Weishaupt WGL40/1-A ZM User manual

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM 83273402 1/2019-02

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
83273402 1/2019-02 La 2-148
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  Normal operation...................................................................................................7
2.3.2  Electrical connection............................................................................................8
2.3.3  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  Serial number..............................................................................................................10
3.3  Function........................................................................................................................11
3.3.1  Air supply ............................................................................................................. 11
3.3.2  Gas supply........................................................................................................... 12
3.3.3  Oil supply............................................................................................................. 14
3.3.4  Electrical components....................................................................................... 15
3.3.5  Program sequence............................................................................................. 16
3.3.6  Inputs and outputs............................................................................................. 20
3.4  Technical data.............................................................................................................21
3.4.1  Approval data...................................................................................................... 21
3.4.2  Electrical data ..................................................................................................... 21
3.4.3  Ambient conditions............................................................................................ 21
3.4.4  Fuels...................................................................................................................... 21
3.4.5  Emissions............................................................................................................. 22
3.4.6  Rating.................................................................................................................... 23
3.4.7  Dimensions.......................................................................................................... 24
3.4.8  Weight.................................................................................................................. 24
4 Installation ........................................................................................................................ 25
4.1  Installation conditions................................................................................................25
4.2  Selecting the nozzles ................................................................................................26
4.3  Burner installation ......................................................................................................28
4.3.1  Rotate burner by 180° (optional).................................................................... 29
5 Installation ........................................................................................................................ 32
5.1  Gas supply ..................................................................................................................32
5.1.1  Installing the gas valve train............................................................................. 33
5.1.2  Carry out soundness test of gas supply line and vent............................... 35
5.2  Oil supply.....................................................................................................................36
5.3  Electrical connection.................................................................................................38

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
83273402 1/2019-02 La 3-148
6 Operation .......................................................................................................................... 40
6.1  Operating panel..........................................................................................................40
6.2  Display..........................................................................................................................42
6.2.1  Info level ............................................................................................................... 43
6.2.2  Service level ........................................................................................................ 44
6.2.3  Parameter level ................................................................................................... 46
6.2.4  Access level ........................................................................................................ 48
6.3  Linearisation ................................................................................................................49
7 Commissioning.............................................................................................................. 50
7.1  Prerequisite .................................................................................................................50
7.1.1  Connect measuring devices............................................................................ 50
7.1.2  Set oil pressure switch ..................................................................................... 52
7.1.3  Check gas connection pressure..................................................................... 53
7.1.4  Check soundness of gas valve train.............................................................. 54
7.1.5  Purging the gas valve train............................................................................... 57
7.1.6  Preset pressure regulator................................................................................. 58
7.1.7  Setting values...................................................................................................... 60
7.1.8  Preset gas and air pressure switch ............................................................... 61
7.2  Adjusting the burner..................................................................................................62
7.2.1  Adjusting gas side ............................................................................................. 62
7.2.2  Adjusting oil side................................................................................................ 69
7.3  Set pressure switches ..............................................................................................74
7.3.1  Set gas pressure switch................................................................................... 74
7.3.2  Set air pressure switch .................................................................................... 75
7.4  Concluding work........................................................................................................76
7.5  Check combustion.....................................................................................................77
7.6  Calculate gas throughput.........................................................................................78
7.7  Subsequent optimisation of operating points .....................................................79
8 Shutdown.......................................................................................................................... 80
9 Servicing............................................................................................................................ 81
9.1  Notes on servicing.....................................................................................................81
9.2  Service plan.................................................................................................................82
9.3  Removing and refitting mixing head.......................................................................84
9.4  Set mixing head..........................................................................................................86
9.5  Removing and refitting nozzle assembly...............................................................87
9.6  Set ignition electrodes..............................................................................................87
9.7  Removing and refitting diffuser...............................................................................88
9.8  Replace nozzles..........................................................................................................89
9.9  Service position..........................................................................................................90
9.10  Removing and refitting fan wheel ........................................................................91
9.11  Removing and refitting oil pump ..........................................................................92
9.12  Removing and refitting oil pump filter .................................................................93
9.13  Removing and refitting air damper actuator......................................................94
9.14  Removing and refitting angle drive......................................................................95
9.15  Removing and refitting gas butterfly valve actuator.........................................96
9.16  Replacing double gas valve coil...........................................................................97
9.17  Replace breather plug of multifunction assembly............................................98

