wallas 85DU w/270 Lid Installation and operation manual

INITIAL INSTALLATION AND START-UP TIPS
WALLAS 85 DU & DP COOKTOP
The 85 series Wallas cook-top is the third generation of cooking devices
from this Finnish company. Starting in 1995, Wallas introduced a #2 diesel
fueled cook-top called the Model 95D, designed primarily for the North
American market. This model was manufactured through 2005.
Though primarily intended for “recreational” use, many 95Ds were placed
into “commercial” use, with reasonable success, and most units,
recreational and commercial, are still in service today. Most 95Ds sold
here in North America were fitted with the model 25 blower lid, that
combination of stove and lid was marketed as the 125D. Early 25 lids had
a wood veneer top, while the later 25E models had a tooled metal top.
In 2006, the current Model 85 started into production. This model grew out
of the information received from nearly 10,000 Model 95D’s sold
throughout the world. Some of the major improvements in the model 85D
over the model 95D include a dramatically strengthened “case” with a
“bonded” ceramic surface, a highly refined PC board with internal hour
meter, and super long life “brushless” motors for combustion and heating.
As of 2011, over 8,000 of these 85D units have been sold and have proven
to have a very robust design and a significantly longer service interval
than the Model 95D. Blower and combustion fan life is many times that of
the 95D.
85DU w/270 Lid 85DP
w/270 Lid

In most cases the 85D has been sold in North America fitted with the 270
blower lid, a significant improvement over the 25 lid, with variable blower
speed to match combustion power level. Both the 95 and 85 have been
made available in DU (flush mounted) and DP (countertop mounted)
versions. The DP models are essentially DU models mounted in an
aluminum enclosure that can sit on top of a counter or table.
TIPS TO INSURE SUCCESSFUL INSTALLATION
In addition to the instructions supplied with your model 85D, please follow
these easy, extra steps during your installation.
PRIOR TO INSTALLATION
1. Please assemble this short list of tools and keep them handy for
installation and future repairs and maintenance:
(1) 12mm end wrench;
(1) #2 Phillips driver;
(1) 1/8” blade slot driver;
(1) small adjustable wrench or vise grip.
2. Take the time to verify that ALL electrical connections on the
underside of the cook-top are secure and tight. The units are
manufactured in Finland and have traveled many miles and
handled many times before your purchase. Things can, and often
do “get loose.”
3. Make sure the two set screws holding the white “male” plug on the
main power wires are tight
4. On units built prior to 2008, the small black plug from the lid blower
assembly must be oriented correctly and inserted fully until it “clicks”
into position in the back of the stove section. The small clip that
holds the power cord securely into the receptacle is always in the
DOWN position. Lids built in 2008 and later do not use this cord and
plug, the lid being captive to the lower assembly (lid not
removable).

AFTER INSTALLATION AND BEFORE START-UP
1. Make sure the black connect cable from the controller to the front
of the cook-top under the counter on the DU model, “clicks” into
position on both the controller and the cook-top.
2. Make sure the red and black power cable with the white plug is
fully inserted into the white receptacle on the back side of the
cook-top under the ceramic.
3. VERY IMPORTANT! The fuel line to fuel pump connection under the
cook-top is critical for proper starting and running of the Wallas 85.
The fuel line fitting is a well designed part and must be assembled
and installed correctly. IF THERE IS EVEN A TINY AIR LEAK AT THIS
CONNECTION, THE UNIT MAY NOT START OR RUN PROPERLY.
4. If assembling a new crimp on fuel fitting, make sure the tiny internal
tube support is fully inserted into the clear plastic fuel line. Slide the
compression nut onto the fuel line, be sure the ferrule is flush with
the end of the plastic fuel line, and then CAREFULLY pre-crimp the
assembly, by fastening the fitting assembly onto the fuel pump
elbow. Remove the fitting and examine the crimp. If satisfied,
retighten the fitting WITH TWO WRENCHES. This connection must be
TIGHT.
INITIAL START-UP
The control panel is dual purpose. It controls the start-up and heat output
of the cook top and it serves as a diagnostic tool. This second purpose is
particularly valuable if the unit will not start. On the panel are two LED
lights. The right side “yellow” light verifies the power supply, and the left
side “red” light verifies that ignition is complete and the unit is starting to
warm up. If either or both lights are blinking there is a problem you need
to solve. This diagnostic feature is described on page 13 in the owner’s
manual. We recommend you copy this page, have it laminated, and
keep in on the boat. Here is an additional description of the “light
messages” you eventually see:

I. Pushing the start switch to “on” will trigger an alternating red and
yellow flashing, changing to a “steady” yellow in a few seconds.
During this initial flashing the unit is doing a self test to insure all
critical components are in working order. The steady yellow
means that voltage at the unit is sufficient for the unit to start and
the glow plug is “on”.
II. A flickering or flashing yellow light ONLY means voltage is NOT
sufficient to start the unit. Check all the power line connections
for tight crimps on the wire and tight connects to the power
source. Check the power source for voltage that is AT LEAST
12.6v. Check the voltage at the white power plug.
III. A persistent, simultaneous flashing of BOTH red and yellow lights
means the units is “locked up” from more than two unsuccessful
starts. This is an intentional indication, not a failure. To unlock the
machine:
a. Leave the power switch in the “on” position.
b. Disconnect the main power supply in some way:
i. Pull the fuse or,
ii. Pull the plug out of the stove or,
iii. Disconnect the battery wire or,
iv. Some other way specific to your application
c. Reconnect power
d. Turn power switch off
e. Turn power switch back on to start stove.
IV. A solid yellow light accompanied by a uniformly flashing red light
means the unit is in “after cooling.” Basically this means the unit
did not start on the last try or the power was disconnected
before the after cooling cycle (about 3 minutes) was
completed. Turn off the switch and wait for the flashing red to
stop before restarting.
If you get a solid yellow light and no flashing red, the unit is now in the start
mode. At this time the lid motor and the combustion motors under the
cook top will start running. You should be able to hear both of them, and
feel the cool air coming from under the lid, and a steady flow of air out
the exhaust. At the same time the glow plug inside the cook-top is
starting to preheat. At the 35 second point after the start cycle has

