Weishaupt WG10 Series Manual Download

Page: 2 / 112

Installation and operating instruction
Gas burner WG10…/0-D ZM-LN

83300902 1/2019-02 La

2-112

User instructions .............................................................................................................. 5

1.1   Target group ..................................................................................................................  5
1.2   Symbols ..........................................................................................................................  5
1.3   Guarantee and Liability ...............................................................................................  6

Safety ..................................................................................................................................... 7

2.1   Designated application ...............................................................................................  7
2.2   When gas can be smelled  .........................................................................................  7
2.3   Safety measures ...........................................................................................................  7

2.3.1   Normal operation ...................................................................................................  7
2.3.2   Electrical connection  ............................................................................................  8
2.3.3   Gas supply ..............................................................................................................  8

2.4   Alterations to the construction of the equipment  .................................................  8
2.5   Noise emission  .............................................................................................................  8
2.6   Disposal  .........................................................................................................................  8

Product description ........................................................................................................ 9

3.1   Type key  .........................................................................................................................  9
3.2   Serial number .............................................................................................................. 10
3.3   Function ........................................................................................................................ 11

3.4 Technical data ............................................................................................................. 17

Installation ........................................................................................................................ 22

4.1 Installation conditions ................................................................................................ 22
4.2 Burner installation ...................................................................................................... 23

4.2.1 Rotate burner by 180° (optional) .................................................................... 24

Installation ........................................................................................................................ 25

5.1 Gas supply .................................................................................................................. 25

5.1.1 Installing the gas valve train ............................................................................. 26
5.1.2 Carry out soundness test of gas supply line and vent ............................... 28

5.2 Electrical connection ................................................................................................. 29

Operation .......................................................................................................................... 30

6.1 Operating panel .......................................................................................................... 30
6.2 Display .......................................................................................................................... 32

6.2.1 Info level ............................................................................................................... 33

Summary of Contents for WG10 Series

Page 1: ...Installation and operating instruction Gas burner WG10 0 D ZM LN 83300902 1 2019 02 ...

Page 2: ...umber 10 3 3 Function 11 3 3 1 Air supply 11 3 3 2 Gas supply 12 3 3 3 Electrical components 13 3 3 4 Program sequence 14 3 3 5 Inputs and outputs 16 3 4 Technical data 17 3 4 1 Approval data 17 3 4 2 Electrical data 17 3 4 3 Ambient conditions 17 3 4 4 Fuels 17 3 4 5 Emissions 18 3 4 6 Rating 19 3 4 7 Dimensions 20 3 4 8 Weight 21 4 Installation 22 4 1 Installation conditions 22 4 2 Burner instal...

Page 3: ...n 60 7 6 Calculate gas throughput 61 7 7 Subsequent optimisation of operating points 62 8 Shutdown 63 9 Servicing 64 9 1 Notes on servicing 64 9 2 Service plan 66 9 3 Removing and refitting mixing head 67 9 4 Set mixing head 68 9 5 Set ionisation and ignition electrodes 69 9 6 Service position 70 9 7 Removing and refitting fan wheel 71 9 8 Remove burner motor 71 9 9 Removing and refitting air damp...

Page 4: ...ZM LN 83300902 1 2019 02 La 4 112 10 2 Rectifying faults 85 10 3 Operating problems 89 11 Technical documentation 90 11 1 Program sequence 90 11 2 Conversion table unit of pressure 92 11 3 Appliance categories 92 12 Spares 96 13 Notes 106 14 Key word index 108 ...

Page 5: ...be carried out by personnel who have the relevant train ing and instruction Persons with limited physical sensory or mental capabilities may only work on the unit if they are supervised or have been trained by an authorised person Children must not play with the unit 1 2 Symbols DANGER Immediate danger with high risk Non observance can lead to serious injury or death WARNING Danger with medium ris...

Page 6: ... 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 unit the installation of additional components which have not been tested with the unit the installa...

Page 7: ...nd safety of the user or third parties cause damage to the unit or other material assets 2 2 When gas can be smelled Avoid open flames and spark generation for example do not operate light switches do not operate electronic equipment do not use mobile telephones Open doors and windows Close gas isolating valve Warn the inhabitants do not ring door bells Leave the building Inform the heating contra...

Page 8: ... liquids to form e g condensate Observe vaporisation pressure and vaporisation temperature of li quid petroleum gas Use only tested and approved sealing materials whilst observing all process in formation Re commission the appliance when changing to a different type of gas Chan ging from LPG to Natural Gas and visa versa requires a conversion Carry out soundness test after each service and fault r...

Page 9: ... 0 D ZM LN 3 Product description 83300902 1 2019 02 La 9 112 3 Product description 3 1 Type key WG10N 0 D ZM LN W Type W burner G Fuel Gas 10 Size N N Natural Gas F Liquid Petroleum Gas 0 Ratings size D Construction ZM Version modulating LN Version LowNOX ...

Page 10: ...on Gas burner WG10 0 D ZM LN 3 Product description 83300902 1 2019 02 La 10 112 3 2 Serial number The serial number on the name plate identifies the product This is required by Weishaupt s customer service department 1 1 Name plate Ser No ...

Page 11: ...ctuator automatically closes the air damper At burner shutdown the air dampers close automatically Fan wheel The fan wheel supplies the air from the air intake housing to the combustion head Diffuser The air gap between flame tube and diffuser is adjusted by positioning the diffuser This adjusts the mixing pressure and the air quantity required for combustion Air pressure switch The air pressure s...

Page 12: ...the combustion manager initiates a safety shutdown The gas pressure switch also monitors if the gas valves are tight It signals the combustion manager if the pressure increases or decreases to an impermissible level during valve proving Valve proving is carried out automatically by the combustion manager after every controlled shutdown prior to burner start following lockout or power outage 1 Test...

Page 13: ... the value set the combustion manager initiates a controlled shutdown P P 7 8 9 6 3 1 2 5 4 V1 V2 3 3 3 Electrical components Combustion Manager The combustion manager W FM is the control unit of the burner It controls the sequence of operation and monitors the flame Operating panel The values and parameters of the combustion manager can be displayed and changed at the operating panel Burner motor...

Page 14: ...n operating point P0 6 Gas valve 1 opens The gas pressure switch reacts Ignition starts 7 Gas valve 2 opens The fuel is released The safety time begins The display shows symbol 8 Flame stabilisation 9 The actuators for the air damper and gas butterfly valve drive to partial load 10 The burner is in operation Load control is activated 11 If heat demand is no longer available the actuators for air d...

Page 15: ...16 Temperature or pressure regulator full load 4 Full load B31 Low gas pressure switch valve proving gas pressure switch 5 Operating phase B33 High gas pressure switch optional TI Initialisation time Test 3 s F2 Temperature or pressure limiter TN Post purge time 2 s ch 6 2 3 K32 Double gas valve TP1 1 Test phase 8 s valve proving valve 1 K33 External valve LPG TP2 2 Test phase 16 s valve proving v...

Page 16: ...tterfly valve actuator 1 Slot for analogue module EM3 3 or fieldbus module EM3 2 2 W FM cover 1 External valve LPG 3C Burner motor for continuous running fan 3N Burner motor 4 Ignition unit 5 Multifunction assembly 6 not used 7 Bridging plug No 7 8 Gas meter impulse generator 11 Air pressure switch air pressure switch for ducted air intake LDW2 12 Low gas pressure switch valve proving gas pressure...

Page 17: ...conformity certifica tion 3 4 2 Electrical data Mains voltage mains frequency 230 V 50 Hz Consumption at start max 220 W Consumption during operation max 120 W Power consumption max 1 0 A Internal unit fuse T6 3H IEC 127 2 5 External fuse max 16 AB 3 4 3 Ambient conditions Temperature in operation 15 40 C Temperature during transport storage 20 70 C relative humidity max 80 no dew point 3 4 4 Fuel...

Page 18: ...tem combustion air temperature and humidity medium temperature Sound levels Dual number noise emission values Measured sound power level LWA re 1 pW Uncertainty value KWA 65 4 dB A 1 dB A Measured sound pressure level LpA re 20 μPa Uncertainty value KpA 61 4 dB A 2 dB A 1 Determined to ISO 9614 2 2 Determined at 1 metre distance from the front of the burner The measured noise levels plus uncertain...

Page 19: ...ad WG10 0 D Capacity graph Capacity graph to EN 676 The capacity data given relates to an installation elevation of 0 m above sea level For installation elevations above 0 m a capacity reduction of approx 1 per 100 m applies A limited capacity graph is valid for ducted air intake 0 8 0 4 0 6 0 2 0 0 2 0 4 0 6 0 8 1 0 1 2 0 5 10 15 20 25 30 35 40 45 50 55 60 1 Combustion heat rating kW 2 Combustion...

Page 20: ...19 02 La 20 112 3 4 7 Dimensions Burner weishaupt 353 mm 330 mm 164 mm 349 mm 90 mm 165 mm 245 mm 115 mm 31 5 mm 270 mm Rp 1 1 140 mm without combustion head extension 240 mm with combustion head extension 100 mm 340 mm with combustion head extension 200 mm 440 mm with combustion head extension 300 mm ...

Page 21: ...902 1 2019 02 La 21 112 Gas valve train 60 mm 60 mm 1 2 4 3 Isolating valve With thermal shut off device Without thermal shut off device 1 Rp approx 310 mm approx 300 mm 2 Rp approx 290 mm approx 280 mm 3 Rp approx 410 mm approx 400 mm 4 Rp approx 390 mm approx 380 mm 3 4 8 Weight approx 14 kg ...

Page 22: ... beyond the front edge of the combustion head The refractory can take a conical shape min 60 Refractory may not be required on boilers with water cooled front unless the man ufacturer gives other instructions Following installation the aperture 4 between flame tube and refractory should be filled with flame proof resilient insulating material Do not make solid Heat exchangers with deep refractorie...

Page 23: ...ng The burner in its standard version is designed for valve train connection from the right For gas valve train connection from the left the burner has to be installed ro tated by 180 ch 4 2 1 To do this additional conversion measures are required ch 5 1 1 Fit flange gasket 2 and burner flange 1 to the heat exchanger using screws 3 The aperture between combustion head and refractory should be fill...

Page 24: ...side of the housing Mount fixing bracket 3 on the opposite side of the housing Rotate burner flange 2 180 and mount with flange gasket Rotate burner 180 and fit screws 4 to burner flange The aperture between combustion head and refractory should be filled with flame proof resilient insulating material do not make solid Check setting of electrodes ch 9 5 Fit mixing head ch 9 3 3 4 1 2 ...

Page 25: ...nts of the gas valve train Close all fuel shut off devices prior to commencing work and protect from acci dental re opening General installation instructions Install manually operated shut off device gas isolating valve in the supply Ensure correct mounting alignment and cleanliness of sealing surfaces Mount valve train free of vibration It must not be allowed to swing Suitable sup ports should be...

