Automatic Heating Gasogen Datasheet

Wood Fired Boiler
Gasogen 29 - 93kW
Installation and Servicing Manual

2
General Information
CONTENTS
1GENERAL INFORMATION ................................................................................................................................................................................. 3
1.1 Symbols used in this manual ....................................................................................................................................................................... 3
1.2 Correct use of the appliance ........................................................................................................................................................................ 3
1.3 Water treatment ............................................................................................................................................................................................. 3
1.4 Information to be passed over to the end user or the person in charge of the appliance ......................................................................... 3
1.5 Safety warnings ............................................................................................................................................................................................. 4
1.6 Data badge .................................................................................................................................................................................................... 5
1.7 General warnings .......................................................................................................................................................................................... 5
2TECHNICAL FEATURES AND DIMENSIONS ................................................................................................................................................... 6
2.1 Technical features ......................................................................................................................................................................................... 6
2.2 Dimensions and water connections ............................................................................................................................................................. 7
2.3 Main components .......................................................................................................................................................................................... 8
2.4 General information ...................................................................................................................................................................................... 8
3INSTALLATION INSTRUCTIONS ..................................................................................................................................................................... 12
3.1 General warnings ....................................................................................................................................................................................... 12
3.2 Installation Codes of Practice ................................................................................................................................................................... 13
3.3 Packaging................................................................................................................................................................................................... 14
3.4 Transportation ............................................................................................................................................................................................ 14
3.5 Installation .................................................................................................................................................................................................. 15
3.6 Boiler system connection .......................................................................................................................................................................... 15
3.7 Connection to the heat exchanger’s drainage .......................................................................................................................................... 16
3.8 Recycling pump ......................................................................................................................................................................................... 16
3.9 Installation instructions .............................................................................................................................................................................. 17
3.10 Water and electrical connection diagrams with standard control panel, without hot water storage tank .............................................. 21
3.11 Water and electrical connection diagrams with optional control panel, without hot water storage tank ............................................... 23
3.12 Water and electrical connection diagrams with optional control panel, with hot water storage tank .................................................... 27
3.13 Flue outlet connection ............................................................................................................................................................................... 40
3.14 Filling the system ....................................................................................................................................................................................... 41
4-5ELECTRICAL CONNECTIONS ........................................................................................................................................................................ 42
4.1 Standard control panel .............................................................................................................................................................................. 43
5.1 Optional control panel ............................................................................................................................................................................... 45
5.2 Functional wiring diagram (Flow chart) .................................................................................................................................................... 46
5.3 Loads and sensors connection diagram ................................................................................................................................................... 48
5.4 Functional description of optional control panel ...................................................................................................................................... 49
5.4.1 Ignition ............................................................................................................................................................................................. 49
5.4.2 Normal boiler operation ................................................................................................................................................................... 49
5.4.3 No wood ........................................................................................................................................................................................... 49
5.4.4 Oil/gas boiler operation ................................................................................................................................................................... 50
5.4.5 Domestic hot water production ....................................................................................................................................................... 50
5.5 Special functions ....................................................................................................................................................................................... 51
5.5.1 Overheating ..................................................................................................................................................................................... 51
5.5.2 Combustion gas temperature control ............................................................................................................................................. 51
5.5.3 Fan overheating protection system ................................................................................................................................................ 51
5.5.4 Temperature sensor failure alarm .................................................................................................................................................. 51
5.5.5 Fireproof thermostat ........................................................................................................................................................................ 52
5.5.6 Waiting time .................................................................................................................................................................................... 52
5.5.7 Return flow sensor installation ....................................................................................................................................................... 52
5.6 Optional control panel wiring diagram ...................................................................................................................................................... 53
6BOILER START-UP ........................................................................................................................................................................................... 54
6.1 Initial lighting ............................................................................................................................................................................................. 54
6.2 Fire wood .................................................................................................................................................................................................... 55
6.3 Wood moisture ........................................................................................................................................................................................... 55
6.4 Fire wood dimensions ................................................................................................................................................................................ 55
6.5 Initial lighting checks ................................................................................................................................................................................. 55
6.6 Start-up ...................................................................................................................................................................................................... 56
6.7 Combustion air adjustment ....................................................................................................................................................................... 57
6.8 Checks to carry out after first start-up ...................................................................................................................................................... 58
6.9 Warnings .................................................................................................................................................................................................... 58
6.10 Thermostat adjustments ............................................................................................................................................................................ 59
6.11 Summer operation ..................................................................................................................................................................................... 59
6.12 Burner adjustment on the back up boiler ................................................................................................................................................. 59
6.13 Fault finding for boilers with standard control panel ................................................................................................................................ 60
6.14 Fault finding for boilers with optional control panel .................................................................................................................................. 61
7SERVICING AND MAINTENANCE SCHEDULE ............................................................................................................................................. 62
Gasogen

