Weishaupt WTC 45-A Installation And Operating Instructions Manual Download

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2.01

Screw M4 x 25 Combi-Torx-Plus

409 258

2.02

Screw M4 x 12 Combi-Torx 20

409 257

2.03

Gas connection piece WTC 15/25-A

481 011 30 19 7

2.04

O ring 23 X 2,5

445 136

2.05

Compact gas combi valve
WTC 45-A

605 569

WTC 60-A

605 570

2.06

Gasket gas valve mixer WTC 45/60-A

481 401 30 30 7

2.07

Screw M 5 X 12 DIN 912 8.8

402 207

2.08

Fixing plate intake damper

481 401 30 24 7

2.09

Screw M 4 X 10 DIN 912 8.8

402 150

2.10

Intake damper WTC 45-A

481 401 30 21 7

2.11

Gasket intake damper WTC 45-A

481 401 30 23 7

2.12

Mixer fan
WTC 45-A with flange gasket

481 401 30 29 2

WTC 60-A with flange gasket

481 601 30 29 2

2.13

Screw M 4 X 12 DIN 912 8.8

402 130

2.14

Gasket mixer fan WTC 45/60-A

481 401 30 31 7

2.15

Gasket mixer air outlet WTC-A

481 401 30 32 7

2.16

Screw M 5 X 16-8.8 DIN 6912

403 263

2.17

Fan
RG130 WTC 32/45-A

652 235

RG148 WTC 60-A

652 236

2.18

Burner cover
WTC 45-A

481 401 30 07 7

WTC 60-A

481 601 30 07 7

2.19

Wsaher nut M 6 A2G ISO 4042

412 508

2.20

Air distributor plate WTC 60-A

481 601 30 16 7

2.21

Screw ISO 1485-A2 4,2x 9,5-C

409 127

2.22

Gasket burner cover
WTC 45-A

481 411 30 65 7

WTC 60-A

481 611 30 07 7

2.23

Burner surface
WTC 45-A

481 401 30 15 7

WTC 60-A

481 601 30 15 7

Pos.

Description

Order No

Pos.

Description

Order No

Summary of Contents for WTC 45-A

Page 1: ...Condensing boilers Weishaupt Thermo Condens WTC 45 A WTC 60 A 83240702 1 2008 Installation and operating instructions manual ...

Page 2: ... 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 requirem...

Page 3: ...nnecting 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 2...

Page 4: ...nction 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 Technical data 67 11 1 Load efficiency emissions 67 ...

Page 5: ...ating 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 inspec...

Page 6: ...ion 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...

Page 7: ...ded 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 ...

Page 8: ...m 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 exchan...

Page 9: ...ting 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 ri...

Page 10: ...let 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 Tempe...

Page 11: ...n of 400l h This should be safeguarded by using a hydraulic de couple or overflow valve 1 2 1 Heating flow 2 Heating 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 thro...

Page 12: ...t 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 ...

Page 13: ...ing 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 ...

Page 14: ... 5 during annual service ATTENTION 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...

Page 15: ...F 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 tran...

Page 16: ...ds 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 ...

Page 17: ... 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 F...

Page 18: ...for the heating system water see also Ch 3 5 should be observed ATTENTION 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 act...

Page 19: ...ction 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 ...

Page 20: ...t 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 ...

Page 21: ...ue 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 fun...

Page 22: ...low 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 config...

Page 23: ...ass 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 ...

Page 24: ...oning 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 buildin...

Page 25: ... 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 show...

Page 26: ...endent 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 g...

Page 27: ...d 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 syst...

Page 28: ...must be certified on the engineers report Open closing screw on test point Pe by approx 1 rotation Connect pressure measuring device to Pe Connect aspirator with T piece Create test pressure The test pressure should be 100 mbar Pressure loss within 5 minutes max 1 mbar Only non corrosive solutions must be used to locate leaks The gas ball valve should be included in the soundness test Soundness te...

Page 29: ...n The continuing procedure corresponds to that of an unconfigured unit 45 WTC 45 A 60 WTC 60 A P Boiler circuit pump with PWM control no internal pump External sensor available t Temperature remote control 4 20 mA N1 Connection B3 N1 not used H Version H H 0 W with water heater Display Unit configured Display Boiler type recognised Unit type Sensors required Display action and or configuration Ver...

