manual

Installation and operating instructions

Weishaupt Gas Burner WM - G10/1-A / ZM-LN (W-FM 100/200) 83243102 - 1/2007

 Conformity Certification
to ISO/IEC Guide 22
Manufacturer Max Weishaupt GmbH

Address: Max Weishaupt Straße

D-88475 Schwendi

Product: Industrial burner

Type: WM-G 10/1-A / Z-LN

The product described above conforms to

Document No.: DIN EN 676

DIN EN ISO 12100-1
DIN EN 61000-6-3/-1
DIN EN 60335-1

In accordance with the directives

GAD 90/396/EEC Gas Appliance Directive

MD 2006/42/EC Machinery Directive
PED 97/23/EC Pressure Equipment Directive
LVD 2006/95/EC Low Voltage Directive
BED 92/42/EEC Boiler Efficiency Directive
EMC 2004/108/EC Electromagnetic
Compatibility Directive

this product is labelled as follows

CE-0085

Schwendi 03.05.2007

ppa. ppa.
Dr. Lück Denkinger

Comprehensive Quality Assurance is ensured by a

certified Quality Management System
to EN ISO 9001.

2
Contents
1 1 General instructions 5

2 2 Safety instructions 6

3 3 Technical description
3.1 Permissible application
8
8
3.2 Basic function 9
3.3 Gas regulating system 10
3.4 Function Combustion Manager W-FM 11

4 4 Installation
4.1 Safety notes on installation
12
12
4.2 Delivery, transport and storage 12
4.3 Preparations for installation 12
4.4 Installing the burner 12
4.5 Installing the valve train 14
4.6 Soundness test of valve train 16
4.7 Electrical connection 18

5 5 Commissioning and operation

5.1 Safety notes on initial commissioning
19
19
5.2 Preparation for initial commissioning 19
5.2.1 Minimum connection and setting pressure 23
5.3 Operating the W-FM 24
5.4 Commissioning and setting 25
5.5 Concluding work following commissioning 27
5.6 Shutdown periods 29

6 6 Fault conditions and procedures for rectification

6.1 General faults on the burner
30
30
6.2 Faults on the W-FM 31

7 7 Servicing
7.1 Safety notes on servicing
32
32
7.2 Servicing 33
7.2.1 Testing, cleaning and function test 33
7.2.2 Criteria for setting / replacement 33
7.3 Removing and refitting mixing head 34
7.4 Setting the ionisation and ignition electrodes 35
7.5 Removing and refitting air damper stepping motor 36
7.6 Removing and refitting gas butterfly valve stepping motor 37
7.7 Removing and refitting FRS spring 38

3
 8 8 Technical data
8.1 Burner equipment
39
39
8.2 Capacity graph 39
8.3 Permissible fuels 40
8.4 Mixing head dimensions 40
8.5 Permissible ambient conditions 40
8.6 Electrical data 41
8.7 Weight 41
8.8 Burner dimensions 42

A Appendix
Combustion analysis
43
43
Gas throughput calculation 44
Spare parts 46
Notes 52

4
1 General instructions 1
These installation and operating instructions Hand over and operating instructions
• are an integral part of the equipment and must be kept The contractor is responsible for passing the operating
permanently on site. instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these
• are supplemented by installation and operating instructions should be kept with the heating appliance. The
instructions Combustion Manager W-FM. address and telephone number of the nearest service
centre should be entered on the reverse of the operating
• are to be used by qualified personnel only. instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
• contain the relevant information for the safe assembly, inspect the plant at least once a year. To ensure regular
commissioning and servicing of the equipment. inspections, -weishaupt- recommends a service contract.

• are for the attention of all personnel working with the The contractor should instruct the plant operator in the use
equipment. of the equipment prior to hand-over and inform him as and
when necessary of any further inspections that are
required before the plant can be used.

Explanation of notes and symbols

This symbol is used to mark instructions, Guarantee and liability
which, if not followed, could result in death or Weishaupt will not accept liability or meet any guarantee
serious injury. claims for personal injury or damage to property arising as
a result of one or more of the causes below:
DANGER
• Failure to use the equipment as intended.
• Improper assembly, commissioning, operating or
This symbol is used to mark instructions, servicing of the equipment.
which, if not followed, could result in life • Operating the appliance with defective safety
threatening electric shock. equipment, or with non-recommended or non-
DANGER
functioning safety and protection devices.
• Failure to follow the information in the Installation and
Operating Instructions.
• Alterations made to the construction of the equipment
This symbol is used to mark instructions, by the plant operator.
which, if not followed, could result in damage • Fitting additional components not tested or approved
to, or the destruction of the equipment and for use with the equipment.
ATTENTION
environmental damage. • Alterations made to the equipment by the plant
operator (e.g. motor ratio - rating and speed).
• Alterations made to the combustion chamber, which
hinders constructive, predetermined flame formation.
• Inadequate monitoring of parts liable to wear and tear.
☞ This symbol is used to mark procedures, which • Improperly executed repairs.
you should follow. • Acts of God.
• Damage caused by continued use despite the
1. Procedures with more than one step are occurrence of a fault.
2. numbered. • Use of incorrect fuel.
3. • Obstruction or damage of the supply lines.
• Use of non-original -weishaupt- spare parts.
❑ This symbol is used when you are required to
carry out a test.

• This symbol is used to list points.

➩ This symbol indicates detailed information.

Abbreviations
Tab. Table
Ch. Chapter

5
 2 2
Safety information
Dangers when using the equipment Electrical safety
Weishaupt products are manufactured in accordance with • Before starting work - isolate plant and protect against
the relevant existing standards and guidelines and the reactivation, check voltage is isolated, the unit is
recognised safety laws. However, improper use of the earthed, and protected from adjacent equipment that
equipment could endanger life of the user or a third party, might still be under voltage!
or result in damage to the plant. • Work on the electrical supply should be carried out by
a qualified electrician.
To avoid unnecessary danger, the equipment is only to be • Electrical components should be checked during
used: servicing. Loose connections and heat damaged
• for its intended purpose cables should be dealt with immediately.
• under ideal safety conditions • The control panel should be locked at all times. Access
• with reference to all the information in the installation should be restricted to authorised key holder
and operating instructions personnel.
• in accordance with inspection and service work • Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed
Faults, which could affect the safe operation of the burner, and tools to EN 60900 must be used. A second
should be rectified immediately. person should be present to switch off the mains
supply in an emergency.

Personnel training Maintenance and fault rectification

Only competent personnel may work on the appliance. • Necessary installation, service and inspection work
Competent personnel according to this operating manual should be carried out at the specified time.
are persons who are familiar with the installation, • Inform the operator before beginning any service work.
mounting, setting and commissioning of the product and • For all service, inspection and repair work, electrically
have the necessary qualifications such as:- isolate the equipment and ensure the mains switch
• Training, instruction , certification and authorisation to cannot be accidentally switched back on. Isolate the
switch electrical circuits and electrical devices on and fuel supply.
off, to earth them and to mark them in accordance with • If, during servicing or testing, control seal joints have to
the safety standards. be opened, these have to be thoroughly cleaned to
• Training, instruction or authorisation to carry out ensure tight sealing when re-assembling.
installation, alteration and maintenance work on the Damaged seals must be replaced.
relevant fuel fired plant. • Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
Organisational measures commissioned by, and may only be replaced by, the
• Everyone working on the plant should wear the manufacturer or an authorised agent.
necessary protective clothing. • Screwed connections, which have been loosened,
• All safety devices should be checked regularly. must be re-tightened without cross-threading.
• Following service work, all safety devices should be
Informal safety measures tested to ensure they are functioning correctly.
• In addition to the installation and operating instructions,
local codes of practice should also be adhered to.
Special attention should be paid to the relevant Alterations to the construction of the equipment
installation and safety guidelines given. • No alterations to the equipment are to be made without
• All safety and danger notices should be kept in a the approval of the manufacturer.
legible condition. All conversions require written confirmation from
Max Weishaupt GmbH.
Safety measures in normal operation • Any parts not in perfect working order should be
• Only use the equipment when all the safety devices are replaced immediately.
fully functional. • No additional components may be fitted, which have
• At least once a year the equipment, including the safety not been tested for use with the equipment.
devices, should be checked for signs of visible damage • Use only -weishaupt- spares and accessories as
and to ensure that the safety devices are operating replacement parts. Parts from other manufacturers are
correctly. not guaranteed to be suitable to meet the necessary
• More frequent safety check may be required depending operational and safety requirements.
on plant conditions.
Alterations to the combustion chamber
Safety measures when gas can be smelled • No alterations are to be made to the combustion
• Avoid open flames and spark generation (e.g. switching chamber, which hinder constructive predetermined
lights and electric units on and off, including the use of flame formation.
mobile phones).
• Open windows and doors. Cleaning of the equipment and waste disposal
• Close gas shut off valve. • All materials used should be handled and disposed of
• Warn all occupants and evacuate the building. correctly, with due regard to the environment.
• Inform heating company/installer and gas supplier
from outside of the building.

6
 2
Noise of the equipment Gas characteristics
The noise a combustion system makes is the result of a The following information must be obtained from
combination of components and factors, such as the gas supplier:
• burner • Type of gas
• flame • Calorific value in MJ/m3 or kWh/m3
• combustion chamber / boiler • Max. CO2 content of flue gas
• flue gas system • Gas supply pressure
• location and type of building.
Depending on these site conditions, noise could be of a
level sufficient to cause hearing damage. In this case the Pipe thread connection
operating personnel must be equipped with ear-defenders • Only tested and approved sealing material should be
or other such protection. used. Please observe the prevailing user instructions!

General information for gas operation

• When installing a gas combustion system, regulations Soundness test
and guidelines must be observed (i.e. Local Codes of • See Ch. 4.8
Practice and Regulations).
• Depending on the type of gas and gas quality the gas
supply must be designed in such a way that the Conversion to other gases
discharge of liquid substances (e.g. through • When converting to another gas type, a conversion kit
condensation) are avoided. This should be particularly and re-commissioning are required.
considered on liquid petroleum gas installations with
reference to the evaporation temperature.
• The subcontractor responsible for the installation or Gas valve train
changes to the gas system must inform the gas • Observe sequence and flow direction. To ensure
supplier of the type and extent of the installation trouble free start conditions, the distance between
planned and the intended work. The subcontractor DMV and burner should be kept to a minimum.
must ascertain that an adequate gas supply to the
installation is ensured.
• Installations, alterations and maintenance work on gas Thermal shut off device TAE
systems in buildings and below ground must only be • If require, the thermal shut off device TAE should be
carried out by installers who have a contract with the fitted upstream of the ball valve.
gas supplier.
• The gas pipe work 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 the test must be
expelled from the pipe work. The pipe work must be
completely purged.

