manual

Installation and operating instructions

Weishaupt Gas Burner WM - G 20/2-A / ZM-LN (W-FM 50) 83250802 - 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 20/2-A / ZM-LN

The product described above conforms to

Document No.: DIN EN 676

DIN EN ISO 12 100
DIN EN 61 000-6-3/-1
DIN EN 60 335-1

In accordance with the directives

GAD 90/396/EC Gas Appliance Directive

MD 2006/42/EC Machinery Directive
PED 97/23/EC Pressure Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic
Compatibility Directive

this product is labelled as follows

CE-0085BS0032

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

4 4 Installation
4.1 Safety notes on installation
11
11
4.2 Delivery, transport and storage 11
4.3 Preparations for installation 11
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
5.4.1 Pre-set points 30
5.4.2 Burner ignition 31
5.5 Concluding work following commissioning 37
5.6 Shut down periods 38

6 6 Fault conditions and procedures for rectification

6.1 General faults on the burner
39
39
6.2 Faults on the W-FM 40

7 7 Servicing
7.1 Safety notes on servicing
41
41
7.2 Servicing 42
7.2.1 Testing, cleaning and function test 42
7.2.2 Criteria for setting / replacement 42
7.3 Removing and refitting mixing head 43
7.4 Setting the ionisation and ignition electrodes 44
7.5 Removing and refitting gas butterfly valve stepping motor 45
7.6 Removing and refitting air damper stepping motor 46
7.7 Air regulator 47
7.8 Removing and refitting FRS spring 48

3
 8 8 Technical data
8.1 Burner equipment
49
49
8.2 Capacity graph 49
8.3 Permissible fuels 50
8.4 Mixing head dimensions 50
8.5 Permissible ambient conditions 50
8.6 Electrical data 51
8.7 Weight 51
8.8 Burner dimensions 52

A Appendix
Combustion analysis
53
53
Gas throughput calculation 54
Spare parts 56

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
• is 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,
which, if not followed, could result in death or Guarantee and liability
serious injury. Weishaupt will not accept liability or meet any guarantee
claims for personal injury or damage to property arising as
DANGER
a result of one or more of the causes below:

• Failure to use the equipment as intended.

This symbol is used to mark instructions, • Improper assembly, commissioning, operating or
which, if not followed, could result in life servicing of the equipment.
threatening electric shock. • Operating the appliance with defective safety
DANGER
equipment, or with non-recommended or non-
functioning safety and protection devices.
• Failure to follow the information in the Installation and
Operating Instructions.
This symbol is used to mark instructions, • Alterations made to the construction of the equipment
which, if not followed, could result in damage by the plant operator.
to, or the destruction of the equipment and • Fitting additional components not tested or approved
ATTENTION
environmental damage. for use with the equipment.
• 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.
☞ This symbol is used to mark procedures, which • Inadequate monitoring of parts liable to wear and tear.
you should follow. • Improperly executed repairs.
• Acts of God.
1. Procedures with more than one step are • Damage caused by continued use despite the
2. numbered. occurrence of a fault.
3. • Use of incorrect fuel.
• Obstruction or damage of the supply lines.
❑ This symbol is used when you are required to • Use of non-original -weishaupt- spare parts.
carry out a test.

• This symbol is used to list points.

➩ This symbol indicates detailed information.

Abbreviations
Tab. Table
Ch. Chapter

5
 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. 4.6
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.
• Installations, alterations and maintenance work on gas Gas valve train
systems in buildings and below ground must only be • Observe sequence and flow direction. To ensure
carried out by installers who have a contract with the trouble free start conditions, the distance between
gas supplier. DMV and burner should be kept to a minimum.
• 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. Thermal shut off device TAE
• The air or purge gas required for the test must be • If require, the thermal shut off device TAE
expelled from the pipe work. The pipe work must be
completely purged.

7
 3 Technical description
3.1 Permissible application
The Weishaupt gas burner type WM-G 20/2-A / ZM-LN is Type codes:
suitable for:
• heat exchangers according to EN 303 Type
• warm water plant WM –G 20 /2 –A / ZM -LN
• intermittent or continuous operation
• warm-air heat exchangers LowNox

The combustion air must be free from aggressive two stage modulating
compounds (Halogen, Chloride, Fluoride, etc.). If the
combustion air within the boiler room is contaminated, Construction type
more frequent cleaning and maintenance will be required.
In these cases operation with ducted air intake is Ratings size
recommended.
Size
Any other use is only permissible with the written
agreement of Max Weishaupt GmbH. Servicing G = Gas
requirements may be at more frequent intervals where
arduous operating conditions demand. Weishaupt burner type Monarch

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 suitable
for operation inside.
• The burner must not be used outside of its capacity
range (capacity graph see Ch. 8.2).

8
 3
3.2 Basic functions
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 EN 676: 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
Combustion manager start-up the gas pressure switch function is delayed by up
• Controls the sequence of operation to 2 secs., this is to allow for static pressure to dissipate.
• Monitors the flame
• Communicates with the stepping motor
• Carries out valve proving of the gas valves FRS gas governor
• Is equipped with speed control (as an optional extra) Equalises variations in pressure from the gas supply
network, thus providing a constant gas control pressure.
The control gas pressure is set with this device.
Limit switch
The limit switch in the burner housing is located in such a
way that hinging open the burner will interrupt the power DMV double solenoid valve
supply. This will immediately shut down the burner and a Automatic release or safety shut off of the gas flow.
restart is prevented. Limiting of the valve stroke, and with it a change of the
pressure drop is possible via adjustment of the setting
screw.
Flame sensor
Monitors the flame during all phases of operation. If the
flame signal does not correspond to the sequence of Gas butterfly valve
operations, a safety lockout will occur. The gas butterfly valve regulates the gas quantity relative
to the control gas pressure.

Stepping motors
Separate stepping motors on: Mixing head
• Air damper Adjustable combustion head relative to the full load rating
• Gas butterfly valve required.
Providing precise, direct control of the correcting elements
in compound.
The setting is checked by optical transmitter fitted in the
stepping motor.

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 sys-
two Class A solenoid valves. Weishaupt gas and dual fuel tem 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 33sek.
secs. 10secs.
10 sek. 33sek.
secs. 10 secs.
10 sek.
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
Installation 4
4.1 Safety notes on 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, this cam result in
explosions.
DANGER

4.2 Delivery, transportation and storage

Check delivery Transportation
Check the delivery to see that it is complete and that there For burner weight see Ch. 8.7.
has been no damage in transit. If the delivery is
incomplete or damaged, contact the deliverer. 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

11
 4
4.4 Burner installation
Prepare heating appliance Combustion head extension
The diagram shows the refractory for a heating appliance Boiler constructions with deep refractories or thick doors
without a cooled front. The refractory must not project require a combustion head extension.
beyond the front edge of the combustion head. The Head extensions of 100, 200 and 300 mm are available.
refractory can take a conical shape (≥ 60°). Dimension l1 then changes relative to the head extension
Refractory may not be required on boilers with water- used. Burners with head extensions can still be hinged
cooled fronts, unless the manufacturer gives other open.
instructions. It is important that the burner can be hinged open by
approx. 90° to allow easy, rearwards removal of the mixing
head, which also has the same length extension.

