gassero wallcon, Installation, User And Service Manual

Page 1: ...INSTALLATION USER AND SERVICE MANUAL WALL HUNG GAS FIRED CONDENSING BOILER RESET 50 67 42 0051 14 ...

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Page 3: ...ng of symbols 1 2 General warnings 2 General 5 2 1 Designated use 5 2 3 5 Boiler room ventilation 2 2 Description of the appliance 5 3 3 1 3 Safety instructions 4 1 4 Regulations and standarts 4 2 4 Packaging label 6 2 5 6 Warning label 2 6 Data label 6 3 1 Wallcon 42 50 67 dimensions 7 3 2 8 Wallcon 42 50 67 hydraulic diagram 3 3 Wallcon 42 50 67 main components 9 3 Technical features 7 3 4 Techn...

Page 4: ... promptly notify Gassero or other authorized qualified personnel Periodically check that the condensate drain is free of blockages Periodically check that the operating pressure of the water circuit when cold is 1 5 bar and less than the maximum limit specified for the appliance If this is not the case contact with Gassero or other aut horized qualified personnel If the boiler is not used for an e...

Page 5: ...tive components which influence the When tightening or loosening the screw connections use only adequate tool The improper use and or the use of inadequate equipment can cause damages If you smell gas If you smell gas follow these safety indications Do not turn on or turn off electrical switches Do not smoke Do not use the telephone Close the mains gas tap Open all windows and doors where the gas ...

Page 6: ...tricholorethylene or hydrogen halides e g contained in aerosols certain adhesives solvents or detergents paints and other aggressive chemicals are used or stored 2 1 DESIGNED TO USE 2 3 BOILER ROOM VENTILATION These installation and maintenance instructions apply to General 5 The WALLCON is a wall hung condensing boiler for CH and DHW with DHW tank purposes with pre mix burner made up of stainless...

Page 7: ...the combustion air is taken from outside the room where the boiler is installed Wallcon boilers operates as a room sealed appliance type C Provide enough clearance to access the safety and control devices and to carry out the servicing operations Check that the index of protection of the boiler is suitable for the characteristics of the room where the appliance is installed If the boilers operate ...

Page 8: ...N 42 50 67 CONNECTIONS AND DIMENSIONS CONNECTIONS Technical features 7 Fd Ad Sc Condensate discharge Ad DIMENSIONS Wallcon 42 W 446 mm L 390 mm H 654 mm Wallcon 67 W 446 mm L 480 mm H 654 mm Wallcon 50 W 446 mm L 390 mm H 654 mm ...

Page 9: ... sensor 14 Fan 15 Safety Relief Valve Technical features 8 Water pressure losses on Wallcon 67 0 10 20 30 40 50 60 70 80 90 0 500 1000 1500 2000 2500 3000 3500 4000 4500 Water flow rate L h Water pressure losses KPa Water pressure losses on Wallcon 42 50 6 11 16 21 26 31 36 41 46 51 800 1200 1600 2000 2400 Water flow rate L h Water pressure losses KPa 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 R G Sc M S...

Page 10: ...de 10 Syphon 11 Venturi 12 Water Flow Connection 13 Safety Drain Connection 14 Gas Supply Connection 15 Water Return Connection 16 Manual Air Vent 17 Heat Exchanger Bracket 18 Gas Valve 19 Chassis Support Bracket 20 Flue Outlet 21 Automatic Air Vent 22 Heat Exchanger 23 Water Flow NTC Sensor 24 Water Return NTC Sensor 25 Safety Relief Valve 26 Fan 27 Air Intake Terminal 16 17 19 18 21 22 23 24 25 ...

Page 11: ... output mass G20 g sec 3 7 17 7 3 7 21 6 6 90 28 40 Combustion products output mass G25 g sec 3 7 17 4 3 7 21 3 7 00 28 40 Combustion products output mass G30 g sec 3 5 16 6 3 5 20 2 6 50 26 50 Gas flow rate G20 m3 h 0 9 4 2 0 9 5 1 1 57 6 7 Gas flow rate G25 m3 h 1 0 4 8 1 0 5 9 1 82 7 8 Gas flow rate G30 m3 h 1 2 0 3 0 3 1 5 0 47 2 0 Fan speed G20 rpm 1250 5100 1250 6000 1700 6500 Fan speed G25 ...

