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• Page 1
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 83300002 1/2019-02…

• Page 2: Table Of Contents

  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A ZM-LN 10.1.3   Display flashes  ……………….. 91 10.1.4   Detailed fault codes  ……………… 92 10.2   Rectifying faults …………………. 93 10.3   Operating problems ……………….. 97 Technical documentation ……………… 98 11.1   Program sequence ……………….. 98 11.2   Conversion table unit of pressure ………….. 100 11.3  …

• Page 5: User Instructions

  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A ZM-LN 3 Product description 3 Product description 3.1 Type key WG40N/1-A ZM-LN Type: W burner Fuel: Gas Size N: Natural Gas F: Liquid Petroleum Gas Ratings size Construction Version: modulating Version: LowNO 9-128 83300002 1/2019-02 La…

• Page 10: Serial Number

  Installation and operating instruction Gas burner WG40…/1-A 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. 10-128 83300002 1/2019-02 La…

• Page 11: Function

  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 Double gas valve Pressure regulators Gas filter 2 The gas filter protects the subsequent valve train components from foreign…

• Page 13
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 3 Product description High gas pressure switch 6 (optional) 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.

• Page 14: Electrical Components

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 3 Product description 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.

• Page 15: Inputs And Outputs

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

• Page 16: Program Sequence

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 3 Product description 3.3.5 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 17
  Installation and operating instruction Gas burner WG40…/1-A 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 18: Technical Data

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 3 Product description 3.4 Technical data 3.4.1 Approval data PIN (EU) 2016/426 CE-0085AS0311 PIN 2014/68/EU Z-IS-TAF-MUC-14-05-376456-004 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 856 W…

• Page 19: Rating

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 3 Product description 3.4.6 Rating Combustion heat rating Natural Gas 55 … 550 kW Liquid Petroleum Gas 80 … 550 kW Combustion head WG40/1-LN 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 WG40…/1-A ZM-LN 3 Product description 3.4.7 Dimensions Burner ½ 72 mm 450 mm 235 mm 577 mm 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.

• Page 21: Installation

  Installation and operating instruction Gas burner WG40…/1-A 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 22: Burner Installation

  Installation and operating instruction Gas burner WG40…/1-A 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 23: Rotate Burner By 180° (Optional)

  Installation and operating instruction Gas burner WG40…/1-A 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 24: Installation

  Installation and operating instruction Gas burner WG40…/1-A 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 25: Installing The Gas Valve Train

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 5 Installation 5.1.1 Installing the gas valve train Only in conjunction with W-MF and gas connection pressure > 150 mbar If the gas connection pressure is > 150 mbar, a pressure regulator has to be fitted upstream of the W-MF.

• Page 26
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 5 Installation 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 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.

• Page 27: Carry Out Soundness Test Of Gas Supply Line And Vent

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 5 Installation Accessories ¾» … 1½» DN 65 DN 80 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: Electrical Connection

  Installation and operating instruction Gas burner WG40…/1-A 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 29
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 5 Installation 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. External fuse of separate supply line: min 10 AT max 16 AT 29-128…

• Page 30: Operation

  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A ZM-LN 6 Operation Pno. Parameters Setting range Factory setting Flame sensor 0: ionisation electrode / flame sensor FLW 1: switch input (X3:14) 2: flame sensor QRB 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…

• Page 37: Access Level

  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A 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 % 100 mbar ±10 % Waiting time for pressure equal-…

• Page 43
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning ¾» …1½» DN 65 DN 80 1 First test phase 2 Second test phase 3 Third test phase 4 Blanking plate 43-128 83300002 1/2019-02 La…
• Page 44
  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A ZM-LN 7 Commissioning 7.1.5 Preset pressure regulator Determine setting pressure Add the combustion chamber pressure in mbar to the setting pressure into the gas butterfly valve. Determine setting pressure from the table and note down. The details given for calorific value H relate to 0 °C and 1013 mbar.

• Page 47
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning Preset setting pressure 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.

• Page 48: Setting Values

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning 7.1.6 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 WG40…/1-A 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. 7.1.7 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 WG40…/1-A ZM-LN 7 Commissioning 7.2 Adjusting the burner 7.2.1 Burner without variable speed drive 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].

