1. No category

Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
83251902 • 2/2008-06
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
1 User instructions .....................................................................................................................
1.1
User guide .............................................................................................................
1.1.1
Symbols .................................................................................................................
1.1.2
Target group .........................................................................................................
1.2
Guarantee and Liability .......................................................................................
4
4
4
4
5
2 Safety ............................................................................................................................................
2.1
Permissible application .......................................................................................
2.2
Safety measures ..................................................................................................
2.2.1
Normal operation .................................................................................................
2.2.2
Electrical connection ...........................................................................................
2.3
Disposal .................................................................................................................
6
6
6
6
6
6
3 Product description ............................................................................................................... 7
3.1
Type key ................................................................................................................. 7
3.2
Variations ............................................................................................................... 7
3.3
Function ................................................................................................................. 9
3.4
Technical data ................................................................................................... 10
3.4.1
Electrical data .................................................................................................... 10
3.4.2
Ambient conditions ........................................................................................... 10
3.4.3
Operating pressure .......................................................................................... 10
3.4.4
Dimensions ......................................................................................................... 11
4
Installation ................................................................................................................................ 13
5 Installation ................................................................................................................................ 18
5.1
Installing the mains connection for the pump ............................................ 18
5.2
Install pump control connection .................................................................... 21
5.3
Installing the de-couple sensor ..................................................................... 22
6
83251902 • 2/2008-06 • La
Key word index ...................................................................................................................... 23
3-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
1 User instructions
1 User instructions
These installation and operating instructions form part of the system and must be kept
on site at all times.
1.1 User guide
1.1.1 Symbols
Immediate danger with high risk.
Non observance can lead to serious injury or death.
DANGER
Danger with medium risk.
Non observance can lead to environmental damage,
serious injury or death.
WARNING
Danger with low risk.
Non observance can cause damage to the equipment
and injury to personnel.
CAUTION
Important information.
Requires direct action.
Result after an action.
Itemisation.
Range.
1.1.2 Target group
These installation and operating instructions are intended for the operator and qualified personnel. It should be observed by all personnel working on the unit.
Work on the unit must only be carried out by personnel who have the relevant training
and instruction.
83251902 • 2/2008-06 • La
4-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
1 User instructions
1.2 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 of the hydraulic system,
▪ non-observance of the installation and operating instruction,
▪ operating the hydraulic system with faulty safety equipment,
▪ continual operation despite a fault,
▪ improper installation, commissioning, operation and service of the hydraulic system,
▪ alterations to the hydraulic system,
▪ the installation of additional components, which have not been tested with the hydraulic system,
▪ repairs, which have been carried out incorrectly,
▪ the use of non original Weishaupt parts,
▪ defects in the supply lines,
▪ acts of God.
83251902 • 2/2008-06 • La
5-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
2 Safety
2 Safety
2.1 Permissible application
The hydraulic system is suitable for connection to up to 4 condensing boilers:
WHB-GB-K-210
WHB-GB-K-300
WHT-2-GB-340-…
WHT-2-GB-810-…
WHT-M2-GB-810-…
WHT-M2-GB-1200-…
WHT-M2.1-GB-810-…
WHT-M2.1-GB-1200-…
WHT-M2.2-GB-810-…
WHT-M2.2-GB-1200-…
for WTC-GB 120-A … 210-A
for WTC-GB 250-A … 300-A
for WTC-GB 120-A … 170-A
for WTC-GB 210-A … 300-A
for WTC-GB 120-A … 300-A
for WTC-GB 210-A … 300-A
for WTC-GB 1120-A … 300-A
for WTC-GB 250-A … 300-A
for WTC-GB 120-A … 170-A
for WTC-GB 210-A … 300-A
Improper use could:
▪ endanger the health and safety of the user or third parties,
▪ cause damage to the unit or other material assets.
2.2 Safety measures
Safety relevant fault conditions must be eliminated immediately.
2.2.1 Normal operation
▪ All labels on the System must be kept in legible condition,
▪ stipulated settings, service and inspection work should be carried out at regular
intervals.
