gassero ALUBOX X-treme 350 Installation And User Manual Download Page 1

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ALUBOX

X-treme

ALUBOX X-treme 350

ALUBOX X-treme 430

ALUBOX X-treme 535

ALUBOX X-treme 640

ALUBOX X-treme 700LX

ALUBOX X-treme 710

INSTALLATION AND USER MANUAL

FLOOR STANDING CONDENSING BOILERS

Summary of Contents for ALUBOX X-treme 350

Page 1: ... 115 125 150 ALUBOX X treme ALUBOX X treme 350 ALUBOX X treme 430 ALUBOX X treme 535 ALUBOX X treme 640 ALUBOX X treme 700LX ALUBOX X treme 710 INSTALLATION AND USER MANUAL FLOOR STANDING CONDENSING BOILERS EN ...

Page 2: ...etpoints 39 10 2 Nominal Load Emission Settings 40 10 3 Minimum Load Emission Settings 40 10 4 Gas Pressure Switch 41 11 Maintenance 41 11 1 Maintenance Process 41 12 Energy Saving Recommendations 43 13 Disposal 43 14 Product Fiche 44 15 Troubleshooting 45 16 Boiler Room Application Recommendations 46 IMPORTANT PLEASE READ INSTRUCTIONS BELOW CAREFULLY BEFORE THE INSTALLATION AND USAGE 1 THIS MANUA...

Page 3: ...equent repairs and modifications Boiler may not be used by persons with inadequate physical mental and perceptual capacity and without experience and knowledge 1 3 SAFETY INSTRUCTIONS IF GAS SMELLS Do not open or close the power switches do not touch the plugs or sockets Do not smoke Do not use your phone Close the gas valve immediately Ventilate the space by opening the doors and windows Notify e...

Page 4: ...ANDARTS AND REGULATIONS This boiler is manufactured in accordance with the following directives and standards EN 15502 1 A1 EN 15502 2 1 A1 Directives EU 2016 426 Gas Appliances Regulation GAR 2014 30 EU Electromagnetic Compatibility EMC 2014 35 EU Low Voltage Directive LVD 92 42 EEC Boiler Efficiency These installation and maintenance instructions are prepared for the Floor Standing condensing bo...

Page 5: ...ter quality and other environmental conditions CONSUMER RIGHTS Consumers can apply for complaints and appeals to consumer courts and consumer arbitration committees In case of defective goods a Withdraw from the contract by stating that it is ready to return the product b If all costs incurred do not incur excessive costs to request free repair of the product c Requesting the replacement of the pr...

Page 6: ...s or by ignition sources Never switch off the power supply of the boiler when the air temperature falls below 0 C against the risk of freezing Read the FROST PROTECTION section ALUBOX X treme condensing boilers must be installed in spaces that have the necessary ventilation openings according to current standards and applicable regulations Do not modify the ventilation openings ventilation ducts v...

Page 7: ...672 4 111 9 650 4 127 6 702 0 710 711 3 880 134 6 685 6 129 6 669 2 145 9 711 3 2 4 WARNING LABEL WARNINGS Read the technical instructions and user manual carefully before the commissioning Commissioning must be made by an authorized Gassero service The boiler must be located in a location that is separate from the living quarters and only in accordance with the ventilation legislation 2 5 PACKAGI...

Page 8: ...8mm D2 106mm 106mm 106mm 106mm 106mm 106mm E DN100 PN6 DN100 PN6 DN100 PN6 DN100 PN6 DN125 PN6 DN100 PN6 E1 1340mm 1340mm 1340mm 1340mm 1360mm 1340mm E2 235mm 300mm 300mm 300mm 263mm 300mm F DN100 PN6 DN100 PN6 DN100 PN6 DN100 PN6 DN125 PN6 DN100 PN6 F1 664mm 664mm 664mm 664mm 647mm 664mm F2 88mm 115mm 115mm 115mm 65mm 115mm G Ø250mm Ø250mm Ø250mm Ø250mm Ø250mm Ø250mm G1 511mm 511mm 511mm 511mm 51...

Page 9: ...Limit Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC Sensor 12 Automatic Air Vent 13 Flue Gas Sensor 14 Flue Gas Outlet 15 Syphon 16 Water Outlet Connection 17 Water Inlet Connection 18 Gas Inlet 19 Air Intake 20 Venturi 21 Syphon Sensor 22 Pressure Safety Valve 23 Drain Hose 24 Air Pressure Switch ALUBOX X treme 350 8 ...

