Weishaupt WG40 /3-A ZM-PLN Series User guide

Installation and operating instruction
Gas burner WG40…/3-A ZM-PLN 83322002 1/2022-10

Installation and operating instruction
Gas burner WG40…/3-A ZM-PLN
83322002 1/2022-10 Luw 2-136
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 ......................................................................................................22
4.2.1  Rotate burner by 180° (optional).................................................................... 26
4.2.2  Rotate air filter box by 180° (optional) .......................................................... 28
5 Installation ........................................................................................................................ 30
5.1  Gas supply ..................................................................................................................30
5.1.1  Installing the gas valve train............................................................................. 31
5.1.2  Carry out soundness test of gas supply line and vent............................... 34
5.2  Electrical connection.................................................................................................35
6 Operation .......................................................................................................................... 36
6.1  Operating panel..........................................................................................................36

Installation and operating instruction
Gas burner WG40…/3-A ZM-PLN
83322002 1/2022-10 Luw 3-136
6.2  Display..........................................................................................................................38
6.2.1  Info level ............................................................................................................... 39
6.2.2  Service level ........................................................................................................ 40
6.2.3  Parameter level ................................................................................................... 41
6.2.4  Access level ........................................................................................................ 43
6.3  Linearisation ................................................................................................................44
7 Commissioning.............................................................................................................. 45
7.1  Prerequisite .................................................................................................................45
7.1.1  Connect measuring devices............................................................................ 46
7.1.2  Check gas connection pressure..................................................................... 47
7.1.3  Check soundness of gas valve train.............................................................. 48
7.1.4  Purging the gas valve train............................................................................... 51
7.1.5  Preset pressure regulator................................................................................. 52
7.1.6  Setting values...................................................................................................... 55
7.1.7  Preset gas and air pressure switch ............................................................... 56
7.2  Adjusting the burner..................................................................................................57
7.3  Check soundness of burner flange........................................................................65
7.4  Set pressure switches ..............................................................................................66
7.4.1  Set gas pressure switch................................................................................... 66
7.4.2  Set fan air pressure switch .............................................................................. 67
7.4.3  Set intake air filter air pressure switch .......................................................... 68
7.5  Concluding work........................................................................................................69
7.6  Check combustion.....................................................................................................70
7.7  Calculate gas throughput.........................................................................................71
7.8  Subsequent optimisation of operating points .....................................................72
8 Shutdown.......................................................................................................................... 73
9 Servicing............................................................................................................................ 74
9.1  Notes on servicing.....................................................................................................74
9.2  Service plan.................................................................................................................76
9.3  Removing and refitting mixture distributor............................................................77
9.4  Set mixture distributor...............................................................................................78
9.5  Service position..........................................................................................................79
9.6  Removing and refitting fan wheel...........................................................................80
9.7  Replace variable speed drive sensor ....................................................................81
9.8  Remove burner motor ...............................................................................................82
9.9  Set ionisation and ignition electrodes...................................................................83
9.10  Removing intake air filter........................................................................................84
9.11  Removing and refitting air damper actuator......................................................85
9.12  Removing and refitting angle drive......................................................................86
9.13  Removing and refitting gas butterfly valve actuator.........................................87
9.14  Removing and refitting burner tube.....................................................................88
9.15  Replacing double gas valve coil...........................................................................90
9.16  Replace breather plug of multifunction assembly............................................91
9.17  Removing and refitting filter insert of multifunction assembly.......................92
9.18  Removing and refitting filter insert in gas filter .................................................93
9.19  Replacing the combustion manager ...................................................................94
9.20  Replacing the fuse ..................................................................................................97

Installation and operating instruction
Gas burner WG40…/3-A ZM-PLN
83322002 1/2022-10 Luw 4-136
10 Troubleshooting ............................................................................................................ 98
10.1  Procedures for fault conditions............................................................................98
10.1.1  Display off.......................................................................................................... 98
10.1.2  Display OFF ...................................................................................................... 99
10.1.3  Display flashes ................................................................................................. 99
10.1.4  Detailed fault codes ......................................................................................100
10.2  Rectifying faults..................................................................................................... 101
10.3  Operating problems............................................................................................. 105
11 Technical documentation.......................................................................................106
11.1  Program sequence............................................................................................... 106
11.2  Conversion table unit of pressure..................................................................... 108
11.3  Appliance categories........................................................................................... 108
12 Project planning...........................................................................................................112
12.1  Continuous running fan or post-purge............................................................ 112
12.2  Additional requirements ...................................................................................... 113
13 Spares...............................................................................................................................114
14 Notes .................................................................................................................................130
15 Key word index ............................................................................................................132

Installation and operating instruction
Gas burner WG40…/3-A ZM-PLN
1 User instructions
83322002 1/2022-10 Luw 5-136
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…/3-A ZM-PLN
1 User instructions
83322002 1/2022-10 Luw 6-136
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…/3-A ZM-PLN
2 Safety
83322002 1/2022-10 Luw 7-136
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…/3-A ZM-PLN
2 Safety
83322002 1/2022-10 Luw 8-136
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…/3-A ZM-PLN
3 Product description
83322002 1/2022-10 Luw 9-136
3 Product description
3.1 Type key
Example: WG40N/3-AZM-PLN
Type
W Series: Compact burner
G Fuel: Gas
40 Size
N N: Natural Gas
F: Liquid Petroleum Gas
3 Ratings size
A Construction
Version
ZM Type of control: modulating
PLN Mixing head: Premix LowNOX

Installation and operating instruction
Gas burner WG40…/3-A ZM-PLN
3 Product description
83322002 1/2022-10 Luw 10-136
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.: