Installation and operating instructions 83045802 1/99

Weishaupt gas burners WG10 and WG20

version LN (Low NOx)
for Natural Gas E and LL and Liquid Petroleum Gas B/P
 Conformity Certification Contents
to ISO/IEC Guide 22 Title Page
Confirmed by: Max Weishaupt GmbH 1. General notes 3
Address: Max Weishaupt Strae 2. Installation and commissioning 4
D-88475 Schwendi 2.1 Burner mounting dimensions 4
2.2 Capacity graphs 4/5
Product: Gas burners with fan 2.3 Burner and valve train mounting 5
Type: WG10, WG20 2.4 Electrical connection 5
2.5 Fusing 5
The products described above conform to 2.6 Soundness test of valve trains 6
2.7 Technical data 7/8
Document No.: EN 676 2.8 Setting single stage burner 9
EN 292 2.9 Setting sliding two stage and
EN 50 081-1 modulating burner 10
EN 50 082-1 2.10 Determination of gas throughput 11
EN 60 335 2.11 Combustion analysis 12
In accordance with the guidelines 3. Technical information 13
3.1 Combustion head dimensions 13
90/396/EEC Gas Appliance Directive 3.2 Mixing head installation 13
89/336/EEC Electromagnetic Compatibility Directive 3.3 Setting ignition and sensor electrodes 13
73/23/EEC Low Voltage Directive 3.4 Burner equipment 14
92/42/EEC Boiler Efficiency Directive 3.5 Burner dimensions 14
98/37/EC Machinery Directive 3.6 Valves train dimensions 15
3.7 Electrical data 15
these products are labelled as follows: 3.8 Permitted ambient conditions 15
WG10N/1-A CE-0085 AO 0115 4. Description of valve trains 16
WG10F/1-A CE-0085 AO 0108 4.1 Double solenoid valve type DMV 16
WG20N/0-A CE-0085 AO 0122 4.2 Pressure regulator type FRS 17
WG20F/0-A CE-0085 AO 0128 4.3 Setting gas pressure switch 18
WG20N/1-A CE-0085 AO 0134 4.4 Setting air pressure switch 18
WG20F/1-A CE-0085 AO 0140 4.5 Flame monitoring 18
Schwendi, 24.09.1999 5. Electrical connection and operation 19
ppa. ppa. 6. Cause and rectification of faults 27
Lck Denkinger

Comprehensive Quality Assurance is ensured by a

certified Quality Management System
to DIN ISO 9001.