Page 10: ...ansformer 8 Limit Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC Sensor 12 Automatic Air Vent 13 Flue Gas Sensor 14 Flue Gas Outlet 15 Syphon 16 Water Outlet Connection 17 Water Inlet Connection 18 Gas Inlet 19 Air Intake 20 Venturi 21 Syphon Sensor 22 Pressure Safety Valve 23 Drain Hose 24 Air Pressure Switch 9 ...

Page 11: ...ansformer 8 Limit Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC Sensor 12 Automatic Air Vent 13 Flue Gas Sensor 14 Flue Gas Outlet 15 Syphon 16 Water Outlet Connection 17 Water Inlet Connection 18 Gas Inlet 19 Air Intake 20 Venturi 21 Syphon Sensor 22 Pressure Safety Valve 23 Drain Hose 24 Air Pressure Switch 10 ...

Page 12: ...ansformer 8 Limit Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC Sensor 12 Automatic Air Vent 13 Flue Gas Sensor 14 Flue Gas Outlet 15 Syphon 16 Water Outlet Connection 17 Water Inlet Connection 18 Gas Inlet 19 Air Intake 20 Venturi 21 Syphon Sensor 22 Pressure Safety Valve 23 Drain Hose 24 Air Pressure Switch 11 ...

Page 13: ...ransformer 8 Limit Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC Sensor 12 Automatic Air Vent 13 Flue Gas Sensor 14 Flue Gas Outlet 15 Syphon 16 Water Outlet Connection 17 Water Inlet Connection 18 Gas Inlet 19 Air Intake 20 Venturi 21 Syphon Sensor 22 Pressure Safety Valve 23 Drain Hose 24 Air Pressure Switch 12 ...

Page 14: ...ansformer 8 Limit Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC Sensor 12 Automatic Air Vent 13 Flue Gas Sensor 14 Flue Gas Outlet 15 Syphon 16 Water Outlet Connection 17 Water Inlet Connection 18 Gas Inlet 19 Air Intake 20 Venturi 21 Syphon Sensor 22 Pressure Safety Valve 23 Drain Hose 24 Air Pressure Switch 13 ...

Page 15: ... 86 28 55 6 65 30 43 Water Flow 50 30 C m h 3 052 15 2 3 941 19 286 5 281 23 454 3 935 28 389 5 54 30 31 6 6 30 5 Hydraulic Loss kPa Gas flow 80 60 C m h 6 93 35 23 8 84 44 6 10 75 53 47 8 45 64 52 12 09 69 82 13 99 71 78 Gas flow 50 30 C m h 6 89 34 6 8 76 44 35 11 63 53 91 8 69 64 13 12 34 70 05 14 02 71 43 Maximum Gas Supply Pressure G20 mBar Minimum Gas Supply Pressure G20 mBar Flue Pressure P...

Page 16: ...ork lift or pallet truck as shown In such transports the boiler must be properly fixed and secured The boiler must not be shaken or laid on its side during transport The boiler can also be moved on its own wheels after being lowered The wheels must always be secured and fixed when the transport is finished During the transportation safety rules must be followed and care must be taken against injur...

Page 17: ... the table boiler will be considered out of warranty Total Hardness d pH Iron Not Diluted Conductivity STAINLESS EXCHANGER 1 00 7 5 9 5 10ppm 2000µS cm ALUMINUMEXCHANGER 1 00 6 5 8 5 10ppm 2000µS cm Gassero Water Specification DYNAMIC AND CHEMICAL WASHING FLUSHING In the newly established systems to aviod the possible substances in the installation metal shavings some oils residues of construction...

Page 18: ...rer cannot be held liable for damages caused by water flow into the boiler or on the ground when excessive pressure is generated in the heating installation Safety valve must not be used as a means of draining water from the system Draining water of the safety valve can be very hot Beware of scalding 4 2 3 CONDENSATION WATER DRAIN Condensation water which is generated during to the combustion tran...

Page 19: ...oiler and the water goes through the installation Only heat transfer occurs here Preferred for many purposes If the water in the system is very dirty chalky or corrosive If the working pressure of the system exceeds the working pressure of the boiler If a part or all of the system is required to operate with lower temperature values eg underfloor heating systems The plate heat exchanger must be us...

Page 20: ...ter must be checked regularly When the air inlet filter becomes dirty Emission values would be deteriorated and efficient combustion wouldn t be achieved The accumulation of soot occurs in the heat exchanger Loud ignition and combustion occurs Overheating leakage and deformation would be observed in the flue system Manufacturer cannot be held liable for damages caused by dirty combustion air Don t...

