Mark GSW+ 30 Technical Manual

Technical manual

MARK GSW+

0660302_R07

Index

Warranty policy 3

1 General information 4

1.1 General recommendations 4

1.2 Description of the units 4

1.3 Operation 5

2 Technicalspecications  6

 2.1 Specications 6

2.2 Relationship load / performance 6

2.3 Description of the components 7

2.4 Dimensions 8

2.5 Electrical overview 9

3 Installation 10

3.1 General rules 10

3.2 Securing of the unit 11

 3.3 Connectionoftheuepipeandairsupply 12

3.4 Connection condensate pipe 16

3.5 Gas connection 17

4 Controls 18

4.1 Comtherm 18

4.2 Connection of the control 21

5 Commissioning 22

5.1 Commissioning 22

5.2 Burner setting 23

6 Troubleshooting  24

6.1 Troubleshooting 24

6.2 Spare parts 25

7 Maintenance 26

8 Recommendations for the end user 28

 8.1 Safetyrules 28

8.2 What to do in case of a problem? 28

Warranty policy

CE-marking

ThereleaseoftheCE-markingistheofcialrecognitionofthequalityofdesign,manufacturerand

performance of this unit. The life and performance will be at the highest level when the implementation

andmaintenanceareproperlycarriedoutanddonebytheregulationsinforce.

Responsibility

ThisunitmayonlybeusedforwhichMARKhasdesignedandfabricatedit.MARKcannotbeheldliablefor

damagestopersons,animalsorpropertyifitiscausedbyerrorofinstallation,controlsormaintenanceor

notpermissibleuseoftheunit.Theunitmayonlybeequippedwithoriginalaccessories.MARKcannotbe

heldliableforanydamagesresultingfromuseofanaccessorythatisnotsuitablefortheunit.

Theunitsmustbeinstalledbyqualiedprofessionals,incompliancewiththeapplicableregulationsand

inaccordancewiththeinstructionsinthismanual.Thereferencestothestandards,rulesandguidelines

mentionedinthismanualareforinformationpurposesandareonlyvalidonthedateofissuethereof.

MARKisresponsiblefortheconformityofthedevicetotheapplicablerules,guidelinesandstandards

atthetimeofcommercialization.Theknowledgeandcompliancewiththelegalprovisions,aswellas

thenormsinherentinthedesign.Projectplanning,startupandmaintenancearetheresponsibilityofthe

consultant,theinstallerandtheuser.

Delivery – Storage

TheGSW+isdeliveredonawoodenpallet,protectedbyacardboardboxandaplasticlm.Immediately

afterarrival,theconditionoftheunitdeliveredmustbechecked(evenifthepackagingisintact).

Additionally,ensurethatthedevicedeliveredcorrespondswiththeorder.Withregardtotheproduct

warranty:thegeneralconditionsofMARKareinforce.

1 General information

1.1 General recommendations

Thegas-redcondensingairheateroftheGSW+seriesareintendedfortheheatingofindustrialand

relatedareas.Theunitsmayonlybeinstalledinside.Theunitsmayonlybeusedinwellventilatedareas.

The proper functioning of the heater depends on proper installation and commissioning.

Installationandmaintenancemustbeinaccordancewiththeapplicableregulationsandbecarriedoutby

qualiedpersonnel.Withthenon-complianceoftheserulesallresponsibilityofthemanufacturerexpires.

DONOTINSTALLGAS-FIREDCONDENSINGAIRHEATERSIN:

–Roomswithexplosionrisk;

–Roomscontainingchlorinefumes(orcombinationsthereof);

–Veryhumidrooms(electricalhazard).

Itistheresponsibilityoftheinstallertoensurethatduringassemblytheinstallationinstructionsdescribed

arefullled.

Itisexpectedfromtheinstallerto:

1°)informtheuserthat:

– Theusermaynotmodifythedesignoftheunitsortheimplementationofthesystemapplication;

–Anymodication(exchange,omission)ofthesafetycomponentsorpiecesthataffecttheefciencyof

 theunitorthecombustion,automaticallymeanstheCE-markingisexpired;

–Itisannuallyrequiredtoperformtheprescribedmaintenanceandcleaningactivities.

2°)handoverthismanualtotheuser.

This is an integral part of the unit and should be kept with the unit even if it is transferred to another

owner or user.

Weareinvolvedwiththequalityofourproductsandwishtoimprovethempermanently.Wetherefore

reservetherighttochangethespecicationincludedinthisdocument.

