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REV

.03-(16.03.2015)

115
125B
160B

INSTALLATION, USER AND SERVICE MANUAL

WALL HUNG GAS FIRED CONDENSING BOILER

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Summary of Contents for wallcon 115

Page 1: ...REV 03 16 03 2015 115 125B 160B INSTALLATION USER AND SERVICE MANUAL WALL HUNG GAS FIRED CONDENSING BOILER RESET ...

Page 2: ...REV 03 16 03 2015 ...

Page 3: ...General 5 2 1 Des gnated use 5 2 3 5 Bo ler room vent lat on 2 2 Descr pt on of the appl ance 5 3 3 1 3 Safety nstruct ons 4 1 4 Regulat ons and standarts 4 2 4 Packag ng label 6 2 5 6 Warn ng label 2 6 Data label 6 3 1 Wallcon 115 125B 160B d mens ons 7 3 2 8 Wallcon 115 125B 160B hydraul c d agram 3 3 Wallcon 115 125B 160B ma n components 9 3 Techn cal features 7 3 4 Techn cal data 10 4 1 1 Pack...

Page 4: ...romptly not fy Gassero or other author zed qual ﬁed personnel Per od cally check that the condensate dra n s free of blockages Per od cally check that the operat ng pressure of the water c rcu t when cold s 1 5 bar and less than the max mum l m t spec ﬁed for the appl ance If th s s not the case contact w th Gassero or other aut hor zed qual ﬁed personnel If the bo ler s not used for an extended p...

Page 5: ... ch nﬂuence the When t ghten ng or loosen ng the screw connect ons use only adequate tool The mproper use and or the use of nadequate equ pment can cause damages If you smell gas If you smell gas follow these safety nd cat ons Do not turn on or turn off electr cal sw tches Do not smoke Do not use the telephone Close the ma ns gas tap Open all w ndows and doors where the gas leakage Contact the gas...

Page 6: ...hops locat ons where tr cholorethylene or hydrogen hal des e g conta ned n aerosols certa n adhes ves solvents or detergents pa nts and other aggress ve chem cals are used or stored 2 1 DESIGNED TO USE 2 3 BOILER ROOM VENTILATION These nstallat on and ma ntenance nstruct ons apply to General 5 The WALLCON s a wall hung condens ng bo ler for CH and DHW w th DHW tank purposes w th pre m x burner mad...

Page 7: ...outs de the room where the bo ler s nstalled Wallcon bo lers operates as a room sealed appl ance type C Prov de enough clearance to access the safety and control dev ces and to carry out the serv c ng operat ons Check that the ndex of protect on of the bo ler s su table for the character st cs of the room where the appl ance s nstalled If the bo lers operate on gas fuel w th a h gher spec ﬁc we gh...

Page 8: ...Fd Ad CONNECTIONS M System ﬂow 1 1 4 R System return 1 1 4 G Gas supply 1 Fd Flue outlet Ø100 mm Ad A r ntake Ø100 mm Sr Safety dra n Ø25 mm Sc Condensate d scharge Ø25 mm DIMENSIONS 115 W 557 mm L 580 mm H 865 mm 125B W 557 mm L 580 mm H 865 mm 160B W 557 mm L 690 mm H 865 mm WALLCON 115 125B 160B ...

Page 9: ...9 Heat exchanger 10 Flue gas tempertaure sensor 11 Ign t on electrode 12 Man fold 13 Ion zat on electrode 14 Fan 15 Ventur adapter 16 Gas valve 17 Pressure transducer Techn cal features 8 Sc 2 3 4 5 6 7 8 10 11 13 12 9 14 15 16 17 M G R 1 115 125 kW Head Losses 0 50 100 150 200 250 300 350 400 500 1500 2500 3500 4500 5500 6500 Flow rate l h Water pressure losses mbar Flow rate l h Water pressure l...

