gassero wallcon 115 Troubleshooting guide

REV.03-(16.03.2015)
115
125B
160B
INSTALLATION, USER AND SERVICE MANUAL
WALL HUNG GAS FIRED CONDENSING BOILER
RESET

REV.03-(16.03.2015)

REV.03-(16.03.2015)
Table of Contents
Table of Contents
2
IMPORTANT
When carryng out commssonng of the boler, you are hghly recommended to perform the followng checks:
–
Make sure that there are no lquds or nflammable materals n the mmedate vcnty of the boler.
–Make sure that the electrcal connectons have been made correctly and the earth wre s connected to a
weel done earthng system.
–Open the gas tap and check the soundness of the connectons, ncludng the burner.
–Make sure that the boler s set for operaton for the type of gas suppled.
–Check that the flue ppe for the outlet of the products of the combuston s unobstructed and has been properly
nstalled.
–Make sure that any shutoff valves are open.
–Make sure that the system s charged wth water and s thoroughly vented.
–Check that the crculaton pump s not locked.
–Purge the system, bleedng off the ar present n the gas ppe by operatng the pressure relef valve on the gas
valve nlet.
–
The nstaller must provde the user wth nstructon n operaton of the boler and safety devces and hand over the
nstructon booklet to the user.
–
The mages shown n ths manual are a smplfied representaton of the product. In ths representaton there may be
slght, unmportant dfferences wth the suppled product.
1 Meanng of the symbols and safety nstructons . . 3
1.1 Meanng of symbols
1.2 General warnngs
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Desgnated use . . . . . . . . . . . . . . . . . . . . . 5
2.3 . . . . . 5Bo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 . . . . . . . . . . . . . . . . . . . . . . 6Warnng label
2.6 Data label . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Wallcon 115-125B-160B dmensons . . . . . . . 7
3.2 . . 8Wallcon 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ng . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Instructons for the nstaller . . . . . . . . . . . . . . . . . . . 11
4.1 . . . . . . . . . . . . . . . . . . . . . . . . 11Installaton
4.1.2 Transport . . . . . . . . . . . . . . . . . . . . . . 11
4.1.3 Mountng . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.4 Clearances . . . . . . . . . . . . . . . . . . . . . 12
4.1.6 Water sde connectons . . . . . . . . . . . . 13
4.1.5 Water qualty and treatment . . . . . . . . . 12
4.1.7 Expanson vessel . . . . . . . . . . . . . . . . . 13
4.1.8 Safety valve . . . . . . . . . . . . . . . . . . . . 13
4.1.9 Condansate dran . . . . . . . . . . . . . . . . 13
4.1.10 Frost protecton . . . . . . . . . . . . . . . . . 13
4.1.11 Drt seperaton . . . . . . . . . . . . . . . . . . 13
4.1.13 Pump . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.12 Automatc ar vent . . . . . . . . . . . . . . . . 13
4.2 Installaton examples . . . . . . . . . . . . . . . . 14
4.2.1 Sngle boler nstallatons . . . . . . . . . . . 14
4.2.2 Cascade nstallaton . . . . . . . . . . . . . . . . 15
4.3 Adjustment of the gas rate . . . . . . . . . . . 16
4.3.1 Descrpton of the adjustment ponts . . . 16
4.3.2 Combuston values adjustment table . . . 16
4.3.3 Maxmum output adjustment . . . . . . . . . 16
4.3.4 Mnmum output adjustment . . . . . . . . . 17
4.4 Gas converson nstructons . . . . . . . . . . . 18
4.5 Flue nstallaton nstructons . . . . . . . . . . . 19
4.5.1 Flue applance types . . . . . . . . . . . . . . . 19
4.5.2 Flue nstallaton types . . . . . . . . . . . . . . 20
4.5.3 Flue kt accesores . . . . . . . . . . . . . . . . . 21
4.6 Electrcal nstallaton . . . . . . . . . . . . . . . . 22
4.6.1 Wrng dagram . . . . . . . . . . . . . . . . . . . . 22
4.6.2 External probe nstallaton . . . . . . . . . . 23
4.6.3 Outdoor temperature control . . . . . . . . 24
5 Operaton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Programmng . . . . . . . . . . . . . . . . . . . . . 27
5.3 Error codes . . . . . . . . . . . . . . . . . . . . . . 28
5.4 Mantenance codes . . . . . . . . . . . . . . . . 29
6 Mantenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Comssonng checklst . . . . . . . . . . . . . . . . . . 34
6.2 Mantenance procedure . . . . . . . . . . . . . 30
Servce nterval record . . . . . . . . . . . . . . . . . . 37
6.3 Troubleshootng . . . . . . . . . . . . . . . . . . . 32

