WIKORA GS 117 E, GS 152 E, GS 192 E Installation Manual Operating Instructions
© Wikora GmbH Page 1 As at November 2013
Errors excepted.
WIKORA GmbH
Friedrichstr. 9
89568 Hermaringen
Phone: (07322) 9605-0
Fax: (07322) 9605-30
email: contact@wikora.de
Installation manual
Operating instructions
Gas Boiler
GS 117 E / GS 152 E / GS 192 E
Installation, calibration and commissioning
must be undertaken by a specialist.
The boiler must be connected according to the
regulations in force and may only be operated in
well vented areas.
Control devices must be checked for functioning.
Fittings, immersion sleeves, connection seals, drain
valve etc must be checked and if necessary
retightened or resealed.
General terms and conditions of warranty state that
all installations must be carried out by a suitably
trained and qualified plumber who observes the
local norms and regulations.
The installation and maintenance record must
be entirely completed and the user has to be
instructed accordingly.
Efficient operation can only be guaranteed if the
instructions of this manual are followed.
Warranty does not cover any damage caused due
to non-observance of this manual and the technical
rules in force.
The system is to be checked annually by a
specialized company. In addition, occurring defects
must be repaired immediately.
This document should be handed over to the
client on completion of the installation.
.
Index
1
General ................................................................................................................................................................................ 2
2
Transport and installation .................................................................................................................................................... 2
3
Dimensions and connections .............................................................................................................................................. 3
4
Technical data ..................................................................................................................................................................... 4
5
Installation ........................................................................................................................................................................... 5
6
Commissioning .................................................................................................................................................................... 7
7
Gas regulation ..................................................................................................................................................................... 8
8
Conversion to other gas types ............................................................................................................................................. 9
9
Technical data - Gas ......................................................................................................................................................... 10
10 Convertion kits .................................................................................................................................................................. 10
11 Maintenance and wear parts ............................................................................................................................................ 11
12 User Information ............................................................................................................................................................... 11
13 Faults ................................................................................................................................................................................ 11
14 Warranties and guarantee ................................................................................................................................................ 13
15 Installation record ............................................................................................................................................................. 14
© Wikora GmbH Page 2 As of November 2013
Errors excepted.
Security advice
When smelling gas
• close gas tap
• open the window
• don’t operate any electric switch
• extinguish open flames
• call (from outside) gas company and authorized specialist
When smelling exhaust gas
• disconnect appliance
• open windows and doors
• call authorized specialist
Explosive and readily flammable material
• Don’t use or store any readily flammable material (paper, thinner, paint etc.) in direct proximity to the appliance.
Combustion air / Ambient air
• Keep combustion air / ambient air free from aggressive substances (e.g. halogen carbon dioxide, hydroxide
containing chlorine or fluorine compounds) to avoid corrosion
1 General
The standing gas boiler is a direct fired multi-gas appliance. It is suited for a maximum working pressure of 10 bar and a
maximum working temperature of 70°C. The pressure resistant boiler can supply several tap connections at the same time.
The flue gas must be dissipated through an authorized flue gas system.
A baffle plate mounted to the flue gas pipe of the tank guarantees an excellent heat transmission. The burner unit consists of a
main burner and pilot burner, control fittings with piezo spark ignition, thermoelectric safety pilot, temperature control as well as
a gas pressure regulator and can be converted to natural gas and liquid gas according to the DVGW process sheet G 260. 2
measuring devices have been fitted at the control unit to regulate pressure in nozzles and connecting pipes. The desired water
temperature can be regulated at the temperature control button. In case of overheating the build in temperature stop control
will cut off the electricity supply at circuit.
The tank is protected against corrosion by double-coated enamel and magnesium anode. An insulation layer between the
internal tank and the steel plate housing minimizes loss of heat. The steel plate housing is lacquered.
The burner unit can be removed at the front for cleaning and maintenance purpose. The tank may only be operated with an
installed protection anode.
Installation, calibration, commissioning and maintenance must be undertaken by a specialist.
