Weishaupt WTC-OB 18-B User manual

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B 83311002 1/2018-03

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
83311002 1/2018-03 La 2-132
1 User instructions.............................................................................................................. 5
1.1  Target group.................................................................................................................. 5
1.2  Symbols.......................................................................................................................... 5
1.3  Guarantee and Liability............................................................................................... 6
2 Safety ..................................................................................................................................... 7
2.1  Designated application............................................................................................... 7
2.2  What to do if flue gas can be smelled .................................................................... 7
2.3  Safety measures........................................................................................................... 7
2.3.1  Normal operation...................................................................................................7
2.3.2  Electrical connection............................................................................................7
2.4  Disposal ......................................................................................................................... 7
3 Product description ........................................................................................................ 8
3.1  Type key ......................................................................................................................... 8
3.2  Serial number................................................................................................................ 8
3.3  Function.......................................................................................................................... 9
3.3.1  Oil carrying parts...................................................................................................9
3.3.2  Water and flue gas carrying parts.................................................................. 10
3.3.3  Electrical components....................................................................................... 11
3.3.4  Safety and monitoring functions..................................................................... 12
3.3.5  Program sequence............................................................................................. 13
3.4  Technical data.............................................................................................................14
3.4.1  Approval data...................................................................................................... 14
3.4.2  Electrical data ..................................................................................................... 14
3.4.3  Ambient conditions............................................................................................ 14
3.4.4  Fuels...................................................................................................................... 14
3.4.5  Emissions............................................................................................................. 15
3.4.6  Rating.................................................................................................................... 15
3.4.7  Hydraulic data..................................................................................................... 16
3.4.8  Flue gas system data......................................................................................... 18
3.4.9  EnEV Product Characteristics ........................................................................ 18
3.4.10  Dimensions........................................................................................................ 19
3.4.11  Weight................................................................................................................ 19
4 Installation ........................................................................................................................ 20
4.1  Installation conditions................................................................................................20
4.2  Installing the appliance .............................................................................................20
5 Installation ........................................................................................................................ 22
5.1  Requirements for the heating water ......................................................................22
5.1.1  Water hardness.................................................................................................. 22
5.1.2  Fill water quantity ............................................................................................... 23
5.1.3  Treat the fill and top-up water......................................................................... 23
5.2  Hydraulic connection ................................................................................................24
5.3  Condensate connection...........................................................................................26
5.4  Oil supply.....................................................................................................................28
5.5  Air supply / flue gas duct .........................................................................................29

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
83311002 1/2018-03 La 3-132
5.6  Electrical connection.................................................................................................30
5.6.1  Wiring diagram ................................................................................................... 31
5.6.2  Connect external three way valve................................................................... 32
5.6.3  Connect external pump .................................................................................... 33
6 Operation .......................................................................................................................... 34
6.1  Operating interface....................................................................................................34
6.1.1  Operating panel.................................................................................................. 34
6.1.2  Display .................................................................................................................. 35
6.2  User level .....................................................................................................................36
6.2.1  User level display ............................................................................................... 36
6.2.2  User level settings.............................................................................................. 37
6.3  Heating engineer level ..............................................................................................38
6.3.1  Info level ............................................................................................................... 39
6.3.2  Parameter level ................................................................................................... 41
6.4  Manual start up...........................................................................................................45
6.5  Start manual configuration.......................................................................................46
6.6  Control options...........................................................................................................47
6.7  Control options...........................................................................................................48
6.7.1  Constant flow temperature .............................................................................. 48
6.7.2  Weather compensated control ....................................................................... 48
6.7.3  DHW operation .................................................................................................. 49
6.7.4  Buffer control with one sensor........................................................................ 50
6.7.5  Buffer control with two sensors...................................................................... 50
6.7.6  De-couple control .............................................................................................. 51
6.8  Circulation pump........................................................................................................52
6.8.1  General information ........................................................................................... 52
6.8.2  Speed controlled pump.................................................................................... 53
6.9  Frost protection..........................................................................................................54
6.10  Inputs/outputs ..........................................................................................................55
6.11  Commissioning programs (parameter 73) ........................................................56
6.12  Special system parameters...................................................................................58
6.13  Chimney sweep .......................................................................................................59
7 Commissioning.............................................................................................................. 60
7.1  Prerequisite .................................................................................................................60
7.1.1  Connect measuring devices............................................................................ 61
7.2  Adjust condensing boiler .........................................................................................62
7.3  Check soundness of flue gas system ...................................................................65
7.4  Check rating................................................................................................................66
7.4.1  Delivery status..................................................................................................... 66
7.4.2  Changing capacity............................................................................................. 66
7.5  Readjustment of combustion ..................................................................................67
7.6  Check combustion.....................................................................................................68
8 Shutdown.......................................................................................................................... 69