REV.03-(16.03.2015)
1 MEANING OF THE SYMBOLS AND SAFETY INSTRUCTIONS
1.1 MEANING OF THE SYMBOLS
WARNINGS
Keywords ndcate the serousness of the hazard n
terms of the consequences of not followng the safety
nstructons.
• NOTE ndcates that materal damage may occur.
• CAUTION ndcates that njures may occur.
• WARNING ndcates that serous njury may occur.
• DANGER ndcates potentally rsk to lfe.
IMPORTANT INFORMATION
Warnngs n ths document are framed and
dentfied wth a warnng con whch s
shown on the left figure.
Electrcal hazards are dentfied by a
lghtnng con surrounded by a warnng
trangle.
Important nformaton n cases where there
s no rsk of njury materal losses s
dentfied by the symbol shown on the left.
It s bordered by horzontal lnes above and
below the text.
After havng removed the packagng, check that the
materal suppled s ntact and complete; f ths s
not the case, contact wth GASSERO or dealers.
The WALLCON Seres b olers must be nstalled by
authorzed person as detaled under any current
standards and law applcable and wth the nstruc-
tons provded by Gassero n the manual gven
wth the applance.
The boler must be used for the purposes t has
been expressly manufactured. Gassero declnes
all contractual and extra-contractual lablty for
damage caused to persons, anmals or thngs, due
to errors n nstallaton, control, servcng or mpro-
per use.
In case of the water leakage, dsconnect the boler
from the mans power supply, close the water sup -
ply and promptly 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 perod, the
followng operatons must be completed:
- move the man system swtch to "off"
- close the fuel cock and the water cocks on the cen -
tral heatng system
- empty the central heatng system f there s the rsk
of frost.
Mantenance and servcng must be done once a year.
Ths manual s an ntegral part of the boler and as a
consequence must be kept wth care. If the manual
s damaged or lost, contact wth Gassero to supply
a new copy.
PLEASE READ THESE INSTRUCTIONS CAREFULLY
BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE
GASSERO BOILER MODELS WRITTEN ON THE
FRONT COVER OF MANUAL ONLY AND MUST NOT
BE USED WITH ANY OTHER BOILER MODELS.
THIS APPLIANCE MUST BE INSTALLED BY A GAS SAFE
REGISTERED, AUTHORIZED PERSON. FAILURE TO
INSTALL CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU HAVE ANY QUESTION CONTACT THE GASSERO
TECHNICAL SERVICE. (techncal.serv[email protected],
PLEASE LEAVE THESE INSTRUCTIONS WITH THE
COMPLETED INSTALLATION CHECKLIST, AND USER
USER MANUAL WITH THE OWNER OR AT THE GAS
METER AFTER INSTALLATION OR SERVICING.
THE INSTALLATION AND COMISSIONING CHECKLIST
CAN BE FOUND IN BACK PAGES THE MANUAL.
1.2 GENERAL WARNINGS
Actons that absolutely must not be
carry out dentfied by the figure on left
Meanng of the Symbols and Safety Instructons
3
[phone] )

REV.03-(16.03.2015)
The boler must not be used by chldren or nvald
persons wthout supervson.
Electrcal devces or applances, such as swtches,
household applances, etc. must not be used f there
s the smell of gas or unburned fuel. In ths case :
- ventlate the room by openng doors and wndows;
- close the fuel stopcock;
- promptly contact Gassero, your gas suppler or
other professonally qualfied personnel.
Do not touch the boler when bare feet or wth wet
parts of the body.
No servce or cleanng operatons may be perfor-
med wthout first havng dsconnected the boler
from the mans power supply , movng the man
system swtch to "off".
The safety or control devces must not be adjusted
wthout the authorsaton and wrtten nstructons
from the manufacturer of the boler.
Do not pull, remove or twst the electrcal cables
comng out of the boler , even f the applance s
dsconnected from the mans power supply.
The ventlaton openngs n the room where the
applance s nstalled must not be plugged or redu-
ced n sze and must comply wth any current stan-
dards and law applcable.
Do not swtch off the boler f the outsde temperatu-
re may decrease below ZERO (rsk of freezng).
Do not leave flammable substances n the room
where the boler s nstalled.
The packagng materal must not be dspersed n
the envronment or left wthn the reach of chldren
as t s a potental source of hazard. It must be
dsposed of accordng to the legslaton n force.
Alteratons to parts connected to the applance
Do not carry out any alteratons for followng parts:
- the boler
- to the gas, ar, water supply ppes and electrcal
- to the flue ppe, safety valve and ts dran ppe
- to the constructve components wh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 socety or a company specalzed n
Indcatons for applances operatng wth propane gas
ensure yourself that before nstallng the applance the
For a correct purgng of the tank contact the lqud gas
suppler or a legalley authorzed person .
If the tank has not been correctly purged problems
could occur durng gnton. If ths occurs contact the
applance’s safe operaton
(for example water or gas leakages).
nstallng and servcng heatng systems
gas tank has been purged.
lqud gas tank’s suppler.
1.4 REGULATIONS AND STANDARTS
Current Gas Safety (Installaton & Use) Regulatons:
All gas applances must be nstalled by a competent
person n accordance wth the above regulatons;
The applance must be nstalled n accordance wth, and
comply to, the current: Gas Safety Regulatons, IEE
Regulatons, Buldng Regulatons, Buldng Standards
and any other local requrements.
Drectves:
• 2009/142/EEC gas applance drectve
• 92/42/EEC boler efficency drectve
• 73/23/EEC low voltage drectve
• 89/336/EEC EMC drectve
• 97/23/EC pressure equpment drectve
• any relevant requrement of the local authorty.
EN 15417Gas-fired central heatng bolers.
Specfic requrements for condensng
bolers wth a nomnal heat nput greater
than 70 kW but not exceedng 1000 kW.
EN 15420Gas-fired central heatng bolers. Type C
bolers of nomnal heat nput exceedng
70 kW, but not exceedng 1000 kW.
Installaton of rated nput greater than 70 kW
Meanng of the Symbols and Safety Instructons
4
1.3 SAFETY INSTRUCTIONS