For the installation, the following regulations should be considered: DIN 18160, DIN 4753, DIN 4109, DVGW TRGI 2008, TRF
1996/97 Part 1 and 2, DIN 1988, the relevant regulations of the suppliers as well as the local legal building regulations in force.
All tank connecting pipes are to be planned, constructed and tested according to the technical rules in force, and the
corresponding norms and regulations in accordance with their application and supply medium.
2 Transport and installation
In order to prevent damage during transport, the packaging should only be removed at the site of installation. During shipment,
it should be ensured that the tank does not come in contact with any spiky or sharp items, nor is damaged through dropping or
knocks.
Always place in a frost free but cool area and close to the chimney. The size of the room and the ventilation necessary is
subject to DVGW-standards. Avoid under all circumstances rooms with any kind of aggressive fumes (propellant, glue, solvents
etc.) as these can cause corrosion in the exhaust system and can lead to combustion or explosion. Cover wooden or synthetic
floor with fire resistant insulator. The tank must be disconnected from any humidity carrying components. Any light flammable
material must be placed at least one meter away. Moreover, sufficient space for maintenance and cleaning must be kept
unobstructed at the front, the sides, above and behind the boiler.
© Wikora GmbH Page 3 As of November 2013
Errors excepted.
3 Dimensions and connections
Illustration1
1 Hot water connection R 3/4
2 Cold water connection R 3/4
3 Gas connection Rp 1/2
4 Flow operated safety device
5 Anode
6 Baffle plate
7 Water tank
8 Circulation immersion pipe R ¾ (Accessory)
9 Insulation
10 Casing
11 Control fittings
12 Main burner
13 Pilot burner
15 Cover plate
17 Drain
20 Temperature control button
22 Piezo spark ignition
a Diaphragm - safety valve min. DN 15
b Drain pipe
c Water stop valve
d Manometer- connection nozzle
e Backflow preventer
f Pressure reducing valve if more than 8 bar connection pressure
g Water stop valve
h Test valve
i Gas stop valve
k Circulation pump
Dimensions:
Type A B C E F G H H1
Height
gas connection
Diameter tube
flue gas
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
GS 117 E
480 480 224 1140 1140 1140 1208 1100
303 80
GS 152 E
480 480 224 1396 1396 1396 1464 1356
303 80
GS 192 E
480 480 224 1713 1713 1713 1781 1673
303 80
Chart 1
Connections:
Type GS 117 E GS 152 E GS 192 E
Cold water / hot water 1/2 R ¾ ¾ ¾
Circulation 3 R ¾ ¾ ¾
Drain 17 Rp ½ ½ ½
Gas connection 18 Rp ½ ½ ½
Anode 19 Rp ¾ ¾ ¾
Chart 2
R = male thread
Rp = female thread
© Wikora GmbH Page 4 As of November 2013
Errors excepted.
4 Technical data
Type GS 117 E GS 152 E GS 192 E
Capacity
[liter] ca. 115 ca. 150 ca. 190
Max. working pressure
[bar] 10 10 10
Output
[kW] 7,12 8,12 9,18
Input (gross)
[kW] 8,0 9,1 10,2
Flue gas temperature
[°C] 155 171 171
Flue gas volume [kg/h] 18,3 19,7 21,5
Flue draft requirement
[mbar] 0,04 0,04 0,04
CO2 by volume
[%] 6,4 6,8 7,0
Time to recover from 10°C to 60°C [ca. min] 52 61 67
Energy loss
[kWh/24h] 4,08 4,85 5,04
Continuous output DHW of 45°C
[l/h] 175 200 226
Hot water starting efficiency
[ca. l/10 min] 160 205 266
Gas consumption
Natural gas group E H
uB
9,4 kWh/m3
[m3/h] 0,85 0,97 1,09
Natural gas group LL H
uB
8,5 kWh/m3
[m3/h] 0,94 1,07 1,20
Liquid gas (propane) H
uB
12,8 kWh/kg
[kg/h] 0,63 0,71 0,8
Nominal Load N
L
(70°)
ca. 1,7 ca. 2,7 ca. 3,4
Weight (empty)
[kg] ca. 65 ca. 80 ca. 90
Chart 3
Necessary flow pressure for gas connection
Natural gas 18 mbar – 25 mbar
Liquid gas 50 mbar +/- 5 mbar
If the flow pressure for gas connection is outside those values, an installation is prohibited (see 6.1, 3 ff)
Gas (at 15°C, 1013 mbar)
according to CE-Norm according to DVGW
E (G20) Wobbeindex: 11,3 – 15,2 kWh/m³ N (H) Wobbeindex: 12,0 – 15,7 kWh/m³
LL (G25) Wobbeindex: 9,5 – 12,4 kWh/m³ N (L) Wobbeindex: 10,5 – 13,0 kWh/m³
P (G31) Wobbeindex: 20,3 – 21,3 kWh/m³ F Wobbeindex: 22,1 – 25,81 kWh/m³
© Wikora GmbH Page 5 As of November 2013
Errors excepted.