Page 26: ...llation er rors by over tightening the flange screws Ensure correct alignment of flange seals Tighten screws evenly diagonally across No additional sealant is required if the thread is coated in blue A A B B A Connection pressure 50 mbar B Connection pressure 50 300 mbar Installing the gas valve train from the left To fit the gas valve train to the burner from the left the burner has to be install...

Page 27: ...Installation and operating instruction Gas burner WG10 0 D ZM LN 5 Installation 83300902 1 2019 02 La 27 112 Accessories 1 1 High gas pressure switch B33 ...

Page 28: ...s burner WG10 0 D ZM LN 5 Installation 83300902 1 2019 02 La 28 112 5 1 2 Carry out soundness test of gas supply line and vent Only the gas supply company or a contract installation company may carry out a soundness test and vent the gas line ...

Page 29: ... against accidental restart The electrical connection must only be carried out by qualified electricians Ob serve local regulations Observe wiring diagram supplied Plug in plug for gas pressure switch 2 and double gas valve 3 and secure with screws Check polarity and wiring of 7 pole connection plug 1 Plug in connection plug 1 Check polarity and wiring of 4 pole connection plug 4 Plug in connectio...

Page 30: ...y possible with display OFF Various actions are only triggered when the key is released for example changing the display reset OFF function Press ENTER L A and G keys simultaneously Immediate lockout with error 18h Operating level The current actuator position can be displayed in the operating level 10 Displaying gas butterfly valve setting Press key G Displaying air damper setting Press key L A F...

Page 31: ...uring troubleshooting ch 11 1 Press and hold and simultaneously for approx 3 seconds The combustion manager changes to operating display The display shows cur rent operating status with a number Back to standard display Press and hold and simultaneously for approx 3 seconds VisionBox Software If the VisionBox Software is connected change over to the access level must be confirmed via the operating...

Page 32: ...tuator runs OPEN 6 Burner in operation 7 Lockout 8 Service level activated Combustion manager performs self test ch 3 3 4 Standby no heat demand Shutdown via contact X3 7 plug No 7 Unprogrammed condition or programming not completed Standby no heat demand shutdown via fieldbus module Insufficient gas low gas pressure switch Current operating phase ch 3 3 4 Under voltage in standby or internal devi...

Page 33: ...s consumption in m3 via X3 8 Reset value Press L A and simultaneously for approx 2 seconds 1 Hours run 2 no function 3 Burner starts 4 Device item number 5 Index of device item number 6 Device number 7 Production date DDMMYY 8 Fieldbus address 9 Valve proving behaviour 11 Not used 12 Current gas consumption 0 1 m3 h 13 Analogue module EM3 3 or Fieldbus module EM3 2 available 0 no 1 yes After infor...

Page 34: ...2 3 Actuator position in operating point P3 4 Actuator position in operating point P4 5 Actuator position in operating point P5 6 Actuator position in operating point P6 7 Actuator position in operating point P7 8 Actuator position in operating point P8 9 Actuator position in operating point P9 10 18 Fault memory most recent fault ninth last occurred fault Display additional information 1 Detailed...

Page 35: ...lation and operating manual of module Fieldbus module response to heat demand 2 Bus default and control circuit T1 T2 activated Analogue module 2 DIP switches activated 2 4 Post purge time 0 4095 s 2 5 Fault memory 0 fault memory is empty 1 fault memory contains data Delete fault memory Press L A and simultaneously for approx 2 seconds 6 Factor for gas consumption Impulse rate of meter per m3 1 65...

Page 36: ...r post purge 0 0 90 0 Change air damper setting Press L A and or 0 L Load shutdown 0 0 4095 seconds If there is no longer a demand for heat the W FM reduces the burner capacity and closes the fuel valves after the time set has elapsed If partial load is reached before the time has elapsed the fuel valves close immediately 0 n Operating mode O2 trim only in conjunction with O2 trim 0 not activated ...

Page 37: ...ated Press key Parameter E0 is displayed Press and hold Enter key and set the parameter using or Press to reach the next parameter Parameters Information Setting range E0 Burner type 0 single fuel burner 1 dual fue burner E1 Operating mode display only no adjust ment possible 0 intermittent operation 1 continuous operation E2 Flame sensor type 0 ionisation electrode flame sensor FLW 1 switch input...

Page 38: ...a straight line is generated from the operating point displayed to P9 The values on the straight are adopted as the new operating points Initiate a calculation after P9 Press ENTER Combustion manager changes to linearisation mode The linearisation mode can be interrupted using the key Confirm with key Linearisation is initiated Example P1 P2 P3 P4 P5 P6 P7 P8 P9 P1 P2 P3 P4 P5 P6 P7 P8 P9 1 2 1 Ca...

Page 39: ...is filled the heat exchanger is filled with medium the regulating control and safety devices are functioning and set correctly the flue gas ducts are unimpeded a measuring point conforming to standards is available to measure the flue gas the heat exchanger and flue gas ducting up to the test point are sound ex traneous air influences the test results the operating instructions of the heat exchang...

Page 40: ...nisation current Remove ionisation cable from the plug coupling Connect current measuring device in series Ionisation current Extraneous light detection from 1 μA Minimum ionisation current 5 μA Recommended ionisation current 9 15 μA Pressure measuring device for mixing pressure Open pressure test point for mixing pressure 1 and connect pressure measur ing device 1 ...

Page 41: ...ator must be installed upstream Check connection pressure DANGER Risk of explosion due to excess gas supply pressure Exceeding the maximum connection pressure see name plate can damage the gas valve train and lead to an explosion Max connection pressure see name plate Check gas connection pressure Connect pressure measuring device to test point 1 Slowly open isolating valve whilst observing the pr...

