Condensing boilers Weishaupt Thermo Condens WTC 45-A / WTC 60-A 83240702 - 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 45-A, WTC 60-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
0085 BO 6112
The product complies with the prototype tested by the
Notified Body 0085.
Schwendi 30.01.2008
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 System calculation
For the calculation basis to EnEV product
characterisitics please see Ch. 11
2
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 10
3.3.1 Components 10
3.3.2 Version - H-0 11
3.3.3 Version - H 11
3.4 Prerequisites 12
3.5 Demands on the heating water 13
3.5.1 Permissible water hardness 13
3.5.2 Fill water quantity 14
3.5.3 Treatment of fill and top up water 14
4 Installation 15
4.1 Safety notes on installation 15
4.2 Delivery, transport, storage 15
4.3 Wall mounting 16
4.4 Mains water connection 18
4.5 Filling with water 18
4.6 Electrical connection 19
4.6.1 External connections WCM 20
4.6.2 Connecting a 3 way change-over valve 21
4.6.3 Connecting an external boiler pump 21
4.6.4 Remote load control 22
4.6.5 Connecting temperature sensors for
calorifier control (variation P1 and P2) 22
4.7 Gas side connection 24
4.8 Condensate - install siphon 25
4.9 Flue gas connection 26
5 Commissioning and operation 27
5.1 Operating controls 27
5.2 Safety notes on initial commissioning 27
5.3 Valve proving with air 28
5.4 Function test without gas 29
5.4.1 Automatic configuration 29
5.4.2 Continued program sequence 30
5.5 Commissioning 30
5.5.1 Gas inlet pressure at nominal load 32
5.5.2 Variable ratings setting 33
5.6 Ratings measurement 34
6 Operating instructions 35
6.1 Operating level 35
6.2 End user level 35
6.2.1 Display mode 35
6.2.2 Setting mode 36
6.3 Heating engineer level 37
6.3.1 Entry to the level 37
6.3.2 Info mode 38
6.3.3 Parameter mode 39
6.3.4 Error memory 43
6.4 Service functions via PC interface 44
6.4.1 Special system parameter 44
1
2
3
4
5
6
4
7 Control variations Weishaupt Condens Manager (WCM) 45
7. 1 Constant flow temperature control 45
7. 2External temperature dependent flow temp. control 46
7. 3DHW load function 47
7. 4Special functions 48
7. 4.1 Standard control of PWM pump 48
7. 4.2 Control of PWM pump 48
7. 4.3 Pump control logic in heating operation 48
7. 4.4 Freely selectable input and outputs 49
7. 4.5 Regulation with one calorifier sensor 50
7. 4.6 Regulation with two calorifier sensors 50
7. 4.7 Regulation with hydraulic de-couple 52
8 Safety and monitoring function 54
8.1 Temperature monitoring 54
8.2 Sensor monitoring 55
8.3 Heating frost protection function 55
8.4 DHW frost protection (version -W) 55
9 Cause and rectification of faults 56
10 Service 61
10.1 Safety notes on servicing 61
10.2 Checklist for servicing WTC 62
10.3 Cleaning the burner and heat exchanger 64
10.4 Chimney sweep function 66
11 Te chnical data 67
11.1 Load, efficiency, emissions 67
11.2 Electrical data 68
11.3 Permissible ambient conditions 68
11.4 Layout of the flue gas system 68
11.5 Weights, dimensions 69
Appendix 70
Conversion to Liquid Petroleum Gas 70
Reducing the heat rating 70
Wobbe table 71
Conversion table O2 – CO2 71
Sensor data 72
Internal boiler wiring 73
Customer service 74
Spares 76
7
8
9
10
11
A
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 45-A/60-A (These instructions can be stored in
the pocket in the lower unit cover.)
Info for the installer:
❑ Installation and operating instructions
WTC 45-A/60-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 equipment 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. 5.5:
Notes for special parameters).
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.
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
8
3Tec hnical description
3
3.1 Permissible application
The Weishaupt Thermo Condens WTC 45-A/60-A is a
condensing wall mounted heating appliance for sliding
setback operation without lower temperature limit with a
a minimum flow of 400l/h through the heat exchanger.
