Weishaupt WG20 Series User manual

Gas Burner WG20.../1-C ZM-LN (W-FM 25) 83055116 • 1/2016-05
Installation and Operating Instructions
manual
Certified for use in USA / Canada
Conforms to / à UL std 795 (R2013), UL std 295 (R2015) and UL std 296 (R2013)
Certified / certifié CSA std 3.4 (R2009)

Front cover: WG20.../1-C ZM-LN
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3
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
1 User instructions........................................................................................................................... 5
1.1 Information for user..............................................................................................................5
1.1.1 Symbols................................................................................................................................. 5
1.1.2 Target group..........................................................................................................................5
1.2 General instructions.............................................................................................................6
2 Safety information........................................................................................................................ 7
3 Technical description..................................................................................................................9
3.1 Permissible applications.....................................................................................................9
3.2 Nomenclature........................................................................................................................9
3.3 Basic functions..................................................................................................................... 9
3.3.1 Air supply.............................................................................................................................10
3.3.2 Gas supply..........................................................................................................................10
3.3.3 Electrical components......................................................................................................11
3.3.4 Program sequence............................................................................................................12
3.3.5 Inputs and outputs............................................................................................................ 14
3.4 Technical data.................................................................................................................... 15
3.4.1 Electrical data.....................................................................................................................15
3.4.2 Ambient conditions........................................................................................................... 15
3.4.3 Permissible fuels................................................................................................................15
3.4.4 Capacity.............................................................................................................................. 16
3.4.5 imensions......................................................................................................................... 17
3.4.6 Weight............................. ...................................................................................................17
4 Installation......................................................................................................................................18
4.1 Preparations prior to installation.....................................................................................18
4.2 Burner installation..............................................................................................................19
4.2.1 Rotate burner by 180º...................................................................................................... 20
4.3 Gas supply..........................................................................................................................21
4.4 Electrical connection........................................................................................................ 22
5 Operation........................................................................................................................................23
5.1 Operating interface........................................................................................................... 23
5.2 isplay................................................................................................................................. 25
5.2.1 Info mode.............................................................................................................................26
5.2.2 Service mode......................................................................................................................27
5.2.3 Parameter mode................................................................................................................ 28
5.2.4 Access mode......................................................................................................................29
5.3 Linearization........................................................................................................................30
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6 Commissioning and startup..................................................................................................31
6.1 Conditions...........................................................................................................................31
6.1.1 Connecting measuring device........................................................................................32
6.1.2 Air pressure switch presetting........................................................................................33
6.1.3 Gas pressure regulator presetting.................................................................................33
6.1.4 Setting values.....................................................................................................................34
6.2 Burner setting.....................................................................................................................35
6.3 Setting air pressure switch..............................................................................................42
6.4 Concluding works............................................................................................................. 42
6.5 Combustion analysis.........................................................................................................43
6.6 Calculating gas throughput.............................................................................................44
6.7 Subsequent optimization of the operating points.......................................................45
7 Shutdown....................................................................................................................................... 46
8 aintenance and service........................................................................................................47
8.1 Notes on maintenance and service................................................................................47
8.2 Service plan........................................................................................................................ 48
8.3 Removing and re-installing the mixing head.................................................................49
8.4 Setting the mixing head....................................................................................................50
8.5 Setting the ionization and ignition electrodes..............................................................51
8.6 Service position................................................................................................................. 52
8.7 Removing and re-installing the blower wheel.............................................................. 53
8.8 Removing the burner motor.............................................................................................54
8.9 Removing and re-installing the air damper stepping motor......................................55
8.10 Removing and re-installing the angle drive...................................................................56
8.11 Removing and re-installing the gas butterfly stepping motor...................................57
8.12 Removing and re-installing the gas butterfly valve...................................................... 58
8.13 Removing and re-installing the air regulator................................................................. 59
8.14 Replacing the combustion manager..............................................................................58
8.15 Replacing the combustion manager’s fuse..................................................................62
9 Faults rectification......................................................................................................................63
9.1 Procedures during fault condition..................................................................................63
9.1.1 isplay off............................................................................................................................63
9.1.2 isplay showing OFF........................................................................................................63
9.1.3 isplay flashing.................................................................................................................. 64
9.1.4 etailed fault codes.......................................................................................................... 65
9.2 Faults codes, causes and rectification..........................................................................66
9.3 Operating problems..........................................................................................................71
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
83055116 • 1/2016-05

5
1 User instructions
1.1 Information for user
This installation and operating instruction is part of the equipment and must be kept at
the installation at all time. As supplement to this document is the Installation and
Operating Instructions for Combustion Manager W-FM 25.