Combustion head Dimensions in mm

d1 d2 d3 d4 d5 I1

WM-G20/2-3a 190 x 60 250 290 M12 270 298 2671…2472

1 Combustion head open

2 Combustion head closed

Refractory and drilling dimensions (basic drawing)

Refractory
Drilling dimensions
on the appliance
60° d3

Flange gasket
45°
l1 d1 d2

Fill the air gap with resilient

refractory insulation material
(do not make solid) d4
d5

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.

12
 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. Fit plug to gas butterfly valve motor.

Mounting the burner

13
 4
4.5 Gas valve train installation
Risk of explosion! ☞ Flange seals must be fitted correctly on machined
Gas leaks can lead to the build-up of explosive faces.
gas/air mixtures. With the presence of an ☞ Tighten screws evenly diagonally opposite.
ignition source, these then result in ☞ Valve trains must be mounted tension-free.
explosions. Do not compensate for misalignment by over-
DANGER tightening.
☞ The valve trains must be fixed and supported securely.
To avoid accidents, please observe the following safety They must not be allowed to vibrate during operation.
instructions on valve train installation. Supports suitable for the site should be fitted during
installation.
☞ Before beginning work, close all the relevant shut off ☞ Observe the maximum permissible total pressure in the
devices and ensure they cannot be accidentally valve trains. Ask your gas supplier for the correct gas
reopened. main supply pressure.
☞ Ensure the valve train components are correctly The supply pressure must not exceed the permissible
aligned and that all the joints are clean. total pressure.

Additional installation notes:

A vent hose leading to atmosphere should be connected To improve start conditions, the distance between burner
to vent the valve train. and solenoid valves (ignition and mains gas) should be as
short as possible.
To allow the appliance door to be hinged open, a flange Observe sequence and flow direction of valve train
‘break-point’ should be fitted - if possible at door level. components.

If a thermal shut off device TAE is required, this must be Installation position of double solenoid valve and FRS
fitted upstream of the ball valve. • DMV and FRS can be positioned with the actuator axis
angled from standing vertical to lying horizontal in
horizontal pipework.
• High pressure regulator see Installation and operating
instruction Pressure regulating units Print No. 12.
Installation example high pressure supply with screwed DMV

1 2 3 4 5 6 7

9 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

14
 4
Installation example low pressure supply with flanged DMV

1 2 3 4 5 6 7

0 9 8

Installation example low pressure supply with screwed DMV

1 2 3 4 5 6 7

0 9

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

15
 4
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 Flanged version
switch 3, ensuring that sealing surfaces are clean.
3. Mount gas pressure switch on the DMV with the
screws 4 provided.

2
3

4
3

Screwed version

1
1

2
2
3
3
4
4

4.6 Soundness test of valve trains

Following service work on gas carrying
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.

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

16
 4
First test phase: Soundness test
Ball valve up to first valve seat
1. Connect test assembly to the filter on inlet of valve 1
(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 V1 V2
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.
5
1
Second test phase:
2
Valve section and second valve seat
1. Connect test assembly to test point between V1 and V2
(valve proving gas pressure switch). 3 3

Third test phase:

Valve train connection parts up to gas butterfly
The third test phase can only be carried out during
operation and by using a leak detection solution.

Note: Only use leak detecting foaming solutions,

which do not cause corrosion.

☞ Following a soundness test close all test points!

Checking zero-flow shut off (only with high pressure

regulator):
1. Open ball valve and wait until the output pressure of 4
the regulator is stabilised.
During this time the safety relief valve (SBV) must not
open.
2. Close the ball valve and check that the pressure differ-
ence between inlet and outlet pressure of the regulator
4
remains constant.

Documentation
☞ Results of the pressure test must be recorded on the 1 Rubber hose with T piece
service/commissioning report. 2 Aspirator
3 Manometer (U tube or pressure gauge)
4 Hose clamp
5 Double solenoid valve DMV

Test points on DMV-D 512 to 520 test points on DMV-D 5065/11 to 5125/11

4 5 6 7 1 2 3 5
1 2 3 4

3 4 pmax. = 500 mbar 6 7

2 pmax. = 500 mbar 4 5 2 5
1 V1 V2
1 3 V1 V2
4
1 2 3 5
1 2 3

Test point 1 and 4 : Pressure into V1 Test point 1, 2 and 6 : Pressure into V1
Test point 2 : Pressure between V1 and V2 Test point 3 : Pressure between V1 and V2
and ignition gas outlet Test point 4 : Ignition gas outlet
Test point 3 : Pressure after V2 Test point 5 and 7 : 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 of terminal box gas valve train
used: It is possible that electrical components • Connect solenoid valve plug Y2 in accordance with the
continue to carry voltage even after the mains burner wiring diagram.
have been switched off because a frequency Depending on plant conditions, the connection of an
converter is fitted. A waiting time of 5 minutes external gas solenoid valve (Y3) may be required.
should therefore be observed prior to starting
work. • Connect low gas pressure switch (F11) and gas
pressure switch for valve proving (F12) in accordance
with the burner wiring diagram.
A burner specific wiring diagram is supplied with the If required, the high gas pressure switch (F33) should
burner. All electrical connections must be made to this also be connected.
wiring diagram. Local regulations must be observed.

Note Carry out electrical installation in such a way Installation fan motor
that it is possible to hinge the burner open. Open terminal box on motor and carry out connection in
accordance with wiring diagram (observe motor rotation).
The motor must be protected against heat radiation and
Installation W-FM short circuits. The use of a motor protection switch is
Connect inputs, outputs, and voltage supply to the recommended. Prior to replacing the motor contactor it is
W-FM in accordance with the wiring diagram supplied. recommended to mark the cables in accordance with the
☞ Use cable entry on burner housing. terminal numbers.

Voltage supply :
It is of paramount importance that the electric supply is Notes for Austria
provided and connected correctly. Local requirements Electrical isolation with a minimum of 3 mm contact gap,
have to be adhered to, and it must be ensured that both acting on all poles, must be fitted adjacent to the burner.
neutral (N) and earth potential (PE) conductors at the Possibilities are:
installation, have zero potential, that is to say exhibits no • Switch (without micro-contacts) with required
trace of any voltage. It might be permissible to connect the separation characteristics
neutral to a proven earth, as this will usually drain any • Circuit breaker
induced voltage. • Contactor
Do not confuse phase (L) and neutral conductor (N) • Screw in type fuse with clearly recognisable
connections, otherwise operational safety will be jeopar- designation
dised. It is also important that the neutral is not switched,
and if it is desirable to isolate the neutral a removable link
is preferred. This is to prevent voltage spikes, and also to
alleviate problems that could occur if the neutral was
switched-off prior to the voltage being switched-off.
Observe the requirements of EMC 89/336/EC and LVD
73/23/EC.