•For wall mounting in enclosed rooms
(installation outdoors is not permitted)
•For heating DHW heating circuits in sealed systems
to DIN EN 12828.
•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 is made from corrosion proof
aluminium alloy.
The flow through the WTC is from bottom to top through
three parallel segments 1 – 3 . The water flow is
distributed between the three segments by the return
distributor and is combined again by the supply
distributor once it has circulated the heat exchanger. An
automatic de-aerator is fitted in the supply collector.
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.
Heat exchanger operating mode
Premix 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
Fully electronic compound regulation
The WTC 45-A/60-A is 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.
Calibration can also be initiated manually.
This is necessary if the following parts are replaced during
servicing or repair:
• Gas valve
• Burner
• SCOT electrode
•WCM electronic
(procedure see Ch. 5.5:
Fine tuning the O
2
value)
During calibration, CO emissions above
1000 ppm occur for a short time
(approx. 2 sec.).
AT TE NTION
Version - H with PWM-pump
The condensing boiler is fitted with a modulating
heating circuit pump as standard.
The maximum modulation range of the pump in its factory
presetting is 20 - 100%. 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. 7.4.1.
Diagram resulting supply pressure
WTC 45-A/60-A with PWM pump
0
100
200
300
400
500
600
700
0400 800 1200 1600 2000 2400 2800
max. speed
min. speed
Pressure [mbar]
Throughput [l/h]
Diagram pressure loss
WTC 45-A/60-A, version H-0 without pump
0
100
200
300
400
500
0 1000 2000 50003000
400 4000
Pressure loss unit -H-0
The diagram on the right shows the pressure loss of the
WTC unit without integrated pump needed to carry out
the hydraulic operation of the installation.
Pressure [mbar]
Throughput [l/h]
Diagram ionisation current control
I
o max
I
o set
Ionisation current[I
O
]
Air number [λ]λ=1 λ≈1.3
Regulating
range
Size Min. throughput Max. throughput
WTC 45-A 400 l/h 3875 l/h
WTC 60-A 400 l/h 5160 l/h
Throughput limits
Minimum flow quantity
WTC 45-A/60-A
Minimum flow quantity
WTC 45-A/60-A
Max. throughput
(WTC45-A)
10
3
3.3 Basic construction and variations
1 Flue gas outlet DN80
2 Air inlet DN125
3 View port with integrated mirror
4 Pressure gauge
5 LCD display
6 Dial knob
7 Enter key
8 Water pressure switch
9 Reset key
0 On/off switch
q PC connection
(Software accessory WCM diagnostic)
w Electrical installation area
e Electrical installation duct
r Heating return Ø 28 mm
t Condensate outlet (for connection of siphon
included in delivery)
z PWM pump (version H only)
u Heating flow Ø 28 mm
i Gas pipe Ø 22 mm
o Flue gas sensor (NTC 5kΩ)
p Inspection opening heat exchanger
a Air intake damper (only on WTC 45-A)
s Heat exchanger made of AlMgSi
d Flow temperature sensor (NTC 5kΩ)
f Fan
g Gas mixture preparation
h Safety temperature sensor STL (NTC 5kΩ)
j Ignition electrode
k SCOT electrode
l Te mperature switch heat exchanger
(with manual reset)
ö Burner cover
y Automatic de-aerator
x Ignition unit
3.3.1 Components
1
2
3
4
5
6
7
8
9
0
q
w
e
rtzui
o
d
f
g
h
x
k
ö
y
p
a
s
j
l
11
3
3.3.3 Version - H
12
1 Heating flow
2Heating return
3.3.2 Version - H-0
Version H-0 is a heating unit without integrated pump.
The heating pump is fitted on site. When installing the
pump on site it should be ensured 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.
When designing the hydraulic installation please observe
that the WTC requires a minimum circulation of 400l/h.
This should be safeguarded by using a hydraulic decouple or overflow valve.
12
1 Heating flow
2Heating return
Version -H is a heating unit with integrated pump.
The unit is designed for use with the directly mountable
hydraulic de-couple (Order No.: 409 000 05 80 2).
In conjunction with the de-couple sensor (B11) fitted, the
pump rating can be controlled in such a way that the
volume flow through the WTC is just sufficient so that an
increase in the return temperature is not possible within
the modulation limit of the pump.
