Gassero Wallcon Troubleshooting guide

INSTALLATION, USER AND SERVICE MANUAL

WALL HUNG GAS FIRED CONDENSING BOILER

RESET

0051-14

Table of Contents

IMPORTANT

When carrying out commissioning of the boiler, you are highly recommended to perform the following checks:

–

Make sure that there are no liquids or inflammable materials in the immediate vicinity of the boiler.

– Make sure that the electrical connections have been made correctly and the earth wire is connected to a

weel done earthing system.

– Open the gas tap and check the soundness of the connections, including the burner.

– Make sure that the boiler is set for operation for the type of gas supplied.

– Check that the flue pipe for the outlet of the products of the combustion is unobstructed and has been properly

installed.

– Make sure that any shutoff valves are open and dirt seperators are installed on the return water connection.

– Make sure that the system is charged with water and is thoroughly vented.

– Check that the circulation pump is not locked.

– Purge the system, bleeding off the air present in the gas pipe by operating the pressure relief valve on the gas

valve inlet.

–

The installer must provide the user with instruction in operation of the boiler and safety devices and hand over the

instruction booklet to the user.

–

The images shown in this manual are a simplified representation of the product. In this representation there may be

slight, unimportant differences with the supplied product.

1 Meaning of the symbols and safety instructions . . 3

1.1 Meaning of symbols

1.2 General warnings

2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Designated use . . . . . . . . . . . . . . . . . . . . . 5

2.3 . . . . . 5Boiler 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 . . . . . . . . . . . . . . . . . . . . . . 6Warning label

2.6 Data label . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Wallcon 42/50/67 dimensions . . . . . . . . . 7

3.2 . . . . 8Wallcon 42/50/67 hydraulic diagram

3.3 Wallcon 42/50/67 main components . . . . . . . 9

3 Technical features . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4 Technical data . . . . . . . . . . . . . . . . . . . . . .. 10

4.1.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Instructions for the installer . . . . . . . . . . . . . . . . . . . 11

4.1 . . . . . . . . . . . . . . . . . . . . . . . . 11Installation

4.1.2 Transport . . . . . . . . . . . . . . . . . . . . . . 11

4.1.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . 11

4.1.4 Clearances . . . . . . . . . . . . . . . . . . . . . 12

4.1.6 Water side connections . . . . . . . . . . . . 13

4.1.5 Water quality and treatment . . . . . . . . . 12

4.1.7 Expansion vessel . . . . . . . . . . . . . . . . . 13

4.1.8 Safety valve . . . . . . . . . . . . . . . . . . . . 13

4.1.9 Condansate drain . . . . . . . . . . . . . . . . 13

4.1.10 Frost protection . . . . . . . . . . . . . . . . . 13

4.1.11 Dirt seperation . . . . . . . . . . . . . . . . . . 13

4.1.13 Pump . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1.12 Automatic air vent . . . . . . . . . . . . . . . . 13

4.2 Installation examples . . . . . . . . . . . . . . . . 14

4.2.1 Single boiler installations . . . . . . . . . . . 14

4.2.2 Cascade installation . . . . . . . . . . . . . . . . 15

4.3 Adjustment of the gas rate . . . . . . . . . . . 16

4.3.1 Description of the adjustment points . . . 16

4.3.2 Combustion values adjustment table . . . 16

4.3.3 Maximum output adjustment . . . . . . . . . 16

4.3.4 Minimum output adjustment . . . . . . . . . 17

4.4 Gas conversion instructions . . . . . . . . . . . 18

4.5 Flue installation instructions . . . . . . . . . . . 19

4.5.1 Flue appliance types . . . . . . . . . . . . . . . 19

4.5.2 Flue installation types . . . . . . . . . . . . . . 20

4.5.3 Flue kit accesories . . . . . . . . . . . . . . . . . 21

4.6 Electrical installation . . . . . . . . . . . . . . . . 22

4.6.1 Wiring diagram . . . . . . . . . . . . . . . . . . . . 22

4.6.2 External probe installation . . . . . . . . . . 23

4.6.3 Outdoor temperature control . . . . . . . . 24

5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.2 Programming . . . . . . . . . . . . . . . . . . . . . 27