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
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9.18  Removing and refitting filter insert of multifunction assembly.......................99
9.19  Removing and refitting filter insert in gas filter .............................................. 100
9.20  Replace spring on pressure regulator ............................................................. 101
9.21  Replacing the combustion manager ................................................................ 102
9.22  Replacing the fuse ............................................................................................... 105
10 Troubleshooting ..........................................................................................................106
10.1  Procedures for fault conditions......................................................................... 106
10.1.1  Display off........................................................................................................106
10.1.2  Display OFF ....................................................................................................106
10.1.3  Display flashes ...............................................................................................107
10.1.4  Detailed fault codes ......................................................................................108
10.2  Rectifying faults..................................................................................................... 109
10.3  Operating problems............................................................................................. 113
11 Technical documentation.......................................................................................114
11.1  Program sequence............................................................................................... 114
11.2  Conversion table unit of pressure..................................................................... 116
11.3  Appliance categories........................................................................................... 116
12 Project planning...........................................................................................................120
12.1  Oil supply ............................................................................................................... 120
12.2  Additional requirements...................................................................................... 122
13 Spares...............................................................................................................................124
14 Key word index ............................................................................................................144

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
1 User instructions
83273402 1/2019-02 La 5-148
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. They should be
observed by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have the relevant train-
ing 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
Immediate danger with high risk.
Non observance can lead to serious injury or death.
WARNING
Danger with medium risk.
Non observance can lead to environmental damage,
serious injury or death.
CAUTION
Danger with low risk.
Non observance can cause damage to the equip-
ment and injury to personnel.
Important information
Requires direct action
Result after an action
Itemisation
… Range of values

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
1 User instructions
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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 forma-
tion,
unsuitable fuels,
defects in the inlet lines.

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
2 Safety
83273402 1/2019-02 La 7-148
2 Safety
2.1 Designated application
The burner is suitable for operation on heat exchangers to EN303, EN267 and
EN676.
If the burner is not used on combustion chambers to EN303, EN267 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 documented.
The combustion air must be free from aggressive compounds (e.g. Halogens). If the
combustion air in the boiler room is contaminated, increased cleaning and servicing
will be required. In this case ducted air intake is recommended.
The burner should only be used in enclosed rooms.
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 gas 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 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.

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
2 Safety
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2.3.2 Electrical connection
For work carried out on live components:
Observe the accident prevention instructions DGUVRegulation3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.
2.3.3 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 pipework 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.
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
Dual fuel burner WGL40/1-A ZM
3 Product description
83273402 1/2019-02 La 9-148
3 Product description
3.1 Type key
WGL40N/1-AZM
W Type: W burner
G Fuel: Gas
L Fuel: Oil EL
40 Size
N N: Natural Gas
F: Liquid Petroleum Gas
1 Ratings size
A Construction
ZM Version: two stage (Oil), modulating (Gas)

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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3.2 Serial number
The serial number on the name plate identifies the product. This is required by
Weishaupt's customer service department.
1
1Name plate
Ser.No.

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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3.3 Function
3.3.1 Air supply
Air damper
The air damper regulates the air quantity required for combustion. The combustion
manager drives the air damper via actuator.
At burner shutdown the the actuator automatically closes the air damper. At burner
shutdown the air dampers close automatically.
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
Dual fuel burner WGL40/1-A ZM
3 Product description
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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
Dual fuel burner WGL40/1-A ZM
3 Product description
83273402 1/2019-02 La 13-148
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
DN 65 / DN 80
2''
¾'' ... 1½''
P
P
PP
786
312
5
4
V1
V2
7
6
312
5
4
V1
V2
76
312
5
4
V1
V2

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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3.3.3 Oil supply
Oil pump
The pump draws the oil through the supply line and carries it under pressure to the
oil nozzle. The pressure regulating valve keeps the oil pressure constant.
Solenoid valves
The solenoid valves open and close the oil supply.
For ignition, the combustion manager opens the stage1 solenoid valve and the
safety solenoid valves. Stage 2 solenoid valve opens or closes depending on heat
demand.
Minimum oil pressure switch
The minimum oil pressure switch monitors the pump pressure in the supply. If the
preset pressure is not achieved, the combustion manager initiates a lockout.
Sequence diagram
P
126543
7
8
1Oil pump on burner
2Additional safety solenoid valve on the oil pump
3Minimum oil pressure switch
4Additional safety solenoid valve
5Stage1 solenoid valve
6Nozzle head with 2 nozzles
7Throttle orifice (Ø 1.2 mm) incorporated in screwed union
8Stage2 solenoid valve

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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3.3.4 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 drives the fan wheel.
Pump motor
The pump motor drives the oil pump.
Ignition unit
The electronic ignition unit creates a spark at the electrode, which ignites the fuel/
air mixture.
Flame sensor
The combustion manager monitors the flame signal via the flame sensor.
If the flame signal becomes too weak, the combustion manager carries out a con-
trolled shutdown.
Fuel selection switch
The relevant fuel is pre-selected using the fuel selection switch. If the fuel selection
switch is set to REMOTE, fuel selection via building management system or ex-
ternal fuel selection switch is possible.