Page 30: ... The electrical wiring must have been tested Water pressure is available cocks are open sufficient heat demand is ensured The WTC has been factory preset Due to its fully automatic compound regulation an adaptation to various gases from one gas family is not required Therefore the values set during first commissioning have to be checked only once The values set can be found in the technical data T...

Page 31: ...ue can be saved by pressing the key 3 The WTC now modulates to the minimum rating where possible deviations in the lower ratings range can be equalised by adjusting P72 The entry is carried out as for P39 as O2 adjustment value Note Following an adjustment with P39 adjustment effective across the total modulating range and or P72 adjustment effective across minimum load range of 27 50 rating the O...

Page 32: ...tem For room air independent operation a soundness test of the flue gas system via an O2 measurement within the internal space of the condensing boiler is required Fit hose 4 through the test point in the supply air aperture 2 into the condensing boiler Seal test point in the supply air aperture 2 Connect test sensor 5 to the hose 4 Close cover of condensing boiler Start condensing boiler in chimn...

Page 33: ... Move the selection cursor below the Chimney sweep symbol by turning the dial knob Note To exit the chimney sweep function select ESC using the dial knob and confirm with key If the heat rating is reduced in the heating engineer level parameter P37 the percentage ratings setting range is also modified that means as the min rating of the boiler is predetermined the percentage value displayed increa...

Page 34: ... 1003 1009 1015 1021 1027 1033 1036 0 0 9378 0 9437 0 9497 0 9546 0 9605 0 9664 0 9724 0 9783 0 9842 0 9901 0 9961 1 0020 1 0079 1 0138 1 0197 1 0227 2 0 9310 0 9369 0 9427 0 9476 0 9535 0 9594 0 9653 0 9712 0 9770 0 9829 0 9888 0 9947 1 0006 1 0064 1 0123 1 0153 4 0 9243 0 9301 0 9359 0 9408 0 9466 0 9525 0 9583 0 9642 0 9700 0 9758 0 9817 0 9875 0 9933 0 9992 1 0050 1 0079 6 0 9176 0 9234 0 9292...

Page 35: ...play for a warning or lockout with relevant identification code or current burner rating in chimney sweep function 6 2 End user level 1 2 3 4 5 6 7 8 9 0 6 1 Operating levels The operation is divided into two operating levels Level 1 is the end user level and can be accessed directly If an FS remote control station is fitted only the chimney sweep function can be called up in level 1 Level 2 The h...

Page 36: ... 2 setting Max rating CODE input Entry into heating 0 254 Ch 6 3 1 engineer level 6 2 2 Setting mode Setting of setpoints and display of other system values Procedure The symbol line is displayed by turning the dial knob By turning the dial knob again the selection cursor can be placed under the relevant symbol If the selection cursor is moved beyond the left or right positions the display mode is...

Page 37: ...e is entered the entry level is exited Press enter key Note Exiting the heating engineer level Turn dial knob until ESC is displayed then press enter key The heating engineer level symbol line is displayed i Info mode P Parameter mode Error memory By turning the dial knob the selection cursor can be placed under a symbol The selection is activated by pressing the enter key ...

Page 38: ...C I39 Temperature calorifier B11 P2 P3 C System info I40 Daily switch cycle counter burner 0 999 I41 Daily operating hours counter burner 0 255 h I42 Switch cycle counter burner x 1000 I43 Operating hours counter burner h x 100 I44 Software version v Version r Revision v r I45 Time since last service h x 10 E ES SC C exit menu 6 3 2 Info mode Here specific system values can be displayed By turning...

Page 39: ...post purge 0 0 Burner off 6 3 3 Parameter mode By turning the dial knob the parameter list can be reviewed and changed if required If a parameter value is to be changed press the key The P symbol and the value of the parameter flash To exit without changing the parameter value press key again to change the value turn the dial knob To save and exit press key Exit parameter mode by turning the dial ...