7
 3 Technical description
3.1 Permissible applications
The Weishaupt gas burner type WM-G 10/1-A / ZM-LN Type codes:
is suitable for:
• heat exchangers according EN 303 Type
• warm water plant WM –G 10 /1 –A / ZM -LN
• steam boilers and hot water plant
• intermittent or continuous operation LowNox
• warm-air heat exchangers
two stage modulating
The combustion air must be free from aggressive
compounds (Halogen, Chloride, Fluoride, etc.). If the Construction type
combustion air within the boiler room is contaminated,
more frequent cleaning and maintenance will be required. Ratings size
In these cases operation with ducted air intake is
recommended. Size

Any other use is only permissible with the written G = Gas

agreement of Max Weishaupt GmbH. Servicing
requirements may be at more frequent intervals where Weishaupt burner type Monarch
arduous operating conditions demand.

To maintain certain NOx limit values specific minimum

combustion chamber dimensions and flue gas installation
layout must be observed.
Furthermore, the quality of fuel can have a negative
influence on NOx values.

• The burner must only be operated with the type of gas

given on the burner name plate.
• The gas connection pressure must not exceed the
gas pressure given on the burner name plate.
• The burner must only be operated under the
permissible ambient conditions (see Ch. 8.5).
• The burner must not be used outside. It is only suited
for operation inside.
• The burner must not be used outside of its capacity
range.

8
 3
3.2 Basic function
Burner type Low gas pressure switch
• Automatic forced draught gas burner for two stage If the gas pressure is inadequate, the low gas program is
or modulating operation. initiated.
• Type tested to EN 676
• NOx to Emission Class 3
• Electronic compound regulation of all correcting High gas pressure switch
elements If the gas pressure exceeds the set value the high gas
• Operation and setting via display and pressure switch activates a safety shutdown at the
operating unit (ABE). combustion manager.
The gas pressure switch is inactive during standby. During
start-up the gas pressure switch function is delayed by up
Combustion manager to 2 secs., this is to allow for static pressure to dissipate.
• Controls the sequence of operation
• Monitors the flame
• Communicates with the stepping motor FRS gas governor
• Carries out valve proving of the gas valves Equalises variations in pressure from the gas supply
• Is equipped with speed control network, thus providing a constant gas control pressure.
The control gas pressure is set with this device.

Flame sensor
Monitors the flame during all phases of operation. If the DMV double solenoid valve
flame signal does not correspond to the sequence of Automatic release or safety shut off of the gas flow. The
operations, a safety lockout will occur. limiting of the valve stroke, and with it a change of the
pressure drop is possible via adjustment of the setting
screw.
Stepping motors
Separate stepping motors on:
• Air damper Gas butterfly valve
• Gas butterfly valve The gas butterfly valve regulates the gas quantity relative to
Providing precise, direct control of the correcting elements the control gas pressure.
in compound.
The setting is checked by optical transmitter fitted in the
stepping motor. Mixing head
Adjustable combustion head relative to the full load rating
required.
Air damper
The air damper control regulates the combustion air
quantity for optimum combustion.

Air pressure switch

Should there be a fall in the air supply pressure the air
pressure switch causes a safety shutdown at the
combustion manager.

9
 3
3.3 Gas regulating system
Valve trains
In accordance with EN 676 all burners must be fitted with In accordance with EN 676 the use of a valve proving
two Class A solenoid valves. Weishaupt gas and dual fuel system is required for thermal inputs of 1,200 kW or more.
burners are fitted with DMV double solenoid valves as Other valve train components such as gas filter and gas
standard. governor can be found in the Weishaupt accessories list.

Valve train with double solenoid valve (DMV)

9 0

V1 V2

P P P

1 2 3 4 5 6 7 8

1 Ball valve 6 Valve proving gas pressure switch

2 Gas filter 7 Double solenoid valve (DMV)
3 Gas pressure governor/regulator 8 Gas butterfly valve
4 High gas pressure switch 9 Pressure gauge with push button valve
5 Low gas pressure switch 0 Burner

Valve proving Sequence diagram valve proving

Following each controlled shutdown, the combustion
manager carries out a valve proving test of the gas 1st Test phase 2nd Test phase
solenoid valves. Following lockout or power failure, the
valve proving test is carried out prior to burner start.
Valve 1
Function 33 secs.
sek. 10 sek.
10 secs. 33 secs.
sek. 10 sek.
10 secs.
1st Test phase: Valve 2
During a controlled shutdown valve 1 closes
immediately, and valve 2 has a slight delay in closing P between
which permits the volume between V1 and V2 to V1 and V2
depressurise via the gas butterfly valve. The section
between V1 and V2 must remain depressurised once Gas press.
switch VP
the second valve has closed.

2nd Test phase:

Valve 1 opens and immediately closes again, allowing
gas pressure build-up between V1 and V2. During the
test phase, the pressure between the valves must not
fall to below the pressure set at the gas pressure
switch 6.

Result of the test

If a pressure increase (1st test phase) or a pressure loss
(2nd test phase) is detected, the combustion manager
initiates a shutdown.

Pressure switch setting

See Ch. 5.5

10
 3
3.4 Function of the W-FM Combustion Manager
Combustion Manager Integrated load controller (optional)
The Combustion Manager controls the following functions: If no external 3-point step controller is fitted, a combustion
• Burner control manager with integrated load controller should be
• Electronic fuel / air compound regulation specified.
• Optional: – Load controller (W-FM100/200) The load controller has 2 internal set values, which can be
– O2 trim (W-FM 200) selected via external instruction switch (cold start function,
– Speed control (W-FM 200) night set-back).
A separate start-up programme is available for cold start,
Because all valves are directly fitted to the unit, external which takes the heating appliance to the required
fuel selection relays are not required. operating temperature or pressure more progressively so
Depending on plant requirements all necessary pressure providing thermal shock protection.
controls can also be connected to the base unit. The unit The load controller can be driven by internal or external set
has basic functions configured at the factory. value as required. It also acts as a setting controller, when
external controllers or management systems are
employed.
Burner control The current status of the burner in all variations can be
• Controls the sequence of operation read off as a unit signal.
• Monitors the flame with QRI flame sensor for
intermittent and continuous operation
• Communicates with the electronic compound O2 trim (optional)
regulation The O2 content of the flue gas is monitored by means of a
• Offers the possibility of transferring operational data, sensor and and is compared with the value determined
error messages or parameters to a master system via during commissioning. Depending on the set point
data bus. deviations, the combustion manager starts the air
regulating units and thus corrects the O2 content.

Valve proving
An integral valve proving programme is provided for valve Speed control (optional)
proving of the gas valves. The frequency converter of the fan motor is started by the
Using an additional pressure switch on the valve train the set point output (0/4-20mA) and the speed is matched to
soundness of the gas valves can be checked without the current burner rating.
additional components. In compound with the stepping motors this supplies the
required combustion air quantity and the electrical
consumption is reduced to a minimum.
Electronic fuel / air compound regulation If it fails, or if the air supply becomes insufficient, an air
The electronic fuel/air compound regulation differs from pressure switch initiates a controlled shutdown.
the usual systems used because of the fail safe CAN-Bus,
which drives the adjusting elements of the stepping
motors of the Display and programming unit – ABE
• air damper The ABE unit, equipped with a data memory module is
• gas butterfly valve used to set the operation specific parameters.
The control parameters are primarily set by an engineer,
and, for protection, can only be accessed via password. Navigation for changing the values of individual
The combustion settings for fuel and combustion air can parameters is carried out with two keys and scrolling
be matched exactly across the whole operating range of selector.
the burner. Each fuel is operated according to defined load The scrolling selector controls the cursor and the value
curves. changes, and with the Enter key the changes are saved.
The stepping motors, having extremely high resolution, are By pressing the Esc key the parameter selection or change
fitted with individual microprocessor. can be stopped and it is also used to return to
An integrated control and monitoring circuit positions the previous menus.
output drives to 0.1 degree accuracy. The Info key is used to return to the operating display.
The desired value setting is transmitted from the base unit
via the Bus. On attaining the exact set position, the The ABE offers an additional three connection
position is constantly monitored via a return signal to the possibilities. A serial interface RS232 (COM1) for the
base unit as confirmation. connection of a PC with the relevant software is located
beneath the cover.
A CAN-Bus plug is located at the base of the unit, which is
used for the connection to the W-FM.
The COM2 interface allows the connection to a building
management system. An external eBus interface is
required for this.

11
 4 4
Installation
4.1 Safety notes for installation
Electrically isolate plant Only valid in Switzerland:
Prior to installation switch off the mains When installing and operating -weishaupt- gas burners in
switch and the safety switch. Failure to Switzerland the regulations of SVGW and VKF, as well as
comply could cause death or serious injury by local and Cantonal regulations must be observed.
electric shock.
DANGER Furthermore, the EKAS guideline (Liquid Petroleum Gas
Guideline, Part 2) should be observed.
Risk of explosion!
Gas leaks can lead to the build-up of
explosive gas / air mixtures. With the presence
of an ignition source, these then result in
explosions.
DANGER

4.2 Delivery, transportation and storage

Check delivery
Check the delivery to see that it is complete and that there
has been no damage in transit. If the delivery is
incomplete or damaged, contact the deliverer.

Transportation
For burner weight see Ch. 8.7.

Storage
Be aware of the permissible ambient conditions for
storage (see Ch. 8.5)

4.3 Preparation for installation

Check burner name plate
❏ The burner rating must be within the operating range
of the heating appliance. The ratings given on the
burner name plate are the minimum and maximum
possible firing rates of the burner; see capacity graphs
(Ch. 8.2).

Space requirement
Burner dimensions see Ch. 8.8

12
 4
4.4 Burner installation
Prepare heating appliance Refractory and drilling dimensions (basic drawing)
The diagram shows the refractory for a heating appliance
without a cooled front. The refractory must not project
beyond the front edge of the combustion head. The Refractory Drilling dimensions
refractory can take a conical shape (≥ 60°). on the appliance
Refractory may not be required on boilers with water- 60° d3
cooled fronts, unless the manufacturer gives other Flange gasket
instructions. 45°
Fill the air gap with l1 d1 d2
Combustion head extension resilient refractory
Boiler constructions with deep refractories or thick doors insulation material
require a combustion head extension. (do not make solid)
Head extensions of 100, 200 and 300 mm are available. d4
d5
Dimension l1 then changes relative to the head extension
used. Burners with head extensions can still be hinged
open.
It is important that the burner can be hinged open by
approx. 90° to allow easy, rearward removal of the mixing
head, which also has the same length extension.

