gassero Wallcon X-treme 42 User manual

INSTALLATION AND USER MANUAL
WALL HUNG CONDENSING BOILERS
EN
WALLCON 42
WALLCON 50
WALLCON 67
WALLCON 70
WALLCON 80
WALLCON
0063-22

CONTENTS
IMPORTANT
PLEASE READ INSTRUCTIONS BELOW CAREFULLY BEFORE THE INSTALLATION AND USAGE
1. THIS MANUAL IS AN INSEPARABLE PART OF THE BOILER AND HAS TO BE STORED TOGETHER WITH THE
BOILER.IF THIS MANUAL DAMAGED OR LOST CONTACT GASSERO FOR ANEW COPY.
2. THE INFORMATION AND INSTRUCTIONS THAT ARE SPECIFIED IN THIS USER'S MANUAL APPLY ONLY FOR THE
BOILER MODELS SPECIFIED IN PAGE 3.
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 ORGANIZATIONS BEFORE THE COMMISSIONING OF
THE BOILER.
5. COMMISSIONING OF THE BOILER MUST BE MADE BY GASSERO’S AUTHORIZED SERVICES. OTHERWISE
BOILER WARRANTY WILL BE CANCELLED.
6. THE MANUFACTURER IS NOT THE RESPONSIBLE OF THE DAMAGE DUE TO WRONG OR IMPROPER
INSTALLATION OF THE BOILER.
7. SOME PARTS OF THE PURCHASED BOILER COULD BE DIFFERENT THAN SHOWN BOILER PARTS IN THIS
MANUAL.
8. MANUFACTURER (GASSERO) RESERVES THE RIGHT TO CHANGE THIS USER'S GUIDE WITHOUT NOTICE.
9. LIFE TIME OF THE BOILER IS 10 YEARS IF ALL OF THE INSTRUCTIONS FOLLOWED ACCORDING TO THIS USER
MANUAL.
10. BOILER MAINTENANCE MUST BE MADE AT LEAST ONCE IN A YEAR.
1
1Meanings of the Symbols and Safety 24.2.6 Automatic Air Relief Valve 15
1.1 Meanings of the Symbols 24.2.7 Deposit and Dirt Separator 15
1.2 General Warnings 24.2.8 Air Inlet Filter 15
1.3 Safety Instructions 24.2.9 Accessories List 16
1.4 Standards and Regulations 34.2.10 Pump 17
2General 34.3 Flue Connections 19
2.1 Purpose of Design 44.3.1 Flue Types 19
2.2 Introduction of the Product 44.3.2 Flue Connection Lengths 20
2.3 Boiler Room and Ventilation 54.4 Electrical Connections 21
2.4 Hydrogen Compatibility 54.4.1 Wiring 21
2.5 Warning Label 64.4.2 Outdoor Temperature Sensor 25
2.6 Packaging Label 65Installation Examples 26
2.7 Information Label 66Operation 30
3Technical Specifications 76.1 General 30
3.1 Dimensions 76.2 Display and Buttons 30
3.2 Hydraulic Diagram 86.3 Error / Fault Codes 32
3.2 Main Components 96.4 Programming 33
3.3 Technical Table 10 7Combustion Adjustment 34
4Installation Introductions 11 7.1 Emission Setpoints 34
4.1 Installation 11 7.2 Nominal Load Emission Settings 35
4.1.1 Packaging 11 7.3 Minimum Load Emission Settings 36
4.1.2 Carrying 11 8LPG Conversion 36
4.1.3 Mounting 11 9Maintenance 39
4.1.4 Water Quality and Treatments 12 9.1 Maintenance Process 39
4.2 Hydraulic Connections 13 10 Energy Saving Recommendations 41
4.2.1 Expansion Tank 13 11 Disposal 41
4.2.2 Safety Valve 13 12 Troubleshooting 42
4.2.3 Condensation Water Drain 14 13 Product/Energy Labels 43
4.2.4 Hydraulic Separator 14 14 Boiler Room Application Recommendations 45

