Weishaupt WG20 1-C Z-LN Series Manual Download

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Installation and operating instruction
Gas burner WG40…/1-A ZM-LN

13 Spares

83300002 1/2019-02 La

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Summary of Contents for WG20 1-C Z-LN Series

Page 1: ...Installation and operating instruction Gas burner WG40 1 A ZM LN 83300002 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 14 3 3 4 Inputs and outputs 15 3 3 5 Program sequence 16 3 4 Technical data 18 3 4 1 Approval data 18 3 4 2 Electrical data 18 3 4 3 Ambient conditions 18 3 4 4 Fuels 18 3 4 5 Emissions 18 3 4 6 Rating 19 3 4 7 Dimensions 20 3 4 8 Weight 20 4 Installation 21 4 1 Installation conditions 21 4 2 Burner instal...

Page 3: ...eck combustion 66 7 6 Calculate gas throughput 67 7 7 Subsequent optimisation of operating points 68 8 Shutdown 69 9 Servicing 70 9 1 Notes on servicing 70 9 2 Service plan 72 9 3 Removing and refitting mixing head 73 9 4 Set mixing head 74 9 5 Set ionisation and ignition electrodes 75 9 6 Service position 76 9 7 Removing and refitting fan wheel 77 9 8 Remove burner motor 78 9 9 Removing and refit...

Page 4: ...1 10 1 4 Detailed fault codes 92 10 2 Rectifying faults 93 10 3 Operating problems 97 11 Technical documentation 98 11 1 Program sequence 98 11 2 Conversion table unit of pressure 100 11 3 Appliance categories 100 12 Project planning 104 12 1 Additional requirements 104 13 Spares 106 14 Notes 124 15 Key word index 125 ...

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: ... 1 A ZM LN 3 Product description 83300002 1 2019 02 La 9 128 3 Product description 3 1 Type key WG40N 1 A ZM LN W Type W burner G Fuel Gas 40 Size N N Natural Gas F Liquid Petroleum Gas 1 Ratings size A Construction ZM Version modulating LN Version LowNOX ...

Page 10: ...on Gas burner WG40 1 A ZM LN 3 Product description 83300002 1 2019 02 La 10 128 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: ...es sure is not achieved 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 lockou...

Page 13: ... Depending on the burner application optional equipment may be required for op timum operation ch 12 1 The high gas pressure switch monitors the setting pressure If the setting pressure exceeds the value set the combustion manager initiates a controlled shutdown P P DN 65 DN 80 2 1 P P P P 7 8 6 3 1 2 5 4 V1 V2 7 6 3 1 2 5 4 V1 V2 7 6 3 1 2 5 4 V1 V2 ...

Page 14: ...d parameters of the combustion manager can be displayed and changed at the operating panel Burner motor The burner motor drives the fan wheel With variable speed drive a frequency converter is connected upstream Ignition unit The electronic ignition unit creates a spark at the electrode which ignites the fuel air mixture Ionisation electrode The combustion manager monitors the flame signal via the...

Page 15: ... 1 Slot for analogue module EM3 3 or fieldbus module EM3 2 2 W FM cover 1 External valve LPG 3C Burner motor or frequency converter for continuous running fan 3N Burner motor or frequency converter 4 Ignition unit 5 Multifunction assembly or double gas valve 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 ga...

Page 16: ...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 17: ...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 18: ...operation 15 40 C Temperature during transport storage 20 70 C relative humidity max 80 no dew point 3 4 4 Fuels Natural Gas E LL Liquid Petroleum Gas B P 3 4 5 Emissions Flue gas To EN 676 the burner complies with emission class 3 The NOx values are influenced by combustion chamber dimensions flue gas system combustion air temperature and humidity medium temperature Sound levels Dual number noise...

Page 19: ...iven 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 Combustion heat rating at combustion head setting Natural Gas Liquid Petroleum Gas Combustion head OPEN 3 5 Combustion head CLOSED 4 6 5 4 6 3 1 2 2 3 1 0 1 2 3 4 600 550 400 350 300 250 200...

Page 20: ... La 20 128 3 4 7 Dimensions Burner 450 mm 577 mm 235 mm 207 mm 480 mm 151 mm 360 mm 72 mm 245 mm Rp1 1 1 235 mm without combustion head extension 335 mm with combustion head extension 100 mm 435 mm with combustion head extension 200 mm 535 mm with combustion head extension 300 mm 3 4 8 Weight approx 35 kg ...

Page 21: ...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 refractories...

Page 22: ...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 23: ...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 4 1 2 3 ...

Page 24: ...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 fitted Mount gas valve train free of stresses ...

Page 25: ...s 150 mbar a pressure regulator has to be fitted upstream of the W MF Install the gas valve train see additional sheet Print No 835109xx Installing the valve train from the right Remove protective foil from gas connection flange Mount gas valve train free from stresses Do not compensate for installation er rors by over tightening the flange screws Ensure correct alignment of flange seals Tighten s...

Page 26: ... be installed rotated by 180 To do this additional conversion measures are required Move the gas pressure switch prior to installing the multifunction assembly Remove closing plug 1 and gas pressure switch 3 Mount gas pressure switch 3 and O ring 2 on the opposite side Mount closing plug 1 on the opposite side DN 65 DN 80 1 2 1 1 1 2 3 2 3 2 3 Continue installation in the same way as for Mount gas...

Page 27: ...7 128 Accessories DN 65 DN 80 1 2 2 2 2 1 1 1 Low gas pressure switch with mechanical interlock B34 2 High gas pressure switch B33 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 28: ...ry voltage and cause elec tric shock even after the voltage supply has been disconnected Wait approx 5 minutes before commencing work Electric voltage has dissipated 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 polarit...

Page 29: ...tallation 83300002 1 2019 02 La 29 128 Separate supply line for burner motor not with variable speed drive Observe wiring diagram supplied Plug supply line for burner motor into connection plug 1 of the contactor 1 External fuse of separate supply line min 10 AT max 16 AT ...

Page 30: ...riable speed drive 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 and or the fan speed can be displayed in the operat ing level 10 Displaying gas butterfly valve setting Press key G Displaying air damper setting Pr...

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 5 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 5 Under voltage in standby or internal devi...

Page 33: ...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 Current fan speed only in conjunction with variable speed drive Display of standardised speed Press key L A 12 Current gas consumption 0 1 m3 h 13 Analogue module EM3 3 or Fiel...

Page 34: ...tion in operating point P1 2 Actuator position in operating point P2 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 ...

Page 35: ...ion analogue module The parameter is dependent on the module used Setting range of parameters see installation 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 ...

Page 36: ...purge 0 0 90 0 Change air damper setting Press L A and or Change fan speed only in conjunction with variable speed drive Press Enter and L A simultaneously and press 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 fu...

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: ...ding 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 Only in conjunction with W MF and gas connection pressure 150 mbar The pressure measuring device must be connected to the pressure regulator Check gas connection pressure see additional sheet print No 835109xx Connect press...

Page 42: ... connected to the pressure regu lator Check soundness of gas valve train see additional sheet print No 835109xx In the first 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 I...

Page 43: ...ion and operating instruction Gas burner WG40 1 A ZM LN 7 Commissioning 83300002 1 2019 02 La 43 128 DN 65 DN 80 1 2 1 2 3 1 2 3 1 2 3 4 1 First test phase 2 Second test phase 3 Third test phase 4 Blanking plate ...

Page 44: ...ng 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 W MF 5xx DMV 525 DMV 5065 DMV 5080 3 3 1 3 1 1 ...

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: ...eter valve train 1 1 2 DN 65 DN 80 W MF 507 W MF 512 W MF 512 DMV 525 DMV 5065 DMV 5080 Natural Gas E Hi 10 35 kWh m3 d 0 606 240 9 0 19 14 12 11 11 11 270 9 1 22 14 12 12 11 11 300 9 2 25 15 13 12 11 11 350 9 3 30 17 13 13 12 11 400 9 4 36 19 14 13 12 11 450 9 5 42 22 15 13 12 11 500 11 7 52 27 18 16 14 14 550 13 0 61 31 21 18 16 15 Natural Gas LL Hi 8 83 kWh m3 d 0 641 240 11 3 26 17 15 14 13 13...

