Condensing boilers Weishaupt Thermo Condens WTC 15-A / WTC 25-A and WTC 32-A 83247602 – 1/2008
Installation and operating instructions
manual
Conformity Certification
to ISO/IEC Guide 22
Manufacturer: Max Weishaupt GmbH
Address: Max Weishaupt Straße
D-88475 Schwendi
Product: Gas Condensing Boiler
Type: WTC 15-A, WTC 25-A, WTC 32-A
The products described above conform to
Document No.:
EN 483, EN 677, EN 50 165, EN 60 335,
EN 61 000-6-1, EN 61 000-6-4, LRV 92:2005
In accordance with the directives:
GAD 90/396/EC Gas Appliance Directive
LV D 2006/95/EC Low Voltage Directive
EED 92/42/EC Efficiency Directive
EMC 2004/108/EC Electromagnetic
Compatibility Directive
these products are labelled as follows
0063 BM 3092
The product complies with the prototype tested by the
Notified Body 0063.
Schwendi 07.01.2008
ppa. ppa.
Dr. Lück Denkinger
Manufacturer certification to 1. BImSchV
This is a declaration that the condensing wall hung gas
boiler WTC 15/25/32 complies with the requirements
of 1. BImSchV.
Comprehensive Quality Assurance is ensured by a
certified Quality Management System to ISO 9001.
EnEV Site calculation
The EnEV characteristic values of the product in
Ch. 11 can be used as calculation basis
3
1 General instructions 5
2 Safety instructions 6
3 Technical description 8
3.1 Permissible application 8
3.2 Function 8
3.2.1 General notes 8
3.2.2 Important components 8
3.3 Basic construction and variations 13
3.3.1 Overview of variations 13
3.3.2 Version -H 13
3.3.3 Version -H-0 14
3.3.4 Version -W 14
3.3.5 Version -C (only WTC 25-A) 15
3.4 Prerequisites 16
3.5 Demands on the heating water 17
3.5.1 Permissible water hardness 17
3.5.2 Fill water quantity 18
3.5.3 Treatment of fill and top up water 18
4 Installation 19
4.1 Safety notes on installation 19
4.2 Delivery, transport, storage 19
4.3 Wall mounting 20
4.4 Mains water connection 21
4.5 Filling with water 21
4.6 Electrical connection 22
4.6.1 External connections WCM 23
4.6.2 Converting unit version -H-0 to version -H 24
4.6.3 Connecting a 3 way change-over valve 25
4.6.4 Connecting an external pump 25
4.6.5 Remote load control 26
4.6.6 Connecting temperature sensors for
calorifier control (variation P1 and P2) 26
4.7 Gas side connection 28
4.8 Condensate 29
4.9 Flue gas connection 30
5 Commissioning and operation 31
5.1 Operating controls 31
5.2 Safety notes on initial commissioning 31
5.3 Valve proving with air 32
5.4 Function test without gas 32
5.4.1 Automatic configuration 32
5.4.2 Continued program sequence 33
5.5 Commissioning 34
5.5.1 Gas inlet pressure at nominal load 36
5.5.2 Variable ratings setting 37
5.6 Ratings measurement 38
Contents
1
2
3
4
5
4
6 Operating instructions 39
6.1 Operating level 39
6.2 End user level 39
6.2.1 Display mode 39
6.2.2 Setting mode 40
6.3 Heating engineer level 41
6.3.1 Entry to the level 41
6.3.2 Info mode 42
6.3.3 Parameter mode 43
6.3.4 Error memory 47
6.4 Service functions via PC interface 48
6.4.1 Special system parameter 48
7 Control variations Weishaupt Condens Manager (WCM) 49
7. 1 Constant flow temperature control 49
7. 2External temperature dependent flow temp. control 50
7. 3DHW load function (version -W only) 51
7. 4DHW function (version -C only) 51
7. 5DHW load function (versions -H / -H-0) 51
7. 6Special functions 52
7. 6.1 PWM pump 52
7. 6.2 Pump control logic in heating operation 52
7. 6.3 Regulating the PWM pump in DHW operation 52
7. 6.4 Freely selectable input and outputs 53
7. 6.5 Regulation with one calorifier sensor 54
7. 6.6 Regulation with two calorifier sensors 54
7. 6.7 Regulation with hydraulic de-couple 56
8 Safety and monitoring function 58
8.1 Temperature monitoring 58
8.2 Sensor monitoring 58
8.3 Heating frost protection function 59
8.4 DHW frost protection (version -W) 59
9 Cause and rectification of faults 60
10 Service 65
10.1 Safety notes on servicing 65
10.2 Checklist for servicing WTC 66
10.3 Cleaning the burner and heat exchanger 68
10.4 Chimney sweep function 70
11 Te chnical data 71
11.1 Load, efficiency, emissions 71
11.2 Electrical data 74
11.3 Permissible ambient conditions 74
11.4 Layout of the flue gas system 74
11.5 Weights, dimensions 75
Appendix 76
Conversion to Liquid Petroleum Gas 76
Reducing the heat rating 76
Wobbe table 76
Conversion table O2 – CO2 77
Sensor data 77
Internal boiler wiring 78
Customer service 79
Spares 80
7
8
9
A
10
11
6
5
1 General instructions
1
Your information package
This is user information included with the unit. You can find
answers to your questions in the following brochures:
Info for the user:
❑ Operating instructions for the operator
WTC 15-A/25-A and WTC 32-A
(These instructions can be stored in the pocket in the
lower unit cover.)
Info for the installer:
❑ Installation and operating instructions
WTC 15-A/25-A and WTC 32-A
These installation and operating instructions
WTC 15-A/25-A and WTC 32-A
•are an integral part of the equipment and must be kept
permanently on site
• are to be used by qualified personnel only
• contain the relevant information for the safe assembly,
commissioning and servicing of the equipment
•are for the attention of all personnel working with the
equipment.
Explanation of notes and symbols
This symbol is used to mark instructions,
which, if not followed, could result in death or
serious injury.
This symbol is used to mark instructions,
which, if not followed, could result in damage
to, or the destruction of the equipment and
environmental damage.
This symbol is used to mark instructions,
which, if not followed, could result in life
threatening electric shock.