1.2 Description of the devices

TheGSW+gas-redcondensingairheaterisastandalonehotairgenerator,makinguseofthefuels

naturalgasorpropane.ItisbuiltandtestedtoEuropeanstandards2009/142/CE,Gasappliancedirective,

(EN1020:2009andEN1196:2011).Certicatenr.0461CN1002issued25/10/2012.

TheGSW+isagas-redcondensingairheater.Forallunitsdescribedinthismanual,theuegasesare

discharged to the outside. Use is made of a fan that is arranged on the discharge side of the combustion

chamber.Thecombustionairmaybesuckedfromtheinsideoroutside.Theseunitscanbeconnectedto

anexhaustsystem,typeC13-C33-C53,orontoachimneyoutlet,typeB23.

1.3 Operation

Thegas-redcondensingairheateroftheGSW+seriesareintendedfortheheatingofindustrialand

relatedareas.TheGSW+airheatersconsistofagas-redboilerandahotwatercoil,placedinthe

airow.Theairthatisblowninbythefanwillbeheatedbythecoil.Thistechniqueprovidesaperfect

homogeneityoftheairtemperature.Unlikeaconventionalairheater,thepartialorcompleterestrictionof

airoworaninterruptionoftheelectricalpowerduringoperationwillnotdamagetheunit.

Thecombustionsectioniscompletelyisolatedfromtheaircircuit,whichmakesitimpossibleforthe

systemairtomixwiththecombustiongases.TheunitisequippedwithaburnerwithlowNoxemissions.

Thecombustionairissuckedinbyafanwithavariableowrate.

Theairissuckedinbyaventurisystem.Thissystemmakessurethatthegasandairovertheentirerange

areintherightproportion.Theair/gasmixtureisfedtotheburner,locatedinthemiddleoftheboiler.

Theameandfumeswillgothroughtheheatexchangertwicetogiveoffmaximumpower.Thanksto

thistechnology,anefciencyofatleast98%atthemaximumloadsand108%atfullmodulationcanbe

achieved.Theoptimizationoftheperformanceofacondensationsystemisinuencedbyitscontrols.The

lowerthepoweroutputoftheairheater,thegreaterthecondensationandthusthehighertheefciency.

ThemodulationrangeoftheGSW+is30%ofthemaximumload.

The electrical control of the air heater is connected to the room thermostat. The control device provides

the continuous modulation of thermal power.

The modulating effect of the GSW+ heater guarantees perfect adaption to the real heat demand of the

building.Inversionsequippedwithfanswithavariableowrate,onecanalsovarytheairsupply.

2 Technicalspecications

Axial models

Thecondensinggas-redairheatersaredesignedwithaxial

fansthatmeettheEuropeanrequirements2009/125/EC.

Optionally,theunitcanbeprovidedwithafanthathasa

variableairow.

Thedeviceisdesignedasfreeblowing,providedwith

horizontal louvres.

2.1 Specications

TYPES

GSW+ 30 GSW+ 40 GSW+ 50 GSW+ 70

max min max min max min max min

Nominalload(highervalue) kW 30 7.5 40 10 50 12.5 70 17.5

Nominalload(lowervalue) kW 27 6.5 36 9 45 11 63 16

Nominal power kW 26.5 8.2 34.9 11.5 44.1 13.6 61.7 18.3

Efciency % 98 108 98 108 98 108 98 108

∆Tofairow °C 25.6 8 28.5 8.8 27.3 8.5 28 8.7

NoxClass Val. 5 5 5 5

Gasconsumption(15°C)

NeutralgasG20(20mbar)

NeutralgasG25(25mbar)

PropaneG31(37mbar)

m³/h

kg/h

2.86

3.16

2.10

0.72

0.79

0.53

3.82

4.21

2.81

0.96

1.05

0.70

4.77

5.26

3.51

1.19

1.32

0.88

6.68

7.37

4.91

1.67

1.84

1.22

Airdisplacement(15°C) m³/h 3000 900* 3600 1080* 4700 1400* 6400

Motor:electricalpower/RPM W/RPM 220/1000 320/1350 500/1350 520/900

Combustion air ø mm 80 80 80 80

Gasueø mm 80 80 80 80

Condensation connection ø mm 32 32 32 32

Gas connection ø 1/2”M 1/2”M 1/2”M 1/2”M

Electrical connection 230/240VIF~50Hz

Electrical power W 340 460 640 730

Watervolume(glycol-15°C) L 6.6 7.2 9.2 11.2

Operating temperatures °C -15/+40 -15/+40 -15/+40 -15/+40

Max.condensateamount l/h 1,8 2,4 2,9 5,2

Weight kg 88 99 110 135

* With modulating EC-fan.

