Wallnofer Walltherm Vajolet Operating Manual Download | Manualshive

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WALLTHERM

®

produced and developed by

Walltherm

®

Vajolet V01 walltherm.com

5/64

1. Introduction

1.a Purpose and contents of the manual

Purpose
The purpose of the manual is to provide the operator with the fundamental knowledge to
allow the user to take the necessary precautions and to have all the human and material
resources required for its correct, safe and lasting use.

Contents
This manual contains all the information necessary for installation, use and maintenance
of the Walltherm

®

boiler stove. By complying scrupulously with the contents of this

manual, you will ensure a high degree of safety and productivity of the boiler stove.

Do not install or use the boiler stove before you haven’t read and understood the
contents of this manual. In case of doubt at any time, do not hesitate to contact
Wallnöfer GmbH for information.

Wallnöfer GmbH reserves the right to modify the technical and/or functional
specifications and features at any time without prior notice.

When planning the installation of a Walltherm

®

boiler stove please consult the chimney

sweeper regarding the chimney system, the combustion air channels and the distances to
keep to flammable material.

Keeping and consulting the manual
The manual must be kept in a safe, dry place and be available at all times for
consultation by the user and by those who see to its installation and maintenance.

The manual with its instructions for operation and maintenance is an integral part of the
boiler stove.

Deterioration or loss
If required, ask Wallnöfer GmbH for another copy of the manual.

Update the manual

This manual reflects the state-of-the-art from the serial number 10000.

If the stove is sold, the user must give the manual to the new owner.

1.b Symbols
Important points in this manual are highlighted with the following symbols:

Indication: indications concerning the correct use of the boiler stove and the
responsibilities of those using it.

Attention: a particularly important note is written here.

Danger: Here you are warned of the possibility of bodily harm or material

damages.

!

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Summary of Contents for Walltherm Vajolet

Page 1: ...iler stove for your living room Especially in connection with a heat storage tank it offers you all the advantages of a radiant heat stove for the living room and furthermore an economical heating system for your whole house Please study this manual it explains how the boiler stove works how you should operate it and how the Walltherm has to be maintained For further information please contact the...

Page 2: ...boiler stove Mod Walltherm invented by the company Wallnöfer GmbH complies with the Machine and Safety Regulations of the European Union CPR and consequent amendments The boiler stove has been tested by TÜV Rheinland Energy GER and is registered by VKF Switzerland In any case the laws and norms valid in the installation country have to be respected Particular respect the correct chimney situation ...

Page 3: ...rmation concerning the manual please contact the producer or any authorized Walltherm dealer Please quote the number of the paragraph and name the topic in question You find our contact data on www wallnoefer it This operating manual is protected by copyright and it or any part thereof must not be printed copied or reproduced without prior consent of Wallnöfer GmbH Technical information graphics a...

Page 4: ...nd load capacity floor 4 d Combustion air 4 e The water connections Pump unit with mixing valve Thermal process safeguard valve Installation scheme 4 f Electrical installation controller WAL03 or thermostat grounding 4 g Information for immuring the insert stove Walltherm Vajolet Basic 5 Using the boiler stove 5 a Control 5 b Lighting 5 c Loading wood logs 5 d Adjustment of the exhaust gas tempera...

Page 5: ...ions and features at any time without prior notice When planning the installation of a Walltherm boiler stove please consult the chimney sweeper regarding the chimney system the combustion air channels and the distances to keep to flammable material Keeping and consulting the manual The manual must be kept in a safe dry place and be available at all times for consultation by the user and by those ...

Page 6: ...nd engineering condition The Walltherm produced by Wallnöfer GmbH must only be used indoors Generally In a wood burning stove a correctly burning flame emits the same amount of carbon dioxide CO2 as would be emitted through the natural decomposition of the wood itself The quantity of CO2 produced by combustion or decomposition of a tree is equal to the quantity of CO2 that the tree would have extr...

Page 7: ... is delivered accurately packed in cardboard and fixed to a wooden pallet so it can be handled by elevator trucks and or other means Don t tilt the wood pallet You will find the following items inside the boiler stove use installation and maintenance manual cleaning brush for the flue ways a thermal process safeguard valve a bleeding valve a brush for the ashes a fire poker ash shovel Attention th...

Page 8: ...ular not to touch or go near the glass door as you could get burned not to touch the flue and air intake not to do any type of cleaning not to pull out the ashes not to touch the lower glass door make sure that children are kept away Open the doors only when the exhaust fume flap is open and if the wood logs are completely burned to ember comply with the indications given in this manual comply wit...