Combustion head Dimensions in mm

Type d1 d2 d3 d4 d5 I1

WMG10-1/3a 127 160 M8 135 160…170 1291…1442

1 Combustion head closed

2 Combustion head open

Limit switch Limit switch

When the burner is hinged closed, a screw on the burner
flange operates the limit switch and electrically completes
the safety circuit.

13
 4
Mounting the burner Danger of getting burned!
Before mounting the burner observe: Some burner parts (e.g. flame tube, burner
❏ Mixing head setting, see Ch. 5.2 flange, etc.) become hot during burner
❏ Ionisation and ignition electrode setting, see Ch. 7.4 operation and should be allowed to cool prior
DANGER to service work being carried out.
1. Screw stud screw to boiler plate.
2. Fit hinge flange and flange gasket to boiler plate with
nuts.
3. Open view port cover.
4. Using suitable lifting equipment lift burner and mount
onto boiler plate and secure with hinge pin (observe
hinging direction).
5. Secure burner housing with nut.
6. Connect the ionisation and ignition cables and close
view port cover.
7. Open gas butterfly valve motor and fit plug.

Mounting the burner

14
 4
4.5 Gas valve train installation
Risk of explosion! Additional installation notes:
Gas leaks can lead to the build-up of explosive A vent hose leading to atmosphere should be connected
gas/air mixtures. With the presence of an to vent the valve train.
ignition source, this can result in
explosions. To allow the appliance door to be hinged open, a flange
DANGER ‘break-point’ should be fitted - if possible at door level.

To avoid accidents, please observe the following safety If a thermal shut off device TAE is required, this must be
instructions on valve train installation. fitted upstream of the ball valve.

☞ Before beginning work, close all the relevant shut off To improve start conditions, the distance between burner
devices and ensure they cannot be accidentally and solenoid valves (ignition and mains gas) should be as
reopened. short as possible.
☞ Ensure the valve train components are correctly Observe sequence and flow direction of valve train
aligned and that all the joints are clean. components.
☞ Flange seals must be fitted correctly on machined
faces. Installation position of double solenoid valve and FRS
☞ Tighten screws evenly diagonally opposite. • DMV and FRS can be positioned with the actuator axis
☞ Valve trains must be mounted tension-free. angled from standing vertical to lying horizontal in
Do not compensate for misalignment by over- horizontal pipe work.
tightening. • High pressure regulator, see installation and operating
☞ The valve trains must be fixed and supported securely. instruction Pressure regulating units Print No. 12.
They must not be allowed to vibrate during operation.
Supports suitable for the site should be fitted during
installation.
☞ Observe the maximum permissible total pressure in the
valve trains. Ask your gas supplier for the correct gas
main supply pressure.
The supply pressure must not exceed the permissible
total pressure.

Installation example low pressure supply with screwed DMV

1 2 3 4 5 6 7

9 0 8

1 Double solenoid valve DMV 6 Pressure gauge with push button valve
2 Test burner 7 Ball valve
3 High gas pressure switch (optional) 8 Low gas pressure switch
4 High pressure pressure regulator/governor 9 Valve proving gas pressure switch
5 Filter 0 Electrical connection W-FM

15
 4
Installation example high pressure supply with screwed DMV

1 2 3 4 5 6 7

9 0 8

1 Double solenoid valve DMV 6 Pressure gauge with push button valve
2 Test burner 7 Ball valve
3 High gas pressure switch 8 Low gas pressure switch
4 High pressure pressure regulator/governor 9 Valve proving gas pressure switch
5 Filter 0 Electrical connection W-FM

Mount gas pressure switch to DMV Mount gas pressure switch to DMV
1. Remove closing plug 1 on DMV.
2. Fit sealing ring 2 included to the gas pressure Screwed version
switch 3, ensuring that sealing surfaces are clean.
3. Mount gas pressure switch on the DMV with the
screws 4 provided.

1
1

2
2
3
3
4
4

16
 4
4.6 Soundness test of valve trains
Following service work on gas carrying Soundness test
fittings and connections a soundness test
should be carried out.
DANGER

❏ Soundness test of the gas train must be carried out

with the main isolating cock and gas valves closed. V1 V2

Test pressure in valve train: ___________ 100 to 150 mbar

Wait. time for pressure equalisation: _________ 5 minutes
Test duration: ____________________________ 5 minutes
Max. permissible pressure loss: ________________ 1 mbar 5
1

First test phase: 2

Ball valve up to first valve seat
1. Connect test assembly to the filter on inlet of valve 1 3 3
(test point 1; low gas pressure switch).
2. Open test point between V1 and V2.

Note When using high pressure regulators it may be

necessary to temporarily close the vent line
during the soundness test. If the safety relief
valve (SBV) opens during the soundness test
pressure is being applied.
It is important to re-open the vent line once the
soundness test is complete.

Second test phase:

Valve section and second valve seat
1. Connect test assembly to test point between V1 and V2
(valve proving gas pressure switch).

Third test phase:

Valve train connection parts up to gas butterfly
The third test phase can only be carried out during 4
operation and by using a leak detection solution.
4
Note: Only use leak detecting foaming solutions,
which do not cause corrosion.
1 Rubber hose with T piece
☞ Following a soundness test close all test points! 2 Aspirator
3 Manometer (U tube or pressure gauge)
4 Hose clamp
Checking zero-flow shut off: 5 Double solenoid valve DMV
1. Open ball valve and wait until the output pressure of
the regulator is stabilised.
During this time the safety relief valve (SBV) must not Test points on DMV-D 507 to 520
open.
2. Close the ball valve and check that the pressure
difference between inlet and outlet pressure of the
regulator remains constant.
4 5 1 2 3

Documentation 2 pmax. = 500 mbar 4 5

☞ Results of the pressure test must be recorded on the
1 3
service/commissioning report. V1 V2

1 2 3

Test point 1 and 4 : Pressure into V1

Test point 2 : Pressure between V1 and V2
and ignition gas outlet
Test point 3 : Pressure after V2
Test point 5 : Pressure after V2
17
 4
4.7 Electrical connection
De-energise plant
Prior to installation switch off the mains switch
and the safety switch.
Failure to comply could cause death or
DANGER serious injury by electric shock.

Note Applicable only if a frequency converter is Installation fan motor

used: It is possible that electrical components Open terminal box on motor and carry out connection in
continue to carry voltage even after the mains accordance with wiring diagram (observe motor rotation).
have been switched off because a frequency The motor must be protected against heat radiation and
converter is fitted. A waiting time of 5 minutes short circuits. The use of a motor protection switch is
should therefore be observed prior to starting recommended. Prior to replacing the motor contactor it is
work. recommended to mark the cables in accordance with the
terminal numbers.

A burner specific wiring diagram is supplied with the General installation notes
burner. All electrical connections must be made to this • Control circuits, which are taken directly via a 16AT
wiring diagram. Local regulations must be observed. pre-fuse from a 3 phase or 1 phase alternating current
supply, must only be connected when an appropriate
Note Carry out electrical installation in such a way that earth potential neutral conductor is available.
it is possible to hinge the burner open. • On a mains supply, which does not have a neutral, then
the control voltage must be supplied via an isolating
transformer.
Installing the display and operating unit • The pole of the transformer, which is to be used as the
The wiring of the ABE to the W-FM is carried out with a neutral conductor, must be earthed.
CAN-Bus plug connection. • Phase and neutral and earth conductors must be poled
This special cable supplies voltage to the ABE and correctly.
transmits the Bus signals. • Ensure the maximum permitted fuse ratings are
not exceeded.
• Earthing and neutral conductors must conform to local
Installing the terminal box - valve train regulations, and must be absolute zero potential.
• Connect double solenoid valve plug Y2 in accordance
with the burner wiring diagram. Notes for Austria
Depending on plant conditions, the connection of Electrical isolation with a minimum 3 mm contact gas,
an external gas solenoid valve (Y3) may be required. acting on all poles. must be fitted adjacent to the burner.
• Connect low gas pressure switch (F11) and gas Possibilities are:
pressure switch for valve proving (F12) in accordance • Switch (without mirco-contacts)
with the burner wiring diagram. with separation characteristics
For TRD the additional high gas pressure switch (F33) • Circuit breaker
should also be connected. • Contactor
• Connect 10 core connection cable via cable entry rail • Screw in type fuse with clearly recognisable
to the W-FM 100 in accordance with the wiring designation
diagram.

Installing the W-FM

Connect inputs and outputs, as well as voltage supply to
the W-FM in accordance with the wiring diagram.
☞ Use cable entry glands on burner housing.

18
5 Commissioning and operation 5
5.1 Safety notes on commissioning
Check installation Safety notes on initial commissioning
All installation work must be completed and The initial commissioning must only be carried out by the
checked prior to commissioning. The burner supplier, manufacturer or their appointed agent. At this
must be fitted to the heating appliance ready time, all the control and safety equipment must be checked
for operation and must be wired to all control to ensure correct operation and, if an item can be adjusted,
DANGER and safety devices it should be checked that it has been set correctly.

Furthermore the correct fusing of the circuits and the

❏ Burner mounted, annulus between the flame tube and measures for contact protection of electrical equipment
refractory filled with ceramic fibre. (see Ch. 4.4). and of all wiring must be checked.
❏ Fuel supply complete
❏ Electrical connections and controls complete

5.2 Preparations for initial commissioning

Venting the gas lines Note If work has been carried out on the gas
The gas supply pipe work should be purged/vented only supply lines, i.e. replacement of parts, fittings
by the local gas authority. These supply lines should be or gas meter, re-commissioning of the burner
purged with gas until the air or the inert gas has been fully may only commence once the affected parts
expelled. of the gas line have been vented and a
soundness test has been carried out by the
local gas authority.

Check gas connection pressure

Risk of explosion! 1. Connect manometer to filter (on high pressure
Excessive gas pressure can damage the valve supplies the inlet to the high pressure regulator is
train components. fitted with a manometer as standard).
The mains gas pressure must not exceed the 2. Slowly open the ball valve on the gas train and
DANGER max. permitted pressure of the valve trains monitor the manometer reading at all times.
listed on the burner nameplate. The mains gas 3. Close the ball valve immediately if the mains gas
pressure must be checked prior to pressure exceeds the max. permitted pressure of the
purging the valve train. valve train.
The burner must not be started!
Contact the plant operator.