2.2 Relation load / efciency

Thepowerratingsapplywithanairreturntemperatureof16°C.Theefcienciesweredeterminedata

waterregime54°C/80°C(maximumpower)and29°C/38°C(minimumpower).Theefciencyvariesin

function of the air return temperature.

2.3 Description of the components

Axialfan

Lineprint

Stainless steel boiler

Burner controls

Gas valve

Siphon

Burner door

Gasmixer

Combustion air fan

           Waterowsensor

Temperature sensor

           Overowvalve

Water pressure sensor

Pump

           Expansiontank

           Horizontallouvre 

window

           Air/waterheat

exchanger

Gas pipe complete

Ef. %

108

107

106

105

104

103

102

101

100

5 10 15 20 25 30 35 40 45 50 55 60 65 70

Power

(kW)

789101112

2.4 Dimensions

A B C E F G I J K L M N

(Air)

(Gas)

GSW+ 30 1079 574 605 120 470 280 450 625 350 400 90 165 80 80

GSW+ 40 1080 624 605 120 470 280 450 674 350 400 90 165 80 80

GSW+ 50 1192 674 605 120 470 280 450 724 350 400 90 230 80 80

GSW+ 70 1277 774 605 120 470 280 450 824 350 400 90 320 80 80

Dimensionsinmilimeters(mm)

2.5 Electrical overview

Comthermsupply(JP18)

Blue-Above

Orange - Center

(seephotoonpage20)

Water pressure sensor

Waterowsensor

Exhausttemperaturesensor

Retour water temperature

sensor

Inletwatertemperaturesensor

Room temperature sensor

ModBus

PWMmodulatingfan

(option)

230Vpowersupply

Maximalthermostat

230Vfanpowersupply

230Vpumppowersupply

230VPowersupply

PWMsignal

Ionizationelectrode

Combustion air vent

Igniteelectrode

Burner control terminal

3 Installation

Theinstallationofthegasunitsmustbedonebyqualiedandcompetentpractitioners.Themethodof

installationdependsonthearea,volume,ventilationfacilitiesandthepossibilitiesthatexistforueand

combustionair.Thisistobedeterminedbytheinstaller.

3.1 General rules

Thecondensingunitcanbeinstalleddirectlyinthetobeheatedroom.Theinstallationmustcomply

withnationalandlocalregulations,particularlyintheeldofappliedfuels.Theinstallermustabidetothe

regulationsinforce.Ifindoubt,askforinformationwiththecontrol-andsafetyregulators.

Aeration

Areaswhereadevicethatworksongasisplaced,musthaveapermanentventilationinaccordancewith

therulesinforceinthecountryofinstallation.

Drainage of the condensate

Theairheatermustbeequippedwiththeincludedsiphontodrainthecondensewater.Itisapartof

thesafetysystem,eachreplacementbyanotherunapprovedtypeisstrictlyprohibited.Thedrainageof

thecondensatemustbecarriedoutinaccordancewiththeapplicablerequirementsinthecountryof

installation.

Gas connection

Beforeconnectingtheunit,youmustmakesurethatthelocalgassupply(typeofgas,pressure)matchthe

settings of the unit that must be installed.

Note:minimumdistancesareessentialforthemaintenanceandsafetyoftheunit.

500 mm

200 mm

300 mm

2500 mm

3.2 Securing the unit

Theunitsthatareconnectedusingaxedgaslinemustbeinstalledrigid.Tomaketheinstallationeasier

we recommend the use of our adjustable hanging brackets. These are adapted to the unit and will position

itincompliancewiththeminimumdistances.Asformounting:consultthemanualdeliveredwiththe

brackets.

Beforetheunitisattachedyoushouldcheckthecarryingcapacityofthewall.

Step 1

– Assemblethemountingbracketusingtheenclosedinstructions.

–Attachthemountingbrackettothewall.Attachthiswithmaterialsuitableforwallmounting.Performa

safetytest,safetyfactor2,tocheckthermness.

Step 2

–Fixtheunittothebracketusingthesuppliedscrews.Securethescrews.

– LevelofftheapplianceusingtheM8adjustmentscrew.

Step 3

–Openthelouvresonthefrontofthedeviceatleast45°sothattheaircanfreelyowout.

Position 1 Position 2

3.3 Placement combustion gas discharge and air supply

TheGSW+unitsaresuitableforfollowingdrainagesystems:C13,C33,C53,B23.Theuegasdrainage

systemmustcomplywithnationalandlocalregulations.Theextensionpipesmusttoleratecondensateand

besuitableforauegastemperatureof100°C.Flueoutletsmustbeofpolypropyleneorstainlesssteel

316L.Thedrainagematerialmustbepositivelyaccessedfortheapplicationofgas-redunits.Thispositive

assessmentmustbedonebyanISO17025accreditedbody.

