHER BOILER MODELS.
THIS APPLIANCE MUST BE INSTALLED BY A GAS SAFE
REGISTERED, AUTHORIZED PERSON. FAILURE TO
INSTALL CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU HAVE ANY QUESTION CONTACT THE GASSERO
TECHNICAL SERVICE. ([email protected],
PLEASE LEAVE THESE INSTRUCTIONS WITH THE
COMPLETED INSTALLATION CHECKLIST, AND USER
USER MANUAL WITH THE OWNER OR AT THE GAS
METER AFTER INSTALLATION OR SERVICING.
THE INSTALLATION AND COMISSIONING CHECKLIST
CAN BE FOUND IN BACK PAGES THE MANUAL.
1.2 GENERAL WARNINGS
Actions that absolutely must not be
carry out identified by the figure on left
Meaning of the Symbols and Safety Instructions
+90 216 394 09 85 )
Manually controlled gas valve shall be placed before
the boiler.
Gas-fired heating boilers - Part 1:
General requirements and tests
Gas-fired central heating boilers
Part 2-1: Specific standard for type C
appliances and type B2, B3 and B5
appliances of a nominal heat input not
exceeding 1 000 kW
EN 15502-2-1:2012 :
The boiler must not be used by children or invalid
persons without supervision.
Electrical devices or appliances, such as switches,
household appliances, etc. must not be used if there
is the smell of gas or unburned fuel. In this case :
-ventilate the room by opening doors and windows;
-close the fuel stopcock;
- promptly contact Gassero, your gas supplier or
other professionally qualified personnel.
Do not touch the boiler when bare feet or with wet
parts of the body.
No service or cleaning operations may be perfor-
med without first having disconnected the boiler
from the mains power supply, moving the main
system switch to "off".
The safety or control devices must not be adjusted
without the authorisation and written instructions
from the manufacturer of the boiler.
Do not pull, remove or twist the electrical cables
coming out of the boiler , even if the appliance is
disconnected from the mains power supply.
The ventilation openings in the room where the
appliance is installed must not be plugged or redu-
ced in size and must comply with any current stan-
dards and law applicable.
Do not switch off the boiler if the outside temperatu-
re may decrease below ZERO (risk of freezing).
Do not leave flammable substances in the room
where the boiler is installed.
The packaging material must not be dispersed in
the environment or left within the reach of children
as it is a potential source of hazard. It must be
disposed of according to the legislation in force.
Alterations to parts connected to the appliance
Do not carry out any alterations for following parts:
- the boiler
- to the gas, air, water supply pipes and electrical
- to the flue pipe, safety valve and its drain pipe
- to the constructive components which influence the
When tightening or loosening the screw connections,
use only adequate tool. The improper use and/or
the use of inadequate equipment can cause damages
If you smell gas :
If you smell gas follow these safety indications:
-
-
-
-
-
-
Do not turn on or turn off electrical switches
Do not smoke
Do not use the telephone
Close the mains gas tap
Open all windows and doors where the gas leakage
Contact the gas society or a company specialized in
Indications for appliances operating with propane gas
ensure yourself that before installing the appliance the
For a correct purging of the tank contact the liquid gas
supplier or a legalley authorized person .
If the tank has not been correctly purged problems
could occur during ignition. If this occurs contact the
appliance’s safe operation
(for example water or gas leakages).
installing and servicing heating systems
gas tank has been purged.
liquid gas tank’s supplier.
1.4 REGULATIONS AND STANDARTS
Current Gas Safety (Installation & Use) Regulations:
All gas appliances must be installed by a competent
person in accordance with the above regulations;
The appliance must be installed in accordance with, and
comply to, the current: Gas Safety Regulations, IEE
Regulations, Building Regulations, Building Standards
and any other local requirements.
Directives:
• 2009/142/EEC gas appliance directive
EN 15502-1:2012 :
Standards
Meaning of the Symbols and Safety Instructions
1.3 SAFETY INSTRUCTIONS
Observe any unusual noises or operating conditions and
make the necessary corrections. Notify responsible
individuals for required corrective action or repair.
Precautions to be taken to limit the level of operating noise of the
installation;
If frost or corrosion preventative is added to the heating
water this can cause changes in the seals and can
cause noises to be created during heating.
A heating boiler noise deadening or similar installation
can be used to provide noise deadening. Gassero
recommends to install the unit on a boiler support
foundation 10mm thick.
It is strictly forbidden to interference with any
sealed components.
2 GENERAL
the following floor standing aluminium condensing gas boilers:
The Alubox series is suitable for use as a single boiler or as
part of a cascade system.
CE LABEL
The appliance complies with the basic
requirements of the relevant European
directives.
Conformity has been substantiated by the
proper documents which, together with
the declaration of conformity, are filed
with the manufacturer.
•Alubox 700
The boiler may only be used to heat up water for heating
systems as standard and/or domestic hot water (DHW)
systems with the connection of DHW tank.
The boiler can be installed either as a single system or as
part of a multiple system (cascade system). A cascade
system enables several boilers of this type to be
connected together, where maximum of 16 boilers
connected together.