For operation without the mounted hydraulic de-couple,
the diagram Resulting supply pressure from Ch. 3.2.2
should be observed when designing the installation.
Furthermore a minimum circulation of 400l/h through the
heat exchanger should be ensured.
12
3
3.4 Prerequisites
Air inlets must be
kept clear!
Unimpeded combustion air
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
•Spacer
•Siphon with hose for condensate drainage
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 duct
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).
☞ If necessary fit sludge strainer in the return
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
13
3
0
5
0
10
20
25
30
15
500 1000 1500 2000 2500 30003000 3500
Max. total hardness of heating water for WTC 45-A
Fill and top up water quantity [ l ]
To tal hardness [°dH]
3.5 Demands on the heating water
3.5.1 Permissible water hardness
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,
• avoid 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.
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 in the
system log book.
0
5
0
10
20
25
30
15
500 1000 1500 2000 2500 30003000 3500
Max. total hardness of heating water for WTC 60-A
Fill and top up water quantity [ l ]
To tal hardness [°dH]
14
3
3.5.3 Treatment of fill and top up water
Demineralisation (recommended by Weishaupt)
☞ Fill and top up water should be demineralised
(Recommendation: mixer bed treatment)
When the heating water has been completely
demineralised, up to 10% of the system content can be
topped up with untreated water. Higher quantities of top
up water must be demineralised.
☞ Check pH value (8.5 ± 0.5) of 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
Stabilisation of hardness
Damage to the unit due to unsuitable
inhibitors:
Corrosion and lime scale could damage the
system.
☞ Only use inhibitors 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.
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
Panel 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.
15
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
4.3 Wall mounting
Fit wall bracket
3°
1
127
320
171
25
52,5
227
320
37,5
80
792
50
1)
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
16
4
4
The cover of the WTC is protected from
accidental opening with screws.
Re-secure the lid once it has been refitted
using the screw.
17
4
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.
Fit and align unit
1
2
DANGER
Unsuitable water results in scaling and
corrosion formation and can cause damage
to the condensing boiler.
18
4
4.4 Mains water connection
Hydraulic connection
1 Gas Ø 22 mm
2 Heating flow Ø 28 mm
3 Condensate outlet Ø 32 mm
4 Heating return Ø 28 mm
Application in sealed heating systems
☞ 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 expansion tank.
☞ Fit sludge trap in return pipe (if required).
40
35
50
18,2
129
50
454
160
300
35
320
4
4
3
3
1
1
2
2
4.5 Filling with water
When filling the heating system, the requirements for the
heating system water (see also Ch. 3.5) should be
observed.
AT TE NTION
☞ 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.
☞ 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.
19
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
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
20
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-E M
ϑ
ϑ
B10
ϑ
WCM-FS
Wiring diagram WCM
4.6.1 External connection WCM
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.
AT TE NTION
•The function of inputs and outputs H1, H2, MFA and
VA depend on the configuration (➩ Chapter 7.4.4).
• Internal boiler wiring see appendix.
• Consumers of other power circuits (external voltage)
must not be switched directly with the VA output.
Mains switch
Main switch
DHW load pump
Calorifier cable
loom (optional)
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. 7.4.5-7.4.7 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. 4.6.4 4…20 mA
B3 10/yellow Tank sensor NTC 12kOhm 0…99°C
Optional: B10 DHW calorifier control sensor NTC 5kOhm
calorifier ➩ Ch. 4.6.5 0…99°C
cable loom
21
4
F10
10A
L N PE
230V 1/N/ PE 50Hz
F10
10A
L N PE
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
4.6.2 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
4.6.3 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
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.
22
4
4.6.5 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 existing
sensor line on plug slot ST20 (➩ Appendix; internal boiler
wiring) must be replaced with the accessory line.
DANGER
DANGER
Push through diaphragm grommet in installation area
Remove flow sensor line
Scope of delivery calorifier sensor connection
Connection calorifier sensor B10)
3. Unplug and remove existing sensor lines on circuit
board (plug slot ST20) and on flow temperature
sensor.
Order No.: 480 401 00 01 2
4.6.4 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.
Diagram
P30
(8°C)
I [mA]
46 20
P31
(78°C)
V
L
[°C]
23
4
4. Plug in circuit board plug (Rast 2.5) at plug slot ST20.
5. Fit new flow sensor line to the unit and plug into
sensor.
