Mark GSW+ 30 User manual

Technical manual EN
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
2

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.
3

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.
4

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.
5

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
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.
6

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 30
102 40
50
101 70
100
99
98
5 10 15 20 25 30 35 40 45 50 55 60 65 70
Power
(kW)
7
1
2
3
4
5
6
789101112
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18

2.4 Dimensions
AB C E FGIJK L M NP
(Air)
Q
(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)
8
C
B
A
Q
P
E
F
G
J
N
M
I
L
K

9
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

10
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.
11
Position 1 Position 2

12
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

13
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.
5
3
2
4
1
1
2
3
4
5
5
1
3
4
2

14
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
3
1
2
1
2
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.
3
1
2
3
1
3

15
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.
1
2
3
4
5
1
5
3
2
4
6

16
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
No
delivery
Filler
Acidwater
Neutralization kit
Neutralized
condensate

17
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
B
C
1
2
3
4
5
A
B
C
1
2
3
4
5

18
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+.

19
Connection diagram
Condensing air heater
 Maintenanceswitch230Vac
Comtherm
Room sensor
C
A
B
D
A
B
C
D

20
Supply Comtherm (Connector JP 18)
RS 485 Bus connector