1. MEANINGS OF THE SYMBOLS AND SAFETY
1.1 MEANİNGS OF THE SYMBOLS
The symbols which are used in this document and their
meanings are as follows:
WARNING:Danger of material damage or damage to
the environment.
ELECTRICAL HAZARD:Danger of death or serious
injury due to electric shock.
DANGER :Actions that are certainly not to be done.
Material damage and severe personal damage may
occur.
Refers to the Information / Recommendations to be
considered by the user
1.2 GENERAL WARNINGS
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 INSTRUCTIONS
IF YOU SMELL GAS:
Do not open or close the power switches, do not
touch the plugs or sockets.
Do not smoke
Do not use your phone
Close the gas valve immediately
Ventilate the space by opening the doors and
windows.
Notify everyone in the building.
Call the emergency service of the gas distribution
company you are connected to.Do not allow
anyone to enter the boiler room until the
emergency service arrives.
If there is asealing due to gas leakage, do not
disassemble the seal, contact the gas distribution
company to disassemble the seal after necessary
repair.
The smell of the waste gas formed after burning
with natural gas may resemble each other.Never
use the boiler in the event of aleak in the waste
gas system.
2

IF WATER LEAKAGE OCCURS 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. In case of leakage or leakage of this
water, inform the authorized service.
IF ELECTRICAL LEAK OCCURS IN THE BOILER:
Never touch the boiler.
Lower the main switch on the board and notify the
authorized service.
Do not touch the pipes or the chimneys.(there may
be aground fault)
Do not cut, pull, or bend the cables even if the
switch is lowered and the power cut off.
DON’T TOUCH THE BOILER WHEN YOUR HANDS
ARE WET OR STEPPING ON A WET AREA.
1.4 STANDARTS AND REGULATIONS
2. GENERAL
These installation and maintenance instructions are prepared for
the wall hung condensing boilers specified below:
WALLCON 42
WALLCON 50
WALLCON 67
WALLCON 70
WALLCON 80
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.
3
This boiler is manufactured in accordance with the following
directives and standards:
EN 15502-1
EN 15502-2-1+A1
(EU) 2016/426 Gas Appliances Regulation (GAR)
2014/30/EU Electromagnetic Compatibility (EMC)
2014/35/EU Low Voltage Directive (LVD)
92/42/EEC Boiler Efficiency Directive (BED)
813/2013 Ecodesign Directive (ErP)
0063-22

2.1 PURPOSE OF DESIGN
Gassero WALLCON Wall Hung Condensing Boilers with Premix
Burners are designed for heating purposes only.For hot water use,
the boiler must also be connected to the DHW tank.Boiler can be
used with in acascade system or standalone.Maximum 16 boilers
can work together in cascade systems.Multi-purpose heating
values can be achieved with cascade systems. For example;
16 units of 50 kW boiler can reach 800 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 elements, connection pipes between the
boilers, main gas pipe and hydraulic mixer (balance vessel) have
been developed.Such accessories make the cascade system easier
to install with less effort.For more detailed information on cascade
systems, please contact your dealer or manufacturer.
This boiler is not suitable for industrial purposes.
The manufacturer cannot be held responsible for
the problems caused by the usage except of the
design purpose.
WARRANTY PERIOD AND LIFE TIME:
Warranty is 2years from the date of invoice,unless other terms are
agreed separately.
Service life of the boiler is 10 years (this period can be change
according to the installation, water quality and other environmental
conditions).
CONSUMER RIGHTS:
Consumers can apply for complaints and appeals to consumer courts
and consumer arbitration committees.
In case of defective goods;
a) Withdraw from the contract by stating that it is ready to return the
product;
b) If all costs incurred do not incur excessive costs,
to request free repair of the product,
c) Requesting the replacement of the product with anon-defective
product,
One of the rights can be used.
2.2 INTRODUCTION OF THE PRODUCT
4
WALLCON is acondensing boiler which is modulated with a
stainless steel heat exchanger and premix burner for central heating
and (optional) hot water production.
BASIC FEATURES OF WALLCON BOILERS:
Stainless steel heat exchanger
NOx 6emission class
Room thermostat and outside temperature sensor provide
comfortable economic heating
Besides the ease of operation via smart digital panel, it provides
fault and error detection.

