Wallnofer Walltherm Vajolet User manual

Walltherm®Vajolet V01 walltherm.com 1/64
OPERATING MANUAL:
Instructions for use & maintenance of the
….Walltherm®Vajolet….
.Version 01 .
The first water heating wood gasification boiler stove.
Dear stove-owner,
you have made an excellent choice purchasing the Walltherm®boiler stove for
your living room. Especially in connection with a heat storage tank, it offers you
all the advantages of a radiant heat stove for the living room and furthermore,
an economical heating system for your whole house. Please study this manual, it
explains how the boiler stove works, how you should operate it and how the
Walltherm has to be maintained.
For further information, please contact the manufacturer or any authorized
Walltherm dealer.
Fam. Wallnöfer

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The manual can be used for the following models:
Model:
Kind of fireplace:
Norm:
Performance class:
Walltherm®Vajolet
Boiler stove
EN13240
10 KW
Walltherm®Vajolet Basic
Insert boiler
stove
EN13229
10 KW
Usage:
The Walltherm was developed for an optimal combustion of air-dried, untreated logs, wood
chips and (partly) briquettes.
The Walltherm®must not be used for
burning waste.
Before firing the boiler stove the
heat exchanger has to be water
filled and connected to the heating
system!!
The heater (wood gasification boiler stove) Mod. Walltherm®, invented by the company
Wallnöfer GmbH, complies with the Machine- and Safety Regulations of the European
Union (CPR) and consequent amendments. The boiler stove has been tested by TÜV
Rheinland Energy (GER) and is registered by VKF (Switzerland).
In any case the laws and norms valid in the installation country have to
be respected.
Particular respect the correct chimney situation, the correct hydraulic connection
to the heating system, the standardized supply for the combustion air and the
security distances to flammable parts.
During the planning, we consider to discuss the installation of the Walltherm®
with the regional chimney sweeper to respect all the regional rules, specially
regarding the chimney installation the combustion air and the distances to
flammable material.
!
!

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This operation manual is directed to the owner of the Walltherm®boiler stove, the
tradesman who installs it, the operators, and the service personal.
In any case of doubt or for further information concerning the manual, please contact the
producer or any authorized Walltherm®dealer. Please quote the number of the
paragraph and name the topic in question. You find our contact data on
www.wallnoefer.it
This operating manual is protected by copyright and it (or any part thereof) must not be
printed, copied or reproduced without prior consent of Wallnöfer GmbH.
Technical information, graphics, and specifications included in this manual must not be
published/distributed.

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Index:
1 Introduction
1.a Purpose and contents of the manual
1.b Symbols
1.c Intended use / combustion technique
1.d Delivery of the boiler stove
2 Safety Precautions
2.a Instructions for installers
2.b Instructions for users
2.c Instruction for maintenance personal
3 The Walltherm®Vajolet wood boiler stove
3.a Parts
3.b Delivery contents
3.c Overview of all important components
3.dDimensions Walltherm®
Vajolet & Vajolet Basic
3 e Technical data
3 f Label with serial number
4 Installation
4.a Safety precautions
4.b The chimney system
4.c Distances to flammable and
non-flammable material
and load capacity (floor)
4.d Combustion air
4.e The water connections
Pump unit with mixing valve
Thermal process safeguard valve
Installation scheme
4.f Electrical installation controller WAL03 or
thermostat, grounding
4.g Information for immuring the insert
stove: Walltherm®Vajolet Basic
5 Using the boiler stove
5.a Control
5.b Lighting
5.c Loading wood logs
5.d Adjustment of the exhaust gas
temperature (flue damper system)
5.e Permissible fuels
6 Cleaning
6.a Cleaning the boiler stove
6.b Cleaning the glass (doors)
7 Maintenance
7.a Doors
7.b Seals
7.c Permissible max/min temperatures
7.d Periodical cleaning of the chimney system
and the flue ways of the boiler stove
8 Recognizing errors and taking measures
against faults
9Legal information:
9.a General information
9.b Guarantee
9.c Manufacturer´s liability
9.d Users characteristics
9.e Technical assistance
9.f Spare parts