Page 47: ...re Only in conjunction with W MF and gas connection pressure 150 mbar The pre pressure must be set to approx 90 mbar Set FRS pressure regulator see additional sheet print No 835109xx Preset setting pressure determined at multifunction assembly De energise pressure regulator 2 DN 80 Remove closing cap 1 and de energise spring 2 1 2 ...

Page 48: ...dimension X and air damper setting required from the diagram and note down Example Example 1 Example 2 Burner capacity required 285 kW 475 kW Combustion chamber pressure 1 5 mbar 3 5 mbar Diffuser setting dimension X 0 mm 10 mm Air damper setting 42 80 2 3 4 1 0 1 2 3 4 600 550 400 350 300 250 200 150 100 50 0 5 6 7 8 9 500 450 0 10 20 30 40 50 60 70 80 5 10 15 0 5 6 3 4 1 Combustion heat rating k...

Page 49: ...lue determined X 1 7 1 7 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 without variable speed drive with variable speed drive approx 6 mbar approx 1 mbar Low gas pressure switch valve proving gas pressure switch 12 mbar High ga...

Page 50: ...bustion manager Unplug 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 d...

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: ...s 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 and if necessary adjust combustion values via gas butterfly valve setting G 4 Drive to full load Press key Burner drives to operating point P1...

Page 53: ...ee ch 7 5 Determine gas throughput once more and adjust if necessary Re set excess air The setting pressure must not be altered once this work has been completed 6 Adjusting operating point P1 Press key P9 is saved Burner drives to operating point P8 Check CO content of combustion and if necessary adjust combustion values via gas butterfly valve setting G Press key Next operating point is initiate...

Page 54: ...ontent of 4 5 above gas butterfly valve setting G Check mixing pressure The mixing pressure in ignition position must be between 0 5 2 0 mbar If necessary adjust mixing pressure via air damper setting L A 8 Perform linearisation ch 6 3 Press key Burner drives to operating point P1 Press ENTER Combustion manager changes to linearisation mode Confirm with key Linearisation is initiated The display t...

Page 55: ...t partial load Press G and L A keys simultaneously Burner drives to partial load The lower operating limit is displayed bu Define partial load whilst observing 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 manag...

Page 56: ...er Unplug 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 usi...

Page 57: ... P1 partial load is displayed Press Enter and L A simultaneously Factory setting fan speed 100 is displayed Press key to confirm factory setting Factory setting operating point P0 ignition position is displayed Press Enter and L A simultaneously Factory setting fan speed 70 is displayed Press key to confirm factory setting Combustion manager is preset ...

Page 58: ... proving is carried out Speed standardisation starts Press key within 20 seconds Speed standardisation is carried out U and the current fan speed are displayed Wait approx 5 seconds until the fan speed has stabilised Press key within 15 seconds Speed standardisation is complete Check sequence of operation Valves open Gas pressure switch reacts Burner start is interrupted Burner does not detect a f...

Page 59: ...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 60: ...ng the ratings data given by the boiler manufacturer and the capacity graph of the burner should be observed ch 3 4 6 Select speed at full load as low as possible but not less than 80 Observe flame stability 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 Det...

Page 61: ...nd flame stability Slowly reduce speed using L A and ENTER key whilst opening air damper setting alternately using the L A key Operating 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 ignit...

Page 62: ...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 63: ...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 64: ...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 condi...

Page 65: ...at ex changer installation location or air supply may make it necessary to vary the set ting of the air pressure switch 1 7 4 Concluding work Check control and safety devices Remove gas pressure measuring devices and close all test points Conclude valve proving of gas valve train fourth test phase ch 7 1 3 Enter combustion values and settings in the commissioning record and or test sheet Enter set...

Page 66: ...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 67: ...asuring time seconds 120 seconds Calculate normal volume Calculate the normal volume VN using the following formula VN QN η Hi VN 500 kW 0 92 10 35 kW m 52 5 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 101...

Page 68: ...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 69: ...Installation and operating instruction Gas burner WG40 1 A ZM LN 8 Shutdown 83300002 1 2019 02 La 69 128 8 Shutdown For breaks in operation Switch off burner Close fuel shut off devices ...