Page 12: ... Obey the transport symbols and instructions on the packaging To lift and carry the boiler place one hand at the bottom of the boiler and the other hand on its top CAUTION Damage to the unit due to it being lifted and carried incorrectly Do not hold the boiler over the control panel to lift and carry it Place the boiler in its packaging on the handtruck and secure it with a strap if necessary Care...

Page 13: ... and condition of the system New systems should be flushed thoroughly to regulations to remove all traces of flux debris grease and metal swarf generated during installation Care to be taken with old systems to ensure any black metallic iron oxide sludge and other corrosive residues are removed again by power flushing ensuring that the system is drained completely from all low points It is importa...

Page 14: ... boiler This Frost Protection provision is for the boiler only and not for the all system 4 1 11 DIRT SEPERATION the return of the boiler is such a way that the boiler water is free check weekly after installation to determine the strainer cleaning interval Instructions for the installer 13 including an air bleed valve so the strainer can be isolated from the heating circuit for servicing Clean wa...

Page 15: ...4 2 BOILER INSTALLATION SYSTEM EXAMPLES 4 2 1 SINGLE BOILER INSTALLATIONS Instructions for the installer 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: ... Expansion vessel 9 Radiator pump 10 Heating system radiator underfloor 11 DHW tank pump 12 DHW tank sensor QAZ36 13 Hot water 14 DHW re circulation pump 15 DHW tank expansion vessel 16 DHW tank 17 Cascade supply sensor QAD36 18 Cascade return sensor QAD36 Key Air Intake Fume discharge 3 2 1 5 6 7 17 18 8 9 10 Air Intake Fume discharge 3 2 1 5 6 18 13 17 7 9 10 8 11 14 15 12 16 RESET RESET SLAVE R...

Page 17: ...t press at least 3 seconds to heating mode when the boiler in mode Controller function stop will appear on the screen Than press information button it will indicate the modulation rate on the screen 100 for max output setting with using of navigation button Then press OK Thus boiler will operate in maximum power Instructions for the installer 16 100 B D A C Model Q min max min max min max CO 2 8 9...

Page 18: ...e to be adjusted with extreme care respecting the values indicated in the table Correct the value by turning the adjustment screw D in clockwise direction to increase the value and in anti clockwise direction in order to decrease the value When the adjustments have done close sampling test point in the flue adapter with the cap Instructions for the installer 17 1 For operating in the min output pr...

Page 19: ...r of the boiler The unit can operate on natural gas or LPG and is factory set for use with one of these two gases as clearly shown on the packing and on the dataplate If a gas different from that for which the unit is arranged has to be used a conversion kit will be required proceeding as follows 3 Remove the air intake pipe from venturi adapter 4 Remove the gas supply pipe from gas valve 1 2 5 Di...

Page 20: ...e potential sources of danger IMPORTANT INFORMATION If the lowest part of the terminal is less than 2 metres above the level of the ground balcony flat roof or place to which any person has access the terminal must be protected by a guard The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of the building The flue outlet duct and the terminal of the boiler...

Page 21: ...ake and fume discharge C 33 Concentric and closely placed ducts connected to a vertical terminal for fresh air intake and fume discharge C 43 Two connecting ducts and two collecting flue one for fresh air intake and other one is for fume discharge Terminal position Minimum spacing A Directly below above or alongside an opening window air vent or other ventilation opening 300 mm B Below guttering d...

Page 22: ...f the terminal allows the free passage of air at all times The air supply and the flue gas exhaust must meet the applicable general regulations Please consult the instructions provided with the flue terminal kits prior to installation The flue for installations in excess of 67 kW must be installed in accordance with the recommendations of IGE UP10 Wallcon 50 B23 C13 C33 C43 C53 C63 C83 Air intake ...

Page 23: ...746600768 Bird guard Accesory Description Code 746600777 Accesory Description Code 746600766 B23 flue kit 1m Accesory Description Code 746600773 Cascade flue kit This flue kit is for two boiler cascade system For larger cascades please contact your Gassero dealer o 87 coaxial elbow o 87 elbow o 45 coaxial elbow o 45 elbow Wall rosette Coaxial extension Extension Coaxial adapter Air intake adapter ...