1.1.1 Symbols
1.1.2 Target group
This installation and operating instruction is designated for the user and qualified
personnel only. It is to be placed at the installed equipment.
Only competent personnel may work on the appliance. Competent personnel, according
to this operating manual, are persons who are familiar with the installation, mounting,
setting and commissioning of the product and have the necessary qualifications and
training.
DANGER
CAUTION
WARNING
u
P
n
...
indicates imminent hazardous situation, which if not avoided
will result in death or serious injury
indicates potential hazardous situation, which if not avoided
could result in death or serious injury
indicates potential hazardous situation, which if not avoided
may result in minor or moderate injury
important information
requires direct action
result of an action
counting
value range
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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6
1 User instructions
1.2 General Instructions
Any work on the burner or applicable interfaced products (controls) must be complet-
ed within the guidelines of the manufacturer’s instructions and applicable local and
national codes. Such work must only be undertaken by fully qualified and trained per-
sonnel, familiar with the products.
The operation of all safety devices including limit circuits, monitoring equipment and
regulating equipment must be tested and correctly adjusted before the installation is
left unattended.
I PORTANT
Burners must have at least one shutdown every 24 hours of operation; otherwise the
burner should be equipped with self-check flame sensing devices.
Installation
Standard Weishaupt burners are designed for indoor use only. For outdoor installa-
tions, contact your Weishaupt representative.
The installation of any Weishaupt product must be carried out by fully qualified and
licensed personnel.
The personnel performing the work must be familiar with, and operate within the appli-
cable local and national codes, such as CAN/CSA B149.1, 2, 3, CAN/CSA B139-00,
NFPA 54/58, NFPA30/31 and all other applicable codes and standards to the satis-
faction of the authority having jurisdiction. The installer is responsible for meeting all
these requirements and codes.
Attention must also be given to the minimum clearance of related appliance to permit
access for service and maintenance purposes and to the distance from combustible
material as required by all applicable codes to ensure safe operation.
General information for gas operation
An independent vent to outside of the building, sized in accordance with the regulator
manufacturer’s instructions, shall be provided. Where there is more than one regulator
at a location, each regulator shall have a separate vent to the outside.
Before being connected to the burner, the gas train shall be pressure tested using
either air or an inert gas as ruled by applicable codes.
The gas manifold pressures listed for each gas or combination gas/oil burner are
approximate figures obtained from tests on test boilers under ideal conditions.
Manifold pressures are only to be used as a guide during start up. The only accurate
method of determining the exact fuel throughput of the burner is by clocking the gas
meter and applying the respective correction factors for pressure and temperature.
aintenance and Services
Burner components such as combustion manager, stepping motors, gas valves, nozzle
heads, etc are not user serviceable. Failure to heed this can cause property damage,
severe personal injury or loss of life.
We recommend regular plant maintenance of all combustion equipment. It saves fuel
and ensures good combustion. Excellent combustion quality is a pre-requisite for an
environment-friendly operation.
The annual maintenance and inspection program should include inspection of elec-
trodes, flame sensors, flame signal strength readings, inspection and testing of all
safeties including air pressure switch, flange switch, gas pressure switches, interlocks,
motor overloads, etc. Also the burner should be inspected for any mechanical damage.