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
83311002 1/2018-03 La 4-132
9 Servicing............................................................................................................................ 70
9.1  Notes on servicing.....................................................................................................70
9.2  Components ...............................................................................................................72
9.3  Servicing display ........................................................................................................73
9.4  Service positions........................................................................................................74
9.4.1  Service position A.............................................................................................. 74
9.4.2  Service position B.............................................................................................. 75
9.5  Cleaning the heat cell ...............................................................................................76
9.6  Set nozzle distance....................................................................................................78
9.7  Check mixing head ....................................................................................................78
9.8  Set ignition electrodes..............................................................................................79
9.9  Removing and refitting ignition electrodes...........................................................79
9.10  Replace oil nozzle....................................................................................................80
9.11  Removing and refitting nozzle shut off................................................................81
9.12  Removing heat exchanger and temperature switch ........................................82
9.13  Removing and refitting air nozzle.........................................................................83
9.14  Removing and refitting oil pump ..........................................................................84
9.15  Remove pump motor ..............................................................................................85
9.16  Removing and refitting fan.....................................................................................86
9.17  Removing and refitting oil pump filter .................................................................87
9.18  Removing and refitting oil filter insert..................................................................88
9.19  Removing and refitting three way valve..............................................................89
10 Troubleshooting ............................................................................................................ 90
10.1  Procedures for fault conditions............................................................................90
10.2  Fault memory ............................................................................................................92
10.3  Warning codes ........................................................................................................94
10.4  Fault codes ...............................................................................................................96
10.5  Operating problems............................................................................................. 100
11 Technical documentation.......................................................................................101
11.1  Probe and sensor variables................................................................................ 101
11.2  Wiring diagram...................................................................................................... 102
11.2.1  Burner connection console .........................................................................102
11.2.2  Boiler electronics WCM-OB-CPU............................................................103
12 Project planning...........................................................................................................104
12.1  Oil supply ............................................................................................................... 104
13 Spares...............................................................................................................................106
14 Notes .................................................................................................................................128
15 Key word index ............................................................................................................129

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
1 User instructions
83311002 1/2018-03 La 5-132
1 User instructions
Translation of original
operating instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the appliance.
1.1 Target group
The manual is intended for the operator and qualified personnel. They should be
observed by all personnel working with the appliance.
Work on the appliance must only be carried out by personnel who have the relevant
training and instruction.
In accordance with EN 60335-1 the following requirements apply
This appliance can be used by children 8 years and above as well as by persons
with limited physical, sensory or mental capacities or lack of experience and know-
ledge, provided they are supervised or have been instructed regarding the safe use
of the appliance and understand the resulting danger. Children must not play with
the appliance. Cleaning and operator maintenance must not be carried out by chil-
dren without supervision.
1.2 Symbols
DANGER
Immediate danger with high risk.
Non observance can lead to serious injury or death.
WARNING
Danger with medium risk.
Non observance can lead to environmental damage,
serious injury or death.
CAUTION
Danger with low risk.
Non observance can cause damage to the equip-
ment and injury to personnel.
Important information
Requires direct action
Result after an action
Itemisation
… Range of values

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
1 User instructions
83311002 1/2018-03 La 6-132
1.3 Guarantee and Liability
Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
non approved application,
non-observance of the manual,
operation with faulty safety equipment,
continual operation despite a fault,
improper installation, commissioning, operation and service,
repairs, which have been carried out incorrectly,
the use of non original Weishaupt parts,
force majeure,
unauthorised modifications made to the appliance,
the installation of additional components, which have not been tested with the
appliance,
changes to the combustion chamber,
unsuitable fuels,
defects in the inlet lines,
on non diffusion tight heating circuits without system separation.

