Weishaupt WG10 0-D ZMI Series Supplement

Installation and operating instruction
Gas burner WG10…/0-D ZMI 83326002 1/2023-10

Installation and operating instruction
Gas burner WG10…/0-D ZMI
83326002 1/2023-10 Ch 2-124
1 User instructions.............................................................................................................. 5
1.1  Target group.................................................................................................................. 5
1.2  Symbols in the manual................................................................................................ 5
1.3  Guarantee and Liability............................................................................................... 6
2 Safety ..................................................................................................................................... 7
2.1  Designated application............................................................................................... 7
2.2  Safety symbols on the device ................................................................................... 7
2.3  When gas can be smelled ......................................................................................... 7
2.4  Safety measures........................................................................................................... 8
2.4.1  Personal protective equipment (PPE) ..............................................................8
2.4.2  Normal operation...................................................................................................8
2.4.3  Electrical work........................................................................................................8
2.4.4  Gas supply..............................................................................................................9
2.5  Alterations to the construction of the equipment ................................................. 9
2.6  Noise emission ............................................................................................................. 9
2.7  Disposal ......................................................................................................................... 9
3 Product description ..................................................................................................... 10
3.1  Type key .......................................................................................................................10
3.2  Type and serial number ............................................................................................10
3.3  Function........................................................................................................................11
3.3.1  Air supply ............................................................................................................. 11
3.3.2  Gas supply........................................................................................................... 12
3.3.3  Electrical components....................................................................................... 13
3.3.4  Program sequence............................................................................................. 14
3.3.5  Inputs and outputs ............................................................................................. 16
3.4  Technical data.............................................................................................................17
3.4.1  Approval data...................................................................................................... 17
3.4.2  Electrical data ..................................................................................................... 17
3.4.3  Ambient conditions............................................................................................ 17
3.4.4  Permissible fuels ................................................................................................ 17
3.4.5  Emissions............................................................................................................. 18
3.4.6  Rating.................................................................................................................... 19
3.4.7  Dimensions .......................................................................................................... 20
3.4.8  Weight .................................................................................................................. 21
4 Installation ........................................................................................................................ 22
4.1  Installation requirements...........................................................................................22
4.2  Burner installation ......................................................................................................23
4.2.1  Rotate burner by 180° (optional).................................................................... 24
5 Installation ........................................................................................................................ 25
5.1  Gas supply ..................................................................................................................25
5.1.1  Fit impulse line to the control pressure regulator ....................................... 26
5.1.2  Installing the gas valve train............................................................................. 26
5.1.3  Fitting gas pressure switch.............................................................................. 27
5.1.4  Accessories......................................................................................................... 27
5.1.5  Fit impulse line to the burner housing ........................................................... 27
5.1.6  Carry out soundness test of gas supply line and vent............................... 28

Installation and operating instruction
Gas burner WG10…/0-D ZMI
83326002 1/2023-10 Ch 3-124
5.2  Electrical connection.................................................................................................29
6 Operation .......................................................................................................................... 30
6.1  Operating panel..........................................................................................................30
6.2  Display..........................................................................................................................32
6.2.1  Info level ............................................................................................................... 33
6.2.2  Service level ........................................................................................................ 34
6.2.3  Parameter level ................................................................................................... 35
6.2.4  Access level ........................................................................................................ 37
6.3  Linearisation ................................................................................................................38
7 Commissioning.............................................................................................................. 39
7.1  Prerequisite .................................................................................................................39
7.1.1  Connect measuring devices............................................................................ 40
7.1.2  Check gas connection pressure..................................................................... 41
7.1.3  Check soundness of gas valve train.............................................................. 42
7.1.4  Purging the gas valve train............................................................................... 45
7.1.5  Preset pressure regulator................................................................................. 46
7.1.6  Setting values...................................................................................................... 48
7.1.7  Set control pressure regulator ........................................................................ 49
7.1.8  Preset gas and air pressure switch ............................................................... 49
7.2  Adjusting the burner..................................................................................................50
7.3  Set pressure switches ..............................................................................................58
7.3.1  Set gas pressure switch................................................................................... 58
7.3.2  Set air pressure switch .................................................................................... 60
7.4  Concluding work........................................................................................................61
7.5  Check combustion.....................................................................................................62
7.6  Calculate gas throughput.........................................................................................63
7.7  Subsequent optimisation of operating points .....................................................64
8 Shutdown.......................................................................................................................... 65
9 Servicing............................................................................................................................ 66
9.1  Notes on servicing.....................................................................................................66
9.2  Service plan.................................................................................................................68
9.3  Removing and refitting mixing head.......................................................................69
9.4  Set mixing head..........................................................................................................70
9.5  Set ionisation and ignition electrodes...................................................................71
9.6  Service position..........................................................................................................72
9.7  Removing and refitting fan wheel...........................................................................73
9.8  Replace variable speed drive sensor ....................................................................74
9.9  Remove frequency converter ..................................................................................75
9.10  Remove burner motor.............................................................................................76
9.11  Removing and refitting air damper actuator......................................................77
9.12  Removing and refitting angle drive......................................................................78
9.13  Removing and refitting gas butterfly valve actuator.........................................79
9.14  Removing and refitting gas butterfly valve.........................................................80
9.15  Removing and refitting air regulator....................................................................81
9.16  Replacing double gas valve coil...........................................................................82
9.17  Replacing the combustion manager ...................................................................83