Regular maintenance saves energy and protects the environment

We recommend regular maintenance of combustion An excellent combustion quality is a pre-requisite for
equipment to all plant operators. It saves fuel and environmentally friendly operation.
ensures constantly good combustion results.
3
1. General instructions
Safety
To ensure safe burner operation, the burner has to be
installed and commissioned by qualified personnel
and all guidelines in these operating instructions have
to be followed.
Special attention should be paid to the relevant
installation and safety guidelines given (e.g. local
Codes of Practice).
Flame monitoring devices, limit controls, correcting
elements and all other safety devices may only be
commissioned or replaced by the manufacturer or the
authorised agent.
Failure to comply can lead to serious injury or death
and can cause considerable damage to the plant.
Qualified personnel according to this operating
manual are persons who are familiar with the
installation, mounting, setting and commissioning of
the product and which have the necessary
qualifications such as:
Training, instruction or authorisation to switch
electrical circuits and electrical devices on and off,
to earth them and to mark them in accordance with
the safety standards.
Training, instruction or authorisation to carry out
installation, alteration and maintenance work on gas
installations in buildings and on site.
Operating instructions
The operating instructions included with each burner must
be displayed clearly in the boiler room. The address of the
nearest service centre must be entered on the reverse side
of the manual.
Instruction of personnel
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with
regard to the operation of the burner. With frequently
occurring burner faults, the nearest service centre must be
notified.
Electrical wiring diagram
Each burner delivery includes a detailed wiring and
connecting diagram.
Maintenance and service
The whole installation including the burner should be
inspected by a qualified engineer of the supplier at least
once a year. The combustion figures should be checked
after each service and each time an error has been
rectified. If, during maintenance, control seal joints have to
be opened, these have to be thoroughly cleaned and new
seals fitted when re-assembling.
Ambient requirements
Material, construction and type of protection of the
burners and gas valve trains in their standard version are
designed for use indoors.
4
General information for gas operation
When installing a gas combustion system, local
regulations and guidelines must be observed.
The subcontractor responsible for the installation or
changes of the gas system must inform the gas supplier of
the type and extent of the installation planned and the
intended work. The subcontractor must ascertain that an
adequate gas supply to the installation is ensured.
Installations, alterations and maintenance work on gas
systems in buildings and below ground, must only be
carried out by installers who have a contract with the gas
supplier.
Gas characteristics
The following information must be obtained from the gas
supplier:
Type of gas, calorific value in kW/hm3, max. CO2 content of
flue gas, gas supply pressure.
Gas line
The gas pipework 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
pipework.
The determination of the pipework diameter usually gives a
diameter, which is at least one diameter larger than the
size of the burner valve train.
Gas valve train
Observe the sequence and flow direction. The distance
between burner and DMV valve should be as small as
possible in order to guarantee trouble free start.
Pipe thread connection
Only tested and approved sealing material should be
used. Please observe individual user instructions!
Soundness test
Brush connection points with foam forming agents or
similar, non-corroding materials.
Conversion to other gases
The burner must only be used with the gas types given on
the name plate. When converting to another gas type, a
conversion kit and re-commissioning are required.
Installation
The valve train must be fixed and supported securely.
Standard connection is from the right.
Gas meter
The siting, size and type of gas meter are the responsibility
of the gas supplier. Only those meters, which have been
approved should be used. If no gas meter is fitted, as for
instance on liquid petroleum gas installations, the operator
has to be made aware that the burner can not be set to its
optimum, because basic testing is not possible.
2. Installation and commissioning
2.1 Burner mounting dimensions

Mounting to the heat exchanger Appliance drilling

This drawing shows the refractory for a heating appliance dimensions
without cooled front. The front edge of the combustion Insulating material d4
head should protrude approx. 30 mm beyond the d5
refractory. If a section without cooling (turning chamber)
is not protected, the refractory can take a conical shape
( 60). Refractory may not be required on boilers with
water cooled fronts, unless the manufacturer gives other d1 d2
instructions. Flange gasket

I1 d3
Fill the gap with
Cerafelt
(do not make solid)

Size Combustion Dimension in mm

head type d1 d2 d3 d4 d5 I1

WG10../1 WG10/1 90 110 130-150 95 M8 131

WG20../0 WG20/0 108 125 150-170 110 M8 145

WG20../1 WG20/1 120 135 150-170 130 M8 145

2.2 Capacity charts

Type WG10.../1-A - single stage Type WG10../1-A - sliding two stage

mbar Burner type WG10../1-A, LN mbar Burner type WG10../1-A, LN

Combustion head WG10/1 Mixing head Combustion head WG10/1 Mixing head
Rating kW 12 - 50 Open Rating kW 12 - 50 Open
12 - 25 Closed 12 - 25 Closed
1.5
1,5 1.5
1,5
1.0
1,0 1,0
1.0
0,5
0.5 0,5
0.5
00 0
0
0.5
-0,5 -0,5
0.5
1.0
-1,0 -1,0
1.0
kW 0 10 20 30 40 50 60 kW 0 10 20 30 40 50 60

Type WG20../0-A - single stage Type WG20.../0-A - sliding two stage

mbar Burner type WG20../0-A, LN mbar Burner type WG20../0-A, LN

Combustion head WG20/0 Mixing head Combustion head WG20/0 Mixing head
Rating kW 30 - 90 Open Rating kW 25 - 90 Open
30 - 60 Closed 25 - 60 Closed
1.5
1,5 1.5
1,5
1.0
1,0 1.0
1,0
0,5
0.5 0,5
0.5
0 0
-0,5
0.5 0.5
-0,5
1.0
-1,0 1.0
-1,0
kW 30 40 50 60 70 80 90 kW 25 30 40 50 60 70 80 90