☞
This symbol is used to mark procedures,
which you should follow.
1. Procedures with more than one step are
2. numbered.
3.
❑ This symbol is used when you are required to
carry out a test.
•This symbol is used to list points
➩ This symbol indicates detailed information
Abbreviations
Ta b. Table
Ch. Chapter
Hand over and operating instructions
The contractor is responsible for passing the operating
instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these
instructions should be kept with the heating appliance. The
address and telephone number of the nearest service
centre should be entered on the reverse of the operating
instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
inspect the plant at least once a year. To ensure regular
inspections, -weishaupt- recommends a service contract.
The contractor should instruct the plant operator in the use
of the equipment prior to hand-over and inform him as and
when necessary of any further inspections that are
required before the plant can be used.
Guarantee and liability
Weishaupt will not accept liability or meet any guarantee
claims for personal injury or damage to property arising as
a result of one or more of the causes below:
• Failure to use the equipment as intended.
•Improper assembly, commissioning, operating or
servicing of the equipment.
•Operating the appliance with defective safety
equipment, or with non-recommended or nonfunctioning safety and protection devices.
• Failure to follow the information in the Installation and
Operating Instructions.
•Alterations made to the construction of the equipment
by the plant operator.
• Fitting additional components not tested or approved
for use with the equipment.
•Alterations to the combustion chamber are not
permitted.
• Inadequate monitoring of parts liable to wear and tear.
• Improperly executed repairs.
• Acts of God.
• Damage caused by continued use despite the
occurrence of a fault.
• Use of incorrect fuel.
•Obstruction or damage of the supply lines.
• Use of non-original -weishaupt- spare parts.
DANGER
AT TE NTION
DANGER
6
2 Safety instructions
2
Dangers when using the equipment
Weishaupt products are manufactured in accordance with
the relevant existing standards and guidelines and the
recognised safety laws. However, improper use of the
equipment could endanger life of the user or a third party,
or result in damage to the plant.
To avoid unnecessary danger, the equipment is only to be
used:
• for its intended purpose
• under ideal safety conditions
•with reference to all the information in the installation
and operating instructions
• in accordance with inspection and service work
Faults, which could affect safe operation should be
rectified immediately.
Installation in agreement with the district
chimney sweep
In accordance with German state law the installation of a
heating system has to be notified and/or a permit has to be
obtained.
Prior to installation please consult your district chimney
sweep with regards to:
• Layout of air supply and flue gas system
• Fuel supply
• Condensate discharge into the waste water system
•Platform in the area of cleaning aperture to
DIN 18160-Part 5
Installation in garages
Only Gas units in version C may be installed in garages.
The distance between floor and bottom edge of the WTC
must be a minimum of 50 cm. The WTC must be protected
from mechanical damage. A suitable metal frame should
therefore be installed around the WTC. The operating
instructions should be placed into a clearly visible position
and should be protected against atmospheric exposure.
Personnel training
Only competent personnel may work on the appliance.
Competent personnel according to this operating manual
are persons who are familiar with the installation,
mounting, setting and commissioning of the product and
have the necessary qualifications such as:-
•Training, instruction or authorisation to switch electrical
circuits and electrical devices on and off, to earth them
and to mark them in accordance with the safety
standards.
•Training, instruction or authorisation to carry out
installation, alteration and maintenance work on gas
fired plant.
Organisational measures
• Everyone working on the plant should wear the
necessary protective clothing.
• All safety devices should be checked regularly.
Informal safety measures
• In addition to the installation and operating instructions,
local codes of practice should also be adhered to.
Special attention should be paid to the relevant
installation and safety guidelines given.
• All safety and danger notices should be kept in a
legible condition.
Safety measures in normal operation
•Only use the equipment when all safety devices are
fully functional.
•At least once a year the equipment, including the safety
devices, should be checked for signs of visible damage
and to ensure that the safety devices are operating
correctly.
• More frequent safety checks may be required
depending on plant conditions.
Electrical safety
• Before starting work - isolate plant and protect against
reactivation, check voltage is isolated, the unit is
earthed, and protected from adjacent equipment that
might still be under voltage!
•Work on the electrical supply should be carried out by
a qualified electrician.
• Electrical components should be checked during
servicing. Loose connections and heat damaged
cables should be dealt with immediately.
• Should it be necessary to carry out work on live parts,
the Regulation for the Prevention of Accidents BGV A3
and/or country specific safety regulations must be
observed and tools to EN 60900 must be used. A
second person should be present to switch off the
mains supply in an emergency.
Maintenance and fault rectification
•Necessary installation, service and inspection work
should be carried out at the specified time.
• Inform the operator before beginning any service work.
•For all service, inspection and repair work, electrically
isolate the equipment and ensure the mains switch
cannot be accidentally switched back on. Cut off the
fuel supply.
• If, during servicing or testing, control seal joints have to
be opened, these have to be thoroughly cleaned to
ensure tight sealing when re-assembling.
Damaged seals must be replaced. Carry out
soundness test.
• Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
commissioned by, and may only be replaced by, the
manufacturer or an authorised agent.
• Screwed connections, which have been loosened,
must be re-tightened without cross-threading.
•Following service work, all safety devices should be
tested to ensure they are functioning correctly.
Alterations to the construction of the equipment
• No alterations to the equipment are to be made without
the approval of the manufacturer.
All conversions require written confirmation from
Max Weishaupt GmbH.
•Any parts not in perfect working order should be
replaced immediately.
• No additional components may be fitted, which have
not been tested for use with the equipment.
•Use only -weishaupt- replacement and connection
parts. Parts from other manufacturers are not
guaranteed to be suitable to meet the necessary
operational and safety requirements.
Cleaning of the equipment and waste disposal
• All materials used should be handled and disposed of
correctly, with due regard to the environment.
7
2
Gas supplier
Date Signature
Type of gas: ____________________________________
Calorific value Hi: _______________________ kWh/m
n
3
max. CO2: ___________________________________ %
Connection pressure: _______________________ mbar
Conversion to other types of gas
The WTC is type tested for Natural Gas and Liquid
Petroleum Gas.
It is factory pre-set for Natural Gas operation.
A setting to 2E or 2LL is not required.
