gassero ALUBOX X-treme Series User manual

50 70 90 115 125 150
ALUBOX
X-treme
ALUBOX X-treme 350
ALUBOX X-treme 430
ALUBOX X-treme 535
ALUBOX X-treme 640
ALUBOX X-treme 700LX
ALUBOX X-treme 710
INSTALLATION AND USER MANUAL
FLOOR STANDING CONDENSING BOILERS
EN

CONTENTS
1 Meanings of the Symbols and Safety 2
1.1 Meanings of the Symbols 2
1.2 General Warnings 2
1.3 Safety Instructions 2
1.4 Standards and Regulations 3
2 General 3
2.1 Purpose of Design 4
2.2 Introduction of the Product 4
2.3 Boiler Room and Ventilation 5
2.4 Warning Label 6
2.5 Packaging Label 6
2.6 Information Label 6
3 Technical Specifications 7
3.1 ALUBOX X-treme Dimensions 7
3.2 Contents 7
3.3 Technical Table 14
4 Installation Introductions 14
4.1 Installation 14
4.1.1 Packaging 14
4.1.2 Carrying 15
4.1.3 Mounting 15
4.1.4 Water Quality and Treatments 16
4.2 Hydraulic Connections 17
4.2.1 Expansion Tank 17
4.2.2 Safety Valve 17
4.2.3 Condensation Water Drain 17
4.2.4 Hydraulic Separator 18
4.2.5 Plate Heat Exchanger 18
4.2.6 Automatic Air Relief Valve 18
4.2.7 Deposit and Dirt Separator 19
4.2.8 Air Inlet Filter 19
4.2.9 Pump 19
4.3 Flue Connections 20
4.3.1 Flue Types 21
4.4 Electrical Connections 21
4.4.1 Wiring Diagram 22
4.4.2 Outdoor Temperature Sensor 27
5 Installation Examples 28
6 Operation 31
6.1 General 31
6.2 Display and Buttons 31
6.3 Operating Mode Selection 33
6.4 Programming 34
6.5 Main Functions 35
6.6 BMS – Boiler 0-10V Management 36
7 Parameters 37
7.1 End User Parameters 37
8 Error / Fault Codes 38
9 Cascade 38
10 Combustion Adjustments 39
10.1 Emission Setpoints 39
10.2 Nominal Load Emission Settings 40
10.3 Minimum Load Emission Settings 40
10.4Gas Pressure Switch 41
11 Maintenance 41
11.1 Maintenance Process 41
12 Energy Saving Recommendations 43
13 Disposal 43
14 Product Fiche 44
15 Troubleshooting 45
16 Boiler Room Application Recommendations 46
IMPORTANT
PLEASE READ INSTRUCTIONS BELOW CAREFULLY BEFORE THE INSTALLATION AND USAGE
1. THIS MANUAL IS AN INSEPARABLE PART OF THE BOILER AND HAS TO BE STORED TOGETHER WITH THE
BOILER. IF THIS MANUAL DAMAGED OR LOST CONTACT GASSERO FOR A NEW COPY.
2. THE INFORMATION AND INSTRUCTIONS THAT ARE SPECIFIED IN THIS USER'S MANUAL APPLY ONLY FOR THE
BOILER MODELS SPECIFIED IN PAGE 3.
3. THE INSTALLATION OF THIS BOILER MUST BE MADE IN ACCORDANCE WITH THE CE DIRECTIVES AND THE
LOCAL GAS ORGANIZATIONS’ INSTRUCTIONS BY AUTHORIZED SERVICES.
4. SPECIFIED GAS MUST BE SUPPLIED BY AUTHORIZED GAS ORGANIZATIONS BEFORE THE COMMISSIONING OF
THE BOILER.
5. COMMISSIONING OFTHE BOILER MUST BE MADE BY GASSERO’S AUTHORIZED SERVICES. OTHERWISE
BOILER WARRANTY WILL BE CANCELLED.
6. THE MANUFACTURER IS NOT THE RESPONSIBLE OF THE DAMAGE DUE TO WRONG OR IMPROPER
INSTALLATION OF THE BOILER.
7. SOME PARTS OF THE PURCHASED BOILER COULD BE DIFFERENT THAN SHOWN BOILER PARTS IN THIS
MANUAL.
8. MANUFACTURER(GASSERO) RESERVES THE RIGHT TO CHANGE THIS USER'S GUIDE WITHOUT NOTICE.
9. LIFE TIME OF THE BOILER IS 10 YEARS IF ALL OF THE INSTRUCTIONS FOLLOWED ACCORDING TO THIS USER
MANUAL.
10. BOILER MAINTENANCE MUST BE MADE AT LEAST ONCE IN A YEAR.
1