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1. Introduction
1.a Purpose and contents of the manual
Purpose
The purpose of the manual is to provide the operator with the fundamental knowledge to
allow the user to take the necessary precautions and to have all the human and material
resources required for its correct, safe and lasting use.
Contents
This manual contains all the information necessary for installation, use and maintenance
of the Walltherm®boiler stove. By complying scrupulously with the contents of this
manual, you will ensure a high degree of safety and productivity of the boiler stove.
Do not install or use the boiler stove before you haven’t read and understood the
contents of this manual. In case of doubt at any time, do not hesitate to contact
Wallnöfer GmbH for information.
Wallnöfer GmbH reserves the right to modify the technical and/or functional
specifications and features at any time without prior notice.
When planning the installation of a Walltherm®boiler stove please consult the chimney
sweeper regarding the chimney system, the combustion air channels and the distances to
keep to flammable material.
Keeping and consulting the manual
The manual must be kept in a safe, dry place and be available at all times for
consultation by the user and by those who see to its installation and maintenance.
The manual with its instructions for operation and maintenance is an integral part of the
boiler stove.
Deterioration or loss
If required, ask Wallnöfer GmbH for another copy of the manual.
Update the manual
This manual reflects the state-of-the-art from the serial number 10000.
If the stove is sold, the user must give the manual to the new owner.
1.b Symbols
Important points in this manual are highlighted with the following symbols:
Indication: indications concerning the correct use of the boiler stove and the
responsibilities of those using it.
Attention: a particularly important note is written here.
Danger: Here you are warned of the possibility of bodily harm or material
damages.
!


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1.c Intended use / combustion technique
The Walltherm®is the first wood boiler stove using the gasification technique.
Walltherm is an innovative, technologically advanced boiler stove for heating, burning fuels
like firewood and wood briquettes providing a healthy and safe way of heating.
This boiler stove features the dual primary and secondary combustion system with
positive effects both on efficiency and on emission of “cleaner smoke”.
The Walltherm®placed in the Livingroom heats directly by radiation and all the residual
room through the central heating system (e.g. radiators/floor heating system). In the
storage tank can also be heated up hot domestic water.
The application of the boiler stove and its configurations as described above are the only
ones permissible by the manufacturer. Do not use the boiler stove in disagreement with
the instructions provided.
The described use of the boiler stove is applicable only for stoves in full structural,
mechanical and engineering condition.
The Walltherm, produced by Wallnöfer GmbH, must only be used indoors.
Generally: In a wood burning stove, a correctly burning flame emits the same amount
of carbon dioxide (CO2) as would be emitted through the natural decomposition of the
wood itself.
The quantity of CO2produced by combustion or decomposition of a tree is equal to the
quantity of CO2that the tree would have extracted from the environment, releasing
oxygen into the air whilst utilizing the carbon for growth during its lifetime.
Unlike wood, when fossil fuels are burned –which are not renewable, like coal, diesel oil
or gas –a huge amount of CO2accumulated in the course of millions of years is emitted
into the atmosphere, increasing the green-house effect. Consequently, the use of wood
as fuel maintains the perfect equilibrium of nature because it is a renewable fuel of which
burning is compatible with nature’s life cycle.
The principle of clean combustion is in perfect harmony with these characteristics and
Wallnöfer GmbH always adheres to it when designing their products.
The gasification burning system and its advantages:
Thanks to the gasification burning system of the Walltherm®- boiler stoves the efficiency
achieves over 90% and the emissions are really low.

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Double combustion: What exactly do we mean by clean
double combustion and how does it work? By controlling the
flow of primary air and by adding secondary air, secondary
combustion, or post-combustion, takes places. This is
indicated by a second characteristically clearer and stronger
flame. By adding new oxygen, this flame consumes the
unburned gasses, remarkably improving heat production and
reducing the harmful emission of CO (carbon monoxide)
caused by incomplete combustion. This is a unique feature of
the Walltherm boiler stove for the living room.
1d Delivery of the boiler stove
The boiler stove is delivered accurately packed in cardboard and fixed to a wooden pallet
so it can be handled by elevator trucks and/or other means.
Don`t tilt the wood pallet!!
You will find the following items inside the boiler stove:
-use, installation and maintenance manual;
-cleaning brush for the flue ways
-a thermal process safeguard valve
-a bleeding valve
-a brush for the ashes
-a fire poker
-ash shovel
Attention: the total weight of the boiler stove is around 300 kg (without water
content). The focus of the weight is on the backside of the boiler stove. Pay
attention on this while moving the boiler stove.
Danger of suffocation: Ensure, that any child isn`t playing with the packaging
material!!
Storage in dry environment: The coating curing will be completed only after
the stove was in function (burned) a few times, therefore avoid contact with
humidity during the storage of the stove. (Corrosion preventing)