Venting the valve train Vented valve train

❏ Ensure gas connection pressure is correct.
1. A hose leading to safe open atmosphere is connected
to test point V1 of the solenoid valve. Use a test burner to ensure that
2. With the ball valve opened the gas mixture in the valve no air is present in the valve train.
train vents via the hose to safe atmosphere until neat
gas is detected.
3. Close the ball valve and remove the venting hose, and
immediately close V1 test point.
4. Use a test burner to ensure that no air is present in the
valve train.

Note The test burner must not be used to vent the

valve train.

19
 5
Setting the mixing head Set dimensions e
The mixing head (dimension e) should be set to the
required combustion heat rating QF. Flame tube setting
open closed
Dimension e:
Distance from hinged flange to flame tube. e
When setting pay attention to the centralisation of the
flame tube, it is therefore recommended to determine
dimension e at three points (120° radially).

Example 1

Required burner rating QF 190 kW

with a combustion chamber pressure of 1.0 mbar
Results in: Flame tube setting (dim. e) 140 mm
Air damper setting 44°

Example 2
Hinge open the burner
Required burner rating QF 275 kW The mixing head can be adjusted while it is fitted to the
with a combustion chamber pressure of 2.0 mbar appliance. The burner can be hinged open towards the
Results in: Flame tube setting (dim. e) 148 mm hinge pin.
Air damper setting greater than 60° ➩ see Ch. 7.3

Setting diagram mixing head (dimension e)

6
Air damper setting
5

30° 40° 50° 60°

4 20°
Combustion chamber pressure [mbar]

10°
2
2

1
1

0 155

-1

-2
Dimension e [mm] 140 145 150

-3
Flame tube setting (dim. e)
-4
0 50 100 150 200 250 300 350
Combustion heat rating [kW]

The setting diagram is sectioned into two areas:

• Flame tube setting (dimension e) 140 mm • Air damper setting greater than 60°
• Air damper setting depending on rating • Flame tube setting (dimension e) depending on rating
required required

20
 5
Connecting manometer Pressure measurement (pressure into mixing head)
To test the fan pressure into the mixing head during initial
commissioning.

Measuring ionisation current Measuring ionisation current

When a flame exists, an ionisation current is produced.

Ionisation current Display flame signal ABE

min. 6 µA DC approx. 50%

max. 85 µA DC approx. 100%

Measuring device:
Multi meter or micro-ammeter.

Connection:
Disconnect the ionisation lead from the plug coupling and
connect meter in series.

Checklist for initial commissioning

❏ The heating appliance must be assembled ready for ❏ Fuel carrying parts must be purged of air.
operation. ❏ Burner hinge flange must be closed and secured
❏ The operating instructions of the heat exchanger must ❏ Soundness test of the valve train must have been
be adhered to. carried out and documented.
❏ The whole plant must be wired correctly. ❏ Gas connection pressure must be correct.
❏ The heating appliance and the heating system must be
sufficiently filled with heating medium.
❏ Flues must be free from obstructions.
❏ Flue gas dampers must be open.
❏ Sufficient clean combustion air must be available.
❏ The required test points for combustion analysis must
be available.
❏ Water level controls and interlocks must be set Note Dependent on site requirements, further
correctly. checks may be necessary. Note the
❏ Thermostat, pressure switch and other safety devices instructions for the individual items of plant
must be in operating position. equipment.
❏ There must be a heat demand.

21
 5
Calculate setting pressure Preset setting pressure
Determine the control pressure setting for full load from
table “Minimum connection pressure and setting pressure”
(see Ch. 5.2.1) and note it down.

Note The combustion chamber pressure has to be

added to the control pressure setting
determined.
Preset setting pressure
❏ Check output pressure range of the spring fitted to the
governor/regulator.

1. De-regulate gas governor/regulator for initial

commissioning.

2. With the ball valve closed, open test point before V1

and connect manometer.

3. Slowly open ball valve and using a test burner

measure available pressure before V1.

4. Adjust the spring setting to the control pressure

already determined.

5. Close ball valve.

Springs for FRS
Type of spring / colour output pressure range

orange 5…20 mbar

blue 10…30 mbar
red 25…55 mbar

Check valve lift on V1 (on DMV) Set valve lift V1

The maximum valve lift should have been set on the DMV.

22
 5
5.2.1 Minimum connection pressure and setting pressure
Burner type: WM-G 10/1-A / ZM-LN

Connection pressure Control pressure

Burner Low pressure supply High pressure supply
rating (gas pressure in mbar into isolating valve, (setting pressure in mbar
pemax = 300 mbar) double solenoid valve)

Nominal diameter of valve trains Nominal diameter of valve trains

3
/4” 1” 11/2” 2” 3
/4” 1” 11/2” 2”
Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve
[kW] 25 25 25 25 25 25 25 25

Natural Gas E (N), Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606

150 15 – – – 8 – – –
175 19 11 8 – 11 6 5 –
200 24 13 10 9 14 7 6 6
225 29 15 11 10 17 8 7 7
250 34 16 11 11 20 9 8 8
275 40 18 12 12 23 10 9 9
300 45 21 13 12 26 11 9 9
325 52 23 14 13 30 12 10 10
350 59 26 16 14 34 13 11 11

Natural Gas LL (N), Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641

150 20 11 8 – 11 6 5 –
175 25 13 10 9 15 7 6 6
200 32 16 11 10 19 9 8 8
225 39 18 12 11 22 10 8 8
250 46 21 13 12 27 11 9 9
275 54 23 15 14 31 13 10 10
300 63 26 16 15 36 14 11 11
325 73 30 18 16 41 16 12 12
350 83 33 19 17 47 17 13 13

Liquid Petroleum Gas B/P (F), Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 1.555
150 – – – – – – – –
175 11 – – – 6 – – –
200 14 9 – – 8 6 – –
225 17 11 9 9 10 7 6 6
250 19 12 10 9 12 7 7 7
275 21 13 10 10 13 8 7 7
300 24 14 11 10 15 9 8 8
325 27 15 12 11 16 9 8 8
350 30 16 12 12 18 10 9 9

The details given for calorific value Hi relate to 0° C and With low pressure supplies, pressure regulators to EN 88
1013 mbar. with safety diaphragm are used.
Maximum permissible connection pressure into isolating
The results of the tables have been calculated on flame valve on low gas pressure installations is 300 mbar.
tubes under idealised conditions. The values are therefore
guidelines for basic settings. Small variations may occur With high pressure supplies HP regulators with safety
when commissioning depending on individual installations. assemblies are used, which can be selected from the
following brochures:
Note The combustion chamber pressure in mbar • Pressure regulators up to 4 bar, Print No. 12
must be added to the minimum gas pressure • Pressure regulators with safety diaphragm,
determined. Print No. 1732
• Pressure regulators over 4 bar, Print No. 1727
The min. connection pressure should not be
below 15 mbar. Maximum permissible connection pressure see name
plate.

23
 5
5.3 Operating the W-FM
For a detailed description of operation, navigation as well Display and operating unit ABE
as individual functions see installation and operating
instructions Combustion Manager W-FM.

Setpoint 80.0°C
ActValue 78.5°C
Load 64.8%
Display
4 lines with scroll function
Flame 98.5%

info esc
Info key
Return to operating display
ESC key
Escape or return
Enter key
Execution
Scroll
Cursor control and value alteration

OFF function
Simultaneous pressing of the ESC and Enter keys initiates
lockout.
The OFF function is stored in the fault memory.

24
 5
5.4 Commissioning and setting
➩ In addition to this chapter the installation and
operating instructions Combustion Manager W-FM
should be observed.
This document includes further information about:
• Menu structure and navigation
• Parameter setting
• Editing of load points
• Function,
• etc.

1. Pre-setting gas and air pressure switches These settings for the gas and air pressure
Air pressure switch: ___________________ approx. 8 mbar switches are only valid for commissioning.
Low gas pressure switch: ___ approx. 1/2 control pressure Once commissioning is complete the gas
High gas pressure switch: _ approx. twice control pressure and air pressure switches should be set as
Valve proving gas pressure switch: ____approx. 1/2 control DANGER detailed in Ch. 5.5.
pressure The setting of the low gas pressure switch
should be corrected once the setting pressure
Note The value set on the valve proving gas has been preset in ignition position.
pressure switch should be greater than the
maximum mixing pressure during pre-purge
and less than the static gas pressure existing.

2. Set to OFF in manual operation

To be able to carry out the following settings the burner
should be switched off.
(Manual operation → Auto/Manual/Off → Burner
Off)

3. Enter password
Select Param + Display and enter engineer’s
password.

4. Load limits for commissioning

Check load limits and adjust if required.
MinLoad: _________________________________ 0.0 %
MaxLoad: _________________________________100 %

5. Check ignition mixing pressure Preset values ignition positions

• Under Special positions, set the parameter
Program stop to 36 IgnPos. Mixing pressure 0.5…2 mbar
• Open fuel shut off devices and start burner IgnPosGas 9°…12°
(Auto/Manual/Off → Burner On). IgnPosAir 4°…6°
• Check rotation direction of combustion air fan.
• Check mixing pressure, if necessary adjust only by
changing the air damper setting (Ignition
position → IgnPosAir).

6. Ignition
• Set Program stop to 52 Interv 2 , burner ignites
and remains in ignition position.
• Preset setting pressure taking the anticipated
combustion chamber pressure into account.
• Carry out combustion analysis (O2 approx. 5%) and if
required optimise by adjusting the air and fuel quantity
(IgnPos).

25
 5
7. Enter ignition load point as Point 1
• Deactivate Program stop.
• Select CurveParams. The ignition load point will be
automatically taken over if Point 1 has not previously
been defined.
• Whilst observing the combustion quality carry out
correction using air and fuel quantities.

8. Set intermediate load points

• Increase burner load setting in Manual using the scroll
button, whilst observing combustion values .
• Set intermediate load point before reaching
combustion limit.
• Carry out combustion analysis and correct intermediate
load point values (see diagram Mixing head setting).
• Repeat procedure until full load (100%) has been
attained.

9. Optimising full load

• Check gas throughput with a 65°-70° gas
butterfly setting and adjust using the setting screw on
the gas governor.
• Determine combustion limit and set excess air
(see appendix Combustion analysis).
• Check fuel quantity throughput once again and
adjust if necessary.
The gas pressure setting must not be
altered once this step has been carried out.