REV.03-(16.03.2015)
2 GENERAL
the followng wall-mounted condensng gas bolers:
The Wallcon 115-125B-160B s sutable for use as a sngle
boler or as part of a cascade system.
CE LABEL
The applance comples wth the basc
requrements of the relevant European
drectves.
Conformty has been substantated by the
proper documents whch, together wth
the declaraton of conformty, are filed
wth the manufacturer.
•Wallcon 115-125B-160B
The boler may only be used to heat up water for heatng
systems as standard and/or domestc hot water (DHW)
systems wth the connecton of DHW tank.
The boler can be nstalled ether as a sngle system or as
part of a multple system (cascade system). A cascade
system enables several bolers of ths type to be
connected together, where maxmum of 16 bolers wth
a total capacty of 1.840 kW can be connected together.
Specal cascade unts (accessores) have been
developed to enable ths boler to be nstalled n a
cascade system. Every cascade unt ncludes an
nstallaton frame, horzontal headers, connecton ppes
for the boler, man gas ppe and vertcal low loss header.
Also, cascade unts are avalable for nstallng the bolers
nlne or back-to-back. These cascade unts make
nstallng a cascade system easer and less labour
ntensve. Please contact your dealer or the
manufacturer for further nformaton about cascade
systems.
CAUTION:
Damage to the nstallaton due to frost.
Install the heatng system n a room
whch s free from frost.
WARNING:
Fre hazard due to flammable materals or
lquds.
Do not store any flammable materals or
lquds n the drect vcnty of the boler.
CAUTION:
Boler damage due to contamnated
combuston ar or contamnated ar n the
boler room.
Never use the boler n an envronment whch
contans lots of dust or aggressve chemcals.
Such as spray shops,hardresser's shops,
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, made up of stanless steel heat exchanger.
The WALLCON bolers can be combned n a cascade
configuraton wth other heat generators to create
modular heatng plants made up of bolers connected to
the same water cr cut and wth electr onc controllers
communcatng va bus. The heat output of each boler
o
unt reaches 116.1 kW (100%, 50
o
C / 30 C)
modulated from 30% to 100%. The ef ficency reaches
107% and the low flue gas outlet temperature 64 o C .
2.2 DESCRIPTION OF THE APPLIANCE
The ndvdual heatng unts n cascadng configuraton
can be actvated, as well as by smple rotaton, n such a
way that when a certan percentage of output s reached
by the first unt, the other unts start automatcally, all wth
the same load factor.
The man features of the WALLCON Bolers are:
- fiber coated premx burner
- output from 29.3 to 116.1 kW (models 115 M and 115 S)
- heat output up to 1.840 kW, by connectng up to 16
bolers n a cascadng configuraton.
- quck connecton of the water and gas headers (opto -
nal)
- mcroprocessor control wth self-dagnoss, shown on
LED and the dsplay
- frost protecton functon actvated accordng to the out-
sde temperature and/or the temperature of the boler
- fitted for room thermostat n the hgh and low tempera-
ture zones
- outsde probe to enable the clmate control functon
- post-crculaton functon for the central heatng and
DHW crcuts
- prorty settable on the DHW, hgh or low temperatur e
crcut
-
- low nvestment costs for cascade operatons ( slave
- chmney sweep functon
-
-solar system & swmmng pool control functons
models can be controlled by Master models, wthout
usng any dsplay modules n slave unts)