1. MEANINGS OF THE SYMBOLS AND SAFETY
1.1 MEANINGS OF THE SYMBOLS
The symbols which are used in this document and their
meanings are as follows:
WARNING:Danger of material damage or damage to
the environment.
ELECTRICAL HAZARD: Danger of death or serious
injury due to electric shock.
DANGER : Actions that are certainly not to be done.
Material damage and severe personal damage may
occur.
Refers to the Information / Recommendations to be
considered by the user
1.2 GENERAL WARNINGS
Your boiler must be used in accordance with the
instructions and purposes specified in the user
manual. The manufacturer cannot be held liable for
damage to the people, animals and property due to
improper installation, subsequent repairs and
modifications.
Boiler may not be used by persons with inadequate
physical, mental and perceptual capacity and
without experience and knowledge.
1.3 SAFETY INSTRUCTIONS
IF GAS SMELLS:
Do not open or close the power switches, do not
touch the plugs or sockets.
Do not smoke
Do not use your phone
Close the gas valve immediately
Ventilate the space by opening the doors and
windows.
Notify everyone in the building.
Call the emergency service of the gas distribution
company you are connected to. Do not allow
anyone to enter the boiler room until the
emergency service arrives.
If there is a sealing due to gas leakage, do not
disassemble the seal, contact the gas distribution
company to disassemble the seal after necessary
repair.
The smell of the waste gas formed after burning
with natural gas may resemble each other. Never
use the boiler in the event of a leak in the waste
gas system.
2

IF WATER LEAKAGE OCCURS IN THE BOILER:
Switch offthe electrical and water connections of
the boiler and notify the authorized service.
Condensation water formed after combustion is
corrosive and corrosive. In case of leakage or
leakage of this water, inform the authorized service.
IF ELECTRICAL LEAK OCCURS IN THE BOILER:
Never touch the boiler.
Lower the main switch on the board and notify the
authorized service.
Do not touch the pipes or the chimneys. (there may
be a ground fault)
Do not cut, pull, or bend the cables even if the
switch is lowered and the power cut off.
DON’T TOUCH THE BOILER WHEN YOUR HANDS
ARE WET OR STEPPING ON A WET AREA.
1.4 STANDARTS AND REGULATIONS
This boiler is manufactured in accordance with the following
directives and standards:
EN 15502-1+A1
EN 15502-2-1+A1
Directives :
(EU) 2016/426 Gas Appliances Regulation (GAR)
2014/30/EU Electromagnetic Compatibility (EMC)
2014/35/EU Low Voltage Directive (LVD) 92/42/EEC
Boiler Efficiency
These installation and maintenance instructions are prepared for
the Floor Standing condensing boilers specified below:
ALUBOX X-treme 350
ALUBOX X-treme 430
ALUBOX X-treme 535
ALUBOX X-treme 640
ALUBOX X-treme 700 LX
ALUBOX X-treme 710
CE LABEL:
This boiler complies with the essential requirements of the
relevant European directives. The CE marking certifies that the
products meet the essential requirements of the applicable
regulations in accordance with the type of label. Manufacturer can
be consulted for the declaration of conformity.
3