The conversion from Natural Gas to Liquid Petroleum
Gas is described in the appendix. When operating with
Liquid Petroleum Gas we recommend the use of
Propane.
☞ When converting from Natural Gas to Liquid
Petroleum Gas or visa versa please check the O
2
content, the unit loading (values see Technical data)
and the designation on the name plate.
Furthermore a calibration is required
(procedure see Ch. 6.3.3:
Notes for special parameters).
Gas characteristics
The following information must be obtained from
the gas supplier:
•Type of gas
•Calorific value in MJ/m
3
or kWh/m
3
• Max. CO2content of flue gas
• Gas supply pressure
Pipe thread connection
• Only tested and approved sealing material should be
used. Please observe the prevailing user instructions!
Soundness test
☞ Check connection joints with foam forming or similar
media, which do not cause corrosion.
Max Weishaupt GmbH D-88475 Schwendi
Nominal heat loading (heating)
reduced to max.__________kW
General information for gas operation
•When installing a gas combustion system, regulations
and guidelines must be observed (i.e. Local Codes of
Practice and Regulations).
•The subcontractor responsible for the installation or
changes to the gas system must inform the gas
supplier of the type and extent of the installation
planned and the intended work. The subcontractor
must ascertain that an adequate gas supply to the
installation is ensured.
• Installations, alterations and maintenance work on gas
systems in buildings and below ground must only be
carried out by installers who have a contract with the
gas supplier.
•The gas pipe work must be subject to a preliminary and
main test or the combined loading test and soundness
test, according to the pressure range intended.
•The inert gas used for the test must be
expelled from the pipe work. The pipe work must be
completely purged.
Safety measures when gas can be smelled
•Avoid open flames and spark generation (e.g. switching
lights and electric units on and off, including the use of
mobile phones).
• Open windows and doors.
• Close gas shut off valve.
•Warn all occupants and evacuate the building.
• Inform heating company/installer and gas supplier
from outside of the building.
8
3Technical description
3
3.1 Permissible application
The Weishaupt Thermo Condens WTC 15-A/25-A and
WTC 32-A is a condensing wall mounted heating
appliance for sliding setback operation without lower
temperature limit.
• for wall mounting in enclosed rooms
(installation outdoors is not permitted)
• for heating DHW heating circuits in sealed systems
• for flue gas ducting in chimneys / flue gas ducts or
directly via wall and roof flue gas systems
•for combustion air supply from the room air or with
room air independent systems.
• for gas families Natural gas E/LL and Liquid
Petroleum Gas B/P.
3.2 Function
3.2.1 General notes
Condensate drain
The condensate created by the condensing boiler
technology is fed into the waste water system via a
siphon built into the unit. The ATV data sheet A251
should be observed.
Combustion air
Depending on the type of operation, the combustion air is
supplied either from the room where the unit is installed
(room air dependent operation) or via a concentric pipe
system (room air independent operation).
Flue gas system
Once the cooled flue gas exits the heat exchanger it
flows through a flue gas duct made from Polypropylene
(PP) to the unit exit, from where a number of different
ducting systems from the Weishaupt flue gas / air system
WAL-PP are available.
☞
Observe installation and operating instructions
WAL-PP!
Safety equipment
An internal flue gas temperature limiter (max. 120 °C) and
a safety temperature limiter switch off the unit at excess
temperature.
3.2.2 Important components
Heat exchanger
The heat exchanger consists of a corrosion proof
aluminium alloy through which the heating water flows
from bottom to top.
The heat exchanger is designed in such a way that the
flue gas is cooled to below the flue gas dewpoint if the
system temperature is adequately low.
It is surrounded by water and has no additional insulation.
Due to the utilisation of the latent flue gas heat the unit
operates with very high efficiency.
The heat exchanger is equipped with inbuilt hydraulic
circuit with integrated pump and three way valve housing
(version -C and -W).
Heat exchanger operating mode
Premix surface burner
The overheat proof radiant burner is made from a highly
stressable metal mesh (FeCr Alloy). Flame monitoring
and the regulation of the gas quantity are carried out by a
SCOT
®
monitoring electrode in conjunction with the fully
electronic compound regulation and the Weishaupt
Condens Manager (WCM).
9
3
Diagram resulting supply pressure
WTC 15-A, WTC 25-A and WTC 32-A with PEA pump
0 100 200 300 600 700 800 900 1000 12001100500400
0
100
200
300
400
500
600
700
800
1300 1400 1500
Resulting supply pressure [mbar]
Throughput [l/h]
Speed
100% .....
80% .....
60% .....
40% .....
20% .....
Version with PEA pump
On condensing boilers with PEA pump (PWM pump with
permanent magnet technology) the maximum modulation
range of the pump in its factory presetting is 30 - 60%
(WTC 15-A), 30 - 70% (WTC 25-A) and 30 - 80% (WTC
32-A). The modulation range can be adjusted in the
heating engineer level using parameter P42 and P43. This
pump matches the unit throughput to the rating and
reduces electrical consumption. The resulting supply
pressure within the modulating range can be determined
using the diagram on the right.
➩ For a detailed description of the controller function see
Ch. 7.6.
Note: Following change-over into DHW operation
(version -W) the pump is driven for 3 minutes
at a rating of 40%. The rating then increases
to the value set in parameter P45.
The following parameter settings are recommended as
standrad to adjust the pump rating :
WTC 15-A WTC 25-A WTC 32-A
❑ P42 = 40 ❑ P42 = 40 ❑ P42 = 40
❑ P43 = 60 ❑ P43 = 70 ❑ P43 = 90
10
3
Diagram resulting supply pressure
WTC 32-A with PWM pump
0 100 200 300 600 700 800 900 1000 12001100500400
0
100
200
300
400
500
1300
600
1400 1500
700
800
Residual supply height [mbar]
Throughput [l/h]
Diagram resulting supply pressure
WTC 25-A with PWM pump
0 100 200 300 600 700 800 900 1000 12001100500400
0
100
200
300
400
500
1300
600
1400 1500
700
800
Resulting supply pressure [mbar]
Throughput [l/h]
Speed
100% .....
80% .....
60% .....
40% .....
20% .....