Page 10: ...sate d scharge 8 System ﬂow 9 Gas supply 10 System return 11 Ventur adapter 12 Ion zat on electrode 13 L m t thermostat 14 A r ntake ﬂex duct 15 Automat c a r vent 16 Flue outlet 17 Flame observat on glass 18 Ign t on electrode 19 Ventur 20 Heat exchanger 21 Ign t on transformer 22 Pressure transducer 23 Safety rel ef valve 24 Fan 25 Gas valve 26 Flue gas temperature sensor 8 9 10 12 18 13 14 17 7...

Page 11: ...g sec 12 70 48 90 7 96 52 61 _ _ Flue Gas Mass G30 g sec 12 20 46 30 7 13 50 14 9 64 65 90 Gas Consupt on G20 m3 h 2 90 11 50 1 77 12 52 2 26 15 61 Gas Consupt on G25 m3 h 3 30 13 40 2 10 14 61 _ _ Gas Consupt on G30 m3 h 0 80 3 40 0 67 4 91 0 89 6 14 Fan Speed G20 rpm 1650 5850 1300 6400 1400 7250 Fan Speed G25 rpm 1650 5850 1300 6400 _ _ Fan Speed G30 rpm 1500 5350 1150 6150 1400 7250 Bo ler Flo...

Page 12: ...nst mpacts Obey the transport symbols and nstruct ons on the packag ng To l ft and carry the bo ler place one hand at the bottom of the bo ler and the other hand on ts top CAUTION Damage to the un t due to t be ng l fted and carr ed ncorrectly Do not hold the bo ler over the control panel to l ft and carry t Place the bo ler n ts packag ng on the handtruck and secure t w th a strap f necessary Car...

Page 13: ... w th the age and cond t on of the system New systems should be ﬂushed thoroughly to regulat ons to remove all traces of ﬂux debr s grease and metal swarf generated dur ng nstallat on Care to be taken w th old systems to ensure any black metall c ron ox de sludge and other corros ve res dues are removed aga n by power ﬂush ng ensur ng that the system s dra ned completely from all low po nts It s m...

Page 14: ... measured w th the RETURN sensor of the bo ler Th s Frost Protect on prov s on s for the bo ler only and not for the all system 4 1 11 DIRT SEPERATION Always nstall a stra ner water ﬁlter and or a d rt separator n the return of the bo ler s such a way that the bo ler water s free of any debr s part cles When us ng a water ﬁlter one should check weekly after nstallat on to determ ne the stra ner cl...

Page 15: ...REV 03 16 03 2015 4 2 BOILER INSTALLATION SYSTEM EXAMPLES 4 2 1 SINGLE BOILER INSTALLATIONS Instruct ons for the nstaller 14 4 1 3 5 7 6 8 10 2 4 3 7 8 9 10 11 12 16 15 14 13 1 1 2 5 6 RESET RESET ...

Page 16: ...perator 8 Expans on vessel 9 Rad ator pump 10 Heat ng system rad ator underﬂoor 11 DHW tank pump 12 DHW tank sensor QAZ36 13 Hot water 14 DHW re c rculat on pump 15 DHW tank expans on vessel 16 DHW tank 17 Cascade supply sensor QAD36 18 Cascade return sensor QAD36 Key A r Intake Fume d scharge 3 2 1 5 6 7 17 18 8 9 10 A r Intake Fume d scharge 3 2 1 5 6 18 13 17 7 9 10 8 11 14 15 12 16 RESET RESET...

Page 17: ...ormat on button t w ll nd cate the modulat on rate on the screen Adjust the rate to 100 for max output sett ng w th us ng of nav gat on button Then press OK Thus bo ler w ll operate n max mum power Instruct ons for the nstaller 16 100 Adjustments must be done by Gassero author zed serv ces A M n mum output adjustment screw B Inlet pressure tap C Max mum output adjustment screw D Burner outlet pres...

