Weishaupt WG40 2-A ZM-PLN Series User guide

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN 83321902 1/2022-10

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
83321902 1/2022-10 Luw 2-128
1 User instructions.............................................................................................................. 5
1.1  Target group.................................................................................................................. 5
1.2  Symbols.......................................................................................................................... 5
1.3  Guarantee and Liability............................................................................................... 6
2 Safety ..................................................................................................................................... 7
2.1  Designated application............................................................................................... 7
2.2  When gas can be smelled ......................................................................................... 7
2.3  Safety measures........................................................................................................... 7
2.3.1  Personal protective equipment (PPE) ..............................................................7
2.3.2  Normal operation...................................................................................................7
2.3.3  Electrical work........................................................................................................8
2.3.4  Gas supply..............................................................................................................8
2.4  Alterations to the construction of the equipment ................................................. 8
2.5  Noise emission ............................................................................................................. 8
2.6  Disposal ......................................................................................................................... 8
3 Product description ........................................................................................................ 9
3.1  Type key ......................................................................................................................... 9
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....................................................................................... 14
3.3.4  Inputs and outputs ............................................................................................. 15
3.3.5  Program sequence............................................................................................. 16
3.4  Technical data.............................................................................................................18
3.4.1  Approval data...................................................................................................... 18
3.4.2  Electrical data ..................................................................................................... 18
3.4.3  Ambient conditions............................................................................................ 18
3.4.4  Fuels...................................................................................................................... 18
3.4.5  Emissions............................................................................................................. 19
3.4.6  Rating.................................................................................................................... 20
3.4.7  Dimensions .......................................................................................................... 21
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).................................................................... 26
4.2.2  Rotate air filter box by 180° (optional) .......................................................... 27
5 Installation ........................................................................................................................ 29
5.1  Gas supply ..................................................................................................................29
5.1.1  Installing the gas valve train............................................................................. 30
5.1.2  Carry out soundness test of gas supply line and vent............................... 32
5.2  Electrical connection.................................................................................................32
6 Operation .......................................................................................................................... 34
6.1  Operating panel..........................................................................................................34

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
83321902 1/2022-10 Luw 3-128
6.2  Display..........................................................................................................................36
6.2.1  Info level ............................................................................................................... 37
6.2.2  Service level ........................................................................................................ 38
6.2.3  Parameter level ................................................................................................... 39
6.2.4  Access level ........................................................................................................ 41
6.3  Linearisation ................................................................................................................42
7 Commissioning.............................................................................................................. 43
7.1  Prerequisite .................................................................................................................43
7.1.1  Connect measuring devices............................................................................ 44
7.1.2  Check gas connection pressure..................................................................... 45
7.1.3  Check soundness of gas valve train.............................................................. 46
7.1.4  Purging the gas valve train............................................................................... 49
7.1.5  Preset pressure regulator................................................................................. 50
7.1.6  Setting values...................................................................................................... 53
7.1.7  Preset gas and air pressure switch ............................................................... 54
7.2  Adjusting the burner..................................................................................................55
7.3  Check soundness of burner flange........................................................................63
7.4  Set pressure switches ..............................................................................................64
7.4.1  Set gas pressure switch................................................................................... 64
7.4.2  Set fan air pressure switch .............................................................................. 65
7.4.3  Set intake air filter air pressure switch .......................................................... 66
7.5  Concluding work........................................................................................................67
7.6  Check combustion.....................................................................................................68
7.7  Calculate gas throughput.........................................................................................69
7.8  Subsequent optimisation of operating points .....................................................70
8 Shutdown.......................................................................................................................... 71
9 Servicing............................................................................................................................ 72
9.1  Notes on servicing.....................................................................................................72
9.2  Service plan.................................................................................................................74
9.3  Removing and refitting mixture distributor............................................................74
9.4  Set mixture distributor...............................................................................................76
9.5  Removing and refitting burner tube .......................................................................77
9.6  Service position..........................................................................................................78
9.7  Removing and refitting fan wheel...........................................................................79
9.8  Replace variable speed drive sensor ....................................................................80
9.9  Remove burner motor ...............................................................................................81
9.10  Set ionisation and ignition electrodes ................................................................82
9.11  Removing intake air filter........................................................................................83
9.12  Removing and refitting air damper actuator......................................................84
9.13  Removing and refitting angle drive......................................................................85
9.14  Removing and refitting gas butterfly valve actuator.........................................86
9.15  Replacing double gas valve coil...........................................................................87
9.16  Replace breather plug of multifunction assembly............................................88
9.17  Removing and refitting filter insert of multifunction assembly.......................89
9.18  Removing and refitting filter insert in gas filter .................................................90
9.19  Replacing the combustion manager ...................................................................91
9.20  Replacing the fuse ..................................................................................................94