5.3 Error codes . . . . . . . . . . . . . . . . . . . . . . 28

5.4 Maintenance codes . . . . . . . . . . . . . . . . 29

6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Comissioning checklist . . . . . . . . . . . . . . . . . . 34

6.2 Maintenance procedure . . . . . . . . . . . . . 30

Service interval record . . . . . . . . . . . . . . . . . . 37

6.3 Troubleshooting . . . . . . . . . . . . . . . . . . . 32

1 MEANING OF THE SYMBOLS AND SAFETY INSTRUCTIONS

1.1 MEANING OF THE SYMBOLS

WARNINGS

Keywords indicate the seriousness of the hazard in

terms of the consequences of not following the safety

instructions.

• NOTE indicates that material damage may occur.

• CAUTION indicates that injuries may occur.

• WARNING indicates that serious injury may occur.

• DANGER indicates potentially risk to life.

IMPORTANT INFORMATION

Warnings in this document are framed and

identified with a warning icon which is

shown on the left figure.

Electrical hazards are identified by a

lightning icon surrounded by a warning

triangle.

Important information in cases where there

is no risk of injury material losses is

identified by the symbol shown on the left.

It is bordered by horizontal lines above and

below the text.

After having removed the packaging, check that the

material supplied is intact and complete; if this is

not the case, contact with GASSERO or dealers.

The WALLCON Series b oilers must be installed by

authorized person as detailed under any current

standards and law applicable and with the instruc-

tions provided by Gassero in the manual given

with the appliance.

The boiler must be used for the purposes it has

been expressly manufactured. Gassero declines

all contractual and extra-contractual liability for

damage caused to persons, animals or things, due

to errors in installation, control, servicing or impro-

per use.

In case of the water leakage, disconnect the boiler

from the mains power supply, close the water sup -

ply and 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 extended period, the

following operations must be completed:

- move the main system switch to "off"

- close the fuel cock and the water cocks on the cen -

tral heating system

- empty the central heating system if there is the risk

of frost.

Maintenance and servicing must be done once a year.

This manual is an integral part of the boiler and as a

consequence must be kept with care. If the manual

is damaged or lost, contact with 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. ([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

Actions that absolutely must not be

carry out identified by the figure on left

Meaning of the Symbols and Safety Instructions

+90 216 394 09 85 )

The boiler must not be used by children or invalid

persons without supervision.

Electrical devices or appliances, such as switches,

household appliances, etc. must not be used if there

is the smell of gas or unburned fuel. In this case :

- ventilate the room by opening doors and windows;

- close the fuel stopcock;

- promptly contact Gassero, your gas supplier or

other professionally qualified personnel.

Do not touch the boiler when bare feet or with wet

parts of the body.

No service or cleaning operations may be perfor-

med without first having disconnected the boiler

from the mains power supply , moving the main

system switch to "off".

The safety or control devices must not be adjusted

without the authorisation and written instructions

from the manufacturer of the boiler.

Do not pull, remove or twist the electrical cables

coming out of the boiler , even if the appliance is

disconnected from the mains power supply.

The ventilation openings in the room where the

appliance is installed must not be plugged or redu-

ced in size and must comply with any current stan-

dards and law applicable.

Do not switch off the boiler if the outside temperatu-

re may decrease below ZERO (risk of freezing).

Do not leave flammable substances in the room

where the boiler is installed.

The packaging material must not be dispersed in

the environment or left within the reach of children

as it is a potential source of hazard. It must be

disposed of according to the legislation in force.

Alterations to parts connected to the appliance

Do not carry out any alterations for following parts:

- the boiler

- to the gas, air, water supply pipes and electrical

- to the flue pipe, safety valve and its drain pipe

- to the constructive 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 leakage

 Contact the gas society or a company specialized in

Indications for appliances operating with propane gas

ensure yourself that before installing the appliance the

For a correct purging of the tank contact the liquid gas

supplier or a legalley authorized person .

If the tank has not been correctly purged problems

could occur during ignition. If this occurs contact the

appliance’s safe operation

(for example water or gas leakages).

installing and servicing heating systems

gas tank has been purged.

liquid gas tank’s supplier.