Type WG20../1-A - single stage Type WG20.../1-A - sliding two stage

mbar Burner type WG20../1-A, LN mbar Burner type WG20../1-A, LN

Combustion head WG20/1 Mixing head Combustion head WG20/1 Mixing head
Rating kW 50 - 160 Open Rating kW 30 - 160 Open
50 - 90 Closed 30 - 90 Closed
1.5
1,5 1.5
1,5
1.0
1,0 1.0
1,0
0.5
0,5 0.5
0,5
00 00
-0,5
0.5 0.5
-0,5
-1,0
1.0 -1,0
1.0
kW 30 50 70 90 110 130 150 kW 30 50 70 90 110 130 150
5
2.3 Burner and valve train mounting

Exploded view Attention!

1 Fixing stud If no elbow is used between pressure regulator and double
2 Burner flange 1 solenoid valve, then a straight pipe 200 mm long must be
3 Valve train flange on burner used.
4 Burner body
2 4
5 Mixing tube with assembly
6 Double solenoid valve DMV
7 Gas valve train components
(installation position see technical
worksheets)
8 Pressure switch
9 Pressure test nipples (fitted to filter 6 3
inlet and DMV test point 1)
7
8
5
9

Assembly alignment and joint cleanliness must be Do not tighten or seal pipe thread connections on the
ensured. The O-ring seals must be fitted correctly on the mounted burner or DMV valves(damage to flange fixing
machined faces. Do not compensate for misalignment by screws).
over tightening.

2.4 Electrical connection

The 7-pole connection plug of the boiler control is fitted

directly to the connection console of the burner. The two
cable plugs from the burner housing are used for
connection to the DMV valve.
(GW = gas pressure switch, DMV = solenoid valves)

The connection plug for the ratings regulator is plugged in

under the servomotor.

2.5 Fusing

To protect the electrical components of the burner a fuse

(T6.3 A) is fitted in the lower part of the connection
console. This can be reached by removing the burner
control. A replacement fuse has also been fitted in the
socket.