Page 18: ... screw A n clockw se d rect on to ncrease the value and n an ant clockw se d rect on n order to decrease the value 3 Check the values at the m n mum and max mum output CO2 Make the requ red adjustments f necessary values CO2 have to be adjusted w th extreme care respect ng the values nd cated n the table When the adjustments have done close sampl ng test po nt n the ﬂue adapter w th the cap Instru...

Page 19: ... the front cover of the bo ler The un t can operate on natural gas or LPG and s factory set for use w th one of these two gases as clearly shown on the pack ng and on the dataplate If a gas d fferent from that for wh ch the un t s arranged has to be used a convers on k t w ll be requ red proceed ng as follows 3 Remove the gas supply p pe from gas valve 4 Remove the a r ntake p pe from ventur 5 Rem...

Page 20: ...to any part of the bu ld ng The ﬂue outlet duct and the term nal of the bo ler MUST NOT be closer than to combust ble mater al It s very mportant to ensure that products of combust on d scharg ng from the term nal cannot re enter the bu ld ng or any other adjacent bu ld ng Through vent lators w ndows doors other sources of natural a r nﬁltrat on or forced vent lat on a r cond t on ng If th s could...

Page 21: ...ll not be nstalled on oppos te walls of the bu ld ng Note The bo ler shall only be nstalled w th a term nal that compl es w th the requ rements of EN 1856 1 see Annex N Only use or g nal GASSERO ﬂue gas d scharg ng systems Flue nstallat ons must be done by author zed person 4 5 2 FLUE INSTALLATION TYPES Flue nstallat ons must be done accord ng to local vent lat on requ rements 20 C43 C83 C53 C13 B...

Page 22: ...00974 Accesory Descr pt on Code 746600975 Accesory Descr pt on Code 746600968 B rd guard Accesory Descr pt on Code 746600977 Accesory Descr pt on Code 746600966 B23 ﬂue k t 1m Accesory Descr pt on Code 746600973 Cascade ﬂue k t Th s ﬂue k t s for two bo ler cascade system For larger cascades please contact your Gassero dealer o 87 coax al elbow o 87 elbow o 45 coax al elbow o 45 elbow Wall rosette...

Page 23: ...e d splay and can be reach by remov ng the front panel of the bo ler and the connector protect on cover For operat on the bo ler needs a power supply of 230VAC 50Hz w th earth Power supply must be removed when you are work ng on the bo ler Electr cal w r ng should be done accord ng to nat onal local or other spec al standards Electr cal works must be done by a qual ﬁed serv ce eng neer that s sk l...

Page 24: ... 23 The correct pos t on ng of the outs de probe s fundamental for the correct operat on of the cl mate control funct on The probe must be nstalled outs de of the bu ld ng be ng heated at a he ght of around 1 2 of the wall fac ng NORTH or NORTH WEST and away from ﬂues doors w ndows and areas exposed to d rect sunl ght Fasten ng the outs de probe to the wall Unscrew the cover on the probe protect o...

Page 25: ...an only be sw tched on or off IMPORTANT INFORMATION To prov de th s funct on follow ng must be observed A room sensor must be connected The Room nﬂuence sett ng must be selected between 1 and 99 No thermostat c rad ator valves should be used n the reference room where the room sensor s located f nstalled such valves must be fully opened and locked n that pos t on The funct on s act vated w th para...

Page 26: ...c operat on Heat ng mode accord ng to the t me program Temperature setpo nts accord ng to heat ng program Reduced setpo nt Protect ve funct ons act ve Automat c summer w nter changeover ECO funct ons Cont nuous operat on or Cont nuous operat on ma nta ns the room temperature Heat ng to the Comfort setpo nt Heat ng to the Reduced setpo nt Character st cs of cont nuous operat on Heat ng mode w th no...

Page 27: ... s act ve unt l the next sw tch ng act on accord ng to the heat ng program occurs automat c operat on D splay ng nformat on The Info button s used to d splay nformat on Certa n nformat on l nes are h dden depend ng on the type of un t un t conﬁgurat on and operat ng state Depend ng on the type of un t conﬁgurat on and operat ng state some of the nfo l nes l sted below may not appear D splays Poss ...