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
2 Safety
83311002 1/2018-03 La 7-132
2 Safety
2.1 Designated application
The appliance is suitable for:
Warm water heating circuits in closed systems to EN12828,
a flow rate of maximum 1500 l/h.
The combustion air must be free from aggressive compounds (e. g. Halogens). If
the combustion air in the boiler room is contaminated, increased cleaning and ser-
vicing will be required. In this case the appliance should be operated room air inde-
pendent.
The appliance should only be used in enclosed rooms.
The installation room must comply with local regulations.
Improper use could:
endanger the health and safety of the user or third parties,
cause damage to the appliance or other material assets.
2.2 What to do if flue gas can be smelled
Switch off appliance and turn of the system.
Open doors and windows.
Notify your heating contractor or Weishaupt Customer Service.
2.3 Safety measures
Safety relevant fault conditions must be eliminated immediately.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution
[ch.9.2].
The design lifespan of the components is listed in the service plan.
2.3.1 Normal operation
All labels on the appliance must be kept in a legible condition.
Stipulated settings, service and inspection work should be carried out at regular
intervals.
Only operate the appliance with its cover closed.
Do not touch moving parts during operation.
2.3.2 Electrical connection
For work carried out on live components:
Observe the accident prevention instructions DGUVRegulation3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.
2.4 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 8-132
3 Product description
3.1 Type key
Example: WTC-OB 18-B VERS. W-PEA
WTC Range: Weishaupt Thermo Condens
O Fuel: Oil
B Type of construction: floor standing
18 Ratings size: 18 kW
B Construction
VERS. W Version: heating mode and DHW mode
VERS. H Version: heating mode only
PEA Speed controlled circulation pump (efficiency class A)
0 Without circulation pump
3.2 Serial number
The serial number on the name plate identifies the product. This is required by
Weishaupt's customer service department.
11
1Name plate
Ser.No.

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 9-132
3.3 Function
3.3.1 Oil carrying parts
1
3
4
2
1Nozzle body
2Connect oil supply
3Oil filter vent combination
4Oil pump

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 10-132
3.3.2 Water and flue gas carrying parts
Image: WTC-OB 18-B VERS. W-PEA
12
5
3
4
6
8
9
0
q
w
7
1Heating circuit flow
2Heating circuit return
3Safety valve connection
4Flue gas connection
5DHW circuit flow
6Flue gas sound attenuator
7DHW circuit return
8Three way valve
9Speed controlled circulation pump
0Siphon
qHeat exchanger
wConnection inlet and outlet tap / expansion vessel

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 11-132
3.3.3 Electrical components
Image: WTC-OB 18-B VERS. W-PEA
4
5
6
7
8
9
q
0
w
e
r
t
1
z
u
i
2 3
1Flow sensor
2Boiler electronics WCM-OB-CPU with electrical connection and appliance
fuse
3Combustion air sensor
4Combustion chamber pressure sensor
5Speed controlled fan
6Flue gas sensor
7Actuator three way valve
8Level switch
9Speed controlled circulation pump
0System pressure sensor/return flow sensor
qIgnition unit (with fixing plate for setting gauge)
wOil preheating
eFlame sensor
rStage 2 oil solenoid valve
tStage 1 oil solenoid valve
zPump motor
uBurner connection console
iBoiler control panel WCM-CUI