3
General Information
1.1 - SYMBOLS USED IN THIS MANUAL
When reading this manual particular care has to be given to the parts marked with the followings symbols:
NOTE! Suggestions for the
user
WARNING! Indicates a potentially
dangerous situation for the
product and the environment
DANGER! Indicates serious
danger for your personal safety
and for your life
1.2 - A CORRECT USE OF THE APPLIANCE
The GASOGEN G3 2S appliance has been designed utilizing today’s heating technology and in compliance
with the current safety regulations.
However, following an improper use, dangers could arise for the safety and life of the user or of other
people, or damage could be caused to the appliance or other objects.
The appliance is designed to be used in pumped hot water central heating systems.
Any other use of this appliance will be considered improper.
Automatic Heating declines any responsibility for any damages or injuries caused by an improper use;
in this case the risk is completely at the user’s responsibility.
In order to use the appliance according to the foreseen scopes it is necessary to carefully follow the
instructions indicated in this manual.
1.3 - WATER TREATMENT (refer to specific guide)
 The hardness of the mains water supply conditions the frequency with which the heat exchanger is cleaned.
 In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is recom-
mended. The choice of this device has to be made taking into consideration the characteristics of the water.
 We recommend you to check the state of cleanliness of the domestic hot water heat exchanger at the end of the
first year and subsequently every two years; in this occasion check the state of wear of the anode.
1.4 - INFORMATION TO BE HANDED OVER TO THE USER OR PERSON IN CHARGE OFTHE
APPLIANCE
The user or the person in charge has to instructed on the use and operation of his heating system, in particular:
- Hand over these instructions to the end user or person in charge of the appliance, together with any other litera-
ture regarding this appliance placed inside the envelope contained in the packaging. The user has to keep these
documents in a safe place in order to always have them at hand for future reference.
- Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that it is absolutely
forbidden to make any alterations to the boiler.
- Inform the user how to check the system’s water pressure as well as informing him how to restore the correct
pressure.
- Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure the
greatest possible fuel economy.
- Remind the user that it is obligatory to service the appliance at least annually and to carry out a combustion
analysis in compliance with the schedule indicated in the national Codes of Practice.
- If the appliance is sold or transferred to another owner or if the present user moves home and leaves the appliance
installed, ensure yourself that the manual always follows the appliance so that it can be consulted by the new
owner and/or installer.
1GENERAL INFORMATION
Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in
accordance with the current laws.
The end user is not qualified to carry out any service work on the boiler.
Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to
persons, animals or damage to property. Automatic Heating shall not be held liable for any injury and/or damage.

4
General Information
1.5 - SAFETY WARNINGS
WARNING!
The installation, adjustment, and servicing of this appliance must be carried out by a competent, qualified
person and installed in accordance with the current standards and regulations. Failure to correctly install
this appliance could cause injury to persons, animals or damage to property. The manufacturer shall not
be held liable for any injury and/or damage.
DANGER!
NEVER try to carry out any repairs or service work on the boiler on your own initiative.
Servicing or repairs of the appliance must be carried out by qualified service engineers;
Automatic Heating recommends drawing up a service contract.
Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to
persons, animals or damage to property for which shall not be held liable.Automatic Heating
Modifications to parts connected to the appliance
Do not carry out any modifications to the following parts:
- the boiler
- to the gas, air, water supply pipes and electrical current
- to the flue pipe, safety relief valve and to the central heating’s drainage pipe
- to the constructive components which influence the appliance’s safe operation
WARNING!
When tightening or loosening the screw pipe connections, use only adequate fork spanners.
The improper use and/or the use of inadequate equipment can cause damages (for example water or gas leakages).
Explosive and easily inflammable substances
Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room
where the appliance has been installed.
Gasogen

5
General Information
1.7 - GENERAL WARNINGS
This instruction manual is an integral and indispensable part
of the product and must be retained by the person in charge of
the appliance.
Please read carefully the instructions contained in this manual
as they provide important indications regarding the safe
installation, use and servicing of this appliance.
Keep this manual in a safe place for future reference.
The installation and servicing must be carried out in accordance
with the regulations in force according to the manufacturer’s
instructions and by legally competent authorized persons.
By a competent person, we imply a person who has a specific
technical qualification in the field of components for central
heating systems for domestic use, domestic hot water
production and servicing. The person must have the
qualifications foreseen by the current laws in force.
Bad or irregular servicing could compromise the safe operation
of the appliance, and could cause injury to persons, animals
or damage to property.The manufacturer shall not be held liable
for any such injury and/or damage.
Before carrying out any cleaning or servicing turn off the
electrical supply to the boiler by means of the ON/OFF switch
and/or by means of the appropriate shutdown devices.
Do not obstruct the intake/outlet terminal ducts.
In the event of failure and/or faulty functioning of the appliance,
switch off the boiler. Do not attempt to make any repairs:contact
qualified technicians.
Any repairs must be carried out by Automatic heating authorized
technicians and using only original spare parts. Non-
observance of the above requirement may jeopardize the safety
of the appliance.
To guarantee the efficiency and correct functioning of the
appliance it is indispensable to have the boiler serviced annually
by a qualified person.
If the boiler remains unused for long periods, ensure that any
dangerous parts are rendered innocuous.
If the appliance is sold or transferred to another owner or if the
present user moves home and leaves the appliance installed,
ensure yourself that the manual always follows the appliance
so that it can be consulted by the new owner and/or installer.
Only original accessories must be used for all appliances
supplied with optional accessories or kits (including electrical
ones).
This appliance must be used only for the purposes for which it
has been expressively designed. Any other use shall be
considered incorrect and therefore dangerous
1.6 - DATA BADGE
The data badge is adhesive and placed inside the documentation envelope; it must be glued on to one side of the casing, on the
external part, by the installer.
The boiler’s serial number is indicated on the plate screwed on the boiler’s front plate (front side, upper right hand side).

