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Weishaupt WG10 1-C Series, Installation And Operating Instructions Manual, Page: 30 / 40

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Weishaupt WG10 1-C Series Installation And Operating Instructions Manual Download Page 30

30

7.10 Removal and refitting air regulator housing

Air regulator housing

➀

➁

Removal

1. Close gas ball valve.
2. Isolate burner from electrical supply (see Ch. 4.7).
3. Remove outlet flange from the multifunction assembly

W-MF (see Ch. 4.5)

4. Remove burner body from head flange on the appliance

(see Ch. 4.4).

5. Unplug air damper servomotor 
6. Remove screws 

➀

and remove air intake housing

7. Remove screws 

➁

and remove air regulator housing.

Refitting

Refit following instructions in reverse.

7.9 Removal and refitting gas butterfly valve 

Removal and refitting gas butterfly valve

➀

➁

➂

➄

➃

➀

Double nipple with
flange

➁

Crank-arm

➂

Kombi Torx screw

➃

Gas butterfly

➄

Gasket

Risk of explosion!

Uncontrolled gas leakage can lead to an
explosive mixture of gas and air. If ignition
source is present this can lead to an explosion.

Removing

1. Close gas ball valve.
2. Isolate burner from electrical supply.
3. Remove outlet flange 

➀

from the multifunction

assembly W-MF (see Ch. 4.5).

4. Remove double nipple.
5. Remove mixing head (see Ch. 7.3). 
6. Remove crank-arm 

➁

.

7. Remove screws 

➂

.

8. Remove gas butterfly valve 

➃

.

Refitting 

When refitting the mixing head ensure correct
fitting and cleanliness of gasket 

➄

.

If necessary replace gasket. During
commissioning check soundness with leak
detecting spray.

1. Fit gas butterfly
2. Fit crank-arm 

➁

.

3. Refit mixing head (note Ch. 7.3).
4. Replace double nipple.
5. Fit outlet flange to multifunction assembly W-MF (note

Ch. 4.5).

6.

Carry out soundness

test (note Ch. 4.6).

7. Switch an electrical supply.
8. Open gas ball valve.
9. Check combustion values, if necessary 

re-commissioning burner.

DANGER

DANGER

Summary of Contents for WG10 1-C Series

Page 1: ...i t i o n e l e c t r o d e C o m b u s t i o n h e a d F l a m e t u b e B a l l v a l v e G a s p r e s s u r e s w i t c h M u l t i f u n c t i o n a s s e m b l y W M F Installation and operating instructions Weishaupt gas burner WG10 1 C version Z LN Low NOx For gas types Natural Gas E LL and Liquid Petroleum Gas B P 83055303 1 2002 G a s b u t t e r f l y v a l v e B u r n e r m o t o r Inf...

Page 2: ...7 EU PED 97 23 EU LVD 73 23 EU MC 89 336 EU EED 92 42 EU these products are labelled as follows CE 0085BM0481 Schwendi 19 03 2002 ppa ppa Dr Lück Denkinger Comprehensive Quality Assurance is ensured by a certified Quality Management System to DIN ISO 9001 Regular maintenance saves energy and protects the environment We recommend regular plant maintenance of all combustion equipment It saves fuel a...

Page 3: ... Servicing 26 7 1 Safety information on servicing 26 7 2 Servicing plan 26 7 3 Mixing head removal and refitting 27 7 4 Mixing head setting 27 7 5 Ignition electrode and sensor electrode setting 28 7 6 Service position of housing cover 28 7 7 Removing and refitting fan motor and fan wheel 29 7 8 Removal and refitting of air servomotor and air damper angle drive 29 7 9 Removing and refitting of gas...

Page 4: ...ator must note that an agent of the contractor or other suitably qualified person must inspect the plant at least once a year To ensure regular inspections weishaupt recommends a service contract The contractor should instruct the plant operator in the use of the equipment prior to hand over and inform him as and when necessary of any further inspections that are required before the plant can be u...

Page 5: ... off valve Warn all occupants and evacuate the building Inform heating company installer and gas supplier from outside of the building Electrical safety Work on the electrical supply should be carried out by a qualified electrician Electrical components should be checked during servicing Loose connections and heat damaged cables should be dealt with immediately The control panel should be locked a...