The flame tube should be inspected for warpage, damage, holes, etc. The mixing head
and diffuser should be inspected for damage, missing bolts, etc. The head setting
should be checked and oil nozzles should be inspected and replaced as required.
epending on the degree of contamination, the combustion air blower wheel, ignition
electrodes, flame sensor and air intake should be cleaned as required.
The moving/rotating burner parts require no lubrication. Motor bearings damage, which
is recognized and serviced quickly, prevents more extensive damage to the burner.
evelopment of noise in the motor bearings should be investigated immediately.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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2 Safety information
Dangers when using the equipment
Weishaupt products are manufactured in accordance with the relevant existing
standards and guidelines, and the recognized safety laws. However, improper use of the
equipment could endanger the life of the user or third party or result in damage to the
plant.
To avoid unnecessary danger, the equipment must only be used:
• For its intended purpose;
• Under ideal safety conditions;
• With reference to all the information in the installation and operating instructions;
• In accordance with inspection and service work.
Faults, which could affect the safe operation of the burner, should be rectified at once.
Personnel training
Only competent personnel may work on the appliance. Competent personnel, according
to this operating manual, are persons who are familiar with the installation, mounting,
setting and commissioning of the product and have the necessary qualifications such as:
• Training, instruction or authorization to switch electrical circuits and electrical devices
on and off, to ground them and to mark them in accordance with the safety standards.
• Training, instruction or authorization to carry out installation, alteration and
maintenance work on gas installations in buildings and on site.
Organizational measures
• The necessary protective clothing should be worn by everyone working in the plant.
• All safety devices should be checked regularly.
Informal safety measures
• In addition to the Installation and Operating Instructions, local codes of practice
should also be adhered to. Special attention should be given to the relevant
installation and safety guidelines.
• All safety and danger notices should be kept in a legible condition.
Safety measures in normal operation
• Only use the equipment when all safety devices are fully functional.
• At least once a year, the equipment, including all safety devices, should be checked
for signs of visible damage and to ensure that all safety devices are operating
correctly.
• More frequent safety checks may be required depending on plant conditions.
Electrical safety
• Work on the electrical supply must be carried out only by a qualified technician.
• Electrical components should be checked during servicing. Loose connections and
damaged cables should be fixed immediately.
• Control panel should be kept locked. Access should be limited to authorized
personnel with the appropriate key or tool.
• Should it become necessary to carry out work on live parts, a second person should
be present to switch off the main supply in case of an emergency.
aintenance and fault rectification
• Necessary installation, service and inspection work should be carried out at the
specified time.
• Inform the operator before beginning any service work.
• Prior to all service, inspection and repair works, electrically isolate the equipment and
ensure the main switch cannot be accidentally switched back on. Cut off the fuel
supply.
• If during servicing or testing, sealed joints have to be opened, these have to be
thoroughly cleaned to ensure tight sealing when reassembling. amaged seals must
be replaced. Carry out a gas train leak test!
• Flame monitoring devices, limit controls, correcting elements and all the other safety
devices must be commissioned by, and may only be replaced by the manufacturer or
an authorized agent.
• Screwed connections, which have been loosened, must be re-tightened without cross
threading.
• Following service work, all safety devices should be tested to ensure their correct and
proper functions.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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2 Safety information
Alteration to the equipment
• No alterations to the equipment are to be made without the approval of the
manufacturer. All conversions require written permission from Weishaupt
Corporation.
• Any parts not in perfect working condition should be replaced immediately.
• No additional components, which have not been tested for use with the equipment,
may be installed.
• Use only genuine -weishaupt- replacement and connection parts.
• Parts from other manufacturers are not guaranteed to be suitable to meet the
necessary operational and safety requirements.
Alterations to the combustion chamber
• No alterations, which hinder constructive predetermined flame formation, are to be
made to the combustion chamber.
Cleaning of the equipment and water disposal
• All used materials should be handled and disposed correctly with due regards to the
environment.