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
83321902 1/2022-10 Luw 4-128
10 Troubleshooting ............................................................................................................ 95
10.1  Procedures for fault conditions............................................................................95
10.1.1  Display off.......................................................................................................... 95
10.1.2  Display OFF ...................................................................................................... 95
10.1.3  Display flashes ................................................................................................. 96
10.1.4  Detailed fault codes ........................................................................................ 97
10.2  Rectifying faults........................................................................................................98
10.3  Operating problems............................................................................................. 102
11 Technical documentation.......................................................................................103
11.1  Program sequence............................................................................................... 103
11.2  Conversion table unit of pressure..................................................................... 105
11.3  Appliance categories........................................................................................... 105
12 Project planning...........................................................................................................109
12.1  Continuous running fan or post-purge............................................................ 109
12.2  Additional requirements ...................................................................................... 109
13 Spares...............................................................................................................................110
14 Notes .................................................................................................................................124
15 Key word index ............................................................................................................125

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
1 User instructions
83321902 1/2022-10 Luw 5-128
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 ob-
served 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
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 equip-
ment and environmental damage.
Important information
Requires direct action
Result after an action
Itemisation
… Range of values
Display text Font for text that appears in the display

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
1 User instructions
83321902 1/2022-10 Luw 6-128
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 WG40…/2-A ZM-PLN
2 Safety
83321902 1/2022-10 Luw 7-128
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.
The combustion air must be free from aggressive compounds (e.g. Halogens).
If the combustion air is contaminated, increased cleaning and servicing may be re-
quired.
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 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 isolating valve.
Warn the inhabitants, do not ring door bells.
Leave the building.
Inform the heating contractor or gas supplier from outside of the building.
2.3 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].
2.3.1 Personal protective equipment (PPE)
Use the necessary personal protective equipment for all work.
2.3.2 Normal operation
All labels on the unit must be kept in a legible condition.
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.

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
2 Safety
83321902 1/2022-10 Luw 8-128
2.3.3 Electrical work
When working on live components please ensure you:
observe the accident prevention instructions 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 dis-
charge (ESD).
When working on circuit boards and contacts:
do not touch circuit boards or contacts
if necessary, take ESD protective measures
2.3.4 Gas supply
Only the gas supply company or an approved agent may carry out installation, al-
teration and maintenance work on gas appliances in buildings and properties.
Pipework must be subject to a combined load and valve proving test and/or us-
ability testing relative to the pressure range intended, e. g. DVGW-TRGI, work-
sheet G 600.
Inform the gas supply company about the type and size of plant prior to installa-
tion.
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 li-
quid petroleum gas.
Use only tested and approved sealing materials, whilst observing all process in-
formation.
Re-commission the appliance when changing to a different type of gas. Chan-
ging from LPG to Natural Gas and visa versa requires a conversion.
Carry out soundness test after each service and fault 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.
Do not use combustion chamber inserts, which hinder flame burnout.
Use only original Weishaupt replacement parts.
2.5 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 oper-
ating personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.
2.6 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 WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 9-128
3 Product description
3.1 Type key
Example: WG40N/2-AZM-PLN
Type
W Series: Compact burner
G Fuel: Gas
40 Size
N N: Natural Gas
F: Liquid Petroleum Gas
2 Ratings size
A Construction
Version
ZM Type of control: modulating
PLN Mixing head: Premix LowNOX

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 10-128
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 WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 11-128
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 air damper
closes automatically. This reduces heat loss in the heat exchanger.
Fan wheel
The fan wheel supplies the air from the air intake housing to the burner tube.
Air pressure switch for fan
The air pressure switch monitors the fan pressure. If the fan pressure is insufficient,
the combustion manager initiates a lockout.
Air pressure switch for intake air filter
The air pressure switch monitors the intake air filter for contamination. If it is heavily
contaminated, the combustion manager initiates a lockout.

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 12-128
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
particles.
Double gas valve 4
The double gas valve opens and shuts off the gas supply.
Pressure regulator 3
The pressure regulator reduces the connection pressure and ensures a constant
setting pressure.
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.
Low gas pressure switch/valve proving gas pressure switch 7
The gas pressure switch monitors the gas connection pressure. If the preset pres-
sure is not achieved, the combustion manager initiates a safety shutdown.
The gas pressure switch also monitors if the gas valves are tight. It signals the
combustion manager if the pressure increases or decreases to an impermissible
level during valve proving.
Valve proving is carried out automatically by the combustion manager:
after every controlled shutdown
prior to burner start following 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 to above the value set 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 to below the value set during these 16 seconds, valve2
is leaking. The combustion manager initiates a controlled shutdown.