Theconnectionoftheuegasmustbeplacedoutside.Fortheintakeofcombustionaircanbechosen

from:

– withtheintakeofcombustionairfromtheoutside(type“C”);

– withtheintakeofcombustionairfromtheroomwheretheheaterisinstalled(type“B”).

Theuseduepipes,terminalsandaccessoriesmustbetested.Useonlysuctionanddischargeterminals

referencedbyMark.Withtheuseofnon-approvedequipmentthewarrantywillexpire.

Placement of the air inlet ring

Unitsthatreceivethecombustionairfromtheinstallationarea(type“B”)mustbettedwithaprotective

grate.Thistopreventlargepartsofcontaminationfromcomingintothecompartmentoftheunit(gures

A).InstallationareaswhereinatypeBunitisinstalledmusthavesufcientairsupply.Atleast100m3/hper

unit.

Unitswherethecombustionairisdrawnfromoutside(type“C”)mustbeprovidedwiththesupplied

mountingring(guresB).

Theextensionsmustbeprovidedwithalipring.Usesoapywatertoeasilyconnectthem.

A1 A2 A2

B1 B2 B3

Connection of the extension pipes type C33 and C13

Closedcombustionrelativetothesurroundings.Theextensionpipesofthecombustionairanduegasare

horizontallyorverticallyplacedoutsidetheinstallationarea.Theextensionpipesmayonlypassthroughthe

installation area.

C33verticaldrainagesystem C13horizontaldrainagesystem

Installationexample:

1 connection ring ø 80

 1extensionpipeø80,L=250mm

 2curvesø80,90°

 1transitionpiece:2xø80toø80/125

1 concentric wall or roof terminal ø 80/125

Theconnectionpipescanbeextendedwithforthispurposesuitablematerials.Thepipediametershould

beatleastequaltotheconnectorontheunit.Neverreducethepipediameterorplugtheventholesin

the installation area.

Don’tplacetherooforwallue:

– onlessthan2mfromaventorwindow/doorway,takethedilutionfactor(NEN2757andother 

 nationalandregionalregulations)intoaccount;

– inatransitzone;

– atlessthan2mfromthegroundordirectlyaccessible(riskofobstructionand/orcombustion).

NOTE

Thesealsbetweentheextensionmustbecloseandtight,makesurethelipringsarepresent.Thetotal

lengthshouldnotexceed8m,assumingthat:1angleof90°of45°=1mpipe.Inahorizontalsection,ensure

thattheextensionpipelieswithaslopetotheunit,toavoidoutowofthecondensation.

Connection of the extension tubes type B23

Non-closedcombustionrelativetothesurroundings.Thecombustionairisdrawndirectlyfromthe

installationareaandtheuegasgoesthroughaverticalpipethroughtherooforahorizontalpipethrough

thewall.Theextensionpipesmayonlypassthroughtheinstallationarea.

B23Horizontal B23 Vertical

NOTE

Thesealsbetweentheextensionmustbecloseandtight,makesurethelipringsarepresent.Thetotal

lengthshouldnotexceed8m,assumingthat:1angleof90°of45°=1mpipe.Inahorizontalsection,ensure

thattheextensionpipelieswithaslopetotheunit,toavoidoutowofthecondensation.

Installationexample:

 Extensionpipeø80,L=250mm

Protection louvre

 Bendø80,90°

Wall duct ø 80

Thewalloutletcanbeextendedwithapproved

pipes and elbows. The pipe diameter should be at

leastequaltotheconnectorontheunit.Never

reduce the pipe diameter or plug the vent holes in

theinstallationarea.Itisrecommendedtouse45°

bends.

Do not place a wall duct on less than 2m from the

ventilation,doororwindow,ofthegroundorina

transit zone.

Installationexample:

 Extensionpipeø80,L=250mm

Protection louvre

 Adhesiveplate(optional)

Roof duct ø 80

Thewalloutletcanbeextendedwithapproved

pipes and elbows. The pipe diameter should be at

leastequaltotheconnectorontheunit.Never

reduce the pipe diameter or plug the vent holes in

theinstallationarea.Itisrecommendedtouse45°

bends.

Connection extension pipes type C53

Closed combustion relative to the surroundings. The combustion air will be drawn from outside. The pipe

shallbeplacedhorizontal.Theuegasshallbebroughtoutvertically.Theextensionpipesmayonlypass

through the installation area.