10. Redefine intermediate load points Note To allow a reduction of MinLoad after
• Drive to Point 1 and analyse combustion. commissioning, point 1 should be set
• Carry out load ratings apportionment (see example). below the required low fire.
• Drive to full load and then delete all intermediate load However, it must lie within the capacity
points. graph of the burner (see Ch. 8.2).
Do not delete full load point (100%) and Point 1. When using in conjunction with an O2 module
• Manually reduce burner load rating and whilst (only with W-FM 200), point 1 must lie at least
observing the combustion values and the load signal 30% below the partial load to be set, to allow
set new intermediate points (min. 5 points; max. 15 subsequent O2 trim across the whole rating
points). range.
• Optimise combustion at each point and carry out
ratings apportionment.

Example ratings apportionment

11. Check start behaviour
• Start burner in manual operation Throughput intermediate load point
• Check start behaviour and correct ignition load setting Rating [%] = • 100
Throughput full load
if required.
36 m3/h
12.Define and optimise partial load Rating [%] = • 100 = 20.0 %
• Whilst observing the data given by the appliance 65 m3/h
manufacturer, set the regulating range within its
capacity range (Ch. 8.2) in menu Load Limits. PointI Load:22.4 PointI Load:20.0
Partial load is defined here via parameter MinLoad. : 2 I Burn:19.5 : 2 I Burn:19.5
Partial load must be within the capacity graph Man. I Air : 8.2 Man. I Air : 8.2
(see Ch. 8.2).

13. Data back-up

Prior to commissioning the second fuel, it is recommended
that a data back-up be made from the W-FM to the ABE.
To do this call up param back-up under Updating and
start back-up LMV → AZL.

26
 5
5.5 Concluding work following commissioning
Set low gas pressure switch Gas pressure switch
The switch point must be checked and if necessary
adjusted during commissioning.
Test point
1. Connect manometer to the test point of the low gas
pressure switch.
2. Start the burner and run it to full load.
3. Slowly close ball valve until either:
• the gas pressure drops to 70% of the control
pressure 10
• flame stability considerably worsens, 20

• the CO value increases,

30

150
• or the flame signal reading falls below the minimum

50

130
value.

70
11
4. Determine gas pressure and open ball valve.
0
90
5. Set the gas pressure determined on the setting dial.
6. Check the switch point at 40-50% of rating:
If the ball valve is now slowly closed again, the switch
off pressure can be checked. The burner control must
not initiate a lockout shutdown.

Set valve proving gas pressure switch Calculate setting pressure gas pressure switch
The switch point is set between regulating pressure PR
and mixing pressure at pre-purge PV.
1. Following controlled shutdown, use test burner to
reduce static gas pressure and determine gas control
pressure PR at inlet of valve V1.
2. Determine maximum mixing pressure at pre-purge PV
downstream of valve V2.
3. Calculate setting pressure using the formula below and
set at gas pressure switch.
4. Check: Following a controlled shutdown, the burner
must carry out a valve proving without
initiating a valve proving lockout shutdown.

PR + PV
= setting pressure
2
PV
PR / PF
Set high gas pressure switch
Must be set to 1.3 x PF (flow pressure at full load).
(Function see Ch. 3.2).

27
 5
Set air pressure switch Differential pressure measurement
The switching point setting must be checked and if
necessary adjusted during commissioning.
1. Remove closing cap from air pressure switch and
connect a manometer. 10 5 2,5
2. Using T piece connect low-pressure hose to

15

m
ba
r
20
manometer.

50
5

45
3. Start burner.
2
30 40 35

4. Carry out differential pressure measurement across the

whole ratings range and determine the lowest
differential pressure.
5. Set 80% of the determined scale value on the setting
dial.

Lowest differential pressure: __________________20 mbar

Switch point air pressure switch:____13 x 0.8 = 10.4 mbar

Note Installation dependant influences on the air

pressure switch, such as flue gas recirculation,
heating appliance installation, or air supply,
may result in slight adjustments having to be
made to the settings.

Concluding work
☞ Operation of the safety devices (i.e. pressure switches,
thermostats, etc.) on the plant should be checked and
adjusted during operation.

☞ Document burner settings and combustion readings.

☞ Inform the operator about the use of the equipment.

28
 5
5.6 Shutdown periods
For short breaks in operation
(e.g. flue cleaning etc.):
☞ Isolate the burner from the power supply.

For longer breaks in operation:

☞ Isolate the burner from the power supply.
☞ Close all fuel shut off devices.

29
 6 6 Fault conditions and procedures for rectification
6.1 General faults on the burner
If the burner is found out of operation in lockout , read error To avoid damage to the plant, do not reset the
codes and proceed according to the error message. burner more than twice. If the burner locks out
If faults occur, check first that the basic requirements for for a third time call for a service engineer.
operation are met.
ATTENTION

❏ Check the electric supply

❏ Check that the correct gas pressure is available from
the gas main and that the ball valve is open. Fault conditions should be rectified only by
❏ Check that all controls e.g. thermostats, pressure qualified and experienced personnel.
switches, and water level interlocks, limit and time
switches are set correctly. DANGER

If it has been established that the lockout is not due to any

of the above, all the burner functions must be checked.

Condition Cause Rectification

Burner motor

Does not run No voltage Check voltage supply

Overload relay or motor protection Check setting

switch has tripped

Contactor defective Replace contactor

Fan motor defective Replace fan motor

Ignition

Ignition failure Ignition electrode Adjust setting

spark gap incorrect

Ignition electrode dirty or wet Replace ignition electrode

Ceramic insulator fault Replace ignition electrode

Ignition cable charred Replace, find cause and rectify

Ignition unit W-ZG defective Replace ignition unit

Combustion manager
with flame sensor

Does not respond to flame Flame signal insufficient Measure flame signal, adjust position of
ionisation electrode; rectify poss. transition
resistance (terminal, plug); correct burner
setting

Ionisation current not With mains supply without a neutral, the

present or too low control neutral must be earthed at the
control circuit transformer.

Break in the flame Repair or replace cable

sensor line

30
 6
Condition Cause Rectification
Solenoid valve

Does not open No voltage Check connections

Coil faulty Replace coil

Does not close tightly Particles on valve seat Replace solenoid valve

Cleaning and lubrication regulations

Depending on the degree of contamination of the combustion air, fan wheel, ignition electrodes, flame sensor and air intake
should be cleaned as required.
Bearing damage, which is recognised and rectified early, will protect the burner from further damage. Pay attention to noise
levels from the motor bearing and replace bearing if necessary.

General operating problems

Start problems, burner does Flame signal insufficient Check burner setting for unstable and
not start, no flame formation pulsating flame. By adjusting flame
despite ignition and fuel supply sensor improve signal.

Pressure into mixing head too high Check mixing pressure at ignition load
setting, if necessary adjust.

Wrong setting of ignition electrode Correct setting (see Ch. 7.4)

Burner or combustion Wrong setting of mixing head Check setting of mixing head,
pulsating or booming distance of the diffuser to front correct position of air stepping motor.
edge of flame tube too small

6.2 Fault conditions W-FM

For error codes see Installation and operating instructions
Combustion Manager.
The error history stores up to 20 faults and 10 lockouts.
These should be selected and checked prior to replacing
the W-FM.

31
 7 Servicing
7.1 Safety notes on servicing
Failure to carry out maintenance and service
work properly can have severe consequences,
including the loss of life. Pay close attention to
the following safety notes.
DANGER

Qualified personnel Endangering operational safety

Only qualified and experienced personnel must carry out Maintenance work on the following parts may only be
maintenance and service work. carried out by the manufacturer or their appointed agent
on the individual components.
Prior to all maintenance and service work: • Stepping motor
1. Electrically isolate the equipment. • Flame sensor
2. Close the ball valve. • Combustion manager
• Pressure regulator
After all maintenance and service work: • Solenoid valves
1. Carry out soundness test and record results • Gas pressure switch
2. Carry out function test. • Air pressure switch
3. Check exhaust gas analysis for CO2 / O2 / CO
values.
4. Complete a test sheet. Risk of explosion due to a gas leak
Take care when dismantling and assembling parts in the
gas line to ensure they are correctly cross bonded,
aligned, clean and in good condition, and that the fixing
screws are correctly tightened.

De-energise plant
Prior to service work switch off the mains
switch and the safety switch.
Failure to comply could cause death or
DANGER serious injury by electric shock.

Danger of getting burned!

Some burner parts (e.g. flame tube, burner
flange, electrodes, etc.) become hot during
burner operation and should be allowed to
DANGER cool prior to service work being carried out.

32
 7
7.2 Servicing
The operator should ensure that combustion plant is
serviced at least once a year by an agent of the supplier or
other suitably qualified person. During this service all
system components with high wear and tear, or
components with a specific life span should be exchanged
and replaced.

7.2.1 Testing, cleaning and function test (checklist)

Checklist Checklist
Test and clean Function test
❏ Fan wheel and air inlet ❏ Carry out soundness test of valve trains
❏ Air damper (when replacing parts; see Ch. 4.6)
❏ Stepping motors ❏ Purge the valve train
- including the coupling to correcting elements, lever (when replacing parts; see Ch. 5.2)
and bearing ❏ Operation of the burner to the correct sequence of
❏ Combustion head and diffuser operation
❏ Gas filter ❏ Ignition
❏ Ignition unit ❏ Air pressure switch
❏ Flame sensor ❏ Gas pressure switch
❏ Flame monitoring
❏ Carry out combustion check and adjust burner if
required

7.2.2 Criteria for setting / replacement

Component Criteria Limit Measure

Ionisation electrode Run time, soiling 2 years Recommendation: replace

Ignition electrode Spark function 2 years Recommendation: replace

Ignition cable Run time visible damage Replace

Air damper Clearance min. 0.3 mm Adjust

Sleeve bearing air damper shaft Play 0 mm Replace air damper shaft

View port cover seal Tightness Air escaping during operation Replace

Adjust clearance of air damper

min. 0.3 mm

If the top clearance is less than 0.3mm, undo screw 1 and

align air damper horizontally (equal clearance
top/bottom).
33
 7
7.3 Removing and refitting the mixing head
On heating appliances with high media
temperatures, such as steam generators,
during burner shutdown parts of the mixing
head become very hot to temperatures above
DANGER 100° C. When removing the mixing head, as
well as during preparation work, protective
gloves should be worn.