Noise levels
ependent on site conditions, noise could be of a sufficient level to cause hearing
damage. In this case, the operating personnel must be equipped with noise protection.
General information for gas operation
• When installing a gas combustion system, regulations and guidelines must be closely
followed (e.g. Local Codes of Practice and Regulations).
• The subcontractor responsible for the installation or changes of the gas system must
inform the gas supplier of the type and extent of the planned installation and the
intended work. The subcontractor must ascertain that an adequate gas supply to the
installation is ensured.
• Installations, alterations and maintenance work on gas systems in buildings and below
ground must only be carried out by installers who have a contract with the gas
supplier.
• The gas train must be subject to a preliminary and main test or the combined loading
test and soundness test, according to the pressure range intended.
• The air or purge gas required for gas train test must be expelled from the gas train.
Gas train must be completely purged and primed prior to starting burner.
Gas characteristics
The following information must be obtained from the gas supplier:
• Type of gas.
• Calorific value in BTU/cu-ft.
• Max. CO2content in the flue gas.
• Gas supply pressure.
Pipe thread connections
• Only tested and approved sealing material should be used. Please observe the
prevailing user instructions.
Soundness test
• Brush connection points with foaming agents or similar, non-corroding materials.
Conversion to other gases
• When converting to another gas type, a conversion kit and re-commissioning are
required.
I PORTANT
Conversion to other gas types
The conversion from one gas to another will require:
1. Re-adjustment of the burner.
2. Possible change of parts in the combustion head.
3. Possible new gas train.
Contact Weishaupt prior to changing the type of gas.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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3 Technical description
3.1 Permissible applications
Weishaupt gas burner WG20.../1-C ZM-LN is suitable for the following applications:
• Installation on heat exchanger.
• Warm water boiler .
• Steam boiler and hot water boiler.
• Intermittent and continuous operation.
• Hot air generator.
Any discrepancy from the above described applications requires written confirmation
from Weishaupt Corporation.
To comply with specific NOx requirement, a minimum specific combustion chamber
dimensions must be followed:
• The burner must only be operated with the type of gas indicated on the burner plate.
• The burner must only be operated under permissible ambient conditions.
• The burner must not be used outdoor. It is only suitable for indoor operation.
• The gas supply pressure must not exceed the rated gas pressure indicated on the
rating plate.
• The burner must not be used outside of its capacity range.
Faults, which could affect the safe operation of the burner, should be rectified
immediately.
3.2 Nomenclature
WG20N/1-C Z -LN
W Type: Weishaupt burner
- G Fuel: Gas
20 Burner size
N N: Natural Gas
F: LPG
/1 Capacity range
-C Revision
ZM Version: sliding two stage or modulating
-LN Version: LowNOx
3.3 Basic functions
• Automatic power gas burner for sliding two stage or modulating operation;
• Electronic ratio controller for all actuators;
• Operation and control via the operating interface.
Combustion manager
• Controlling the sequence of operation;
• Flame monitoring;
• Communicating with the stepping motors.
Ionization electrode
Monitors the flame during all phases of operation. If the flame signal does not
correspond to the sequence of operations, a safety lockout will be initiated.
Actuators
Stepping motors mounted on:
• Air damper;
• Gas butterfly valve.
These motors allow precise and direct regulation in conjunction with the electronic fuel –
air ratio controller.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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3 Technical description
3.3.1 Air supply
Air damper
The air damper actuator controls the amount of combustion air for optimum combustion.
When the burner is in stand-by position, the air damper closes automatically.
Blower fan
The blower fan is driven by the burner motor. It supplies air through the air inlet via air
damper to the mixing head.
Air pressure switch
In case of failed air supply, the air pressure switch initiates a safety lockout.
ixing head
The air gap between the flame tube and the diffuser is adjusted depending on the burner
maximum firing rate.