2.3 BOILER ROOM AND VENTILATION
5
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 be placed 400 mm away from the easily flammable
materials of the C3 class which can be ignited by themselves or
by ignition sources.
Never switch off the power supply of the boiler when the air
temperature falls below 0°C against the risk of freezing.
WALLCON condensing boilers must be installed in spaces that
have the necessary ventilation openings according to current
standards and applicable regulations
Do not modify the ventilation openings, ventilation ducts,
ventilation vents and do not block them after the commissioning.
Never use the boiler in places where excessive amounts of dust
are stored, where corrosive, explosive chemicals are stored or
used.
If the boiler receivesthe combustion air from the environment,
there should not be any low pressure due to other systems /
boilers in the boiler room.
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.
2.5 WARNING LABEL
WARNINGS !
Read the technical instructions
and user manual carefully before
the commissioning.
Commissioning must be made by
an authorized Gassero service.
The boiler must be located in a
location that is separate from the
living quarters and only in
accordance with the ventilation
legislation.
2.4HYDROGEN COMPATIBILITY
The Wallcon 42-50-67-70-80 boilers have been tested for mixing of
%20 hydrogen to natural gas, and can be used with %20 hydrogen-
natural gas mixtures.

2.6 PACKAGING LABEL
2.7 INFORMATION LABEL
6
Gas categories and pressure
Appliance
category
Supply
pre ssu re s
[mbar]
Ga s u se d Country of destination
20
AT, BG, CH, CY, CZ, DK, EE,
ES, FI, GB, GR, HR, IE, IT,
LT, LV, NO, PT, RO, SE, SI,
SK, TR
25 HU
I
2E
20 G20 DE, NL, PL, RO
30
CY, CZ, DK, EE, FR, GB,
HR, HU, IT, LT, NL, NO, RO,
SE, SI, SK
37 PL
50 AT, CH, CY, CZ, DE, FR, SK
I
3+
30/37 G30/G31
BE, CH, CY, CZ, ES, FR,
GB, GR, IE, IT, LT, PT, SI,
SK, TR
20, 30
CY, CZ, DK, EE, GB, HR, IT,
LT, NO, RO, SE, SI, SK
25, 30 HU
20, 50 AT, CH, CY, CZ, SK
II
2H3+
20, 30/37
G20,
G30/G31
CH, CY, CZ, ES, GB, GR, IE,
IT, LT, PT, SI, SK, TR
20, 30 NL, RO
20, 37 PL
20, 50 DE
II2E3P
20, 50 G20, G31 DE
II2ELL3P
20, 50
G20, G25,
G31
DE
II
2E3B/P
G202, G30
I
2H
G20
I
3B/P
G30
II
2H3B/P
G20, G30
A B C D E F G H I
42 41.3 kW 110 W 37.2 kW 39.4 kW 7.0 kW 38.3 kW 7.6 kW
50 50.1 kW 131 W 38.4 kW 48.0 kW 8.1 kW 46.3 kW 8.9 kW
67 67.0 kW 170 W 411.2 kW 63.0 kW 11.0 kW 61.0 kW 12.0 kW
70 69.9 kW 180 W 411.2 kW 66.0 kW 10.9 kW 64.5 kW 12.1 kW
80 80.9 kW 204 W 411.2 kW 76.0 kW 10.9 kW 74.1 kW 12.1 kW

3TECHNICAL SPECIFICATIONS
3.1 DIMENSIONS
7
WALLCON
42
WALLCON
50
WALLCON
67
WALLCON
70
WALLCON
80
A (Width) [mm] 486 486 486 486 486
B (Length) [mm] 490 490 540 540 540
C (Height) [mm] 612 612 612 612 612
D (Gas inlet) 3/4" 3/4" 3/4" 3/4" 3/4"
D1 [mm] 230 230 230 230 230
D2 [mm] 222 222 222 222 222
E (Water outlet conn.) 1" 1" 1" 1" 1"
E1 [mm] 145 145 145 145 145
E2 [mm] 158 158 158 158 158
F (Water inlet conn.) 1" 1" 1" 1" 1"
F1 [mm] 145 145 145 145 145
F2 [mm] 116 116 116 116 116
G / H (Waste Gas Out / Air Inlet ) [mm]
Ø80 / Ø80 Ø80 / Ø80 Ø80 / Ø80 Ø80 / Ø80 Ø80 / Ø80
G1 [mm] 147 147 147 147 147
G2 [mm] 223 223 223 223 223
J (Condensate drain) [mm] Ø25 Ø25 Ø25 Ø25 Ø25

