Weishaupt WG10 Series Manual
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Weishaupt WG10 Series Manual

Weishaupt WG10 Series Manual

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

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Summary of Contents for Weishaupt WG10 Series

  • Page 1 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 83300902 1/2019-02...

  • Page 2: Table Of Contents

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 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  ...
  • Page 3 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6.2.2   Service level  ...................... 34 6.2.3   Parameter level  .................... 35 6.2.4   Access level  ...................... 37 6.3   Linearisation  ........................ 38 Commissioning ...................... 39 7.1   Prerequisite  ......................... 39 7.1.1   Connect measuring devices ................ 40 7.1.2  ...
  • Page 4 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10.2   Rectifying faults ...................... 85 10.3   Operating problems .................... 89 Technical documentation .................. 90 11.1   Program sequence .................... 90 11.2   Conversion table unit of pressure ................ 92 11.3   Appliance categories .................... 92 Spares .......................... 96 Notes  .......................... 106 Key word index  ...................... 108 4-112 83300902 1/2019-02 La...

  • Page 5: User Instructions

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 1 User instructions 1 User instructions This manual forms part of the equipment and must be kept on site. Translation of original Carefully read the manual prior to working on the unit. operating instructions 1.1 Target group The manual is intended for the operator and qualified personnel.

  • Page 6: Guarantee And Liability

    Weishaupt parts, force majeure, unauthorised modifications made to the unit, the installation of additional components, which have not been tested with the...

  • Page 7: Safety

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 2 Safety 2 Safety 2.1 Designated application The burner is suitable for operation on heat exchangers to EN 303 and EN 676. If the burner is not used on combustion chambers to EN 303 and EN 676, a safety assessment of combustion and flame stability during individual process conditions and of the shutdown limits of the combustion plant has to be carried out and docu- mented.

  • Page 8: Electrical Connection

    Carry out soundness test after each service and fault rectification. 2.4 Alterations to the construction of the equipment All conversions require written approval from Max Weishaupt GmbH. No additional components may be fitted, which have not been tested for use with the equipment.

  • Page 9: Product Description

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3 Product description 3.1 Type key WG10N/0-D ZM-LN Type: W burner Fuel: Gas Size N: Natural Gas F: Liquid Petroleum Gas Ratings size Construction Version: modulating Version: LowNO 9-112 83300902 1/2019-02 La...

  • Page 10: Serial Number

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.2 Serial number The serial number on the name plate identifies the product. This is required by Weishaupt's customer service department. 1 Name plate Ser.No. 10-112 83300902 1/2019-02 La...

  • Page 11: Function

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.3 Function 3.3.1 Air supply Air damper The air damper regulates the air quantity required for combustion. The combustion manager drives the air damper via actuator. At burner shutdown the the actuator automatically closes the air damper. At burner shutdown the air dampers close automatically.

  • Page 12: Gas Supply

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.3.2 Gas supply Gas isolating valve 1 The gas isolating valve opens and shuts off the gas supply. Multifunction assembly 8 The multifunction assembly contains: Gas filter 2 The gas filter protects the subsequent valve train components from foreign particles.

  • Page 13: Electrical Components

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description FRS pressure regulator 9 (optional) Only required for a connection pressure > 50 ... 300 mbar. The pressure regulator reduces the connection pressure to the permissible inlet pressure of the multifunction assembly. High gas pressure switch 6 (optional) Depending on the burner application, optional equipment may be required for op- timum operation.

  • Page 14: Program Sequence

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.3.4 Program sequence The operating phases for commissioning the burner are shown on the display. Phase Function After the power supply has been switched on the combustion manager performs a self-test. TEST At heat demand, the actuators for the air damper and the gas butterfly valve drive to the reference point.
  • Page 15 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description W-FM 25 T1 T2 1234 1234 Ionisation electrode CLOSED position Air pressure switch Ignition position Temperature or pressure regulator Partial load Temperature or pressure regulator full load Full load Low gas pressure switch/valve proving gas Operating phase pressure switch...

  • Page 16: Inputs And Outputs

    Air damper actuator Gas butterfly valve actuator Slot for analogue module EM3/3 or fieldbus module EM3/2 W-FM cover External valve LPG Burner motor for continuous running fan -weishaupt- Burner motor Ignition unit Multifunction assembly not used Bridging plug No. 7...