2.2.2 Electrical connection
For all work carried out on live parts:
▪ Observe the accident prevention instructions BGV A3 and adhere to local directives,
▪ tools according to EN 60900 should be used.
2.3 Disposal
Dispose of all materials used in a safe and environmentally friendly way. Observe local
regulations and Codes of Practice.
83251902 • 2/2008-06 • La
6-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
3 Product description
3 Product description
3.1 Type key
Example: WHB-GB-K-210
WHB
-GB
-K
-210
Basic Weishaupt hydraulic connection assembly
on WTC-GB
Cascade
Ratings range in kW
Example: WHT-2-GB-340-R
WHT
-2
-M2
-M2.1
-M2.2
-GB
-340
-R
Weishaupt Hydraulic Twinbloc
Compact version 2 WTC
Basic module for 2 WTC
Extension module for 1 additional WTC
Extension module for 2 additional WTC
for WTC-GB
Ratings range in kW
Assembly: right
3.2 Variations
Basic connection assembly (WHB-GB-K-…)
1 Flow
2 Return
Twinbloc compact version (WHT-2-GB-…)
-R
83251902 • 2/2008-06 • La
-L
7-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
3 Product description
Twinbloc basic module (WHT-M2-GB-…)
-R
-L
Twinbloc extension module (WHT-M2.1-GB-…) + WTC
-R
-L
Twinbloc extension module (WHT-M2.2-GB-…) + WTC
-R
83251902 • 2/2008-06 • La
-L
8-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
3 Product description
3.3 Function
1
2
3
4
5
6
7
8
9
0
q
Twinbloc WHT-GB-R with insulation
Basic connection assembly WHB-GB-K-... with pump in return
Hydraulic de-couple
Vent valve
Immersion sleeve for de-couple sensor
Connection for magnetite collector (optional)
Desludging valve
Condensing boiler WTC-GB
Non return valve
Stand
Connection for external expansion vessel Rp 1"
Basic connection assembly WHB
The basic connection assembly connects the flow and return of the condensing boiler
with the Twinbloc hydraulic de-couple WHT. The water supply can be opened or
closed using the ball valves on the basic connection assembly.
The speed controlled pumps are used to control the throughput quantity in the boiler
circuit. They are driven by the relevant condensing boiler.
83251902 • 2/2008-06 • La
9-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
3 Product description
Twinbloc WHT
The hydraulic de-couple in the Twinbloc uncouples the water flows in the heating
system. It allows different volume flows for the boiler circuit and for the heating circuit.
For example it prevents:
▪ exceeding the maximum permissible heating water flow through the condensing
units,
▪ any influences of differing circulation water quantities on installations with multiple
heating circuits.
The water circuit can be vented and desludged via the hydraulic de-couple. An optional magnetite collector in the de-couple bonds magnetite from the water. The
temperature of the heating water can be determined using an immersion sleeve in the
flow.
The hydraulic system can be aligned with the height of the condensing boiler using
its adjustable stand.
The Twinbloc (-R) for installation to the right or the Twinbloc (-L) for installation on
the left can be used to meet site requirements.