8
3.2 Hydraulic Diagram
Wallcon 42-50-67
Wallcon 70-80

3.3 MAIN COMPONENTS
9
1. Fan
2. Gas Valve
3. Control Panel
4. Heat Exchanger
5. Ionization Electrode
6. Ignition Electrode
7. Ignition Transformer
8. Limit Termostat
9. Pressure Sensor
10. Flow NTC Sensor
11. Return NTC Sensor
12. Automatic Air Vent
13. Flue Gas Sensor
14. Flue Gas Outlet
15. Syphon
16. Water Inlet Conn.
17. Water Outlet Conn.
18. Gas Inlet
19. Air Intake
20. Venturi
21. Syphon Sensor
22. Pressure Safety Valve
23. Recirculation Pump
24. Electric Box
25. Cut-Off
26. LGW-Air Pressure Switch

3.4 TECHNICAL TABLE
10
* G30 combustion values are given at page 41.
** Gas consumption values are calculated at normal conditions, 15 °C and 101,325 kPa.
WALLCON 42 WALLCON 50 WALLCON 67 WALLCON 70 WALLCON 80
Nominal heat input Qn kW 7.2/39.4 8.4/48.0 11.2/63.0 11.2/66.0 11.2/76.0
Nominal heat output Pn (80/60°C) kW 7.0/38.3 8.1/46.3 11.0/61.0 10.9/64.5 10.9/74.1
Nominal heat output Pnc (50/30°C) kW 7.6/41.3 8.9/50.1 12.0/67.0 12.1/69.9 12.1/80.9
Heating efficiency ꞃu.n (80/60°C) %96.30/97.37 95.62/97.40 98.02/97.62 97.31/97.72 97.31/97.61
Heating efficiency ꞃu.n (50/30°C) %106.42/105.21 106.96/105.14 107.42/106.58 107.98/106.57 107.98/106.55
Partial load efficiency ꞃu (36/30°C) %108,20 108,08 108,16 108,39 108,34
Turndown ratio -19-100 18-100 18-100 17-100 15-100
Working water pressure bar 0.8/3.0 0.8/3.0 0.8/4.0 0.8/4.0 0.8/4.0
Water flow rate m³/h 0.28/1.70 0.31/2.12 0.43/2.89 0.43/2.63 0.43/2.89
Pump delivery head mWC 6.0 5.5 3.5 3.5 3.5
Max. operating temp. ˚C 80 80 80 80 80
Limit thermostat shut offtemp. ˚C 95 95 95 95 95
Heat exchanger water volume lt 2.74 2.74 3.52 3.52 3.52
Hydraulic loss kPa 30 40 44 40 55
Gas type* -G20 G20 / G30 G20 / G30 G20 / G30 G20 / G30
Gas supply pressure mbar 20 20/30 20/30 20/30 20/30
Flue Type -B23
Flue gas pressure Pa 100 140 170 190 210
Combustion products mass flow rate g/sn 3/17 4/21 5/28 5/28 5/30
Max flue length (C13/C33/C43/C53/C63/C83) m15 15 15 14 -
CO2 emission %8.90/9.10 9.00/9.30 9.03/9.25 9.20/9.10 9.20/9.40
COemission ppm 2/44 2/40 12/81 1/82 12/115
O2 %5.00/4.70 5.50/5.50 4.97/4.37 4.90/5.00 4.90/4.50
Flue gas temp. (80/60˚C) (min/ma x) ˚C 63.5/65.3 64.8/66.6 56.9/69.9 62.7/72.8 62.7/75.4
Flue gas temp. (50/30˚C) (min/max) ˚C 40.4/42.1 43.4/46.5 35.1/47.7 39.6/51.8 39.6/54.6
Flue gas overheat temperature ˚C
NOx class -66666
NOx value mg/kWh 42 25 21 21 22,8
Gas consumption** m³/h 0.70/3.86 0.81/4.85 1.09/6.43 1.11/6.85 1.11/7.48
Integrated backdraught shutter -Yes Yes Yes Yes Yes
Boiler water inlet/outlet diameter DN 25/25 25/25 25/25 25/25 25/25
Air inlet/outlet diameter (B23) mm 80/80 80/80 80/80 80/80 80/80
Air inlet/outlet diameter
(C13/C33/C43/C53/C63/C83)
mm 125/80 125/80 125/80 125/80 -
Gas supply diameter DN 20 20 20 20 20
Power supply V/Hz 230/50 230/50 230/50 230/50 230/50
Electrical consumption W120 130 190 180 204
Exchanger type -Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel
Energy efficiency class -AAAAA
Sound power level (Lwa) dB(A) 53.50 55.50 63.00 70.00 71.10
Sound pressure level (from 1m distance ) dB(A) 45.52 47.52 55.02 65.10 66.10
Boiler dimensions (Width/Length/Height) mm 485x490x612 485x490x612 485x490x612 485x540x612 485x540x612
Boiler weight (Net) kg 46 46 50 50 50
Packing dimensions (Width/Length/Height) mm 1020x580x550 1020x580x550 1020x640x550 1020x640x550 1020x640x550
Boiler weight (Gross) kg 53 53 57 57 57
Thermal Specifications for G20
Gas Specifications
Hydraulic Specifications
Combustion Specifications for G20
Connection Specifications
Electrical Specifications
General Specifications
Packaging Specifications
B23/C13/C33/C43/C53/C63/C83
105