  • Page 17: Technical Data

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.4 Technical data 3.4.1 Approval data PIN (EU) 2016/426 CE-0085BM0481 Basic standards EN 676:2008 Additional standards, see EU 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...

  • Page 18: Emissions

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.4.5 Emissions Flue gas To EN 676 the burner complies with emission class 3. The NO values are influenced by: combustion chamber dimensions flue gas system combustion air (temperature and humidity) medium temperature Sound levels Dual number noise emission values...

  • Page 19: Rating

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.4.6 Rating Combustion heat rating Natural Gas 12.5 … 50 kW Liquid Petroleum Gas 12.5 … 50 kW Combustion head 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.

  • Page 20: Dimensions

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description 3.4.7 Dimensions Burner Rp¾ –weishaupt– 31.5 mm 330 mm 115 mm 349 mm 1 140 mm without combustion head extension 240 mm with combustion head extension (100 mm) 340 mm with combustion head extension (200 mm)

  • Page 21: Weight

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 3 Product description Gas valve train Isolating With thermal shut off device Without thermal shut off device valve 1 Rp½ approx. 310 mm approx. 300 mm 2 Rp½ approx. 290 mm approx. 280 mm 3 Rp½...

  • Page 22: Installation

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 4 Installation 4 Installation 4.1 Installation conditions Burner type and capacity graph Burner and heat exchanger must be matched. Check burner type and burner capacity. Installation location Prior to installation ensure that: sufficient space is available for normal and service position [ch. 3.4.7], sufficient combustion air is available, if necessary install ducted air intake, Prepare heat exchanger...

  • Page 23: Burner Installation

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 4 Installation 4.2 Burner installation Only valid in Switzerland When installing and operating the regulations of SVGW, VKF, local and Cantonal regulations and the EKAS guideline (LPG Guideline Part 2) must be observed. Remove mixing head [ch. 9.3].

  • Page 24: Rotate Burner By 180° (Optional)

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 4 Installation 4.2.1 Rotate burner by 180° (optional) Mount operating panel 1 on the opposite 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°...

  • Page 25: Installation

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 5 Installation 5 Installation 5.1 Gas supply Risk of explosion due to leaking gas Gas leaks can lead to a build-up of explosive gas/air mixture. With an ignition source present this can result in an explosion. Install gas supply with care.

  • Page 26: Installing The Gas Valve Train

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 5 Installation 5.1.1 Installing the gas valve train 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.
  • Page 27 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 5 Installation Accessories 1 High gas pressure switch (B33) 27-112 83300902 1/2019-02 La...

  • Page 28: Carry Out Soundness Test Of Gas Supply Line And Vent

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 5 Installation 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. 28-112 83300902 1/2019-02 La...

  • Page 29: Electrical Connection

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 5 Installation 5.2 Electrical connection Risk of electric shock Working on the device when voltage is applied can lead to electric shock. Isolate the device from the power supply prior to starting any work. DANGER Safeguard against accidental restart.

  • Page 30: Operation

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6 Operation 6.1 Operating panel [G] Gas Select gas butterfly valve actuator [–] Change values [L/A] Air Select air damper actuator [Enter] Reset burner: call up information press for approx. 0.5 seconds: Info level press for approx.
  • Page 31 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation Operating status The exact operating status of the combustion manager can also be displayed. This simplifies determining the cause of a fault during troubleshooting [ch. 11.1]. Press and hold [–] and [+] simultaneously for approx. 3 seconds. The combustion manager changes to operating display.

  • Page 32: Display

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6.2 Display The display shows the current operating statuses and operating data. 1 Setting level activated 2 Start phase activated 3 Info level activated 4 Actuator runs CLOSED 5 Actuator runs OPEN 6 Burner in operation 7 Lockout 8 Service level activated...

  • Page 33: Info Level

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6.2.1 Info level Burner data can be interrogated in the Info level . Press [Enter] for approx. 0.5 seconds. The Info level is activated. Press [Enter] to reach the next information. l,m³...

  • Page 34: Service Level

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6.2.2 Service level The service level gives information about: Actuator position of the individual operating points, the most recent fault, flame signal during burner operation. Press [Enter] for approx. 2 seconds. The service level is activated.

  • Page 35: Parameter Level

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6.2.3 Parameter level The parameter level can only be called up in Standby (OFF) mode. Press [+] and [Enter] keys simultaneously for approx. 2 seconds. The parameter level is activated. Press [+] key.
  • Page 36 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation Pno. Parameters Setting range Factory setting Display mode 0: E-parameter is not activated in the access level 1: E-parameter is activated in the access level Settings 2 and 3 are required for O trim, see supplementary sheet O trim W burners (Print No. 835587xx).