C53 Vertical

NOTE

Thesealsbetweentheextensionmustbecloseandtight,makesurethelipringsarepresent.Thetotal

lengthshouldnotexceed8m,assumingthat:1angleof90°of45°=1mpipe.Inahorizontalsection,ensure

thattheextensionpipelieswithaslopetotheunit,toavoidoutowofthecondensation.

Installationexample:

Connection ring ø 80

 Bendø80,90°

Wall duct ø 80

 Extensionpipeø80,L=250mm

Roof duct ø 80

 Adhesiveplate(optional)

Theinletanduegasmaybeextendedwithapprovedpipesandelbows.Neverreducethepipe

diametertoadiametersmallerthantheconnectiontothedevice.Neverclosetheairinletopenings.Itis

recommendedtousebendsof45°insteadof90°.If90°bendsareunavoidable,donotapplymorethantwo

pieces.

3.4 Connection condensate pipe

Thegas-redcondensingairheatermustbettedwithasiphontodrainthecondensatewater.The

suppliedsiphonmustbettedduringinstallation.Notethatthedischargeofthecondensatemustbe

carriedoutwithmaterialwhichisresistanttoacidwaterwithapHof3.Neverusecopperorgalvanized

ironpipes.ForthedisposalofcondensedwateryoumustusePVCpipeswithadiameterthatisequalto

thisoftheunit(PVCØ32).Makesurethepipingisplacedonsufcientslope.Checkthetightnessofthe

plumbingofthecondensate.Beforeusingtheunit,llthesiphonwithwaterthroughthellercap.This

avoids that combustion gas will get into the sewer during the start-up.

Anti-freeze protection

Thecondensatedrain,includingthesiphon,mustbeprotectedagainstfrost.Itispreferredtokeepthe

drainsfrost-freeasbestaspossible.Incasetheyfalloutsidethebuilding,thepipepartbehindthesiphon

shouldbeopentoavoidtheformationoficewhichwillblockthedischarge.Takethenecessaryprecautions

toavoidsuchanincident,asthismaycauseirreversibledamagetotheheater.

Neutralization of the condensate

Theacidityofthecondensatefromthecombustionofnaturalgasis3,5-3,8pH.Incertainregionsitis

requiredthatthecondensatemustbetreatedbeforeitcanbedischarged.Inthesecasesyoushouldtake

on a neutralization kit in the condensate circuit.

Included in

delivery

Filler

Acidwater

Neutralization kit

Neutralized

condensate

3.5 Gas connection

Foremostyoushouldcheckwhetherthedeliveredunitismadeforthegasthatunitwillbeconnectedto.

Thisdataofthedeviceismentionedonthetypeplateontheinsideofthedoor.Thegassupplymustbe

suitablefortheloadofthedeviceandmustbeequippedwithallthesafetyandcontroldevicesrequiredby

theregulationsinforce.Thediameterofthepipemustbeaccuratelydetermined.Importantfactorsforthis

are,amongothers,thegasowandthelengthandrouteofthepipes.

Themaximumallowablelinelossesmaynotbegreaterthan5%ofthenominalsupplypressure.Thegas

connections must be installed in accordance with national and regional regulations and must be performed

byauthorizedpersonnel.Beforecommissioningtheunitmustbepressuretestedinaccordancewiththe

applicableregulationsandbecleaned.Themaximumallowablepressureofthegasis60mbar.

Note,beforeopeningthegasyoumustcheckthesealonthethrottle.

Gas connection:

Connectionpressurenaturalgashigherthan50mbar;

 connectionpressurenaturalgaslowerthan50mbar;

 LPGsupply.

Gas connection set:

 Gasket(supplied);

 Suitableconnection(supplied);

 Gaspressureregulator;

 Filter;

Gas tap.

A

4 Controls

4.1 Comtherm

The Comtherm is a modulating temperature controller. The room temperature sensor is integrated in the

housingofthecontroller.TheComthermisequippedwithaclockfunction,day-nightcontrol,continuous

runningfanandcontinuesdaytime.Basedontheprevailingroomtemperatureandthedesiredtemperature,

thecapacityisdetermined.Thecontrollerstandardlycomeswitha9metercable.Maximumcablelengthis

100m. The cable must be shielded.

ForfurtherinformationabouttheComtherm,pleaserefertothemanualofthiscontroller.AComtherm

can control one GSW+.

Connection diagram

Condensing air heater

 Maintenanceswitch230Vac

Comtherm

Room sensor

Supply Comtherm (Connector JP 18)

RS 485 Bus connector

Mark GSW+ 30, GSW+ 40, GSW+ 50, GSW+ 70 Technical Manual

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