gassero Wallcon X-treme 115 Installation And User Manual Download

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INSTALLATION AND USER

MANUAL

115

125

150

WALL HUNG

CONDENSING BOILERS

-treme

Summary of Contents for Wallcon X-treme 115

Page 1: ...INSTALLATION AND USER MANUAL 115 125 150 WALL HUNG CONDENSING BOILERS X treme EN ...

Page 2: ...nstallation Introductions 12 4 1 Installation 12 4 1 1 Packaging 12 4 1 2 Carrying 13 4 1 3 Mounting 13 4 1 4 Water Quality and Treatments 14 4 2 Hydraulic Connections 15 4 2 1 Expansion Tank 16 4 2 2 Safety Valve 16 4 2 3 Condensate Water Drain 16 4 2 4 Hydraulic Seperator 17 4 2 5 Plate Heat Exchanger 17 4 2 6 Automatic Air Relief Valve 18 4 2 7 Deposit and Dirt Seperator 18 4 2 8 Air Inlet Filt...

Page 3: ...OILER 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 2 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 ...

Page 4: ...gs 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 INSTR...

Page 5: ...t is heavier than air Sweep the gas accumulated near the ground to the outside IF WATER LEAKAGE ACCOURS IN THE BOILER Switch off the 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 ACCOURS IN THE BOILER N...

Page 6: ...specified below Wallcon X treme 115 Wallcon X treme 125 Wallcon X treme 150 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 WARRANTY PERIOD AND ...

Page 7: ...Maximum 16 boilers can work together in cascade systems Multi purpose heating values can be achieved with cascade systems For example 16 units of 150 kW boiler can reach 2400 kW heating power with cascade system 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 ele...

Page 8: ... server provides remote control of the boiler Solar systems and pool temparature can be operated on the same control panel 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 ...

Page 9: ...bove from the floor 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 2 4 WARNING LABEL WARNINGS Read the tec...

Page 10: ...5 PACKAGING LABEL 2 6 INFORMATION LABEL A B C D E F G H I 115 115 5 350 27 108 5 26 1 105 4 29 5 115 5 125 126 360 17 121 16 6 116 2 18 4 126 150 150 460 21 143 19 5 138 22 7 150 WALLCON X treme 115 125 150 ...

Page 11: ...57mm 557mm B 580mm 580mm 580mm C 865mm 865mm 865mm D 1 1 1 D1 SIT 398mm 398mm 444mm D1 EBM 192mm 192mm 269mm D2 SIT 197mm 197mm 197mm D2 EBM 217mm 217mm 217mm E 1 1 4 1 1 4 1 1 4 E1 130mm 130mm 157mm E2 82mm 82mm 103mm F 1 1 4 1 1 4 1 1 4 F1 130mm 130mm 157mm F2 130mm 130mm 195mm G Ø100mm Ø100mm Ø100mm G1 112mm 112mm 112mm G2 330mm 330mm 330mm H Ø110 Ø110 Ø110 J Ø25mm Ø25mm Ø25mm ...

Page 12: ...Venturi EBM 21 Syphon Sensor 22 Air Gas Mix Pipe 23 Pressure Safety Valve 24 Drain Hose 25 Over Heat Sensor For Heat Exchanger 26 Circulation Pump 27 Air Pressure Switch 1 Fan SIT 2 Gas Valve SIT 3 Control Panel 4 Hat Exchanger 5 Ionization Electrode 6 Ignıtion Elektrode 7 Ignıtion Transformer 8 Limıt Thermostat 9 Pressure Sensor 10 Flow NTC Sensor 11 Return NTC sensor 12 Automatic Air Vent 13 The...

Page 13: ...RATURE C LIMIT TEMPARATURE C EFFICIENCY 80 60 C 97 31 97 26 95 27 97 09 96 49 97 01 EFFICIENCY 50 30 C 107 19 106 53 106 11 106 19 106 49 105 30 PARTIAL LOAD EFFICIENCY 36 30 C FLUE TEMPARATURE 80 60 C C 58 9 78 3 57 6 80 1 62 9 83 FLUE TEMPARATURE 50 30 C C 33 6 40 6 32 1 42 2 38 1 65 8 CO2 EMISSION 9 1 9 1 9 1 9 1 9 4 9 8 TURNDOWN RATIO 1 4 1 7 1 7 NOx CLASS Class NOx VALUE mg kWh FLUE GAS MASS ...