REV.03-(16.03.2015)
General
6
2.4 PACKAGING LABEL
2.5 WARNING LABEL
WARNINGS !
.Read the techncal nstructons before nstallng
the boler.
.Installaton and comssonng must be done by
authorzed qualfied techncans.
.The boler may only be nstalled n a room whch
comples wth the approprate ventlaton requre-
2.6 DATA LABEL
Wall Hung Gas Condensng Bolers
Model : Wallcon J
Efficency Level :
Standards : EN 15417 / EN 15420
Flue (applance)
Types : B
Producton Year :
IP Class : X4D
Istanbul Endustr ve Tcaret Serbest Bolges
( FREE ZONE ) , 4. Sok. Parsel 110
34957 , Tuzla, Istanbul, TURKEY
www.gassero.com
ATTENTION : The boler s
adjusted n the Factory to Gas
Pressure of G20 - 20 mbar .
Pressure
Gas
Category
Gas
Desn aon
Countries of
NO Class : Z
X
Power Supply : 230V / 50 Hz
Power Consumpton : A
Max. Workng Temperature :
o
90 C
Max. Workng Pressure(PMS) : 6bar
Nomnal Heat Input Qn
o
Nomnal Useful Output at ( 80/60 C)
o
Nomnal Useful Output at ( 50/30 C)
.Read the user nstructons before operatng the
boler.
ments and whch s seperated from lvng rooms.
The Wallcon condensng bolers must be nstalled n rooms
used exclusvely for ths purpose, provded wth adequately
szed ventlaton openngs, n complance wth any current
standards and low applcable. If the combuston ar s taken
from 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ght than ar, the electrcal parts must be located at
least 500 mm from the floor.
The bolers cannot be nstalled outsde as they are
not desgned for outdoor operaton.
When nstallng and operatng the bolers t s necessary to
keep a safe 200 mm dstance from combustble materals
wth combustblty degrees B,C1,C2 .
For easly flammable materals wth combustblty degree C3
whch burn quckly and by themselves also after the gnton
source removal the safe dstance s doubled t means 400 mm.
0051 -12
1 2 3 4 5 6 7 8 9 0 1 2 3
Product Model : J
Seral Number :
1 2 3 4 5 6 7 8 9 0 1 2 3
Heat Output : Y
Gas Type : 2H G20-20 mbar-N.Gas
Countres of
Destnaton
1 2 3 4 5 6 7 8 9 0 1 2 3
Product Code :
Seral Number :
Product Code :
1 2 3 4 5 6 7 8 9 0 1 2 3
MASTER
SLAVE
Qn Max. (kW): C
Qn Mn. (kW) : D
Pn Max. (kW) : E
Pn Mn. (kW) : F
Pn Max. (kW) : G
Pn Mn. (kW) : H
Ĥ Y Z A B C D E F G H
115 116,1 5 300 W B23,C13,C33,C43,C53,C63,C83 27 108,5 26,1 105,4 29,3 116,1
125B 126 5 300 W B23,C43,C53,C63,C83 17 121 16,4 116,2 18,4 126
160B 158,8 4 400 W B23,C43,C53,C63,C83 21,5 152 20,9 146 23,4 158,8

REV.03-(16.03.2015)
3 TECHNICAL FEATURES
3.1 WALLCON 115-125B-160B DIMENSIONS
Techncal features
7
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

REV.03-(16.03.2015)
3.2 WALLCON 115-125B-160B HYDRAULIC DIAGRAM
KEY
1 - Pump (★ 160 kW Optonal)
2 - Safety relef valve
3 - Syphon
4 - Lmt thermostat
5 - Flow temperature sensor
6 - Return temperature sensor
7 - Automatc ar vent
8 - Flue outlet
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 losses (mbar)
160 kW Head Losses

REV.03-(16.03.2015)
3.3 WALLCON 115-125B-160B MAIN COMPONENTS
Techncal features
9
KEY
1 - Pump (★ 160 kW Optonal)
2 - Syphon
3 - Thermalfuse
4 - Return water NTC sensor
5 - Supply water NTC sensor
6 - Ar ntake termnal
7 - Condensate 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
89 10
12
18
13
14
17
7
1★
2
4
15
3
5