• Page 51
  Installation and operating instruction Gas burner WG40…/1-A 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 WG40…/1-A 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 WG40…/1-A ZM-LN 7 Commissioning 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 V ) required [ch. 7.6].
• Page 54
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning 7. Adjust ignition load Press [-] key. Burner drives to operating point P0 (ignition position). Check combustion values in operating point P0 (ignition position). Set O content of 4 … 5 % above gas butterfly valve setting [G]. Check mixing pressure The mixing pressure in ignition position must be between 0.5 …
• Page 55
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning 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.

• Page 56: Burner With Variable Speed Drive (Optional)

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning 7.2.2 Burner with variable speed drive (optional) 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].

• Page 57
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning Press [+] key. Factory setting operating point 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.
• Page 58
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 7 Commissioning 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. Speed standardisation starts.
• Page 59
  Installation and operating instruction Gas burner WG40…/1-A 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 60
  Installation and operating instruction Gas burner WG40…/1-A 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 61
  Installation and operating instruction Gas burner WG40…/1-A 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 62
  Installation and operating instruction Gas burner WG40…/1-A 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 63
  Installation and operating instruction Gas burner WG40…/1-A 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 64: Set Pressure Switches

  Installation and operating instruction Gas burner WG40…/1-A 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 65: Set Air Pressure Switch

  Installation and operating instruction Gas burner WG40…/1-A 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 66: Check Combustion

  Installation and operating instruction Gas burner WG40…/1-A 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 67: Calculate Gas Throughput

  Installation and operating instruction Gas burner WG40…/1-A 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 68: Subsequent Optimisation Of Operating Points

  Installation and operating instruction Gas burner WG40…/1-A 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 69: Shutdown

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

• Page 70: 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 71
  Installation and operating instruction Gas burner WG40…/1-A 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 72: Service Plan

  Installation and operating instruction Gas burner WG40…/1-A 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 73: Removing And Refitting Mixing Head

  Installation and operating instruction Gas burner WG40…/1-A 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 74: Set Mixing Head

  Installation and operating instruction Gas burner WG40…/1-A 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 75: Set Ionisation And Ignition Electrodes

  Installation and operating instruction Gas burner WG40…/1-A 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. 75-128 83300002 1/2019-02 La…

• Page 76: Service Position

  Installation and operating instruction Gas burner WG40…/1-A 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]. Unplug plug 4 from ignition unit. Remove cover 2 and remove plugs.

• Page 77: Removing And Refitting Fan Wheel

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

• Page 78: Remove Burner Motor

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 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.

• Page 79: Removing And Refitting Air Damper Actuator

  Installation and operating instruction Gas burner WG40…/1-A 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 5. Remove actuator with fixing plate 3 and shaft 2. Refitting Damage to the actuator caused by turning the hub Actuator could be damaged.

• Page 80: Removing And Refitting Angle Drive

  Installation and operating instruction Gas burner WG40…/1-A 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 screws 2. Remove angle drive. Refitting Turn shaft 1 to its stop (air damper Open) and hold. Fit angle drive to shaft.

• Page 81: Removing And Refitting Gas Butterfly Valve Actuator

  Installation and operating instruction Gas burner WG40…/1-A 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 82: Replacing Double Gas Valve Coil

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 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.

• Page 83: Replace Breather Plug Of Multifunction Assembly

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 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. 83-128 83300002 1/2019-02 La…

• Page 84: Removing And Refitting Filter Insert Of Multifunction Assembly

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 9.14 Removing and refitting filter insert of multifunction assembly Observe notes 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.

• Page 85: Removing And Refitting Filter Insert In Gas Filter

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 9.15 Removing and refitting filter insert in gas filter Observe notes on servicing [ch. 9.1]. Ensure no dirt enters the multifunction assembly when removing and replacing the filter insert. Removing Remove screws 1. Remove cover 2.

• Page 86: Replacing The Combustion Manager

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 9.16 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 87
  Installation and operating instruction Gas burner WG40…/1-A 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 88
  Installation and operating instruction Gas burner WG40…/1-A 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 89: Replacing The Fuse

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 9 Servicing 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 Replacement fuse 89-128 83300002 1/2019-02 La…

• Page 90: 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 91: Display Flashes

  Installation and operating instruction Gas burner WG40…/1-A 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 92: Detailed Fault Codes

  Installation and operating instruction Gas burner WG40…/1-A 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 93: Rectifying Faults

  Installation and operating instruction Gas burner WG40…/1-A 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 94
  Installation and operating instruction Gas burner WG40…/1-A 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 95
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification Actuator does not drive to reference point cor- Check freedom of movement of air damper and / rectly or angle drive and gas butterfly valve Replace actuator…
• Page 96
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification No flame signal after safety time Set ignition electrode [ch. 9.5] Check the ignition unit and replace if necessary Check solenoid valve coil and cable, replace if necessary Check the ionisation electrode and cable, re-…

• Page 97: Operating Problems

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Cause Rectification Connection to actuator faulty Rectify the fault using the following procedure: Interrupt voltage supply. Plug in plug on combustion manager correctly Fit W-FM cover [ch. 3.3.4].