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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3.3.5 Program sequence
Gas operation
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.
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 air damper and gas butterfly valve
actuators close.
OFF Standby, no heat demand.

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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Gas operation
TV
TS
TN
TP1
TP2
B4
P11
W-FM 25
K33
3N
P
B16
T6 T8T7
B10
P
11
B31
P
12
B33
P
15 5
K32
6
21 B1
13
M
1
M1
3N
T1
4
P
P
B15
LT1 T2
F2
N
LN
M
M20
1234
M
M38
1234 5
TI
L/A G
FLW
B1 Flame sensor 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)
K33 External valve LPG TP2 2. Test phase: 16 s (valve proving valve2)
M1 Burner motor TVPre-purge time: 20 s
M20 Air damper actuator TSSafety time: 3 s
M38 Gas butterfly valve actuator Voltage is applied
P11 Control lamp operation (optional) Flame signal present
T1 Ignition unit Current path

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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Oil operation
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.
LAt heat demand, the air damper actuator drives to the reference point.
1The combustion manager monitors for extraneous light.
2The air damper actuator drives to pre-purge, to air damper setting stage 2 (operating point P9).
3The burner motor, pump motor and ignition starts.
The oil safety solenoid valve on the oil pump opens. The min. oil pressure switch is activated.
4Pre-purge. The remaining pre-purge time is displayed.
5The air damper actuator drives to ignition position (operating point P0).
6Waiting time in ignition position.
7Stage 1 oil solenoid valve and the safety valve open. The fuel is released. The safety time begins. The
display shows symbol .
8Post-ignition time starts, this aids flame stabilisation.
9The air damper actuator drives to air damper setting stage 1 (operating point P1).
10 The burner is in operation. Depending on the regulator demand for stage 2, the stage 2 oil solenoid
valve opens or closes.
15 If there is no longer a heat demand, the solenoid valves close and stop the fuel supply. Following the
post-purge phase the burner motor switches off. The air damper actuator closes.
OFF Standby, no heat demand.

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
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Oil operation
B4
P11
W-FM 25
P
P
B15
L
T1
T2
F2
N
L
N
K11
1
K14
3N
K15
1
K13
6
M
M20
M
1
M1
3N
M
1
M2
3N
T
I
T
V
T
N
T1
4
T
S
P
B16
T6 T8T7
B1
13
FLW
L/A
B36
P
12
1234 5
B1 Flame sensor 1Operating point P0 (ignition position)
B15 Temperature or pressure regulator 2Operating point P1 (stage1)
B16 Temperature or pressure regulator stage2 3Operating point P2 (solenoid valve stage2)
B36 Minimum oil pressure switch 4Operating point P9 (stage2)
F2 Temperature or pressure limiter 5Operating phase
K11 Stage1 oil solenoid valve TIInitialisation time (Test): 3 s
K13 Stage2 oil solenoid valve TNPost-purge time: 2 s [ch.6.2.3]
K14 Oil safety solenoid valve on the oil pump TSSafety time: 3 s
K15 Oil safety solenoid valve TVPre-purge time: 20s
M1 Burner motor Voltage is applied
M2 Pump motor Flame signal present
M20 Air damper actuator Current path
P11 Control lamp operation (optional)
T1 Ignition unit

Installation and operating instruction
Dual fuel burner WGL40/1-A ZM
3 Product description
83273402 1/2019-02 La 20-148
3.3.6 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 FU NA P TWI
8
11
15
12
X6
X7
F7
1
2
TWI TWI interface (VisionBox, accessory)
P O2 sensor (accessory)
NA not used
FC not used
AM Operating panel
L/A Air damper actuator
G Gas butterfly valve actuator
1Slot for analogue module EM3/3 or fieldbus module EM3/2
2W-FM cover
1 Stage 1 oil solenoid valve and safety valve
3C Voltage supply fuel change-over and
connection plug continuous running fan
3N Burner motor and pump motor and
oil safety shut off valve on the oil pump and
external LPG valve
4 Ignition unit
5 Gas valve 1
6 Stage 2 oil solenoid valve and gas valve 2
7 Bridging plug No. 7
8 Fuel change-over
11 Air pressure switch / air pressure switch for ducted air intake
(LDW2)
12 Low / valve proving gas pressure switch and oil pressure switch
13 Flame sensor
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)