Page 14: ...tions 4 1 2 CARRYING Carry the boiler together at least two persons together by holding from the top and the bottom Do not carry or lift the boiler by holding the control panel After the boiler is removed from the box it should not be placed on the gas water and condensate connections 4 1 3 MOUNTING The wall must be strong enough to hold a water filled boiler If the carrying capacity of the wall i...

Page 15: ...ng efficiency Piping and installation companents 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...

Page 16: ... cleaner preservative or inhibitor type stopper preventive products or you can contact with SENTINEL or FERNOX companies 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 perfor...

Page 17: ... can be very hot Beware of scalding 4 2 3 CONDENSATION WATER DRAIN Condansation 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 drai...

Page 18: ...er 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...

Page 19: ...hanger 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 Wallcon X treme boilers will be used in to a dirty air environment they must be...

Page 20: ...d for the flue and chimney must be resistant to the temperature corrosive effect of condensation water and mechanical stresses and must be gas tight Never use the new boiler with the flues which are used for solid liquid fuel boilers or shunt chimneys Chimney system and the condensation drainage systems connected to it should be checked once a year and cleaned if necessary 19 Wallcon X treme 115 W...

Page 21: ...system that takes the combustion air from the outside and throws flue gas to the outside with seperate flue pipes C53 It is a flue system that takes the combustion air from the outside and throws flue gas to the outside with the vertical and horizontal concentric flue pipe system C63 It is a flue system that flue pipes are not supplied by the manufacturer It has to be applied according to one of t...

Page 22: ...ons must be made properly All cables must be fitted with a ferrule The manufacturer cannot be held liable for damages caused by negligence or incorrect operation in the earthing of the boiler 21 Wallcon X Treme 115 C13 C33 C43 C53 C63 C83 Air inlet 150 mm 150 mm 150 mm Flue 100 mm 100 mm 100 mm Max length 17 m 17 m 17 m Max output Δp 100 Pa 100 Pa 100 Pa Wallcon X Treme 125 C13 C33 C43 C53 C63 C83...

Page 23: ...K BROWN BROWN BLACK BLUE BLUE BLACK PURPLE GREY BOILER SIDE CONNECTIONS 2 X 0 75 2 X 0 75 2 X 0 75 2 X 0 75 2 X 0 75 2 X 0 75 PUMP PWM 0 10 V CONTROL Room Thermostat Outside Sensor Immersion Type DHW Temperature Sensor Connects to the supply collector the hydraulic seperator or the plate heat exchanger Measures the flow temperature It operates from 0 C to 95 C with 0 5 0 5 K tolerance It provides ...

Page 24: ...Supply 2 x 1 5 Supply 3 x 1 5 Supply 3 x 1 5 Communcation 2 x 0 75 Outdoor Sensor 2 x 0 75 Sensor 2 x 0 75 Sensor 2 x 0 75 Pump control 2 x 1 5 Pump control 2 x 1 5 Supply 3 x 1 5 Supply 3 x 1 5 Outdoor Sensor 2 x 0 75 Sensor 3 x 1 5 Communcation 2 x 0 75 ELECTRICAL PANEL ELECTRICAL PANEL ...

Page 25: ...24 WALLCON X treme 115 125 150 ...

Page 26: ...and vents Open the sensor housing cover by turning it counterclockwise to access the sensor connection terminal and the wall fixing holes Mark the fixing points on the wall and drill the wall using the storage box as a template Secure the box to the wall using the two anchors provided Connect the two wire cable from the boiler to the terminal box nonpolar Tighten the nut in the housing box to ensu...

Page 27: ...6 Thermometer 7 Manometer 8 Air seperator 9 Deposit and dirt seperator 10 Hydraulic seperator or plated heat exchanger 11 Expansion tank 12 Pumps seconder system 13 DHW sensor 5 INSTALLATION EXAMPLES 26 WALLCON X treme 115 125 150 Condensation drain Water filling unit Water softener unit ...

Page 28: ...sor 3 Globe valve 4 Check Valve 5 Strainer 6 Thermometer 7 Manometer 8 Air seperator 9 Deposit and dirt seperator 10 Hydraulic seperator or plated heat exchanger 11 Expansion tank 12 Pumps seconder system 13 DHW sensor Condensation drain Water softener unit Water filling unit ...