Page 40: ...m 7 Heating circuit pump remotely controlled via WCM FS with address 1 P14 0 7 4 Function variable output VA Ch 7 4 4 0 Liquid petroleum gas pre valve 1 Forward reporting of lockout 2 Feeder pump in front of hydr de couple 3 Heating circuit pump 4 DHW load pump 3 way change over valve 5 DHW circulation pump 6 Program controlled via FS Addr 1 Circulation programme 7 Heating circuit pump remote cont...

Page 41: ...K Volume flow control in conjunction with Only on version H with internal hydr de couple adjustable control differential PWM pump and hydraulic de couple Ch 7 4 7 Deactivated P45 x 20 100 60 Pump rating domestic hot water Only with internal PWM pump Domestic hot water operation vers W P50 x 10 30 20 K Flow temperature overload at The max flow temperature is limited domestic hot water loading to 85...

Page 42: ...important if the system is extended at a later stage e g if an external sensor is fitted 20 sec P17 P18 special level If parameter P17 has been programmed for the function Special level with the setting 2 the WTC can provide an additional temperature level If contact H2 is closed the boiler heats up to the temperature level defined in parameter P18 Other heat demands are not considered however DHW...

Page 43: ...tting elem Sensors 30 Flow temperature at safety C temperature sensor 31 Flue gas temperature C 32 Ionisation signal p 33 External temperature B1 X C 34 DHW temperature B3 X C ESC Exit menu Table of warning and error messages cause and rectification of lockouts see Ch 9 Exiting the level Turn the dial knob until ESC is displayed and confirm with key By pressing the enter key again the system condi...

Page 44: ...re and a detailed description of the system parameters can be found in the user instructions of the Software 6 4 1 Special system parameters Parameters marked in this way are safety relevant for the operation of the system Changes are only permitted following discussions and approval from Weishaupt service department 6 4 Service functions via PC interface The Weishaupt Condens Manager WCM is equip...

Page 45: ... normal operation P17 1 45 7 Control variations Weishaupt Condens Manager WCM 7 7 1 Constant flow temperature control The WCM not only carries out the regulating and control functions for the boiler but also the control of the heating systems and domestic hot water operation The heating controller contains basic functions which have an effect in all the following variations The boiler flow tempera...

Page 46: ...eating reference line gradient for radiator heating circuit 8 Heating reference line gradient for underfloor heating circuit 35 30 25 20 15 10 9 7 5 4 6 8 9 5 12 5 3 27 5 22 5 17 5 90 80 70 60 50 40 30 20 35 2 5 20 15 10 5 0 5 10 15 20 25 30 35 Diagram heating reference line 90 80 70 60 50 40 30 20 20 15 10 5 0 5 10 15 20 25 30 35 Diagram influence room temperature setpoint with room setpoint T 20...

Page 47: ...ecognises this modification and indicates the configuration in parameter P10 with a W A change over valve or a separate DHW pump can be driven via outputs VA and MFA electrical connection see Ch 4 6 2 and Ch 4 6 3 The speed of the internal boiler pump for DHW operation can be defined with parameter P45 The domestic hot water operation has priority over the heating operation DHW operation is carrie...

Page 48: ...f the boiler circuit is assigned to the required burner rating The modulating limits for the pump can be adjusted P42 P43 heating engineer level The pump is operated at minimum rating when the burner is switched off During the first minute in heating operation the pump is operated at the rating defined in P43 Parametere settings P42 minimum pump rating C P43 maximum pump rating B P45 pump rating D...

Page 49: ...r setpoints of additional heating circuits are also considered DHW operation takes priority Lockout function P17 3 This function is intended for the connection of a underfloor heating thermostat If the contact of the thermostat is closed the unit and pump switch off frost protection is not activated At the same time warning F24 is displayed If the contact opens the warning automatically terminates...

Page 50: ...lorifier is not possible If the MFA VA is operated in function DHW pump P13 P15 4 the pump does not run on after DHW operation is completed For this type of regulation calorifier sensors NTC 5kΩ Order No 660 228 must be fitted to both sensor inputs B10 B11 Ch 4 6 5 This type of regulation should be selected if full loading of the total calorifier by the WTC is required Switch on critereia for the ...

