Ecodense WT 65 Installation guide

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www.ecodense.com
CONDENSINGBOILER INSTALLATION,OPERATING
ANDMAINTENANCEMANUAL
ECODENSE WT 65
ECODENSE WT 80
ECODENSE WT 100
ECODENSE WT 115
ECODENSE WT 125
ECODENSE WT 150

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DEAR USER,
TheCondensing BoilersECODENSE WT 65,ECODENSEWT80,ECODENSE
WT100,ECODENSEWT115,ECODENSEWT 125,ECODENSEWT 150are
constructedand manufacturedaccording tothemost advancetechnologicalinventionsand
the safetyrules. Itis easytouse forourcustomers.
We recommendthat you readthis manual andsafety warningsthoroughlybeforethe
useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.
Ifyouencounteranyissuethat is notexplainedclearlyinthismanual oryoucould
not understand,please contact withour service department.
We thank youforchoosingECODENSE brand.
This OperatingManualisanintegralpartof thedeviceandmust bemaintainedin a
plasticdossierand hungat a clearlyvisible placebythedevice.
TERMO ISI S STEMLER SAN.VET C.A.Ş.
EsentepeMah.MilangazCad. No:75 K:3
KartalMonumentoPlaza
Kartal/ STANBUL/TÜRK YE
Tel: [phone]
Fax:[phone]
www.ecodense.com
e-mail:[e-mail]

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CONTENTS
1. WARNINGS .......................................................................................................................................3
1.1. Warning Symbolsand Descriptions .............................................................................................3
1.2. General Safety Rules....................................................................................................................4
2. TERMS OFWARRANTY..................................................................................................................6
2.1. Out ofWarranty Conditions.........................................................................................................6
3. GENERAL CHARACTERISTICSOF CONDENSINGBOILER......................................................7
3.1. Usage of CASCADE....................................................................................................................7
3.2. ECODENSEComponents...........................................................................................................8
4. CONDENSINGBOILERGAS, FLUE GAS ANDHEATING WATER SCHEMA........................10
5. CIRCUITSCHEMES........................................................................................................................11
6. CLOSEDCIRCUITCOMPONENTS...............................................................................................19
6.1. BalanceTank..............................................................................................................................19
6.2. SizingTableForExpansion Tank..............................................................................................20
6.3. ExpansionTank..........................................................................................................................21
6.4. Manometer .................................................................................................................................21
6.5. Strainer.......................................................................................................................................21
6.6. AirSeparator..............................................................................................................................21
7. WATER QUALITY..........................................................................................................................22
8. TECHNICAL DATA ........................................................................................................................23
8.1. Capacity Table...........................................................................................................................23
8.2. Condensing BoilerDimensions..................................................................................................24
8.3. NoiseLevel ................................................................................................................................24
9. CONDENSINGBO LERHANDLINGINFORMATION................................................................25
10. INSTALLATION..........................................................................................................................26
10.1. General Controls.....................................................................................................................26
11. STACKCONNECTIONS.............................................................................................................27
12. ASSEMBLY..................................................................................................................................30
12.1. ECODENSEAssembly Instructions.......................................................................................30
12.2. ECODENSESingle/CASCADEAssembly Instructions........................................................30
12.3. Assembly ofCondensingFluidDrain.....................................................................................31
13. ECODENSECONTROL INSTRUCTIONS BEFORE START-UP..............................................32
14. ELECTRICAL DIAGRAM...........................................................................................................33
15. COMMISSIONING.......................................................................................................................34
15.1. Before Commissioning...........................................................................................................34
15.2. ChecksDuring Commissioning..............................................................................................35
16. ADJUSTING COMBUSTINPARAMATERS..............................................................................35
16.1. Adjustment andMeasurement Points......................................................................................35
17. CONTROLPANELBUTTON SPECIFICATIONS......................................................................36
17.1. AdjustingMinimumCapacity.................................................................................................36
17.2. AdjustingMediumCapacity...................................................................................................36
17.3. AdjustingMaximumCapacity................................................................................................37
17.4. AdjsutingTimeSchedule........................................................................................................37
18. MAINTENANCE..........................................................................................................................38
18.1. MonthlyMaintenance.............................................................................................................38
18.2. Seasonal Maintenance.............................................................................................................38
19. LISTOF ERRORCODE...............................................................................................................39
20. SOLUTION RECOMMENDATIONSFORSOMEOFTHE PROBLEMS.................................43
21. AFTERSALES SERVICES..........................................................................................................44
22. NOTES..........................................................................................................................................45

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1. WARNINGS
1.1. WarningSymbolsandDescriptions
Symbols SymbolDescriptions
Important information and usefulhints.
Warning of danger to lifeor property.
Warningofelectrical voltage.
Product handling information.
GAZ HATTINITEM ZLEY NZ.
CLEAN GAS LINE.
ЧИСТАЯ ЛИНИЯ ГАЗ.
"Cleanthegasline" warningongasline.
Carry inanupright position.Fragile Item.Protectagainstwater.