Page 42: ...phase the valve train section from the gas isolating valve up to the first valve of the multifunction assembly is tested Switch off burner Close gas isolating valve Connect test equipment Open test point between valve 1 and valve 2 Carry out test to table Second test phase In the second phase the interspace in the multifunction assembly is tested Connect test equipment Carry out test to table Thir...

Page 43: ...uction Gas burner WG10 0 D ZM LN 7 Commissioning 83300902 1 2019 02 La 43 112 A B 2 2 1 1 4 3 A Connection pressure up to 50 mbar B Connection pressure 50 mbar 1 First test phase 2 Second test phase 3 Third test phase 4 Blanking plate ...

Page 44: ...ommissioning A leak detecting spray or electronic gas detector should be used for testing 1 Use only leak detecting foam solutions which do not cause corrosion see DVGW TRGI worksheet G 600 Check all components intersections and test points of the gas valve train between multifunction assembly and burner Document result of the soundness test on the engineers report Test points 1 2 3 1 Pressure int...

Page 45: ...int into valve 1 ch 7 1 3 Connect an approved vent hose to the test point Vent hose must lead to atmosphere Slowly open gas isolating valve The gas air mixture in the valve train vents via the hose to safe atmosphere Close gas isolating valve Remove vent hose and immediately close test point Use a test burner to ensure no air is present in the valve train ...

Page 46: ...lues are there fore guide values for basic settings Full load kW Setting pressure into gas butterfly valve mbar Min connection pressure into isolating valve mbar low pressure supply Nominal diameter valve train Valve train construction only W MF 055 50 mbar W MF 055 with FRS pressure reg ulator 50 300 mbar Natural Gas E Hi 10 35 kWh m3 d 0 606 25 7 9 12 14 30 7 2 11 14 35 5 9 11 13 40 6 9 12 15 45...

Page 47: ...d at multifunction assembly One rotation corresponds to approx 1 mbar 1 7 1 6 Set FRS pressure regulator optional Only required for a connection pressure 50 300 mbar If the spring used in the pressure regulator is orange 5 20 mbar Turn setting screws clockwise to its stop The setting pressure is reduced to 20 mbar Do not change this setting on the pressure regulator ...

Page 48: ...dimension X and air damper setting required from the diagram and note down Example Example 1 Example 2 Burner capacity required 27 5 kW 42 5 kW Combustion chamber pressure 0 25 mbar 0 75 mbar Diffuser setting dimension X 0 mm 5 7 mm Air damper setting 27 80 6 5 2 1 10 15 20 25 30 35 40 45 50 55 0 6 1 0 0 8 0 4 0 2 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 8 6 4 2 50 20 30 0 10 3 80 4 1 Combustion heat rating ...

Page 49: ...w 1 until dimension X equals the value determined 1 X 7 1 8 Preset gas and air pressure switch The presetting of the pressure switches is only valid during commissioning Once commissioning has been completed the pressure switches must be set correctly ch 7 3 Air pressure switch approx 2 mbar Low gas pressure switch valve proving gas pressure switch 12 mbar High gas pressure switch optional approx ...

Page 50: ...g bridging plug No 7 on combustion manager Switch on voltage supply Combustion manager drives to Standby Press G and L A keys simultaneously Combustion manager changes to access level Press key Combustion manager changes into the setting level for step points Press key Factory setting operating point P9 full load is displayed Press and hold L A key and set air damper setting determined using the o...

Page 51: ...Combustion manager is preset 2 Check sequence of operation Open gas isolating valve Pressure in gas valve train increases Close isolating valve Plug in bridging plug No 7 on combustion manager Burner starts Valve proving is carried out Check sequence of operation Valves open Gas pressure switch reacts Burner start is interrupted Burner does not detect a flame and goes to lockout Reset burner using...

Page 52: ...es to setting level Open test point for setting pressure and connect pressure measuring device Open gas isolating valve Briefly press and keys simultaneously The display shows E ACCESS Press key Burner starts according to the sequence of operation and stops at operating point P0 ignition position Preset setting pressure determined at multifunction assembly ch 7 1 5 Check CO content of combustion a...

Page 53: ...n reached 5 Adjust full load When adjusting the ratings data given by the boiler manufacturer and the capacity graph of the burner should be observed ch 3 4 6 Calculate gas throughput operating volume VB required ch 7 6 Optimise setting pressure and or gas butterfly valve setting G until gas throughput VB has been reached Check combustion values Determine combustion limit and set excess air via ai...

Page 54: ...ating point P1 must lie within the capacity graph ch 3 4 6 Determine gas throughput and if necessary adjust via gas butterfly valve setting G Check combustion values Determine combustion limit and set excess air of approx 20 25 via air damper setting L A 7 Adjust ignition load Press key Burner drives to operating point P0 ignition position Check combustion values in operating point P0 ignition pos...

Page 55: ...ion mode Confirm with key Linearisation is initiated The display then shows operating point P1 Calculation from P1 to P9 was carried out 9 Optimising the operating points Check combustion values Press and hold G and optimise combustion values using or key Press key Next operating point is initiated Repeat steps at each operating point until P9 has been reached Press G and L A keys simultaneously T...

Page 56: ...serving data supplied by boiler manufacturer burner capacity graph ch 3 4 6 Determine gas throughput if necessary adjust partial load bu using key Press G and L A keys simultaneously Combustion manager changes to operating level 10 Combustion manager is programmed 11 Check start behaviour Switch off and restart burner Check start behaviour and if necessary correct operating point P0 ignition pos i...