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 12-132
3.3.4 Safety and monitoring functions
Flow sensor eSTB
The fuel supply is shut off and the fan and the pump run-on are activated if the tem-
perature exceeds 95 °C (W12). The appliance restarts automatically if the temperat-
ure drops below the target supply value for 1minute.
The fuel supply is shut off and the fan and the pump run-on are activated if the tem-
perature exceeds 105 °C. The system goes to lockout (F11). This locking function
of the supply sensor replaces the water deficiency safety function in accordance
with EN 12828.
Flue gas sensor
The fuel supply will be switched off and the fan and pump run-on activated if the
flue gas temperature exceeds the values defined in parameter33 (factory setting
120 °C) (F13). On proximity to the safety temperature stage1 is started, at 5 K dif-
ference (115 °C) the burner shuts down (W16).
Differential temperature flow / return
The boiler is switched off if the difference between the supply temperature and re-
turn flow temperature exceeds a preset value (W15). The installation goes to lockout
after 30 warnings with (F15).
System pressure sensor
If the system pressure drops below the value of parameter39, a waring message
is issued (W36). If the system pressure drops below 0.5 bar, the appliance shuts
down (F36). If the pressure increases above 0.5 bar, the appliance automatically
restarts.
Combustion chamber pressure sensor
The appliance shuts down if the combustion chamber pressure exceeds the prede-
termined value (W19). The installation goes to lockout after 3 warnings with (F19).
When approaching the specified value, a service message appears in the display,
the spanner icon flashes intermittently (twice briefly, long pause).
Level switch
The level switch is used to monitor leakage from water and oil carrying components
in the appliance. If the termination well is filled with liquid, the burner shuts down
(W25).

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 13-132
3.3.5 Program sequence
Oil preheating
At heat demand1, the heat exchanger2 heats the oil in the nozzle assembly. The
display shows an H. When a temperature of approx. 45 °C is reached, the temper-
ature switch3 closes.
Pre-purge
The fan4 starts and runs to the pre-purge speed.
Ignition
The ignition5 and the pump motor6 are switched on.
Stage17 and stage28 solenoid valves open (burner starts with stage2).
A flame9 is formed. Oil preheating2 is switched off.
Flame stabilisation
Ignition is switched off once the safety time and post-ignition phase0 has
elapsed. The flame stabilisation timeq follows.
Operation
The burner is in operation. The flame sensor monitors the flame. The boiler elec-
tronics active the solenoid valve for stage28 depending on heat demand.
Post-purge
If there is no longer a heat demand, the solenoid valves close and stop the fuel
supply. Following the post-purge phasew the fan switches off.
10 2 3 4 5 6 7 8 0
1
2
3
4
5
6
7
8
q
w
w
0
9
i10 Operating phase [ch.6.3.1]

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 14-132
3.4 Technical data
3.4.1 Approval data
Method of installation B23, B33, C13(1, C33, C53, C63(2, C93
DIN CERTCO 3R279/...
VKF 22349
(1 France and Belgium only
(2 Not for Belgium
Basic standards EN 267: 2011
EN 303-1: 2003
EN 303-2: 2003
EN 15034: 2007
EN 15035: 2007
Additional standards, see EU conformity certifica-
tion.
3.4.2 Electrical data
Mains voltage / mains frequency 230 V/50 Hz
Consumption max 350 W
Power consumption without circulation pump max 140 W
Power consumption standby 4 W
Internal appliance fuse T6.3H, IEC 127-2/5
Fuse max 16 A
Type of protection IP 42D
3.4.3 Ambient conditions
Temperature in operation +3 … +30 °C
Temperature during transport / storage -10 … +60 °C
relative humidity max 80 %, no dew point
3.4.4 Fuels
Fuel oil EL low-sulphur (max 50 mg/kg sulphur)
to DIN 51603-1 or similar national standards,
fuel oil EL A Bio 10 low-sulphur (max 50 mg/kg sulphur)
to DIN 51603-6 or similar national standards.
Addition of ash-forming additives is prohibited.