Gassero ALUBOX X-treme Floor Standing Condensing Boilers
with Premix Burners are designed for heating purposes only. For
hot water use, the boiler must also be connected to the DHW
tank. Boiler can be used with in a cascade system or stand alone.
Maximum 16 boilers can work together in cascade systems. Multi-
purpose heating values can be achieved with cascade systems.
Examples of stand alone and cascade systems are shown in the
SAMPLE INSTALLATION DIAGRAMS section.
For cascade systems, special cascade accessories such as
mounting frame, horizontal flue elements, connection pipes
between the boilers, main gas pipe and hydraulic mixer (balance
vessel) have been developed. Such accessories make the
cascade system easier to install with less effort. For more detailed
information on cascade systems, please contact your dealer or
manufacturer.
WARRANTY PERIOD AND LIFE TIME:
Warranty is 2 years from the date of invoice.
Service life of the boiler is 10 years (this period can be change
according to the installation, water quality and other environmental
conditions).
CONSUMER RIGHTS:
Consumers can apply for complaints and appeals to consumer
courts and consumer arbitration committees.
In case of defective goods;
a) Withdraw from the contract by stating that it is ready to return
the product;
b) If all costs incurred do not incur excessive costs,
to request free repair of the product,
c) Requesting the replacement of the product with a non-defective
product,
One of the rights can be used.
2.1 PURPOSE OF DESIGN
This boiler is not suitable for commercial or
industrial purposes. The manufacturer cannot be
held responsible for the problems caused by the
usege except of the design purpose.
2.2 INTRODUCTION OF THE PRODUCT
ALUBOX X-treme is a modulating floor standing boiler which has
a AL-Mg-Si casting exchanger with a premix burner and designed
for central heating and DHW (optional) applications.
BASIC FEATURES OF ALUBOX X-treme BOILERS:
% 108 boiler efficiency through premix burner (See the
technical table)
1/5 turndown ratio and NOx 6 emission class for ALUBOX X-
treme 350-460-535-710
1/8 turndown ratio and NOx 6 emission class for ALUBOX X-
treme 640
1/6 turndown ratio and NOx 6 emission class for ALUBOX X-
treme 700 LX
4
2 GENERAL

Through intelligent electronic control panel, it has 13 safety
systems and 3 separate zone control options
Room thermostat and outside temperature sensor provide
comfortable economic heating
Besides the ease of operation via smart digital panel, it
provides fault and error detection
Web server provides remote control of the boiler
Solar systems and pool temperature can be operated on the
same control panel
ALUBOX X-treme MODEL BOILERS ARE DESIGNED
TO WORK ONLY WITH NATURAL GAS.
They cannot be used with LPG.
2.3 BOILER ROOM AND VENTILATION
This boiler provides IPX4D electrical protection class. Check
that the place where the boiler is located complies with this
protection class.
Boilers must be placed 200 mm away from flammable
materials with flammability class B, C1, C2.
Boilers must be placed 400 mm away from the easily
flammable materials of the C3 class which can be ignited by
themselves or by ignition sources..
Never switch off the power supply of the boiler when the air
temperature falls below 0°C against the risk of freezing. Read
the FROST PROTECTION section.
ALUBOX X-treme condensing boilers must be installed in
spaces that have the necessary ventilation openings according
to current standards and applicable regulations
Do not modify the ventilation openings, ventilation ducts,
ventilation vents and do not block them after the
commissioning.
Never use the boiler in places where excessive amounts of
dust are stored, where barber shops, corrosive, explosive
chemicals are stored or used.
If the boiler receives the combustion air from the environment,
there should not be any low pressure due to other systems /
boilers in the boiler room.
The boiler must be installed in accordance with the electrical
voltages, gas and water pressures specified in the technical
table.
Grounding of the electrical line is mandatory.
Never switch off the mains when the boiler is in operation.
Such behavior may cause abnormal heat build-up and damage
the heat exchanger and other units of the system.
5