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2 Safety Precautions
2.a Instructions for installers
comply with the indications given in this manual
check that the flue and air intake are suitable for the type of
installation opted for (12-15 pa draft –max 25 pa)
the electrical connections must not be done using temporary or non-
insulated leads
make sure the electric system’s grounding is effective
always use individual safety devices and other protections means
Danger: Check the loadability of the lifting carriage. The user of the lifting
carriage has the full responsibility for the lifting up.
Check if the static can load the complete weight of the stove including water
content and wood logs …
2.b Instruction for users
Before firing the boiler stove the heat exchanger has to be water filled
and connected to the heating system!!
Since the boiler stove is an appliance that heats, its outer surfaces can get very
hot. For this reason we advise maximum caution when it is working, in particular:
not to touch or go near the glass door as you could get burned;
not to touch the flue and air intake;
not to do any type of cleaning;
not to pull out the ashes;
not to touch the lower glass door;
make sure that children are kept away.
Open the doors only when the exhaust fume flap is open and if the wood logs
are completely burned to ember!!
comply with the indications given in this manual
comply with the instructions and warnings given on the plates on the boiler
stove
these plates are accident prevention devices and as such must be easily and
perfectly legible; if not, it is compulsory to change them by asking the
manufacturer for an original plate
only use fuel that complies with the indications given in the chapter referring to
fuel characteristics
keep strictly to the routine and extraordinary maintenance program
do not use the boiler stove if there is a malfunction, a suspicion of breakage or
unusual noises
do not throw water on the boiler stove when it is lit or to put the fire out
do not clean the boiler stove until the structure and ashes are completely cold
all works must be carried out in maximum safety and calmly.
Only authorized personal are allowed to do the maintenance for the
fittings and electric parts.

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2.c Instruction for maintenance personal
comply with the indications given in this manual
always use individual safety devices and other protection means
before embarking on any maintenance work the boiler stove must be completely cold
even if only one of the safety devices is incorrectly calibrated or not working, the
boiler stove is to be considered “not working”
the electricity must be disconnected before any work is done on switches and
connectors. Make sure all parts of the boiler stove are cold.
Make sure the ashes are completely cold and not burning.
Use the individual protective gear as established by the EEC directive 89/391.
Check that the main line switch is off (if an electrical thermostat is used).
Make sure that the power supply cannot be switched on accidentally. Take the plug
out of the wall socket.
Do not remove or disconnect parts of the water pipes if they are under pressure.
Always use the most appropriate maintenance tools.
Once the maintenance or repair work is finished reinstall all the protections and
reactivate all the safety devices before switching the boiler stove back on.

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3 The Walltherm® Vajolet wood boiler stove
3 a Parts
A) Exhaust fume flap
B) Lever upper door
C) Lever lower door
D) Lever secondary air
E) Lever primary air
F) Adjustment screw flue damper system
G) Chimney
H) Iron cast grids (4 pz)
I) Injector block
J) Air intake (backside and bottom)
K) Water connection
L) Air bleeder, sensor water temp, sensor exhaust gas temp., sensor thermal
process safeguard valve
Lever primary air
A)
G)
B)
C)
D
E)
F)
A) Open = exhaust fume flap open
„Lighting period –produce
ember“
Closed = exhaust fume flap closed
„gasification flame activated"
chimney
Adjustment screw of
flue damper system
Rauchzüge
Chimney connection
Exhaust fume flap
Lever door superior
combustion chamber
Lever secondary air
Lever door inferior
combustion chamber
Lever of cover
(Access primary air)
G)

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H)
Iron cast grids
(2 pz per side)
I)
Injector block
J)
J)
Air intake bottom
K)
Forward flow ¾“
K)
L)
Area for different sensors
and the air bleeder
Cold water inlet
(thermal process
safeguard valve)
Internal parts upper combustion chamber
Return flow ¾“
Air intake backside
Drain
(thermal process safeguard valve)

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Pump unit:
3.b Delivery contents:
You get following items with the boiler stove:
-Use, Installations and maintenance manual;
-Cleaning brush for the flue ways
-Pump unit with thermal mixing valve
-Thermal process safeguard valve
-Manual air bleeder
-Brush for ashes
-Fire poker
-Ash shovel
1Filling and drain valve (optional)*
2Thermometer return flow to boiler stove
3 Thermometer forward flow storage tank
4 Thermometer return flow storage tank
5 High efficiency pump
6 Thermal mixing valve
6a Thermostatic head for adjustments from pos. 1 –7
6b Sensor thermal mixing valve
7 Security pressure valve 3 bar (provided by customer)**
*We recommend the installation of filling and drain valves
between pump unit and boiler stove to clean the water
circuit and to bleed the system with external pump unit.
**A security pressure valve 3 bar has to be installed in the
boiler stoves water circuit.
(1)
(1)
(6b)
(16)
(6a)
(6)
(3)
(19)
(5)
(2)
(4)
forward flow return flow
storage tank
forward flow return flow
boiler
stove
(7)
!