Page 70: ...lectric 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 will be ex...

Page 71: ...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 72: ...n Damage Replace Double gas valve multifunction assembly with valve testing system valve proving Fault identified Replace Double gas valve multifunction assembly without valve testing system valve proving Function soundness less than DN 25 200 000 burner starts or 10 years 2 DN 25 to DN 65 100 000 burner starts or 10 years 2 DN 80 50 000 burner starts or 10 years 2 Replace Breather plug multifunct...

Page 73: ...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 74: ...ad 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 the indicating bolt 5 is flush with the nozzle as sembly 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 scr...

Page 75: ...00002 1 2019 02 La 75 128 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 1 5 2 m m 1 5 2 mm c a 7 m m 1 2 ...

Page 76: ...e 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 Unplug plug 4 from ignition unit Remove cover 2 and remove plugs Remove hoses 3 Hold housing cover and remove screws 1 Place housing cover onto hanging bolts 5 1 2 4 3 5 ...

Page 77: ... refitting fan wheel Observe notes on servicing ch 9 1 Removing Place housing cover into service position ch 9 6 Remove grub screw 1 and remove fan wheel Refitting Refit fan wheel in reverse order and ensure correct alignment of the spring washer 2 screw in new grub screw 1 turn fan wheel to ensure it moves freely 1 2 1 2 ...

Page 78: ...128 9 8 Remove burner motor Observe notes on servicing ch 9 1 Remove fan wheel ch 9 7 Unplug plug 1 Hold motor and remove screws 2 Remove motor Only in conjunction with variable speed drive The variable speed drive sensor is fitted to the burner motor If necessary remove variable speed drive sensor 1 2 ...

Page 79: ... to the actuator 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 damp...

Page 80: ...002 1 2019 02 La 80 128 9 10 Removing and refitting angle drive Observe notes on servicing ch 9 1 Removing Remove air damper actuator ch 9 9 Remove screws 2 Remove angle drive Refitting Turn shaft 1 to its stop air damper Open and hold Fit angle drive to shaft Secure angle drive 1 2 ...

Page 81: ...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 82: ...82 128 9 12 Replacing double gas valve coil Observe notes on servicing ch 9 1 Ensure correct voltage and solenoid number when replacing the solenoid coil Undo screw s 1 Remove cap 2 With DMV also remove metal plate 4 Replace solenoid coil 3 DMV 5065 DMV 5080 DMV 525 W MF 5xx 3 3 3 4 4 2 2 2 1 1 1 1 1 ...

Page 83: ...A ZM LN 9 Servicing 83300002 1 2019 02 La 83 128 9 13 Replace breather plug of multifunction assembly Observe notes on servicing ch 9 1 A breather plug with integrated filter is fitted to protect the breather orifice against soiling Replace breather plug 1 1 ...

Page 84: ...otes on servicing ch 9 1 Ensure no dirt enters the multifunction assembly when removing and replacing the filter insert Removing Remove screws 4 Remove cover 3 Remove filter insert 1 If necessary replace filter insert 1 and seal 2 Refitting Refit in reverse order ensuring correct alignment of filter 1 and seal 2 1 4 2 3 Carry out soundness test ch 7 1 3 Vent gas valve train ch 7 1 4 ...

Page 85: ...icing ch 9 1 Ensure no dirt enters the multifunction assembly when removing and replacing the filter insert Removing Remove screws 1 Remove cover 2 Remove filter insert 4 If necessary replace filter insert 4 and O ring 3 Refitting Refit in reverse order ensuring correct alignment of filter insert 4 and O ring 3 1 4 2 3 Carry out soundness test ch 7 1 3 Vent gas valve train ch 7 1 4 ...

Page 86: ...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 87: ...sing 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 If required set value using ENTER and keys 1 fan control burner without variable speed drive 3 variable speed drive burner with variable s...

Page 88: ...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 89: ...truction Gas burner WG40 1 A ZM LN 9 Servicing 83300002 1 2019 02 La 89 128 9 17 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 90: ...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 91: ...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 92: ...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 93: ...he burner if fault reoccurs replace the combustion manager ch 9 16 Internal unit fault Interrupt the voltage supply temporarily Reset the burner if fault reoccurs replace the combustion manager ch 9 16 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 values in parame...