3.4 Technical data
3.4.1 Electrical data
Pump type
Supply voltage / line frequency
Nominal current
Consumption
Type of protection
external motor protection is not required
WHB-GB 210
Grundfos Magna
32-100
230 V/50 Hz
0.1 … 1.23 A
10 … 180 W
IP 44
WHB-GB 300
Grundfos Magna
32-120 F
230 V/50 Hz
0.17 … 1.8 A
25 … 430 W
IP 44
3.4.2 Ambient conditions
Temperature in operation
Temperature during transport / storage
relative humidity
3.4.3 Operating pressure
max 6 bar
83251902 • 2/2008-06 • La
10-23
+3 … +40 °C
-10 … +55 °C
max 80 %, no dew point
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
3 Product description
3.4.4 Dimensions
10
870
80
Installation right
550
All dimensions in mm
WHT-2
(2 boilers)
810
1910
WHT-M2 + M2.1
(3 boilers)
340
810
1200
1 1890 mm
1990 mm,
2059 mm,
1230 mm(1
1230 mm(1
2 800 mm
745
745 mm
730 mm
3 173 mm
210
210 mm
245 mm
4 1085 mm
1085 mm
1085 mm
1140 mm
5 150 … 225 mm 150 … 225 mm 150 … 225 mm 150 … 225 mm
6 DN80
DN 100
DN 100
DN 150
7 2707 mm
2747 mm
3979 mm
4097 mm
8 180 mm
220 mm
220 mm
310 mm
9 546 mm
566 mm
566 mm
606 mm
(1
Distance between second and third stand
83251902 • 2/2008-06 • La
11-23
WHT-M2 + M2.2
(4 boilers)
810
1200
1990 mm,
2059 mm,
2460 mm(1
2460 mm(1
745 mm
730 mm
210 mm
245 mm
1085 mm
1140 mm
150 … 225 mm 150 … 225 mm
DN 100
DN 150
5207 mm
5327 mm
220 mm
310 mm
566 mm
606 mm
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
3 Product description
10
870
80
Installation left
550
All dimensions in mm
WHT-2
(2 boilers)
810
745 mm
210 mm
1910 mm
WHT-M2 + M2.1
(3 boilers)
340
810
1200
1 800 mm
745 mm
730 mm
2 172.5 mm
210 mm
245 mm
3 1890 mm
1990 mm,
2059 mm,
1230 mm(1
1230 mm(1
4 1085 mm
1085 mm
1085 mm
1140 mm
5 150 … 225 mm 150 … 225 mm 150 … 225 mm 150 … 225 mm
6 180 mm
220 mm
220 mm
310 mm
7 2300 mm
2360 mm
3670 mm
3789 mm
8 DN80
DN 100
DN 100
DN 150
9 115 mm
155.5 mm
155 mm
275.5 mm
0 546 mm
566 mm
566 mm
606 mm
(1
Distance between second and third stand
83251902 • 2/2008-06 • La
12-23
WHT-M2 + M2.2
(4 boilers)
810
1200
745 mm
730 mm
210 mm
245 mm
1990 mm,
2059 mm,
2460 mm(1
2460 mm(1
1085 mm
1140 mm
150 … 225 mm 150 … 225 mm
220 mm
310 mm
4900 mm
5019 mm
DN 100
DN 150
155 mm
275.5 mm
566 mm
606 mm
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
4 Installation
4 Installation
1 Boiler flow R 2"
2 Boiler return R 2"
▶ Fit ball valves 1 of the basic connection assembly with sealing material to the
▶
▶
▶
83251902 • 2/2008-06 • La
Twinbloc.
If necessary, adjust height of the Twinblocs using the stand.
Screw adapter 3 with sealing material to boiler flow or boiler return.
Fit union nut 2 with seal to adapter.
13-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
4 Installation
Rotate pump 32-120 F
Installation position cable entry vertical downward.
▶ Undo screws.
▶ Slightly lift pump motor and rotate by 180°.
▶ Tighten screws.
180°
▶ Install pump with seals between the connection components in the return, observe
the flow direction of the pump.
▶ Secure Twinbloc to the floor using suitable fixings.
▶ Connect expansion vessel to the connection sleeve Rp 1" 1 in the return
– or – plug off connection sleeve.
▶ Connect pump (see Ch. 5).
WHB-GB 210
83251902 • 2/2008-06 • La
WHB-GB 300
14-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
4 Installation
CAUTION
Excess voltage due to insulation resistance testing
Test voltage damages the pump electronics.
▶ Electrically isolate the pump from the system prior to carrying out any testing.
Installing the magnetite collector (optional)
▶ Remove closing cap 2.
▶ Screw in magnetite collector 1 with seal.
83251902 • 2/2008-06 • La
15-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
4 Installation
Install insulation on WHT-GB-K-340
▶ Fit insulation to the sides of the Twinbloc.