Cables:
The cross sectional area of the cables for L, N, and E, and
of the safety circuit must be in accordance with the
nominal current of the prefusing (max.16 AT).
All other cable connections must be designed in
accordance with the internal unit fusing (6.3 AT).

For the cable length the following applies:

• Display and operating unit, BCI maximum 10 m
(100 pF/m).
• Load controller, safety circuit, burner flange, reset
button maximum 20 m (100 pF/m).

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 supplies the inlet to the high pressure regulator is
valve 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 3. Close the ball valve immediately if the mains gas
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.
When setting pay attention to the centralisation of the e
flame tube, it is therefore recommended to determine
dimension e at three points (120° radially).

Example 1

Required combustion heat rating QF 800 kW

with combustion chamber pressure of 2.5 mbar
Result: Flame tube setting (dimension e) 209 mm
Air damper setting 35°

Example 2

Required combustion heat rating QF 1325 kW Hinge open the burner

with combustion chamber pressure of 3.5 mbar The mixing head can be adjusted while it is fitted to the
Result: Flame tube setting (dimension e) 221 mm appliance. The burner can be hinged open towards the
Air damper setting greater than 50° hinge pin.
➩ see Ch. 7.3

Setting diagram mixing head (dimension e)

11
Air damper setting 20° 30° 40° 50°
10

8 10°
Combustion chamber pressure [mbar]

3 2

2 1

0 229

-1

-2
209e [mm]
Dimension 214 219 224
-3
Flame tube setting (dim. e)
-4
200 400 600 800 1000 1200 1400 1600

Combustion heat rating [kW]

The setting diagram is sectioned into two areas:

• Flame tube setting (dimension e) 209 mm • Air damper setting greater than 50°
• 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. 4 µA DC approx. 30%

max. 16...40 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 ❏ Soundness test of the valve train must have been
must 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
correctly. Note Dependent on site requirements, further
❏ Thermostat, pressure switch and other safety devices checks may be necessary. Note the
must be in operating position. instructions for the individual items of plant
❏ There must be a heat demand. equipment.

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 deter-
mined.
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.

Spring for FRS
Type of spring / colour output pressure range

orange 5 to 20 mbar
blue 10 to 30 mbar
red 25 to 55 mbar
yellow 30 to 70 mbar
black 60 to 110 mbar
pink 100 to 150 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 20/2-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) into double solenoid valve)

Nominal diameter of valve trains Nominal diameter of valve trains

1” 11/2” 2” 65 80 100 125 1” 11/2” 2” 65 80 100 125
Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve
[kW] 65 65 65 65 65 65 65 65 65 65 65 65 65 65

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

700 61 22 17 12 10 9 9 21 11 11 8 7 7 7
800 79 28 21 15 12 11 11 28 15 14 11 9 9 8
900 98 34 25 18 15 13 13 35 18 18 13 11 11 10
1000 120 41 30 21 17 15 15 42 22 21 15 13 12 12
1100 144 49 35 24 19 17 17 50 25 25 18 15 14 14
1200 170 56 39 26 21 19 18 58 29 28 20 17 15 15
1300 197 64 45 29 23 20 19 67 32 32 22 18 17 16
1400 227 72 50 32 25 22 20 76 36 35 24 20 18 17
1500 259 81 56 35 27 23 22 86 40 39 26 21 20 19
1600 293 91 62 38 29 25 23 97 45 43 29 23 21 20

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

700 85 29 21 14 12 11 10 29 14 14 10 8 8 7
800 110 37 26 18 14 13 12 37 18 18 13 11 10 10
900 139 46 32 21 17 15 14 47 23 22 16 13 12 12
1000 170 55 39 25 20 18 17 57 28 27 19 16 14 14
1100 204 65 45 29 23 20 19 69 33 32 22 18 17 16
1200 241 76 52 33 25 22 20 80 38 37 25 20 18 17
1300 281 87 59 37 28 24 22 93 43 42 27 22 20 19
1400 – 99 67 41 30 26 24 106 48 47 30 24 22 21
1500 – 112 75 45 33 28 26 121 54 52 33 26 24 22
1600 – 126 83 49 36 30 27 136 60 58 37 29 25 24

Liquid Petroleum Gas B/P (F), Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 1.555
700 29 13 11 – – – – 11 7 7 – – – –
800 37 16 13 – – – – 15 9 9 – – – –
900 46 20 16 – – – – 19 12 12 – – – –
1000 56 24 19 – – – – 23 14 14 – – – –
1100 67 28 22 – – – – 27 17 17 – – – –
1200 77 31 24 – – – – 30 18 18 – – – –
1300 89 34 26 – – – – 34 20 19 – – – –
1400 101 38 29 – – – – 38 22 21 – – – –
1500 114 42 31 – – – – 42 23 23 – – – –
1600 129 46 34 – – – – 47 25 25 – – – –

The details given for calorific value Hi relate to 0° C and With low gas pressure supplies pressure
1013 mbar. governors/regulators to EN 88 with safety diaphragm are
used. Maximum permissible connection pressure into
The results of the tables have been calculated on flame isolating valve is 300 mbar on low gas pressure
tubes under idealised conditions. The values are therefore installations.
guidelines for basic settings. Small variations may occur
when commissioning depending on individual installations. With high pressure supplies HP regulators to DIN 3380
are selected from the following technical brochures:
Note The combustion chamber pressure in mbar • Pressure regulating devices up to 4 bar, Print No. 12
must be added to the minimum gas pressure • Pressure regulating devices with safety diaphragm,
determined. Print No. 1732
• Pressure regulating devices larger than 4 bar,
The min. connection pressure should not be Print No. 1727
below 15 mbar.
Maximum connection pressure, see nameplate.

23
 5
5.3 Operating the W-FM
Button designation Button designation

Button Function

1 Enter:
Saves value changes.
Access to parameters and values

Info:
Press for approx. 3 seconds = Info level
Press for approx. 5 seconds = Service level S
P
2/3 + or –: i 1
Navigation through the parameter structure
info
Change setting values m3 m3/h l l/h %
VSD esc
2&3 Press + and – simultaneously (esc):
Stop / return via Escape function F A – +
5 2
4 A (Air):
Selects the air stepping motor 4 3
5 F (Fuel)
Selects the fuel stepping motor

4&5 Press A and F simultaneously (VSD):

Selects the frequency convertor (accessory)

Off function
Simultaneous pressing of ‘Enter/Info’ and one other button
will initiate an immediate lockout.