6. Install the cable for the calorifier sensor down
towards the cable entry and pass it through the
diaphragm grommet.
7. Connect wire ends to plug part B10 and secure with
tension relief (cable ties).
8. Connect calorifier sensor to socket B10 and plug in.
9. When retro-fitting 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. 7.4.5 and Ch. 7.4.6.
24
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.
Safety solenoid valve
AT TE NTION
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 of output MFA or VA to LPG
safety valve. Set parameter P13 or P14 (see Ch.
6.3.3) to parameter value 0.
Control via MFA: P13 = 0
Control via VA: P14 = 0
☞ Conversion of type of gas Natural Gas - Liquid
Petroleum Gas, see appendix.
25
4
4.8 Condensate - installing siphon
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.
If the siphon is empty, flue gas will escape
into the boiler room. During prolonged
shutdown or if operating the installation with
high return temperatures ( > 55°C ) the water
level of the siphon should be checked.
DANGER
Installing and filling siphon Fill siphon supplied with water and install to WTC as
shown.
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).
26
4
4.9 Flue gas connection
Flue gas lines approved by planning law
The WTC is equipped with a concentric flue gas
connection Ø 125/80 located at the top of the unit. The
flue gases should be extracted via temperature and
corrosion resistant flue gas duct:
• in vertical ducting
• via external wall connections
•for roof heating centres with vertical flue gas duct
• air-flue gas chimney
The combustion air can be introduced:
• from the boiler room (room air dependent operation)
• by concentric pipe systems
(room air independent operation)
• by non-closing supply air ducts
Only CE certificated or locally tested and approved flue
gas systems must be used.
The Weishaupt Flue gas - air - system WAL-PP,
see installation and operating manual WAL-PP, offers
approved kits and individual components.
The flue gas duct must be gas tight.
☞ Carry out soundness test.
Note: If a plastic flue gas system is connected,
which is approved for flue gas temperatures
up to 80°C, the maximum flue gas
temperature must be set to 80°C. Use
parameter P33 (see Ch. 6.3.3). The
Weishaupt flue gas-air system WAL-PP is
approved for temperatures up to 120°C.
Flue gas connection
1 Boiler connection piece
2 Test point in the supply air aperture
3 Flue gas sampling point
1
2
3
27
5 Commissioning and operation
5
Four operating controls are located below the front flap.
Dial knob
This is used to change values and settings by rotation.
Clockwise turn:
• Values are increased
• Markings are moved to the right or down
Rotation to the left:
• Values are reduced
• Markings are moved to the left or up
Enter button
This is used to select menus and to confirm entries
Reset button
Pressing this button resets lockouts.
If there is no lockout, this button is used to initiate a
restart of the system.
On/Off switch
Symbol bar
This appears, when the dial knob is rotated.
5.1 Operating controls
The initial commissioning must only be carried out by the
supplier, manufacturer or their appointed agent. At this
time, all the control and safety equipment must be
checked to ensure correct operation and – if any item
can be adjusted – it should also be checked that it has
been set correctly.
Furthermore the correct fusing of the circuits and the
measures for contact protection of electrical equipment
and of wiring must be checked.
Checklist for initial commissioning
Please tick the work carried out and enter
the relevant measurement values.
Commissioning protocol Remarks/
Measurement value
✔ Heating system flushed, filled
and vented (see Ch. 4.5.). .....................bar
✔ Radiators and mixer open. ❑
✔ Combustion air ducts, flue gas ducts
checked. ❑
✔ Unit siphon filled. ❑
✔ condensate hose connected. ❑
✔ Gas soundness test carried out. ❑
✔ Automatic configuration saved
(see Ch. 5.4.1). ❑
✔ O2content checked. ................%O
2
✔ Gas connection pressure (flow pressure)
define at nominal load. ..................mbar
✔ Nominal load determined. .....................kW
✔ Heat rating set in % of nominal
load. ........................%
✔ DHW rating set in % of nominal
load (only version -W, -C). ........................%
✔ End user instructed, documentation handed over.
Confirmation by end user in appendix completed
and signed. ❑
5.2 Safety notes on initial commissioning
Operating elements
Loading...