Page 9: ...re any work is done on switches and connectors Make sure all parts of the boiler stove are cold Make sure the ashes are completely cold and not burning Use the individual protective gear as established by the EEC directive 89 391 Check that the main line switch is off if an electrical thermostat is used Make sure that the power supply cannot be switched on accidentally Take the plug out of the wal...

Page 10: ...k J Air intake backside and bottom K Water connection L Air bleeder sensor water temp sensor exhaust gas temp sensor thermal process safeguard valve Lever primary air A G B C D E F A Open exhaust fume flap open Lighting period produce ember Closed exhaust fume flap closed gasification flame activated chimney Adjustment screw of flue damper system Rauchzüge Chimney connection Exhaust fume flap Leve...

Page 11: ...Iron cast grids 2 pz per side I Injector block J J Air intake bottom K Forward flow K L Area for different sensors and the air bleeder Cold water inlet thermal process safeguard valve Internal parts upper combustion chamber Return flow Air intake backside Drain thermal process safeguard valve ...

Page 12: ... to boiler stove 3 Thermometer forward flow storage tank 4 Thermometer return flow storage tank 5 High efficiency pump 6 Thermal mixing valve 6a Thermostatic head for adjustments from pos 1 7 6b Sensor thermal mixing valve 7 Security pressure valve 3 bar provided by customer We recommend the installation of filling and drain valves between pump unit and boiler stove to clean the water circuit and ...

Page 13: ...WALLTHERM produced and developed by Walltherm Vajolet V01 walltherm com Link Index 13 64 3 c Overview off all important components ...

Page 14: ...HERM produced and developed by Walltherm Vajolet V01 walltherm com Link Index 14 64 3 d Dimensions Walltherm Vajolet and Vajolet Basic Walltherm Vajolet boiler stove front side backside left side right side ...

Page 15: ...WALLTHERM produced and developed by Walltherm Vajolet V01 walltherm com Link Index 15 64 top view bottom ...

Page 16: ...WALLTHERM produced and developed by Walltherm Vajolet V01 walltherm com Link Index 16 64 Walltherm Vajolet Basic insert boiler stove front side backside left side right side ...

Page 17: ...KW Technical data for the boiler stoves Walltherm Vajolet and Vajolet Basic Efficiency 90 Nominal heat output 10 KW Heat output min max 8 15 KW Division of heat output up to 80 water heat output 20 heat output by radiation Operating pressure max 2 5 Bar Weight without water content 300 kg Water content approx 80 lt Flue gas mass flow 8 8 g s Chimney draught 12 Pa max 20 Pa Exhaust gas temp with ga...

Page 18: ...ber is attached on the boiler stoves backside If you have to order spare parts please send us your serial number Label Walltherm Vajolet Label Walltherm Vajolet boiler stove insert boiler stove Note the serial number of your boiler stove It is recommended to note the serial number because often the backside of the stove isn t easily accessible ...

Page 19: ...ns If other technicians are called in please make sure they are truly qualified Before the assembler starts either assembling or dismantling the boiler stove he must comply with the following safety precautions a he must not work in adverse conditions b he must be in perfect psychophysical condition to work and ensure that the individual and personal accident prevention devices are complete functi...

Page 20: ...fore having the first angle If possible the pipe then should enter the chimney by using a 45 angle better drought than with 90 The diameter of the chimney should be around 150 mm do not use a very big chimney because of the low exhaust gas temperature 6 m vertical chimney would be the best length The material of the chimney can be stainless steel or ceramic with insulation Info A chimney out of st...

Page 21: ... other heating systems provided by a fan oil boilers heaters chimneys etc Exception the chimney sweeper gives permissions Ventilation systems extractor hoods ventilations etc even if they are running separately Attention Due to unfavorable conditions of the extractor hood several bends curves unsuited chimney etc the smoke outlet may not work optimally In such a case please contact the technical c...

Page 22: ...n any case it is necessary to maintain a distance of 5 cm to all sides also to non flammable material The metal sheets has to be removable If combustion air will be taken from the living room maintain 5 cm of space between stoves backside and the wall fig 4 c 1 Eventuelle Holzbalken über dem Heizofen und dem Rauchrohr müssen mit feuerfestem Material isoliert werden fig 4 c 2 E flammable material a...

Page 23: ... problems Attention If there are other fireplaces near the Walltherm boiler stove the combustion air must be obtained from outside Danger The norms forbid air supply from garages storerooms where fuel and other materials are kept and rooms where combustible activities are practiced Please obey the laws and norms valid in the installation country Combustion air from outside If you would like to obt...