A B C D E F G H I
350 351,7 360 65,0 335,0 63,7 328,3 70,2 351,7
430 445,9 450 85,0 425,0 82,5 416,0 91,6 445,9
535 540,6 670 102,0 510,0 99,9 489,9 107,1 540,6
640 641,4 900 75,0 615,0 73,8 601,4 81,0 641,4
700 LX 702,0 942 118,4 672,4 111,9 650,4 127,6 702,0
710 711,3 880 134,6 685,6 129,6 669,2 145,9 711,3
2.4 WARNING LABEL
WARNINGS !
Read the technical instructions and
user manual carefully before the
commissioning.
Commissioning must be made by
an authorized Gassero service.
The boiler must be located in a
location that is separate from the
living quarters and only in
accordance with the ventilation
legislation.
2.5 PACKAGING LABEL
2.6 INFORMATION LABEL
6

ALUBOX X-treme 350 – 430 – 535 – 640 – 710
ALUBOX
X-TREME 350
ALUBOX
X-TREME 430
ALUBOX
X-TREME 535
ALUBOX
X-TREME 640
ALUBOX
X-TREME 700 LX
ALUBOX
X-TREME 710
A 835mm 935mm 935mm 935mm 935mm 935mm
B 1220mm 1705mm 1705mm 1705mm 1745mm 1705mm
C 1600mm 1600mm 1600mm 1600mm 1600mm 1600mm
D DN50(PN16) DN65(PN16) DN65(PN16) DN65(PN16) DN65(PN16) DN65(PN16)
D1 248mm 350mm 542mm 443mm 338mm 348mm
D2 106mm 106mm 106mm 106mm 106mm 106mm
E DN100(PN6) DN100(PN6) DN100(PN6) DN100(PN6) DN125(PN6) DN100(PN6)
E1 1340mm 1340mm 1340mm 1340mm 1360mm 1340mm
E2 235mm 300mm 300mm 300mm 263mm 300mm
F DN100(PN6) DN100(PN6) DN100(PN6) DN100(PN6) DN125(PN6) DN100(PN6)
F1 664mm 664mm 664mm 664mm 647mm 664mm
F2 88mm 115mm 115mm 115mm 65mm 115mm
G Ø250mm Ø250mm Ø250mm Ø250mm Ø250mm Ø250mm
G1 511mm 511mm 511mm 511mm 511mm 511mm
G2 364mm 394mm 394mm 394mm 394mm 394mm
H Ø200 Ø200 Ø200 Ø200 Ø200 Ø200
J Ø25mm Ø25mm Ø25mm Ø25mm Ø25mm Ø25mm
3 TECHNICAL SPECIFICATIONS
3.1 ALUBOX X-treme DIMENSIONS
7

3.2 CONTENTS
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. İonization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Thermostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Outlet Connection
17. Water Inlet Connection
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Drain Hose
24. Air Pressure Switch
ALUBOX X-treme 350
8

ALUBOX X-treme 430
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. İonization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Thermostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Outlet Connection
17. Water Inlet Connection
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Drain Hose
24. Air Pressure Switch
9

ALUBOX X-treme 535
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. İonization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Thermostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Outlet Connection
17. Water Inlet Connection
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Drain Hose
24. Air Pressure Switch
10

ALUBOX X-treme 640
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. İonization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Thermostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Outlet Connection
17. Water Inlet Connection
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Drain Hose
24. Air Pressure Switch
11

ALUBOX X-treme 700 LX
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. İonization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Thermostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Outlet Connection
17. Water Inlet Connection
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Drain Hose
24. Air Pressure Switch
12

ALUBOX X-treme 710
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. İonization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Thermostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Outlet Connection
17. Water Inlet Connection
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Drain Hose
24. Air Pressure Switch
13