▶ Insulate pumps with insulation supplied.
▶ Secure insulation with the Velcro straps 1.
83251902 • 2/2008-06 • La
16-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
4 Installation
Install insulation on WHT-GB-K-810 and WHT-GB-M2
▶ Fit insulation to the sides of the Twinblocs.
▶ Insulate pump with insulation supplied.
▶ On extension modules WHT-GB-M2.1 and WHT-GB-M2.2: Locate end
piece 1 accordingly.
▶ Secure insulation with straps 2.
83251902 • 2/2008-06 • La
17-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
5 Installation
5 Installation
DANGER
Electric shock when working with voltage applied
The consequence is serious injury or death.
▶ Isolate unit prior to carrying out work and protect against accidental reconnection
to the mains.
The electrical installation must only be carried out by qualified electricians, local regulations must be observed.
When connecting extra-low and low voltage cables, separate cable ducts should be
considered for the wiring in the condensing boiler.
1 Cable duct for signal and sensor lines.
2 Cable duct for low voltage 230 V
5.1 Installing the mains connection for the pump
Pump 32-100
▶ Fit plug supplied 2 to a cable provided by others.
▶ Connect plug to the mains connection of the pump 1.
83251902 • 2/2008-06 • La
18-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
5 Installation
Pump 32-120 F
▶ Open pump terminal box.
▶ Connect mains connection to the following connection diagram.
L
N
PE
L
N
PE
Install mains connection on WTC-GB
▶ Install the mains connection through the cable duct for low voltage 1 on the
condensing boiler.
The mains connection for the pump can be connected to terminal No. 5 (MFA 2) or
terminal No. 6 (VA) of the WTC connection box 2.
6
5
VA
MFA 2
L N PE
83251902 • 2/2008-06 • La
19-23
1
2
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
5 Installation
▶ Connect connection to terminal MFA 2 or VA according to the following connection
▶
▶
▶
▶
diagram.
Set parameter 41 on condensing boiler to 1 min pump run on time.
Set parameter 43 on condensing boiler to 1.
MFA 2: Set parameter 14 on condensing boiler to 2.
VA: Set parameter 15 on condensing boiler to 2.
1
230V
2
MFA 1
5
MFA 2
L N PE
83251902 • 2/2008-06 • La
20-23
3
H1
4
H2
5
MFA 2
6
VA
4
H2
L E
7
eBUS
8
B11
5
MFA 2
L N PE
6
VA
1 2
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
5 Installation
5.2 Install pump control connection
Pump 32-100
S/S
MIN
MAX
0-10V
7
8
9
10
11 12
GND
GND
▶ Open pump terminal box.
▶ Connect terminals 11 and 12 with a cable supplied by others.
1
-
+
2
3
NC NO C
DC 0 ... 10 V
A
Y
B
X
4
5
6
21
Q
Z
22 23
Pump 32-120 F
Y
B
MIN
MAX
0-10V
4
5
6
7
9
10
11 12 21 22 23
GND
A
GND
▶ Open pump terminal box.
▶ Connect terminals 11 and 12 with a cable supplied by others.
▶ Bridge terminals 7 and 9.
X
+
Q
-
DC 0 ... 10 V
83251902 • 2/2008-06 • La
21-23
Z
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
5 Installation
Install control connection on WTC-GB
▶ Install the control connection through the cable duct for low voltage 1 on the
condensing boiler.
▶ Connect control connections to plug 11 on the WTC connection box 2:
▪ Terminal 11 (pump) on 1,
▪ Terminal 12 (pump) on M.
11
1 M
11 12
The pump is preset to external 0 … 10 V control and constant characteristic:
▪ 32-100 stage 50
▪ 32-120 F stage 60.
The pump can be adapted to system specific requirements using the setting keys on
the pump housing. Fine adjustment is possible via the remote control R100 (Grundfos
accessory).
5.3 Installing the de-couple sensor
▶ Remove adapter 1 with clamping rubber from immersion sleeve and insert de-
couple sensor 2.