REV.03-(16.03.2015)
3.4 TECHNICAL DATA
Techncal features
10
mn. max. mn. max. mn. max.
Gas category
Fuel type
Nomnal Heat Input Qn kW 27 108,5 17 121 21,5 152
Nomnal Heat Output Pn at ( 80 - 60 °C ) kW 26,1 105,4 16,4 116,2 20,9 146
Nomnal Heat Output Pn at ( 50 - 30 °C ) kW 29,3 116,1 18,4 126 23,4 158,8
Water Operatng Pressure bar 0,8 6 0,8 6 0,8 6
Maxmum Operaton Temperature °C
Water Content l
Condensng Water Mass kg/h
Heatng Effcency Qmn ( 80 - 60 °C ) %
Heatng Effcency Qmax ( 80 - 60 °C ) %
Heatng Effcency Qmn ( 50 - 30 °C ) %
Heatng Effcency Qmax ( 50 - 30 °C ) %
Partal Load, Return 30°C (Drect Method) %
Flue Gas Temperature ( 50 - 30 °C ) °C 33 64 31,5 64,8 32,4 62,6
Flue Gas Temperature ( 80 - 60 °C ) °C 59 77 56,3 88 59,4 82,5
Gas Daphragm (G20 -G25) mm
Gas Daphragm (G31) mm
CO2 Emssons (G20) %8,8 9,3 8,7 9,4 9,2 9,4
CO2 Emssons (G25) %8,7 9,2 8,8 9,6 _ _
CO2 Emssons (G30) %10,3 10,9 11,1 11,2 10,3 10,7
NOX Emssons (G20) mg/kWh
NOX Emssons (G25) mg/kWh
NOX Emssons (G30) mg/kWh
NOX Class
Flue Gas Mass (G20) g/sec 12,60 48,40 8,03 53,53 9,69 67,24
Flue Gas Mass (G25) 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 Flow Connecton "
Boler Return Connecton "
Gas Suppy G 20 "
Safety Relef Valve Connecton "
Sphon Connecton for Condens Water Ø
Flue Gas Ppe Dameter Ø
Fresh Ar Connecton Ø
Power Suppy V/Hz
Electrcal Power W
IP Class IP
Dmensons WxLxH mm
Weght kg
25 25 25
108,2
104,1
109,2
109,0
104,5
109,1
108,4
107,0
107,6
10,7
7
_
9,5
96,8
97,1
2H,2E,2LL,3+ ,3B/P
Doğalgaz / LPG
B23,C13,C33,C53
14,9
22,4
97,2
96,1
Effcecy & Emssons
11,7
17,5
96,4
96
11,7
16
_
9,5
98,76
102,64
_
5 5 4
17,1
26,43
38,61
51,72
54,83
98,97
Boler Connectons
Electrcal Connectons
Boler Dmensons & Weght
1 1/4"
1 1/4"
1"
1/2"
100
100 100
1 1/4"
1 1/4"
1"
1/2"
100
100
1 1/4"
1 1/4"
1"
1/2"
100
230-50
400
X4D
557x580x865
92
557x580x865
92
557x690x865
98
230-50
300
X4D
230-50
300
X4D
Model
90 90 90
Type Of Flue Installaton B23,C43,C53,C63,C83
C43,C63,C83
115 125B 160B

REV.03-(16.03.2015)
The Wallcon bolers are suppled fully assembled n a
strong cardboard box.
After havng unpacked the boler check that t s ntact and
undamaged.
Keep the packagng materal (cardboard box,
plastc bags, polyester protecton etc .) out of
the reach of chldren as they can be
dangerous.
GASSERO refuses all lablty for njury to persons,
anmals or damage to property dervng from
not havng respected the above mentoned
recommendatons.
In the packagng, n addton to the boler, you can also find
the followng contents:
- Installaton and servce manual
- Warranty card
- Flue adapter for smoke evacuaton
4.1.2 TRANSPORT
CAUTION: Damage to the nstallaton due to
mpacts.
The boler contans parts whch can be
damaged by mpacts.
Durng further transport all parts must be
protected aga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.
Carefully transport the boler to the nstallaton
place.
The Wallcon Boler must be secured to a sold brck
or concrete wall usng the wall hangng brackets.
For nstallaton:
-Poston the bracket on the wall usng correct
level to make sure that the holes are perfectly
horzontal(1)
- Mark the fastenng holes on the wall (1)
- Drll the holes and nsert the expanson plugs(2)
- Fasten the bracket to the wall usng the screws
- Hook the boler to the bracket.
4.1.3 MOUNTING
Instructons for the nstaller
11
4 INSTRUCTIONS FOR THE INSTALLER
4.1 INSTALLATION
4.1.1 PACKING
- Wall hangng brackets
1
2
RESET