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1.2. General Safety Rules
•All personnel engagedininstallation,disassembly,commissioning,operation,control,
maintenanceand repair should havereceived thenecessarytrainingandfullyread and understood
thismanual.
•Nochangesthat might damagethe safety of the devicemustbemadebypersonsand/or
organizations onthe device.
•All operation,commissioning and installation works (except for burningadjustment) should be
carried out when thedeviceisnotoperating and after disconnecting the powersupply.
Noncompliancewith theserules may lead to seriousbodilyinjuriesand even death by electrical
shocksoruncontrolled flameformation.
•Repairs concerned withsafety elementsshould becarriedout only bythemanufacturingcompany.
•The deviceshouldnever be usedbychildren,mentally handicapped and inexperienced persons.
•Children mustnot be allowed to playwith the device.
•Keep the deviceaway fromexplosiveand flammable materials.
•Devicemustintakeair,and ventilationand air discharge holesmust notbe closed.
Ifyou sensegas leakage;
•Shutdownvalvesofall gasdevices.
•Open all doorsand windows.
•Donotturnonelectricdevices or donot turn themoffifthey areworking.
•Donotuseburner derived tools such as match andlighter.
•Informthe gascompany.
Do not store any inflammablematerials inboiler room.
Wear hearingprotectorsifthereisnoiseinboiler room.
Incaseoffıreorother emergency;
Switchoff the mainswitch
Closethemain fuel shut-offvalveoutside the plant.
Takeappropriate actions

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Before commissioning and Ifthere ispressureloss in the systemdueto seasonal maintenance;
Afterwater addition process,itis necessary to carry out that air removal process andmust be
observedthat there is absolutely no air in thesystem. Ifthere is air inthe system repeatthe
deaerationprocess.
Ifyou receieve 110 (Lock-out) failure onthe control panel,please do no resetthe boiler,Call
AuthorisedService company.
For The High-riseBuildings, Ifheight of structuremore than 25mt.Or morethan10 thfloor ,
in ordertoensurethat condensingboiler cascadesystemoperatescomfortably atlowpressures,a
plate heat exchanger mustbeinstalled inordertodistinguishthehighpressure between 2nd
circuit and the Primary circuit.the static pressure appearancedduetotheheightof building, theboiler
systemis not allowedtooperate under the influenceofhigh pressure.
BOILERROOM
Condensing Boilersmust be installed inasuitable room/floor with minimumexternal air openings
and sufficient toensure optimumgas-air mixturecombustion,incompliance with theregulations.
Airopenings ofthe boilerroom,burner fan intakeventsor airductsmuststay open tothe
atmosphereand Birdcage shouldbeinstalled inorder topreventanyBird,foreign bodyentrance
a.The buildupof toxic / explosivegasmixturesintheboiler room,
b.Combustionwith insufficient air, resultingin hazardous, anti-economical and polluting ope-
ration.
TheCondensing boiler mustbe always protected fromrain,snowand frosttoprevent corrosionand
paint deformations.
Keep the condensingboiler roomcleanandfree of solidvolatilesubstances, whichcouldbesucked
intothefan and clogtheinternal boilerorcombustion airducts.
Every 6months, afterfirstcommissioning ofboiler,theboilerdevicesshouldbecleaned with
protectivechemicals to preventcalcification and resultant blocking andcorrosiononthemetallic
surfaces.
Flushing;
On the Currently operating systems,appropriatechemical solution with the pHrange of 4-6 shouldbe
selected for cleaning the pipeline installation forsafety commissioning thecondensing boiler.
Inthenew buildinginstallationsand boiler heat exchangers,maintenanceshouldbe applied with
chemicalswith neutral pH (neutral) effectand preventive maintenancemust be carried outperiodically.

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2. TERMS OFWARRANTY
Main andauxiliary equipment and allcomponents usedin ECODENSEWT65, ECODENSEWT
80, ECODENSEWT100,ECODENSEWT 115,ECODENSEWT125,ECODENSE WT 150
Condensing Boilersareguaranteed for 1year by TERMOISIS STEMLER A.Ş. starting fromthedate
of commissioning under the maintenance,adjustment, operating conditionsand relevant mechanic,
chemical and thermaleffects explained herein.
Pleasenote that this warranty isonlyvalid ifthedevice(s)is commissioned and maintained byour
authorizedservices.
Our company reserves the right to makeanymodificationson the product and all instructions
thereof for improvement purposes.
2.1. OutofWarranty Conditions
•Any damage arising out oforin relation to customers’non-complianceto their responsibilities
with regardstoinstallation, commissioning,operation andmaintenance,
•Any damage arising out ofor inrelation to commissioning,repairsand maintenancecarried out by
unauthorized services,
•Any damage thatmayoccur during transportationorstorageofthe product,
•Not preserving the productinits original packaginguntiltheinstallationstage,
•Incorrectand poorelectrical connections,Failuresdue toincorrect voltage applications,frequent
repetition ofvoltage fluctuations,
•Any damagethat may occur as aresultofincorrect fuel usage or,foreign substancesinthe fuel
used or using ofthe productwithoutanyfuel,
•Any damage that mayoccur dueto foreignparticles entered into theproduct during installation
andoperation,
•Failuresdue toincorrectdeviceselection,
•Any damage tounitduetonatural disasters,
•Deviceswithoutany warranty certificates,
•Warranty Certificateswithoutthe stampand signature ofthe authorizeddealer or service,
•Devices with anyfalsification onthewarranty certificate or without an originalserial number.
•The risks during transportation ofdevice undertheresponsibilityof customerbelong to the
customer.
•Presenceofmisuse faults areindicated inthe reportsissued by authorized servicestationsor our
authorizedagent,dealer,representative orour factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