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 15-132
3.4.5 Emissions
Sound levels
Dual number noise emission values
Measured sound power level LWA (re 1 pW)
Uncertainty value KWA
57
4
dB(A)(1
dB(A)
Measured sound pressure level LpA (re 20 μPa)
Uncertainty value KpA
50
4
dB(A)(2
dB(A)
(1 Determined to ISO 9614-2.
(2 Determined at 1 metre distance from the front of the appliance.
The measured noise levels plus uncertainty values form the upper limit value, which
could occur when measuring.
3.4.6 Rating
Stage 1 Stage 2
Combustion heat rating QB11.6 kW 17.6 kW
Boiler capacity at 80/60 °C 11.3 kW 17.2 kW
Boiler capacity at 50/30 °C 12.2 kW 18.3 kW
Condensate quantity at 50/30 °C 0.8 l/h 1.0 l/h

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 16-132
3.4.7 Hydraulic data
Water content version H 11 litres
Water content version W and H-0 13 litres
Boiler temperature max 85 °C
Operating pressure max 3 bar
Throughput limit 1500 l/h
Resulting supply pressure version W-PEA
0 150 300 450 600 750 900 1050 1200 1350 1500
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
100 %
80 %
60 %
40 %
23 %
1
2
3
1Throughput [l/h]
2Resulting supply pressure [mbar]
3Circulation pump capacity

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 17-132
Resulting supply pressure version H-PEA
0 150 300 450 600 750 900 1050 1200 1350 1500
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
100 %
80 %
60 %
40 %
23 %
1
2
3
1Throughput [l/h]
2Resulting supply pressure [mbar]
3Circulation pump capacity
Pressure loss version H-0
Observe the pressure loss of the appliance and the maximum flow rate limit when
determining the hydraulic layout of the heating system.
0
300
250
200
150
100
50
0
150 450 750 1050300 600 900 1200 1350 1500
1
2
1Throughput [l/h]
2Pressure loss [mbar]

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 18-132
3.4.8 Flue gas system data
Stage 1 Stage 2
Residual supply pressure at flue gas outlet 40 Pa 60 Pa
Flue gas mass flow rate 4.8 g/s 7.1 g/s
Flue gas temperature at 80/60 °C 56 °C 58 °C
Flue gas temperature at 50/30 °C 34 °C 39 °C
3.4.9 EnEV Product Characteristics
Boiler efficiency factor at 100 % capacity and at
medium boiler temperature 70 °C
97.6 % Hi (92.1 % Hs)
Boiler efficiency factor at 30 % capacity and at re-
turn temperature 30°C
104.7 % Hi (98.8 % Hs)
Standby loss at 50K above room temperature 1.2 %; 215 W
Standby loss at 30 K above room temperature 0.7 %; 115 W

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
3 Product description
83311002 1/2018-03 La 19-132
3.4.10 Dimensions
680 mm
1002 mm
730 mm
29 ... 35 mm
162 mm
159 mm
125 mm
78 mm
84 mm
149
mm
787 mm
241 mm
638 mm
46 mm
28 mm
3
2
4
9
8
5
7
6
1
1Flow fresh water storage G1
2Return fresh water storage G1
3Inlet and outlet tap / expansion vessel G¾
4Condensate outlet
5Supply air/flue gas DN 125/80
6Heating circuit return G1½
7Heating circuit flow G1½
8Safety vale G¾
9Oil supply G3/8
3.4.11 Weight
Weight empty approx.107 kg

Installation and operating instruction
Oil condensing boiler WTC-OB 18-B
4 Installation
83311002 1/2018-03 La 20-132
4 Installation
4.1 Installation conditions
Prior to installation ensure that:
the minimum distance is maintained [ch.4.2],
the condensate can drain away,
the transport route is free and stable [ch.3.4.11],
the footprint is stable and level,
the space for the hydraulic connection is sufficient,
the installation location is frost free and dry.
4.2 Installing the appliance
Removing front panel
Open flap 1 on boiler control panel.
Undo screw 2 and remove front panel.
1
2