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Weishaupt WTC 60-A User Manual

Weishaupt WTC 60-A
90 pages
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Condensing boilers Weishaupt Thermo Condens WTC 45-A / WTC 60-A 83240702 - 1/2008
Installation and operating instructions
manual

Table of Contents

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Weishaupt WTC 60-A Specifications

General IconGeneral
TypeCondensing Boiler
Max Heat Output60 kW
EfficiencyUp to 109% (Hi)/ 98% (Hs)
Fuel TypeNatural Gas
Burner TypeModulating gas burner

Summary

General Instructions

Explanation of Notes and Symbols

Explains the meaning of symbols used throughout the manual for safety and operational guidance.

Guarantee and Liability

Outlines Weishaupt's terms regarding liability and warranty claims for product misuse or defects.

Safety Instructions

Operational Safety and Dangers

Covers potential hazards during equipment use and essential safety practices in normal operation.

Electrical Safety and Maintenance

Details critical electrical safety precautions, maintenance procedures, and fault rectification guidelines.

Installation and Component Alterations

Addresses safety requirements for installation, modifications, and disposal of the equipment.

Technical Description

Permissible Applications and Gas Compatibility

Specifies the allowed uses and gas types (Natural Gas, LPG) for the WTC boiler.

Function and Key Components

Describes the operational principles, including condensate drain, combustion air, and major parts like the heat exchanger and burner.

Construction Variations and Prerequisites

Details unit versions (H-0, H), component breakdown, and necessary installation prerequisites.

Heating Water Demands and Treatment

Outlines requirements for heating water quality, hardness, fill quantities, and necessary treatment methods.

Installation Procedures

Installation Safety and Handling

Emphasizes electrical isolation, delivery, transport, storage safety, and general installation precautions.

Mounting and Hydraulic Connections

Guides on wall mounting, pipe connections, expansion tanks, and filling the system with water.

Electrical Connections and Wiring

Covers electrical installation by qualified personnel, wiring diagrams, and connecting external components like WCM.

Gas and Condensate Connections

Details the gas supply connection, safety valves, and correct installation of the condensate siphon.

Flue Gas System Integration

Explains requirements for flue gas ducting, combustion air supply, and system soundness tests.

Commissioning and Operation

Operating Controls and Initial Commissioning

Introduces the unit's operating controls and outlines essential safety checks during initial system commissioning.

Function Tests and Configuration

Covers soundness tests for air and gas systems, and automatic unit configuration based on connected sensors.

Commissioning and Rating Settings

Details the steps for system commissioning, including gas inlet pressure checks, O2/CO measurements, and variable rating adjustments.

Operating Instructions

Operating Levels and Display Modes

Explains the different operating levels (end user, heating engineer) and how to interpret the unit's display modes.

Heating Engineer Level Functions

Covers accessing the heating engineer level, accessing info mode, parameter settings, and managing error memory.

Service Functions via PC Interface

Describes using PC software for diagnostics, system data evaluation, and setting special system parameters.

WCM Control Variations

Constant and External Temperature Control

Details basic flow temperature control methods, including constant setpoint and external temperature dependency.

DHW Operation and Special Functions

Explains domestic hot water (DHW) functions, pump control, and various special functions like pump logic and input/output configurations.

Calorifier and Hydraulic Regulation

Describes methods for calorifier control using one or two sensors, and regulation via hydraulic de-coupling.

Safety and Monitoring Functions

Temperature Monitoring and Limits

Covers boiler and flue gas temperature monitoring, safety limiters, and differential temperature monitoring.

Sensor and Frost Protection

Covers sensor monitoring and the integrated frost protection mechanisms for heating and DHW.

Fault Cause and Rectification

Temperature Related Faults

Lists fault codes and causes related to boiler and flue gas temperature issues.

Burner and Sensor Faults

Details faults related to burner operation, flame detection, and sensor failures.

Actuator, Electronics, and Communication Faults

Covers faults in actuators, electronic components, and communication issues within the system.

Service and Maintenance

Safety Notes and Service Interval

Emphasizes safety for qualified personnel, service intervals, and procedures for shutdown periods.

Servicing Checklist and Cleaning Procedures

Provides a comprehensive checklist for WTC servicing, including gas checks, O2/CO measurements, and cleaning instructions for the burner and heat exchanger.

Chimney Sweep Function

Details the procedure and purpose of the chimney sweep function for boiler rate adjustment and flue gas analysis.

Technical Data

Ratings, Efficiency, and Emissions

Presents detailed specifications on heat ratings, efficiency at different temperatures, and emission factors for NOx and CO.

Electrical, Ambient, and Flue Gas Data

Includes electrical specifications, permissible ambient conditions, and data related to the flue gas system design.

Weights and Dimensions

Provides physical dimensions and weight specifications for the WTC units.

Appendix

Gas Conversion and Heat Rating Adjustment

Explains the procedure for converting the unit to Liquid Petroleum Gas and reducing the heat rating.

Gas Data and Sensor Information

Includes tables for gas types, calorific values, CO2 content, and sensor variable data (resistance vs. temperature).

Wiring Diagrams and Customer Service

Shows internal boiler wiring diagrams, connection terminals, and provides guidance on customer service and fault tracking.

Spare Parts Identification

Lists and illustrates various spare parts with their corresponding order numbers for maintenance and repair.

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