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3.c Overview off all important components

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3.d Dimensions Walltherm®Vajolet and Vajolet Basic
Walltherm®Vajolet:
(boiler stove)
front side backside
left side right side

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top view: bottom:

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Walltherm®Vajolet Basic:
(insert boiler stove)
front side backside
left side right side

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top view: bottom:
3.e Technical data:
Model:
Kind of fireplace:
Norm:
Performance class:
Walltherm®Vajolet
Boiler stove
EN13240
10 KW
Walltherm®Vajolet Basic
Insert boiler
stove
EN13229
10 KW
Technical data for the boiler stoves Walltherm®Vajolet and Vajolet Basic:
Efficiency:
>90%
Nominal heat output:
10 KW
Heat output min/max:
8 - 15 KW
Division of heat output:
up to 80% water heat output
20 % heat output by radiation
Operating pressure max:
2,5 Bar
Weight (without water content):
300 kg
Water content:
approx. 80 lt
Flue gas mass flow:
8,8 g/s
Chimney draught:
12 Pa (max 20 Pa)
Exhaust gas temp. with gasification flame:
130 °C - 170 °C
Exhaust gas temp. lighting period:
Up to 400 °C

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3.f Label with serial number
The label with serial number is attached on the boiler stoves backside.
If you have to order spare parts please send us your serial number.
Label Walltherm®Vajolet Label Walltherm®Vajolet
(boiler stove): (insert boiler stove):
Note the serial number of your boiler stove:
It is recommended to note the serial number because often the backside of the stove isn`t easily
accessible.


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4 Installation
4.a Safety precautions
The responsibility for any work done in the space where the boiler stove is to be installed
is, and remains, the users. The user is also entrusted with carrying out the checks
regarding the proposed installation solutions. Boiler stove assembly and dismantling
instructions are for specialized technicians only. It is always advisable for the user to call
our assistance service when they need qualified technicians. If other technicians are
called in, please make sure they are truly qualified.
Before the assembler starts either assembling or dismantling the boiler stove, he must
comply with the following safety precautions:
a) he must not work in adverse conditions;
b) he must be in perfect psychophysical condition to work and ensure that the
individual and personal accident prevention devices are complete, functional and in
perfect working order;
c) he must wear accident prevention gloves;
d) he must wear accident prevention footwear;
e) he must use electrically insulated tools;
f) he must make sure that the load-bearing capacity of the area he is working in for
assembling/dismantling the boiler stove is adequate referring to the boiler stove’s
weight.

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4.b The chimney system
After having found an appropriate place for installing the stove, please try to install the
exhaust pipe, while taking into consideration paragraph 4.c.
For the smoke outlet use rigid, varnished steel pipes (min. 1,5 mm) or high-grade
stainless steel pipes (min. 0,5 mm) with 15 cm diameter including sealing.
The vertical chimney with ca. 6 m has to be insulated with min. 20 mm.
The single wall smoke pipes should have an inspection
opening.
The covers on the upper part of the stove for flue ways
and exhaust fume flap have to be accessible for
maintenance.
Attention: For a correctly working
drought, the pipe has to exit the stove
vertically for at least 0,3 - 0,5 m before
having the first angle.
If possible, the pipe then should enter the
chimney by using a 45° angle (better drought
than with 90°).
The diameter of the chimney should be around 150
mm (do not use a very big chimney because of the
low exhaust gas temperature) 6 m vertical chimney
would be the best length.
The material of the chimney can be stainless steel or
ceramic with insulation.
Info: A chimney out of stainless steel reduces the
time of the lighting phase.
It is very important to insulate the chimney pipe with suitable materials (rock wool) or
to use double insulated steel pipes. If the chimney is not isolated, the Walltherm will most
probably not work!
If horizontal smoke pipes are necessary maintain an inclination of min. 10° and contact Fa.
Wallnöfer.
The chimney tube is inserted into the muff of the Walltherm
stove (see picture). The gap between the chimney pipe and the
stove muff needs a sealing.
Dimensions chimney connection: internal Ø 150 mm,
external Ø 154 mm
!
Fig. 4.b