CAUTION:
Damage to the installation due to frost.
Install the heating system in a room
which is free from frost.
WARNING:
Fire hazard due to flammable materials or
liquids.
Do not store any flammable materials or
liquids in the direct vicinity of the boiler.
CAUTION:
Boiler damage due to contaminated
combustion air or contaminated air in the
boiler room.
Never use the boiler in an environment which
contains lots of dust or aggressive chemicals.
Such as spray shops,hairdresser's shops,
locations where tricholorethylene or hydrogen
halides (e.g. contained in aerosols, certain
adhesives, solvents or detergents, paints)
and other aggressive chemicals are used or
stored.
2.1 DESIGNED TO USE
2.3 BOILER ROOM & VENTILATION
These installation and maintenance instructions apply to
General
TheAlubox is a floor standing aluminium condensing boiler
for CH and DHW(with DHW tank) purposes, with pre-mix
burner, made up of cast aluminium sectioned heat exchanger.
The Alubox boilers can be combined in a cascade
configuration with other heat generators to create
modular heating plants made up of boilers connected to
the same water circuit and with electronic controllers
communicating via bus.
2.2 DESCRIPTION OF THE APPLIANCE
The individual heating units in cascading configuration
can be activated, as well as by simple rotation, in such a
way that when a certain percentage of output is reached
by the first unit, the other units start automatically, all with
the same load factor.
The main features of the Alubox Boilers are:
- fiber coated premix burner
- output 540,700,1100 kW
- heat output up to 17.600 kW, by connecting up to 16
boilers in a cascading configuration
-flanged connection of the water and gas headers
- microprocessor control with self-diagnosis, shown on
LED and the display
- frost protection function activated according to the out-
side temperature and/or the temperature of the boiler
- fitted for room thermostat in the high and low tempera-
ture zones
- outside probe to enable the climate control function
- priority settable on the DHW, high or low temperature
circuit
-
- low investment costs for cascade operations ( slave
- chimney sweep function
-
-solar system & swimming pool control functions
models can be controlled by Master models, without
using any display modules in slave units)
•Alubox 1100
•Alubox 540
1015-14
Production year :
Istanbul Endustri ve Ticaret Serbest Bolgesi
( FREE ZONE ) , 4. Sok. Parsel 110
34957 , Tuzla, Istanbul, TURKEY
www.gassero.com
1015-14
1
1
3 TECHNICAL FEATURES
3.1.2 Alubox 1100 DIMENSIONS
Technical features
R
M
G
F
3.1.1 Alubox 540 - 700 DIMENSIONS
F
G
M
R
A
A
W
L
H
H
LW
CONNECTIONS :
M: System flow : DN80
R : System return : DN80 mm
G: Gas supply : DN65
F : Flue outlet: 250 mm
W: 838 mm L:1630 mm H:1630 mm
CONNECTIONS :
M: System flow : DN100
R : System return : DN100 mm
G: Gas supply : DN65
F : Flue outlet: 250 mm
W:890 mm L:1970 mm H:1720 mm
Counter-flanges and sealing gaskets will be delivered together with the boiler (gas and water connections).
10 7
8
9
2
620
24 19 23 1
3
4
5
21
13
12
17
11
18
15
14
22
16
10- Fan adapter
11- Return NTC sensor
12- Heat exchanger
13- Water outlet connection
14- Water flow collector
15- Return water collector
16- Pressure sensor
17- Chassis
18- Fan
19- Flow NTC sensor
20- Limit thermostat
21- Electrical panel
22- Electrical connection panel
23- Web-server(Optional)
24- Ignition transfomer
2- Condensate collector cleaning cover
Alubox 540 Alubox 700 Alubox 1100
101,4 661,0
100,9 660,6
97,8 643,1
107,8 708,4
0,8 6
90
95
96,5
97,3
107,0
107,4
108,6
34,2 34,5
61,4 65,8
8,9 9,4
5 33
5 32
10 28
10 29
8,9 9,4
0,047 0,292
0,047 0,291
10,53 68,67
10,48 68,63
DN 80
DN 80
DN 65
250
510
150,5 1029,6
150,1 1035,7
146,0 1001,8
162,7 1107,6
0,8 6
90
95
97,0
97,3
107,1
107,0
108,0
29,4 33,8
61,9 64,6
9,0 9,3
6 44
7 46
16 29
12 27
9,3 9,3
0,069 0,457
0,068 0,459
15,64 106,97
15,8 107,1
DN 100
DN 100
DN 65
250
630
81,9 517,0
81,0 521,0
79,1 503,0
84,7 539,2
0,8 6
90
95
96,6
97,3
105,0
104,0
106,7
30,3 40,1
55,5 63,6
8,9 9,0
2 29
2 38
8 16
5 15
8,75 9,2
0,038 0,237
0,038 0,232
6,9 43,9
6,88 43,86
DN 80
DN 80
DN 65
250
450
N.G 2H-G20 21 mbar N.G 2H-G20 21 mbar N.G 2H-G20 21 mbar
Ce manuel convient aux modèles suivants
3
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