1.4 REGULATIONS AND STANDARTS

Current Gas Safety (Installation & Use) Regulations:

All gas appliances must be installed by a competent

person in accordance with the above regulations;

The appliance must be installed in accordance with, and

comply to, the current: Gas Safety Regulations, IEE

Regulations, Building Regulations, Building Standards

and any other local requirements.

Directives:

• 2009/142/EEC gas appliance directive

• 92/42/EEC boiler efficiency directive

• 73/23/EEC low voltage directive

• 89/336/EEC EMC directive

• 97/23/EC pressure equipment directive

• any relevant requirement of the local authority.

EN 483 Gas-fired central heating boilers.

Type C boilers of nominal heat input not

exceeding 70 kW.

EN 677 Gas-fired central heating boilers. Specific

requirements for condensing boilers with

a nominal heat input not exceeding

70 kW.

Installation not exceeding 70 kW rated input

Meaning of the Symbols and Safety Instructions

1.3 SAFETY INSTRUCTIONS

2 GENERAL

the following wall-mounted condensing gas boilers:

The Wallcon 42/50/67 is suitable for use as a single boiler or as

part of a cascade system.

CE LABEL

The appliance complies with the basic

requirements of the relevant European

directives.

Conformity has been substantiated by the

proper documents which, together with

the declaration of conformity, are filed

with the manufacturer.

•Wallcon 50

The boiler may only be used to heat up water for heating

systems as standard and/or domestic hot water (DHW)

systems with the connection of DHW tank.

The boiler can be installed either as a single system or as

part of a multiple system (cascade system). A cascade

system enables several boilers of this type to be

connected together, where maximum of 16 boilers with

can be connected together.

Special cascade units (accessories) have been

developed to enable this boiler to be installed in a

cascade system. Every cascade unit includes an

installation frame, horizontal headers, connection pipes

for the boiler, main gas pipe and vertical low loss header.

Also, cascade units are available for installing the boilers

inline or back-to-back. These cascade units make

installing a cascade system easier and less labour

intensive. Please contact your dealer or the

manufacturer for further information about cascade

systems.

CAUTION:

Damage to the installation due to frost.

Install the heating system in a room

which is free from frost.

WARNING:

Fire hazard due to flammable materials or

liquids.

Do not store any flammable materials or

liquids in the direct vicinity of the boiler.

CAUTION:

Boiler damage due to contaminated

combustion air or contaminated air in the

boiler room.

Never use the boiler in an environment which

contains lots of dust or aggressive chemicals.

Such as spray shops,hairdresser's shops,

locations where 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

The WALLCON is a wall-hung condensing boiler, for

CH and DHW(with DHW tank) purposes, with pre-mix

burner, made up of stainless steel heat exchanger.

The WALLCON boilers can be combined in a cascade

configuration with other heat generators to create

modular heating plants made up of boilers connected to

the same water circuit and with electr onic controllers

communicating via bus. The heat output of each boiler

unit reaches 42kW (100%, 50

C / 30 C) for Wallcon 42

,o o

51kW (100%, 50 C / 30 C) for Wallcon 50 and 67 kW

2.2 DESCRIPTION OF THE APPLIANCE

The individual heating units in cascading configuration

can be activated, as well as by simple rotation, in such a

way that when a certain percentage of output is reached

by the first unit, the other units start automatically, all with

the same load factor.

The main features of the WALLCON Boilers are:

- cold burner door with premix burner

- output from 8.5 to 42 kW (models 42 M and 42 S)

- output from 8.5 to 51 kW (models 50 M and 50 S)

- microprocessor control with self-diagnosis, shown on

LED and the display

- frost protection function activated according to the out-

side temperature and/or the temperature of the boiler

- fitted for room thermostat in the high and low tempera-

ture zones(optional)

- outside probe to enable the climate control function

- post-circulation function for the central heating and

DHW circuits

- priority settable on the DHW, high or low temperatur e

circuit

- low investment costs for cascade operations ( slave

- chimney sweep function

-solar system & swimming pool control functions

models can be controlled by Master models, without

using any display modules in slave units)

•Wallcon 67

•Wallcon 42

for Wallcon 67 modulated from 16 % to 100%.

output from 16 to 67.1 kW (models 67 M and 67 S)

General

2.4 PACKAGING LABEL

2.5 WARNING LABEL

WARNINGS !