Any other service work should only be

carried out once the mixing head has been
allowed to cool completely.
Removal Refitting
➩ Observe safety note Ch. 7.1. Refit the mixing head in reverse order.
❑ Has the hinge pin been fitted to the correct side?
Ensure correct alignment of mixing head.
1. Remove view port cover 1.
2. Unplug ionisation and ignition cables 2.
3. Remove cover nut 3 and hinge open the burner.
4. Loosen lock nut 4.
5. Lift mixing chamber 5 and remove.

Removing the mixing head

34
 7
7.4 Setting ionisation and ignition electrodes
Setting ignition electrode Note Certain plant conditions (start problems,
Undo screw on fixing plate and set ignition electrode to the weak flame signal) may require an adjustment
dimensions given. to the positioning of the electrode tip.

Setting ionisation electrode

Undo screw on fixing plate and set ionisation electrode as
shown below.

Setting electrodes

Ignition electrode Ionisation electrode

approx. 1.5 to 2 mm

ap
pr
ox
.5
to
6 mm

35
 7
7.5 Removing and refitting air damper stepping motor
Removing Stepping motor address
➩ Observe safety notes Ch. 7.1. If a stepping motor is replaced, check the address and if
1. Remove cover 1 of air inlet housing and stepping necessary re-address (see installation and operating
motor cover 3. instructions Combustion Manager W-FM).
2. Place stepping motor in 0 position.
If a faulty stepping motor makes it impossible to drive to
0 position, the air damper shaft can be rotated Note Following the replacement of a stepping
manually. motor carry out a combustion analysis
3. Undo plug connections and remove cable and adjust the burner as required.
entry plate 4.
4. Undo lock nut 2 on the coupling
5. Loosen stepping motor 5 and remove from air
damper shaft.

Refitting
Refit the stepping motor in reverse order, paying attention
to the correct fit of the shaft key 6.

Removing and refitting air damper stepping motor

4
5

36
 7
7.6 Removing and refitting gas butterfly stepping motor
Removal Stepping motor address
➩ Observe safety notes Ch. 7.1 If a stepping motor is replaced, check the address and if
1. Open stepping motor cover 1. necessary re-address (see installation and operating
2. Remove electrical connections and remove cable instructions Combustion Manager W-FM).
gland plate 2.
3. Remove view port 3 from intermediate housing 4
and loosen grub screw of coupling 5. Note Following the replacement of a stepping
4. Undo fixing screws and carefully remove stepping motor carry out a combustion analysis
motor 6 (do not damage coupling). and adjust the burner as required.
5. Loosen second grub screw and pull off coupling from
drive shaft.
6. Remove shaft key 7.
7. Undo fixing screws and remove intermediate
housing 4.

Note Steps 5 to 7 are only necessary if the

intermediate housing or the coupling
require replacing.

Refitting
Refit in reverse order, ensuring correct fit of the
shaft key 7.
The coupling should slide onto the shaft without
having to use force.
Removing and refitting gas butterfly stepping motor

7 3

7
4 5

1
2

37
 7
7.7 Removing and refitting FRS spring
Removing Remove and refit spring on pressure regulator
1. Remove protective cap 1.
2. De-regulate the spring by turning the adjusting screw
2 anticlockwise until you reach its stop.
3. Remove complete adjusting device 3. 1
4. Remove spring 4.

Refitting 2
Refit in reverse order.
Please note: 3
☞ If the spring range is changed stick new label for new
spring onto the nameplate.

4
Springs for FRS
Type of spring / colour Outlet pressure range

orange 5… 20 mbar
blue 10… 30 mbar
red 25… 55 mbar

38
8 Technical data 8
8.1 Burner equipment
WM-G 10/1-A / ZM-LN

Combustion Manager Motor Stepping motors

W-FM D90/50-2/1 EC90/90-2/1 Air damp./Gas butterfly:

380-400 V, 3~ 220-230 V, 1~ SQM 45.29…
50 Hz; 2800 rpm 50 Hz; 2880 rpm 10 secs./90°
0.76 kW; 2.1 A 0.76 kW; 6 A 3 Nm
Cond. 25µF

Flame sensor Ignition unit

Ionisation electrode W-ZG 02/V

2 x 7000V

8.2 Capacity graph

Burner type WM-G 10/1-A / ZM-LN The capacity graphs are in accordance with EN 676, and
relate to an installation at sea level. There is a rating
Combustion head WMG10-1/3-a reduction dependent on the altitude of the installation:
Combustion heat rating 55…350 kW approx. 1% per 100 m above sea level.

Ratings range
The burner has a maximum turndown ratio of 8:1. Please
note that the lowest operating point must lie within the
burner’s capacity chart.

6
Rating with
combustion head
5
N/LPG CLOSED
LPG OPEN
4
Combustion chamber pressure [mbar]

-1

-2

-3

-4
0 50 100 150 200 250 300 350
Combustion heat rating [kW]

39
 8
8.3 Permissible fuels
Natural Gas E
Natural Gas LL
Liquid Petroleum Gas B/P

8.4 Mixing head dimensions

Burner type Flame tube Diffuser

Type external internal external internal

D1 [mm] D2 [mm] D3 [mm] D4 [mm]

WM-G10/1-A / ZM-LN WM-G10/1-3a 127 102 105 36

Dimensions are approximate. We reserve the right to make changes in line with future development

D4 D3 D2 D1

8.5 Permissible ambient conditions

Temperature Humidity Requirements for Low voltage guideline
EMC

In operation: Guideline 2004/108/EC Guideline 2006/95/EC

-15°C …+40°C max. 80% rel. humidity EN 61 000-6-1 EN 60335
no dew point EN 61 000-6-4

Transport/storage:
-20…+70°C max. 95% rel. humidity
no dew point

40
 8
8.6 Electrical data
Mains voltage Pre-fuse Electrical rating

Burner control 230V 16 AT (external) Inrush 250 VA*

50Hz, 1~ 6.3 AT (internal) Operation 160 VA

Fan motor 380 - 400 V, 50Hz, 3~ 10 A approx. 1.2 kW

220 - 230 V, 50Hz, 1~ 20 A approx. 1.3 kW
* Ignition start rating

8.7 Weights

Burner
approx. 56 kg

Gas valve trains

3
Nominal diameter /4” 1” 11/2” 2”

Weight in kg 7 9 10 11

Gas valve train consists of double solenoid valve and reducing flange elbow

Screwed gas valve train (3/4” to 2”)

41
 8
8.8 Burner dimensions

139 445

313

167
88

279
8
71

127

307
68
2

8 205

144…129
803

42
Appendix A
Combustion analysis
For safe, economic and environmentally friendly operation Determination of flue gas losses
of the plant, flue gas measurements are essential when The oxygen content of the undiluted flue gas and the
commissioning. difference between the flue gas and the combustion air
temperature must be determined. The oxygen content and
Example of a simplified calculation for determining the the flue gas temperature must be measured at the same
CO2 setting value time at one point. Instead of oxygen content, the carbon
dioxide content of the flue gas can also be measured. The
Given that: CO2 max. = 12% combustion air temperature is measured in the proximity of
the burner air intake.
At CO limit (≈ 100 ppm), measured: CO2meas. = 11.5%
The flue gas losses are calculated when measuring the
CO2 max. 12 oxygen content according to the equation:
Gives excess air: λ ≈ = ≈ 1.04
CO2meas. 11.5 A2
qA = (tA - tL) • ( +B)
To provide for a safe amount of excess air, increase air λ by 21 – O2
15% to 20% (soiling of intake air, deviations in intake air
temperature and chimney draughts, etc. should be If the carbon dioxide content is measured instead of the
included in the calculation): oxygen content, the calculation is carried out according to
the equation:
1.04 + 0.15 = 1.19
A1
CO2 value to be set with excess air λ = 1.19 and 12% qA = (tA - tL) • ( +B)
CO2max.: CO2

CO2 max. 12 whereby:

CO2 ≈ = ≈ 10.1 % qA = flue gas losses in %
λ 1.19 tA = flue gas temperature in °C
tL = combustion air temperature in °C
The CO content must not be more than 50 ppm. CO2 = % volume of carbon dioxide content in dry flue
gas
Observe flue gas temperature O2 = % volume of oxygen content in dry flue gas
Flue gas temperature for full load (nominal load) is the
result of burner setting at nominal loading.
The flue gas temperature at partial load is the result of the Natural Towns Coke LPG and
commissioned control range. The appliance gas gas oven LPG/Air mix
manufacturer’s instructions must be adhered to in respect gas
of the partial load setting. This might be 50 - 60% of
nominal load setting,or even higher with an air heater, A1 = 0.37 0.35 0.29 0.42
whereas a condensing boiler may require the maximum A2 = 0.66 0.63 0.60 0.63
available turndown within the burners capacity range. B = 0.009 0.011 0.011 0.008
Often the partial load is shown on the appliance;s data
plate.
The flue gas installation should also be set out to protect
against damage through condensation (excluding
acid proof chimneys).

Calorific values and max. CO2 (guide values) of various types of gases.

Gas type Calorific value Hi CO2 max.

MJ/m3 kWh/m3 %

1st gas family

Group A (Town Gas) 15.12…17.64 4.20…4.90 12…13
Group B (Grid Gas) 15.91…18.83 4.42…5.23 10

2nd gas family

Group LL (Natural Gas) 28.48…36.40 7.91…10.11 11.5…11.7
Group E (Natural Gas) 33.91…42.70 9.42…11.86 11.8…12.5

3rd gas family

Propane P 93.21 25.99 13.8
Butane B 123.81 34.30 14.1

For the various maximum CO2 contents contact the gas supplier..