REV.03-(16.03.2015)
4.1.5 WATER QUALITY AND TREATMENT
If the water mght contan alumnum partcles, ths should
be maxmum 8,5 ppm. If there s any doubt of the water
stayng free of any knd of debrs/contamnaton n the perod
after nstallng, one should nstall a plate heat exchanger
to separate the boler crcut from the heatng crcut. To
avod to the maxmum any presence of oxygen n the
system, we recommend to prevent as much as possble
ar ntake and water leakage durng nstallaton. Power flush
the ppes and radators thoroughly to remove all fluxes and
debrs before connectng the boler to the central heatng
system n accordance wth local regulatons.
Instructons for the nstaller
12
The manufacturer declnes any lablty for damage caused to
the boler by falure to nstall or nadequate nstallaton of
ths filter. Before swtch on the boler, water must be crculate at
least 2 hours for elmnaton the mpurtes from the system
trough the mcro mpurty seperator. In the end of the operaton,
safety dran valve must be opened for removng the mpurtes.
It s also possble to use plate heat exchangers accordng the
system characterstcs. In any case, mcro mpurty seperators
must be used n the system n the boler. Before nstallaton,
carefully wash all the ppes of the system to remove any
resduals or mpurtes that could affect proper operaton of the
unt. Flter must also be nstalled on the system return ppng to
prevent mpurtes or sludge from the system cloggng and
damagng the boler.
CAUTION:
Boler damage due to corroson.
NOTE:
Damage to the nstallaton due to nsufficent or mproper
cleanng and mantenance.
Inspect and clean the heatng system as requred once a
year.
Carry out mantenance as requred.
Immedately remedy faults. Ths wll avod further damage
to the system!
DO NOT treat the water wth antfreeze.
Sutable chemcals and ther use should be dscussed wth a
specalst water treatment company pror to carryng out any
work (envronmental aspects, health aspects). The specficaton
of the system and manufacturers recommendatons must
be taken nto account, along 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 mportant to check the nhbtor
concentraton after nstallaton, system modficatons, fillng the
system and every servce n accordance wth these nstructons.
For the correct dosage and the sutablty of nhbtors for use
wth our bolers and for further nformaton on water treatment
or system cleanng we advse drect contact wth Gassero
servce.
The gas and water connectons are located on the bottom of
the boler whlst the ar ntake and flue outlet s located on the
top of the boler. The boler s suppled as standard wth ppe-
work tals to allow connectons facng downwards. For nstallaton,
servcng and nspecton mn. 600 mm n front of the boler s
requred. If ths free space s obtaned by openng a door or
removng a panel, the boler may be nstalled for nstance n a
closed cupboard. For ease of nstallaton we recommend
clearances of 0.5 cm at the sde so that the unt s easy to open,
wth a free space of 25 cm under the applance and 25 cm above
the applance, as the mnmum requrement.
4.1.4 CLEARENCES
860
The pH value of the water must fall wthn the followng lmts:
7 < pH < 9 n non-treated water. Ths pH value s achevable
after steady condtons when after fillng the mans network
water ( pH around 7 ) nsde the nstallaton and the ar
elmnaton operaton has been done.Treated water hardness
must wthn lmts 7 < pH < 8,5 The plumbng system must be cleaned usng wth sutable -
regstered produts before startng the nstallaton of the boler.
Neutral, non-acdc and non-alkal cleaners( SENTINEL X300,
X400, FERNOX ) must be used for preventng the metal,
plastc and rubber parts n the nstallaton system. Please obey
the nstructons of the manufacturer, when usng these type of
cleaners.
Note: Rust partcles and mpurtes n the heatng system can
caused problems.( overheatng, un-efficent and nosy work)
Problems and damages due to wrong nstallatons and wrong
plumbng systems s out of warranty.