Diagram resulting supply pressure
WTC 15-A with PWM pump
0 100 200 300 600 700 800 900 1000 12001100500400
0
100
200
300
400
500
600
700
800
1300 1400 1500
Resulting supply pressure [mbar]
Throughput [l/h]
Speed
100% .....
80% .....
60% .....
40% .....
20% .....
Speed
100% .....
80% .....
60% .....
40% .....
20% .....
Version with PWM pump
On condensing boilers with PWM (Pulse width
modulation) modulating heating circuit pump the maximum
modulation range of the pump in its factory presetting is
30 - 60% (WTC 15-A), 30 - 70% (WTC 25-A) and 30 80% (WTC 32-A). The modulation range can be adjusted
in the heating engineer level using parameter P42 and
P43. This pump matches the unit throughput to the rating
and reduces electrical consumption. The resulting supply
pressure within the modulating range can be determined
using the diagram on the right.
➩ For a detailed description of the controller function see
Ch. 7.6.
Note: Following change-over into DHW operation
(version -W) the pump is driven for 3 minutes
at a rating of 40%. The rating then increases
to the value set in parameter P45.
11
3
Diagram resulting supply pressure WTC 15-A
with 3 stage pump
Version with 3 stage pump (WTC 15-A/25-A)
On condensing boilers with 3 stage pump the pump
stage can be set manually at the pump. The pump is
supplied preset to pump stage 2.
For the hydraulic design of the installation the resulting
supply pressure should be be taken from the table on the
right. Depending on the installation, the pump rating may
be reduced.
500 1000 15000
0
100
200
300
400
500
600
Resulting supply pressure [mbar]
Throughput [l/h]
Stage 3
Stage 2
Stage 1
Diagram pressure loss
WTC 15-A/25-A/32-A, version -H-0 without pump
700
600
500
400
300
200
100
600
0
1200
0
800400200 20001800160014001000 2200
800
Pressure loss [mbar]
Throughput [l/h]
Pressure loss unit -H-0
The diagram on the right shows the pressure loss of the
WTC unit without integrated pump to be able to carry out
the hydraulic design of the installation.
Size Min. throughput Max. throughput
WTC 15-A 0 l/h 1300 l/h
WTC 25-A 0 l/h 2200 l/h
WTC 32-A 0 l/h 2200 l/h
Throughput limits
Diagram resulting supply pressure WTC 25-A
with 3 stage pump
700
600
500
400
300
200
100
5000 1000 1500
0
Resulting supply pressure [mbar]
Throughput [l/h]
Stage 3
Stage 2
Stage 1
12
3
Fully electronic compound regulation
The WTC 15-A/25-A and WTC 32-A are equipped with
fully automatic compound regulation. This regulates the
gas quantity depending on the measured ionisation
current. The regulation of the air quantity is carried out via
the speed controlled fan. The basis for the regulation is
the diagram on the right. The maximum of the ionisation
current occurs with all gas types at λ = 1.0. This
maximum is redetermined from time to time during
recalibration. Calibrations are carried out
•after every power outage
•after 100 hours of burner operation
•after 500 burner starts
• after certain faults have occurred (e.g. F21, W22, …)
The maximum value determined is used to calculate the
setpoint value.
Note: Calibration can also be initiated manually.
This is necessary if the following part were
changed during servicing or repair :
• Burner
• SCOT electrode, ionisation cable
•WCM electronic controls
•Gas valve
(Procedure see Ch. 6.3.3:
Notes about special parameters)
Diagram ionisation current regulation
During calibration, CO emissions above
1000 ppm occur for a short time
(approx. 2 sec.).
AT TE NTION
I
o max
I
o soll
Ionisation current [I
O
]
Air number [λ]λ=1 λ≈1.3
Ragulating
range
Expansion vessel
The table enables an evaluation to establish if the
expansion vessel fitted (content 10 l) is sufficient or if an
additional expansion vessel is required.
The following key data was taken into account for the
table:
• Flow pressure of the expansion vessel is equal to the
static installation height above the heat exchanger
(e.g. height 10 m ➪ flow pressure 1.0 bar)
•Maximum operating pressure: 3 bar
•Operating pressure differential safety valve: 0.5 bar
•Water trap 2 l
Note: In accordance with DIN 4807-2, expansion
vessel must be serviced annually. The values
set during initial commissioning must be
re-set when recommissioning.
Example:
A max. flow temperature of 50°C, installation
height 7.5 m and flow pressure 0.75 bar result in a
maximum installation content of approx. 260 l. If this
installation content is exceeded an additional expansion
vessel should be installed.
Maximum permissible total water content of the heating system with integral expansion tank
2)
1)
The supply pressure of the expansion vessel has to be
altered accordingly.
2)
A detailed object related calculation is required.
Maximum Installation elevation
Size flow
expansion tank temperature 5 metre
1)
7.5 metre 10 metre
1)
12.5 metre
1)
15 metre
1)
10 Litre 40 °C 500 400 300 210 120
50 °C 320 260 200 140 80
60 °C 220 180140100 60
70 °C 170 130 100 70 40
80 °C 130 100 80 50 30
13
3
reset
0
1
1 Flue gas outlet
2 Supply air inlet
3 Expansion vessel (for WTC 15-A/25-A)
4 Pressure gauge
5LCD display
6Dial knob
7 Enter key
8 Reset key
9 On/Off switch
10 PC connection
11 Electrical installation area
12 Electrical cable duct
13 Heating return Ø 18 mm
14 Cover 3 way valve
15 Gas pipe Ø 18 mm
16 Cleaning opening siphon
17 Siphon
18 Heating flow Ø 18 mm
19 Pump
20 Condensate outlet hose
21 Flue gas sensor (NTC 5kΩ
)
22 Inspection opening heat exchanger
23 Fully electronic compound regulation
24 Heat exchanger made from Al Mg is
25 Ignition electrode
26 SCOT electrode
27 Burner
28 Flow sensor (NTC 5kΩ)
29 Quick action vent valve
Version -H: Heating unit only without DHW function.
Version -H-0: Heating unit only, but without pump and
expansion vessel.
Version -W: Unit with integrated 3 way valve for
DHW preparation in combination with
Weishaupt water heaters.