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3. GENERAL CHARACTERISTICSOFCONDENSINGBOILER
ECODENSEWT 65,ECODENSE WT80,ECODENSEWT 100,ECODENSE WT115,
ECODENSE WT125, ECODENSE WT 150 areheatingdevices operating withnaturalgasor LPGwith
avery lowsuctionpower,and equipped with high-duty,premix condensingcontrol systemwithmicro-
processor.The boileris composed ofaheat exchangerwith aluminumcoolingfins andasteel premix
burner equipped with ignitionand ionization flame control,modulating fanand gas valve.ECODENSE
WT 65,ECODENSE WT80,ECODENSEWT100,ECODENSEWT 115,ECODENSE WT125,
ECODENSEWT150are designedfor use asstandaloneas well as cascade.
The structure ofcascadeto beformedby the product group increasesthe usability in collective
housingandindividualbuilding applications withitsefficientcomposition.
3.1. Usage ofCASCADE
Premix condensing technology is used inECODENSE WT 65, ECODENSEWT 80,ECODENSE
WT 100, ECODENSE WT115, ECODENSEWT 125,ECODENSEWT 150wall typecondensing
boilers inorder toreach higher efficiencyand energy-saving.With suitableconnectionsand approval
fromgas distributioncompanies, ECODENSEWT65,ECODENSE WT 80,ECODENSEWT100,
ECODENSEWT115, ECODENSEWT 125, ECODENSEWT 150boilerscan be connected as much as
requiredcapacity.Maximumoperationpressure oftheseboilersis 4bar (6bar for specificapplications).
Circulation pump,expansion tankandsafety valve are not present intheseboilers. Thesearerequired to
be provided bycustomer and are mandatory touse.

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3.2. ECODENSE Components
ECODENSEWT65 –ECODENSEWT80
No. Material
1 Venturi 13 Reset
2 Flueoutlet 14 Control card
3 Gasvalve 15 Boiler body
4 Ignitiontransformer 16 Heater circuitreturn
5 Ignitionelectrode 17 Heater circuitsupply
6 Fan 18 Ionizationelectrode
7 Automaticair reliefcock 19 Condensingwater releaseoutlet
8 Water pressuresensor 20 Condensingwater trap
9 Water flowsensor 21 Gasinlet
10 Condensingwater collection tray 22 Burner
11 Control panel 23 Bulls eye
12 Start/Stop

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ECODENSEWT100–ECODENSEWT115-ECODENSE WT 125- ECODENSE WT150
No. Material
1 Venturi 13 Reset
2 Flueoutlet 14 Control card
3 Gasvalve 15 Boiler body
4 Ignitiontransformer 16 Heater circuitreturn
5 Ignitionelectrode 17 Heater circuitsupply
6 Fan 18 Ionizationelectrode
7 Automaticair reliefcock 19 Condensingwater releaseoutlet
8 Water pressuresensor 20 Condensingwater trap
9 Water flowsensor 21 Gasinlet
10 Condensingwater collection tray 22 Burner
11 Control panel 23 Bulls eye
12 Start/Stop

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4. CONDENSING BOILER GAS,FLUEGASANDHEATINGWATERSCHEMA

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5. CIRCUITSCHEMES

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6. CLOSEDCIRCUITCOMPONENTS
6.1. Balance Tank
Balance Tank (Separator) must bevertical.
Advantages:
ØNohydraulic response occurs between the boilercircuitand the heating circuit.
ØBoilers and heatingzonesoperateundersuitablewater flow.
Sizing ofBalanceTank:
ØIn ordertoensurehealthy operation of thebalancetank, accurate sizing must bemade.
ØThe boiler’s exitwater temperature shouldbemeasured ontheupper partofbalance tank.
ØForthis,a½”muffshouldbe weldedontotank,andalsoanair reliefcock shouldbemounted.
ØDimensions shown in the picture represent minimumdimensionsrequired tobeapplied.