Page 6: ...ave a contract with the gas supplier The gas pipework must be subject to a preliminary and main test or the combined loading test and soundness test according to the pressure range intended Burner must be isolated The air or purge gas required for the test must be expelled from the pipework The pipework must be completely purged Gas characteristics The following information must be obtained from t...

Page 7: ...se Red Burner lockout Flashing orange red Low voltage or internal safety fault Flashing green red Flame Simulation flashing red orange Over voltage short pause Flashing red Low gas Servomotor A servomotor on the air damper controls the gas air ratio via mechanical compound with the gas butterfly valve Multifunction assembly W MF with the following functions Pressure regulator Ensures a constant ga...

Page 8: ...hird attempt at restarting the burner will commence after a further waiting time of 10 minutes After the fifth unsuccessful attempt to start the burner the start will only be attempted after a waiting time of one hour Valve proving Following a controlled shutdown of the burner valve proving is automatically activated The combustion manager sequentially checks for incorrect pressure increase and de...

Page 9: ...e and that there has been no damage in transit If the delivery is incomplete or damaged contact the supplier Transport For transport weights of burners and valve trains see Ch 8 8 Storage Please note the permissible ambient conditions for storage see Ch 8 5 Check burner nameplate The burner rating must be within the operating range of the heating appliance The ratings given on the burner nameplate...

Page 10: ... solid Heat exchanger drilling dims Refractory Flange gasket Refractory and drilling dimensions Burner installation Burner mounting 1 Remove mixing head see Ch 7 3 2 Remove screws 3 Separate burner flange with flame tube from housing 4 Fix burner flange with screws to the boiler plate 5 Place burner housing onto stay bolts 6 Fit screws and tighten 7 Check setting of ignition and ionisation electro...

Page 11: ...to vibrate during operation Supports suitable for the site should be fitted during installation Only sealing agents tested and approved by the gas supplier must be used The double nipples supplied have already been coated with an approved substance Mounting the valve train from the right 1 Remove the protective film from the gas connection flange 2 Mount the components pre assembled in the order s...

Page 12: ...fly valve 1 Fit blanking plate see notes Ch 7 3 2 Fit measuring device to test point 3 Remove blanking plate once soundness test is complete 4 Tighten Torx screws on mixing head Note To carry out an external soundness test brush connection points with foam forming agents or similar non corrosive material or use an electronic gas detector Soundness test 1st Test phase 2nd Test phase 3rd Test phase ...

Page 13: ...and multifunction assembly plugs are coded and tighten screws Connection to the mains supply should be carried out to the wiring diagram relevant for the type of unit Notes for Austria Electrical isolation having a minimum of 3 mm contact gap acting on all poles must be fitted adjacent to the burner Possibilities are Switch without micro contacts with required separation characteristics Circuit br...

Page 14: ...ed out after the relevant lines have been purged by the local gas authority Check gas supply pressure Purging the valve train Max Weishaupt GmbH 88475 Schwendi N max mbar kW kg h BN V Hz A gl kW kW 0085 Burner type Version Cat Conn press min Rating Oil to DIN 51 603 Mains El rating Serial No Gas type Y of m Purging the valve train The gas supply pressure must be correct 1 Connect a hose leading ou...

Page 15: ... fresh air must be available The required test points for combustion analysis must be available Ensure that the heat exchanger and the flue gas section up to the test opening are sound so that the test results are not corrupted by extraneous air Liquid level controls must be set correctly Thermostat pressure switch and other safety devices must be in operating position There must be a demand for h...

Page 16: ... to EN 303 Therefore small variations may occur when commissioning depending on individual installations These values result in an air factor of λ 1 15 Example 1 Required combustion heat rating 60 kW Combustion chamber pressure 1 0 mbar Results in Diffuser setting 0 mm Air damper setting 50 1 0 0 5 0 0 5 1 0 1 5 2 0 2 5 20 30 40 50 60 70 80 90 100 110 0 2 4 6 8 10 10 20 30 40 50 60 70 80 Combustio...

Page 17: ...r calorific value Hi and the Wobbe index Wi relate to 0 C and 1013 25 mbar Burner Setting pressure Connection pressure min rating after pressure flow pressure in mbar into shut off valve kW regulator mbar Valve train NB W MF 507 3 4 Natural Gas E Hi 37 26 MJ m3 10 35 kWh m3 d 0 606 Wi 47 84 MJ m3 40 6 2 10 0 50 6 4 10 0 60 6 4 10 0 70 6 6 10 0 80 7 0 10 0 90 7 2 11 0 100 7 4 12 0 110 7 6 13 0 Natu...