6
Technical features and dimensions
2.1 - TECHNICAL FEATURES
The GASOGEN G3 2S boiler is a steel made wood fired unit
, with complete wood gasification combustion, inverted flame,
with a pressurised room chamber.
The following models are available:
GASOGENG3252S
GASOGENG3402S
GASOGENG3502S
GASOGENG3652S
GASOGENG3802S
The GASOGEN G3 2S boiler is equipped with all the safety
and control devices in compliance to the current standards.
DESCRIPTION OF COMPONENTS
- Steel body with a partially refractory-lined combustion
chamber;
- Refractory burner;
- Horizontal flue channels;
- Front fire box lined with refractory material;
- Intermediate door complete with combustion air regulations;
- Lower cleaning door lined with refractory material and
equipped with a flame inspection sight;
- Rear flue chamber with side inspection doors and ash
removal
-Flue evacuation via a pressure blower.
-Patented thermostatic valves system
-Safety heat exchanger
-Insulated boiler body with 60 mm thickness mineral wool
mattress
-Powder painted steel casing
-Recirculation pump kit (optional)
-Recirculation pump kit for buffer tank (optional), provided
the standard control panel is replaced by the model code
23557
-Standard control panel for electromechanical operation
-Optional control panel, code 23557, for integral control of a
buffer tank, according to the Standard EN 303-5 and with
the possibility of operating with a back up oil or gas fired
boiler.
STANDARD CONTROL PANEL COMPONENTS:
- Power On light indicator
- Boiler thermometer
- Safety thermostat in case of boiler overheating
- Boiler temperature adjustment thermostat
OPTIONAL CONTROL PANEL COMPONENTS:
- Power On light indicator
- Boiler thermometer
- Safety thermostat in case of boiler overheating
- Boiler temperature adjustment thermostat
2TECHNICAL FEATURES
AND DIMENSIONS
Gasogen

7
Technical features and dimensions
AF
30
BT1
T4
T6
T4
T3
T5
T1
T4
T3
T2-T8
E
1
7
8
3
2
4
9
D
C
G
T2
T8
T7
6
5
2.2 - DIMENSIONS AND
WATER CONNECTIONS
fig. 1
1. Control panel
2. Primary air adjustment
3. Secondary air adjustment
4. Flame sight control
5. Cleaning door
6. Rear smoke chamber
7. Loading door
8. Fan
9. Bottom inspection and cleaning door
T1. Central Heating flow
T2. Central Heating return
T3. Chimney connection
T4. Safety heat exchanger connections
T5. Bulb holder connection for heat discharge
valve
T6. Bulb holder for safety thermostat
T7. Bulb holder for thermometer and high limit
and minimum working thermostat,
T8. Boiler drainage
* Output obtained with good quality wood with a 15% .moisture content.
** Pressure losses for a flow rate corresponding to 15 K Delta T.
MODELS
GASOGEN
G3 25 2S
GASOGEN
G3 40 2S
GASOGEN
G3 50 2S
(kW) 15 23 29
AVERAGE OUTPUT
MINIMUM OUTPUT
MAXIMUM USEFUL OUTPUT*
(kW) 26 37 47
(kW) 29 47 58
MAXIMUM OUPUT (kW) 34 55 69
DIMENSIONS:
A
B
C
D
E
F
G
560
700
655
700
655
900
1225 1355
190
315
190
315
245
1030
1355
190
315
245245
1140 1140
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
CONNECTIONS T1 - T2
T3
T4
T5 - T6 - T7 - T8
UNI ISO 7/1
(Ø mm)
UNI ISO 7/1
Rp 1¼
150
R½
Rp ½
Rp 1½
200
R½
Rp ½
Rp 1½
200
R½
Rp ½
BOILER WATER CONTENT
WATER SIDE PRESSURE DROP**
SMOKE SIDE PRESSURE DROP
MAX. WORKING PRESSURE
FIRE BOX STORAGE VOLUME
FIRE BOX DIMENSIONS
WEIGHT
WOOD LOGS LENGTH
(m c.a.)
(l) 90
0,10
110
0,08
140
0,12
0,60,40,3
(mm c.a.)
(bar)
(l)
(mm)
(kg)
3
95
290x340
386
3
135
350x440
475
3
185
350x440
593
(cm) 50 50 70
GASOGEN
G3 65 2S
41
64
76
88
755
955
1405
190
315
245
1180
Rp 2
220
R¾
Rp ½
170
0,06
0,3
3
235
340x520
630
70
GASOGEN
G3 80 2S
52
76
93
109
755
1255
1405
190
315
245
1180
Rp 2
220
R¾
Rp ½
220
0,10
0,5
3
325
340x520
850
100
UNI ISO 7/1