Version -C: Unit with integrated DHW preparation
via plate heat exchanger and throughput
sensor for acquisition of water quantity
drawn.
3.3.2 Version -H
3
4
5
6
7
8
9
10
11
12
13141516171819
21
22
15
23
24
18
25
26
27
28
29
12
20
3.3 Basic construction and variations
3.3.1 Overview of variations
WTC 15-A: Available in versions -H, -H-0 and -W.
Versions with circulation pump
available with optional three stage or
speed controlled PWM pump.
WTC 25-A: Available in versions -H, -H-0, -W
and -C. Versions with circulation pump
available with optional three stage or
speed controlled PWM pump.
WTC 32-A: Available in versions -H, -H-0 and -W.
Versions with circulation pump are fitted
with integrated speed controlled PWM
pump. The WTC 32-A is only supplied
with expansion vessel in version -W.
3.3.4 Version -W
The 3 way valve is flanged directly to the heat exchanger.
The valve consists of two parts, the base with integrated
valve body and the motor, which can be removed via the
bayonet connection. The valve runs in both settings on a
limit switch, it therefore does not require any electrical
energy except when changing from one valve setting to
the other. The valve can be set to its centre position
manually with the catch of the lever on the motor of the 3
way changeover valve. In this setting, all 3 ways are open
(see Ch. 4.5). In comparison to version -H, version -W is
equipped with connection pipes for connecting a water
heater.
Note: The expansion tank is integrated in
WTC 15-A, WTC 25-A as well as
WTC 32-A vers. W.
13 42
1 Heating flow
2Heating return
3Flow to water heater
4 Return from water heater
3.3.3 Version -H-0
Version -H-0 is a unit for heating operation without DHW
preparation. The heating pump and the expansion vessel
are usually fitted on site. When installing the pump on
site it should be observed that a minimum installation
pressure of 1 bar is maintained if the pump is fitted in the
flow. The pressure loss diagram from Ch. 3.2.2 should
be used when sizing the pump. Weishaupt recommend
the pump is installed in the return of the heating system
of the unit.
12
1 Heating flow
2Heating return
14
3
15
3
Hard domestic water can lead to scaling of
version -C .
If the water hardness is above 21° dH, a
water softener should be used in conjunction
with version C.
Version -C contains the same 3 way valve as version -W.
The drawn water quantity is determined exactly by a
throughput sensor (6) and evaluated by the Weishaupt
Condens Managers (WCM).
To ensure a constant DHW outlet temperature, version -C
is fitted with a temperature sensor (5) in the DHW
outlet. It is possible to maintain the DHW temperature so
that warm water is available immediately the tap is opened.
This function can be switched off.
Version -C is equipped with a booster function to ensure
total DHW comfort, which increases the burner rating to
approx. 28 kW with a drawn quantity of over 4
l
/
min
and an
outlet temperature > 50°C . This function can be switched
off in the heating engineer level (parameter P62).
The plate heat exchanger (8) can be removed forwards by
undoing the two flange screws (7).
3.3.5 Version -C (WTC 25-A only)
1853426
77
1 Heating flow
2Heating return
3 DHW outlet
4Cold water inlet
5DHW sensor
6Throughput sensor
7 Fixing screws plate heat exchanger
8Plate heat exchanger
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16
3
3.4 Prerequisites
Included in delivery
The ready-to-use unit is delivered in a cardboard box.
The following parts are enclosed loose:
• End user documents
•Wall bracket
• Screw set with wall plugs
• Installation template
•Spacer
Application instructions
When transporting and storing the unit, the following
should be avoided:
•mechanical impact, such as: distortion,
warping, scratching
• contamination of any kind, e.g.: water, oils, greases,
solvents, dust, debris, aggressive steam, etc.
• electrical impact, e.g.: through electrostatic discharge
or unnaturally large electric fields, see DIN EN 100
015 Part 1 and "Instruction for handling
electrostatically sensitive components" (techn.
information 821005 from Valvo)
• climatic exposure, such as: temperatures outside of
the range -10°C...+60°C, condensation caused by
dew, rel. humidity above 75% as annual average.
Requirements relating to the installation location
The installation location, which should be frost free and
protected from humidity, must comply with local
regulation (combustion by-law, fire regulations).
Observe special regulations:
• DVGW-TRGI (Germany)
•SVGW-Guidelines (Switzerland)
Requirements relating to combustion air
The combustion air must be free from aggressive
compounds (Halogene, Chloride, Fluoride, etc.) and from
contaminants (dust, building material, steam, etc.). The
unit should not be operated until all building work in the
installation location has been completed.
Flue gas connection to chimneys
Due to the water vapour content in flue gases with low
temperature and the additional condensation created in
the chimney, condensing boilers can only be connected to
moisture resistant house chimneys. The flue gas ducts
must comply with local authority regulations and country
specific requirements:
•(DE) DVGW (TRGI)
•(AT) ÖVGW
•(CH) SVGW, VKF Guidelines, Number 3.4.8
(Issue 1993)
Building regulation approved flue gas duct
The flue gas duct should have the same diameter as the
boiler flue gas socket.
• Consultation with the appropriate district master
chimney sweep
• Flue gas duct soundness test must be carried out
Air inlets must be
kept clear!
Unimpeded combustion air
Important - Warranty for boiler replacement!
Supply air ducts, which have previously been used as a
chimney for solid fuel or oil firing plants, must only be used
as supply air duct once they have been thoroughly
cleaned. Thoroughly clean means that dust, sulphur, soot,
dirt and any diffused gases have been removed from the
duct material (e.g. paint, render, insulation). If unsure, the
internal sides of the duct should be sealed or concentric
flue gas pipes (accessory) should be used.
If the WTC is integrated into an existing heating system, it
must be ensured that rust, dirt and sludge have been
removed. Non oxygen diffusion resistant plastic pipes must
only be connected via a separate heat exchanger,
otherwise deposits can cause damage and lead to
operational influences (localised overheating, noise or
similar). On version -C it should be noted that galvanised
steel pipes must not be connected to the DHW
connections.
☞ If necessary fit sludge strainer in the return
Flue gas duct
17
3
Note: In accordance with VDI-Guideline 2035
the following demands must be met by the
heating water.