Page 51: ...automatically terminates Liquid Petroleum Gas pre valve P13 P14 0 As soon as the burner starts due to a heat demand the contact is closed This allows the control of an additional liquid petroleum gas valve This option cannot be used on installations with gas pressure switch Lockout and warning transmission P13 P14 1 The contact is open if the installations is operating without fault As soon the WC...

Page 52: ...e DHW operation With DHW operation the modulation control is carried out via the internal flow sensor Consequently the hydraulic alignment of the DHW circuit before the de couple using a 3 way valve is also possible DHW operation is completed with a pump run on of 3 minutes 7 4 7 Regulation with hydraulic de couple P3 Sensor connection variation P3 1 230V 2 230V 3 H1 4 H2 5 MFA 6 VA 7 eBUS 8 B11 9...

Page 53: ... not activated At the same time warning F24 is displayed If the contact opens the warning automatically terminates Liquid Petroleum gas pre valve P13 P14 0 As soon as the burner starts due to a heat demand the contact is closed This allows the control of an additional liquid petroleum gas valve This option cannot be used on installations with gas pressure switch Lockout and warning transmission P1...

Page 54: ... pressing the reset key Flue gas system The following functions for flue gas temperature monitoring are combined in one sensor Safety temperature limiter for flue gas Temperature measurment for display Safety temperature limiter STL flue gas If the programmed STL switch off temperature for the flue gas circuit is exceeded the fuel supply is shut off and the fan and pump run on is initiated fault d...

Page 55: ...mp continuous run on TA act Tsystem frost protection Pump continuous run off Frost protection is also effective on outputs MFA and VA with function heating circuit pump P13 P14 With calorifier regulation P1 P2 the system frost protection has no effect on the boiler circuit pump internal or connected to MFA VA TDHW 8 C Frost protection heating on TDHW 8 C switch differential DHW 2 P51 Frost protect...

Page 56: ...C No water in boiler top up water Air in boiler vent boiler No boiler throughput check function of pump clean water side of heat exchanger 12 Warning Boiler temperature 95 C No water in boiler top up water Air in boiler vent boiler No boiler throughput check function of pump clean water side of heat exchanger 13 Fault Flue gas temperature 120 C Heat exchanger heavily soiled 14 Warning Flow tempera...

Page 57: ...ent Check wiring to SCOT electrode Check SCOT electrode if necessary replace With room air independent operation carry out soundness test of flue gas system Kap 5 5 23 Fault Flame simulation Check earth connections Replace WCM circuit board 24 Fault4 Underfloor heating thermostat on Check mixer input H2 is activated Check flow setpoint Check pump function 2 After 5 unsuccessful start attempts the ...

Page 58: ... 44 Fault Fan standby faulty Replace fan Electronics 51 Fault System fault boiler control New configuration with P10 Check all available parameters as per Ch 6 3 3 if necessary use WCM diagnostic Application fault BCC plug Plug in BCC Install BCC of version 3 X Invalid unit configuration Replace WCM CPU 52 Fault System fault combustion control Replace WCM CPU Invalid configuration data set Carry o...

Page 59: ...exceeds Check flue gas circulation flue gas system is factory preset limits gas tight Ch 5 5 External influences on the unit supply air due to flue gas dust or other contaminants 65 Fault New calibration value deviates too Supply air contaminated by dust and soot much from the previous value 100 calibration was not carried out following the repalcement of SCOT electrode WCM CPU or burner Ch 5 5 P3...

Page 60: ...able connection transmits a valid setpoint FS or EM defective 84 Warning WCM EM 4 or FS 4 no longer Check cable connection transmits a valid setpoint FS or EM defective 85 Warning WCM EM 5 or FS 5 no longer Check cable connection transmits a valid setpoint FS or EM defective 86 Warning WCM EM 6 or FS 6 no longer Check cable connection transmits a valid setpoint FS or EM defective 87 Warning WCM EM...

Page 61: ...t 4 Complete a test sheet 5 Complete an inspection card Variable rating setting in chimney sweep mode Ch 5 5 2 To leave chimney sweep mode turn dial knob until ESC appears then press key Service interval The operator should ensure that the combustion appliance is inspected or serviced at least once a year by an agent of the manufacturer or other suitably qualified person Set service interval The t...

