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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...
1 General instructions 2 Safety instructions 3 Technical description 3.1 Permissible application 3.2 Function 3.2.1 General notes 3.2.2 Important components 3.3 Basic construction and variations 3.3.1 Components 3.3.2 Version - H-0 3.3.3 Version - H 3.4 Prerequisites 3.5 Demands on the heating water 3.5.1 Permissible water hardness 3.5.2 Fill water quantity 3.5.3 Treatment of fill and top up water...
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7 Control variations Weishaupt Condens Manager (WCM) 7.1 Constant flow temperature control 7.2 External temperature dependent flow temp. control 7.3 DHW load function 7.4 Special functions 7.4.1 Standard control of PWM pump 7.4.2 Control of PWM pump 7.4.3 Pump control logic in heating operation 7.4.4 Freely selectable input and outputs...
The address and telephone number of the nearest Operating instructions for the operator service centre should be entered on the reverse of the WTC 45-A/60-A (These instructions can be stored in operating instructions. The plant operator must note that the pocket in the lower unit cover.) an agent of the contractor or other suitably qualified person must inspect the plant at least once a year.
Safety instructions Dangers when using the equipment Safety measures in normal operation Weishaupt products are manufactured in accordance • Only use the equipment when all safety devices are with the relevant existing standards and guidelines and fully functional. the recognised safety laws. However, improper use of the •...
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: ___________________________________ % Connection pressure: _______________________ mbar Conversion to other types of gas The WTC is type tested for Natural gas and Liquid Max Weishaupt GmbH D-88475 Schwendi Petroleum Gas. It is factory pre-set for Natural gas operation. A setting to 2E or 2LL is not required.
(PP) to the unit exit, from where a number of different siphon built into the unit. The ATV data sheet A251 ducting systems from the Weishaupt flue gas / air system should be observed. WAL-PP are available.
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5000 Throughput [l/h] Fully electronic compound regulation Diagram ionisation current control 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 o max regulation of the air quantity is carried out via Regulating the speed controlled fan.
Flue gas sensor (NTC 5kΩ) 5 LCD display p Inspection opening heat exchanger 6 Dial knob a Air intake damper (only on WTC 45-A) 7 Enter key s Heat exchanger made of AlMgSi 8 Water pressure switch d Flow temperature sensor (NTC 5kΩ)
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.
3.4 Prerequisites Included in delivery Important - Warranty for boiler replacement! The ready-to-use unit is delivered in a cardboard box. Supply air ducts, which have previously been used as a The following parts are enclosed loose: chimney for solid fuel or oil firing plants, must only be used as supply air duct once they have been thoroughly •...
3.5.1 Permissible water hardness The permissible water hardness is determined relative to Max. total hardness of heating water for WTC 45-A the fill and top up water quantity. Determine if measures for water treatment are necessary using the diagram.
25 l/kW based on the heating requirements of the building. 3.5.3 Treatment of fill and top up water Demineralisation (recommended by Weishaupt) Check pH value (8.5 ± 0.5) of demineralised water: Fill and top up water should be demineralised •...
Electrically isolate the system Only valid for Switzerland: Prior to installation switch off the unit When installing and operating a -weishaupt- gas burner and safety switch, as well as the mains in Switzerland the regulations of SVGW and VKF as well switch.
4.3 Wall mounting Fit wall bracket 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.
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Fit and align unit 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.
4.4 Mains water connection Application in sealed heating systems Hydraulic connection 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).
4.6 Electrical connection Electrical installation by qualified personnel only! Plug cover Local regulations and codes of practice, as well as regulations from the energy supplier must be observed. DANGER Mains and emergency switch The external mains switch for the heating system must have at least 3 mm contact distance.
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4.6.1 External connection WCM Wiring diagram WCM Mains switch F1 230V WCM - CPU 4,0 AT 230V . 230V . eBus B1/N1 L N PE L N PE L N PE Calorifier cable loom (optional) ϑ ϑ ϑ ϑ L N PE 230V WCM-FS WCM-EM...
4.6.2 Connecting a 3 way change-over valve For DHW operation, the 3 way change-over valve is Connect 3 way change-over valve connected to the 230V output and either the MFA or VA. Control via MFA WCM - CPU To enable the 3 way change-over valve to function, the MFA or VA must be configured accordingly.