8
Technical features and dimensions
3
8
11
121413
17
12
15
7
18
M
R
9
10
16
4
6
5
2.3 - MAIN COMPONENTS
1. Control panel
2. Upper casing panel
3. N° 2 side casing panels
4. Smoke proof hinged door
5. Refractory-lined loading door with sealing gasket
6. Central door with gasket and primary and secondary
air adjustment screws
7. Fan
8. Refractory-lined combustion chamber door, sealing
gasket and flame sight
9. Thick steel plated combustion chamber
10. Heat exchange baffle
11. Boiler drainage
12. Safety heat exchanger
13. By-pass with command rod
14. Boiler body mineral wool insulation
15. Steel boiler body
16. Refractory burner with fire bars and grate
17. Flue chamber
19. Thermostatic valve
MC.H.flow
R C.H. return
fig. 2
N.B.:
The fire bars and the refractory steel grate are subject to wear; it is therefore advisable
to carry out an annual inspection to prevent bad boiler operation.
2.4 - GENERAL INFORMATION:
REVERSED FLAME COMBUSTION
Every body knows that to make a match last it must be held
with its head upwards.
This is because it is necessary that the flame, in its convective
motion, does not meet another fuel in addition to the one which
it has generated it. As in residential heating the fuel is in form
of wood logs which are loaded from the top, the flame has to
go in the opposite way, i.e. downwards.
Natural draught is a very variable source of depression,
according to the type of chimney, on the weather conditions,
onthetypeoffuel,etc.
Therefore it is necessary to integrate it with forced ventilation
in order to stabilize it.
By fitting a fan it is possible to considerably reduce the section
of the gas passages on the grate and furthermore there are no
problems with cold starts.
The small grate permits a more controlled passage of
combustion air, contrarily to what happens with the large
traditional grates.
The air can be perfectly dosed because the grate covered with
fired wood has the same crossing resistance and thus the
combustion will be always optimal.
Automatic Heating has already used this principal for many
years with the GASOGEN G3 2S boiler.
The GASOGEN G3 2S boiler today has reached such a high
level of perfection that it can pass all the most stringent tests
foreseen by the European Standards in force concerning the
environment.
Gasogen

9
Technical features and dimensions
M
R8
7
9
10
1
2
3
4
5
6
fig. 3
GASOGEN G3 2S - BOILER CONSTRUCTION
The boiler body is made of two oval elements, one placed inside
the other, so as to form a water cavity (fig.3).
The large fire box , in its rear wall, has a refractory insulation,
which is particularly resistant to heat and mechanical stresses,
in order to keep the by-pass zone dry in every working
condition.
We can distinguish the following parts (fig.3):
1. Fire box, drying area
2. Gasification zone
3. Embers zone
4. Refractory burner
5. Combustion chamber
6. Heat exchange surface
7. Refractory steel cradle
8. Boiler water
9. Thermostatic system
10. Safety heat exchanger
M C.H. system flow
R C.H. system return
GASIFICATION ZONE (2)
The gasification takes place In the lower part of the fire box .
It is very important that the gasification is as regular as possible,
so as not to overburden the burner with gas. The gasification
speed depends on the quantity of the wood and the dimensions
of the drying area. Generally, it is better to use large logs if
they are dry and small logs if the wood is wet . The quantity of
primary air, proportional to the delivered output, is regulated
via the adjustment system.
EXCHANGE SURFACE (6)
As the boiler operates on wood, and because the sulphur
concentrations are not very high , it is important to obtain very
low smoke temperatures in order to increase the water
efficiency.
To obtain this Automatic Heating has opted for an exchange
surface with dry smoke passes (fig. 4), which have already
been extensivelytested in oil fired boilers working at low water
temperature, thus permitting low smoke temperatures without
danger of condensate forming.
The surfaces of the dry passages “A” (fig. 4) have had incisions
made on them in order to avoid dilatation problems.
The solid residues of combustion (ashes), which lie on the
high temperature refractory-lined cradle (fig. 3, pos. 7,) will
become with time always lighter until they will be dragged by
the gas speed and will deposit themselves in the lowest area
of the rear smoke chamber, from which they will be removed
during the cleaning operation.
REFRACTORY BURNER (4)
The burner is made up of refractory stone (fig. 3, pos. 4).
This stone has an oval central opening through which the flame
passes.
The embers lie directly on the main stone which divides the
fire box from the lower combustion chamber.
Furthermore the main refractory stone has a rectangular seat
in which the opportunely grooved cast iron fire bars are placed
(fig. 5, pos. 2), which receive the secondary air from a front
distributor.
The embers are prevented from falling by cylindrical pieces of
refractory steel. The combustion gases, poor in oxygen and
fig. 4
fig. 5
1. Metallic grate
2. Cast iron fire bars