  • Page 37: Access Level

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6.2.4 Access level In the access level, the configuration can be adapted relative to the burner type or version. In the parameter level, the display mode must be configured to 1, to enable access to parameters E0 … E3 [ch. 6.2.3].

  • Page 38: Linearisation

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 6 Operation 6.3 Linearisation During commissioning it is possible to carry out linearisation of the operating points in gas operation. During linearisation a straight line is generated from the operating point displayed to P9.

  • Page 39: Commissioning

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7 Commissioning 7.1 Prerequisite Commissioning must only be carried out by qualified personnel. Only correctly carried out commissioning ensures the operational safety. Prior to commissioning ensure that: all assembly and installation work has been carried out correctly, sufficient combustion air is available, if necessary install ducted air intake the annulus between flame tube and heat exchanger is filled the heat exchanger is filled with medium...

  • Page 40: Connect Measuring Devices

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.1.1 Connect measuring devices Measuring device for ionisation 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...

  • Page 41: Check Gas Connection Pressure

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.1.2 Check gas connection pressure Minimum connection pressure Add the combustion chamber pressure in mbar to the minimum connection pres- sure. The connection pressure should not fall below 15 mbar. Determine minimum connection pressure for low pressure installations from table [ch. 7.1.5].

  • Page 42: Check Soundness Of Gas Valve Train

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.1.3 Check soundness of gas valve train Carry out soundness test: prior to commissioning, after all service and maintenance work. First test phase Second and third test phase Test pressure 100 mbar ±10 % 50 mbar ±10 % Waiting time for pressure equal-...
  • Page 43 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 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 43-112 83300902 1/2019-02 La...
  • Page 44 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning Fourth test phase In the fourth test phase, the joint to the mixing head 1 is tested for soundness. The test phase can only be carried out during or after burner commissioning. A leak detecting spray or electronic gas detector should be used for testing.

  • Page 45: Purging The Gas Valve Train

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.1.4 Purging the gas valve train Open test point 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.

  • Page 46: Preset Pressure Regulator

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.1.5 Preset pressure regulator Determine setting pressure An additional pressure regulator is required for connection pressure > 50 mbar. Set FRS pressure regulator [ch. 7.1.6]. Add the combustion chamber pressure in mbar to the setting pressure. Determine setting pressure from the table and note down.

  • Page 47: Set Frs Pressure Regulator (Optional)

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning Preset setting pressure Preset setting pressure determined at multifunction assembly. One rotation corresponds to approx. 1 mbar. 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.

  • Page 48: Setting Values

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.1.7 Setting values Set mixing head relative to the combustion heat rating required. For this, the dif- fuser setting and the air damper setting should be matched. Determine diffuser setting and air damper setting Do not operate the burner outside of the capacity graph.

  • Page 49: Preset Gas And Air Pressure Switch

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning Set diffuser With dimension X = 0 mm the indicating bolt is flush with the cover of the nozzle assembly. Turn screw 1, until dimension X equals the value determined. 7.1.8 Preset gas and air pressure switch The presetting of the pressure switches is only valid during commissioning.

  • Page 50: Adjusting The Burner

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.2 Adjusting the burner Risk of electric shock Touching the ignition device can lead to electric shock. Do not touch ignition device during the ignition process. DANGER Check flame signal during commissioning [ch. 7.1.1]. 1.
  • Page 51 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning Press [+] key to confirm factory setting. Factory setting operating point P0 (ignition position) is displayed. Press [+] key to confirm factory setting. Combustion manager is preset. 2. Check sequence of operation Open gas isolating valve.
  • Page 52 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 3. Preset setting pressure If a controlled shutdown or lockout occurs during setting: Briefly press [G] and [L/A] keys simultaneously. Press [+] key. Combustion manager changes to setting level. Open test point for setting pressure and connect pressure measuring device. Open gas isolating valve.
  • Page 53 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 4. Drive to full load Press [+] key. Burner drives to operating point P1. Check CO content of combustion and if necessary adjust combustion values via gas butterfly valve setting [G]. Press [+] key.
  • Page 54 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 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.
  • Page 55 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 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 then shows operating point P1. Calculation from P1 to P9 was carried out.
  • Page 56 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 10. Adjust 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].