Page 94: ...5 failed Second detailed fault code EFh Extension module to W FM 25 not compatible Check version 1dh EMC interference Optimise EMC measures 40h Speed standardisation outside of limits set Carry out speed standardisation 41h First detailed fault code 01h Speed differs for too long Check parameters 44 and 45 First detailed fault code 02h Speed difference is too great Check speed signal First detaile...

Page 95: ...ance fault gas actuator or frequency con verter Check freedom of movement of gas butterfly valve Replace actuator Check frequency converter or fan replace if ne cessary First detailed fault code 03h Tolerance fault gas actuator Check freedom of movement of gas butterfly valve Replace actuator First detailed fault code 04h Tolerance fault air actuator or frequency con verter Check freedom of moveme...

Page 96: ...tch Check air pressure switch and cable replace if necessary Check burner motor and cable replace if necessary ch 9 8 Adh Insufficient gas low gas pressure switch Check gas connection pressure ch 7 1 5 Set gas pressure switch ch 7 3 1 Check gas pressure switch AEh Valve 1 leaking during valve proving Check soundness of gas valve train ch 7 1 3 Check setting and function of gas pressure switch ch 7...

Page 97: ...gnal X7 B5 Find and eliminate external voltage source Internal unit fault Interrupt the voltage supply temporarily Reset the burner if fault reoccurs replace the combustion manager ch 9 16 10 3 Operating problems The following faults must only be rectified by qualified personnel Observation Cause Rectification Poor start behaviour of burner Mixing pressure too high Reduce mixing pressure in igniti...

Page 98: ...speed standardisation confirmation 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 ti...

Page 99: ...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 100: ...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 101: ...0 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 102: ...0 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 103: ...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 104: ...Designed for continuous opera tion greater than 1200 kW X Flame monitor flame sensor self checking X Control device air fuel ratio EN 12067 2 X X X Air monitoring device air pres sure switch Min pressure switch to EN 1854 X X X Minimum fuel pressure monitor ing device Low gas pressure switch to EN 1854 X X X Maximum fuel pressure monitor ing device High gas pressure switch to EN 1854 X X X Valve m...

Page 105: ...Installation and operating instruction Gas burner WG40 1 A ZM LN 12 Project planning 83300002 1 2019 02 La 105 128 ...

Page 106: ... operating instruction Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 106 128 13 Spares 1 21 1 04 1 11 1 02 1 01 1 07 1 18 1 15 1 13 1 17 1 19 1 20 1 14 1 10 1 05 1 10 1 05 1 12 1 03 1 08 1 06 1 09 1 16 1 19 ...

Page 107: ...r gas butterfly valve 232 400 01 057 1 12 Housing cover 241 400 01 457 1 13 Threaded socket R WES6 453 010 1 14 Bracket for cable 241 400 01 367 1 15 Intermediate flange 241 400 01 427 1 16 Protective cap DN 6 SELF 50 2 CF 232 300 01 047 1 17 Burner flange 241 400 01 437 Screw M10 x 35 DIN 912 402 600 Washer A10 5 DIN 125 A4 430 603 1 18 Flange gasket 8 x 238 5 x 238 5 241 400 01 147 1 19 Stay bol...

Page 108: ... WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 108 128 Burner without variable speed drive 2 24 2 20 2 30 2 29 2 22 2 23 2 28 2 25 2 27 2 26 2 21 2 01 2 05 2 12 2 13 2 19 2 18 2 17 2 15 2 15 2 07 2 04 2 14 2 16 2 10 2 09 2 11 2 03 2 02 2 06 2 08 2 24 ...

Page 109: ...02 032 2 12 Shaft air damper angle drive 241 400 02 147 2 13 Angle drive 241 110 02 062 2 14 Air actuator STE 4 5 24 V 651 103 2 15 Screw M4 x 30 Torx Plus metric 409 245 2 16 Fixing plate 241 400 02 222 2 17 Screw M4 x 10 Torx Plus 20IP 409 236 2 18 Guide sleeve 241 400 02 207 2 19 Shaft angle drive actuator 241 400 02 157 2 20 Pressure switch LGW 10 A2 1 10 mbar 691 370 2 21 Hose 4 0 x 1 75 250 ...