• Page 98: Technical Documentation

  Installation and operating instruction Gas burner WG40…/1-A 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 99
  Installation and operating instruction Gas burner WG40…/1-A 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 100: 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 101
  Installation and operating instruction Gas burner WG40…/1-A 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 102
  Installation and operating instruction Gas burner WG40…/1-A 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 103
  Installation and operating instruction Gas burner WG40…/1-A 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 104: Project Planning

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 12 Project planning 12 Project planning 12.1 Additional requirements Additional requirements for burner for liquid and gaseous fuels in accordance with EN 676: the pressure equipment operates in accordance with the Pressure Equipment Directive 2014/68/EU, as components of industrial thermal process plants in accordance with EN 746-2,…

• Page 105
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 12 Project planning 105-128 83300002 1/2019-02 La…

• Page 106: Spares

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 13 Spares 1.01 1.18 1.17 1.19 1.13 1.20 1.02 1.15 1.16 1.19 1.10 1.11 1.12 1.05 1.03 1.21 1.09 1.07 1.10 1.08 1.04 1.05 1.06 1.14 106-128 83300002 1/2019-02 La…

• Page 107
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 1.01 Cover 241 400 01 112 1.02 Screw M8 x 16 DIN 7991 404 412 1.03 Burner housing 241 400 01 447 1.04 Intake housing complete 241 400 01 082 –…
• Page 108
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Burner without variable speed drive 2.10 2.09 2.11 2.08 2.06 2.12 2.16 2.14 2.24 2.13 2.19 2.25 2.18 2.21 2.07 2.23 2.27 2.03 2.17 2.02 2.28 2.15 2.22 2.26 2.20 2.24 2.30 2.29…
• Page 109
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 2.01 Motor ECK06/A-2 230 V / 50 Hz 240 400 07 032 2.02 Screw M8 x 20 DIN 912 402 511 2.03 Shaft key 4 x 5 DIN 6888 490 154 2.04 Capacitor set 16.0 µF 420 V…
• Page 110
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Burner with variable speed drive 3.14 3.13 3.15 3.12 3.10 3.16 3.20 3.18 3.09 3.17 3.23 3.22 3.11 3.25 3.03 3.21 3.02 3.04 3.26 3.19 3.24 3.09 3.28 3.27 3.01 3.19 3.29 3.07…
• Page 111
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 3.01 Motor DK06A-2 3~ 230 V / 50 Hz 652 026 3.02 Screw M8 x 20 DIN 912 402 511 3.03 Shaft key 4 x 5 DIN 6888 490 154 3.04 Speed sensor KJ1.5-Q8MB40-NA-X complete…
• Page 112
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 4.01 4.03 4.05 4.04 4.06 4.08 4.09 4.07 4.02 4.16 4.16 4.09 4.08 4.24 4.10 4.23 4.14 4.22 4.13 4.11 4.15 4.17 4.20 4.19 4.12 4.18 4.26 4.21 4.25 112-128 83300002 1/2019-02 La…
• Page 113
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 4.01 Mixing head WG40N/1-A cpl. (Natural Gas) – Standard 232 400 14 052 – extended by 100 mm* 230 400 14 022 – extended by 200 mm* 230 400 14 132 –…
• Page 114
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 4.01 4.03 4.05 4.04 4.06 4.08 4.09 4.07 4.02 4.16 4.16 4.09 4.08 4.24 4.10 4.23 4.14 4.22 4.13 4.11 4.15 4.17 4.20 4.19 4.12 4.18 4.26 4.21 4.25 114-128 83300002 1/2019-02 La…
• Page 115
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description 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…
• Page 116
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 5.21 5.22 5.23 5.03 5.01 5.19 5.20 5.08 5.02 5.04 5.05 5.06 5.07 5.24 5.09 5.11 5.10 5.12 5.17 5.14 5.13 5.18 5.16 5.15 116-128 83300002 1/2019-02 La…
• Page 117
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 5.01 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 5.02 Micro fuse T6.3H, IEC 127-2/5…
• Page 118
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 6.01 6.03 6.02 6.04 6.05 6.08 6.06 6.07 6.11 6.06 6.16 6.10 6.09 6.13 6.14 6.14 6.15 6.12 118-128 83300002 1/2019-02 La…
• Page 119
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 6.01 O ring 45 x 3 NBR 70, DIN 3771 445 518 6.02 Flange Rp1½ 232 400 26 027 6.03 Pressure test nipple G 453 001 6.04 Double nipple R1½…
• Page 120
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 7.01 7.04 7.03 7.05 7.07 7.06 7.15 7.08 7.09 7.02 7.11 7.10 7.12 7.09 7.14 7.13 7.18 7.22 7.08 7.19 7.20 7.17 7.08 7.21 7.16 120-128 83300002 1/2019-02 La…
• Page 121
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 7.01 O ring 45 x 3 NBR 70, DIN 3771 445 518 7.02 Valve train gr. press. reg. R2 DMV 525/12 232 400 26 252 7.03 Flange Rp1½…
• Page 122
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares 8.04 8.01 8.03 8.05 8.16 8.06 8.02 8.08 1) 1) 8.09 8.08 8.12 8.10 8.11 8.15 8.07 8.13 8.14 8.20 8.11 8.21 8.17 8.11 8.18 8.11 8.19 8.11 8.22 122-128 83300002 1/2019-02 La…
• Page 123
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 13 Spares Pos. Description Order No. 8.01 O ring 45 x 3 NBR 70, DIN 3771 445 518 8.02 Valve train flange DN 40 232 400 26 212 8.03 Flange Rp1½ 232 400 26 027 8.04 Pressure test nipple G 453 001…