Page 62: ...pliance Close gas isolating valve Check burner and burner gasket Ch 10 3 Clean heat exchanger if pressure loss is 3 5 mbar WTC 45 or 5 0 mbar WTC 60 cleaned Service instructions cleaning kit 4 mbar Check ionisation electrode replace if SCOT base value 78 points WTC 45 replaced or 75 points WTC 60 Test ignition electrode and check spark gap 3 mm 0 3 mm Clean and refill condensate water siphon check...

Page 63: ... gas isolating valve Check burner and burner gasket Ch 10 3 Clean heat exchanger if pressure loss is 3 5 mbar WTC 45 or 5 0 mbar WTC 60 Service instructions cleaning kit Check ionisation electrode replace if SCOT base value 78 points WTC 45 or 75 points WTC 60 Test ignition electrode and check spark gap 3 mm 0 3 mm Clean and refill condensate water siphon check condensate drain Reassemble heat exc...

Page 64: ... burner cover with seal and flange connected gas air compound unit 6 Remove burner surface 7 Remove the 4 fixing screws on the service cover and remove service cover Cleaning the burner If the burner surface is soiled brush out the burner fleece a normal domestic brush can be used to do this Once cleaned ensure that the fibres of the burner fleece in the vicinity of the ionisation electrode do not...

Page 65: ... Fit burner cover to the stay bolts and tighten the nuts to 4 Nm torque 5 Connect the gas valve to the gas pipe and tighten the union nut Fit new gas seal Order No 441 076 6 Reconnect the electrically connection to theappliance and gas valve Concluding work 1 Open gas isolating valve 2 Check soundness of gas connections Ch 5 3 and burner cover opening 3 Switch on the appliance 4 Carry out soundnes...

Page 66: ...himney sweep function by pressing the key The function remains active for 15 minutes The 3 digit display shows the current boiler rate The 2 digit display shows the current boiler temperature To exit the chimney sweep function turn dial knob until ESC appears then press the key After approx 90 seconds the standard display appears 90 sec ...

Page 67: ...n Standard max mbar 20 25 30 20 25 30 Gas flow pressure LPG B P min Standard max mbar 42 5 50 57 5 42 5 50 57 5 Gas flow pressure LPG B P min Standard max mbar 25 37 45 25 37 45 Standard efficiency at 75 60 C 105 6 95 1 Hs 105 5 95 0 Hs Standard efficiency at 40 30 C 108 3 97 6 Hs 108 4 97 7 Hs Standard emission factors 40 30 C Nitrous Oxide NOx mg kWh 38 39 Carbon Monoxide CO mg kWh 16 15 O2 Natu...

Page 68: ...e ambient conditions Weishaupt Gas Condensing Unit WTC 45 A WTC 60 A Temperature in installation location C 3 30 3 30 Temperature transport storage C 10 60 10 60 Humidity relative humidity max 80 max 80 A 11 2 Electrical data Weishaupt Gas Condensing Unit WTC 45 A WTC 60 A Nominal voltage 230 VAC 1N 50Hz 230 VAC 1N 50 Hz Nominal load version H H O W 151 62 170 85 Max prefusing A G 16 G 16 Unit fus...

Page 69: ...69 11 A 11 5 Weights dimensions Weishaupt Gas Condensing unit WTC 45 A WTC 60 A Weight incl cladding kg 61 65 640 320 125 40 4 35 50 17 129 8 50 792 25 80 80 320 157 ca 453 160 300 35 320 ...

Page 70: ...prox 30 rotations Natural Gas left stop Liquid Petroleum Gas right stop 4 Retighten plug for voltage supply to gas valve 5 Switch on boiler 6 In heating engineer level Ch 6 3 set parameter P11 to F 7 Carry out calibration using parameter 39 see page 43 8 Burner commissioning and O2 check to Ch 5 5 9 Note setting of type of gas on name plate C Reduction of heat rating Gas rate adjustment Procedure ...