5 Installation
5.1 Water connection
Erect boiler vertically and straight with the aid of a spirit level and if necessary place metal strips underneath. Water
connections should have removable connections and must be checked for tightness. A safety group must be installed in the
cold-water connection and if water pressure is above 8 bar a pressure reducing valve is to be installed. Appropriate filters
should be used to prevent dirt or particles from entering the boiler.
The safety valve must be set at 10 bar excess pressure and must be tested and executed at least with DN 15. It is to be
installed in the cold water connection and must not be cut off through the hot water tank. It must be well accessible for control
purpose. The functional capacity of the safety valve in the cold water connection must be checked at regular intervals by
venting.
The exhaust pipe must be at least as big as the safety valve outlet in width. It may not have more than 2 bends and should not
be longer than 2 m. The exhaust pipe must be installed with downward gradient. It must be ensured that people cannot be
endangered by escaping hot water or steam.
The drain line behind the funnel must feature at least the double width of the valve entrance. The exhaust pipe and drain pipe
must be protected against freezing and should not lead outside.
A sign is to be attached close to the exhaust pipe of the safety valve or on the safety valve itself. „For safety reasons water
may leak from the exhaust pipe during the heating process! Do not lock!”
To avoid an excessive loss of water an appropriated expansion valve can be installed between the tank and the safety valve
inside the cold water pipe.
5.2 Circulation pipe
Should a circulation pipe be necessary it must be carefully insulated for economical reasons. To ensure a flawless and energy
saving functioning, the circulation pipe must be fitted at the tank only with an original connection attachment (available as
spare parts) at the connection point. Connect the circulation pump and reverse flow stopcock between warm water supply and
circulation connection. The circulation pump should be regulated through thermal control (Pump should only start operation
when the temperature in the circulation falls beneath 30° C) to keep operating cost low. Should no circulation be needed
during the night an extra time control switch is recommended to turn off the circulation pump.
5.3 Gas connection
The gas connection is to be fitted at the front of the control fittings in adequate dimension and only after having cleared the
pipe by blowing through and airing. Contamination of the control fittings through dirt and thickening materials must be avoided.
The stopcock for the gas is to be fitted on site and has to be at least NW1/2’. The connections must be checked for tightness.
Checked pressure max. 50mbar (500mm WS). Should it be necessary to use more pressure to check for leaks in the gas
connection pipe then the gas connection pipe is to be removed from the control unit.
5.4 Exhaust connection
Check chimney for suitability to transport exhaust fumes. Cross section and durability have to
comply with DVGW-TRGI regulations.
Check if pipe sockets (b) are still correctly fitted with the baffle plate (d) in the exhaust pipe.
The pipe sockets have to be pushed into the exhaust pipe up to their bulge.
At first installation: remove cover plate (15) and cap (a) with screws from the base. Place cap (a)
onto pipe sockets (b) and fix securely with 3 screws (c).
Connect corrosion resistant exhaust pipe airtight at the pipe sockets of the flow operated safety
device. Place exhaust pipe elevating towards the chimney at shortest possible distance. It must
not penetrate the cross section of the chimney. The distance needed between the flows operated
safety device and the exhaust bend to the chimney must be no less than 160mm. No covers are to
be placed over nor are any alterations to be made to the flow operated safety device.
Illustration 2
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