Installation and operating instruction
Gas burner WG10…/0-D ZMI
83326002 1/2023-10 Ch 4-124
9.18  Replacing the fuse ..................................................................................................86
10 Troubleshooting ............................................................................................................ 87
10.1  Procedures for fault conditions............................................................................87
10.1.1  Display off.......................................................................................................... 87
10.1.2  Display OFF ...................................................................................................... 87
10.1.3  Display flashes ................................................................................................. 88
10.1.4  Detailed fault codes ........................................................................................ 89
10.2  Rectifying faults........................................................................................................90
10.3  Operating problems................................................................................................95
11 Technical documentation......................................................................................... 96
11.1  Program sequence..................................................................................................96
11.2  Conversion table unit of pressure........................................................................98
11.3  Appliance categories..............................................................................................99
12 Project planning...........................................................................................................104
12.1  Continuous running fan or post-purge............................................................ 104
13 Spares...............................................................................................................................106
14 Notes .................................................................................................................................118
15 Key word index ............................................................................................................120

Installation and operating instruction
Gas burner WG10…/0-D ZMI
1 User instructions
83326002 1/2023-10 Ch 5-124
1 User instructions
Translation of original
operating instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the unit.
1.1 Target group
The manual is intended for the operator and qualified personnel. It should be
observed by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have had the relevant
training 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 in the manual
DANGER
Danger with high risk.
Non observance can lead to serious injury or death.
WARNING
Danger with medium risk.
Non observance can lead to serious injury or death.
CAUTION
Danger with low risk.
Non observance can cause injury to personnel.
NOTICE
!
Non observance can cause damage to the
equipment and environmental damage.
Important information
Requires direct action
Result after an action
Itemisation
… Range of values
02 Replacement character for digits, e.g. language key
for Print No.
Display text Font for text that appears in the display

Installation and operating instruction
Gas burner WG10…/0-D ZMI
1 User instructions
83326002 1/2023-10 Ch 6-124
1.3 Guarantee and Liability
Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
non approved application
non-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 installation of combustion chamber inserts, which impede full flame formation
unsuitable fuels
defects in the inlet lines