Page 24: ... mm on the boiler stoves backside on the aperture on boiler stoves bottom is fixed a closed flange cover If you want to connect the external air channel on the bottom exchange the adapter on the backside with the closed flange of the bottom Flap in the external air On the external air channel you should install a flap so you can avoid that cold temperature comes inside the Walltherm when it isn t ...

Page 25: ...the water temperature falls down under 40 C More information about the system you find in the manual of the controller WAL03 and in chapter 4 f Electrical air flap for installation in the air channel 2 x Ø125 mm Electrical air flap with flange for the installation on boiler stoves body 1 x Ø125 mm 1 x flange Info We can deliver two types of the electrical air flap The standard el air flap for inst...

Page 26: ...ve which get connected with two pipes the cold water inlet and with a pipe to discharge hot water Also the 3 bar pressure safety valve has to be connected in the circuit between boiler stove and it s pump unit The water in the heating system has to be conform with the guideline VDI 2035 This guideline protects against water side corrosion In this case ions of calcium and magnesium are replaced by ...

Page 27: ...nit An expansion vessel with enough capacity has to be installed in the heating system Fig 4 e 1 Pump unit with mixing valve To avoid that the boiler stoves heating exchanger cools down and to avoid the development of condensation because of a too low water return temperature under 60 C the pump unit is equipped with a 3 way mixing valve This mixing valve makes the heating water partly re circulat...

Page 28: ... boiler stoves upper right side you find a manual air bleed valve Open it to bleed the boiler stove Before a new heating season starts it is recommended to bleed the boiler stove Manual air bleeder The return flow temperature displayed on the thermometer it should be at 60 C Thermostat head of mixing valve Normally at pos 5 7 Forward flow temperature Can be between 60 75 C The return flow temperat...

Page 29: ...rocess safeguard and the cold water pipe from the water net On its outlet get connected the drain pipe Function In case of an interruption in the water circuit pump error the water temperature inside the stoves heat exchanger achieves 95 C and the thermal process safeguard opens Now cold water from the water net flows through the security heat exchanger cools down the boiler stove and the water of...

Page 30: ...he pressure raises over 3 bar In this case the heating water can flow to the drain to avoid to high pressure inside the water circuit Look Fig 4 e 1 Expansion vessel The heating circuit has to be provided with an expansion vessel which has the correct dimension and a manometer When the pressure safety valve opened the pressure of the heating system is low and therefore authorized personal plumber ...

Page 31: ...rces heat up the heating water of the storage tank The storage tank Logix24 has additionally a stratification solar heat exchanger in copper to guaranty the best usage of the solar plant Due to the stratification module the solar plant heats up primarily the upper part of the storage tank to get already after a few time hot domestic water The heat exchanger for hot domestic water is a stainless st...

Page 32: ...requirement sensor F4 or F5 of the floor heating or radiators the heating water in the storage tank must have a minimum temperature e g 60 C If the minimum temperature is reached the pump of the heating system can circulate as the temperature of the storage tank sinks to a set value e g 30 C F1 Example Thermostat 60 C minimum temperature with OFF Hysteresis 30 C heating controller controller for f...

Page 33: ...e temperatures storage tank you decide to load the needed quantity of wood Or if the electrical air flap is installed you have to open it by pushing the start button on the controller Buttons For navigation in the menu or change a value and START button el air flap Set to confirm or activate a value Esc ESC button to cancel or to return previous menu For navigation in the menu or change a value Yo...

Page 34: ...rnal air channel or directly on the boiler stove Our target is to avoid cold air circulation to the stove and the chimney system when the stove isn t in use The function Before the Walltherm gets lighted you have to push the start button for 2 seconds Then the el air flap opens for min 2 hours and remain open until the water temperature in the Walltherm cools down under 40 C Thanks to this functio...

Page 35: ...l flap Wiring of the WAL03 depending on your system Wiring of a system with Walltherm and storage tank B1 storage tank F1 Walltherm boiler stove R2 pump boiler stove no PWM R3 el air flap T1 sensor water Walltherm T2 sensor lower storage tank Sensor position lower storage tank but higher than the return flow of the boiler stove T4 sensor fume temperature Walltherm red cable T5 sensor higher storag...

Page 36: ...1 pump solar system without PWM R2 pump boiler stove without PWM R3 el air flap T1 sensor solar panel T2 sensor lower storage tank Sensor position lower storage tank but higher than the return flow of the boiler stove T3 sensor water Walltherm T4 sensor fume temperature Walltherm red cable T5 sensor higher storage tank Important The regulation WAL03 can only work with high efficiency pumps without...