Display Display
The black dashes of the symbols show the status of the
inputs and outputs, the unit of values and the active level.
1 2 3 4 5 6
1 Heat demand by heater controls
2 Burner fan motor
3 Ignition S
4 Fuel valve u P
5 Flame signal on z i
6 Flame failure or lockout t
7 Load point angle setting
8 Percentage value m3 m3/h l l/h %
9 not used
0 Throughput Oil (total)
r e w q 0 9 8 7
q not used
w Throughput Gas (total)
e Stepping motor opening
r Stepping motor closing
t Service level
z Info level
u Parameter mode (service expert level)

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 settings
• Editing of load points
• Function, etc.

Voltage supply ON Display for commissioning

The display shows either OFF or OFF UPr.
S S
P P

OFF = burner off i i

UPr = not programmed m3 m3/h l l/h % m3 m3/h l l/h %

not programmed programmed

Enter password Enter password

1. Press button [F] and [A] simultaneously until the dis-
play shows CodE.
2. Using button [+] or [–] enter first digit and confirm with
[ENTER]. S
Repeat procedure until password has been entered. P
i
3. Exit password entry via [ENTER]. S
The display shows PArA for a short time and then m3 m3/h l l/h % P
i
changes over to 400: SEtand a black dash appears
next to the P symbol. m3 m3/h l l/h %

S
P
i

S
P m3 m3/h l l/h %
i

m3 m3/h l l/h %

Burner ON Burner on
1. Open fuel shut off devices.
S

2. Check appliance's safety devices, STB, pressure and P

i
temperature controllers, etc. must be in operating
position. m3 m3/h l l/h %

3. Start burner in manual operation.

A black dash appears below the S symbol on the
display.
For the duration of the commissioning a heat demand is
required from the appliance controller, that means
signal on input X5-03/1.

25
 5
Start setup Start setup
Press [ENTER] button.
S
P
If the combustion manager has been pre-set, the display i

shows run. You can now start the adjustment of m3 m3/h l l/h %
operating point P1.

or

If the combustion manager has not been programmed programmed not programmed
(i.e. first commissioning) the display shows parameter S S
P P
201 and the following parameters have to be defined i i

prior to any adjustment being made. m3 m3/h l l/h % m3 m3/h l l/h %

201 : Type of operation

542 : Activation frequency convertor
641 : Speed standardisation

Now adjustments can be made, starting with the

pre-setting of ignition load point P0.

Set type of operation Set type of operation

1. Press [ENTER] button, the display shows only
the parameter value. S
P
i

2. Using [+] or [–] set type of operation 1 (direct ignition) m3 m3/h l l/h %
and confirm with [ENTER].
S
P
3. Exit entry using [esc]. i

The display shows parameter 201 with the current S

P m m /h l l/h %
3 3

type of operation. i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

26
 5
Activate/deactivate frequency converter Activate/deactivate frequency converter
1. Press [+] button, the display shows parameter 542.

2. Press [ENTER] button, the display now only shows the

parameter value. S
P
i
3. Using [+] or [–] activate or deactivate the frequency
m3 m3/h l l/h %
converter and confirm by pressing [ENTER].
0 = without frequency converter S

1 = with frequency converter P

i

S
P m m /h l l/h %
3 3

4. Exit entry using [esc]. i

The display shows parameter 542 with the current
m3 m3/h l l/h %
setting.
S
P
i

m3 m3/h l l/h %

Carry out speed standardisation Speed standardisation

1. Press [+] button, the display shows parameter 641.

Note Speed standardisation should only be carried

out if a frequency converter is fitted. S

If a frequency converter is not fitted, the P

i
following steps can be skipped.
m3 m3/h l l/h %

2. Press [ENTER] button. S

P
i
3. Using [+] set value to1 and start standardisation by S
P m m /h l l/h %
3 3

pressing [ENTER]. i
The fan motor starts when the air damper opens.
m3 m3/h l l/h %
Once standardisation is complete, the display changes
from 1 to 0.

4. Exit speed standardisation using [esc]. S

P
i

S
P m3 m3/h l l/h %
i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

27
 5
Pre-set ignition and full load points Pre-setting ignition and full load points
For details of pre-set values for fuel and air stepping mo-
tors see burner installation and operating instructions. S
P
i

Note The ignition and full load point must only be m3 m3/h l l/h %
pre-set on combustion managers, which have
not been programmed. If the combustion
manager has already been programmed,
pre-setting is skipped. S
P
i

1. Press [+] button, the display shows the ignition m3 m3/h Pl

S
l/h %
load point P0. i

m3 m3/h l l/h %
2. Press and hold button [A] and using buttons [+]/[–]
enter air damper position 2° - 5°. S
P
i

3. Press and hold button [F] and using buttons [+]/[–] m3 m3/h l l/h %
enter gas butterfly valve position 10° - 13°.
S VSD
P
4. Press and hold button [A] and [F] (VSD) i
only when using a
simultaneously and using button [+]/[–] enter speed S
frequency converter
P m3 m3/h l l/h %
(only when using a frequency converter). i

The ignition speed should not fall below 70%. m3 m3/h l l/h %

5. Press [+] button, the display shows the full load

point P9.
S
P
6. Press and hold button [A] and using buttons [+]/[–] i

enter air damper position 50° - 60°. m3 m3/h Pl

S
l/h %
i

7. Press and hold button [F] and using buttons [+]/[–] m3 m3/h l l/h %
enter gas butterfly valve position 45° - 50°.
S
P
8. Press and hold buttons [A] and [F] (VSD) i

simultaneously and using buttons [+]/[–] enter speed m3 m3/h l l/h %

(only when using a frequency converter).
The full load speed should not fall below 100%. S VSD
P
i
only when using a
9. Press [+] button, exit pre-setting. S
frequency converter
P m3 m3/h l l/h %
The display changes over to run. i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

28
 5
Select type of setting Select type of setting
Pre-setting without flame and adjustment with flame can
be selected. S
P
Pre-setting without flame is only used, if the operating i

points are already known, for example if the combustion m3 m3/h l l/h %
manager is exchanged.