.Read the technical instructions before installing

the boiler.

.Installation and comissioning must be done by

authorized qualified technicians.

.The boiler may only be installed in a room which

complies with the appropriate ventilation require-

2.6 DATA LABEL

Wall Hung Gas Condensing Boilers

Model : Wallcon

Efficiency Level :

Standards :

Flue (appliance) Types : B23, C13, C33,

C43, C53, C63, C83

Production Year :

Istanbul Endustri ve Ticaret Serbest Bolgesi

Parsel 110

34957 , Tuzla, Istanbul,

www.gassero.com

ATTENTION : The boiler is

Pressure of G20 - 21 mbar .

Pressure

Gas Category

Gas

Destination

Countries of

NO Class : 5

Power Consumption :

Max. Working Temperature :

85 C

Max. Working Pressure(PMS) : bar

oC)

.Read the user instructions before operating the

boiler.

ments and which is seperated from living rooms.

The Wallcon condensing boilers must be installed in rooms

used exclusively for this purpose, provided with adequately

sized ventilation openings, in compliance with any current

standards and low applicable. If 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 on gas fuel with a higher specific

weight than air, the electrical parts must be located at

least 500 mm from the floor.

The boilers cannot be installed outside as they are

not designed for outdoor operation.

When installing and operating the boilers it is necessary to

keep a safe 200 mm distance from combustible materials

with combustibility degrees B,C1,C2 .

For easily flammable materials with combustibility degree C3

which burn quickly and by themselves also after the ignition

source removal the safe distance is doubled it means 400 mm.

0051 -14

1234567890123

Product Model :

Serial Number :

1234567890123

Heat Output :

Gas Type : 2H G20-21 mbar-N.Gas

Countries of

Destination

1234567890123

Product Code :

Serial Number :

Product Code :

1234567890123

MASTER

SLAVE

Pn Max. (kW) :

Pn Min. (kW) :

Pn Max. (kW) :

Pn Min. (kW) :

MASTER

SLAVE

3 TECHNICAL FEA

3.1 WALLCON 42/50/67 CONNECTIONS AND DIMENSIONS

CONNECTIONS :

Technical features

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

KEY

1 - Pump

2 - Venturi Adapter

3 - Gas Valve

4 - Ignition Electrode

5 - Heat Exchanger

6 - Thermal fuse

7 - Flue Gas Temperature Sensor

8 - Automatic Air Vent

9 - Manuel Air Vent

10 - Flue gas tempertaure sensor

11 - Ionization electrode

12 - Syphon

13 - NTC sensor

14 - Fan

15 - Safety Relief Valve

Technical features

Water pressure losses on Wallcon 67

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

800 1200 1600 2000 2400

Water flow rate(L/h)

Water pressure losses (KPa)

WALLCON 42/50/67 HYDRAULIC DIAGRAM

3.3 WALLCON 42/50/67 MAIN COMPONENTS

Technical features

KEY

1 - Pump

2 - Pump Air Vent

3 - Venturi Adapter

4 - Air intake flexi duct

5 - Ignition Electrode

6 - Flue thermalfuse

7 - Flue Gas Temperature Sensor

8 - Flame Observation Glass

9 - Ionization Electrode

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

20 27

14 15

3.4 TECHNICAL DATA

Technical features

min. max. min. max. min. max.

Installation types

Gas categories

Fuel type

Nominal heat input Qn kW 8 39,4 8 48 15 63

Nominal heat output Pn at ( 80 - 60 oC ) kW 7,6 38,3 7,6 46,3 14,4 61

Nominal heat output Pn at ( 50 - 30 oC ) kW 8,5 42 8,5 51 16 67,1

Working pressure bar 0,8 3 0,8 3 0,8 4

Max. working temperature oC

Water content l

Condensate discharge rate kg/h

Efficiency at Qmin ( 80 - 60 oC ) %

Efficiency at Qmax ( 80 - 60 oC ) %

Efficiency at Qmin ( 50 - 30 oC ) %

Efficiency at Qmax ( 50 - 30 oC ) %

Partial load return 30 oC%

Efficiency level

Flue gas temperature ( 50 - 30 oC ) oC42 52 43 64 39,8 62,7

Flue gas temperature ( 80 - 60 oC ) oC63 75 63 82 62,9 82

Gas nozzle (G20) mm

Gas nozzle (G25) mm

Gas nozzle (G31) mm

CO2emissions (G20) % 8,9 9,2 8,9 9,2 8,9 9,2

CO2emissions (G25) % 8,9 9,4 8,9 9,4 8,9 9,2

CO2emissions (G30) % 10,6 11,1 10,6 11,1 10,7 11,1

NOxemissions (G20) mg/kWh

NOxemissions (G25) mg/kWh

NOxemissions (G30) mg/kWh

NOxclass

Combustion products 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) rpm 1300 5100 1300 6250 1700 6500