43
 A Calculation of gas throughput

To provide the correct thermal input to the heat exchanger, Example:

the required gas throughput must be determined Height above sea level = 500 m
beforehand. Barometric air pressure PBaro. from tab. = 953 mbar
Gas pressure PG at meter = 30 mbar
Conversion from standard to operating conditions Total pressure Pmeas.(PBaro+PG) = 983 mbar
The calorific value (Hi) of combustible gases is generally Gas temperature tG = 10 °C
given in relation to the standard barometric conditions Conversion factor f from Tab. = 0.933
(0° C, 1013 mbar). Appliance rating QN = 275 kW
Efficiency η (assumed) = 90 %
Calorific value Hi = 10.35 kWh/m3

Normal volume VN:

QN 275
VN = VN = → VN ≈ 29.5 m3/h
η • Hi 0.90 • 10.35

Operating volume VB:

VN QN 29.5
VB = or VB = VB = → VB ≈ 31.6 m3/h
f η • Hi,B 0.933

Measuring time in seconds for 10m3 of gas Measuring time when gas meter reads 2 m3:
throughput:
3600 • 2
3600 • 10 [ m3 ] Meas. = –––––––––– → Meas. time ≈ 228 s
Measuring =
time 31.6
time [ s ] VB [ m3/h ]
Operating volume when gas meter reads 1 m3 after
Calculation based upon a stop watch meter reading
114 s measuring time:
volume.:
3600 • V [ m3 ]
3600 • 1.0
VB [ m3/h ] =
VB [ m3/h ] = –––––––––– → VB = 31.5 m3/h
Measuring time [s]
114

Determination of factor f
Total pressure PBaro + PG Conversion factor f
in Gas temperature tG in °C
mbar1) 0 5 10 15 20 25
900 0.888 0.872 0.857 0.842 0.828 0.813
920 0.908 0.892 0.876 0.861 0.846 0.832
940 0.928 0.911 0.895 0.880 0.865 0.850
960 0.948 0.931 0.915 0.899 0.884 0.868
980 0.967 0.950 0.933 0.917 0.901 0.886

1000 0.987 0.969 0.952 0.936 0.920 0.904

1020 1.007 0.989 0.972 0.955 0.939 0.922
1040 1.027 1.009 0.991 0.974 0.957 0.941
1060 1.046 1.027 1.009 0.992 0.975 0.958
1080 1.066 1.047 1.029 1.011 0.994 0.976
1100 1.086 1.066 1.048 1.030 1.012 0.995
1120 1.106 1.086 1.067 1.048 1.031 1.013
1140 1.125 1.105 1.086 1.067 1.049 1.031
1160 1.145 1.124 1.105 1.085 1.067 1.049
1180 1.165 1.144 1.124 1.104 1.086 1.067
1200 1.185 1.164 1.144 1.123 1.104 1.085
1220 1.204 1.182 1.162 1.141 1.122 1.103
1240 1.224 1.202 1.181 1.160 1.141 1.121
1260 1.244 1.222 1.200 1.179 1.159 1.140
1280 1.264 1.241 1.220 1.198 1.178 1.158
1300 1.283 1.260 1.238 1.216 1.196 1.175
1320 1.303 1.280 1.257 1.235 1.214 1.194
1340 1.323 1.299 1.277 2.254 1.233 1.212
1360 1.343 1.319 1.296 1.273 1.252 1.230
1380 1.362 1.338 1.314 1.291 1.269 1.248
1400 1.382 1.357 1.334 1.310 1.288 1.266
1420 1.402 1.377 1.353 1.329 1.307 1.284
1440 1.422 1.396 1.372 1.348 1.325 1.303
1460 1.441 1.415 1.391 1.366 1.342 1.320
1480 1.461 1.435 1.410 1.385 1.362 1.338
1500 1.481 1.454 1.429 1.404 1.380 1.357
1520 1.500 1.473 1.448 1.422 1.398 1.374
1540 1.520 1.493 1.467 1.441 1.417 1.392
1560 1.540 1.512 1.486 1.460 1.435 1.411
1580 1.560 1.532 1.505 1.479 1.454 1.429

44
 A
Total pressure PBaro + PG Conversion factor f
in Gas temperature tG in °C
mbar1) 0 5 10 15 20 25
1600 1.579 1.551 1.524 1.497 1.472 1.446
1620 1.599 1.570 1.543 1.516 1.490 1.465
1640 1.619 1.590 1.562 1.535 1.509 1.483
1660 1.639 1.610 1.582 1.554 1.528 1.501
1680 1.658 1.628 1.600 1.572 1.545 1.519
1700 1.678 1.648 1.619 1.591 1.564 1.537
1720 1.698 1.667 1.639 1.610 1.583 1.555
1740 1.718 1.687 1.658 1.629 1.601 1.574
1760 1.737 1.706 1.676 1.647 1.619 1.591
1780 1.757 1.725 1.696 1.666 1.638 1.609
1800 1.777 1.745 1.715 1.685 1.656 1.628
1820 1.797 1.765 1.734 1.704 1.675 1.646
1840 1.816 1.783 1.752 1.722 1.693 1.663
1860 1.836 1.803 1.772 1.741 1.711 1.682
1880 1.856 1.823 1.791 1.759 1.730 1.700
1900 1.876 1.842 1.810 1.778 1.748 1.718
1920 1.895 1.861 1.829 1.796 1.766 1.736
1940 1.915 1.881 1.848 1.815 1.785 1.754
1960 1.935 1.900 1.867 1.834 1.803 1.772
1980 1.955 1.920 1.887 1.853 1.822 1.791
2000 1.974 1.938 1.905 1.871 1.840 1.802
2050 2.024 1.988 1.953 1.919 1.886 1.854
2100 2.073 2.036 2.000 1.965 1.932 1.899
2150 2.122 2.084 2.048 2.012 1.978 1.944
2200 2.172 2.133 2.096 2.059 2.024 1.990
2250 2.221 2.181 2.143 2.106 2.070 2.034
2300 2.270 2.229 2.191 2.152 2.116 2.079
2350 2.320 2.278 2.239 2.199 2.162 2.125
2400 2.369 2.326 2.286 2.246 2.208 2.170
2450 2.419 2.375 2.334 2.293 2.255 2.216
2500 2.468 2.424 2.382 2.340 2.300 2.261
2550 2.517 2.472 2.429 2.386 2.346 2.306
2600 2.567 2.521 2.477 2.434 2.392 2.351
2650 2.616 2.569 2.524 2.480 2.438 2.396
2700 2.665 2.617 2.572 2.526 2.448 2.441
2750 2.715 2.666 2.620 2.574 2.530 2.487
2800 2.764 2.714 2.667 2.620 2.576 2.532
2850 2.813 2.762 2.715 2.667 2.662 2.577
2900 2.863 2.812 2.763 2.714 2.668 2.623
2950 2.912 2.860 2.810 2.761 2.714 2.667
3000 2.962 2.909 2.858 2.808 2.761 2.713
3100 3.060 3.005 2.953 2.901 2.852 2.803
3200 3.159 3.102 3.048 2.995 2.944 2.894
3300 3.258 3.199 3.144 3.089 3.036 2.984
3400 3.356 3.296 3.239 3.181 3.128 3.074
3500 3.455 3.393 3.334 3.275 3.220 3.165
3600 3.554 3.490 3.430 3.369 3.312 3.255
3700 3.653 3.587 3.525 3.463 3.405 3.346
3800 3.751 3.684 3.620 3.556 3.496 3.436
3900 3.850 3.781 3.715 3.650 3.588 3.527
4000 3.949 3.878 3.811 3.744 3.680 3.617

1 mbar = 1 hPa = 10.20 mm w.g. 1 mm w.g. = 0.0981 mbar = 0.0981 hPa

The figures in the table are based on the following simple The moisture content of the gas is negligible and therefore
formula: is not considered in the table or the conversion formula.

PBaro + PG 273
f = •
1013 273 + tG

Average yearly air pressure

Average altitude from 1 51 101 151 201 251 301 351 401 451 501 551 601 651 701
of installation to 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Average yearly air pressure mbar 1016 1013 1007 1001 995 989 983 977 971 965 959 953 947 942 936 930

Legend:
QN = Appliance rating [kW] f = Conversion factor
η = Efficiency [%] PBaro. = Barometric pressure [mbar]
Hi = Calorific value [kWh/m3] PG = Gas pressure at meter [mbar]
Hi,B = Operating calorific value [kWh/m3] tG = Gas temperature at meter [°C]
45
 A Spare
D parts

1. Burner housing
Pos. Description Order No.

1.1 View port cover WM10 complete 211 104 01 02 2

1.2 View port glass 211 153 01 15 7

1.3 View port closing cover 211 104 01 13 2

incl. spring clip

1.4 View port cover seal 211 104 01 12 7

1.5 Hinge pin 14 x 208 111 652 01 04 7

1.6 Circlip 10 431 604

1.7 Hinge flange WM10 217 104 01 02 7

– screw M10 x 35 402 600
– washer A 10.5 430 600

1.8 Screw M12 x 45 421 068

1.9 Dome nut M12 DIN 1587 412 401

1.10 Washer B 13 430 801

1.11 Flange gasket 194 x 136 217 104 01 04 7

1.12 Cable entry W-FM complete 211 104 01 05 2

1.13 Intake cover WM10 211 104 02 02 2

incl. foam lining

1.14 Cable entry set 211 104 01 50 2

1.15 -weishaupt- badge 211 104 01 10 7

2. Fan + air regulator

Pos. Description Order No. Pos. Description Order No.

2.01 Motor including contactor 2.18 Air damper

– D90/50-2/1 220-230/380-400 50Hz 211 104 07 02 0 – LGW 50 A2P 691 373
– EC90/90-2/1 220-230 50Hz 211 103 07 02 0 – LGW 10 A2P (with speed control) 691 385
– Cap for LGW 446 011
2.02 Contactor B7-30-10; 220-240V 702 818

2.03 Cable gland WM-L10 211 104 01 50 2 2.19 Hose 4.0 x 1.75 600mm long 151 518 24 03 7

2.04 Motor D90/50-2/1 220-230/380-400 50Hz 211 104 07 04 0 2.20 Threaded socket R1/8 453 003
for frequency converter fitted
2.21 Threaded socket M12 x 1 x G1/4 x 37.5 217 104 24 01 7
2.05 Frequency converter MI 75/3 111 155 07 04 7

2.06 Shaft key 5 x 6.5 DIN 6888 490 151

2.07 Fan wheel 200 x 90 S1 211 353 08 08 2

– Fan wheel puller (tool) 111 111 00 01 2

2.08 Inlet nozzle ø 161mm WM10 211 104 02 17 7

2.09 Inlet mesh WM-L10/1-A + WM-G10/1+2A 211 104 02 06 7

2.10 Air damper WM10 211 104 02 12 7

– screw M4 x 10 DIN 912 with TufLoc 402 264

2.11 Fixing plate for intake cover WM10 211 104 02 08 7

2.12 Intake cover bracket WM10 211 104 02 15 7

2.13 Stepping motor SQM45.291 A9 3Nm 651 470

2.14 Shaft key 3 x 3.7 DIN 6888 490 157

2.15 Air damper shaft with coupling WM10 prem. 211 104 02 09 2

2.16 Sleeve bearing set air regulator WM10 211 104 02 50 2

2.17 Adjusting ring 24x10x16 211 104 02 16 7

– threaded pin M5 x 14 with TufLoc 420 497

46
 A
1. Burner housing

1.1 1.7
1.2 1.5
1.3
1.6 1.8
1.11
1.4

1.10
1.9

1.15

1.12
1.13

1.14

2. Fan + air regulator

2.05

2.13
2.04
2.20 2.01 2.14

2.15
2.19
2.02 2.06

2.06 2.16
2.03
2.21 2.18

2.07 2.20

2.19

2.16 2.11

2.08
2.17

2.09 2.12

2.10

47
 A
3. Mixing head
Pos. Description Order No.

3.1 Flame tube WM-G10/1-3a 217 103 14 01 2

– Extension tube by 100 mm* 250 103 14 01 7
– Extension tube by 200 mm* 250 103 14 02 7
– Extension tube by 300 mm* 250 103 14 01 2