3.3.2 Gas supply
Gas train
Weishaupt gas and dual fuel burners are equipped as standard with dual safety gas
valves, in single or double valve body configuration.
* This gas train configuration is for reference only. Actual gas train configuration may
vary depending on applicable codes/ regulations
1 Gas shut off valve
The gas shut off valves open and shut off the gas supply to the burner and/or pilot.
2 Gas pressure regulator SKP25
The SKP25 is a motorized valve actuator with integrated pressure regulator. It opens and
shuts the V2 valve according to the burner startup or shutdown sequence and it also
regulates the gas pressure to the burner corresponding to the burner’s firing rate.
3 Dual gas valves
The dual gas valves open and shut the gas supply to the burner and are controlled by the
combustion manager.
4 Gas butterfly valve
The butterfly valve controls the amount of gas corresponding to the burner firing rate.
The combustion manager controls the gas butterfly valve via dedicated stepping motor.
5 High gas pressure switch
A high gas pressure switch is connected to the safety interlock causing a lockout
whenever the gas pressure is higher than the set point.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
83055116 • 1/2016-05
V1V2
P
P
2
7
P
5
6
1
4
13

Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
11
83055116 • 1/2016-05
3 Technical description
3.3.2. Gas supply (cont.)
6 Low gas pressure switch
The low gas pressure switch monitors the gas supply pressure. With too low gas
pressure, the burner start will be prevented.
7 Additional low gas pressure switch
The additional low gas pressure switch monitors the gas pressure downstream of the
pressure regulator SKP25. For the burner start, the additional low gas pressure switch is
bridged by a timer for max. 5 sec. If the gas pressure switch is closed when the time has
elapsed, the V2 valve remains powered. If the output pressure drops below the setting
point, the pressure switch opens and cuts the power supply to the V2 valve actuator.
The V2 valve closes and the combustion manager initiates a lockout.
3.3.3 Electrical components
Combustion manager
The W-FM combustion manager is the main burner control unit. It controls the sequence
of burner operations, monitors the flame and communicates with all related components
in the system.
Operating interface
Via the operating interface, the operational related values and parameters of the com-
bustion manager can be displayed and changed. It is connected to the main unit via a
dedicated communication cable.
Burner motor
The burner motor drives the blower wheel. The combustion manager controls a motor
starter to run the burner motor.
Ignition device
The electronic ignition device generates spark at the electrodes to ignite the fuel-air mix-
ture during the ignition sequence.
Ionization electrode
The combustion manager monitors the flame signal via the ionization electrode. Should
the flame signal becomes too weak, a safety shutdown will be initiated.

12
3 Technical description
3.3.4 Program sequence
The burner operating phases are shown on the display, as following:
Phase Function
TEST After the power supply is switched on, the combustion manager performs a self-test.
G L At call for heat, the air and gas stepping motors drive to the reference position.
1 The combustion manager monitors for extraneous light or flame.
2 The air damper stepping motor drives to pre-purge (operating point P9 ). The gas butterfly stepping
motor drives to ignition position (operating point P0 ).
3 The pre-purge is started. The air pressure switch is checked and must be closed.
4 Pre-purge. The remaining pre-purge time is displayed.
5 The air damper stepping motor drives to ignition position (operating point P0 ).
6 Gas valve V1 opens. The low gas pressure switch is checked and must be closed. Ignition spark starts.
7 Gas valve V2 opens. The gas is released. The safety time begins. The display shows the symbol
8 Flame stabilization. The high gas pressure switch is checked and must be closed.
9 The air damper and gas butterfly valve stepping motors drive to low fire.
10 The burner is in operation. Ready for modulation.
11...14 Valves proving sequence is activated - optional, for special applications.