Page 37: ...s only for the Wallnöfer product Wallnöfer does not make any representations regarding the validity and eventually changes of the product see manual thermostat Grounding Danger The system must be grounded and fitted with a circuit breaker as provided for by current laws fig circuit diagram 4 g Information for immuring the insert Walltherm Vajolet Basic Requirement 1 Important the Walltherm should ...

Page 38: ...o be accessible also from the side possible Also the position of the sensors upper right side has to be accessible for possible maintenance D The lever of the exhaust fume flap has to be accessible E The lever for primary air below the lower door has to be accessible for daily utilization F If you connect an electrical air flap directly on the boiler stove it has to be accessible for maintenance C...

Page 39: ...pening pressure installed Is the thermal process safeguard installed to the security heat exchanger Is the stove provided with combustion air Are all flaps in the air channel open Control if the el flap on the WAL03 is open Press start button 2 seconds Is the primary air lever open Pull the lever to Is the pump connected to its controller Test if the pump is working If you work with the WAL03 cont...

Page 40: ... burning time keep the doors closed Important Before lighting the boiler stove control the storage tanks temperature to guarantee it can store more energy hot water If you have the controller WAL03 you can display the upper and lower temperature of the storage tank A Open the exhaust fume flap Turn the lever of the exhaust fume flap to position OPEN lever has to pointing down position OPEN Attenti...

Page 41: ...l the primary air lever completely to direction Lever primary air Function Push in direction less or no primary air Pull in direction primary air open If the Walltherm is provided with air from an air channel open all valves flaps On the controller WAL03 you have to open the electrical air flap if connected Push the start button for 2 seconds El air flap open Start button upper arrow Push for 2 se...

Page 42: ...ery important that the injector block is put inside the stove correctly See the chapter Using and Cleaning of the Walltherm boiler stove C Lighting Use ecologically lighter and put them on the 2 grids of the upper combustion chamber Then spread highly inflammable kindling and wood logs over the complete width of the grids To create enough ember 3 4 cm add also some bigger wood logs 2 3 pc Now you ...

Page 43: ...er the water temperature is hot and the chimney is heated up you can put in split wood logs Ø 8 10 cm and max length 35 cm max humidity 20 over the whole burning chamber Please try to avoid hollow spaces Avoid hollow spaces under the wood logs Info Please insert only as much wood as the buffer tank is able to take up and to convert into energy After putting in the wood logs the exhaust gas tempera...

Page 44: ...exhaust fume flap to position CLOSED lever in horizontal position CLOSED By closing the exhaust fume flap the gasification starts Info If the gasification flame stops or gets smaller after some time you need to reopen the exhaust fume flap to heat up more the chimney system and to create more ember Maybe the wood needs to be adjusted with the fire poker avoid hollow spaces ...

Page 45: ...n the upper combustion chamber are not layered and there are hollow spaces or the wood is burned down Fuel problems wood logs to humid to big to old more than 8 years The chimney drought is to less less than 12 PA 1 2 mm WS The combustion electrical air flap is closed or the primary air is partly closed The grids or the injector block are blocked with ash The exhaust gas temperature is to low 100 ...

Page 46: ...d as the buffer tank is able to take up and to convert into energy It s necessary to have a layer about 3 4 cm of ember otherwise you have to create it again with some wood logs Then put the wood logs compactly in the upper combustion chamber There must be a layer of wood and no hollow space After putting in the wood logs the exhaust gas temperature should be about 300 400 C and the chimney should...

Page 47: ...ase 300 400 C During the gasification the exhaust gases are clean and cannot cause a sootiness of the chimney If the exhaust gas temperature is to low 100 C it s possible to reduce the resistant in the heat exchanger For this you need to adjust the flue damper flap of the heat exchanger If the exhaust gas temperature is to high by increasing the resistant of the flue damper flap the exhaust gas te...

Page 48: ...oodchips maximum water content 25 Pressed wood briquettes of shaving wood which are not produced with binders if 50 log of wood are added Therefore the proportion of pressed wood can be 50 The boiler stove is only for the combustion of the above mentioned wood fuels and combinations suited For the use of other fuels we do not take any responsibility for the boiler s function and working life INFO ...

Page 49: ...ut an uninterrupted running an a long lifetime Daily cleaning Always remove the ash from the injector block and the grids before firing up the stove Insert the angular shovel into the lower combustion chamber and use a little brush to sweep the ash off the grid in the lower combustion chamber Sweep the ash to the openings of the injector block where it can fall into the shovel Remove the shovel wi...

Page 50: ...rids The grids need to be tilt up The removing of the ash under the grids is very important for the combustion air because the combustions air streams through the grids into the upper combustion chamber Remove grids remove injector block remove cover Important Also clean the internal air channel like on the pictures above and below ...