Page 18: ...crew 1 12 Plug in connection plug 4 pole 18 DANGER Two stage operation 1 Remove 4 pole connection plug and replace with plug switch order No 130 103 1501 2 2 Open gas ball valve and switch on burner 3 Pre purge starts in full load position 4 Following pre purge the servomotor goes to ignition load 5 Flame formation following valve proving 6 Set setting pressure to table value 7 Drive to full load ...

Page 19: ...sation current If a flame is present an ionisation current flows Response sensitivity of the flame sensor __________ 1 µA Minimum recommended ionisation current ________ 5 µA Test unit Multimeter or micro ammeter Connection A meter connection plug is provided in the ionisation cable Measuring ionisation current Setting the gas pressure switch Factory pre setting 12 mbar The switch point must be ch...

Page 20: ...ifferential pressure value 5 Set 80 of the lowest differential pressure at the setting adjuster dial Example Lowest differential pressure ________________ 3 2 mbar Switch point air pressure switch ___ 3 2 x 0 8 2 6 mbar Note Installation dependant influences on the air pressure switch such as flue gas system heat exchanger installation or air supply the settings may result in adjustments having to...

Page 21: ... TN 24 secs Servomotor run time in operation full setting movement 0 90 approx 3 secs Valve proving Following a power cut the low gas pressure programme or a burner lockout valve proving is activated at the beginning of the next burner start Sequence of operation diagram Boiler control Burner motor Air pressure switch Ignition unit Gas pressure switch Flame signal 1st valve 2nd valve 3rd valve Rat...

Page 22: ...ontroller F4 Temperature pressure controller full load F7 Internal fuse 6 3A F10 Air pressure switch F11 Low gas pressure switch H1 Fault lamp remote H2 Operation lamp remote M1 Burner motor P1 Hours counter optional S1 Main switch S2 Remote reset optional T1 Ignition unit X3 Plug console X4 Printed circuit boards direct plug servomotor X5 Printed circuit boards direct plug Bus S2 X6 X7 Burner con...

Page 23: ...ager ATTENTION Burner operation switch off 1 sec Data transfer ON 5 secs Data transfer OFF 5 secs green orange flickering red flickering red green green orange green Burner lockout reset 1 sec Burner lockout diagnostic code ON 5 secs Burner lockout diagnostic code OFF 1 sec Lockout diagnostic code data transfer ON Lockout diagnostic code data transfer OFF 1 sec red green red orange flashing red fl...

Page 24: ...NTION Combustion manager W FM10 Signal lamp codes Red Lockout Diagnostic codes for probable causes press reset button approx 5 seconds 2 x flashes no flame at end of safety time 3 x flashes air pressure switch fault 4 x flashes flame simulation 6 x flashes servomotor fault 7 x flashes flame failure during operation partial load 9 x flashes flame failure during operation full load 10 x flashes no s...

Page 25: ...min gas supplier To interrupt the low gas program Press reset button Gas pressure switch does not switch Replace gas pressure switch Burner operation is interrupted Gas pressure drop i e Replace filter signal lamp flashes red due to soiled gas filter automatic restart after 10 min Ignition No ignition audible Ignition electrode gap too large Adjust ignition electrode see Ch 7 5 Lockout Ignition el...

Page 26: ...xplosion due to a gas leak Take care when dismantling and assembling parts in the gas line to ensure they are correctly aligned clean and in good condition and that the fixing screws are correctly tightened Danger of getting burnt Some burner parts e g flame tube burner flange electrodes etc become hot during burner operation and should be allowed to cool prior to service work being carried out DA...

Page 27: ... Torx screw Gas gasket 7 4 Mixing head setting The distance between the diffuser disc and the edge of the flame tube dimension S1 cannot be measured whilst it is mounted To check remove the mixing head and measure dimension L 1 Remove the mixing head see Ch 7 3 2 Turn the setting screw until it is level with the mixing chamber housing scale setting 0 or dimension X 0 3 Loosen screws 4 After settin...