15 Following the post-purge, the burner motor is turned off. The air damper and gas butterfly valve are closed.
OFF Stand-by, no call for heat.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
3 Technical description
B1 Ionization electrode 1CLOSE position
B10 Air pressure switch 2Ignition position
B15 Temperature/pressure operating ctrl. (On/Off) 3Low fire
B16 Temperature/pressure 2-stage or modulating ctrl. 4High fire
B31 Low gas pressure switch 5Operating phase
B33 High gas pressure switch TIInitialization time (test): 3 sec
F2 Temperature/pressure safety limit TNPost-purge time: 2 sec
K32 ouble gas valve TP1 1. Test phase: 8 sec (proving V1 - optional)
K33 External valve LPG (optional) TP2 2. Test phase: 16 sec (proving V2 - optional)
M1 Burner motor TVPre-purge time: 60 sec
M20 Air damper stepping motor TSSafety time: 4 sec
M38 Gas butterfly valve stepping motor The device is energized
P11 Burner status light (optional) Flame signal is present
T1 Ignition unit Current path
S32 Proof of Closure switch V2 (POC2) S34 Proof of Closure switch V1 (POC1)
Operating phases 11 to 14 are only applicable if the valve proving system (VPS) is
activated.
TV
TS
TN
TP1
TP2
B4
P11
W-FM 25
K33
1
P
B16
T6T8T7
B10
P
11
B31
P
14
B33
P
15 5
K32
5
21
M
1
M1
3
T1
4
P
P
B15
LT1 T2
F2
N
LN
M
M20
1234
M
M38
1234 5
TI
L/AG
B1
13
S34
12
S32

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Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
3 Technical description
3.3.5 Inputs and outputs
See the wiring diagram - Ch. 3.3.4
TWI TWI Interface (VisionBox)
P Not used
NA Speed signal (Namur)
VS Variable speed drive
AM Operating panel
L/A Air damper stepping motor
G Gas butterfly valve stepping motor
1Slot for analogue module EM3/3 or Fieldbus module EM3/2
1 External valve LPG (optional)
3C Burner motor for continuous running blower
3N Burner motor for normal blower operation
4 Ignition unit
5 ouble gas valves
6 Not used
7 Bridging plug No. 7
8 Gas meter (impulse generator)
11 Air pressure switch
12 Gas valves Proof of Closure switches (POC)
13 Ionization electrode
14 Low gas pressure switch
15 High gas pressure switch
X6 7-pole connection plug (power supply, On/Off control, status signals)
X7 4-pole connection plug (2-stage or modulating control)
F7 Internal unit fuse, 6.3 AT
-weishaupt-
13
3
N
7
3
C
4
1
6
5
14
L
N
T1
T2
S3
B4
B5
T6
T7
T8
G L/A AM FU NA P TWI
8
11
15
12
X6
X7
F7
1

15
3 Technical description
3.4 Technical data
3.4.1 Electrical data
Burner control
Mains voltage / frequency 110 V / 60Hz
Power consumption - start max 436 W
Power consumption - operation max 336 W
Operating current max 3 A
Internal fuse 6.3 AT
External fuse 15 AT
Burner motor ECK04/A-2/1
Mains voltage/ frequency 110 V, 60 Hz - 1~
Power 0.31 HP (0.23 kW)
Current 3.7 A @ 110 V
Speed 3,460 rpm
External fuse 10 AT
3.4.2 Ambient conditions
Operating temperature 5 ... 100° F (-15 ... +40° C)
Transport / storage temperature -4 ... 158° F (-20 ...+70° C)
Relative humidity max 80%, no condensation
3.4.3 Permissible fuels
- Natural gas
- Propane
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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3 Technical description
3.4.4 Capacity
Firing rate
Natural gas 119 ... 682 MBTU/H
Propane 119 ... 682 MBTU/H
Combustion head WG20-C
Capacity graph
The capacity graph is based on fuel with low calorific value and tested at sea level.
Capacity reduction should be applied depending on the altitude of the installation:
approx. 1% per 328 ft. (100 m) above sea level.
Capacity reduction might be required for burners with ducted air intake.
-0.25
0
0.25
0 100 200 300 400 500 600 700
2
1
0.5
0.75
1.0
1.25
1Firing rate in MBTU/H
2Combustion chamber backpressure in “w.c.