•The untreated fill and top up water must be of
domestic water quality (colourless, clear, without
scaling),
• the fill and top up water must be pre-filtered
(mesh width max. 25 µm),
• the pH value must be 8.5 ± 0.5,
• avoiud oxygenation of the heating water
(max. 0.05 mg/l),
• if any system components are not diffusion resistant
the unit should be separated from the heating circuit
using a system separator.
3.5 Demands on the heating water
3.5.1 Permissible water hardness
The permissible water hardness is determined relative to
the fill and top up water quantity.
☞ Determine if measures for water treatment are
necessary using the diagram.
If the fill and top up water lies in the range of the upper limit
curve:
☞ Treat fill and top up water.
If the fill and top up water lies in the range of the lower limit
curve, the water does not need to be treated.
Note: Document fill and top up water quantity.
0 200 400 600 800 1000 1200 1400 18001600
0
5
10
15
20
25
30
Max. total hardness of heating water for WTC 15-A
Fill and top up water quantity [ l ]
To tal hardness [°dH]
0 200 400 600 800 1000 1200 1400 18001600
0
5
10
15
20
25
30
Max. total hardness of heating water for WTC 25-A
Fill and top up water quantity [ l ]
To tal hardness [°dH]
0 200 400 600 800 1000 1200 1400 18001600
0
5
10
15
20
25
30
Max. total hardness of heating water for WTC 32-A
Fill and top up water quantity [ l ]
To tal hardness [°dH]
Stabilisation of hardness
Damage to the unit due to unsuitable
inhibitors:
Corrosion and lime scale could damge the
system.
☞ Only use inhibitorsen if the manufacturer
can guarantee the following:
the requirements relating to the heating
water are met,
the heat exchanger of the unit will not
corrode,
no sludge will form within the heating
system.
☞ Treat the fill and top up water with inhibitors.
☞ Check pH value (8.5 ± 0.5) according to the
instructions of the inhibitor manufacturer.
18
3
3.5.3 Treatment of fill and top up water
Demineralisation (recommended by Weishaupt)
☞ Fill and top up water sgould be demineralised
(Recommendation: mixer bed treatment)
When the heating water has been completely
demineralised, up to 10% of the system contentents can
be topped up with untreated water. Higher quantities of
top up water must be demineralised.
☞ Check pH value (8.5 ± 0.5) dof demineralised water:
•following commissioning,
•after approx. 4 weeks of operation,
• during the annual service.
☞ If necessary, adjust pH value of heating water by
adding Trisodium Phosphate.
Softening (cation exchanger)
Damage to the unit due to raised pH value:
Corrosion could damage the system.
☞ Following softening by cation exchanger
the pH value must be stabilised due to
the self-alkalisation of the heating water.
☞ Soften the fill and top up water.
☞ Stabilise pH value.
☞ Check pH value (8.5 ± 0.5) during annual service.
AT TE NTION
AT TE NTION
3.5.2 Fill water quantity
If information about the fill water quantity is not available,
the following table can be used to estimate the quantity.
On calorifier systems the calorifier content must be taken
into consideration.
Heating system Estimated fill water quantity
(1
55/45 °C 70/55°C
Pipe and steel radiators 37 l/kW 23 l/kW
Cast iron radiators 28 l/kW 18 l/kW
Plate radiators 15 l/kW 10 l/kW
Air conditioning 12 l/kW 8 l/kW
Convectors 10 l/kW 6 l/kW
Underfloor heating 25 l/kW 25 l/kW
(1
based on the heating requirements of the building.
19
4 Installation
4
Electrically isolate the system
Prior to installation switch off the unit
and safety switch, as well as the mains
switch. Failure to comply could cause death
or serious injury by electric shock.
Only valid for Switzerland:
When installing and operating a -weishaupt- gas burner in
Switzerland the regulations of SVGW and VKF as well as
local and cantonal regulations must be observed.
Furthermore, the EKAS guideline (Guideline for Liquid
Petroleum Gas, part 2) must be observed.
DANGER
4.1 Safety notes on installation
4.2 Delivery, transport, storage
Packaged in shipment box
The WTC is delivered complete with accessories
packaged in one strong shipment box.
The shipment packaging is best removed with the unit
upright.
☞ Only transport in shipment box.
☞ Observe shipment instructions on box.
☞ Do not place WTC onto gas or water connections
without polystyrene pad.
Packaging
The cover of the WTC is protected from
accidental opening with screws.
Re-secure the lid once it has been refitted
using the screw.
20
4
Fit and align unit
1
2
4.3 Wall mounting
Fit and align unit
☞ Fit spacers provided to the left and right of the rear of
the unit, as low as possible.
☞ Place unit into the wall bracket 1. Check safe overlap
in the wall bracket.
☞ Once fitted, horizontally align the unit with the
2 setting screws 2.
☞ Fit flue gas connection (accessory).
☞ It is recommended to remove the cover of the WTC
before continuing with the installation. Remove the
locking screw on the clamp fastener on the
underside of the unit, open clamp fastener and
remove cover upwards.
DANGER
Fit wall bracket
40
50
790
127
25
61,5
227
46,5
1
260
Fit wall bracket
☞ Fit wall bracket 1 enclosed to the wall with the
fixing screws supplied.
❏ The suitability of the wall plugs enclosed should be
checked depending on the construction of the wall.
❏ A gradient of 3° towards the unit should be provided
for the flue gas ducting (at 1metre this is equal to
approx. 5.5 cm).
❏ There should be sufficient space available below the
unit for the hydraulic connection assembly.
❏ For servicing purposes, a distance of approx. 30 mm
to wall units or similar should be maintained.
Further unit dimensions see Ch. 11.5.
1)
Boiler connection piece new
Order No. 480 000 05 32 2
Dimension 234 mm is valid for old boiler connection
pieces
Order No. 480 000 10 01 2 or
Order No. 480 000 06 52 7
171
1)
3°
21
4
4.4 Mains water connection
Hydraulic connection
1 Heating flow Ø 18 mm
2 Flow water heater or DHW Ø 15 mm
3 Gas Ø 18 mm
4 Return water heater or cold water Ø 15 mm
5 Heating return Ø 18 mm
6 Condensate outlet Ø 25 mm
Application in sealed heating systems
☞ On version -W: Connect flow and return pipes of
water heater.