3.3 TECHNICAL TABLE
min max min max min max min max min max min max
Compatible Chimney Types: Type
Nominal Heat Input Qn kw
65,00 335,00 85,00 425,00 102,00 510,00 75,00 615,00 118,4 672,4 134,6 685,6
Nominal Heat Power Pn (80-60⁰C) kw
63,70 328,30 82,50 416,00 99,90 499,80 73,80 601,40 111,9 650,4 129,6 669,2
Nominal Heat Power Pn (50-30⁰C) kw
70,20 351,70 91,60 445,90 107,10 540,60 81,00 641,40 127,6 702,0 145,9 711,3
Working Pressure bar
0,8 60,8 60,8 60,8 60,8 60,8 6
Maximum Working Temparature ˚C
Limit Temperature ˚C
Heating Efficiency (80-60⁰C) %
96,26 98,04 96,75 97,94 97,11 98,23 96,98 97,91 96,38 97,04 95,72 97,77
Heating Efficiency (50-30⁰C) %
107,06 106,21 107,96 105,03 107,64 106,11 107,47 106,42 108,12 104,82 108,69 104,1
Partial Load, Return 30°C (Direct Method) %
Flue Gas Temperature (80-60) oC ˚C
57,8 68,7 59 69 57,7 69,5 58,1 67,9 60,2 73,5 60 70
Flue Gas Temperature (50-30) oC ˚C
30,7 45,4 31,2 46,1 29,7 47,6 31 44,9 31,6 48,3 31,3 43
CO2 Emissions (G20) %
9,11 9,16 9,16 9,15 8,69 8,91 8,83 9,13 8,91 9,09 8,95 9,07
Modulation Ratio
1: 6
NOx Class Class
NOx Value mg/kWh
Flue Gas Mass g/sec
31 154 40 201 47 238 39 271 54 308 63 314
Water Flow (80/60˚C) m³/h
2865 14653 3541 18238 4219 21752 3,44 26,251 4,86 28,55 6,65 30,43
Water Flow (50/30˚C) m³/h
3,052 15,2 3,941 19,286 5,281 23,454 3,935 28,389 5,54 30,31 6,6 30,5
Hydraulic Loss kPa
Gas flow (80-60⁰C) m³/h
6,93 35,23 8,84 44,6 10,75 53,47 8,45 64,52 12,09 69,82 13,99 71,78
Gas flow (50/30⁰C) m³/h
6,89 34,6 8,76 44,35 11,63 53,91 8,69 64,13 12,34 70,05 14,02 71,43
Maximum Gas Supply Pressure G20 mBar
Minimum Gas Supply Pressure G20 mBar
Flue Pressure Pa
Flue Gas Pipe Diameter mm
Net Weight kg
B23-C43-C53-C63-C83
ALUBOX X-treme
710
95
95
95
90
90
90
90
90
95
95
ALUBOX X-treme
700 LX
90
95
ALUBOX X-treme
350
ALUBOX X-treme
430
ALUBOX X-treme
535
ALUBOX X-treme
640
1:5
1:5
1:5
1:5
1:8
107,52
107,56
107,38
107,55
108,53
108,76
6
6
6
6
6
6
25
19
24,02
24,8
24,284
33
34
39
21
16
25,00
22,72
21
21
21
21
21
21
17
17
17
17
17
17
60
71
78
195
220
220
Ø250
Ø250
Ø250
Ø250
Ø250
Ø250
305
381
425
452
510
525
4 INSTALLATION INTRODUCTIONS
4.1 INSTALLATION
4.1.1 PACKAGING
ALUBOX X-treme boilers are shipped on pallets as they are
completely assembled, tested and protected against damage
by wooden frame and nylon.
PACKAGE INCLUDED :
•User manual / Warranty certificate
•Outdoor sensor
•Immersion type temperature sensor
•DHW sensor (optional)
•Air inlet filter (optional)
At any stage should not put anything else on the
boiler, stacking should not be done.
When the boiler is unpacked, check the contents of
the package, contact the dealer if there is any
damage or missing components.
14