  • Page 57: Set Pressure Switches

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.3 Set pressure switches 7.3.1 Set gas pressure switch Low gas pressure switch/valve proving gas pressure switch The switch point must be checked and if necessary adjusted during commission- ing. Connect pressure measuring device to test point 1 of the low gas pressure switch.

  • Page 58: Set Air Pressure Switch

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.3.2 Set air pressure switch The switch point must be checked and if necessary adjusted during commission- ing. Connect pressure measuring device for differential pressure measurement. Start the burner. Carry out differential pressure measurement across the whole capacity range of the burner and determine the lowest differential pressure.

  • Page 59: Concluding Work

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 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.

  • Page 60: Check Combustion

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.5 Check combustion Determine excess air Slowly close air damper(s) in the relevant operating point, until the combustion limit is reached (CO content approx. 100 ppm). Measure and document O content.

  • Page 61: Calculate Gas Throughput

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.6 Calculate gas throughput Formula symbol Explanation Example values Operating volume [m – Volume measured at gas meter at current pressure and temperature (gas throughput). Standard volume [m – Volume gained by gas at 1013 mbar and 0 °C. Conversion factor –...

  • Page 62: Subsequent Optimisation Of Operating Points

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 7 Commissioning 7.7 Subsequent optimisation of operating points If necessary, the combustion values can subsequently be corrected. Unplug bridging plug No. 7 on combustion manager. Combustion manager drives to Standby. Briefly press [–] and [+] simultaneously. Combustion manager changes to access level.

  • Page 63: Shutdown

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

  • Page 64: Servicing

    The design lifespan of the components is listed in the service plan [ch. 9.2]. Weishaupt recommends a service contract is entered into to ensure regular in- spections.
  • Page 65 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing Following servicing Risk of electric shock Touching the ignition device can lead to electric shock. Do not touch ignition device during the ignition process. DANGER Check tightness of gas carrying components. Check function of: ignition, flame monitoring,...

  • Page 66: Service Plan

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.2 Service plan Components Criteria / design lifespan Service procedure Fan wheel Soiling Clean Damage Replace Air duct Soiling Clean Air damper Soiling Clean Air pressure switch Switch point Check 250 000 burner starts or 10 years Replace Ignition cable...

  • Page 67: Removing And Refitting Mixing Head

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.3 Removing and refitting mixing head Observe notes on servicing [ch. 9.1]. Risk of explosion due to leaking gas It is possible for gas to leak out if the gasket 3 is seated incorrectly. Following work on the mixing head, ensure the gasket is clean and seated cor- DANGER rectly, if necessary replace.

  • Page 68: Set Mixing Head

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.4 Set mixing head Observe notes on servicing [ch. 9.1]. The distance between diffuser and flame tube front edge S1 can not be measured with the burner mounted. This is only possible indirectly with the mixing head re- moved, with dimension Lx.

  • Page 69: Set Ionisation And Ignition Electrodes

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 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. 69-112 83300902 1/2019-02 La...

  • Page 70: Service Position

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 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.

  • Page 71: Removing And Refitting Fan Wheel

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.7 Removing and refitting fan wheel Observe notes on servicing [ch. 9.1]. Removing Place housing cover into service position [ch. 9.6]. Remove screws 4 and remove 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,...

  • Page 72: Removing And Refitting Air Damper Actuator

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.9 Removing and refitting air damper actuator Observe notes on servicing [ch. 9.1]. Removing Remove actuator plug 4 from combustion manager. Remove screws 3. Remove actuator and shaft 2. Refitting Damage to the actuator caused by turning the hub Actuator could be damaged.

  • Page 73: Removing And Refitting Angle Drive

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.10 Removing 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.

  • Page 74: Removing And Refitting Gas Butterfly Valve Actuator

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.11 Removing and refitting gas butterfly valve actuator Observe notes on servicing [ch. 9.1]. Removing Remove actuator plug 1 from combustion manager. Remove screws 2. Remove actuator. Refitting Damage to the actuator caused by turning the hub Actuator could be damaged.

  • Page 75: Removing And Refitting Gas Butterfly Valve

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.12 Removing and refitting gas butterfly valve Observe 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.

  • Page 76: Removing And Refitting Air Regulator

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.13 Removing 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.

  • Page 77: Replacing Coil On Multifunction Assembly

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 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.