• Page 124: Notes

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 14 Notes 14 Notes 124-128 83300002 1/2019-02 La…

• Page 125: Key Word Index

  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 15 Key word index 15 Key word index Diffuser ………….. 11, 48, 49 Dimensions……………. 20 Access level ………….. 31, 37 Display ……………. 30, 32 Actuator…………….. 79 Display and operating unit ………. 30 Adjustment ……………. 68 Disposal ………………  8 Air damper ………….

• Page 126
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 15 Key word index Operating level ………….. 30 Operating panel ………… 14, 90 Heat exchanger ………….. 21 Operating problems ………… 97 High gas pressure switch ………  13, 64 Operating status ………. 31, 92, 98 Hours run ……………. 33 Operating volume …………… 67 Housing cover………….. 76 Outputs …………….. 15…
• Page 127
  Installation and operating instruction Gas burner WG40…/1-A ZM-LN 15 Key word index Temperature …………….. 18 Test points……………. 44 Test pressure …………… 42 Transport……………. 18 Troubleshooting ………….. 97 Type key ………………  9 Type of gas………….. 18, 100 Unit ……………… 100 Unit of pressure………….. 100 Valve proving………….. 12, 64 Valve train ……………. 25 Variable speed drive………… 14 Variable speed drive sensor ………. 78…
• Page 128
  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…

1. Manuals
2. Brands
3. Weishaupt Manuals
4. Burner
5. WG40N/1-A ZM-LN
6. Manual

• Contents

• Table of Contents

• Troubleshooting

• Bookmarks

— мощность 55-550 кВт;
— Плавно-двухступенчатая или модулируемая;  
— основное топливо — природный газ;
— воздушная заслонка — c сервоприводом;

Ключ краткого обозначения:

• W  Горелка Weishaupt типоразмера W
• G/L   Газ/жидкое топливо
• 5/10/20/30-40   Типоразмер
• N/F природный газ E и LL / сжиженный газ B/P
• 1/2/3/4   Индекс смесительного устройства
• A/B/C   Без модификации/ первая/ вторая модификация и т.д.
• LN   одноступенчатая
• Z    Двухступенчатая
• ZM  Плавно-ступенчатая или модулируемая
• ZM-LN   с низким выбросом оксидов азота (LowNOx)

Комплектация Weishaupt WG:

• Газовый мультиблок
• Шаровой кран
• Встроенная звукоизоляция
• Фланец
• Электродвигатель переменного тока
• Высокопроизводительный вентилятор
• Датчик контроля давления воздуха
• Смесительное устройство и горелочная труба
• Трансформатор зажигания с комбинированным электродом
• Кожух горелки
• Крепежные детали с уплотнителем фланца