6
2.6 Soundness test of valve trains
Soundness test of the gas train must be carried out
with the main isolating cock and DMV valves closed.
Proceed as follows:
Legend:
1 Rubber hose with T piece
2 Aspirator
3 U-tube manometer or electronic manometer
4 Hose clamp
5 Blanking plate
1. Test phase: ball cock up to 1st valve seat (V1)
The test assembly is connected to the gas filter and DMV
inlet. During pressure testing, the test point 2 between
DMV valve seats V1 and V2 has to be open.
2. Test phase: at test point 2 (between V1 and V2)
The test assembly is fitted to the DMV test point 2. Test
point 3 is open.
3. Test phase: Outlet of DMV and gas butterfly valve
The test assembly is fitted to the DMV outlet. For pressure
testing, the blanking plate supplied must be fitted between
mixing head and the gas butterfly.
Attention!
Following a successful pressure test, the blanking
plate must be removed, ensuring a gas tight seal is
made.
The test pressure in the gas train must be a minimum of
100 - 150 mbar.
A 5 minute waiting time for pressure stabilisation must be
allowed.
The gas train is considered gas tight if, over a 5 minute
period, there is a drop in pressure of less than 1 mbar.
Leaks on external components can be detected during a
soundness test by brushing with leak detecting fluid.
Results of the pressure test must be recorded on the
service/commissioning report.
Attention!
After all maintenance and commissioning work on gas
supplying components a soundness test must be
carried out.
Sequence test without gas
Wiring connection check
Check that the wiring to all parts, especially the valve train,
is carried out in accordance with the wiring diagram
supplied with the burner.
Checking sequence of operation (without gas)
When the gas and electric side of the installation has been
checked, the burner sequence test is carried out.
The isolation valve must be closed.
Using the aspirator connected to test point 1, air is
pumped into the valve train. The pressure must correspond
at least to the subsequent operating pressure.
The plant is then switched on.
It is necessary to understand the sequence of the burner
control.
4
5
1
2 3
4
1st Test phase 2nd
1. Dichtheitsphase 2. Test phase 3rd
Prfphase 3. Test phase
Prfphase
Fault signals are described in the program sequence
of the controller.
Purging the gas line
Lines have to be purged with gas until the existing air
or inert gas has been expelled from the line. This work
is carried out by qualified gas fitters. If work has been
carried out on the gas line, e.g. exchanging of parts,
valve trains or gas meters, re-commissioning may only
be carried out after the relevant lines have been
purged by a qualified gas fitter.
Purging the gas valve train
Before switching on for initial commissioning the valve train
must also be purged. A hose, leading out to atmosphere, is
connected to the test point 1 of the DMV valve to purge
the air.
The isolating valve is opened and the gas in the pipework
vents to atmosphere via the hose. Small amounts of gas
can be burnt off at the exit of the hose via a suitable burner,
i.e. test burner.
If the replacement of parts is needed when working on
valve trains, purging and testing for air has to be carried
out before re-commissioning the burner.
Checking the heat exchanger
The following should be checked prior to first
commissioning:
the heating appliance is adequately filled with water
on air heaters the fan is operating correctly
flue ways are clear and explosion flaps are free to move
refractory, where used, is installed correctly
a measuring point is provided for flue gas sampling
correct setting of temperature regulator or pressure
regulator and limit controls
is the gas connection pressure correct?
7
2.7 Technical description

Gas/air compound regulation WG10/1

On the WG10 and WG20 gas burners, the servomotor Diagram:

adjusts the gas and air quantities in compound to the Servomotor and diffuser setting depending
relevant load setting. The air damper in the air intake of the on burner rating
fan and the gas butterfly valve are mechanically connected Setting screw diffuser (scale)
by a regulating rod. An additional setting possibility of the
0 2 4 6 8 9

Compound eccentric or gas butterfly valve setting

mixing head results in an intensive inter-mixing of gas and 8
air and therefore improved combustion. On burners with
sliding two stage and modulating regulation, the required 7
gas mixing can be regulated across the whole ratings
range by a separate gas setting screws. 6

5
Mixing head
4
It is important to use the whole angle range of the
servomotor to achieve a sensitive regulation, which means 3
full load setting is usually at 80, and relevant diffuser
setting (interpolate intermediate value). Not all burner 2
types require the whole setting range of the diffuser. On
smaller ratings (e.g. < 33kW on WG10) setting is carried 1
out on the compound eccentric.
0
0 10 20 30 40 50
The setting screw diffuser remains on scale 2. Burner rating in kW (combustion chamber pressure = 0)

If necessary the diffuser setting screw can be readjusted Table:

from the works setting (2) to 0. Setting pressure and min. connection pressure
DN Setting Servom. Compound
screw setting eccentric Setting Connection
For dimension X see chapter 3.2. scale Dim. X in setting pressure pressure
0-9 in mm degrees 0-8 in mbar min. in mbar
Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606,
Wi = 47.84 MJ/m3, (13.29 kWh/m3)
2 14.2 80 0.5-8 9 15
4 16.4 80 8 11 17
3/8" 6 18.6 80 8 14 20
8 20.8 80 8 16 24
9 22.0 80 9 19 26
2 14.2 80 0.5-8 9 15
4 16.4 80 8 10 15
1/2" 6 18.6 80 8 13 15
8 20.8 80 8 15 17
9 22.0 80 9 17 19
Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641,
Wi = 39.67 MJ/m3, (11.02 kWh/m3)
2 14.2 80 0.5-8 13 19
4 16.4 80 8 15 22
3/8" 6 18.6 80 8 19 27
8 20.8 80 8
9 22.0 80 9
2 14.2 80 0.5-8 9 15
4 16.4 80 8 10 16
The results of the following diagrams and tables have been 1/2" 6 18.6 80 8 13 19
calculated on flame tubes under idealised conditions. The 8 20.8 80 8 15 22
values are therefore guidelines for basic setting. Small 9 22.0 80 9 17 25
variations can occur depending on individual installations. Liquid Petroleum Gas B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d =
1.555, Wi = 74.74 MJ/m3, (20.76 kWh/m3)
2 14.2 80 0.5-8 8 15
4 16.4 80 8 9 15
3/8" 6 18.6 80 8 11 16
8 20.8 80 8 13 19
9 22.0 80 8 15 21
2 14.2 80 0.5-8 7 15
4 16.4 80 8 8 15
1/2" 6 18.6 80 8 10 15
8 20.8 80 8 11 16
9 22.0 80 8 13 17

The information given for calorific value Hi and the Wobbe index Wi relate
to 0C and 1013.25 mbar.

8
WG20/0 WG20/1

Diagram:
Servomotor and diffuser setting depending
on burner rating
Setting screw diffuser (scale) Setting screw diffuser (scale)

Compound eccentric or gas butterfly valve setting

0 2 4 6 0 2 4 6 8
8 8

7 7

6 6

5 5
Compound eccentric

4 4

3 3

2 2

1 1

0 0
0 10 20 30 40 50 60 70 80 90 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Burner rating in kW (combustion chamber pressure = 0) Burner rating in kW (combustion chamber pressure = 0)

Table:
Setting pressure and min. connection pressure
DN Setting Servom. Compound DN Setting Servom. Compound
screw setting eccentric Setting Connection screw setting eccentric Setting Connection
scale Dim. X in setting pressure pressure scale Dim. X in setting pressure pressure
0-9 in mm degrees 0-8 in mbar min. in mbar 0-9 in mm degrees 0-8 in mbar min. in mbar
Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606, Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606,
Wi = 47.84 MJ/m3, (13.29 kWh/m3) Wi = 47.84 MJ/m3, (13.29 kWh/m3)
2 11.3 80 0.5 - 8 9 15 2 15.3 80 0.5 - 8 8 19
1/2 4 12.6 80 8 11 17 4 18.6 80 8 11 24
6 14.0 80 8 13 20 1/2 6 22.0 80 8 13 30
8 25.3 80 8 16 36
2 11.3 80 0.5 - 8 9 15
3/4 4 12.6 80 8 10 15 2 15.3 80 0.5 - 8 8 15
6 14.0 80 8 12 16 4 18.6 80 8 9 16
3/4 6 22 80 8 12 20
2 11.3 80 0.5 - 8 8 15 8 25.3 80 8 14 23
1 4 12.6 80 8 9 15
6 14.0 80 8 11 15 2 15.3 80 0.5 - 8 6 15
4 18.6 80 8 7 15
Natural Gas LL, Hi = 31.79 MJ/m3 8.83 kWh/m3 , d = 0.641, 1 6 22.0 80 8 9 15
Wi = 39.67 MJ/m3, (11.02 kWh/m3) 8 25.3 80 8 10 16
2 11.3 80 0.5 - 8 12 18
1/2 4 12.6 80 8 14 22 Natural Gas LL, Hi = 31.79 MJ/m3 8.83 kWh/m3 , d = 0.641,
6 14.0 80 8 17 27 Wi = 39.67 MJ/m3, (11.02 kWh/m3)
2 15.3 80 0.5 - 8 11 25
2 11.3 80 0.5 - 8 11 15 4 18.6 80 8 14 32
3/4 4 12.6 80 8 13 18 1/2 6 22.0 80 8 18 41
6 14.0 80 8 16 21 8 25.3 80 8
2 11.3 80 0.5 - 8 10 15 2 15.3 80 0.5 - 8 10 17
1 4 12.6 80 8 12 15 4 18.6 80 8 12 21
6 14.0 80 8 14 18 3/4 6 22 80 8 16 26
Liquid Petroleum Gas B/P, Hi =93.20 MJ/m3 (25.89 kWh/m3) , d = 8 25.3 80 8 19 31
1.555, Wi = 74.74 MJ/m3, (20.76 kWh/m3) 2 15.3 80 0.5 - 8 7 15
2 11.3 80 0.5 - 8 16 20 4 18.6 80 8 9 15
3/8 4 12.6 80 8 19 24 1 6 22.0 80 8 11 18
6 14.0 80 8 8 25.3 80 8 13 20
2 11.3 80 0.5 - 8 10 15 Liquid Petroleum Gas B/P, Hi =93.20 MJ/m3 (25.89 kWh/m3) , d =
1/2 4 12.6 80 8 12 16 1.555, Wi = 74.74 MJ/m3, (20.76 kWh/m3)
6 14.0 80 8 14 19 2 15.3 80 0.5 - 8 7 15
2 11.3 80 0.5 - 8 10 15 4 18.6 80 8 8 16
3/4 4 12.6 80 8 12 16 1/2 6 22.0 80 8 11 20
6 14.0 80 8 14 19 8 25.3 80 8 13 23
2 15.3 80 0.5 - 8 7 15
The information given for calorific value Hi and the Wobbe index Wi relate 4 18.6 80 8 9 15
to 0C and 1013.25 mbar. 3/4 6 22.0 80 8 10 16
8 25.3 80 8 12 18