REV.03-(16.03.2015)
4.1.6 WATER SIDE CONNECTION INSTRUCTIONS
The heatng capacty of the unt must be prevously establshed
by calculatng the buldng's heat requrement accordng to
current regulatons. The system must be provded wth all the
components for correct and regular operaton. In partcular,
provde for all the protecton and safety devces prescrbed by
current regulatons for the complete system.
We strongly recommend to nstall two ball valves
under the boler, so the boler can be solated from
the heatng system when needed.
4.1.7 EXPANSION VESSEL
Wallcon 115 s not suppled wth an expanson vessel;
therefore ts connecton must be carred out by the qualfied
nstaller. The capacty of the expanson vessel must be chosen
and nstalled to match the capacty of the central heatng
system and the statc pressure. We suggest you nstall the
expanson vessel n the return lne of the central heatng
system. It can be combned wth the dran valve for servcng.
4.1.8 SAFETY VALVE
Safety valve outlet must be connected to collecton ppe to
prevent water spurtng onto the floor n case of overpressure
n the heatng crcut. Otherwse, f the dscharge valve cuts n
and floods the room, the boler manufacturer cannot be held
lable.
4.1.9 CONDANSATE DISCHARGE
The condensate dran s n the left sde at the bottom of the
boler and has a 25mm hose dscharge. Connect ths flexble
hose to the sewer system. Use only plastc parts wth the
condensate dran. Metal lnes are not allowed. Blockage of ths
dran may cause damage to the boler. The dran connecton s
correct when the condensate can be seen flowng away, e.g.
usng a funnel. Any damage that may occur s not covered by
the warranty of the boler. There should be an open connecton
between the condensate hose from the boler, to the sewage
system. An under pressure n the sewage system should never
be able to suck on the boler condensate dran hose. The
condensate dran must be connected n accordance wth
current regulatons.
Do not use the water system ppes to earth electrcal
applances.
4.1.10 FROST PROTECTION
Wallcon seres boler has bult-n frost protecton, automatcally
actvatng the central heatng pump when the boler return
water temperature drops below 5°C. The pump and/or burner
wll shut down as soon as the return temperature has reached
demanded pont. The above-mentoned temperatures relates
to the temperature 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 cleanng
nterval.
Instructons for the nstaller
13
ncludng an ar bleed valve so the straner can be solated from
the heatng crcut for servcng. Clean water s mportant,
blocked heat exchangers do not fall under warranty. The filter
should be nstalled when replacng bolers n exstng systems.
The manufacturer declnes any lablty for damage caused to
the boler by falure to nstall or nadequate nstallaton of
ths filter. Before swtch on the boler, water must be crculate at
least 2 hours for elmnaton the mpurtes from the system
trough the mcro mpurty seperator. In the end of the operaton,
safety dran valve must be opened for removng the mpurtes.
It s also possble to use plate heat exchangers accordng the
system characterstcs. In any case, mcro mpurty seperators
must be used n the system n the boler. Before nstallaton,
carefully wash all the ppes of the system to remove any
resduals or mpurtes that could affect proper operaton of the
unt. Flter must also be nstalled on the system return ppng to
prevent mpurtes or sludge from the system cloggng and
damagng the boler.
We advse to mount valves before and after the straner
There s an automatc ar vent mounted n the boler to remove
ar from the water crcut. Ths automatc ar vent s only for
elmnate the ar n the heat exchanger of the boler. One or more
external automatc ar vent(s) and/or ar separators should
always be nstalled n the heatng system to elmnate ar trapped
n the heatng crcut.
4.1.13 PUMP
The WALLCON 115 bolers are suppled wth a bult-n
crculaton pump wth 3-poston electrc speed control. The
pump s the sngle-phase type (230 V - 50 Hz). To ensure
optmal boler operaton, n the case of new systems (sngle
ppe and module) t s recommended to use the pump at
maxmum speed. The pump runs when heat s requred. When
heat s no longer requred, the pump wll contnue to run for
another 3 mnutes before t stops. The 24-hour cycle starts as
soon as the power supply to the boler s actvated.
4.1.12 AUTOMATIC AIR VENT
Drt
seperator
Ar
seperator
Low loss
header
Plate heat
exchanger
Flter
0
1
2
3
4
5
6
7
H
[m]
0
10
20
30
40
50
60
70
[kPa]
p
0 1 2 3 4 5 6 7 8 Q [m /h]
QH Chart
3

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
11
2
5
6
RESET
RESET

REV.03-(16.03.2015)
Instructons for the nstaller
15
4.2.2 CASCADE INSTALLATIONS
1 - Wallcon condensng boler
2 - Room thermostat (QAA55)
3 - Outsde probe (QAC34)
4 - Condansate dscharge
5 - Ar seperator
6 - Plate heat exchanger / Low loss header
7 - Drt seperator
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
15
6
18
13
17
7
9
10
8
11
14
15
12
16
RESET RESET
SLAVE
RESET
SLAVE
RESET
SLAVE
RESET
SLAVE

REV.03-(16.03.2015)
4.3 ADJUSTMENT OF THE GAS RATE
All the nstructons wrtten below are for the exclusve
use of qualfied servce techncans or nstallers. All the
bolers are suppled already calbrated and tested.
Adjustments are only be made wth specal tools.
4.3.1 Descrpton of the adjustment ponts
4.3.2 Combuston values adjustment table
4.3.3 Maxmum output adjustment
1 - Connect the gas analyser probe to the samplng test pont
Wallcon
on the flue adapter.
2
WARNING:
Damage to the boler by ncorrect adjustment of the
gas/ar-rato.
To ensure correct operaton the values have to be
adjusted wth extreme care respectng the values
ndcated n the table.
- For operatng n the max. output, press at least 3 seconds to
heatng mode when the boler n mode.Controller functon stop
wll appear on the screen.Than press nformat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) pressure tap
mn. max. mn. max. mn. max.
CO2 Emsson (G20) %8,8 9,3 8,7 9,4 9,2 9,4
CO Emsson (G20) ppm 1 98 1 144 1 174
Gas Consumpton (G20)
m3/h 2,9 11,5 1,77 12,52 2,26 15,61
Fan Speed (G20) rpm 1650 5850 1300 6400 1400 7250
Combuston Mass Flow (G20) g/sec 12,6 48,4 8,03 53,53 9,69 67,25
Gas Daphragm (G20) mm
mn. max. mn. max. mn. max.
CO2 Emsson (G25) %8,7 9,2 8,8 9,6 _ _
CO Emsson (G25) ppm 2 110 1 186 1 _
Gas Consumpton (G25) m3/h 3,3 13,4 2,1 14,61 _ _
Fan Speed (G25) rpm 1650 5850 1300 6400 _ _
Combuston Mass Flow (G25) g/sec 12,7 48,9 7,96 52,61 _ _
Gas Daphragm (G25) mm 10,7 _ _
Model 115
Model 115 125B 160B
10,7 _ _
125B 160B

