gassero Alubox Series, Installation, User And Service Manual

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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