9
2.8 Setting single stage burner

Control cam:
I Full load
II Closed position

Setting screw
diffuser

30
Gas/air eccentric

Disengage motor by pressing in and

turning 90 (see symbols)

8
7
4
6
5 3
s
2 ga
nd
Z
1

Setting screw ignition gas

gas setting screws 1 and 2 Gas butterfly valve setting

Burner pre-setting: 1. On pre-setting diffuser setting = 2 and compound

Gas/air compound eccentric or gas butterfly valve eccentric setting < 8
setting to diagram (factory setting 8) Engage servomotor, burner runs to full load
Setting screw diffuser to diagram (factory setting 2) Combustion quality test
Full load limit switch 80 b (factory setting) Match gas throughput to the required value by changing
Setting screw ignition gas and all setting screws open the setting on the compound eccentric (see diagram).
1/2 rotation (factory setting)
2. On pre-setting diffuser setting > 2, compound
Burner setting: eccentric setting = 8
Open ball valve and switch on burner Engage servomotor, burner runs to full load
Burner runs to full load and pre-purge begins Gas throughput is matched to the required value by
After that the servomotor runs to switch 2 adjusting the gas pressure setting
(= ignition setting) If the combustion values are not reached, the mixing
Disengage gears on the servomotor once switch 2 head can be re-adjusted via the setting screw diffuser
position has been reached Adjustment : reduced excess air
Await flame formation Adjustment + : increased excess air
Set outlet pressure at regulator approx. 0.5 - 1 mbar
above values in table (equals pressure loss on full load) Ratings setting full load:
Set the O2 or CO2 value relevant to the gas used with The exact ratings setting is always carried out by the
the ignition gas setting screw setting of the calculated gas throughput. The setting
pressure value in the table is a setting and control aid.
CO2 O2
Final checking and documentation
Natural gas LL 8.8 - 9.3 % 5-4% Set gas pressure switch on full load and test.
Natural gas H 9.0 - 9.5 % 5-4% Test air pressure switch on ignition load
LPG 10.3 - 11.0 % 5-4% Record all test results

Engage servomotor until the gas butterfly valve reaches After all maintenance and commissioning work on gas
setting 1, disengage servomotor, set combustion with supplying components a soundness test must be
gas setting screw. carried out by brushing with leak detecting fluid.
Engage servomotor until the gas butterfly valve reaches
setting 2, disengage servomotor, set combustion with
gas setting screw 2. According to burner rating and
setting of the mixing head there are two ways to
proceed:

10
2.9 Setting sliding two stage and modulating burners
Control cam:
I Full load
II Closed position
III Zndlast = Kleinlast

Setting screw
diffuser

00

30
30
Gas/air eccentric

Disengage motor by pressing in and

turning 90 (see symbols)
8
7
4
6
5 3
s
2 ga
nd
Z
1
Setting screw ignition gas
gas setting screws 1 - 8 Gas butterfly valve setting

Burner pre-setting: According to burner rating and setting of the mixing head
Gas/air compound eccentric or gas butterfly valve there are two ways to proceed:
setting to diagram (factory setting 8)
Setting screw diffuser to diagram (factory setting 2) 1. On pre-setting diffuser setting > 2, compound
Full load limit switch 80 b (factory setting) eccentric setting = 8
Setting screw ignition gas and all setting screws open Match gas throughput to the required value by changing
1/2 rotation (factory setting) the setting on the compound eccentric (see diagram).
Limit switch for partial load is adjusted once initial
settings have been carried out ( 5 b factory setting). 2. Bei Voreinstellung Stauscheibenstellung > 2,
Exzenterstellung = 8
Burner setting: Gas throughput is matched to the required value by
Open ball valve and switch on burner adjusting the gas pressure setting
Burner runs to full load and pre-purge begins If the combustion values are not reached, the mixing
After that the servomotor runs to partial load switch head can be re-adjusted via the setting screw diffuser
(= ignition setting) Adjustment "" : reduced excess air
Disengage gears on the servomotor once Closed Adjustment "+" : increased excess air
position has been reached (or use socket switch No.
130 103 1501/2) If large gas pressure changes are made, the gas setting
Await flame formation screws will need to be rechecked.
Set outlet pressure at regulator approx. 0.5 - 1 mbar
above values in table Ratings setting full load:
Set the O2 or CO2 value relevant to the gas used with The exact ratings setting is always carried out by the
the ignition gas setting screw setting of the calculated gas throughput. The setting
pressure value in the table is a setting and control aid.
CO2 O2
Final checking and documentation
Natural Gas LL 8.8 - 9.3 % 5-4% Set gas pressure switch on full load and test.
Natural Gas H 9.0 - 9.5 % 5-4% Test air pressure switch on ignition load
LPG 10.3 - 11.0 % 5-4% Record all test results
Combustion setting at the gas butterfly setting 1 up to After all maintenance and commissioning work on gas
the preset max. setting. supplying components a soundness test must be
Engage servomotor until the gas butterfly valve reaches carried out by brushing with leak detecting fluid.
setting 1, disengage servomotor, set combustion with
gas setting screw 1.

Engage servomotor until the gas butterfly valve reaches

setting 2, disengage servomotor, set combustion with
gas setting screw 2.
and so on to setting screw 8

11
2.10 Determination of gas throughput
Conversion from standard to operating conditions
General: Example:
The calorific value (Hi,n) of combustible gases is generally Height above sea level = 500 m
given in relation to the standard conditions (0C, 1013 Barometric air pressure PBaro. as tab. = 953 mbar
mbar). Gas pressure PG at meter = 20 mbar
Total pressure Pges (Bo+PG) = 973 mbar
Throughput calculation: Gas temperature tG = 10 C
To determine the correct loading of the heat exchanger, the Conversion factor f as tab. = 0.9266

gas throughput must be determined before hand. Boiler rating QN = 25 kW
Efficiency (assumed) = 90 %
Calorific value Hi,n = 10.35 kWh/m3
Normal volume Vn:

QN
25
Vn = Hi,n
Vn = Vn 2.7 m3/h
0.90 10.35
Actual volume VB:
2.7

Vn QN
VB = 0.9266 VB 2.9 m3/h
or
VB = VB =
f Hi,B
Measuring time in seconds for 100 litres gas throughput
Measuring 3600 0.1
Measuring time in seconds for 100 litres gas throughput time = Measuring time = 124 s
2.9
3600 0.1[m3]
Meas. time [s]= For two stage burners, partial load is calculated and
controlled the same way!
VB [m3/h]