11
4INSTALLATION INTRODUCTIONS
4.1 INSTALLATION
4.1.1 PACKAGING
The Wallcon boilers are fully assembled,tested and packed in a
cardboard box which maintained with styrofoam.
PACKAGE CONTENTS :
Outdoor sensor
Wall hung equipments (2pcs.12 mm wall plug and 2pcs.12
mm hook)
User manual /Warranty certificate
Cascade sensor
DHW sensor (optional)
Air inlet filter (optional)
When the boiler is unpacked,check the contents of
the package, contact the dealer if there is any
damage or missing components.
Disposing of packaging materials and leaving them
accessible to children can be dangerous.
Disposing of packaging materials can be harmful
for people, animals and the environment.
Manufacturer is not liable for harmes that may arise
from such situations.Such wastesmust be treated
according to current regulations.
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 awater filled boiler.If
the carrying capacity of the wall is not sufficient, an external
suspension device must be provided.For example; a footed
device may be used.
For easeof service oparation to the boiler, the necessary
distances must be left around the boiler.
Wallcon

12
Wall Mount:
The dimensions of the hanger spaces behind the boiler are shown below.
Drill the holes you marked with a 12 point drill.
Screw the hooks and hanger hooks into place.
Hang the boiler from the sling slots on the wall.
Hanger Hooks
4.1.4 WATER QUALITY AND TREATMENTS
Paying attention to the following issues related to water quality will
greatly reduce the problems that may arise during the life time of
the boiler and ensure the continuity of the working efficiency:
Piping and installation components 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 the
system should be separated from each other as
primary and secondary.
Faults that may arise if the water conditions are not
in accordance with the values specified in the table,
boiler will be considered out of warranty.