Page 57: ...hes 12 mbar or the gas flow pressure drops to 50 Determine gas pressure Slowly open gas isolating valve Set the pressure determined as switch point at the setting cam 2 minimum value 12 mbar Check switch point Restart the burner Slowly close gas isolating valve If the low gas program starts the gas pressure switch has been set correctly If a lockout occurs or if the combustion reaches a critical c...

Page 58: ...across the whole capacity range of the burner and determine the lowest differential pressure Calculate switch point 80 of release pressure or lowest differential pressure Undo screw 2 Set the switch point determined at the setting cam 1 Tighten screw 2 Example Lowest differential pressure 2 0 mbar Switch point air pressure switch 80 2 0 mbar 0 8 1 6 mbar Site specific influences on the air pressur...

Page 59: ... sheet Enter setting values on the sticker 1 supplied Adhere sticker to the burner Mount cover on burner Inform the operator about the use of the equipment Hand the installation and operating manual to the operator and inform him that this should be kept with the appliance Point out to operator that the installation should be serviced annually Brennereinstellung Datum Stauscheiben einstellung mm G...

Page 60: ...mperature Check flue gas temperature Ensure that the flue gas temperature complies with the data provided by the boiler manufacturer If necessary adjust flue gas temperature e g Increase burner capacity in partial load to avoid condensation in the flue gas ducts except on condensing units Reduce burner capacity in full load to improve efficiency Adjust heat exchanger to the data provided by the ma...

Page 61: ...asuring time seconds 120 seconds Calculate normal volume Calculate the normal volume VN using the following formula VN QN η Hi VN 50 kW 0 92 10 35 kW m 5 25 m h Calculate conversion factor Determine gas temperature tGas and pressure PGas at gas meter Determine barometric air pressure PBaro from table Height above sea level m 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 PBaro mbar 1013...

Page 62: ...eously Combustion manager changes to access level Press Combustion manager changes to setting level Plug in bridging plug No 7 on combustion manager Burner starts and stops in operating point P0 ignition position Initiate the other operating points using the or key and optimise if required Exit setting level Press G and L A simultaneously The upper operating limit bo is displayed Press G and L A s...

Page 63: ...Installation and operating instruction Gas burner WG10 0 D ZM LN 8 Shutdown 83300902 1 2019 02 La 63 112 8 Shutdown For breaks in operation Switch off burner Close fuel shut off devices ...

Page 64: ...g work Electric voltage has dissipated WARNING Danger of getting burned on hot components Hot components can lead to burns Allow components to cool Servicing must only be carried out by qualified personnel The combustion plant should be serviced annually Depending on site conditions more frequent checks may be required Components which show increased wear and tear or whose design lifespan is or wi...

Page 65: ...ice during the ignition process Check tightness of gas carrying components Check function of ignition flame monitoring gas carrying components gas connection pressure and setting pressure pressure switch control and safety devices Check combustion values if necessary re adjust the burner Enter combustion values and settings in the commissioning record Enter setting values on the sticker supplied A...

Page 66: ...place Ionisation electrode Soiling Clean Damage wear Replace Recommendation at least every 2 years Flame tube diffuser Soiling Clean Damage Replace Multifunction assembly with valve testing system valve proving Fault identified Replace Multifunction assembly without valve testing system valve proving Function soundness 200 000 burner starts or 10 years 2 Replace Gas pressure regulator Setting pres...

Page 67: ...as to leak out if the gasket 3 is seated incorrectly Following work on the mixing head ensure the gasket is clean and seated cor rectly if necessary replace Check for leaks see Fourth test phase ch 7 1 3 Removing Unplug ionisation cable 5 Unplug ignition cable 1 Undo screws 4 Turn mixing head 2 to the left up to the recess and remove Refitting Refit mixing head in reverse order ensuring correct al...

Page 68: ... mixing head re moved with dimension Lx Dimension Lx changes according to the combustion head extension used Remove mixing head ch 9 3 Turn setting screw 1 until it is flush with the nozzle assembly cover dimension X 0 mm Check dimension Lx If the value measured deviates from dimension Lx Undo screws 2 Adjust flame tube 3 until dimension Lx has been reached Re tighten screws 2 If the screws 2 have...

Page 69: ...83300902 1 2019 02 La 69 112 9 5 Set ionisation and ignition electrodes Observe notes on servicing ch 9 1 Remove mixing head ch 9 3 Undo screw 1 Set ignition electrode and re tighten screw Undo screw 2 Set ionisation electrode and re tighten screw 5 mm 5 mm 1 5 2 mm 1 5 2 mm 1 2 ...

Page 70: ...19 02 La 70 112 9 6 Service position Observe notes on servicing ch 9 1 The burner mounted rotated by 180 cannot be placed into the service position Remove mixing head ch 9 3 Remove cover 2 and remove plugs Hold housing cover and remove screws 1 Place housing cover onto hanging bolts 3 1 2 3 ...

Page 71: ...emove reducing ring 3 Remove grub screw 1 and remove fan wheel Refitting Refit fan wheel in reverse order and ensure correct alignment on the motor shaft 2 screw in new grub screw 1 turn fan wheel to ensure it moves freely 2 1 3 4 1 2 9 8 Remove burner motor Observe notes on servicing ch 9 1 Remove fan wheel ch 9 7 Unplug plug number 3 and 11 Disconnect and hoses Undo screws 1 and remove air press...