10
Technical features and dimensions
SSS
M
F
F
R
P
F
P
P
S
P-S
M=C.H.flow
R=C.H.return
P = Primary air
S = Secondary air
F = Flue
fig. 7
still rich in carbon not yet combined, travel across the embers
and enter the opening in the centre of the main stone.
Inside this pre-combustion chamber, the gases combine with
the pre-heated secondary air coming through the grooves of
the two cast iron fire bars.
The resulting flame will be highly oxygenated and have a light
blue colour. This flame comes out from the oval opening and
invades the combustion chamber.
Due to the high temperatures the refractory burner will become
a bright red colour.
THERMOSTATIC VALVE (9)
As well known, wood normally has a high moisture content
when compared with other types of fuels. The first operation
which occurs inside the fire box is therefore the drying phase.
The high moisture content can then cause condensation
phenomena within the boiler and also in the chimney.
To limit the inconvenience in the boiler it is necessary to
maintain high working temperatures.
For this reason the boiler is equipped with a patented
thermostatic system (fig. 6) which permits the boiler
temperature to be kept constantly high and in particular, in the
fire box, where
the condensation phenomena is more likely to occur.
In order to reduce the consequences of condensate formation
(formation of layers of tar, corrosion, etc.) it is advantageous
to dimension, time by time, the wood load to the actual needs,
so as to prevent long stop overs with the wood storage
completely full of humid wood.
Nevertheless all these expedients do not impede the formation
of condensate in the chimney. Therefore we suggest, when
building the chimney, to use air-tight components, to avoid the
condensate damaging the building structure.
COMBUSTION CHAMBER (5)
The combustion is optimised by increasing the flame
temperature and producing a strong turbulence in the bottom
chamber.
For this reason the flame, in addition to not to touching cold
walls irrigated by the water, rebounds and is divided on a
semicircular cradle which rests on the lower exchange surfaces
(baffles), which, as well delimiting the smoke passages, also
has the task of collecting the ashes and possible embers.
The flames, after having bounced off the walls of the bottom
area and the refractory ones, direct themselves with a whirling
motion towards the front part of the combustion chamber and
enter the flue ducts.The combustion will be complete and clean
and the dominant colour will be that of the ashes: white.
Firewood, as is well known, normally has a high moisture
content when compared to other types of fuels. The first
operation which occurs inside the fire box is therefore the
drying phase.
The high moisture content can cause condensate
phenomenons inside the boiler and also in the chimney.
In order to limit this problem it is necessary to maintain the
boiler at a high working temperature.
Therefore, in order to adjust the flow temperature it is necessary
toinstalla3or4waymixingvalve.
If the mixing valve is not installed it will make the guarantee
void.
Always in order to reduce the consequences of condensate
formation (tar formation , corrosion, etc.) it is advantageous to
dimension, time by time, the wood load to the actual needs, so
fig. 6
1
2
3
T1
Gasogen

11
Technical features and dimensions
as to prevent long stop overs with the wood storage completely
full of humid wood. Nevertheless all these expedients do not
impede the formation of condensate in the chimney. Therefore
we suggest, when building the chimney, to use air-tight
components, to avoid the condensate damaging the building
structure.

12
Instructions for the installer
3INSTALLATION
INSTRUCTIONS
3.1 - GENERAL WARNINGS
WARNING!
This boiler is to be destined only to the use
for which it has expressly been designed for.
Every other use is to be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.
WARNING!
These appliances are exclusively designed
for indoor installations or installed in
adequate sitings.Therefore these appliances
must not be installed and operated
outdoors. An outdoor installation could
cause malfunctioning and could be
dangerous. For outdoor installations, it is
recommended to use appliances which have
been specifically designed for this purpose.
Before installing the boiler the following points
have to be carried out by a professionally
qualified person:
a) The whole system should be thoroughly
flushed in order to remove any residual dirt or
grime which could compromise correct boiler
operation.
b) Check that the chimney/flue pipe has an
adequate draught, does not have any
constrictions, and that no other appliance’s flue
outlets have been fitted, unless the chimney is
serving more than one heating appliance,
according to the specific standards and
regulations in force. The connection between
the boiler and chimney/flue outlet can be made
only after this verification has been carried out.
WARNING!
The appliance must be installed by a
qualified, registered engineer, whom, under
his own responsibility, guarantees the
compliance of the standards according to
the latest regulations.
NOTE:
The boiler must be connected to a heating system
which is compatible to its performance and output.
Gasogen

13
Instructions for the installer
3.2 - INSTALLATION CODES OF PRACTICE
The GASOGEN G3 2S is a boiler foreseen for operation with
firewood. The appliance must be installed in compliance with
all applicable laws and regulations.