Page 51: ... The openings on the injector block has to show to the doorside Look picture below Injector block Openings on the front doorside Protection stone lower combustion chamber To protect the door glass of the gasification flame and it s high temperatures up to 1000 C we position the protection stone behind the door in the lower combustion chamber In the lower combustion chamber you find an edge stop wh...

Page 52: ...p Information The flam wall can move during the transport of the stove We recommend to check the position of the flame deviator and if necessary to adjust it Push it back into the lower combustion chamber until it gets in contact with an edge stop which is on the top A few times you should clean the air supply sheets for the glass cleaning system upper combustion chamber To prevent the glass from ...

Page 53: ...ft and the wood quality isn t so good the cleaning should be done more often For this cleaning the Walltherm is delivered with a steel brush Cleaning of the flue way channels To clean the flue way channels remove the top cover with flue damper system behind the exhaust fume muff on top of the stove then you see the heat exchanger Look pictures Remove the cover with flue damper system Clean all cha...

Page 54: ...channels with the steel brush Advice Using a vacuum reduces the dirt cause by blown up dust The ash and the soot fall down into the backside of lower combustion chamber Space behind flame wall To take out the ash with the ash shovel or the vacuum of the lower combustion chamber you must take out the flame wall Before taking out the flame wall by pulling it with the fire porker you must take out th...

Page 55: ... the heat exchanger The injector block should be cleaned as well It s very important the holes openings of the injector block point to the front of the stove doorside See picture above 6 b Cleaning the glass doors Clean the glass with a damp cloth newsprint or damp paper rubbed in ashes You can also use ordinary oven cleaners Do not clean the glass while the stove is working and do not use abrasiv...

Page 56: ... are allowed to do the maintenance for the water parts and electric parts See chapter 2 a and 2 c 7 a Doors The boiler stove must never be operated with open doors Eventually out coming glowing materials can cause fire Before opening the doors please open the exhaust fume flap so the smoke is taken up gradually through the chimney and cannot escape through the door The doors should only be opened ...

Page 57: ...g phase Continuous undercutting endangers the boiler stove s working life and the supplier s guarantee lapses 7 d Periodical cleaning of the chimney system and the flue ways of the boiler stove Clean the chimney twice a year at the beginning and halfway through the winter season In case of horizontal flues please remove all ash and soot deposits before they have the chance to clog the smoke passag...

Page 58: ...he grids and the injector block High water temperature in the boiler stove Pump doesn t work control the settings of the controller thermostat Pump hanged up blocked start the pump once a month Set the start temp at 60 C or 70 C Control also if the difference between lower storage tank part and boiler stove is adjusted at 5 C Bleed the pump and clean it To less operating pressure Set the operating...

Page 59: ...ge tank completely at a temperature 80 C No water consumption no heating system activated Boiler stove in function whilst the storage tank was at high temp A second heat source works at the same time as the boiler stove a Start the pump of the room heating system b Use hot domestic water 9 Legal information 9 a General information Information If there is an exchange of information with the boiler ...

Page 60: ...icks For all the valves and other components the user may only make use of the legal guarantee as under the EEC directive 1999 44 CE if he has scrupulously complied with the regulations indicated in this manual and more specifically to work always within the boiler stove s range of use maintenance must be constant and accurate only allow people who are capable and who have been suitably trained to...

Page 61: ...om corrosion Please control the external coating before you install the Walltherm when you find defect parts please contact immediately your reseller After the installation of the Walltherm we can only resolve the problem with sprays To avoid coating problems during the operation please take note of the following tips a Please clean the external parts only with water and soap do never use alcohol ...

Page 62: ... or indirect due to Before housing the boiler stove an installer plumber who is capable and who has been suitable trained to use the boiler stove has to control the correct combustion of the boiler stove and the correct hydraulic connections and has to send a copy of the installation protocol to Wallnöfer GmbH The user should learn how to use the boiler stove before housing the boiler stove The ma...

Page 63: ...e The main office will help you find the nearest authorized assistance center 9 f Spare parts Use genuine spare parts only Do not wait until the components are worn from use before changing them Changing a worn component before it breaks makes it easier to prevent accidents that could otherwise lead to serious harm to people or damage to things See also Guarantee Carry out routine maintenance chec...

Page 64: ...____ _______________________________________ Address Walltherm specialist dealer _______________________________________ _______________________________________ _______________________________________ Thank you very much and a South Tyrolean HERZLICHES VERGELT S GOTT Thank you very much for having chosen the Walltherm boiler stove and please enjoy this innovative natural down draught wood gasifica...

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