begun the fuel pump will start pulsing (making a subtly “clicking” sound)
and fuel will start to travel from the fuel tank towards the cook-top.
The start cycle is timed to about 5 minutes. If the fuel does not reach the
inside of the combustion chamber in that time period, the red light will
start flashing telling you the unit did not start. Not to worry. Turn the switch
off and wait for the red light to stop flashing (about 3 minutes.) Turn the
start switch on again and proceed as before. If the fuel is coming from a
remote plastic “day tank” and is within a few feet of the cook-top, the
unit should start on the second try and the red light will come on steady.
Full heat will occur in about 12 minutes. We tell customers that you can
boil a pint of cold water in 20 minutes from a cold start.
If your fuel is coming from a “main” tank and/or the fuel run is more than a
few feet, it will take several and possibly many tries for the fuel to reach
the cook-top. REMEMBER, the unit will “lock-up” after two unsuccessful
tries to start (both light flashing on the third try.) You may want to pre-fill
the fuel line as best you can if the run is longer than 5-6 feet.
TROUBLESHOOTING
It is important to understand that initial start-up of the Model 85 may be
challenging for some owners because of the many variables encountered
during the large variety of installations. Please be assured that once these
shortcomings are overcome, your unit will give you hundreds and often
thousands of hours of trouble free use. Here are a few of the simple
“problems” we solve every day over the telephone:
Problem: “The unit will not start, and the operator only gets a flashing
red light after a few minutes.”
Solution: The most likely cause for this situation is that the unit is not
getting enough fuel (if any). Please make these checks:
1. Make sure the fuel line fitting is assembled correctly and is DOUBLE
WRENCH TIGHT.
2. Check ALL electrical connections. If the externally available
connections are good and the system still does not function
properly, remove the protection “cage” on the DU model.
a. Make sure that the blue and red power leads from the PC
board to the back side of the white power plug are tight
using a small slot driver on the two set screws. Check all
connections inside the cage area and re-assemble the cage
to the body of the stove.

3. Make sure that the fuel pump is ACTUALLY “clicking” starting at the
35 to 90 second point after starting. If you can’t hear the clicking,
put your thumb and forefinger on the fuel line to fuel pump
connection, You should feel a “pulse”, much like a human pulse at
about 30 beats per minute.
a. If there is no pulse or click, the small piston inside the pump
may be dry or stuck. The piston can most often be “unstuck”
by several sharp taps to the fuel line to fuel pump connection
with the end of the 12mm end wrench.
b. If there IS clicking, verify that fuel is actually moving along the
fuel line. If not, the pump may need to be primed.
Disconnect the fuel line and squirt a small amount of light oil
into the bottom of the pump and retighten the line securely.
i. Make sure there are no vacuum leaks at the inline filter
if the fuel is coming from a main tank.
ii. Make sure the fuel has its own dedicated fuel pickup if
it is coming from a main tank, and that the fuel supply
does not share a common supply with ANY other
device.
iii. Make sure the fuel line and filter have not been pushed
too far into a day tank and the filter is now above the
fuel level.
Here are some more common problems and solutions:
Problem: “I have two lights flashing at start-up.”
Solution: In this case the unit is “locked up.” Perform the unlock
procedure in section III. a, above. However, the reason for “lock up” is
likely that the unit would not start after two tries for lack of fuel. Please
review the seven checks above.
Problem: “I always have a solid yellow and red flashing at start up.”
Solution: In this case, the most likely cause is that the small black lid
plug has been inserted under the cook-top incorrectly, OR that the plug
on the cord has a loose wire. Look closely at the plug end for proper
construction. Units built in 2008 or later do not have this feature.

Problem: “I have a flickering yellow light and the unit won’t do
anything.”
Solution: The control panel has determined that the voltage is
insufficient for starting. Check all the power wire connections all along the
main power leads and inside the cage on the DU model. Test for voltage
at the unit and charge your battery as necessary.
While it is not a permanent solution, you may try starting your main
engine and then start the stove while the main engine runs. If the stove
starts successfully, wait five minutes and then stop your engine. Wallas
devices require more voltage/amperage to start than they do to run. If
you continue running your Wallas, take care not to run your battery(s) so
low you can’t start your engine!
SUMMARY
We here at Scan Marine hope this supplement will help you with a trouble-
free installation. We know that in theory the installation of Model 85 does
not require any special skills or tools for installation, but we also recognize
that some meaningful time spent in planning your installation, along with a
good measure of patience, some care, and a few specialized tools will
usually insure quick success in using this unique and most remarkable
product.
Should you need any additional assistance with the installation, or have
any questions about operation or maintenance of the Model 85 please
feel free to contacts the staff during business hours by phone at (206)285-
3675 or our toll free number below.
HAPPY BOATING
2144 Westlake Avenue North, Suite D
Seattle, Washington 98109
Phone: [phone] Toll Free: 1.888.606.6665 Fax: [phone]
© 2011 Two Mac Inc.