☞ On version -C: Connect cold and hot water pipes.
☞ Connect flow and return (pipes should be rinsed
thoroughly before connecting).
☞ Install boiler, inlet and outlet valves
(available as an accessory).
☞ Install safety valve (available as accessories).
☞ Fit sludge trap in return pipe (if required).
☞ Fit expansion tank (WTC 32-A)
335
50
120
ca. 800
77,5
260
35
50
99,2
240
12 3 4 5
6
6
1
2
3
4
5
40
4.5 Filling with water
When filling the heating system, the requirements for the
heating system water (see also Ch. 3.4) should be
observed.
Unsuitable water results in scaling and
corrosion formation and can cause damage
to the condensing boiler.
Centre position three way valve
☞ Check pre-pressure of the diaphragm expansion
vessel.
☞ Prior to first commissioning, the heating system
should be flushed with at least twice the amount of
the system content to remove contaminants. Swarf,
rust, scale, sludge etc. can influence the operational
safety.
☞ Set three way valve of condensing boiler to it centre
position (only on version -W and -C).
☞ Open all thermostatic valves in the system.
☞ Loosen cap of quick action vent valve.
☞ Open service cocks for heating flow and return.
☞ Slowly fill heating system from tap connected to the
heating return (minimum system pressure >1.0 bar).
Observe all relevant regulations.
☞ Vent all radiators.
☞ Once the system has been vented, check system
supply pressure, if necessary repeat fill procedure.
☞ Seal joints and screwed unions should be checked to
ensure they are tight.
Note: The unit and any separately fitted pumps
must be switched off during filling.
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22
4
Electrical installation by qualified personnel only!
Local regulations and codes of practice, as
well as regulations from the energy supplier
must be observed.
Mains and emergency switch
The external mains switch for the heating system must
have at least 3 mm contact distance.
☞ Connection to plug assignment, Ch. 4.6.1.
Electrical connection 230V/50 Hz
The gas condensing boiler WTC is wired ready for
connection. The cover of the electrical installation duct
must be removed for the electrical installation.
Insert the cable from the rear through the recess into the
unit.
The electrical connection must be carried out by a
qualified electrician. Changes to the internal boiler wiring
are not permitted.
Shell clamps should be used if flexible
cables are connected.
Approved sleeve cable should be used for
all other connection lines.
4.6 Electrical connection
DANGER
AT TE NTION
Plug cover
23
4
F10
230V
B3
S3
F1 230V
4,0 AT
S10
EM
M
B11
B1
NTC 5k NTC 600 NTC 12k
B10
NTC 5k
L N PE
230V 1/N/PE 50Hz
Max.10A gL
MFA
123456 78910
230V—
L N PE
230V˜
L N PE
H1
L E
H2
L E
MFA
L N PEVA1 2
eBus
+ -
B11
1 M
B1/N1
1 MB31 M
H2
H1
NL
ϑ
eBus
Modul
WCM - CPU
CPU
WCM-FS WCM -EM
ϑ
ϑ
B10
ϑ
Wiring diagram WCM
4.6.1 External connection WCM
Mains switch
Main switch
The external connection is made in the electrical installation duct
Plug Number/ Connection Operating
colour range
Mains, 230V 1/black 230 VAC supply input
230V 2/grey 230 VAC supply output max. 250 VA
H1 3/turquoise H1 Opto input 230VAC 0.002A function dep. on configuration
H2 4/red H2 Opto input 230VAC 0.002A function dep. on configuration
MFA, 230V 5/lilac MFA relay output: 230 VAC max. 150VA,
VA 6/brown VA potential free relay output 230VAC 8A / DC 60V 5A
function dep. on configuration
eBUS 7/blue Connection of add. control components WCM - FB, - EM, - KA
B11 8/white De-couple sensor (variation: P2/P3) ➩ Ch. 7.6.6-7.6.7 0…99°C
B1 9/green External sensor type QAC 31 (Order No. 660 186), -40…50°C
NTC 600 Ohm,
N1 4-20 mA remote load control ➩ Ch. 4.6.5 4…20 mA
B3 10/yellow Tank sensor NTC 12kOhm 0…99°C
Optional: B10 DHW calorifier control sensor NTC 5kOhm
calorifier ➩ Ch. 4.6.6 0…99°C
cable loom
DHW load pump
Calorifier cable
loom (optional)
Note: • Local regulations must be observed when
connecting the boiler to the 230 VAC
mains supply, to ensure safe
disconnection from the mains is possible.
•The sum of all consumer load currents on
plugs 2 and 5 must not be more than
2 A continuous current.
•The function of inputs and outputs H1, H2, MFA and
VA depend on the configuration.
➩ Ch 7.6.4
• Internal boiler wiring see appendix.
• Consumers of other power circuits (external voltage)
must not be switched directly with the VA output.
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24
4
4.6.2 Converting unit version -H-0 to version -H
Connecting an internal boiler pump
The following pumps are available as accessories for
fitting into WTC:
WTC 15-A/25-A:
•3 stage pump
•PWM pump
WTC 32-A:
•PWM pump
The pump is supplied ready to plug in and should be
connected to plug slot 17.
12345678910
Connect internal boiler pump
St 17 St 18St 20St 19
Internal boiler plug rail
Control line only
with PWM pump
230V H1
F1 (230V/4AT)
230V H2 MFA VA eBUS B11 B1/N1 B3
eBus
PC
F2 (24V/4AT)
10
Reset key
Enter
key
Dial
knob
25
4
F10
10A
L N PE
230V 1/N/ PE 50Hz
F10
10A
L N PE
230V 1/N/ PE 50Hz
12345678910
230V—
L N PE
230V˜
L N PEH1L EH2L E
MFA
L N PEVA1 2
eBus
+ -
B11
1 M
B1/N1
1 MB31 M
WCM - CPU
12345678910
230V—
L N PE
230V˜
L N PEH1L EH2L E
MFA
L N PEVA1 2
eBus
+ -
B11
1 M
B1/N1
1 MB31 M
WCM - CPU
S10
S10
4.6.3 Connecting a 3 way change-over valve
For DHW operation, the 3 way change-over valve is
connected to the 230V output and either the MFA or VA.