Adjustment with flame (Ch. 5.4.2):

Press [ENTER] button, the burner starts pre-purge
and stops in ignition position without igniting. The with flame without flame
display shows the ignition load point P0. S S
P P
i i

or m3 m3/h l l/h % m3 m3/h l l/h %

Pre-setting without flame (Ch. 5.4.1):

Press [esc] button, the display shows the S
P
operating point P1 and the black dash below the i

S symbol disappears. m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

29
 5
5.4.1 Pre-set points
Pre-set operating points (without flame) Pre-set operating stages
This step must only be carried out, if the type of setting
“without flame” has been selected. S
P
The adjustment with flame is not replaced by this process. i

S
m3 m3/h Pl l/h %
1. Press and hold button [A] and using buttons [+]/[–] i

pre-set air damper position. m3 m3/h l l/h %

Press and hold button [F] and using buttons [+]/[–]
pre-set fuel stepping motor position. S
P
Press and hold buttons [A] and [F] (VSD) i

simultaneously and using buttons [+]/[–] pre-set the S

m3 m3/h l l/h %
P
speed (only when using a frequency converter). i

m3 m3/h l l/h %
2. Press [+] button, the combustion manager starts
the calculation. The display briefly shows CALC and
then changes over to P2.
S
P
3. Set fuel and air damper stepping motor positions and i

speed. S
m3 m3/h l l/h %
P
i

4. Using the [+] button select and pre-set points P3 to P9 m3 m3/h Pl

S
l/h %
in sequence. i

m3 m3/h l l/h %
Note If the [+] button is pressed for more than
4 secs., a new calculations starts from the S
P
point displayed. i

S
P m3 m3/h l l/h %
5. Exit pre-setting using [esc], the display i

shows 400 SEt. m3 m3/h l l/h %

6. Press [ENTER] button, the display shows run.

7. Press [ENTER] button, the burner starts pre-purge and S

P
stops in ignition position without igniting, the display i

shows the ignition load point P0. m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

30
 5
5.4.2 Burner ignition
Set mixing pressure in ignition position Set mixing pressure in ignition position
approx. 0.5…2 mbar
S
P
1. Press and hold button [A] and using buttons [+]/[–] i

set air damper position. m3 m3/h Pl

S
l/h %
i

2. Press and hold buttons [A] and [F] (VSD) S

m3 m3/h l l/h %
P
simultaneously and using buttons [+]/[–] set the speed i

(only when using a frequency converter). m3 m3/h l l/h %

Ignition speed min. 70%.

Ignition Ignition
Press [+] button, the burner ignites and stops in ignition
position.
The display shows the operating phases:
Ph 38 (ignition on), S

Ph 40 (fuel valve), P
i
Ph 42 (ignition off), S
m3 m3/h l l/h %
Ph 44 (flame in ignition position). P
i

S
P m3 m3/h l l/h %
i

S
P m3 m3/h l l/h %
i

S
P m3 m3/h l l/h %
i

m3 m3/h l l/h %

Pre-set fuel pressure

The setting pressure can be found in table Setting
pressure (see Ch. 5.2).

Carry out combustion analysis

Determine CO and O2 values and if necessary optimise
combustion by adjusting the ignition positions.

31
 5
Pre-set operating point P1 Pre-set operating point P1
1. Press [+] button, the display shows the
operating point P1.

2. Pre-set fuel throughput and air quantity whilst S

observing the combustion values. Operating point P1 P

i
should lie below the required partial load and within
m3 m3/h l l/h %
the capacity graph (see Ch. 8.2).
S

Note When using a frequency converter, operating P

i
point P1 should have a minimum speed of
m3 m3/h l l/h %
50%. To achieve this, open air damper and
reduce speed alternately. S
P
i
3. Press [+] button, the display shows operating
m3 m3/h l l/h %
point P2.
If no other points have been defined, the combustion S VSD
manager carries out a calculation and calculates all P only when using a
i
frequency converter
missing points up to P9. S
m3 m3/h l l/h %
The display briefly shows CALC. P
i

m3 m3/h l l/h %

S
P
i

S
P m3 m3/h l l/h %
i

m3 m3/h l l/h %

32
 5
Drive to full load Start operating points P2 to P9
1. Using the [+] button drive to points P2 to P9 in
sequence. P
S

2. Check and correct combustion values (air excess, m3 m3/h Pl

S
l/h %
flame stability) at each point. i

It is usually sufficient to alter the fuel throughput. P

S
m3 m3/h l l/h %
i

Note If the [+] button is pressed for more than m3 m3/h l l/h %
4 secs., a new calculations starts from the
point displayed.
S
P
i

m3 m3/h l l/h %

S
P
i

S
m3 m3/h Pl l/h %
i

S
P m3 m3/h l l/h %
i

m3 m3/h l l/h %

Adjusting full load Adjusting full load

1. Determine and set fuel throughput in full load P9 whilst
observing the ratings information given by the boiler S
P
manufacturer and the capacity graph of the burner. i

Adjust gas throughput at approx. 60°…70° gas m3 m3/h Pl

S
l/h %
butterfly setting using the setting screw on the i

pressure regulating valve. m3 m3/h l l/h %

2. Determine combustion limit and set excess air. S

P
When using a frequency converter, the fan speed i

should be selected as slow as NOx and flame stability m3 m3/h l l/h %

permit, however it should not be less than 80%.
S VSD
3. Re-determine fuel quantity throughput and adjust if
P only when using a
i
frequency converter
necessary. S
m3 m3/h l l/h %
P
i

➩ See burner installation and operating instructions for m3 m3/h l l/h %

detailed notes on combustion analysis.

Note The fuel pressure must not be altered once

this work has been completed.

33
 5
Initiate a calculation Initiate a calculation
To achieve a linear air damper and/or speed setting, it is
necessary to initiate a calculation of points P9 to P1. P
S

1. Press [–] button for approx. 4 seconds, until the display m3 m3/h l l/h %
shows CALC.
approx. 4 secs.
2. Release [–] button, the display shows the operating
point P8. P
S

m3 m3/h l l/h %
S
P
i

m3 m3/h l l/h %

Adjusting the operating points Adjusting the operating points

The combustion optimisation of the operating points
should only be carried out using the gas butterfly valve S
P
stepping motor. i

If the air quantity is altered, this influences the linearity, m3 m3/h Pl

S
l/h %
which has a negative effect on the load control and/or i

speed control. S
m3 m3/h l l/h %
P
i

1. Carry out combustion analysis. m3 m3/h l l/h %

2. Press and hold button [F] and using buttons [+]/[–]

optimise combustion.
S
P
3. Repeat procedure until operating point P1 has been i

reached. m3 m3/h l l/h %

Note If a calculation is triggered accidentally, any

operating points already adjusted will be S
P
overwritten. i

S
m3 m3/h Pl l/h %
i

S
P m3 m3/h l l/h %
i

m3 m3/h l l/h %

34
 5
Set upper load limit Upper load limit
Full load can be limited via parameter 546.
S
P
1. Exit setting mode using [esc], the display shows 546 i

(– – – – = no load limit). m3 m3/h l l/h %

If no load limit is to be defined skip steps 2 to 4.