Page 72: ...ctuator caused by turning the hub Actuator could be damaged Do not turn hub manually or with tool Plug in actuator plug 4 at the combustion manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply The combustion manager checks the actuator and drives to the reference point Interrupt voltage supply Fit shaft 2 to actuator Set indicator 1 on angle drive to 0 air damper Closed...

Page 73: ...and refitting angle drive Observe notes on servicing ch 9 1 Removing Remove air damper actuator ch 9 9 Remove frame 1 Remove angle drive 2 Refitting Remove intake housing Open air damper 3 until position 4 has been reached and hold tight Fit angle drive to shaft Secure angle drive Mount intake housing Fit frame 1 1 2 4 3 ...

Page 74: ...emove actuator Refitting CAUTION Damage to the actuator caused by turning the hub Actuator could be damaged Do not turn hub manually or with tool Plug in actuator plug 1 at the combustion manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply The combustion manager checks the actuator and drives to the reference point Interrupt voltage supply Fit actuator rotated by appro...

Page 75: ...notes on servicing ch 9 1 Removing Remove screws 3 Unscrew flange with double nipple 4 Remove mixing head ch 9 3 Remove screws 1 and remove gas butterfly valve 2 Refitting Refit gas butterfly valve 2 in reverse order secure flange to multifunction as sembly whilst ensuring correct seating of the O ring 5 on the flange 2 4 1 3 5 Carry out soundness test ch 7 1 3 ...

Page 76: ...and refitting air regulator Observe notes on servicing ch 9 1 Removing Remove bolts 1 Remove burner from heat exchanger ch 4 2 Remove actuator plug 6 Remove bolts 2 Remove intake housing 5 Remove bolts 4 Remove air regulator 3 2 4 3 5 1 1 6 Refitting Refit air regulator in reverse order Carry out soundness test ch 7 1 3 ...

Page 77: ... 83300902 1 2019 02 La 77 112 9 14 Replacing coil on multifunction assembly Observe notes on servicing ch 9 1 Ensure correct voltage and solenoid number when replacing the solenoid coil Loosen cover 1 Remove circuit board 2 and if necessary replace Replace solenoid coil 3 1 3 2 ...

Page 78: ...lug all plugs Undo screws 1 Push combustion manager upwards and replace 1 Connect all plugs again Preset combustion manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply The unprogrammed condition of the combustion manager is indicated by a flash ing display The burner goes to lockout Press ENTER Burner has been reset Combustion manager drives to Standby ...

Page 79: ... single fuel burner if necessary adjust using ENTER and key Press E1 is displayed The value of parameter E1 can not be altered 0 intermittent operation Standard 1 continuous operation Press E2 is displayed Adopt value 0 ionisation electrode if necessary adjust using ENTER and key Press E3 is displayed Adopt value 1 fan control if necessary set using ENTER and or key Press Combustion manager change...

Page 80: ...mbar Einstellungen am Feuerungsmanager Voreinstellung Luftklappe bei Großlast P9 Punkt G L A n P0 P1 P2 P3 P4 P5 P6 P7 P8 P9 bo bu Unterschrift 1 Deactivate E Parameters Following commissioning set parameter E to 0 Press Enter and keys simultaneously for approx 2 seconds The parameter level is activated Press Press Enter key until parameter E is displayed Set parameter E to 0 E Parameters are not ...

Page 81: ...truction Gas burner WG10 0 D ZM LN 9 Servicing 83300902 1 2019 02 La 81 112 9 16 Replacing the fuse Observe notes on servicing ch 9 1 Unplug connection plug from combustion manager Replace fuse T6 3H IEC 127 2 5 1 1 Replacement fuse ...

Page 82: ...ng switch Temperature limiter or pressure limiter on heat exchanger has triggered 1 Reset temperature limiter or pressure limiter on heat exchanger Low water safety interlock on heat ex changer has triggered 1 Top up water Reset low water safety interlock on heat exchanger 1 Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly 10 1 2 Display OFF The followi...

Page 83: ...ed flashing Read error code e g A7h Rectify cause of fault ch 10 2 Resetting WARNING Damage resulting from incorrect fault repair Incorrect fault repair can cause damage to the equipment and injure personnel Do not carry out more than 2 lockout resets successively Faults must be rectified by qualified personnel Press ENTER Burner has been reset Fault memory The last 9 faults are saved in the fault...

Page 84: ...n the error in more detail can be dis played by pressing a button The first detailed fault code and the second detailed fault code are only relevant for the following faults 03h 18h 41h 65h First detailed fault code operating status Press key 1 2 1 First detailed fault code 2 Operating status Second detailed fault code Press and keys simultaneously Repetition counter Press key G ...

Page 85: ...h 3 4 3 Reset the burner if fault reoccurs replace the combustion manager ch 9 15 Internal unit fault Interrupt the voltage supply temporarily Reset the burner if fault reoccurs replace the combustion manager ch 9 15 04h More than 5 resets in the last 15 minutes Press and hold reset key for 5 seconds Display flashes Reset burner 0Ch Burner configuration incorrect Check burner configuration Check v...

Page 86: ...15 Second detailed fault code E1h E7h Calibration values in EEPROM incorrect Second detailed fault code EEh Communication to W FM 25 failed Second detailed fault code EFh Extension module to W FM 25 not compatible Check version 1dh EMC interference Optimise EMC measures 44h Operating points were changed without approval Re adjust burner Parameter E3 set incorrectly Check parameter E3 ch 6 2 4 47h ...