To enable the 3 way change-over valve to function, the
MFA or VA must be configured accordingly.
To do this, parameter P13 or P14 (see Ch. 6.3.3) should
be set to parameter value 4.
Control via MFA:P13 = 4
Control via VA: P14 = 4
3 way change-over valve
(Order No.: 409 000 05 73 2)
Servomotor with connection cable
(Order No.: 409 000 05 71 2)
Connect 3 way change-over valve
4.6.4 Connecting an external boiler pump
brown
Control via MFA WCM - CPU
Control via VA WCM - CPU
black
blue
brown
black
blue
The external boiler pump can be controlled via output
MFA or VA.
To achieve the required function of the pump (DHW or
heating) parameter P13 or P14 need to be configured
accordingly (see Ch. 6.3.3).
Note: When connecting an electronically controlled
pump (E pump) the replacement of the
suppressor element is recommended
(-w- Order No. 713 404).
F10
10A
L N PE
230V 1/N/ PE 50Hz
12345678910
230V—
L N PE
230V˜
L N PEH1L EH2L E
MFA
L N PEVA1 2
eBus
+ -
B11
1 M
B1/N1
1 MB31 M
WCM - CPU
S10
Connecting an external boiler pump
1. Open cover of WTC.
The cover of the WTC is protected from
accidental opening by a screw.
Ensure this screw is refitted when refitting
the cover.
2. Open cover of electrical installation area (see Ch. 4.6)
and puncture through the diaphragm grommet.
26
4
4.6.6 Connecting temperature sensors for calorifier control (variations P1 and P2)
Prior to starting work electrically isolate the
unit and protect from accidental
reconnection.
Failure to comply could cause serious injury
or death by electric shock.
To be able to install the calorifier sensor B10, the
accessory line must be installed on plug slot ST20.
Note: The connection of calorifier sensors is only
possible on unit version -H, -H-0 and -W.
DANGER
DANGER
Push through diaphragm grommet in installation area
Scope of delivery calorifier sensor connection
Connecting calorifier sensor (B10)
Order No.: 481 000 00 16 2
4.6.5 Remote load control
The control cable (4…20 mA) is connected to input
B1/N1 (plug 9) independent of polarity.
The WCM automatically recognises the signal and
displays configuration _t _ when it is switched on.
The available signal is interpreted as supply setpoint,
which is incorporated into the setpoint formation parallel
to other heat demands from the heating circuits, whereby
4 mA is equal to the minimum supply setpoint set in
parameter P30. 20 mA is equal to the maximum supply
setpoint set in parameter P31. The range of 4 - 6 mA
switches the unit off.
If a control signal is switched on input B1/N, no more
than 6 extension modules (addresses #2 to #7) can be
installed.
Note: Remote load control is not possible on
WTC-A, vers. C.
Diagram
P30
(8°C)
I [mA]
46 20
P31
(78°C)
V
L
[°C]
27
4
3. Plug in circuit board plug (Rast 2.5) at plug slot ST20.
4. Install the cable for the calorifier sensor down
towards the cable entry and pass it through the
diaphragm grommet.
5. Connect wire ends to plug part B10 and secure with
tension relief (cable ties).
6. Connect calorifier sensor to socket B10 and plug in.
7. W hen retrofitting to an existing installation, the unit
has to be reconfigured via parameter P10
(Ch.: 6.3.3).
Connecting calorifier cable loom
ST20
Note: Detailed description for the control of
calorifier tanks see Ch. 7.6.5 and Ch. 7.6.6.
28
4
Gas characteristics
The gas characteristics should be obtained from the gas
board. The Wobbe index WSshould be checked
according to the valid gas groups. The gas connection
pressure must lie within the following ranges:
• Natural gas 17...30 mbar
• Liquid petroleum gas 25...57.5 mbar
For higher gas connection pressures the
WTC should be fitted with an additional
gas pressure switch.
If the gas pressure is lower, contact the
gas board. Do not commission the WTC.
4.7 Gas side connection
Gas installation by qualified personnel only!
Local regulations and codes of practice, as well as
regulations from the local gas board must be observed.
Venting the gas supply line
The local gas board or their appointed sub-contractor are
responsible for venting the gas line. If work such as
replacing components, valve train or gas meter, has been
carried out on the gas supply line, recommissioning may
only be carried out once the appropriate components have
been vented by the gas board or their appointed
sub-contractor.
Unit connection
Use the elbow or straight gas connection cock available as
an accessory, to connect the unit to the gas supply.
The gas board will also inform you if you require an
approved gas filter or thermal shut off valve required to
comply with some regional building laws.
Note: Due to the fully automatic compound
regulation the setting to a gas type within a
gas family is not required.
Liquid Petroleum gas safety valve
For liquid petroleum gas operation below ground level it is
recommended to fit an additional safety solenoid valve in
the gas supply line to avoid the accumulation of gas near
the boiler room.
☞ Connection to plug configuration Ch . 4.6.1,
plug MFA (5) or VA (6).
☞ Parameter setting for output MFA or VA to LPG
safety solenoid valve see heating engineer level
parameter P13 or P14.
☞ Conversion of type of gas natural gas - liquid petroleum
gas, see appendix.
Safety solenoid valve
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29
4
4.8 Condensate
Condensate discharge into the waste water system
The condensate of the WTC complies with the
requirements as stipulated in the ATV data sheet A 251for
condensate discharge into the waste water system of the
property. Neutralisation is usually not required.
If necessary, the water board should be informed about the
discharge.
If the boiler is mainly operated in the non-condensing
range, the internal siphon must always be filled with water.
If the siphon is empty, flue gas can escape.
☞ Fill siphon with water - top up if flue gas can be
smelled.
Note: When installing the siphon ensure that the
condensate is expelled completely, as a blockage
in the condensate line will cause operational
problems. Therefore do not connect the
condensate hose permanently to the waste pipe,
but mount it free-flowing (e.g. into an
outlet hopper).
If the siphon is empty, flue gas will escape into
the boiler room. During prolonged shutdown
or if operating the installation with high return
flow temperatures ( > 55°C ) the water level of
the siphon should be checked.
DANGER
Fill siphon
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