Page 29: ...ulic seperator Plate heat exchanger 17 Cascade sensor 4 Check valve 11 Expansion tank 5 Strainer 12 Safety valve 6 Thermometer 13 3 way motorized valve 7 Manometer 14 Zone pumps seconder system 28 WALLCON X treme 115 125 150 Condensation drain Water filling unit Water softener unit Under floor heating system with mixing valve Radiator system DHW ...

Page 30: ...nal modules All comissioning installation maintenance etc must be performed by authorized personnel Improper interventions may cause loss of life and property increased fuel consumption and deterioration in safe and comfortable operation Manufacturer cannot be held liable for any problems caused by incorrect adjustments and interventions Display symbols Comfort setting for heating Reduced heating ...

Page 31: ...UTTON H Used for to choose and select 4 different heating modes DHW MODE BUTTON I Used for to turn on or off the DHW mode NAVIGATION AND ADJUSTMENT KNOB B Changes comfort temparature setting Additionally it also used for increase decrease temperatures choose and select sub menus Change the settings OK BUTTON C Used for to apply selected value or setting In the parameters section this button is use...

Page 32: ...rner will held into standby mode pumps will be energised periodically mixing valves ran into middle position This function will be turned off automatically after the cycle FLUE FUNCTION E Used for flue gas emission measuring During this function boiler will be operated according to maximum adjusted temperature until it reach the exact value Then this function will be turned off automatically INFO ...

Page 33: ...d the boiler is switched on to operate synchronously with the units that produce hot water DHW tank plate heat exchanger etc This function can be switched off or on Pressing the button once will be activate the boiler to heat the DHW tank Pressing it again disables DHW tank heating Pressing the button for 3 seconds activates the Quick Water Heating Mode for faster hot water production ADJUSTING TH...

Page 34: ...he system all personalized settings parameters fault resets will be made via the control panel E g Date and time adjustment Push OK button Select Date and time setting then push OK button again Push OK button for adjusment Push OK button to adjust hour and minute settings Turn the adjusment knob one click and set mounth and day with pushing OK button Push OK button to adjust the year as a final st...

Page 35: ...y functions activated Summer Winter automatic switching activated ECO functions activated Press button 1x again Safety mode on with Heating off Temperature by frost protection Safety functions activated Controller Stop Mode Press button 3 sec 304 Controller Stopp mode insert setpoint Press button 3 sec again after 3 sec Main menu appears Press button 1x INFO Segment displayed Press button 1x again...

Page 36: ...y Month tt MM 01 01 31 12 653 Periode End Day Month tt MM 01 01 31 12 658 Operating level Frost protection 661 Preselection Period 1 662 Period Start Day Month tt MM 01 01 31 12 663 Periode End Day Month tt MM 01 01 31 12 668 Operating level Frost protection 710 Comfort setpoint C Value from Line no 712 35 20 712 Reduced setpoint C 4 Value from Line no 710 16 714 Frost protection setpoint C 4 Valu...

Page 37: ...ector temperature 1 sensor error 177 Water pressure 2 too low 349 Buffer return valve Y15 not available 78 Water pressure sensor error 178 Limit thermostat heating circuit 1 350 Puffer address sensor 82 LPB address collision 179 Limit thermostat heating circuit 2 351 Primary controller system pump address error 83 BSB wire short circuit 183 Unit in parameterization mode 352 Pressureless header add...

Page 38: ...nly ensuring high efficiency and long life time 9 CASCADE In cascade systems one of the boilers is used as MASTER LEADER others are used as SLAVES FOLLOWERS While all settings of the cascade system are done via the MASTER boiler SLAVE boilers work under the control of the MASTER boiler MASTER boiler has a display In the MASTER and SLAVE boilers the RESET button is located in different places MASTE...

Page 39: ... be used during to the combustion adjustments 10 1 EMISSION SETPOINTS 40 WALLCON X treme 115 125 150 SIT EBM A B D C Wallcon X treme boilers have two different gas valve options SIT and EBM gaz valve setpoints are mentioned below min max min max min max CO2 emission 9 1 9 1 9 1 9 1 9 4 9 8 Gas consumption m3 h 1 22 5 12 0 77 5 26 0 92 6 04 Flue gas mass flow g sec 12 00 47 00 8 00 49 00 9 00 60 00...

Page 40: ...ODE BUTTON INFO BUTTON OK BUTTON ADJUSTMENT KNOB Turn the Nominal Gas Flow Adjustment Screw A clockwise to increase the CO2 value If you turn it counterclockwise the gas flow rate will decrease and therefore the CO2 value will decrease Before operating the boiler at nominal load ensure that the valves in the system are open the condensate drain line is open the flue connections are gas tight and t...