14
Instructions for the installer
1
23
4
3.3 - PACKAGING
The GASOGEN G3 2S is supplied dismantled: the casing, the
fan, the control panel, the handles and the cleaning accessories
are delivered separately in carton boxes
(fig. 8).
After having unpacked everything, make sure that
the consignment is intact and undamaged.
In case of doubt do not to use the appliance and
inform the supplier.
Keep the packaging material (cardboard box,
plastic bags, polyester protection etc.) out of
the reach of children since they can be
dangerous.
Automatic Heating refuses all liability for injury
to persons, animals or damage to property
deriving from not having respected the above
mentioned recommendations.
Packages description:
1. Boiler body
2. Package containing the casing and boiler insulation
3. Package containing the control panel
4. Package containing: insulation fixing kit, fan, air manifold
group, smoke
chamber inspection doors, handles, flame sight mirror.
In the documents, placed in the fire box, you will find:
- User’s instruction guide
- Installation and servicing instruction manual
- Warranty
- Adhesive data plate
- Adhesive label with ventilation requirements
If the boiler will not be used for a long period,
it should be adequately protected.
fig. 8
3.4 - TRANSPORTATION
To facilitate the transport, the loading and unloading of the
boiler, on the upper part of the boiler body there are suitable
hooks (fig. 8) for lifting.
Gasogen

15
Instructions for the installer
600
1000
1300 600
600
3.5 - INSTALLATION
The boiler does not differ from a normal solid fuel fired boiler;
therefore there are no particular installation codes of practice
other than the applicable national and local safety regulations
and laws.
The installation room must be properly ventilated via openings,
which should have a total surface of at least 0,5 m².
To facilitate cleaning of the flue circuit, a free space, not inferior
to the length of the boiler, must be left in front of the boiler.
In addition ensure that the doors can open 90° without meeting
any obstacles.
The boiler can be placed directly on the floor, because it is
equipped with a self-supporting frame.
Nevertheless, in case of installation in very damp boiler rooms,
it is preferable to fit a concrete support.
When installation is completed, the boiler should be in a
horizontal position and stable so as to reduce possible
vibrations and noise.
An adequate clearing must be left behind the boiler for
servicing.
INSTALLATION IN BOILER ROOM
Note:
The minimum clearances indicated in figure 9 are compulsory
only for boilers with an output higher than 35 kW.
fig. 9
3.6 - BOILER SYSTEM CONNECTION
Warning!
Make sure the connection of the pipelines
is free of mechanical stresses, in order to
avoid pressure losses!
The C.H. flow and return must be connected to the respective
connections in the boiler, as indicated on page 8.
When determining the size of the CH circuit pipes it is essential
to bear in mind the pressure losses induced by any of the
system’s components and by the configuration of the same
system.
The piping route has to be designed taking all the necessary
precautions in order to avoid air locks and to facilitate the
continuous purging of the system.
Ensure yourself that the system’s piping is not
used as earth clamps for the electrical or
telephone system. They are absolutely
unsuitable for this use.In a short time this could
cause serious damage to the piping, boiler and
radiators.

16
Instructions for the installer
SCARICO
1
2ALIMENTAZIONE
3.7 - CONNECTION TO SAFETY HEAT
EXCHANGER DRAIN
Solid fuel fired boilers have to be installed
with the safety devices foreseen by
applicable
regulation and laws.
For this purpose the GASOGEN G3 2S
boilers are fitted with a safety heat
exchanger.
On this safety heat exchanger the installer must fit a heat
discharge valve, whose control bulb has to be inserted in the
bulb holder placed onto the rear wall of the wood fired boiler.
The inlet and outlet connections can be inverted.
However we recommend that the valve be fitted on the cold
water inlet.
In correspondence of the safety heat exchanger
outlet, we recommend fitting a drainage pipe
with a funnel and siphon that lead to an
adequate drainage. The drainage has to be
visible.
Warning!
In absence of this precautionary measure, the eventual
intervention of the heat discharge valve could cause
damages to people, animals or property.The manufacturer
shall not be held liable for any such injury and/or damage.
3.8 - RECIRCULATION PUMP
For correct boiler operation it is necessary to
install a recirculation pump in the boiler.
The recirculation pump, supplied as an
optional kit in two different versions, basic or
for buffer storage tank control, will have to be
connected as shown in figs. 19 and 20.
If the recirculation pump is not installed, besides limiting
the boiler’s life span, it will invalidate the warranty.
WARNING!
The hardness of the mains water supply conditions the
boiler’s life span.
Depending on the hardness of the of the mains water
supply the possibility of installing a water
softener has to be taken into consideration.
In hard water areas where the main water can exceed 15°f
total hardness, water treatment is always recommended.
fig. 10
MAINS
DRAIN
Gasogen