REV.03-(16.03.2015)
3 - Connect the pressure gauge connecton tube to the postve
port of the testng npple and check the gas supply pressure.
4 - Connect the pressure gauge connecton tube to the burner
pressure tap and check the burner supply pressure. Burner
pressure must be adjust accordng to the table. Check that
the CO values are wthn the values ndcated n the table.
2
Correct the value by turnng the adjustment screw (C) n
clockwse drecton to decrease the value and n an ant-
clockwse drecton n order to ncrease the value.
4.3.4 Mnmum output adjustment
2 - Connect the pressure gauge connecton tube to the burner
pressure tap and check the burner supply pressure. Burner
pressure must be adjust accordng to the table. Check that
the CO values are wthn the values ndcated n the table.
2
Correct the value by turnng the adjustment 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. valuesCO2
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.
Instructons for the nstaller
17
1- For operatng n the mn. output, press at least 3 seconds to
heatng mode when the boler n mode.Controller functon stop
wll appear on the screen.Than press nformaton button, t wll
ndcate the modulaton rate (%) on the screen. Adjust the rate to
0% for mn. output settng wth usng of navgaton button. Then
press OK . Thus, boler wll operate n mnmum power.
0 %
...... mbar...... mbar
Burner(outlet) pressure tap
D
Maxmum output
adjustment screw
C
1Remove the screw
3Fasten the screw
Connect the gauge
...... mbar
2
...... mbar
2
Inlet pressure tap
B
Mnmum output adjustment screw
A
...... mbar...... mbar
Burner(outlet) pressure tap
D

REV.03-(16.03.2015)
Instructons for the nstaller
18
4.4 GAS CONVERSION INSTRUCTIONS
All the nstructons wrtten below are for the exclusve
use of qualfied servce techncans or nstallers.
1 - Close the gas valve and gas supply ppe to the boler.
2 - Remove 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 - Remove the ventur
screws for dsconnectng
from gas valve.

REV.03-(16.03.2015)
Instructons for the nstaller
19
7 - Remove the o-rng.
8 - Remove the current gas nozzle than nstall the rght gas
nozzle ncludng the enclosed O-rng for the type of gas
supply.
G20 / G25 nozzle dameter : 10.7 mm
G30 butane/G31 propane nozzle dameter : 7.0 mm
***Lower calorfic powers at 15°C, 1013mbar:
3
N.Gas G20 : H = 34,02 MJ/m
3
N.Gas G25 : H = 29,25 MJ/m
3
Butane G30 : H = 116,09 MJ/m
3
Propane G31 : H = 88,0 MJ/m
WARNING:
Please contact wth Gassero servces for nozzle types.
Gas conversons must done by authorzed qualfied
servce techncans.
4.5 FLUE INSTALLATION INSTRUCTIONS
The flue and the fittng to the flue must be made n
complance wth the standards and the legslaton n
force, as well as wth local regulatons.
The ppes used must be rgd and resstant to
temperature, condensate and mechancal stress,
and artght.
Non-nsulated flues are potental sources of danger.
IMPORTANT INFORMATION
If the lowest part of the termnal s less than 2 metres above the
level of the ground, balcony, flat roof or place to whch any
person has access, the termnal must be protected by a guard.
The flue assembly shall be so placed or shelded as to prevent
gnton or damage 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 occur the applance MUST
be turned off, and sgned as unsafe untl correctve
acton can be taken.
4.5.1 FLUE APPLIANCE TYPES
B =
23
The combuston
ar s ntaken drectly from the room where the
boler s nstalled.
Smoke evacuaton duct connected to outsde from
room where the boler s nstalled.
C =
13 Concentrc and closely placed ducts connected to
a horzontal termnal for fresh ar ntake and fume
dscharge.
C =
33 Concentrc and closely placed ducts connected to
a vertcal termnal for fresh ar ntake and fume
dscharge.
C =
43 Two connectng ducts and two collectng flue ;
one for fresh ar ntake and other one s for fume
dscharge.
nozzle
o-rng
mn. max. mn. max. mn. max.
CO2 Emsson (G31) %10,3 10,9 11,1 11,2 10,3 10,7
CO Emsson (G31) ppm 2 168 1 125 1 210
Gas Consumpton (G31) m3/h 0,8 3,4 0,67 4,91 0,89 6,14
Fan Speed (G31) rpm 1500 5350 1150 6150 1400 7250
Combuston Mass Flow (G31) g/sec 12,2 46,3 7,13 50,14 9,64 65,9
Gas Daphragm (G31) mm
Model 115 125B 160B
79,5 9,5