Fan speed (G30) rpm 1200 4750 1200 5750 1350 5900

System flow "

System return "

Gas inlet "

Safety drain "

Condensate discharge

Flue outlet

Air intake

Power supply V/Hz

Power consumption W

Electric insulation class IP

Dimensions mm

Weight kg

Efficiency&Combustion

2,5

94,9

97,1

7,5

35,68

39,77

42,65

2,5

Model Wallcon 42

7,7

9,5

5,5

94,9

96,4 96,9

106,0

106,8

106,0

106,3

106,9106,7

107,2

106,5

107,9

3,5

96,0

B23, C13, C33, C43, C53, C63, C83

2H, 2E, 2LL, 3+ and 3B/P

Natural Gas / LPG

34,1

37,89

73,53

X4D

230 - 50

250

3/4

1/2

42,99

38,38

72,81

446x390x654 446x390x654 446x480x654

230 - 50

280

X4D

3/4

1/2

33 33 44

1/2

Electrical

Connections

3/4

230 - 50

220

X4D

Dimensions & Weight

The Wallcon boilers are supplied fully assembled in a

strong cardboard box.

After having unpacked the boiler check that it is intact and

undamaged.

Keep the packaging material (cardboard box,

plastic bags, polyester protection etc.) out of

the reach of children as they can be

dangerous.

GASSERO refuses all liability for injury to persons,

animals or damage to property deriving from

not having respected the above mentioned

recommendations.

In the packaging, in addition to the boiler, you can also find

the following contents:

- Installation and service manual

- Warranty card

- Flue adapter for smoke evacuation

4.1.2 TRANSPORT

CAUTION: Damage to the installation due to

impacts.

The boiler contains parts which can be

damaged by impacts.

During further transport all parts must be

protected against impacts.

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.

Carefully transport the boiler to the installation

place.

The Wallcon Boiler must be secured to a solid brick

or concrete wall using the wall hanging brackets.

For installation:

-Position the bracket on the wall using correct

level to make sure that the holes are perfectly

horizontal(1)

- Mark the fastening holes on the wall (1)

- Drill the holes and insert the expansion plugs(2)

- Fasten the bracket to the wall using the screws

- Hook the boiler to the bracket.

4.1.3 MOUNTING

Instructions for the installer

4 INSTRUCTIONS FOR THE INSTALLER

4.1 INSTALLATION

4.1.1 PACKING

- Wall hanging brackets

RESET

4.1.5 WATER QUALITY AND TREATMENT

If the water might contain aluminium particles, this should

be maximum 8,5 ppm. If there is any doubt of the water

staying free of any kind of debris/contamination in the period

after installing, one should install a plate heat exchanger

to separate the boiler circuit from the heating circuit. To

avoid to the maximum any presence of oxygen in the

system, we recommend to prevent as much as possible

air intake and water leakage during installation. Power flush

the pipes and radiators thoroughly to remove all fluxes and

debris before connecting the boiler to the central heating

system in accordance with local regulations.

Instructions for the installer

The manufacturer declines any liability for damage caused to

the boiler by failure to install or inadequate installation of

this filter. Before switch on the boiler, water must be circulate at

least 2 hours for elimination the impurities from the system

trough the micro impurity seperator. In the end of the operation,

safety drain valve must be opened for removing the impurities.

It is also possible to use plate heat exchangers according the

system characteristics. In any case, micro impurity seperators

must be used in the system in the boiler. Before installation,

carefully wash all the pipes of the system to remove any

residuals or impurities that could affect proper operation of the

unit. Filter must also be installed on the system return piping to

prevent impurities or sludge from the system clogging and

damaging the boiler.