Installation and operating instruction
Gas burner WG10…/0-D ZMI
2 Safety
83326002 1/2023-10 Ch 7-124
2 Safety
2.1 Designated application
The burner is suitable for operation with process equipment systems. The
combustion chambers must comply with EN303 and EN676.
If the burner is not used in combustion chambers with dimensions that comply with
EN303 and EN676, a safety assessment of combustion and flame stability during
the individual process conditions, as well as the shutdown limits of the combustion
system has to be carried out and documented.
The Technical data must be adhered to [ch.3.4].
The combustion air must be free from aggressive compounds (e. g. Halogens).
If the combustion air is contaminated, increased cleaning and servicing will be
required. In this case ducted air intake is recommended.
The burner should preferably be operated indoors.
If the burner is not operated indoors, weather protection is required to protect from
rain and direct sunlight. The ambient conditions must be adhered to [ch.3.4.3].
Improper use could:
endanger the health and safety of the user or third parties
cause damage to the unit or other material assets
2.2 Safety symbols on the device
Symbol Description Position
Warning of electrical voltage Frequency converter
Burner housing
Dangerous electric voltage Ignition unit
2.3 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 isolation valve.
Warn the inhabitants, do not ring door bells.
Leave the building.
Inform the heating contractor or gas supplier from outside of the building.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
2 Safety
83326002 1/2023-10 Ch 8-124
2.4 Safety measures
Safety relevant fault conditions must be eliminated immediately.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution.
The design lifespan of the components is listed in the service plan [ch.9.2].
2.4.1 Personal protective equipment (PPE)
Use the necessary personal protective equipment for all work.
Personal protective equipment protects the user when working on the device.
Safety shoes must be worn during all work carried out on the device.
Further necessary PPE is shown in the respective section by a mandatory symbol.
Symbol Description Information
Use hand protection Wear suitable protective gloves.
2.4.2 Normal operation
All labels on the unit must be kept in a legible condition and replace if necessary.
Stipulated settings, service and inspection work should be carried out at regular
intervals.
Only operate the unit with its cover closed.
Ensure combustion air supply is unimpeded.
2.4.3 Electrical work
When working on live components please ensure you:
observe the accident prevention instructions (e.g.DGUV Regulation 3) and
adhere to local directives
use tools in accordance with EN IEC 60900
The device contains components, which could be damaged by electrostatic
discharge (ESD).
When working on circuit boards and contacts:
do not touch circuit boards or contacts
if necessary, take ESD protective measures

Installation and operating instruction
Gas burner WG10…/0-D ZMI
2 Safety
83326002 1/2023-10 Ch 9-124
2.4.4 Gas supply
Only the gas supply company or an approved contract installation company may
carry out installation, alteration and maintenance work on gas appliances in
buildings and properties.
Pipework must be subject to a combined load and valve proving test and/or
usability testing relative to the pressure range intended, e. g. DVGW-TRGI,
worksheet G 600.
Inform the gas supply company about the type and size of plant prior to
installation.
Local regulations and guidelines must be observed during installation, e. g.
DVGW-TRGI, worksheet G 600; TRF Band 1 and Band 2.
The gas supply pipe work should be suitable for the type and quality of gas and
should be designed in such a way that it is not possible for liquids to form, e.g.
condensate. Observe vaporisation pressure and vaporisation temperature of
liquid petroleum gas.
Use only tested and approved sealing materials, whilst observing all process
information.
Re-commission the appliance when changing to a different type of gas.
Changing from LPG to Natural Gas and visa versa requires a conversion.
Carry out soundness test after each service and fault rectification.
2.5 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.
Do not use combustion chamber inserts, which hinder flame burnout.
Use only original Weishaupt replacement parts.
2.6 Noise emission
The noise emissions are determined by the acoustic behaviour of all components
fitted to the combustion system.
Prolonged exposure to high noise levels can lead to loss of hearing. Provide
operating personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.
2.7 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 10-124
3 Product description
3.1 Type key
WG10N/0-DZMI
Type
W Series: Compact burner
G Fuel: Gas
10 Size
N N: Natural Gas
F: Liquid Petroleum Gas
0 Ratings size
D Construction
Version
ZMI Type of control: modulating, extended turndown ratio
3.2 Type and serial number
The type and serial number on the type plate clearly identify the product. They are
required by Weishaupt's customer service department.
1
1Name plate
Type: Ser. No.:

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 11-124
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 actuator automatically closes the air damper. This reduces
heat loss in the heat exchanger.
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 switch monitors the fan pressure. If the fan pressure is insufficient,
the combustion manager initiates a lockout.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 12-124
3.3.2 Gas supply
Gas isolation valve 1
The gas isolation valve opens and shuts off the gas supply.
Gas filter 2
The gas filter protects the subsequent valve train components from foreign
particles.
Pressure regulator 3
The pressure regulator reduces the connection pressure and ensures a constant
set pressure.
Double gas valve 4
The double gas valve opens and shuts off the gas supply.
Gas butterfly valve 5
The gas butterfly valve regulates the gas quantity depending on the rating required.
The combustion manager drives the gas butterfly valve via actuator.
High gas pressure switch 6 (optional)
Depending on the burner application, optional equipment may be required for
optimum operation.
The high gas pressure switch monitors the set pressure. If the set pressure
exceeds the set value, the combustion manager initiates a controlled shutdown.
Low gas pressure switch/valve proving gas pressure switch 7
The gas pressure switch monitors the gas connection pressure. If the preset
pressure 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 lockout or power outage
1. Test phase (function sequence for valve proving valve1):
valve 1 closes
valve 2 closes after a delay
the gas escapes and the pressure between valve1 and valve2 reduces
both valves remain closed for 8 seconds
If the pressure increases above the set value during these 8 seconds, valve1 is
leaking. The combustion manager initiates a controlled shutdown.
2. Test phase (function sequence for valve proving valve2):
valve 1 opens, valve 2 remains closed
pressure between valve1 and valve2 increases
valve 1 closes again
both valves remain closed for 16 seconds
If the pressure decreases below the set value during these 16 seconds, valve2 is
leaking. The combustion manager initiates a controlled shutdown.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 13-124
Control pressure regulator 8
The fan pressure influences the pressure at the outlet of the control regulator via an
impulse line. If the fan pressure increases, the pressure at the outlet of the control
regulator also increases and visa versa. This extends the turndown ratio of the
burner.
V1
V2
P P
68
31
7
42
5
3.3.3 Electrical components
Combustion Manager
The combustion manager W-FM is the control unit of the burner.
It controls the sequence of operation and monitors the flame.
Operating panel
The values and parameters of the combustion manager can be displayed and
changed at the operating panel.
Burner motor
The burner motor is driven via a frequency converter.
The burner motor drives the fan wheel.
Frequency converter
The frequency converter regulates the speed of the burner motor according to the
burner capacity required.
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 ionisation electrode.
If the flame signal becomes too weak, the combustion manager carries out a
controlled shutdown.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 14-124
3.3.4 Program sequence
The operating phases for commissioning the burner are shown on the display.
Phase Function
TEST After the power supply has been switched on the combustion manager performs a self-test.
G L At heat demand, the actuators for the air damper and the gas butterfly valve drive to the reference
point.
1The combustion manager monitors for extraneous light.
2The air damper actuators drives to pre-purge (operating point P9). The gas butterfly valve actuator
drives to ignition position (operating point P0).
3Pre-purge is initiated. The air pressure switch reacts.
4Pre-purge. The remaining pre-purge time is displayed.
5The air damper actuator drives to ignition position (operating point P0).
6Gas valve1 opens. The gas pressure switch reacts. Ignition starts.
7Gas valve2 opens. The fuel is released. The safety time begins. The display shows symbol .
8Flame stabilisation.
9The 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 damper and gas butterfly valve drive to
partial load. The fuel supply is shut off. The burner motor continues to run.
Valve proving starts.
1. Test phase (function sequence for valve proving valve1):
valve 1 closes
valve 2 closes after a delay
the gas escapes and the pressure between valve1 and valve2 reduces
12 Test time valve1.
13 2. Test phase (function sequence for valve proving valve2):
valve 1 opens, valve 2 remains closed
pressure between valve1 and valve2 increases
valve 1 closes again
14 Test time valve2.
15 Following the post-purge phase the burner motor switches off. The actuators of the air damper and
gas butterfly valve close.
OFF Standby, no heat demand.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 15-124
TV
TS
TP1
TP2
B4
P11
W-FM 25
P
B16
T8 T6T7
B 10
P
11
B31
P
12
B33
P
15 5
K32
5
21
3
T1
4
P
P
B15
LT1 T2
F2
N
LN
M
M20
1234
M
M38
1234 5
TI
L/A G
B1
13
T20 M1
M
3
T
N
B1 Ionisation electrode 1CLOSED position
B10 Air pressure switch 2Ignition position
B15 Temperature or pressure regulator 3Partial load
B16 Temperature or pressure regulator full load 4Full load
B31 Low gas pressure switch/valve proving gas
pressure switch
5Operating phase
B33 High gas pressure switch (optional) TIInitialisation time (Test): 3 s
F2 Temperature or pressure limiter TNPost-purge time: 2 s [ch.6.2.3].
K32 double gas valve TP1 1. Test phase: 8 s (valve proving valve1)
M1 Burner motor TP2 2. Test phase: 16 s (valve proving valve2)
M20 Air damper actuator TVPre-purge time: 20 s
M38 Gas butterfly valve actuator TSSafety time: 3 s
P11 Control lamp operation (optional) Voltage is applied
T1 Ignition unit Flame signal present
T20 Frequency converter Current path