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
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17
3 Technical description
3.4.5 Dimensions
–weishaupt–
14-3/4” (376 mm)
14-1/8” (358 mm)
7” (178 mm)
15-5/8”
(397 mm)
4-3/4”
(120 mm)
7-1/8”
(182 mm)
10-3/8”
(264 mm) 3/4”
(20 mm)
6-1/4”
(158 mm)
1-1/4”
(32 mm)
10-5/8”
(270 mm)
Rp1”
1
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
83055116 • 1/2016-05
15-1/2” (140 mm) - without combustion head extension
9-1/2” (240 mm) - with 3-7/8” (100 mm) combustion head extension
13-3/8” (340 mm) - with 7-7/8” (200 mm) combustion head extension
17-3/8” (440 mm) - with 11-3/4” (300 mm) combustion head extension
3.4.6 Weight
Approx. 61 lbs (28 kg).

18
4 Installation
4.1 Preparation prior to installation
Check burner’s rating plate and capacity graph
uCheck the burner type and rating.
uThe burner rating must be within the operating range of the heating appliance. The
ratings given on the burner plate are the minimum and maximum possible firing rates
of the burner. See the capacity graph in chapter 3.4.4.
Check the installation space
uEnsure sufficient space for the burner installation and maintenance.
uEnsure sufficient fresh air supply to the burner - if required, install air ducting.
Preparing the heating appliance
The refractory 3 must not protrude beyond the front edge of the combustion head. The
refractory can take a conical shape (min 60°). Refractory may not be required on boilers
with water-cooled fronts, unless the manufacturer gives other instructions.
The gap 4between the flame tube and the refractory must be filled with resilient
insulation material (do not make solid).
Heat exchangers with deep refractories or thick doors, or heat exchangers with reverse
flame combustion chambers may require a combustion head extension. Head extensions
of 3-7/8” (100 mm), 7-7/8” (200 mm) and 11-3/4” (300 mm) are available. The
dimension 2changes accordingly with the used head extension.
45°
6-3/4”
(170 mm)
M8
5-1/8”
(130 mm)
60°
5-3/8”
(135 mm)
4-3/4”
(120 mm)
2
1
4
3
1Boiler plate
25-1/2” (140 mm)
3Refractory
4Gap
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
83055116 • 1/2016-05 18
83055116 • 1/2016-05

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4 Installation
4.2 Burner installation
SWITCH OFF POWER FIRST!
uPrior to the installation, switch off the mains switch and the safety switch. Failure to
comply could cause death or serious injury by electric shock.
The burner in its standard version is designed for gas train connection from the right. For
left side gas train connection, the burner must be installed rotated by 180° and
additional conversion measures are required.
uAttach the flange gasket 2 and the burner flange 1 to the heat exchanger using
screws 3.
uThe gap between the flame tube and the refractory should be filled with flame-proof,
resilient insulating material (do not make solid!).
uInstall burner to the burner flange using screws 1.
uCheck the ignition and ionization electrodes’ settings.
uInstall the mixing head.
1
32
Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
83055116 • 1/2016-05
DANGER
1

Installation and Operating Instructions
Gas burner WG20.../1-C ZM-LN (W-FM 25)
20
83055116 • 1/2016-05 20
83055116 • 1/2016-05
4 Installation
4.2.1 Rotate burner by 180°
uInstall the operating interface 1on the opposite side of the burner’s housing.
uInstall the fixing bracket of the burner housing 3on the opposite side of the burner’s
housing.
uRotate the burner flange 2by 180° and installed it with the flange gasket.
uRotate the burner by 180° and install screws 4 to the burner flange.
uThe gap between the flame tube and the refractory should be filled with flame-proof,
resilient insulating material (do not make solid!).
uCheck the ignition and ionization electrodes’ settings.
uInstall the mixing head.
3
4
1
2