4.6.4 Remote load control The control cable (4…20 mA) is connected to input Diagram B1/N1 (plug 9) independent of polarity. The WCM automatically recognises the signal and [°C] displays configuration _t _ when it is switched on. The available signal is interpreted as supply setpoint, (78°C) which is incorporated into the setpoint formation parallel to other heat demands from the heating circuits, whereby...
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4. Plug in circuit board plug (Rast 2.5) at plug slot ST20. Connecting calorifier cable loom 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.
4.7 Gas side connection Gas installation by qualified personnel only! Gas characteristics Local regulations and codes of practice, as well as The gas characteristics should be obtained from the gas regulations from the local gas board must be observed. board. The Wobbe index W should be checked according to the valid gas groups.
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4.8 Condensate - installing siphon Fill siphon supplied with water and install to WTC as Installing and filling siphon shown. 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.
1 Boiler connection piece 2 Test point in the supply air aperture The Weishaupt Flue gas - air - system WAL-PP, 3 Flue gas sampling point see installation and operating manual WAL-PP, offers approved kits and individual components.
5 Commissioning and operation 5.1 Operating controls Four operating controls are located below the front flap. Operating elements 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: •...
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5.3 Soundness test with air During the soundness test, the gas ball valve and gas Soundness test combi valve must be closed. A soundness test must be carried out at every service. The result of the soundness test must be certified on the engineers report.
5.4 Function test without gas 5.4.1 Automatic configuration The gas ball valve must be closed. The Weishaupt Condens Manager (WCM) automatically All electric wiring should have been tested. recognises the type of unit connected and carries out the There must be water pressure available in the heating necessary parameter settings.
5.4.2 Continued program sequence The continued sequence can be found in the sequence Sequence diagram diagram on the right. Flame stabilisation period Safety period Flame signal Ignition V1 / V2 Post purge speed Ignition Modulating speed operation Heat demand The unit carries out 5 ignition attempts. Display After the fifth unsuccessful attempt the display shows the code F21.
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Fine tuning the O value Fine tuning the O value is included in an automatic function sequence with 3 steps. This sequence allows the combustion to be optimised on site using parameters P39 and P72. Procedure 1. Select parameter 39 in the heating engineer level and call up the entry mode by pressing the key, the unit carries out a calibration (duration...
Soundness test of flue gas system Soundness test of flue gas system For room air independent operation, a soundness test of the flue gas system via an O 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.
5.5.2 Variable ratings setting Move the selection cursor below the “Chimney sweep” Change over to chimney sweep mode by pressing the symbol by turning the dial knob. key. The 3 large numbers show the current rating and the 2 smaller number show the current boiler temperature. By pressing the key again the setting level, in which Turn the dial knob anticlockwise until the desired ratings...
5.6 Ratings measurement The burner rating for nominal load has to be determined. Legend: · Proceed as follows: = Burner rating in kW = Barometric air pressure [ mbar ] to table Baro. · • Gas quantity to operating volume V = Gas pressure at meter [ mbar ] •...
6 Operating instructions 6.1 Operating levels The operation is divided into two operating levels. Level 1 Operating elements 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 heating engineer level is protected by a CODE.
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 shown.
6.3 Heating engineer level 6.3.1 Entry into the level • Turn dial knob until selection cursor under “Spanner” The heating engineer level symbol line is displayed. symbol. • Press enter key. = Info mode • Set Service CODE (11). = Parameter mode If an incorrect code is entered, the entry level is = Error memory exited!
6.3.2 Info mode Here, specific system values can be displayed. By turning the dial knob, the individual operating status values can be interrogated. Each value can be assigned to the next list via a row number. Limited Code Process value display Unit System...
Table of operating phases Display Phase description Standby control fan prepurge speed achieved Tv...0 Countdown of prepurge in secs. Ignition speed achieved 0...Tz Flame formation time in 0.1 x secs. Burner in operation, control active Gas valve control V1 Gas valve control V2 Post-purge speed achieved and post-purge Burner off...
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Des. Limited Parameter Factory Unit Explanation Special features display value presetting Basic configuration 3 digit H A P Current configuration ( Ch. 5.4.1) 1. Character: H = heating unit W = DHW unit Code Save configuration ( Ch. 5.4.1) 2. Character:A = Ext. sens. fitted t = Temp.