Page 24: ...d can be reach by removing the front panel of the boiler and the connector protection cover For operation the boiler needs a power supply of 230VAC 50Hz with earth Power supply must be removed when you are working on the boiler Electrical wiring should be done according to national local or other special standards Electrical works must be done by a qualified service engineer that is skilled in ele...

Page 25: ...correct positioning of the outside probe is fundamental for the correct operation of the climate control function The probe must be installed outside of the building being heated at a height of around 1 2 of the wall facing NORTH or NORTH WEST and away from flues doors windows and areas exposed to direct sunlight Fastening the outside probe to the wall Unscrew the cover on the probe protection box...

Page 26: ... switched on or off IMPORTANT INFORMATION To provide this function following must be observed A room sensor must be connected The Room influence setting must be selected between 1 and 99 No thermostatic radiator valves should be used in the reference room where the room sensor is located if installed such valves must be fully opened and locked in that position The function is activated with parame...

Page 27: ...ion Heating mode according to the time program Temperature setpoints according to heating program Reduced setpoint Protective functions active Automatic summer winter changeover ECO functions Continuous operation or Continuous operation maintains the room temperature Heating to the Comfort setpoint Heating to the Reduced setpoint Characteristics of continuous operation Heating mode with no time pr...

Page 28: ...ntil the next switching action according to the heatingprogram occurs automatic operation Displaying information The Info button is used to display information Certain information lines are hidden depending on the type of unit unit configuration and operating state Depending on the type of unit configuration and operating state some of the info lines listed below may not appear Displays Possible e...

Page 29: ...the time of day When pressing the ESC button you go back one step adjusted values will not be adopted If any setting is made for 8 minutes the unit will automatically return to the basic display Operating lines may be hidden depending on the type of unit the configuration anduser level operation Display example Description 1 0 4 8 12 16 20 24 AUTO Room temperature You will see the basic display If...

Page 30: ...r temperature 1 sensor error 25 Boiler temperature solid fuel sensor error 26 Common flow temperature sensor error 28 Flue gas temperature sensor error 30 Flow temperature 1 sensor error 38 Flow temperature primary 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 error 52 DH...

Page 31: ...olar integration missing 344 146 Solar controlling element buffer K8 missing 345 146 Solar controlling element swimming pool K18 missing 346 146 Solid fuel boiler pump Q10 missing 347 146 Solid fuel boiler comparative sensor missing 348 146 Solid fuel boiler address error 349 146 Buffer storage tank return valve Y15 missing 350 146 Buffer storage tank address error 351 146 Primary controller syste...

Page 32: ...ot damaged Un assembling the Burner Un assembling the burner unit Remove the 6 x M6 nuts and the electrode cables and move the burner unit forward Remove the plug of the fan cable from the fan when the burner has been pulled half way from the heat exchanger Dismantle the air gas mixing box on the intake side of the fan and check the blade wheel of the fan Insulation The insulation of the heat exch...

Page 33: ...ectrodes there is a risk of breaking or tearing the electrode Check if there are any tears cracks in the electrodes after bending them If so then replace the electrode with a new one Also change the electrode if any cracks can be seen in the ceramic electrode insulation If the electrode is changed the gasket should also be replaced 7 00 0 2 mm Burner When defects are found that cannot be fixed by ...

Page 34: ...ality of combustion Gas valve Check that 230 V AC is present at the terminals on the gas valve check wiring and con nections Burner gas pressure Delays in ignition with pulsating operation of the burner Check adjustment Ignition electrode Check positioning and condition The boiler becomes dirty in a short time Check flame colour Check combustion adjustments The burner does not start when recieivin...

Page 35: ...entral heating system is cold Vent the system Pump fault Reset the pump Replace the pump Check the electrical connections of the pump Boiler controller Thermal overload on the heat generator Check correct operation Check set temperature Check electrical wiring Check position of the sensors REASON SOLUTION PROBLEM Troubleshooting 34 System expansion vessel Check efficiency Pressure in heating syste...

Page 36: ...REDUCER BEEN FITTED YES NO WHAT TYPE 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 INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S...

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Page 38: ...CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATUR...

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Page 40: ...i ve Ticaret Serbest Bölgesi 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 right to change specification without prior notice Consumers statutory rights are not affected ...