Insert
de-couple sensor into immersion sleeve up to the stop and secure with
▶
adapter.
✓ The clamping rubber holds the de-couple sensor in place in the immersion sleeve.
▶ Connect cable of de-couple sensor to terminal B22 on the cascade manager (see
installation and operating instructions WCM-KA).
83251902 • 2/2008-06 • La
22-23
Installation and operating instruction
Hydraulic system WHB-GB-K-... and WHT-GB
6 Key word index
A
Ambient conditions .............................................................10
Storage .................................................................................10
Supply voltage .....................................................................10
B
T
Basic connection assembly ................................................ 9
C
Cable duct ............................................................................18
Consumption .......................................................................10
Control connection .............................................................21
Temperature .........................................................................10
Transport ...............................................................................10
Type of protection ...............................................................10
V
Vent valve ............................................................................... 9
Voltage supply .....................................................................10
D
De-couple sensor ...............................................................22
Desludging valve ................................................................... 9
Dimensions ...........................................................................11
E
Electrical data ......................................................................10
Electrical installation ...........................................................18
G
Guarantee ............................................................................... 5
H
Hydraulic de-couple ............................................................. 9
I
Immersion sleeve ........................................................... 9, 10
Installation .............................................................................13
Insulation ...............................................................................16
L
Liability ..................................................................................... 5
M
Magnetite collector ..................................................... 10, 15
Mains connection pump ....................................................18
N
Nominal current ...................................................................10
Non return valve .................................................................... 9
O
Operating pressure ............................................................10
P
Parameter .............................................................................20
Pump ................................................................................ 9, 14
Pump control connection ..................................................21
Pump type ............................................................................10
S
Safety measures ................................................................... 6
83251902 • 2/2008-06 • La
23-23
Max Weishaupt GmbH, D-88475 Schwendi
www.weishaupt.de
Weishaupt (UK) Limited Neachells Lane, Willenhall, WV13 3RG
www.weishaupt.co.uk
Printed in Germany. All rights reserved.
Product
Description
Performance
W-Burners
The compact series, proven millions of times over:
Up to 570 kW
Economical, reliable, fully automatic. Gas, oil and
dual fuel burners for domestic and commercial applications. The purflam burner gives almost soot-free
combustion of oil with greatly reduced NOx emissions.
Monarch and
industrial burners
The legendary industrial burner:
Tried and tested, long lived, clear construction.
Gas, oil and dual fuel burners for district heat
provision.
Up to
11,700 kW
multiflam® burners
Innovative Weishaupt technology for large burners:
Minimal emission values particularly at ratings over
one megawatt. Oil, gas and dual fuel burners with
patented fuel distribution system.
Up to
16,000 kW
WK
industrial burners
Modular powerhouses:
Adaptable, robust, powerful.
Oil, gas and dual fuel burners for industrial plant.
Up to
22,000 kW
Thermo Unit
The Thermo Unit heating systems from cast iron or
steel: Modern, economic, reliable.
For environmentally friendly heating.
Fuel: Gas or oil as desired.
Up to 55 kW
Thermo Condens
The innovative condensing boilers with the SCOT
system: Efficient, low in emissions, versatile. Ideal for
domestic heating. Floor standing gas condensing
boiler with ratings of up to 1200 kW (cascade), for
higher heat demands.
Up to
1,200 kW
Heat pumps
The heat pump programme offers solutions for
utilisation of heat from air, soil and ground water.
The systems are suitable for refurbishment or new
builds.
Up to 130 kW
Solar systems
Free energy from the sun:
Perfectly coordinated components, innovative, proven.
Pleasantly shaped flat roof collectors to support
heating and of domestic water
Water heater /
energy reservoir
The attractive domestic water heating range
includes classic water heaters which are supplied
through a heating system and energy reservoirs
which can be fed through solar systems.
Control technology /
building
management
From control panels to complete building management
systems – at Weishaupt you can find the entire
spectrum of modern control technology.
Future oriented, economical and flexible.
83251902 • 2/2008-06 • La