Page 28: ...over permits Cleaning of the air channel and fan wheel Access to the air damper The removal and refitting of the fan and motor Note If the burner has been mounted rotated through 180 it is not possible to put the fan housing cover in the servicing position Procedure 1 Disconnect electrical supply 2 Remove mixing head note Ch 7 3 3 Remove cover screws whilst supporting fan housing 4 Place fan housi...

Page 29: ...nd drive shaft Air damper opens due to spring tension 5 Remove screws to remove frame 6 Remove screws and remove angle drive Refitting Damage to the servomotor Do not turn the shaft of the servomotor either by hand or with a tool 1 Mount angle drive The air damper must be fully open 90 see Chap 7 11 2 Refit frame and tighten screws 3 Refit crank arm to servomotor 4 Set indicator of the angle drive...

Page 30: ... can lead to an explosive mixture of gas and air If ignition source is present this can lead to an explosion Removing 1 Close gas ball valve 2 Isolate burner from electrical supply 3 Remove outlet flange from the multifunction assembly W MF see Ch 4 5 4 Remove double nipple 5 Remove mixing head see Ch 7 3 6 Remove crank arm 7 Remove screws 8 Remove gas butterfly valve Refitting When refitting the ...

Page 31: ...ing carry out function test Solenoid replacement on W MF 7 12 Removal and refitting gas filter on W MF Removal 1 Close gas ball valve 2 Remove screws 3 Remove cover 4 Remove filter insert 5 Check gasket in cover replace if necessary Refitting 1 Carefully fit new filter insert 2 Fit gasket ensuring correct location 3 Replace cover 4 Fit screws and tighten 5 Carry out soundness test see Ch 4 6 6 Ven...

Page 32: ...32 7 13 Replacing internal fuse W FM10 T6 3H250V ...

Page 33: ...A External fusing ___________________________ 16 A slow Internal fusing ____________________________ 6 3A slow 8 3 Permissible fuels Natural gas E Natural gas LL Liquid petroleum gas B P The capacity graph is in accordance with EN 676 There is a rating reduction dependent on the altitude of the installation approx 1 per 100 m above sea level 8 Technical data 8 1 Burner equipment 8 2 Capacity graph...

Page 34: ...mensions Dims in mm I1 I2 I3 I4 b1 b2 b3 h1 h2 h3 h4 h5 d1 d2 d3 d4 Rp α 349 140 31 5 115 330 164 165 353 93 5 25 270 165 108 M8 110 150 170 3 4 45 weishaupt h4 h2 Rp d1 h1 b1 l1 l2 l3 b2 h5 b3 d4 d3 d2 α h3 l4 ...

Page 35: ...d e f g 8 7 Valve train 8 8 Weight Burner ____________________________ approx 13 5 kg Valve train ____________________________ approx 6 kg Connection Components R a b c d e f g 3 4 W MF507 3 4 x 80 3 4 3 4 x 50 3 4 W MF507 3 4 3 4 Gas valve train approx dims in mm Type W MF507 3 4 70 350 338 325 313 without thermal shut off device ...

Page 36: ...09 0 8955 0 9011 0 9067 0 9122 0 9178 0 9233 0 9289 0 9344 0 9400 0 9456 0 9511 0 9567 0 9594 20 0 8738 0 8793 0 8848 0 8894 0 8949 0 9005 0 9060 0 9115 0 9170 0 9225 0 9281 0 9336 0 9391 0 9446 0 9501 0 9529 22 0 8679 0 8734 0 8788 0 8834 0 8889 0 8944 0 8998 0 9053 0 9108 0 9163 0 9218 0 9273 0 9327 0 9382 0 9437 0 9464 24 0 8620 0 8675 0 8729 0 8775 0 8829 0 8883 0 8938 0 8992 0 9047 0 9101 0 9...

Page 37: ...mneys Determination of flue gas losses The oxygen content of the undiluted flue gas and the difference between the flue gas temperature and the combustion air inlet temperature must be determined The oxygen content and the flue gas temperature must be measured at the same time at one point Instead of oxygen content the carbon dioxide content of the flue gas can also be measured The combustion air ...

Page 38: ...38 Notes ...

Page 39: ...39 Notes ...

Page 40: ...al fuel burners types WK up to 17 500 kW WK types are decidedly industrial burners Advantages Built to the modular system load dependent variable combustion head sliding two stage or modulating operation easy to service Product and service are the complete Weishaupt achievement An extensive service organisation guarantees Weishaupt customers the greatest possible reliability In addition our custom...

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