Page 21: ...V PUMP CONNECTION EXAMPLE The use of an unsuitable primary pump can result an uneconomic uncomfortable operation and damage to your boiler and your installation The manufacturer is not liable for damages that may arise from such situations 4 3 FLUE CONNECTIONS Flue and chimney connections must be carried out in accordance with applicable regulations and relevant standards Materials which are used ...

Page 22: ...E certified flue pipes C83 It is a flue system which takes the combustion air from the outside with horizontal flue pipes and throws flue gas to the self contained negative pressure chimney For the operation of the boiler a grounded electrical supply 230 VAC 50Hz is required tolerance must be between 15 ve 10 Electric supply of the boiler must be cut off via a fuse during the maintenance Electrica...

Page 23: ...LUE NEUTRAL YELLOW GROUND has to be connected to a 6A fuse 3 X 1 5 Q1 BOILER PUMP CABLE SECTION PICTURE CONNETION EXPLANATION RED RED BLACK BLACK BLACK WHITE YELLOW YELLOW BLACK BROWN BROWN BLACK BLUE BLUE BLACK BROWN BLUE PURPLE GREY YELLOW GREEN 2x1 5 PUMP PWM CONTROL 0 10 V It connects to frequency controlled modulating primary pumps 0 10 terminal It controls the modulation of the pump 2x1 5 Fl...

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Page 27: ...OCI 351 Modbus Module 26 ...

Page 28: ...s and vents Open the sensor housing cover by turning it counterclockwise to access the sensor connection terminal and the wall fixing holes Mark the fixing points on the wall and drill the wall using the storage box as a template Secure the box to the wall using the two anchors provided Connect the two wire cable from the boiler to the terminal box nonpolar Tighten the nut in the housing box to en...

Page 29: ...tank should be used for condensate water occurring in systems with a total power o f 200 kW and above Pump Expansion Tank Safety Valve Air Seperator Deposit and Dirt Seperator Outdoor Sensor Water Softener UNit Temperature Sensor Globe Valve Termometer Manometer Non Return Valve Hydraulic Seperator Gas Regulator Strainer Neutralization Tank WATER SOFTENER UNIT HYDRAULIC SEPERATOR RADIATOR CIRCUIT ...

Page 30: ... must be used in the system A neutralization tank should be used for condensate water occurring in systems with a total power o f 200 kW and above Pump Expansion Tank Safety Valve Air Seperator Deposit and Dirt Seperator Outdoor Sensor Water Softener UNit Temperature Sensor Globe Valve Termometer Manometer Non Return Valve Hydraulic Seperator Gas Regulator Strainer Neutralization Tank Air Relief V...

Page 31: ...e Plate Heat Exchanger RADIATOR CIRCUIT DHW CIRCUIT FLOOR HEATİNG CIRCUIT MECHANICAL SCHEME WITH PLATE HEAT EXCHANGER Installation of 2 FLOOR STANDING CONDENSING BOILERS in cascade with 1 FLOOR HEATING CIRCUIT 1 RAD IATOR CIRCUIT 1 DHW CIRCUIT WATER SOFTENER UNIT Water Softener Unit must be used in the system A neutralization tank should be used for condensate water occurring in systems with a tot...

Page 32: ...enance etc must be performed by authorized personnel Improper interventions may cause loss of life and property increased fuel consumption and deterioration in safe and comfortable operation Manufacturer cannot be held liable for any problems caused by incorrect adjustments and interventions Display symbols Comfort setting for heating Reduced heating setting for heating Frost protection setting fo...

Page 33: ...dby mode pumps will be energised periodically mixing valves ran into middle position This function will be turned off automatically after the cycle FLUE FUNCTION E Used for flue gas emission measuring During this function boiler will be operated according to maximum adjusted temperature until it reach the exact value Then this function will be turned off automatically INFO BUTTON F Used for the di...

Page 34: ...ress OK Turn the Navigation Knob to select Heating circuit 2 and press OK Adjust the desired room temperature and press OK Press ESC button to return upper menu and adjust other heating circuits REDUCED TEMPERATURE A temperature limit for the room temperature When the room temperature falls below the set temperature the boiler will be activated and keep the room temperature constant Factory settin...

Page 35: ... unit etc in the system all personalized settings parameters fault resets will be made via the control panel E g Date and time adjustment Push OK button Select Time of day and date then push OK button again Push OK button for adjusment Push OK button to adjust hour and minute settings Turn the adjusment knob one click and set mounth and day with pushing OK button Push OK button to adjust the year ...