Des. Limited Parameter Factory Unit Explanation Special features display value presetting Heat exchanger 8 ... °C Minimum flow temperature setpoint (P31- P32) (P30 + P32) °C Maximum flow temperature setpoint ... 85 (±) 1 ... 7 (±) 3 Flow temperature switch differential 80 ...
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Notes for special parameters P10 - WTC configuration Procedure: This parameter is used to reset the configuration • Call up entry mode by pressing key. manually. This is important, if the system is extended at a • Turn dial knob until --- is displayed. later stage, e.g.
6.3.4 Error memory Here, the last 6 error messages can be called up in the form of an error code (see Ch. 9) of the WTC using the dial knob. Error message 1…6 Error code By pressing the enter key again, the system conditions Overview) which existed when the error occurred can be called up using the dial knob.
The Weishaupt Condens Manager (WCM) is equipped Service software WCM diagnostic with an interface for PC connection. Data transfer is carried out via Weishaupt eBUS adapter (W-EA) from eBUS via RS 232 interface to PC. The W-EA, as well as the Service Software WCM Diagnostic are available as accessories.
7 Control variations Weishaupt Condens Manager (WCM) 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: •...
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7.2 External temperature dependent flow temperature control An external sensor QAC 31is required for this variation. Installation example The sensor should be fitted to a north or northwest facing wall. Avoid the following unfavourable factors: • Direct exposure to the sun. •...
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7.3 DHW function The WTC can control an external DHW circuit. To do A heat up procedure is initiated in setback operation, if this, the DHW sensor B3 must be connected. the DHW minus the subtraction value is not The WCM-CPU recognises this modification and maintained.
7.4.1 Standard regulation of the PWM pump The PWM pump has variable speed and is controlled by Diagram regulating range PWM pump the Weishaupt Condens Manager. The pump rating of the boiler circuit is assigned to the required burner rating. Pump...
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7.4.4 Freely selectable inputs and outputs Using the two freely selectable outputs MFA (plug 5) and Variable digital input H1 (heating release) VA (plug 6) a multitude of applications can be realised. The MFA is a potential linked relay output with a •...
7.4.5 Regulation with one calorifier sensor For this type of regulation a calorifier sensor (NTC 5kΩ, Sensor connection variation P1 Order No.: 660 228) has to be connected to sensor input B10 ( Ch. 4.6.5). Input B11 is not connected. 230V 230V eBUS...
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Freely selectable inputs and outputs for calorifier control P1/P2 Using the two freely selectable outputs MFA (plug 5) and Variable digital input H1 (heating release) VA (plug 6) a multitude of applications can be realised. The MFA is a potential linked relay output with a •...
7.4.7 Regulation with hydraulic de-couple For this type of regulation, the de-couple sensor Prerequisites: (NTC 5kΩ, Order No.: 660 228) has to be connected to • Unit version with integrated PWM pump input B11. • De-couple sensor (B11) installed Heating operation: Sensor connection variation P3 The WTC controls the modulation in the heating operation directly with the de-couple sensor.
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Freely selectable inputs and outputs for de-couple regulation P3 Using the two freely selectable outputs MFA (plug 5) and Variable digital input H1 (heating release) VA (plug 6) a multitude of applications can be realised. The MFA is a potential linked relay output with a •...
Safety and monitoring function 8.1 Temperature monitoring Boiler circuit Flue gas system The following functions are combined in the safety The following functions for flue gas temperature temperature sensor of the boiler circuit: monitoring are combined in one sensor: • Safety temperature limiter •...
8.2 Sensor monitoring Display of sensor faults 8.3 Heating frost protection function Boiler frost protection (without external sensor System frost protection (with external sensor QAC 31) QAC 31) Tv < 8°C < T P23) A act. system frost protection Burner on with minimum load Pump starts every 5 hrs., •...
Cause and rectification of faults Most irregularities and faults of the boiler are recognised by the WCM and shown on the display. The display differentiates between faults (boiler lockout) and warnings. Faults (crossed out flame signal flashes) Proceed as follows with faults: •...
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Continuation of fault and warning message CODE Message Cause Possible fault/rectification Burner Fault No flame formation at burner start • Contaminated combustion air (dust, soot) Clean burner • Gas supply closed • Ignition electrode soiled/incorrect spark gap • Faulty wiring to ignition electrod •...