3.2 Locking nut M12 x 75 251 103 01 11 7

3.3 Gasket gas butterfly DN40 151 101 00 05 7

3.4 Gas butterfly DN25/40, complete 217 104 25 01 0

3.5 Intermediate housing for gas butterfly 217 704 25 01 7

3.6 Sight glass 33 x 33 x 6 211 404 17 02 7

3.7 Spring coupling bar 217 704 15 08 7

3.8 Stepping motor SQM45.291A9 3Nm 651 470

3.9 Combustion head, complete (Nat. Gas)

– WM-G10N/1 217 103 14 02 2
– WM-G10N/1, ext. by 100 mm* 217 103 14 16 2
– WM-G10N/1, ext. by 200 mm* 217 103 14 18 2
– WM-G10N/1, ext. by 300 mm* 217 103 14 20 2

Combustion head, complete (LPG)

– WM-G10F/1 217 103 14 04 2
– WM-G10F/1, ext. by 100 mm* 217 103 14 17 2
– WM-G10F/1, ext. by 200 mm* 217 103 14 19 2
– WM-G10F/1, ext. by 300 mm* 217 103 14 21 2

3.10 Sensor electrode 232 100 14 20 7

3.11 Ignition electrode 132 101 14 03 7

3.12 Diffuser 105 x 36 232 310 14 15 7

3.13 Nozzle element 232 310 14 16 7

3.14 Distributor star 232 310 14 12 7

3.15 Combustion head (Nat. gas)

– WM-G10N/1 217 103 14 06 2
– WM-G10N/1, ext. by 100 mm* 217 103 14 10 2
– WM-G10N/1, ext. by 200 mm* 217 103 14 11 2
– WM-G10N/1, ext. by 300 mm* 217 103 14 12 2

3.16 Bracket for electrode 232 400 14 18 7

3.17 Ionisation cable 290 mm long 251 103 14 03 2

– 390 mm long* 251 103 14 05 2
– 490 mm long* 251 103 14 07 2
– 590 mm long* 251 103 14 09 2

3.18 Ignition line 550 mm long 151 518 11 02 2

– 650 mm long* 217 304 11 01 2
– 750 mm long* 150 518 11 01 2
– 850 mm long* 217 504 11 01 2

* only in conjunction with head extension

48
 A
3. Mixing head
3.1
3.2

3.9

3.3

3.6
3.4

3.7

3.8

3.5

3.11

3.12
3.10
3.13

3.14
3.16

3.15

3.18
3.16
3.17

49
 A
4. Combustion Manager + ignition unit
Pos. Description Order No. Pos. Description Order No.

4.01 ABE for W-FM 100/200 – X9-03 Gas- max./min. 716 321
– Western Europe 1 (GB, D, F, I, E, P) 600 434 – X10-01 Transformer 230/12V 716 322
– Western Europe 2 (GB, NLB, DK, S, N, FIN) 600 437 – X10.03 Ionisation 716 323
– Eastern Europe 1 (GB, PL, H, CZ, SLO) 600 436 – X50 CAN-Bus ABE 716 325
– Eastern Europe 2 (GB, RUS, BG,R, PRC) 600 435 – X51 CAN-Bus Stepping motor 716 326
– X52 Transformer 2 x 12V 716 327
4.02 Plug cable W-FM…ABE – X60 Temperature sensor 716 328
– ABE fitted to housing 217 706 12 10 2 – X61 Actual value U/I 716 329
– ABE fitted externally 4000 mm 217 706 12 19 2 – X62 Set value U/I 716 330
– ABE fitted externally 2500 mm 217 706 12 43 2 – X63 Output 4-20mA 716 331
– ABE fitted externally 1500 mm 217 706 12 42 2 – X70 Proximity switch motor 716 333
– X73 Frequency converter 716 336
4.03 Cover incl. seal
and fixing sleeve for W-FM 4.06 Plug cable
- ABE inbuilt 211 104 12 01 2 – W-FM to SQM... air reg. 217 706 12 11 2
- ABE external 211 104 12 02 2 – SQM4... to SQM4... 1400 mm 217 706 12 17 2

4.04 Combustion Manager 230V; 50-60Hz 4.07 Stay bolt cover W-FM WM10 211 104 12 03 7
– W-FM 100 without load controller 600 450
– W-FM 100 with load controller 600 451 4.08 Mounting plate W-FM100 211 104 12 05 7
– W-FM 200 600 453
4.09 Transf. f. W-FM 100/200 AGG 5.220 230V 600 331
4.05 W-FM Plug
– X3-01 Motor On 716 300 4.10 Plug cable W-FM Transf. 230V/12V 217 706 12 01 2
– X3-02 Air pressure switch 716 301
– X3-03 Limit switch burner flange 716 302 4.11 Plug cable W-FM WM10 Transf. 12-0-12V 217 104 12 01 2
– X3-04 Mains and safety circuit 716 303
– X4-01 Oil/gas changeover 716 304 4.12 Limit switch WM 211 104 01 06 2
– X4-02 Ignition unit 716 305
– X4-03 Solenoid valve venting APS 716 306 4.13 Ignition unit type W-ZG02/V 217 704 11 03 2
– X5-03 Control circuit 716 309
– X6-01 Start release 716 310 4.14 Sealing ring for W-ZG 02 44 x 18 x 4 211 163 11 02 7
– X7-03 Start delay Gas 716 315
– X8-01 Oil / Gas display 716 316
– X9-01 Gas, PV, V1, V2, SV 716 319
– X9-02 N, PE 716 320

5. Valve train
Pos. Description Order No. Pos. Description Order No.

5.1 Double solenoid valve: 5.9 Mounting plate terminal box W-FM
DMV-D 507/11; 230V 605 204 – for 503 /507 217 304 26 09 7
DMV-D 512/11; 230V 605 206 – for 512 /520 217 304 26 10 7
DMV-D 520/11; 230V 605 208
5.10 Terminal box for gas valve train W-FM:
5.1.1 Solenoid, complete for: without GW-max 217 704 26 33 2
507/11 type 1111 220-240V / 50-60Hz 605 941 with GW-max 217 704 26 34 2
512/11 type 1211 220-240V / 50-60Hz 605 942
520/11 type 1212 220-240V / 50-60Hz 605 943 5.11 Cable entry W-FM complete 211 104 01 05 2

5.2 DMV plug 4 pole, 250V AC, 16A 217 304 26 01 2

5.3 GW plug 4 pole, 250V AC, 16A 217 304 26 02 2

5.4 Gas pressure switch

– GW 50 A5/1 5-50 mbar 691 378
– GW 150 A5/1 10-150 mbar 691 379

5.5 O ring GW A5/1 10.5 x 2.25 445 512

5.6 Gas pressure switch

– GW 50 A6/1 5-50 mbar 691 381
– GW 150 A6/1 10-150 mbar 691 382

5.7 Flange DMV 507 RP 3/4 605 227

DMV 512 RP 1 605 228
DMV 520 RP 1 1/2 605 230
DMV 520 RP 2 605 231

5.8 Adapter set DMV 605 251

50
 A
4. Combustion Manager + Ignition unit

4.12

4.08

4.07
4.14
4.05 4.04 4.09
4.13

4.03

4.10

4.01 4.11

4.06

4.02

5. Armatur

5.2

5.7
5.1
5.1.1
5.9
5.8
5.3
5.6
5.3

5.5 5.4
5.5

5.10
5.4
5.7
5.11

51
 A Notes

52
A

53
 Max Weishaupt GmbH
D - 88475 Schwendi
Tel.: (07353) 830, Fax.: (07353) 83358
www.weishaupt.de

Print No. 83243102, October 2007

Printed in Germany. All rights reserved.

Weishaupt (UK) Limited

Neachells Lane, Willenhall, WV13 3RG
Tel: (01902) 609 841, Fax: (01902) 633 343
www.weishaupt.co.uk

Product Description Performance

W-Burners The compact series, proven millions of times over: Up to 570 kW

Economical, reliable, fully automatic. Gas, oil and
dual fuel burners for domestic and commercial
applications. The purflam burner gives almost soot-free
combustion of oil with greatly reduced NOx emissions.
Monarch and The legendary industrial burner: Up to
industrial burners Tried and tested, long lived, clear construction. 10,900 kW
Gas, oil and dual fuel burners for district heat provision.

multiflam® burners Innovative Weishaupt technology for large burners: Up to

Minimal emission values particularly at ratings 12,000 kW
over one megawatt. Oil, gas and dual fuel burners with
patented fuel distribution system.

WK Modular powerhouses: Up to
industrial burners Adaptable, robust, powerful. 18,000 kW
Oil, gas and dual fuel burners for industrial plant.

Thermo Unit The Thermo Unit heating systems from cast iron or Up to 55 kW
steel: Modern, economic, reliable.
For environmentally friendly heating.
Fuel: Gas or oil as desired.

Thermo Condens The innovative condensing boilers with the SCOT system: Up to
Efficient, low in emissions, versatile. Ideal for domestic 1,200 kW
heating. Floor standing gas condensing boiler
with ratings of up to 1200 kW(cascade), for higher
heat demands.
Heat pumps The heat pump programme offers solutions for utilisation Up to 130 kW
of heat from air, soil and ground water. The
systems are suitable for refurbishment or new builds.

Solar systems Free energy from the sun:

Perfectly coordinated components, innovative, proven.
Pleasantly shaped flat roof collectors to support
heating and of domestic water.

Water heater / The attractive domestic water heating range

energy reservoir includes classic water heaters which are supplied
through a heating system and energy reservoirs which
can be fed through solar systems.

Control technology / From control panels to complete building management

building systems – at Weishaupt you can find the entire
management spectrum of modern control technology.
Future oriented, economical and flexible.