Page 110: ...WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 110 128 Burner with variable speed drive 3 11 3 28 3 14 3 05 3 06 3 27 3 26 3 25 3 24 3 01 3 16 3 17 3 23 3 22 3 21 3 19 3 19 3 30 3 09 3 29 3 18 3 20 3 13 3 15 3 03 3 09 3 02 3 04 3 07 3 10 3 12 3 07 3 08 ...

Page 111: ...2 Air guide 232 400 01 047 3 13 Air damper complete 241 400 02 012 3 14 Bearing left 241 400 02 037 3 15 Bearing right with bearing bush 241 210 02 032 3 16 Shaft air damper angle drive 241 400 02 147 3 17 Angle drive 241 110 02 062 3 18 Air actuator STE 4 5 24 V 651 103 3 19 Screw M4 x 30 Torx Plus metric 409 245 3 20 Fixing plate 241 400 02 222 3 21 Screw M4 x 10 Combi Torx Plus counter sunk 409...

Page 112: ...ng instruction Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 112 128 4 08 4 07 4 06 4 04 4 05 4 26 4 25 4 21 4 15 4 12 4 02 4 11 4 01 4 03 4 20 4 22 4 23 4 24 4 16 4 16 4 08 4 19 4 18 4 09 4 10 4 17 4 14 4 13 4 09 ...

Page 113: ...0 400 14 182 extended by 200 mm 230 400 14 202 extended by 300 mm 230 400 14 222 4 04 Nozzle element 232 400 14 167 4 05 Screw M4 x 22 Torx Plus 20IP 409 238 4 06 Diffuser 120 x 41 232 400 14 157 4 07 Screw M4 x 8 Torx Plus 20IP 409 235 4 08 Bracket for electrodes 232 400 14 187 4 09 Screw M4 x 10 Torx Plus 20IP 409 236 4 10 Ignition electrode 232 200 14 217 4 11 Sensor electrode 232 100 14 207 4 ...

Page 114: ...ng instruction Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 114 128 4 08 4 07 4 06 4 04 4 05 4 26 4 25 4 21 4 15 4 12 4 02 4 11 4 01 4 03 4 20 4 22 4 23 4 24 4 16 4 16 4 08 4 19 4 18 4 09 4 10 4 17 4 14 4 13 4 09 ...

Page 115: ...ription Order No 4 21 Adjusting screw M6 x 88 241 400 10 097 4 22 Spring washer A6 DIN 137 431 615 4 23 Hexagonal nut M6 DIN 934 8 411 301 4 24 Hexagonal nut M6 DIN 985 6 411 302 4 25 Screw G A DIN 908 St 409 004 4 26 Sealing ring 10 x 13 5 x 1 5 DIN 7603 441 033 Only in conjunction with combustion head extension ...

Page 116: ...n and operating instruction Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 116 128 5 19 5 03 5 01 5 02 5 20 5 04 5 18 5 09 5 10 5 12 5 11 5 07 5 13 5 14 5 16 5 15 5 08 5 05 5 06 5 24 5 17 5 23 5 21 5 22 ...

Page 117: ... 12 082 5 09 Plug cable No 3 motor 241 050 12 062 5 10 Plug cable No 3 N frequency converter 230 310 12 122 5 11 Plug cable No 3 motor supply VSD 230 310 12 142 5 12 Plug cable No 11 air pressure switch 232 400 12 032 5 13 Ionisation cable No 13 232 310 12 012 5 14 Plug cable No 14 remote reset 230 110 12 362 5 15 Plug cable No 12 gas pressure switch 232 400 12 022 5 16 Plug cable No 5 W FM DMV 23...

Page 118: ...Installation and operating instruction Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 118 128 6 13 6 14 6 14 6 15 6 08 6 07 6 01 6 05 6 06 6 06 6 16 6 10 6 04 6 11 6 09 6 12 6 03 6 02 ...