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Continuation of fault and warning message CODE Message Cause Rectification Sensor Warning Safety temperature sensor defective • Check cable + sensor Fault Flue gas sensor defective • Check cable + sensor Warning External sensor B1 defective • Check cable + sensor Warning DHW sensor B3 defective •...
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Continuation of fault and warning message CODE Message Cause Possible fault/rectification Electronic compound regulation Fault Deviation of ionisation signal to • Wrong setting of gas type at gas valve, setpoint too large check setting • Parameter P11 set to wrong gas type •...
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Continuation of fault and warning message CODE Message Cause Possible fault/rectification eBus communication Warning WCM cascade manager no longer • Check Bus connection/Bus supply transmits valid setpoint • Check WCM-KA P12 is set to address #A…E • Check address setting P12 and no setpoint transmitter connected e.g.: WCM cascade manager Warning...
1 0 Service 1 0.1 Safety notes on servicing Service only by qualified personnel! Service interval Failure to carry out maintenance and service The operator should ensure that the combustion work properly can have severe consequences appliance is inspected or serviced at least including serious injury or the loss of life.
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1 0.2 Check list for servicing the WTC Service task Carried out on 18.07.08 Read out burner operating hours Ch. 6.3.2; I43) I43 = 1500 Read out fault memory 2x F22 Ch. 6.3.4) Fault 1x F42 Safety and function check including the safety and control components Check function and safety of air/flue gas system.
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Continuation checklist for service Service task Carried out on Read out burner operating hours Ch. 6.3.2; I43) I43 = Read out fault memory Ch. 6.3.4) Fault Safety and function check including the safety and control components Check function and safety of air/flue gas system. Check soundness of flue gas system.
The heat exchanger should be checked for flue gas side soiling and if necessary cleaned annually. A Weishaupt cleaning kit for this task is available, order No.: 480 000 00 26 2. The check of the degree of soiling is carried out by a differential pressure measurement.
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Re-assembling following cleaning: 1. Refit cover of cleaning opening on siphone and fill siphon with water (see Ch. 4.8). 2. Fit service cover with new seal and tighten the screws to 4 Nm torque. 3. Install pre-mix burner, ensuring correct alignment on the adjusting struts.
1 0.4 Chimney sweep function • Activate symbol rail by turning dial knob and place cursor below the chimney sweep symbol. • Activate chimney sweep function by pressing key. • The function remains active for 15 minutes. • The 3 digit display shows the current boiler rate. •...
Technical data 1 1.1 Rating, efficiency, emissions Weishaupt Gas Condensing Unit Category (DE): II2ELL3B/P, (AT): II3H3P, (CH): II2H3P Type of installation B23/B23P*/B33/C13x/C33x/C43x/C53x/C63x/C83x CE -No. 0085 BO 6112 SVGW-Reg.-No. 04-023-4 ÖVGW Quality Mark G2.596 WTC 45-A WTC 60-A Min. load Nominal load Min. load Nominal load...
9. Note setting of type of gas on name plate. regulation when calibrating during operation (messages F61, F62). ATTENTION R eduction of heat rating !!Gas rate adjustment!! Max Weishaupt GmbH D-88475 Schwendi Procedure: In heating engineer level ( Ch. 6.3.3) set parameter P37 accordingly.
W obbe table Calorific values and CO (guide values) of different types of gas 2 max. Gas type Calorific value H max. MJ/m kWh/m 2. Gas family Group LL (Natural Gas) 28.48…36.40 7.91…10.11 11.5…11.7 Group E (Natural Gas) 33.91…42.70 9.42…11.86 11.8…12.5 3.
Internal boiler wiring 24 V DC Water pressure switch Temperature switch heat exchanger Safety temp. sensor Flue gas sensor Control gas Entre setting element Dial knob Flow temperature sensor Calorifier sensor Heating circuit pump SCOT electrode Fan 230V Gas valvers Ext.
Customer service Heating systems consist of a number components, which Information at the heating installation: have been installed and tested by experts. This checklist Functions (commissioning, faults, shutdown) aids fault limitation: Operation and service on the display control • Voltage supply - specialistd electician Poss.
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Control technology / From control panels to complete building management building systems – at Weishaupt you can find the entire management spectrum of modern control technology. Future oriented, economical and flexible.
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