  • Page 78: Replacing The Combustion Manager

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 9.15 Replacing the combustion manager Observe notes on servicing [ch. 9.1]. Unplug all plugs. Undo screws 1. Push combustion manager upwards and replace. Connect all plugs again. Preset combustion manager Unplug bridging plug No. 7 on combustion manager. Switch on voltage supply.
  • Page 79 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing Press [G] and [L/A] simultaneously. Combustion manager changes to access level. Press [+]. Setting level (parameter E0) is displayed. Adopt value 0 (single fuel burner), if necessary adjust using [ENTER] and [-] key. Press [+].
  • Page 80 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing Determine the operating points from the sticker 1. Set the burner using these operating points and adjust [ch. 7.2]. Brennereinstellung Datum: Stauscheiben- einstellung: Gaseinstelldruck bei Großlast: mbar Einstellungen am Feuerungsmanager: Voreinstellung Luftklappe bei Großlast (P9): °...

  • Page 81: Replacing The Fuse

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 9 Servicing 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 Replacement fuse 81-112 83300902 1/2019-02 La...

  • Page 82: Troubleshooting

    Top up water. changer has triggered Reset low water safety interlock on heat exchanger. Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly. 10.1.2 Display OFF The following faults may be corrected by the operator: Fault...

  • Page 83: Display Flashes

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting 10.1.3 Display flashes A burner fault has occurred. The burner is in lockout. The error code is displayed flashing. Read error code, e. g. A7h. Rectify cause of fault [ch. 10.2]. Resetting Damage resulting from incorrect fault repair Incorrect fault repair can cause damage to the equipment and injure personnel.

  • Page 84: Detailed Fault Codes

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting 10.1.4 Detailed fault codes Additional information, which breaks down 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,...
  • Page 85 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting 10.2 Rectifying faults The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification 01h … 02h Internal unit fault Interrupt the voltage supply temporarily Reset the burner, if fault reoccurs replace the 05h …...
  • Page 86 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification Switch off via PC Software – Second detailed fault code: A1h Check Bus address Invalid Bus address Second detailed fault code: A5h Check configuration at output B4 Configuration at output B4 incorrect...
  • Page 87 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification First detailed fault code: 00h Check freedom of movement of air damper and / or angle drive Tolerance fault air actuator, gas actuator Check freedom of movement of gas butterfly valve...
  • Page 88 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification Air pressure switch does not react Check air pressure switch setting [ch. 7.3.2] Check hoses on air pressure switch Check air pressure switch and cable, replace if necessary Check burner motor and cable, replace if...

  • Page 89: Operating Problems

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 10 Troubleshooting 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 ignition position Ignition electrode set incorrectly Set ignition electrode [ch. 9.5]...

  • Page 90: Technical Documentation

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 11 Technical documentation 11 Technical documentation 11.1 Program sequence The exact operating status of the combustion manager can also be displayed. Ac- tivate operating status [ch. 6]. Operating phase Operating status Condition / function Fault present F ..
  • Page 91 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 11 Technical documentation Operating phase Operating status Condition / function Restart interlock 16 ..Reference search actuator - air damper and gas butterfly valve Test gas butterfly valve actuator 105° Drive to Standby position Internal sequence Insufficient gas, low gas pressure switch (X3:14) OFFGd...

  • Page 92: Conversion Table Unit Of Pressure

    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 .
  • Page 93 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 11 Technical documentation Alternative appliance category to I2R Country of destination Appliance category Test gas Connection pressure mbar AL (Albania) G 20 AT (Austria) G 20 BA (Bosnia) G 20 BE (Belgium) I2E+, I2N, I2E(R)B G 20 + G 25 Pressures...
  • Page 94 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 11 Technical documentation Alternative appliance category to I3R Country of destination Appliance category Test gas Connection pressure mbar AL (Albania) I3+, I3P, I3B G 30 + G 31 Pressures 28 - 30 / 37 AT (Austria) I3B/P, I3P G 30 + G 31...
  • Page 95 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 11 Technical documentation Alternative appliance category to II2R/3R Country of destination Appliance category Test gas Connection pressure Test gas Connection pressure mbar mbar AL (Albania) II2H3+, II2H3P G 20 G 31 AT (Austria) II2H3B/P, II2H3P G 20 G 30 + G 31...