Page 87: ...or Check freedom of movement of air damper and or angle drive Replace actuator First detailed fault code 07h Time in setting mode run out Plugs of actuators for gas and air mixed up Press key within 30 minutes in setting mode Change over plugs A2h Safety circuit is open Check safety circuit A4h Reverse voltage valve 1 Check wiring to double solenoid valve A5h Reverse voltage valve 2 Check wiring t...

Page 88: ...ame simulation extraneous light at start up Find and eliminate extraneous light source Check ionisation electrode bbh Burner shutdown via contact X3 7 plug No 7 CAh Valve proving faulty Check low gas pressure switch valve proving gas pressure switch Check double gas valve Cdh No signal on input X3 15 Check wiring CEh Bridging plug No 15 is missing Plug in bridging plug High gas pressure switch doe...

Page 89: ...n ignition position Ignition electrode set incorrectly Set ignition electrode ch 9 5 Mixing head set incorrectly Set mixing head ch 9 4 Combustion pulsating or burner booming Mixing head set incorrectly Set mixing head ch 9 4 Incorrect combustion air quantity Adjust burner Stability problems Mixing pressure too high Decrease mixing pressure No display at operating panel Plug from operating panel n...

Page 90: ...9 Internal sequence 10 Start burner motor 11 Waiting for air pressure 4 12 Pre purge 13 Internal sequence 5 14 Driving air damper actuator to ignition position 6 15 Gas pressure check on low valve proving gas pressure switch 16 Ignition 7 17 First safety time fuel release 18 First safety time flame detection 8 19 First stabilisation time 20 Stop setting mode P0 A 21 Second safety time 22 Second st...

Page 91: ...Operating status Condition function 16 33 Restart interlock G L 40 Reference search actuator air damper and gas butterfly valve G 41 Test gas butterfly valve actuator 105 G L 42 Drive to Standby position 43 Internal sequence OFFGd 44 Insufficient gas low gas pressure switch X3 14 16 45 Low gas programme OFF S 46 Safety circuit open X3 7 ...

Page 92: ...rmined and listed under point 5 1 2 table 5 are used to provide the evidence of service performance of the burner during type testing As weishaupt gas and dual fuel burners fulfil this requirement completely the ap pliance category as well as the test gases used with the permissible connection pressure range are listed on the name plate when labelling the burner to point 6 2 This clearly defines t...

Page 93: ... G 25 20 DK Denmark I2H G 20 20 EE Estonia I2H G 20 ES Spain I2H G 20 20 FI Finland I2H G 20 20 FR France I2Esi I2E I2L G 20 G 25 Pressures 20 25 GB United Kingdom I2H G 20 20 GR Greece I2H G 20 20 HR Croatia I2H G 20 20 HU Hungary I2H G 20 20 IE Ireland I2H G 20 20 IS Iceland I2H G 20 20 IT Italy I2H G 20 20 LT Lithuania LU Luxembourg I2E G 20 20 LV Latvia MD Moldova I2H G 20 20 MK Macedonia I2H ...

Page 94: ... 37 FI Finland I3B P G 30 G 31 30 28 30 FR France I3 I3P I3B G 30 Pressures 28 30 37 G 31 Pressures 112 148 GB United Kingdom I3 I3P I3B G 30 G 31 Pressures 28 30 37 GR Greece I3B P I3 I3P I3B G 30 G 31 Pressures 28 30 37 HR Croatia I3B P I3P G 30 G31 50 HU Hungary I3B P G 30 G31 50 IE Ireland I3 I3P I3B G 30 G 31 Pressures 28 30 37 IS Iceland I3B P IT Italy I3B P I3 I3P G 30 G 31 Pressures 28 30 ...

Page 95: ...2E 3P G 20 20 G 30 Pressures II2Esi3B P 28 30 37 G 31 Pressures 112 148 GB United Kingdom II2H3 II2H3P G 20 20 G 30 G 31 Pressures 28 30 37 GR Greece II2H3B P II2H3 G 20 20 G 30 G 31 Pressures II2H3P 28 30 37 HR Croatia II2H3B P G 20 20 G 30 G 31 30 28 30 HU Hungary II2H3B P G 20 20 G 30 G 31 IE Ireland II2H3 II2H3P G 20 20 IS Iceland II2H3B P G 20 20 G 30 G 31 30 28 30 IT Italy II1a2H II2H3B P G ...

Page 96: ...n and operating instruction Gas burner WG10 0 D ZM LN 12 Spares 83300902 1 2019 02 La 96 112 12 Spares 1 03 1 03 1 02 1 01 1 08 1 07 1 06 1 17 1 16 1 15 1 18 1 11 1 14 1 14 1 05 1 10 1 16 1 13 1 12 1 12 1 04 1 09 ...

Page 97: ...tective cap DN 6 SELF 50 2 CF 232 300 01 047 1 09 Grommet for connection cable 241 200 01 247 1 10 Grommet 241 400 01 177 1 11 Housing cover 232 110 01 027 1 12 Threaded socket R GES4 453 004 1 13 Bracket for cable 241 400 01 367 1 14 Screw M6 burner housing 241 110 01 297 1 15 Burner flange 241 110 01 057 Screw M8 x 30 DIN 912 402 517 Washer 8 4 DIN 433 430 504 1 16 Stay bolt for burner flange 24...

Page 98: ...ing instruction Gas burner WG10 0 D ZM LN 12 Spares 83300902 1 2019 02 La 98 112 2 17 2 27 2 09 2 22 2 12 2 13 2 14 2 15 2 08 2 18 2 10 2 02 2 01 2 06 2 06 2 23 2 07 2 11 2 25 2 04 2 05 2 03 2 19 2 28 2 21 2 20 2 16 2 24 2 26 ...