Page 119: ...57 6 09 Pressure switch GW 50 A5 1 5 50 mbar with screws and O ring 691 378 6 10 O ring 10 5 x 2 25 for pressure switch 445 512 6 11 Breather plug with filter element G1 8 605 302 6 12 Filter insert W MF 507 605 253 W MF 512 605 254 6 13 Flange with pressure test nipple DMV 507 Rp 232 110 26 092 DMV 512 Rp1 232 210 26 252 DMV 512 Rp1 232 310 26 062 6 14 Double nipple R x 50 139 000 26 117 R x 100 ...

Page 120: ...operating instruction Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 120 128 1 7 10 7 02 7 08 7 16 7 17 7 13 7 12 7 01 7 05 7 06 7 07 7 08 7 18 7 09 7 19 7 08 7 22 7 11 7 21 7 09 7 15 7 14 7 04 7 03 1 1 7 20 ...

Page 121: ...Rp2 DMV 525 12 625 031 7 10 Gasket set for flange DMV 525 12 625 033 7 11 Solenoid valve DMV 525 12 220 240 V 625 040 7 12 O ring 10 5 x 2 25 for pressure switch 445 512 7 13 Pressure switch GW 50 A5 1 5 50 mbar 691 378 7 14 Valve train group DMV 525 R2 w GW 230 V 232 400 26 242 7 15 Solenoid coil DMV 525 12 220 240 V 625 022 7 16 Elbow A1 2 Zn A EN10242 453 112 7 17 Double nipple R2 x160 139 000 ...

Page 122: ... Gas burner WG40 1 A ZM LN 13 Spares 83300002 1 2019 02 La 122 128 8 14 8 13 8 03 8 05 8 08 8 09 8 08 8 10 8 11 8 01 8 16 8 12 8 15 8 11 1 1 1 1 1 1 1 1 1 1 1 1 1 8 07 8 11 8 11 8 11 8 19 8 22 1 8 04 8 02 8 06 8 20 1 1 1 1 8 18 1 8 17 8 21 ...

Page 123: ... 327 26 737 8 11 Sealing ring EN 1514 1 DMV 5065 12 77 x 127 x 2 441 861 DMV 5080 12 90 x 142 x 2 441 044 8 12 Solenoid valve DMV 5065 12 220 240 V 625 007 DMV 5080 12 220 240 V 625 009 8 13 O ring 10 5 x 2 25 for pressure switch 445 512 8 14 Pressure switch GW 50 A5 1 5 50 mbar 691 378 8 15 Solenoid coil DMV 5065 12 220 240 V 625 024 DMV 5080 12 220 240 V 625 026 8 16 Circuit board DMV 5065 12 50...

Page 124: ...Installation and operating instruction Gas burner WG40 1 A ZM LN 14 Notes 83300002 1 2019 02 La 124 128 14 Notes ...

Page 125: ... 41 46 Consumption 18 Contactor 29 Control unit 86 Conversion factor 67 Conversion table 100 Corrections 68 Current measuring device 40 D Design lifespan 7 70 Detailed fault codes 92 Device fuse 89 Diffuser 11 48 49 Dimensions 20 Display 30 32 Display and operating unit 30 Disposal 8 Double gas valve 12 24 Drilling diagram 21 Ducted air intake 7 19 E Electrical connection 28 Electrical data 18 Ele...

Page 126: ...r 29 MPa 100 Multifunction assembly 12 N Name plate 10 Noise 97 Nominal diameter 46 O OFF function 30 Operating level 30 Operating panel 14 90 Operating problems 97 Operating status 31 92 98 Operating volume 67 Outputs 15 P Pa 100 Parameter level 35 Partial load 55 63 Pascal 100 Post purge time 17 Pre purge time 17 Pressure measuring device 40 Pressure regulator 12 24 Pressure switch 11 65 Pressur...

Page 127: ...2019 02 La 127 128 T Temperature 18 Test points 44 Test pressure 42 Transport 18 Troubleshooting 97 Type key 9 Type of gas 18 100 U Unit 100 Unit of pressure 100 V Valve proving 12 64 Valve train 25 Variable speed drive 14 Variable speed drive sensor 78 VisionBox 31 Voltage supply 18 W Weight 20 ...

Page 128: ...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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