  • Page 96: Spares

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares 12 Spares 1.01 1.18 1.02 1.15 1.06 1.16 1.08 1.07 1.17 1.16 1.14 1.04 1.11 1.14 1.03 1.09 1.03 1.12 1.05 1.12 1.10 1.13 96-112 83300902 1/2019-02 La...
  • Page 97 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares Pos. Description Order No. 1.01 Cover 232 110 01 112 1.02 Screw M8 x 16 DIN 7991 404 412 1.03 Mounting bracket for cover 241 400 01 207 1.04 Burner housing 241 110 01 307 1.05 Intake housing complete...
  • Page 98 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares 2.22 2.12 2.13 2.11 2.10 2.14 2.08 2.15 2.23 2.02 2.06 2.09 2.18 2.25 2.16 2.27 2.17 2.06 2.01 2.20 2.21 2.24 2.19 2.07 2.28 2.05 2.26 2.03 2.04 98-112 83300902 1/2019-02 La...
  • Page 99 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares Pos. Description Order No. 2.01 Motor ECK02/H-2/1 230V 50Hz 652 093 2.02 Screw M4 x 10 409 323 2.03 Capacitor set 713 472 2.04 Pressure switch LGW 3 A1 0.4 - 3.0 mbar 691 446 2.05 Connection flange for LGW...
  • Page 100 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares 3.01 3.03 3.05 3.04 3.02 3.08 3.09 3.06 3.07 3.19 3.18 3.17 3.17 3.13 3.10 3.14 3.15 3.12 3.16 3.11 3.21 3.22 3.20 100-112 83300902 1/2019-02 La...
  • Page 101 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares Pos. Description Order No. 3.01 Mixing head WG10N/0-D cpl. (Natural Gas) – Standard 232 110 14 152 – extended by 100 mm* 230 110 14 202 – extended by 200 mm* 230 110 14 222 –...
  • Page 102 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares 4.16 4.17 4.18 4.03 4.01 4.14 4.15 4.07 4.02 4.04 4.05 4.06 4.19 4.08 4.09 4.12 4.10 4.13 4.12 102-112 83300902 1/2019-02 La...
  • Page 103 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares Pos. Description Order No. 4.01 Combustion manager W-FM 25 / 230 V – intermittent operation without O trim 600 487 – intermittent operation with O trim 600 491 – continuous operation (PO-O2) 600 489 4.02 Micro fuse T6.3H, IEC 127-2/5...
  • Page 104 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares 5.01 5.08 5.02 5.03 5.09 5.13 5.02 5.06 5.12 5.04 5.05 5.06 5.10 5.02 5.07 5.11 5.02 5.14 5.11 5.15 104-112 83300902 1/2019-02 La...
  • Page 105 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 12 Spares Pos. Description Order No. 5.01 Nipple N4/1- ¾ x ½-Zn-A 453 084 5.02 Double nipple R 1/2 x 50 with Loctite 139 000 26 717 5.03 Elbow A1- ½-Zn-A 453 104 5.04 Flange Rp½...

  • Page 106: Notes

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 13 Notes 13 Notes 106-112 83300902 1/2019-02 La...
  • Page 107 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 13 Notes 107-112 83300902 1/2019-02 La...

  • Page 108: Key Word Index

    Installation and operating instruction Gas burner WG10…/0-D ZM-LN 14 Key word index 14 Key word index Device fuse................ 81 Diffuser .............. 11, 48, 49 Access level .............. 31, 37 Dimensions................ 20 Actuator................. 72 Display ................ 30, 32 Adjustment ................ 62 Display and operating unit .......... 30 Air damper ..........
  • Page 109 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 14 Key word index Guarantee................ 6 Operating level .............. 30 Operating panel ............ 13, 82 Operating problems ............ 89 Operating status .......... 31, 84, 90 Heat exchanger .............. 22 Operating volume ............... 61 High gas pressure switch .........  13, 57 Outputs ................. 16 Hours run ................ 33 Housing cover.............. 70...
  • Page 110 Installation and operating instruction Gas burner WG10…/0-D ZM-LN 14 Key word index Temperature ................. 17 Test points................ 44 Test pressure ............... 42 Transport................ 17 Troubleshooting .............. 89 Type key ..................  9 Type of gas.............. 17, 92 Unit .................. 92 Unit of pressure.............. 92 Valve proving.............. 12, 57 Valve train ................ 26 VisionBox ................ 31 Voltage supply .............. 17...
  • Page 111 83300902 1/2019-02 La...
  • Page 112 Max 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. The complete program: Reliable technology and prompt, professional service W Burners up to 570 kW...

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