2. Press [ENTER] button, the display shows only the

parameter value. P
S

3. Set load limit using buttons [+] or [–] and confirm with m3 m3/h l l/h %
[ENTER].
S
P
4. Exit entry using [esc] button. i

The display shows parameter 546 with the current 3

S
P m m /h l
3
l/h %
load limit. i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

Set lower load limit (partial load) Lower load limit

Partial load can be limited via parameter 545.
S
P
1. Press [+] button, the display shows 545 i

(– – – – = no load limit). m3 m3/h l l/h %

2. Press [ENTER] button, the display shows only the

parameter value.
S
P
3. Using buttons [+] or [–] set load limit and confirm with i

[ENTER], burner drives to value set. m3 m3/h l l/h %

4. Measure fuel throughput and if necessary adjust the P

S

value. i

S
P m m /h l l/h %
3 3

5. Exit entry using [esc] button. i

The display shows parameter 545 with the current m3 m3/h l l/h %
load limit.
S
P
i

m3 m3/h l l/h %

35
 5
Save points Exit commissioning
1. Exit level using [esc] button, the display shows
400 SEt. P
S

2. Exit entry using [esc] button, the black dash m3 m3/h l l/h %
next to the P symbol disappears and the display shows
oP with the current load.
S
P
i

m3 m3/h l l/h %

S
P
i

m3 m3/h l l/h %

Check start behaviour

1. Switch off burner and restart.

2. Check start behaviour. If necessary adjust ignition load.

Note If the ignition load setting has been changed,

the start behaviour has to be re-checked.

36
 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 high fire (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 (< 1000 ppm),

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 PV
2
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).

37
 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:___________________13 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.

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.

38
6 Fault conditions and procedures for rectification 6
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
codes and proceed according to the error message. the burner more than twice. If the burner
If faults occur, check first that the basic requirements for locks out for a third time call for a service
operation are met. engineer.
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 has tripped Check setting

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

no high voltage spark at
the tip of the ignition electrode

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

39
 6
Beobachtung Ursache Beseitigung
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 rotor, 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 W-FM 50.
The error history stores up to 25 errors. These should be
selected and checked prior to replacing the W-FM.

40
7 Servicing 7
7.1 Safety notes on servicing
Failure to carry out maintenance and service
work properly can have severe conse-
quences, 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 do: • Solenoid valves
1. Function test. • Gas pressure switch
2. Check exhaust gas analysis for CO2 / O2 / CO • Air pressure switch
values.
3. 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.

41
 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, (when replacing parts; see Ch. 5.2)
lever 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 (see Ch. 7.7)

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

View port cover seal Tightness Air escaping during operation Replace

42
 7
7.3 Removal 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 head 5 and remove.

Removing the mixing head

43
 7
7.4 Setting ionisation and ignition electrodes
Set ignition electrode 1
Undo screw on fixing plate and set ignition electrode to
the measurements given.

Note Unfavourable site conditions (start difficulties)

may require alternative positioning of the
electrode tip.

Set ionisation electrode 2

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

Set electrodes

Natural Gas
approx. 5 mm mm approx. 1.5…2 mm
ox. 2
appr

2 1

Liquid Petroleum Gas

approx. 5 mm mm approx. 1.5…2 mm
prox. 2
ap

2 1

44
 7
7.5 Removing and refitting gas butterfly stepping motor
Removing Refitting
➩ Observe safety notes Ch. 7.1. Refit in reverse order, ensuring correct fit of shaft key 6.
1. Undo screwed connection and remove plug 1. The coupling should slide onto the shaft without having to
2. Remove view port glass 2 from intermediate use force.
housing 3 and loosen grub screw of coupling 4.
3. Loosen fixing screws and carefully remove stepping Note Following the replacement of a stepping motor
motor 5 (do not damage coupling). carry out a combustion analysis and adjust
4. Loosen second grub screw and carefully pull off burner as required.
coupling 4 from the drive shaft.
5. Remove shaft key 6
6. Loosen fixing screws and remove intermediate
housing 3

Note Steps 4 to 6 are only necessary if the

intermediate housing or coupling require
replacing.

Removing and refitting gas butterfly stepping motor

2
6

6
3 4

45
 7
7.6 Removing and refitting air damper stepping motor
Removing Refitting
➩ Observe safety notes Ch. 7.1. Refit the stepping motor in reverse order, paying attention
1. Remove cable entry cover 1 and cable seal 2. to the correct fit of the shaft key 7.
2. Remove cover 3.
3. Unplug stepping motor plug 4 on combustion
manager. Note Following the replacement of a stepping motor
4. . carry out a combustion analysis and adjust
5. Remove lock nut 5 on the coupling. burner as required.
6. Loosen stepping motor 6 and remove from the air
damper shaft.

Removing and refitting air damper stepping motor

2 6
7
1

46
 7
7.7 Air regulator
Setting the air dampers Setting the air dampers
➩ Observe safety notes Ch. 7.1.
The gap between the air damper blades and the 0,3 mm
housing on the stepping motor side must be min. 0.3 mm.

Set distance:
1. Undo screws 1.
2. Adjust air damper blades 2 and re-tighten (only
Tuflock tamper proof screws should be used). 2
3. Check air damper blades can move freely.

Check play 2
It must not be possible to axially move the air dampers
without using force.
If play is detected during testing, the sleeve bearings must
be replaced.

Note If these steps cannot be carried out due to 1 0 mm

installation position, the air regulating section Play
should first be removed.

Removing Removing and refitting air regulating section

1. Remove stepping motor (see Ch. 7.6)
2. Undo the bottom two screws 1 on the air regulator
housing.
3. Undo all screws 2 and remove air regulating
section 3.

Refitting
Refit in reverse order.

2
3
2

47
 7
7.8 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 to 20 mbar
blue 10 to 30 mbar
red 25 to 55 mbar
yellow 30 to 70 mbar
black 60 to 110 mbar
pink 100 to 150 mbar

48
8 Technical data 8
8.1 Burner equipment
WM-G 20/2-A / ZM-LN

Combustion Manager Motor Stepping motor Flame sensor Ignition unit

W-FM 50 D112/110-2/2 Air damp./Gas b/fly.: Ionisation electrode W-ZG 02/2

380-400 V STE 50… 2 x 7000V
50 Hz; 2900 rpm 4.5 secs./90°
3 kW; 6 A 1.2 Nm

8.2 Capacity graph

Burner type WM-G 20/2-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 WM-G20/2-3a 190 x 60 reduction dependent on the altitude of the installation:
Combustion heat rating 250…1600kW approx. 1% per 100 m above sea level.

Ratings range
The burner has a maximum turndown ratio of 5:1. Please
note that the lowest operating point must lie within the
burner’s capacity chart.