Total Hardness
°d
pH
Iron
(Not Diluted)
Conductivity
STAINLESS EXCHANGER 1,00 7,5-9,5 <10ppm ≤2000µS/cm
ALUMINUM EXCHANGER 1,00 6,5-8,5 <10ppm ≤2000µS/cm
Gassero Water Specification
DYNAMIC AND CHEMICAL WASHING / FLUSHING:
In the newly established systems, to aviod the possible substances
in the installation (metal shavings, some oils, residues of
construction wastes etc.) flushing treatment is a mandatory.
Likewise, it is amandatory to apply the flushing treatment without
water given to the boiler in conversion of older systems.
The methods of washing / flushing are described in detail in the
manual GASSERO DYNAMIC AND CHEMICAL WASHING /
FLUSHING.
Neutral-based, non-acidic, non-alkaline registered products can be
used to clean the installation or keep the water conditions at desired
levels. You can get information from GASSERO for 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 perform their
duty. Protective and safety devices must be used in the heating
system as described in the current legislation.
In order to separate the boiler from the installation, two
ball valves should be placed on the supply and the
return lines.
4.2.1 EXPANSION TANK
WALLCON boilers do not have an expansion tank. So the capacity
of the expansion tank should be selected according to the capacity
of the heating system and the static pressure.
It is recommended to place the expansion tank on the
turn of the central heating system.
4.2.2 SAFETY VALVE
WALLCON boilers are equipped with a safety valve. The hose of
this safety valve must be connected to a drain. Manufacturer
cannot be held liable for damages caused by water flow into the
boiler or on the ground when excessive pressure is generated in
the heating installation.
Safety valve must not be used as a means of
draining water from the system.
Draining water of the safety valve can be very hot.
Beware of scalding.
13

4.2.3 CONDENSATION WATER DRAIN
Condensation water which is generated during 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 drain with the shortest way
possible. For health and environmental reasons it mustn’t transfer such places
near people, animals and plants.
Condensation water must not be connected to rain drain systems.
The condensate drain line must have a slope of at least 3%.
A neutralization tank should be used for condensate water occurring in
systems with a total power of 200 kW and above.
It is mandatory to comply with the relevant local regulations for the discharge
of condensate water.
4.2.4 HYDRAULIC SEPARATOR
These are used to compensate the pressure differences in systems where multiple
pumps and / or heating circuits are used, to eliminate excessive pressure
differences between boiler’s inlet and outlet water temperatures and to prevent
thermal stresses in the boiler.
Dimensions, input and output distances should be selected correctly.
Via a sensor to be placed on it, the general temperature of the system is
determined by the hydraulic separator.
There must be an automatic air relief valve on the hydraulic separator.
In case the water in the system is dirty, chalky or corrosive, plate
heat exchanger should be used instead of balance container.
4.2.5 PLATE HEAT EXCHANGER
Plate heat exchangers are hydraulic equipmentsthat separates the boiler and the
installation (primary and secondary zones). Unlike the hydraulic separator
circulating water in the plate heat exchanger 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 apart or all of the system is required to operate with lower temperature
values. (eg.underfloor heating systems)
The plate heat exchanger must be used in the following cases
and the system must be separated into primary and secondary.
-Heating systems which are consist of partly of fully
floor heating,
-Used, older systems,
-Systems that are dirty, corrosive, bacterial and
calcareous water.
Periodic inspection and maintenance of the plate heat
exchanger is important for the efficiency of the system.
Condensate outlet shall not be blocked or tampered with!
14

4.2.6 AUTOMATIC AIR RELIEF VALVE
Wallcon boilers have an automatic relief valve for the evacuation of
the air accumulated in the heat exchanger. However, for the
evacuation of the air that may occur in the installation, it is
necessary to place one or more automatic air relief valves in the
appropriate places of the installation. Local regulations must be
followed in this regard.
4.2.7 DEPOSIT AND DIRT SEPARATOR
To remove the dirt and particles form the water, a strainer or deposit
and dirt separator must be placed on the return line of the boiler.
When the dirt, particles and similar deposits in the system water
are not cleaned;
The efficiency of the system decreases,
Installation equipments(pumps, valves, plate heat exchanger,
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 seperators on the system
should be checked frequently and cleaned if
necessary.
4.2.8 AIR INLET FILTER (OPTIONAL)
If WALLCON boilers will be used in to a dirty air environment, they
must be supported with the air inlet filters. This optional filter must be
checked regularly.
When the air inlet filter becomes dirty;
Emission values would be deterioratedand efficient combustion
wouldn’t be achieved.
The accumulation of soot occurs in the heat exchanger.
Loud ignition and combustion occurs.
Overheating, leakage and deformation would be observed in the
flue system.
Manufacturer cannot be held liable for damages
caused by dirty combustion air.
Don’t block the air filter partially or totally.
15