17
Instructions for the installer
3.9 - INSTALLATION
INSTRUCTIONS
Installation of the insulation and
casing
A) Fit the ball grip pos. 4 onto the upper
door closing handle.
B) Fit the screw and nut on the upper
and lower door and screw down the ball
grip (pos. 1, 2, 3).
C) Fit the 4 supporting feet on the lower
L profiles of the boiler body.
D) Fit the cleaning doors onto the smoke
chamber.
E) Fit the flame sight mirror (pos. 5) onto
the lower door’s sight glass.
F) Fit the thermal discharge valve’s bulb
holder (pos. 2, fig. 18).
G) Fit the body insulation and make a
suitable hole near the flow connection
pipe.
H) After fitting the fibre glass insulation
onto the boiler body, pass the plastic
strap provided around it, and insert an
end part in the slot as shown in detail 1
(fig. 12).
Make appropriate cuts in
correspondence of the thermostatic
valves.
I) Keeping the end of the plastic strap
already inserted steady, proceed with
the other end by bending, towards the
inside, the plastic pin as shown in detail
2.
L) Pull the ends of the strap (as shown
in details 3 & 4) till it adheres completely
to the glass wool covering the boiler
body.
Please do not pull the strap too much,
as too much compression of the rock
wool insulation will cause an
uniformed insulation
fig. 11
fig. 12
fig. 13
FIG. 12
1
2
3
4
1
32
B
D
A
C
5
If the boiler needs to be serviced it is possible to remove the
plastic strap by removing the blocking devices.
Fit the microswitch onto its support and adjust the pushing
washer axially in order to allow the microswitch to be regularly
controlled when the upper loading door is closed.
Check that the by-pass disk is perfectly closed when the door
is closed and the boiler in operation.
It is possible to verify this by simulating the closing of the upper
door and observing, from the inside of the fire box, if there are
any spaces.
If necessary, adjust the length of the by-pass shaft, acting on
the front threaded shaft.

18
Instructions for the installer
B
DETTAGLIO B
B
DETTAGLIO B
1
4
5
6
32
7
98
2
1
3
7
54
6
fig. 14
- Hook the L.H. side casing panel (pos. 1) to the boiler body.
- Hook the R.H. side casing panel (pos. 2) to the boiler body.
- Before fitting the upper panel (pos.3) to the side panel (pos.1
& 2), install the control panel (pos. 4).
- Fit the rear profile supporting the cable clamps (pos. 7).on
the upper panel
- Open the control panel by unscrewing the two side screws.
Lift the control panel’s cover, making it rotate frontwards.
Fit all the thermostat capillaries inside, unrolling them carefully,
the fan(s) connecting cable(s) (outlet), the microswitch cable
door opening control (inlet), and the incoming supply cable
through the two rectangular slots on the base of the control
panel.
- Position the upper casing panel onto the boiler by directing
the capillaries towards the boiler rear.
- Stick the boiler DATA PLATE onto the R.H. side casing panel
after having cleaned the interested area.
Remove the adhesive from the DATA PLATE and stick it on the
boiler making it adhere perfectly.
fig. 15
Ref. fig.15 (Models GASOGEN G3 25 2S, GASOGEN G3 40
2S,GASOGENG3502S)
- Fit the air manifold (pos. 1) on to the intermediate door.
- Fit the gasket (pos. 4) and the plate (pos. 5) to the manifold.
- Fit the fan (pos. 7) to the plate.
- Make sure the air non-return plate is not blocked, by moving
the air manifold’s external lever manually.
The primary and secondary air draught adjustment is described
on page 57.
- Wire the electrical connections (see general wiring
diagram on page 44 and practical wiring
diagrams on
page 21 & 22).
On the optional control panel (code 23557)
DUPLO IT version, the wiring of the electrical
connections must be carried out as indicated
in the diagrams in 3.11 & 3.12, on pages 24, 26, 29, 31, 33,
36 and 39.
Models: GASOGEN G3 25 2S
GASOGENG3402S
GASOGENG3502S
Models: GASOGEN G3 65 2S
GASOGENG3802S
Ref. fig. 16 (Mod. GASOGEN G3 65 2S, GASOGEN G3 80
2S)
- Fit the air manifolds on to the intermediate door.
- Fit the gaskets and the plates to the manifolds.
- Fit the fans to the plates.
- Make sure the air non-return plates are not blocked, by moving
the air manifold’s external lever manually.
The primary and secondary air adjustment is
described on page 57.
- Wire the electrical connections (see general
wiring diagram on page 44 and practical wiring
diagrams on page 21 & 22).
On the optional control panel (code 23557)
DUPLO IT version, the wiring of the electrical
connections must be carried out as shown in the
diagrams in 3.11 & 3.12, on pages 24, 26, 29, 31,
33, 36 and 39.
fig. 16
DETAIL B
DETAIL B
Gasogen