4.1.3 MOUNTING
MINIMUM DISTANCES:
Gaps required for the installation, service and maintenance
are indicated left side.
•The installation and chimney pipes must be connected in
such a way that they do not interfere with the service and
maintenance operations.
•If the chimney connections are at the top of the boiler,
the detachability of the boilers’ top covers should be
checked.
•The gas regulator must be installed at least 1 meter away
from the boiler.
4.1.2 CARRYING
The boiler can be moved with a fork-lift or pallet truck as
shown. In such transports, the boiler must be properly fixed
and secured.
The boiler must not be shaken or laid on its side during
transport.
The boiler can also be moved on its own wheels after
being lowered.
The wheels must always be secured and fixed when the
transport is finished.
During the transportation, safety rules must be
followed, and care must be taken against injuries
and crushing.
The manufacturer cannot be held liable for damage
to people, animals or property due to transportation
faults.
In order to protect the boiler from water, it is
recommended to place the boiler on a base with 10cm
high and suitable width for the boiler.
50mm
500 mm 700 mm
500 mm
15

4.1.4 WATER QUALITY AND TREATMENTS
Paying attention to the following issues related to water quality will
greatly reduce the problems that may arise during the life time of
the boiler and ensure the continuity of the working efficiency:
Piping and installation components must be cleaned before
installation.
In old installations, iron oxide, sludge, sediment and similar
deposits should be cleaned.
The water in the system should be analyzed in terms of
hardness, pH, iron content and conductivity.
If all or a part of the heating installation is to be
operated by UNDERFLOOR HEATING SYSTEM,
PLATE HEAT EXCHANGER should be used and the
system should be separated from each other as
primary and secondary.
Faults that may arise if the water conditions are not
in accordance with the values specified in the table,
boiler will be considered out of warranty.
Total Hardness
°d
pH
Iron
(Not Diluted)
Conductivity
STAINLESS EXCHANGER
1,00 7,5-9,5 <10ppm
≤2000µS/cm
ALUMINUM EXCHANGER
1,00 6,5-8,5 <10ppm
≤2000µS/cm
Gassero Water Specification
DYNAMIC AND CHEMICAL WASHING / FLUSHING:
In the newly established systems, to aviod the possible
substances in the installation (metal shavings, some oils, residues
of construction wastes etc.) flushing treatment is a mandatory.
Likewise, it is a mandatory to apply the flushing treatment without
water given to the boiler in conversion of older systems.
The methods of washing / flushing are described in detail in the
manual GASSERO DYNAMIC AND CHEMICAL WASHING /
FLUSHING.
Neutral-based, non-acidic, non-alkaline registered products can be
used to clean the installation or keep the water conditions at
desired levels. You can get information from GASSERO for
cleaner, preservative or inhibitor type (stopper, preventive)
products or you can contact with SENTINEL or FERNOX
companies.
16

4.2 HYDRAULIC CONNECTIONS
According to the current legislation; total heating capacity of the
boiler or cascade system must be calculated to meet the building's
heat demand. All necessary components must be installed and
supplied correctly in the installation in a manner to perform their
duty. Protective and safety devices must be used in the heating
system as described in the current legislation.
In order to separate the boiler from the installation, two
ball valves should be placed on the supply and the
return lines.
4.2.1 EXPANSION TANK
ALUBOX X-treme boilers do not have an expansion tank. So the
capacity of the expansion tank should be selected according to the
capacity of the heating system and the static pressure.
It is recommended to place the expansion tank on the
turn of the central heating system.
4.2.2 SAFETY VALVE
ALUBOX X-treme boilers are equipped with a safety valve. The
hose of this safety valve must be connected to a drain.
Manufacturer cannot be held liable for damages caused by water
flow into the boiler or on the ground when excessive pressure is
generated in the heating installation.
Safety valve must not be used as a means of
draining water from the system.
Draining water of the safety valve can be very hot.
Beware of scalding.
4.2.3 CONDENSATION WATER DRAIN
Condensation water which is generated during to the combustion,
transfers to the water drain connection by the syphon and drain
hose.
Condensation water is acidic and corrosive (approx. 2 ph). So all
of the connections which are made for condensation water must be
made with PP type pipes. Condensation water must be transferred
to the drain with the shortest way possible. For health and
environmental reasons it mustn’t transfer such places near people,
animals and plants.
Condensation water must not be connected to rain drain
systems.
The condensate drain line must have a slope of at least 3%.
A neutralization tank should be used for condensate water
occurring in systems with a total power of 200 kW and above.
It is mandatory to comply with the relevant local regulations for
the discharge of condensate water.
Syphon Sensor
17