Page 71: ... 12 5 3 Gas family Propane P 93 21 25 99 13 8 Butane B 123 81 34 30 14 1 Contact the gas supplier for the various maximum CO2 contents E Conversion table O2 CO2 O2 content CO2 content dry Natural Gas E Natural Gas LL Propane v 11 7 CO2 max 11 5 CO2 max 13 7 CO2 max 3 9 9 5 9 4 11 2 4 1 9 4 9 3 11 0 4 3 9 3 9 1 10 9 4 5 9 2 9 0 10 8 4 7 9 1 8 9 10 6 4 9 9 0 8 8 10 5 5 1 8 9 8 7 10 4 5 3 8 7 8 6 10 ...

Page 72: ...550 15 18670 70 2140 20 14920 75 1810 25 12000 80 1540 30 9710 85 1310 35 7900 90 1120 ϑ C R Ω ϑ C R Ω ϑ C R Ω ϑ C R Ω ϑ C R Ω 20 48380 10 9948 40 2662 70 874 100 337 15 36382 15 7856 45 2183 75 738 105 291 10 27609 20 6246 50 1799 80 626 110 253 5 21134 25 5000 55 1491 85 533 0 16312 30 4028 60 1241 90 456 5 12691 35 3265 65 1039 95 391 Sensor variables Boiler 4 core flue gas 4 core DHW sensor ve...

Page 73: ... Dial knob eBUS Internal boiler terminal rail Terminals for external electrical equipment F2 24V 4AT 1 The cable loom installed at plug slot ST20 is replaced with the cable loom for calorifier control to enable the connection of calorifier sensor B10 control variation P1 and P2 2 The heating circuit pump is only available with unit version H 3 230V supply voltage for fan motor is only available wi...

Page 74: ..._____________ _________ __________________________________ Comments Information at the heating installation Functions commissioning faults shutdown Operation and service on the display control Poss control units Poss test certificate Poss night setback summer operation Water pressure water top up What to do if gas can be smelled Combustion air supply Condensate outlet into domestic water system Th...

Page 75: ...75 A ...

Page 76: ...76 L Spare parts A 1 30 1 28 1 23 1 29 1 26 1 27 1 07 1 08 1 10 1 09 1 16 1 14 1 10 1 06 1 11 1 13 1 06 1 02 1 12 1 05 1 04 1 03 1 02 1 01 1 19 1 20 1 22 1 21 1 24 1 23 1 25 1 15 1 17 1 31 1 10 1 18 ...

Page 77: ...over elec conn WTC 45 60 A 481 401 22 33 2 1 13 Traction relief WTC A 481 011 22 32 7 1 14 Screw 4 X 14 WN1412 K40 A2K 409 352 1 15 Screw 4 X 35 WN1412 K40 A2K 409 354 1 16 Fuse 4A T 481 011 22 21 7 1 17 Screw 4 X 12 WN1411 K40 409 351 1 18 Closing cap igniton WTC 45 60 A 481 401 22 02 7 1 19 Screw DIN 7981 St4 2x13 C Z 409 123 1 20 Cover cable duct WTC 45 60 A 481 401 02 05 2 1 21 Washer 3 5 X 10...

Page 78: ...78 A 2 23 2 22 2 20 2 18 2 19 2 15 2 14 2 13 2 12 2 09 2 10 2 11 2 08 2 07 2 07 2 06 2 05 2 16 2 21 2 04 2 03 2 02 2 17 2 01 ...

Page 79: ...an WTC 45 A with flange gasket 481 401 30 29 2 WTC 60 A with flange gasket 481 601 30 29 2 2 13 Screw M 4 X 12 DIN 912 8 8 402 130 2 14 Gasket mixer fan WTC 45 60 A 481 401 30 31 7 2 15 Gasket mixer air outlet WTC A 481 401 30 32 7 2 16 Screw M 5 X 16 8 8 DIN 6912 403 263 2 17 Fan RG130 WTC 32 45 A 652 235 RG148 WTC 60 A 652 236 2 18 Burner cover WTC 45 A 481 401 30 07 7 WTC 60 A 481 601 30 07 7 2...