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 13-128
High gas pressure switch 6 (optional)
Depending on the burner application, optional equipment may be required for op-
timum operation [ch.12.2].
The high gas pressure switch monitors the setting pressure. If the setting pressure
exceeds the value set, the combustion manager initiates a controlled shutdown.
PP
2''
¾'' ... 1½''
P
P
786
312
5
4
V1
V2
7
6
312
5
4
V1
V2

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 14-128
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.
A frequency of 55Hz is required for the maximum burner capacity.
Frequency range: approx. 22…55Hz.
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 con-
trolled shutdown.
Flame sensor
If the flame monitor detects a flame that burns back, the combustion manager initi-
ates a lockout.

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 15-128
3.3.4 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 External valve LPG
3C Frequency converter for continuous running fan
3N Frequency converter
4 Ignition unit
5 Multifunction assembly or double gas valve
6 Not used
7 Bridging plug No. 7
8 Gas meter (impulse generator)
11 Air pressure switch for fan / air pressure switch for intake air filter
(LDW3)
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 WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 16-128
3.3.5 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 par-
tial load. The fuel supply is shut off. The burner motor continues to run. 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 WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 17-128
TV
TS
TP1
TP2
W-FM 25
K33
1
P
B16
T8 T6T7
B31
P
12
B33
P
15 5
K32
5
21
T1
4
P
P
B15
LT1 T2
F2
N
LN
B4
P11
51234
M
M20
L/A
TI
1234
M
M38
G
B 10
B11
P
P
11
B1
B2
13
A 10
T20 M1
3
M
1
T
N
B1 Ionisation electrode 1CLOSED position
B2 Flame sensor 2Ignition position
B10 Air pressure switch 3Partial load
B11 Air pressure switch for intake air filter 4Full load
B15 Temperature or pressure regulator 5Operating phase
B16 Temperature or pressure regulator full load TIInitialisation time (Test): 3 s
B31 Low gas pressure switch/valve proving gas
pressure switch
TNPost-purge time: 2 s [ch.6.2.3].
B33 High gas pressure switch (optional) TP1 1. Test phase: 8 s (valve proving valve1)
F2 Temperature or pressure limiter TP2 2. Test phase: 16 s (valve proving valve2)
K32 double gas valve TVPre-purge time: 20 s
K33 External valve LPG TSSafety time: 3 s
M1 Burner motor Voltage is applied
M20 Air damper actuator Flame signal present
M38 Gas butterfly valve actuator Current path
P11 Control lamp operation (optional)
T1 Ignition unit
T20 Frequency converter

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 18-128
3.4 Technical data
3.4.1 Approval data
PIN (EU) 2016/426 CE-0085AS0311
Basic standards EN676:2003 + A2:2008
Additional standards, see EU conformity declaration.
3.4.2 Electrical data
Mains voltage / Mains frequency 230 V/50 Hz
Consumption at start max724 W
Consumption during operation max714 W
Power consumption max 2.4 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 Fuels
Natural Gas E/LL
Liquid Petroleum Gas B/P

Installation and operating instruction
Gas burner WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 19-128
3.4.5 Emissions
Flue gas
In accordance with EN676, the burner meets the requirements of emission class 3.
The NOx values are influenced by:
combustion chamber dimensions
flue gas system
Fuel
combustion air (temperature and humidity)
medium temperature
O2 content in the flue gas
Combustion chamber dimensions, see Weishaupt Partner Portal / Documents and
Applications / Online Applications / NOX calculation for burners.
Sound levels
Dyad noise emission values
Measured sound power levelLWA (re 1 pW)
Uncertainty value KWA
80
4
dB(A)(1
dB(A)
Measured sound pressure level LpA (re 20 μPa)
Uncertainty value KpA
75
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 WG40…/2-A ZM-PLN
3 Product description
83321902 1/2022-10 Luw 20-128
3.4.6 Rating
Combustion heat rating
Natural Gas
LPG
60…600 kW
70…600 kW
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.
-2
-3
-1
0
1
2
3
4
600 650550400350300250200150100500
5
6
7
8
9
10
500450
1
2
4
5
7, 5 6 56,5
3
1Combustion heat rating [kW]
2Combustion chamber pressure [mbar]
3Natural Gas
4Liquid Petroleum Gas
5O2 content [%]
O2 content NOX content Natural Gas NOX content LPG
7.5 % approx. 20 mg/kWh –
6.5 % approx. 30 mg/kWh approx. 60 mg/kWh
6.0 % approx. 50 mg/kWh approx. 80 mg/kWh
5.0 % approx. 80 mg/kWh approx. 140 mg/kWh