Page 36: ...ess button 1x again Safety mode on with Heating off Temperature by frost protection Safety functions activated Controller Stop Mode Press button 3 sec 304 Controller Stopp mode insert setpoint Press button 3 sec again after 3 sec Main menu appears Press button 1x INFO Segment displayed Press button 1x again Status Boiler room temperature Press button 1x again room temperature minimum Status DHW ro...

Page 37: ...ion 5960 parameter should set Consumer Request CC1 10V from configuration menu 2 5963 64 65 66 parameter should set for heat and value assignment 3 Heating Circuit 5710 and 5715 parameter should set OFF from configuration menu 4 DHW Domestic Hot Water Circuit sensor should be cancelled from boiler ...

Page 38: ...l Frost protection 651 Preselection Period 1 652 Period Start Day Month tt MM 01 01 31 12 653 Periode End Day Month tt MM 01 01 31 12 658 Operating level Frost protection 661 Preselection Period 1 662 Period Start Day Month tt MM 01 01 31 12 663 Periode End Day Month tt MM 01 01 31 12 668 Operating level Frost protection 710 Comfort setpoint C Value from Line no 712 35 20 712 Reduced setpoint C 4 ...

Page 39: ...ximum duration of the refill per charging 353 Common flow sensor B10 not available 85 BSB RF communication error 196 Maximum duration of the refill per week exceeded 371 Flow temperature 3 heating circuit 3 supervision 91 EEPROMerror lockout information 209 Fault heating circuit 372 Limit thermostat heating circuit 3 98 Extension module 1 error collective error 214 Monitoring of motor 373 Extensio...

Page 40: ...X X TREME LX 700 G20 ALUBOX X TREME 350 ALUBOX X TREME 430 ALUBOX X TREME 535 ALUBOX X TREME 640 10 COMBUSTION ADJUSTMENTS These combution settings mentioned below must be issued by authorized GASSERO services Flue gas analyzer must be used during to the combustion adjustments ALUBOX X treme boilers are offer to sale after all required combusiton efficiency and safety controls Emission settings mu...

Page 41: ...stem are open the condensate drain line is open the flue connections are gas tight and the pumps are running Due to the danger of burning and scalding be careful of the boiler and plumbing pipes which will become very hot 10 2 NOMINAL LOAD EMISSION SETTINGS 10 3 MINIMUM LOAD EMISSION SETTINGS Minimum load emission setting is done by measuring the CO2 value in the flue gas The following steps shoul...

Page 42: ...l be ensured The loss of comfort will be prevented by avoiding possible faults errors When the emissions of waste gases released into the environment are controlled the environment will be protected Life time of the boiler installation and environment must be take into account information error fault histories should be evaluated Issues such as fault history operating times can be displayed via th...

Page 43: ...ng the boiler with water check that the water treatment units are running and active A sample should be taken from the water filled in the boiler and the results of the analysis will be written to the service document Water gas air chimney and electrical connections will be checked Gas leakage control will be made For gas leakage control a gas detector or leakage detection sprays may be used Chimn...

Page 44: ...h the applicable regulations Similarly local regulations will be followed for the packaging wastes Leaving the non functional units spare parts and packaging materials in the environment and leaving them accessible to children can be dangerous Such wastes must be treated in accordance with the applicable regulations Ignoring this warning may harm people animals and may cause property damage Manufa...

Page 45: ... CE directives EU type inspection Module B has been made by Szutest in Brno laboratory Production process inspection has been made by Kiwa certification organisation in order to module D production process based on quality assurance Conformity marking CE 0063 This document has been prepared in order to EU 811 2013 regulation Electricity Consumption Temperature controls Product fiche ERP Informatio...

Page 46: ...15 TROUBLESHOOTING 45 ...

Page 47: ...y to use a suitable diameter filter and check valve to the boiler return line pipe at each boiler turn Please contact our service department about detail of collector connection in installation of floor type boiler Additional zone control modules and sensors must be requested if there are equipment such as three way valves and boilers that must be checked on the heating collector Please contact ou...

Page 48: ...ed MANUFACTURER Gassero Isi Teknolojileri Sanayi Limited Sirketi İstanbul Endüstri ve Ticaret Serbest Bolgesi 4 Sokak No 8 34957 Tuzla Istanbul TURKEY Phone 90 216 394 09 85 86 87 Fax 90 216 394 24 91 www gassero com 200600120 15102019 1 ...

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