11

10 Rating with
combustion head
9 OPEN
CLOSED
8
Combustion chamber pressure [mbar]

-1

-2

-3
200 400 600 800 1000 1200 1400 1600
Combustion heat rating [kW]

49
 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-G 20/2-A / ZM-LN WM-G20/2-3a 250 177 190 60

D1 D2 D3 D4

8.5 Permissible ambient conditions

Temperature Humidity Requirements for EMC Low voltage guideline

In operation: max. 80% rel. humidity Guideline 2004/108/EC Guideline 2006/95/EC

-15° C to 40° C no dew point EN 61 000-6-1 EN 60335
Transport / storage: EN 61 000-6-4
-20 C to +70° C

50
 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
∆-Start 16 A max. approx. 3.7 kW

50Hz, 3~ DOL start 20 A
* Ignition start rating

8.7 Weights

Burner
approx. 86 kg

Gas valve trains

Nominal diameter 1” 11/2” 2” DN 65 DN 80 DN 100 DN 125

Weight in kg 9 10 11 19 28 35 57

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

Screwed valve train (1” to 2”) Flanged valve train (DN65 to DN125)

51
 8
8.8 Burner dimensions

250 240

182
565

400

128 217

251 333
9
83

330

406
85
8

254

247…267
1010

52
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.

53
 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 = 1300 kW
Efficiency η (assumed) = 90 %
Calorific value Hi = 10.35 kWh/m3
Normal volume VN:
QN
VN =
η • Hi 1300
VN = → VN ≈ 139.5 m3/h
0.90 • 10.35
Operating volume VB:
VN QN
VB = or VB =
f η • Hi,B 139.5
VB = → VB ≈ 149.6 m3/h
0.933
Measuring time in seconds for 10m3 of gas
throughput: Measuring time when gas meter reads 2 m3:
3
3600 • 10 [ m ] 3600 • 2
Measuring = Meas. = –––––––––– → Meas. time ≈ 48 s
3
time [ s ] VB [ m /h ] time 149.6
Calculation based upon a stop watch-meter reading Operating volume when gas meter reads 2.5 m3 after
volume.: 60s measuring time:
3600 • V [ m3 ] 3600 • 2.5
VB [ m3/h ] = VB [ m3/h ] = –––––––––– → VB = 150 m3/h
Measuring time [s] 60

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

54
 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]
55
 A Spare
D parts

1.11

1.07
1.01

1.02
1.03 1.06
1.08
1.04 1.05

1.10
1.09

1.17

1.12

1.14
1.13

1.15

1.16

56
 A
Pos. Description Order No.

1.01 View port cover WM 20 complete 211 204 01 02 2

1.02 View port glass 211 153 01 15 7

1.03 View port closing cover

incl. spring clip 211 104 01 13 2

1.04 View port cover seal 211 204 01 04 7

1.05 Hinge pin 14 x 277 211 304 01 07 7

1.06 Circlip 10 431 604

1.07 Hinge flange WM-G 20 217 204 01 01 7

– screw M12 x 35 421 028
– washer B 13 430 801
– hexagonal nut M12 411 600

1.08 Screw M12 x 70 401 701

1.09 Dome nut M12 DIN 1587 412 401

1.10 Washer B 13 430 801

1.11 Flange gasket 330 x 255 151 707 00 05 7

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

1.13 Air regulator housing WM20 powder coated 211 204 02 09 7

1.14 Foam cladding WM 20 211 204 02 03 7

1.15 View port glass WM 20 211 204 02 11 7

1.16 Cable gland set 211 104 01 50 2

1.17 -weishaupt- badge WM 20 211 204 01 06 7

57
 A

2.05

2.04

2.01

2.07
2.02 2.06

2.06
2.03 2.26

2.09 2.25

2.08

2.11

2.17

2.12
2.18 2.13
2.19
2.20
2.14
2.15
2.16

2.21
2.20

2.22

2.24 2.20
2.23 2.10

2.10
2.22

58
 A
Pos. Description Order No.

2.01 Motor including contactor

D112/110-2/2 380-400V 50Hz 3~ 211 204 07 05 0

2.02 Motor contactor B7, 230V 50Hz 702 818

2.03 Cable entry set 211 104 01 50 2

2.04 Motor for frequency converter fitted

D112/110-2/2 380-400V 50Hz 3~ 211 204 07 03 0

2.05 Frequency converter MI 300/3 795 791

2.06 Motor shaft key 6 x 6 x 45 490 316

2.07 Fan wheel TS 268 x 100 (50Hz) 211 204 08 01 2

Fan wheel puller (tool) 111 111 00 01 2

2.08 Inlet nozzle WM20 285 x 209 x 43 (50Hz) 211 204 02 01 7

2.09 Inlet mesh 68 x 284.5 211 304 02 04 2

2.10 Air damper WM20 211 204 02 07 7

– screw M4 x 10 DIN 912 with Tuflock 402 264

2.11 Stepping motor STE 50 1.2 Nm f. W-FM50 651 475

2.12 Shaft key 3 x 3.7 DIN 6888 490 157

2.13 Air damper shaft with coupling WM20 211 204 02 05 2

2.14 Thrust washer GTM 1828-015 499 291

2.15 Compensating disc KAS 19.3 x 25.8 x 0.3 465 019

2.16 Sleeve bearing bush GFM 1820-12 499 289

2.17 Air damper shaft with spring pin WM20 211 204 02 06 2

2.18 Thrust washer GTM 1018-010 499 285

2.19 Washer 10.5 x 15.8 x 0.2 465 018

2.20 Sleeve bearing bush GFM 1012-07 499 290

2.21 Threaded pin M5 x 14 DIN 914 with Tuflock 420 497

2.22 Adjusting lever 211 104 02 04 7

2.23 Threaded pin M5 x 20 DIN 914 with Tuflock 420 496

2.24 Double crank arm EGZM 06-75 EK 499 288

– screw M6 x 14 with Tuflock 402 265

2.25 Air pressure switch LGW 50 A2P 691 373

– cap for LGW 446 011
– hose 4 x 1.75 250 mm long 232 101 24 03 7

2.26 Threaded socket 217 104 24 01 7

59
 A
3.01

3.02*
3.03

3.11

3.04

3.06
3.08
3.05
3.06
3.09
3.10

3.07

3.14

3.15
3.12
3.17
3.18

3.13
3.17
3.16

3.19

3.20

60
 A
Pos. Description Order No.

3.01 Flame tube WM-G20/2-3a 217 204 14 31 2

3.02 Extension tube*

– extended by 100 mm* 150 707 14 06 7
– extended by 200 mm* 150 707 14 07 7
– extended by 200 mm* 150 707 14 08 7