CAUTION:

Boiler damage due to corrosion.

NOTE:

Damage to the installation due to insufficient or improper

cleaning and maintenance.

Inspect and clean the heating system as required once a

year.

Carry out maintenance as required.

Immediately remedy faults. This will avoid further damage

to the system!

DO NOT treat the water with antifreeze.

Suitable chemicals and their use should be discussed with a

specialist water treatment company prior to carrying out any

work (environmental aspects, health aspects). The specification

of the system and manufacturers recommendations must

be taken into account, along with the age 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 important to check the inhibitor

concentration after installation, system modifications, filling the

system and every service in accordance with these instructions.

For the correct dosage and the suitability of inhibitors for use

with our boilers and for further information on water treatment

or system cleaning we advise direct contact with Gassero

service.

The gas and water connections are located on the bottom of

the boiler whilst the air intake and flue outlet is located on the

top of the boiler. The boiler is supplied as standard with pipe-

work tails to allow connections facing downwards. For installation,

servicing and inspection min. 600 mm in front of the boiler is

required. If this free space is obtained by opening a door or

removing a panel, the boiler may be installed for instance in a

closed cupboard. For ease of installation we recommend

clearances of 0.5 cm at the side so that the unit is easy to open,

with a free space of 25 cm under the appliance and 25 cm above

the appliance, as the minimum requirement.

4.1.4 CLEARENCES

The pH value of the water must fall within the following limits:

7 < pH < 9 in non-treated water. This pH value is achievable

after steady conditions when after filling the mains network

water ( pH around 7 ) inside the installation and the air

elimination operation has been done.Treated water hardness

must within limits 7 < pH < 8,5 The plumbing system must be cleaned using with suitable -

registered produts before starting the installation of the boiler.

Neutral, non-acidic and non-alkali cleaners( SENTINEL X300,

X400, FERNOX ) must be used for preventing the metal,

plastic and rubber parts in the installation system. Please obey

the instructions of the manufacturer, when using these type of

cleaners.

Note: Rust particles and impurities in the heating system can

caused problems.( overheating, un-efficient and noisy work)

Problems and damages due to wrong installations and wrong

plumbing systems is out of warranty.

4.1.6 WATER SIDE CONNECTION INSTRUCTIONS

The heating capacity of the unit must be previously established

current regulations. The system must be provided with all the

components for correct and regular operation. In particular,

provide for all the protection and safety devices prescribed by

current regulations for the complete system.

We strongly recommend to install two ball valves

under the boiler, so the boiler can be isolated from

the heating system when needed.

4.1.7 EXPANSION VESSEL

therefore its connection must be carried out by the qualified

installer. The capacity of the expansion vessel must be chosen

and installed to match the capacity of the central heating

system and the static pressure. We suggest you install the

expansion vessel in the return line of the central heating

system. It can be combined with the drain valve for servicing.

4.1.8 SAFETY VALVE

Safety valve outlet must be connected to collection pipe to

prevent water spurting onto the floor in case of overpressure

in the heating circuit. Otherwise, if the discharge valve cuts in

and floods the room, the boiler manufacturer cannot be held

liable.

4.1.9 CONDENSATE DISCHARGE

The condensate drain is in the left side at the bottom of the

boiler and has a 25mm hose discharge. Connect this flexible

condensate drain. Metal lines are not allowed. Blockage of this

drain may cause damage to the boiler. The drain connection is

correct when the condensate can be seen flowing away, e.g.

using a funnel. Any damage that may occur is not covered by

the warranty of the boiler. There should be an open connection

between the condensate hose from the boiler, to the sewage

system. An under pressure in the sewage system should never

be able to suck on the boiler condensate drain hose. The

condensate drain must be connected in accordance with

current regulations.

Do not use the water system pipes to earth electrical

appliances.

4.1.10 FROST PROTECTION

Wallcon series boiler has built-in frost protection, automatically

activating the central heating pump when the boiler return

will shut down as soon as the return temperature has reached

demanded point. The above-mentioned temperatures relates

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

including an air bleed valve so the strainer can be isolated from

the heating circuit for servicing. Clean water is important,

blocked heat exchangers do not fall under warranty. The filter

should be installed when replacing boilers in existing systems.