4.2.9 Accessories List
42 50 67 70 80
OUTSIDE TEMPERATURE SENSOR 400050026 •••••
IMMERSION TEMPERATURE SENSOR 400050020 •••••
STRAP-ON TEMPERATURE SENSOR 400050021 •••••
EXTENSION MODULE
EBM
400050093 •••••
COAXIAL Apparatus
Ø80/125
100115073 •••••
Boileradapter PPs/Alu
Ø80/125
400050035 •••••
PPs/Alu bend 90°
Ø80 /125
400050036 •••••
PPs/Alu pipe
Ø80 /125
L = 1000 mm
400050037 •••••
PPs/Alu Wall Terminal
Ø80 /125
400050038 •••••
Chimney Set (For Separate System)
(800 mm ) L=1000 mm
( Elbow 90 ° + Extending Piece + Vent Termination )
400050030 •••••
PPs Extending Piece
Ø80
L=1000 mm
400050031 •••••
PPs Extending Piece
Ø80
L=500 mm
400050032
•••••
PPs Elbow 90°
Ø80 400050033
•••••
Non-Return Valve
80/80/80 mm
400050034 •••••
Replacement Air Intake Filter 400090080 •••••
Air Intake Filter Conversion Kit 400090090 •••••
PICTURE
DESCRIPTION
ITEM CODE
WALLCON
16

4.2.10 PUMP
Wallcon boilers are equipped with modulated pumps according to
the latest ErP regulation.
Wallcon boilers shall not be used without a suitable
pump, but according to customer request they can be
delivered without the circulation pump. I such a case a
suitable pump shall be selected according to pressure
loss of the boiler + primary circuit, and the flow rate given
in the technical table for each boiler capacity.
The selected pumps shall be compatible with control
board of the boiler (voltage, current, connections, etc.)
The electrical connection of pumps in Wallcon boilers
shall be made on the terminal block according to
instructions pages 20, 21, 22 .
2,5 3,0 3,52,01,51,00,500
20
40
60
80
H/m Wilo-Yonos PARA RS KU
15/7.5 , 20/7.5 , 25/7.5
1-230 V - Rp ½, Rp / , Rp 1
p/k Pa
max.
Δp-v.
34
0
2
4
6
8
WALLCON
42
WALLCON
50
WALLCON
67
WALLCON
70
WALLCON
80
Water flow rate m³/h 0.28/1.70 0.31/2.12 0.43/2.89 0.43/2.63 0.43/2.89
Pump delivery head mWC 6.00 5.5 3.5 3.5 3.5
17

The pumps of Wallcon model boilers can be mounted in 2 different ways:
1. Pump is mounted integrally by placing it between 2 fittings on boiler return pipe,
2. Pump is mounted externally below the bottom cover on the boiler return pipe.
Option 1 :
Option 2 :
18

4.3 FLUE CONNECTIONS
Flue and chimney connections must be carried out in accordance with applicable regulations and relevant
standards. Materials which are used 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.
4.3.1 FLUE TYPES
B23 = It is a flue system that takes the combustion air from the environment and throws flue gas to the outside.
C13 = It is a flue system that takes the combustion air from the outside and throws flue gas to the outside with the
horizontal concentric flue pipe system.
C33 =It is a flue system that takes the combustion air from the outside and throws flue gas to the outside with the vertical
concentric flue pipe system.
C43 = It is a flue system that takes the combustion air from the outside and throws flue gas to the outside with seperate
flue pipes connected to only a natural draught chimney.
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 the
applicable flue systems which are mentioned in technical table in flue types section with CE certified flue pipes.
C83 = It is a flue system which takes the combustion air from the outside with horizontal flue pipesand throws flue gas to
the self contained (negative pressure) chimney.
*For C₅ and C₆ type boilers, terminals for the combustion air supply and flue gas outlet shall not be installed on
opposite wall!
19