Page 28: ...ett ng the t me of day When press ng the ESC button you go back one step adjusted values w ll not be adopted If any sett ng s made for 8 m nutes the un t w ll automat cally return to the bas c d splay Operat ng l nes may be h dden depend ng on the type of un t the conﬁgurat on and user level operat on D splay example Descr pt on 1 0 4 8 12 16 20 24 AUTO Room temperature You w ll see the bas c d sp...

Page 29: ... 20 Bo ler temperature 1 sensor error 25 Bo ler temperature sol d fuel sensor error 26 Common ﬂow temperature sensor error 28 Flue gas temperature sensor error 30 Flow temperature 1 sensor error 38 Flow temperature pr mary controller sensor error 40 Return temperature 1 sensor error 46 Cascade return temperature sensor error 47 Common return temperature sensor error 50 DHW temperature 1 sensor err...

Page 30: ...3 146 Solar ntegrat on m ss ng 344 146 Solar controll ng element buffer K8 m ss ng 345 146 Solar controll ng element sw mm ng pool K18 m ss ng 346 146 Sol d fuel bo ler pump Q10 m ss ng 347 146 Sol d fuel bo ler comparat ve sensor m ss ng 348 146 Sol d fuel bo ler address error 349 146 Buffer storage tank return valve Y15 m ss ng 350 146 Buffer storage tank address error 351 146 Pr mary controller...

Page 31: ...condensate from the ﬂue gas p p ng Gas l nes connect ons The gas l nes need to be checked for gas leakage Also check f the p p ng s properly mounted and not damaged Un assembl ng the Burner Un assembl ng the burner un t Remove the 6 x M6 nuts and the electrode cables and move the burner un t forward Remove the plug of the fan cable from the fan when the burner has been pulled half way from the hea...

Page 32: ...If so then replace the electrode w th a new one Also change the electrode f any cracks can be seen n the ceram c electrode nsulat on If the electrode s changed the gasket should also be replaced When defects are found that cannot be ﬁxed by the serv ce eng neer he has to nform the end user about the defects and should adv se the end user to have them ﬁxed Th s should also be ment oned on the serv ...

Page 33: ... ons The qual ty of combust on Gas valve Check that 230 V AC s pr esent at the term nals on the gas valve check w r ng and con nect ons Burner gas pressure Delays n gn t on w th pulsat ng operat on of the burner Check adjustment Ign t on electrode Check pos t on ng and cond t on The bo ler becomes d rty n a short t me Check ﬂame colour Check combust on adjustments The burner does not start when re...

Page 34: ...but the central heat ng system s cold Vent the system Pump fault Reset the pump Replace the pump Check the electr cal connect ons of the pump Bo ler controller Thermal overload on the heat generator Check correct operat on Check set temperature Check electr cal w r ng Check pos t on of the sensors REASON SOLUTION PROBLEM Troubleshoot ng 33 System expans on vessel Check efﬁc ency Pressure n heat ng...

Page 35: ...ER SCALE REDUCER BEEN FITTED YES NO WHATTYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE 3 ft hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLETTEMPERA TURE C HOTWATER OUTLETTEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLYCONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTU...

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Page 37: ...AME TELNo CORGI ID CARD SERIALNo COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANYNAME TELNo CORGI ID CARD SERIALNo COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANYNAME TELNo CORGI ID CARD SERIALNo COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANYNAME TELNo CORGI ID CARD SERIALNo COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANYNAME TELNo CORGI ID CARD SERIALNo COMMENTS SI...

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Page 40: ...ul Endüstr ve T caret Serbest Bölges FREE ZONE 4 Sok Parsel 110 34957 Tuzla Istanbul Turkey ﬁrstcontact gassero com T 90 216 394 09 85 www gassero com Gassero reserves the r ght to change spec ﬁcat on w thout pr or not ce Consumers statutory r ghts are not affected ...

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