Page 99: ...09 261 2 12 Air damper complete 241 110 02 102 2 13 Bearing for air damper shaft 241 110 02 107 2 14 Shaft air damper angle drive 241 210 02 057 2 15 Angle drive 241 110 02 062 2 16 Screw 4 x 12 Torx Plus Remform 409 320 2 17 Shaft angle drive actuator 241 400 02 157 2 18 Air actuator STE 4 5 24 V 651 103 2 19 Screw 4 x 35 Combi Torx Plus Remform 409 355 2 20 Frame for actuator 241 210 02 037 2 21...

Page 100: ...ion and operating instruction Gas burner WG10 0 D ZM LN 12 Spares 83300902 1 2019 02 La 100 112 3 01 3 02 3 03 3 16 3 17 3 17 3 18 3 19 3 09 3 04 3 05 3 12 3 10 3 20 3 21 3 22 3 07 3 06 3 08 3 15 3 14 3 13 3 11 ...

Page 101: ...02 extended by 200 mm 230 110 14 322 extended by 300 mm 230 110 14 342 3 04 Nozzle element 232 100 14 297 3 05 Screw M4 x 16 Torx Plus 20IP 409 224 3 06 Diffuser 24 x 74 232 100 14 237 3 07 Nozzle insert 232 100 14 227 3 08 Screw M4 x 8 Torx Plus 20IP 409 235 3 09 Bracket for electrodes 232 100 14 257 3 10 Ignition electrode isolator 6 x 80 232 200 14 217 3 11 Sensor electrode 232 100 14 207 3 12 ...

Page 102: ...Installation and operating instruction Gas burner WG10 0 D ZM LN 12 Spares 83300902 1 2019 02 La 102 112 4 14 4 03 4 01 4 02 4 15 4 08 4 09 4 06 4 10 4 12 4 13 4 12 4 07 4 04 4 05 4 19 4 18 4 16 4 17 ...

Page 103: ... 546 4 06 Bridging plug No 7 241 400 12 042 4 07 Bridging plug No 15 232 110 12 082 4 08 Plug cable No 3 motor 241 050 12 062 4 09 Plug cable No 11 air pressure switch 132 101 12 052 4 10 Ionisation cable No 13 232 310 12 012 4 11 Plug cable No 14 remote reset 230 110 12 362 4 12 Plug cable No 12 gas pressure switch 232 050 12 022 4 13 Plug cable No 5 W FM DMV 232 400 12 012 4 14 Fixing bracket 24...

Page 104: ...nstallation and operating instruction Gas burner WG10 0 D ZM LN 12 Spares 83300902 1 2019 02 La 104 112 5 02 5 02 5 06 5 06 5 10 5 02 5 14 5 02 5 04 5 05 5 07 5 11 5 15 5 08 5 01 5 03 5 09 5 11 5 13 5 12 ...

Page 105: ...3 NBR70 ISO 3601 445 027 5 07 Multifunction assembly W MF055 S22 230V with gas pressure switch 605 284 5 08 Pressure switch GW 50 A5 1 5 50 mbar with screws and O ring 691 378 5 09 O ring 10 5 x 2 25 445 512 5 10 Flange Rp MF055 inlet with pressure test nipple 232 110 26 082 5 11 Pressure test nipple G A 453 005 5 12 Solenoid W MF055 220 240V 605 290 5 13 Circuit board W MF055 220 240V 605 292 5 1...

Page 106: ...Installation and operating instruction Gas burner WG10 0 D ZM LN 13 Notes 83300902 1 2019 02 La 106 112 13 Notes ...

Page 107: ...Installation and operating instruction Gas burner WG10 0 D ZM LN 13 Notes 83300902 1 2019 02 La 107 112 ...

Page 108: ...ction pressure 25 26 41 46 Consumption 17 Control unit 78 Conversion factor 61 Conversion table 92 Corrections 62 Current measuring device 40 D Design lifespan 7 64 Detailed fault codes 84 Device fuse 81 Diffuser 11 48 49 Dimensions 20 Display 30 32 Display and operating unit 30 Disposal 8 Double gas valve 12 25 Drilling diagram 22 Ducted air intake 7 19 E Electrical connection 29 Electrical data ...

Page 109: ... Multifunction assembly 12 N Name plate 10 Noise 89 Nominal diameter 46 O OFF function 30 Operating level 30 Operating panel 13 82 Operating problems 89 Operating status 31 84 90 Operating volume 61 Outputs 16 P Pa 92 Parameter level 35 Partial load 56 Pascal 92 Post purge time 15 35 Pre purge time 15 Pressure measuring device 40 Pressure regulator 12 13 25 Pressure switch 11 58 Pressure switches ...

Page 110: ...14 Key word index 83300902 1 2019 02 La 110 112 T Temperature 17 Test points 44 Test pressure 42 Transport 17 Troubleshooting 89 Type key 9 Type of gas 17 92 U Unit 92 Unit of pressure 92 V Valve proving 12 57 Valve train 26 VisionBox 31 Voltage supply 17 W Weight 21 ...

Page 111: ...83300902 1 2019 02 La ...

Page 112: ...Weishaupt GmbH 88475 Schwendi Weishaupt close by Addresses telephone numbers etc can be found at www weishaupt de We reserve the right to make changes All rights reserved Water heaters Energy storage The diverse program of potable water and energy storage for various heat sources includes storage volumes of 70 to 3 000 litres In order to minimize storage losses potable water cylinders from 140 to ...

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