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 16-124
3.3.5 Inputs and outputs
Observe wiring diagram supplied.
-weishaupt-
13
3
N
7
3
C
4
1
6
5
14
L
N
T1
T2
S3
B4
B5
T6
T7
T8
GL/A AM FC NA P TWI
8
11
15
12
X6
X7
F7
1
2
TWI TWI interface (VisionBox, accessory)
P O2 sensor (accessory)
NA Speed signal (Namur)
FC Frequency converter
AM Operating panel
L/A Air damper actuator
G Gas butterfly valve actuator
1Slot analogue module EM3/3 or Fieldbus module EM3/2
2W-FM cover
1 Not used
3C Frequency converter for continuous running fan
3N Frequency converter
4 Ignition unit
5 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 gas pressure switch/valve proving gas pressure switch
13 Ionisation
14 Remote reset or low gas pressure switch (optional)
15 Bridging plug No. 15 or high gas pressure switch
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (T6.3H, IEC 127-2/5)

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 17-124
3.4 Technical data
3.4.1 Approval data
PIN (EU) 2016/426 -
Basic standards EN676:2020
Additional standards, see EU Declaration of
Conformity.
3.4.2 Electrical data
Mains voltage / Mains frequency 230 V/50 Hz
Consumption at start max307 W
Consumption during operation max207 W
Power consumption max 1.4 A
Internal unit fuse T6.3H, IEC 127-2/5
External fuse max 16 AB
3.4.3 Ambient conditions
Temperature in operation –15 … +40 °C
Temperature during transport/storage –20 … +70 °C
relative humidity max 80 %, no dew point
Installation elevation max 2000 m(1
(1 Consultation with Weishaupt is required for higher installation elevation.
3.4.4 Permissible fuels
Natural Gas E/LL
Liquid Petroleum Gas B/P

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 18-124
3.4.5 Emissions
Sound levels
Dyad noise emission values
Measured sound power levelLWA (re 1 pW)
Uncertainty value KWA
68
4
dB(A)(1
dB(A)
Measured sound pressure level LpA (re 20 μPa)
Uncertainty value KpA
63
4
dB(A)(2
dB(A)
(1 Determined to ISO 9614-2.
(2 Determined at 1 metre distance from the front of the burner.
The measured noise levels plus uncertainty values form the upper limit value, which
could occur when measuring.

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 19-124
3.4.6 Rating
Combustion heat rating
Natural Gas
LPG
4.5…60 kW
5.5…60 kW
Capacity graph
The capacity data given relates to an installation elevation of 0m above sea level.
For installation elevations above 0m a capacity reduction of
approx.1%per100m applies.
A limited capacity graph is valid for ducted air intake.
Combustion heat rating at combustion head setting:
Natural Gas Liquid Petroleum Gas
Combustion head OPEN 3 5
Combustion head CLOSED 4 6
-7
-8
-9
-6
-5
-4
-3
-2
-1
1
65 70
60
55
40
35
30
25
20
15
10
5
0
0
50
45
2
5
4
6
3
1Combustion heat rating [kW]
2Combustion chamber pressure [mbar]

Installation and operating instruction
Gas burner WG10…/0-D ZMI
3 Product description
83326002 1/2023-10 Ch 20-124
3.4.7 Dimensions
Burner
–weishaupt–
Rp¾
110 mm
165 mm
90 mm
270 mm
245 mm
115 mm
31,5 mm
353 mm
330 mm
164 mm
349 mm
1
2
1210 mm without combustion head extension
310 mm with combustion head extension (100 mm)
410 mm with combustion head extension (200 mm)
510 mm with combustion head extension (300 mm)
2140 mm without combustion head extension
240 mm with combustion head extension (100 mm)
340 mm with combustion head extension (200 mm)
440 mm with combustion head extension (300 mm)