Page 80: ... 3 60 3 54 3 53 3 52 3 50 3 49 3 42 3 48 3 46 3 45 3 44 3 42 3 43 3 51 3 57 3 56 3 58 3 59 3 17 3 19 3 07 3 01 3 40 3 39 3 33 3 34 3 41 3 47 3 36 3 26 3 27 3 29 3 31 3 05 3 55 3 19 3 32 3 38 3 07 3 28 3 30 3 28 3 35 3 13 3 20 3 21 3 22 3 19 3 23 3 04 3 18 3 17 3 16 3 03 3 04 3 24 3 16 3 61 3 53 3 52 3 51 3 59 3 17 3 35 3 63 3 64 3 65 3 36 3 40 3 66 ...

Page 81: ...gn unit ZAG 1 220 240V 50 60Hz 10VA 603 189 3 33 Double nipple R1A X G1 1 4A X 44 481 401 30 08 7 3 34 Collect supply WTC 45 60 A compl 481 401 30 02 2 3 35 Teflon washer 16 x 6 5 x 0 15 WTC 45 60 A 481 401 30 42 7 3 36 Gasket ionisation electrode WTC A 481 011 30 25 7 3 37 Ionisation electrode WTC 45 60 A 481 401 30 04 2 3 38 Ignition cable WTC 45 60 A 481 401 30 13 2 3 39 Ignition electrode WTC ...

Page 82: ...82 A 4 09 4 07 4 01 4 02 4 13 4 14 4 15 4 16 4 17 4 12 4 12 4 18 4 19 4 20 4 21 4 22 4 10 4 11 4 03 4 06 4 05 4 04 4 08 ...

Page 83: ...0 Chassis PE 481 011 22 07 2 4 10 Cable loom ST19c gas valve fan 481 601 22 10 2 4 11 Cable loom ST19c gas valve WTC45 A 481 401 22 10 2 4 12 Insert bridge 2 pole 716 232 4 13 Plug No 1 3 pole black Rast 5 716 220 4 14 Plug No 2 3 pole grey Rast 5 716 221 4 15 Plug No 3 2 pole turquoise Rast 5 716 222 4 16 Plug No 4 2 pole red Rast 5 716 223 4 17 Plug No 5 3 pole violet Rast 5 716 224 4 18 Plug No...

Page 84: ...84 A 5 01 5 02 5 03 5 09 5 14 5 13 5 05 5 04 5 06 5 04 5 10 5 12 5 11 5 09 5 08 5 07 5 09 ...

Page 85: ...2 WTC 60 A 481 601 30 41 2 5 07 Gasket 17 X 24 X 2 DIN 2690 441 076 5 08 Fixing bracket RL WTC 45 60 A vers H 481 401 40 07 7 5 09 Gasket 20 x 29 x 2 1 481 401 40 04 7 5 10 Conn pipe return pump H 481 401 40 03 2 5 11 Fixing plate ret pipe to pump WTC 45 60 A 481 401 40 12 7 5 12 Screw M 4 X 10 DIN 912 402 150 5 13 Circulation pump WTC 45 60 A with gasket 481 401 40 10 2 5 14 Conn pipe flow pump d...

Page 86: ...86 A 6 01 6 02 6 05 6 04 6 06 6 07 6 01 6 08 6 03 ...

Page 87: ...1 113 40 10 7 6 04 Screw M 5 X 8 DIN 912 402 223 6 05 Gas pipe fixing plate 481 401 02 13 7 6 06 Gas pipe with union nut G3 4 WTC 45 A 481 401 30 41 2 G3 4 WTC 60 A 481 601 30 41 2 6 07 Gasket 17 X 24 X 2 DIN 2690 441 076 6 08 Connection pipe return WTC 45 A vers H O 481 401 40 05 2 WTC 60 A vers H O 481 601 40 05 2 Pos Description Order No Pos Description Order No ...

Page 88: ...88 A ...

Page 89: ...89 A ...

Page 90: ...plant Thermo Unit The Thermo Unit heating systems from cast iron or Up to 55 kW steel Modern economic reliable For environmentally friendly heating Fuel Gas or oil as desired Thermo Condens The innovative condensing boilers with the SCOT system Up to Efficient low in emissions versatile Ideal for domestic 1 200 kW heating Floor standing gas condensing boiler with ratings of up to 1200 kW cascade f...

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Weishaupt WTC 45-A, Installation And Operating Instructions Manual

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