19
Instructions for the installer
TERMOSTATO
DI ESERCIZIO (Te)
TERMOMETRO
MOLLA
DI CONTATTO
TERMOSTATO
DI MINIMA (Tsc)
MOLLA DI
FISSAGGIO
TERMOSTATO
DI MASSIMA (Tmax)
TERMOSTATO
DI SICUREZZA (Ts)
MOLLA DI
FISSAGGIO
fig. 17
Insert the bulbs of the thermostats in their relevant bulb holders
as shown in fig. 17 and secure them in place with the fixing
springs.
In the optional control panel (code 23557) DUPLO IT
version, the bulbs of the sensors/thermostats to be placed
in the bulb holders are the following:
- Flow sensor (Tc).
- Boiler thermometer
- Safety thermostat (small bulb holder).
The flue sensor bulb must not be inserted.
For the return sensor’s electrical connection (Tr) and for
the relevant problems connected with it, see 5.5.7 (page
52) “Return sensor installation”.
fig. 18
Wire the electrical connections as indicated on the general
wiring diagram on page 44 and practical wiring diagrams on
page 21 & 22).
Fit the heat discharge valve (pos. 1) on the safety coil inlet and
insert its sensor in the relevant bulb holder (pos. 2).
It is advisable to redirect the heat safety valve discharge to the
sewage.
The heat discharge valve can be fitted , indifferently, at the
inlet or outlet of the safety coil, provided the valve sensor is
inserted in it relevant bulb holder.
See also chapter 3.7.
SCARICO
1
2ALIMENTAZIONE
TERMOSTATO DI ESERCIZIO (Te) = WORKING THERMOSTAT
TERMOMETRO = THERMOMETER
TERMOSTATO DI MINIMA (Tsc) = MINIMUM THERMOSTAT
MOLLA DI FISSAGGIO = FIXING CLIP
MOLLA DI CONTATTO = CONTACT SPRING
TERMOSTATO DI MASSIMA (Tmax) = HIGH LIMIT THERMOSTAT
MOLLA DI FISSAGGIO = FIXING CLIP
TERMOSTATO DI SICUREZZA (Ts) = SAFETY THERMOSTAT

20
Instructions for the installer
1
4
5
6
2
3
7
8
10
11
12
13
14
15
9
23
22
1
56
14
15
16
17
24
18
19
20
8
9
10
21
11
12
13
3
4
2
25
7
15
28
26
27
To ensure correct operation of the GASOGEN G3 2S boilers it
is necessary to fit a recirculation pump in order to avoid low
temperature water returns that could jeopardize the boiler’s
life span.
Automatic Heating, to favour her clients, has developed a water
recirculation kit that optimizes the water recirculation within
the boiler.
This kit is supplied separately as an option and is available, on
request, by indicating the appropriate part number .
The pump’s electric connection must be carried out according
to the general wiring diagram shown on page 44 and the
practical wiring diagrams shown on page 21 & 22.
On the optional control panel (code 23557) DUPLO IT
version, the wiring of the electrical connections must be
carried out as shown in the diagrams in 3.11 & 3.12, on
pages 24, 26, 29, 31, 33, 36 and 39.
fig. 19
RECIRCULATION KIT FOR OPERATION WITH HOT WATER
STORAGE TANK (see 3.12 on page 27)
NOTE: For correct control of the storage tank, in addition
to fitting the recirculation kit, foreseen for this purpose,
the optional control panel code 23577 must be fitted.
To ensure correct operation of the GASOGEN G3 2S boilers,
when a storage tank is used, it is indispensable to install
the return sensor (Tr), as shown in the diagrams in figs. 29,
31, 33, 35 and 37.
Automatic Heating has developed a RECIRCULATION KIT FOR
OPERATION WITH A STORAGE TANK.
This kit is supplied separately as an option and can be ordered
by indicating the code of your own boiler.
The return sensor (Tr) has to be inserted in the bulb holder
pos. 26, placed in the boiler C.H. return connection.
Please refer to the control panel’s instruction manual, in 5.5.7
“Return flow sensor installation” for the return sensor’s (Tr)
electrical connection and for any problems connected with it.
Note: The “MAXP” function (heat discharge pump) will be
carried out by the “MKP” pump (central heating pump) (see
5.3 “Loads and sensors connection diagram”); then connect
the jumper 30-38.
On the optional control panel (code 23557)
DUPLO IT version, the wiring of the electrical
connections must be carried out as shown in the
diagrams in 3.11 & 3.12, on pages 24, 26,
29, 31, 33, 36 and 39.
fig. 20
Gasogen