Page 41: ... nozzle mm 9 00 9 00 G31 Wallcon X treme 125 Wallcon X treme 150 LPG EMISSION SETTINGS Minimum load emission setting is done by measuring the CO2 value in the flue gas The following steps should be followed for this instant measurement on a boiler operating at minimum capacity HEATING MODE BUTTON INFO BUTTON OK BUTTON ADJUSTMENT KNOB To run the boiler at minimum load Press and hold Heating Mode bu...

Page 42: ...embled companents after the nozzles installed with the care of tightness Use the flue gas analyzer to provide the values which are given in the table of values for LPG 43 Before the commissioning of the boiler all parameters must be regenerated according to the LPG This process must be made by authorized Gassero services WALLCON X treme 115 125 150 11 1 SIT GAS VALVE LPG CONVERSION ...

Page 43: ...alve and gas supply pipe 2 Seperate the air inlet pipe and the venturi WALLCON X treme 115 125 150 44 4 Remove the 3 screws on the gas valve 3 Remove the group of fan venturi and gas valve 11 2 EBM GAS VALVE LPG CONVERSION ...

Page 44: ...embled companents after the nozzles installed with the care of tightness Use the flue gas analyzer to provide the values which are given in the table of values for LPG Before the commissioning of the boiler all parameters must be regenerated according to the LPG This process must be made by authorized Gassero services nozzle WALLCON X treme 115 125 150 45 ...

Page 45: ...e must be made by authorized GASSERO services Malfunctions resulting from unauthorized interventions will be considered out of warranty 12 1 MAINTENANCE PROCEDURE The following procedures and instructions must be applied by authorized Gassero services Service history Life time of the boiler installation and environment must be take into account information error fault histories should be evaluated...

Page 46: ... of the sensors can be done by checking the temperature resistance tables to detect that sensors are working properly Burner and Heat Exchanger will be cleaned Burner and heat exchanger surfaces pores can be cleaned with a non metal brush or compressed air The burner gasket or heat exchanger cap gasket fuse will be checked and has to be replaced if deformed Siphon will be cleaned and the drain lin...

Page 47: ...hecked Gas leakage control will be made For gas leakage control a gas detector or leakage detection sprays may be used Chimney connections will be checked for leakage of gas or condensation water If there is an air inlet filter in the boiler it will be checked and replaced if necessary Electrical connections sockets grounding terminals will be checked Automatic air relief valves thermometers manom...

Page 48: ...ss fuel ADJUSTING RIGHT TEMPERATURE VALUES Selecting COMFORT and REDUCED TEMPERATURE values will save energy Excessively selected COMFORT temperature will increase the energy consumption To save more energy use REDUCED TEMPERATURE function more often CORRECT PROGRAMMING Selecting the correct operation ranges for automatic mode will save energy INSTALLATION INSULATION Insulation of pipes collectors...

Page 49: ...will be followed for the packaging wastes Leaving the non functional units spare parts and packaging materials in the environment and leaving them accessible to children can be dangerous Such wastes must be treated in accordance with the applicable regulations Ignoring this warining may harm people animals and may cause property damage Manufacturer is not liable for damages that may arise in such ...

Page 50: ...5 mg kWh 37 mg kWh Seasonal Space heating efficiency ŋs 95 80 95 80 96 20 Annual energy consumption QHE 304 3 GJ 324 6 GJ 398 5 GJ Sound power level indoors LWA 63 7 dB A 67 1 dB A 67 7 dB A Condensing boiler yes yes yes Low temperature boiler no no no B1 boiler no no no Combination heater no no no Cogeneration space heater no no no Supplier name Siemens TURKEY Siemens TURKEY Siemens TURKEY Model ...

Page 51: ...16 TROUBLESHOOTING WALLCON X treme 115 125 150 52 WALLCON X treme 115 125 150 ...

Page 52: ...WALLCON X treme 115 125 150 53 ...

Page 53: ...knolojileri Sanayi Limited Şirketi İstanbul Endüstri ve Ticaret Serbest Bölgesi 4 Sokak No 8 34957 Tuzla Istanbul TÜRKİYE Telefon 90 216 394 09 85 86 87 Faks 90 216 394 24 91 www gassero com Technical modification rights reserved ...

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