3.03 Locking screw 151 907 01 10 7

3.04 Gasket 77 x 185 x 2 rubber cork 151 707 00 02 7

3.05 Gas butterfly DN65, complete 217 405 25 02 2

3.06 Shaft key 3 x 3.7 DIN 6888 490 157

3.07 Intermediate housing f. gas butterfly Series B 217 704 25 02 7

3.08 View port glass 33 x 33 x 6 211 404 17 02 7

3.09 Spring coupling bar Series 2 217 704 15 10 7

3.10 Stepping motor STE 50 1,2 Nm f. W-FM50 651 476

3.11 Mixing head complete

– WM-G20ZM-LN (N-Gas) 217 205 14 30 2
– WM-G20ZM-LN (N-Gas) ext. by 100 mm* 250 205 14 30 2
– WM-G20ZM-LN (N-Gas) ext. by 200 mm* 250 205 14 32 2
– WM-G20ZM-LN (N-Gas) ext. by 300 mm* 250 205 14 34 2

– WM-G20ZM-LN (F-Gas) 217 205 14 32 2

– WM-G20ZM-LN (F-Gas) ext. by 100 mm* 250 205 14 31 2
– WM-G20ZM-LN (F-Gas) ext. by 200 mm.* 250 205 14 33 2
– WM-G20ZM-LN (F-Gas) ext. by 300 mm* 250 205 14 35 2

3.12 Ignition electrode isolator 6 x 80 Kanthal A1 132 101 14 03 7

3.13 Sensor electrode Kanthal A1 132 101 14 04 7

3.14 Diffuser
– 190 x 60 WM-G20 ZM-LN (Nat. Gas) 217 204 14 33 7
– 190 x 60 WM-G20 ZM-LN (LPG) 217 204 14 34 7

3.15 Nozzle insert 80 x 16 Bo. 4 x 4 151 707 14 51 7

3.16 Mixing head G7/1-D-LN 151 707 14 28 1

3.17 Clamp 2 x 17 x 20 251 303 14 08 7

3.18 Ignition cable

– 650 mm lang 217 404 11 02 2
– 750 mm long ext. by 100 mm* 150 518 11 01 2
– 850 mm long ext. by 200 mm* 217 504 11 01 2
– 950 mm long ext. by 300 mm* 290 504 11 03 2

3.19 Ionisation cable 1x1

– 490 mm long 250 103 14 26 2
– 590 mm long ext. by 100 mm* 150 518 14 09 2
– 690 mm long ext. by 200 mm* 150 707 14 20 2
– 790 mm long ext. by 300 mm* 150 707 14 21 2

3.20 Ionisation cable 640 mm long 151 316 00 02 2

* only in conjunction with combustion head extension

61
 A

4.04
4.15
4.03

4.14

4.02 4.13
4.05

4.06
4.01

4.10

4.12

4.08

4.11
4.07

4.09

62
 A
Pos. Description Order No.

4.01 ABE for W-FM 50 600 405

4.02 Cover incl. gasket

and fixing sleeves for W-FM
- ABE inbuilt 211 204 12 01 2
- ABE external 211 204 12 02 2

4.03 Stay bolt cover W-FM 211 104 12 03 7

4.04 Mounting plate WM for W-FM 50 211 204 12 04 7

4.05 W-FM Plug

– X3-02 Air pressure switch 716 301
– X3-03 Limit switch burner flange 716 302
– X3-04 Mains and safety circuit 716 303
– X3-05 Fan, alarm 716 410
– X4-02 Ignition unit 716 305
– X5-01 Low pressure switch 716 307
– X5-02 High pressure switch 716 308
– X5-03 Control circuit 716 309
– X6-03 Safety valve 716 312
– X7-01 DMV Valve 2 716 313
– X8-02 DMV Valve 1 716 317
– X8-04 Operation + LO Reset 716 411
– X9-04 Valve proving press. switch 716 418
– X10-05 Flame sensor 716 413
– X74 Connection frequency converter 716 417
– X75 Fuel meter 716 415

4.06 Combustion Manager WFM50 230 V 600 400

4.07 Plug cable ABE-W-FM 50 600 406

4.08 Plug cable W-FM 50 mains / safety circuit 217 104 12 02 2

4.09 Plug cable W-FM 50 for DMV 217 104 26 01 2

4.10 Plug cable W-FM 50 for

– Low gas pressure switch 217 104 26 02 2
– High gas pressures switch 217 104 26 03 2
– Valve proving pressure switch 217 104 26 04 2

4.11 Plug cable W-FM50 speed cont. FC 217 104 12 10 2

4.12 Plug cable W-FM50 motor contactor 217 104 12 09 2

4.13 Ignition unit W-ZG 02/V for W-FM 230V 217 704 11 03 2

4.14 Sealing ring for W-ZG 02 44 x 18 x 4 211 163 11 02 7

4.15 Limit switch WM 211 104 01 06 2

63
 A

5.03

5.02

5.04

5.01

5.11

5.05

5.11
5.07

5.07
5.06

5.03

5.05

5.08 5.02

5.04

5.01

5.05 5.10
5.05
5.08

5.07 5.06
5.07

5.06

5.09

64
 A
Pos. Description Order No.

5.01 Double solenoid valve:

– DMV-D 512/11; 230V 605 206
– DMV-D 520/11; 230V 605 208
– DMV-D 5065/11; 230V 605 216
– DMV-D 5080/11; 230V 605 218
– DMV-D 5100/11; 230V 605 220
– DMV-D 5125/11; 230V 605 222

5.02 Solenoid 230V, complete for:

– 512/11 type 1211 605 942
– 520/11 type 1212 605 943
– 5065/11 type 1411 605 945
– 5080/11 type 1511 605 946
– 5100/11 type 1611 605 947
– 5125/11 type 1711 605 948

5.03 Circuit board DMV-D; 230V

DMV-D 512, 520, 5065, 5080 605 997
DMV-D 5100 + 5125 605 998

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

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

5.06 Gas pressure switch

– GW 50 A5/1 5-50 mbar 691 378
– GW 150 A5/1 10-150 mbar 691 379
– GW 500 A5/1 100-500 mbar 691 380

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

5.08 Gas pressure switch

– GW 50 A6/1 5-50 mbar 691 381
– GW 150 A6/1 10-150 mbar 691 382
– GW 500 A6/1 100-500 mbar 691 383

5.09 Flange
– DMV 512 RP 1 605 228
– DMV 520 RP 1 1/2 605 230
– DMV 520 RP 2 605 231

5.10 Adaptor set DMV 605 251

5.11 Sealing ring DIN 2690

– DN65 77 x 127 x 2 441 861
– DN80 90 x 142 x 2 441 044
– DN100 115 x 162 x 2 441 045
– DN125 141 x 192 x 2 441 046

65
 Max Weishaupt GmbH
D - 88475 Schwendi
Tel.: (07353) 830, Fax.: (07353) 83358
www.weishaupt.de

Print No. 83250802, May 2007

Printed in Germany. All rights reserved.

Weishaupt (UK) Limited

Neachells Lane, Willenhall, WV13 3RG
Tel: (01902) 609841, Fax: (01902) 633343
www.weishaupt.co.uk

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