4.2.4 HYDRAULIC SEPARATOR
These are used to compensate the pressure differences in systems
where multiple pumps and / or heating circuits are used, to eliminate
excessive pressure differences between boiler’s inlet and outlet
water temperatures and to prevent thermal stresses in the boiler.
Dimensions, input and output distances should be selected
correctly.
Via a sensor to be placed on it, the general temperature of the
system is determined by the hydraulic separator.
There must be an automatic air relief valve on the hydraulic
separator.
In case the water in the system is dirty, chalky or
corrosive, plate heat exchanger should be used
instead of balance container.
4.2.5 PLATE HEAT EXCHANGER
Plate heat exchangers are hydraulic equipments that separates the
boiler and the installation (primary and secondary zones). Unlike the
hydraulic separator circulating water in the plate heat exchanger
never interfere with the water goes through the boiler and the water
goes through the installation. Only heat transfer occurs here.
Preferred for many purposes;
If the water in the system is very dirty, chalky or corrosive,
If the working pressure of the system exceeds the working
pressure of the boiler,
If a part or all of the system is required to operate with lower
temperature values. (eg. underfloor heating systems)
The plate heat exchanger must be used in the
following cases and the system must be separated
into primary and secondary.
-Heating systems which are consist of partly of fully
floor heating,
-Used, older systems,
-Systems that are dirty, corrosive, bacterial and
calcareous water.
Periodic inspection and maintenance of the plate
heat exchanger is highly important for the efficiency
of the system.
4.2.6 AUTOMATIC AIR RELIEF VALVE
ALUBOX X-treme boilers have an automatic relief valve for the
evacuation of the air accumulated in the heat exchanger. However,
for the evacuation of the air that may occur in the installation, it is
necessary to place one or more automatic air relief valves in the
appropriate places of the installation. Local regulations must be
followed in this regard.
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4.2.7 DEPOSIT AND DIRT SEPARATOR
To remove the dirt and particles form the water, a strainer or
deposit and dirt separator must be placed on the return line of the
boiler.
When the dirt, particles and similar deposits in the system
water are not cleaned;
The efficiency of the system decreases,
Installation equipments (pumps, valves, plate heat exchanger,
etc.) may be damaged due to overheating
A boiler damage may occur due to heat exchanger clogging.
Manufacturer cannot be held liable for damages that may
occur in such cases.
Strainers or deposit and dirt sepertors on the
system should be checked frequently and cleaned if
necessary.
4.2.8 AIR INLET FILTER (OPTIONAL)
If ALUBOX X-treme boilers will be used in to a dirty air
environment, they must be supported with the air inlet filters. This
optional filter must be checked regularly.
When the air inlet filter becomes dirty;
Emission values would be deteriorated and efficient
combustion wouldn’t be achieved.
The accumulation of soot occurs in the heat exchanger.
Loud ignition and combustion occurs.
Overheating, leakage and deformation would be observed in
the flue system.
Manufacturer cannot be held liable for damages
caused by dirty combustion air.
Don’t block the air filter partially or totally.
4.2.9 PUMP
Pumps aren’t included in ALUBOX X-treme model boilers. The
primary pumps, which are determined according to the hydraulic
pressure losses of the boiler, are offered by Gassero as an option.
If a different primary pump is to be used, pump must be selected
in accordance with the values given in the table on the below.
min max
mwc
ALUBOX X-TREME 350 3,052 15,2 5
ALUBOX X-TREME 430 3,941 19,286 6
ALUBOX X-TREME 535 5,281 23,454 6
ALUBOX X-TREME 640 3,935 28,389 6
ALUBOX X-TREMELX 700 5,54 30,31 5
ALUBOX X-TREME 710 6,65 30,43 6
WATER FLOW
(m3/h)
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