Weishaupt WTC-GB 90-A User guide

Installation and operating instruction
Gas condensing boiler WTC-GB 90-A 83266502 • 1/2010-08

48200000
Conformity certification
Manufacturer:
Address:
Product: Gas condensing boiler
The product described above conforms with
the regulations of directives:
This product is labelled as follows:
Schwendi, 14.07.2010
ppa. ppa.
Dr. Lück Denkinger
Max Weishaupt GmbH
Max-Weishaupt-Straße
D-88475 Schwendi
WTC-GB 90-A, WTC-GB 120-A,
WTC-GB 170-A, WTC-GB 210-A,
WTC-GB 250-A, WTC-GB 300-A
GAD 2009 / 142 / EC
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
BED 92 / 42 / EEC
CE-0085
Sprachschlüssel 02

1 User instructions ..................................................................................................................... 6
1.1 User guide ............................................................................................................. 6
1.1.1 Symbols ................................................................................................................. 6
1.1.2 Target group ......................................................................................................... 6
1.2 Guarantee and Liability ....................................................................................... 7
2 Safety ............................................................................................................................................ 8
2.1 Permissible application ....................................................................................... 8
2.2 When gas can be smelled ................................................................................. 8
2.3 What to do if flue gas can be smelled ............................................................ 8
2.4 Safety measures .................................................................................................. 8
2.4.1 Normal operation ................................................................................................. 8
2.4.2 Electrical connection ........................................................................................... 8
2.4.3 Gas supply ............................................................................................................ 9
2.5 Disposal ................................................................................................................. 9
3 Product description ............................................................................................................. 10
3.1 Type key .............................................................................................................. 10
3.2 Function .............................................................................................................. 11
3.2.1 Components ...................................................................................................... 11
3.2.2 Electrical parts ................................................................................................... 12
3.2.3 Safety devices ................................................................................................... 13
3.2.4 Program sequence ........................................................................................... 14
3.3 Technical data ................................................................................................... 15
3.3.1 Approval data ..................................................................................................... 15
3.3.2 Electrical data .................................................................................................... 15
3.3.3 Ambient conditions ........................................................................................... 15
3.3.4 Permissible fuels ............................................................................................... 15
3.3.5 Emissions ............................................................................................................ 15
3.3.6 Rating .................................................................................................................. 16
3.3.7 Heat exchanger ................................................................................................. 16
3.3.8 Flue gas system data ....................................................................................... 16
3.3.9 EnEV Product Characteristics ....................................................................... 17
3.3.10 Dimensions ......................................................................................................... 18
3.3.11 Weight ................................................................................................................. 19
4 Installation ................................................................................................................................ 20
5 Installation ................................................................................................................................ 22
5.1 Requirements for the heating water ............................................................. 22
5.1.1 Permissible water hardness ........................................................................... 22
5.1.2 Fill water quantity .............................................................................................. 23
5.1.3 Treatment of fill and top-up water ................................................................. 23
5.2 Hydraulic connection ....................................................................................... 24
5.3 Condensate connection .................................................................................. 25
5.4 Gas supply ......................................................................................................... 26
5.5 Routing of air/ flue gas circulation ................................................................ 27
Installation and operating instruction
Gas condensing boiler WTC-GB 90-A
83266502 • 1/2010-08 • La 3-95

5.6 Electrical installation ......................................................................................... 28
5.6.1 Wiring diagram .................................................................................................. 29
5.6.2 Connection additional pump via output VA1 ............................................. 30
5.6.3 Connection additional safety valve LPG via output VA1 ......................... 30
6 Operation .................................................................................................................................. 31
6.1 Operating interface .......................................................................................... 31
6.1.1 Operating panel ................................................................................................ 31
6.1.2 Display ................................................................................................................. 32
6.2 End User Level .................................................................................................. 33
6.2.1 Display End User Level ................................................................................... 33
6.2.2 Settings End User Level .................................................................................. 34
6.3 Heating Engineer Level ................................................................................... 35
6.3.1 Info level .............................................................................................................. 36
6.3.2 Parameter level .................................................................................................. 38
6.4 Manual start up .................................................................................................. 41
6.5 Start manual configuration .............................................................................. 42
6.6 Control options .................................................................................................. 43
6.7 Control options .................................................................................................. 44
6.8 Boiler circuit pump ........................................................................................... 46
6.8.1 General information .......................................................................................... 46
6.8.2 Speed controlled pump ................................................................................... 46
6.9 Frost protection ................................................................................................. 47
6.10 Inputs and outputs ............................................................................................ 48
6.11 Special system parameters ............................................................................ 50
6.12 Chimney sweep function ................................................................................ 51
7 Commissioning ...................................................................................................................... 52
7.1 Prerequisite ........................................................................................................ 52
7.1.1 Check soundness of gas valve train ............................................................. 53
7.1.2 Check gas connection pressure ................................................................... 54
7.2 Adjusting the boiler .......................................................................................... 55
7.3 Change gas type ............................................................................................... 58
7.4 Calculating the burner rating ......................................................................... 60
8 Shutdown .................................................................................................................................. 61
9 Servicing .................................................................................................................................... 62
9.1 Safety components .......................................................................................... 63
9.2 Servicing display ............................................................................................... 63
9.3 Check differential pressure at air pressure switch .................................. 64
9.4 Replacing electrodes ....................................................................................... 65
9.5 Removing and refitting burner tube .............................................................. 66
9.6 Cleaning the heat exchanger ......................................................................... 68
9.7 Check flue gas pressure switch .................................................................... 69
9.8 Check gas pressure switch ............................................................................ 70
9.9 Removing and refitting fan .............................................................................. 71
10 Troubleshooting .................................................................................................................... 72
10.1 Procedures for fault conditions ..................................................................... 72
10.2 Fault history ........................................................................................................ 73
Installation and operating instruction
Gas condensing boiler WTC-GB 90-A
83266502 • 1/2010-08 • La 4-95

10.3 Rectifying faults ................................................................................................. 74
10.3.1 Warning codes .................................................................................................. 74
10.3.2 Error codes ......................................................................................................... 76
10.3.3 Operating problems ......................................................................................... 77
11 Spares ......................................................................................................................................... 78
12 Technical documentation ................................................................................................. 90
12.1 Internal boiler wiring ......................................................................................... 90
12.2 Sensor variables ................................................................................................ 91
12.3 Pneumatic control lines ................................................................................... 92
12.3.1 Air pressure switch connection diagram ..................................................... 92
12.3.2 Flue gas pressure switch connection diagram .......................................... 92
12.4 Conversion table O2/CO2 ............................................................................. 93
13 Key word index ...................................................................................................................... 94
Installation and operating instruction
Gas condensing boiler WTC-GB 90-A
83266502 • 1/2010-08 • La 5-95