Determination of conversion factor f

Gas pressure PBaro. + PGas [mbar]
950 956 962 967 973 979 985 991 997 1003 1009 1015 1021 1027 1033 1036
0 0.9378 0.9437 0.9497 0.9546 0.9605 0.9664 0.9724 0.9783 0.9842 0.9901 0.9961 1.0020 1.0079 1.0138 1.0197 1.0227
2 0.9310 0.9369 0.9427 0.9476 0.9535 0.9594 0.9653 0.9712 0.9770 0.9829 0.9888 0.9947 1.0006 1.0064 1.0123 1.0153
4 0.9243 0.9301 0.9359 0.9408 0.9466 0.9525 0.9583 0.9642 0.9700 0.9758 0.9817 0.9875 0.9933 0.9992 1.0050 1.0079
Gas temperature tG [C]

6 0.9176 0.9234 0.9292 0.9341 0.9399 0.9457 0.9514 0.9572 0.9630 0.9688 0.9746 0.9804 0.9862 0.9920 0.9978 1.0007
8 0.9111 0.9169 0.9226 0.9274 0.9332 0.9389 0.9447 0.9504 0.9562 0.9619 0.9677 0.9734 0.9792 0.9850 0.9907 0.9936
10 0.9047 0.9104 0.9161 0.9209 0.9266 0.9323 0.9380 0.9437 0.9494 0.9551 0.9609 0.9666 0.9723 0.9780 0.9837 0.9866
12 0.8983 0.9040 0.9097 0.9144 0.9201 0.9257 0.9314 0.9371 0.9428 0.9484 0.9541 0.9598 0.9655 0.9711 0.9768 0.9796
14 0.8921 0.8977 0.9033 0.9080 0.9137 0.9193 0.9249 0.9306 0.9362 0.9418 0.9475 0.9531 0.9587 0.9644 0.9700 0.9728
16 0.8859 0.8915 0.8971 0.9017 0.9073 0.9129 0.9185 0.9241 0.9297 0.9353 0.9409 0.9465 0.9521 0.9577 0.9633 0.9661
18 0.8798 0.8854 0.8909 0.8955 0.9011 0.9067 0.9122 0.9178 0.9233 0.9289 0.9344 0.9400 0.9456 0.9511 0.9567 0.9594
20 0.8738 0.8793 0.8848 0.8894 0.8949 0.9005 0.9060 0.9115 0.9170 0.9225 0.9281 0.9336 0.9391 0.9446 0.9501 0.9529
22 0.8679 0.8734 0.8788 0.8834 0.8889 0.8944 0.8998 0.9053 0.9108 0.9163 0.9218 0.9273 0.9327 0.9382 0.9437 0.9464

24 0.8620 0.8675 0.8729 0.8775 0.8829 0.8883 0.8938 0.8992 0.9047 0.9101 0.9156 0.9210 0.9265 0.9319 0.9373 0.9401

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. The table allows for
conversion factors in the low pressure range (up to 100
PBaro. + PG 273 mbar).
f=
1013 273 + tG The factor can also be determined in the high pressure
range according to the formula to the left.

Mean annual barometric pressure

Average geodetic height from 1 51 101 151 201 251 301 351 401 451 501 551 601 651 701
of supply area to 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750

mean ann. air pres. above sea level mbar 1016 1013 1007 1001 995 989 983 977 971 965 959 953 947 942 936 930

Legend:
QN = Boiler rating [kW] f = Conversion factor
= Efficiency [%] PBaro. = Barometric pressure [mbar]
Hi,n = Lower standard calorific value [kWh/m3] PG = Gas pressure at meter [mbar]
Hi,B = Lower operating calorific value [kWh/m3] tG = Gas temperature at meter [C]

12
2.11 Combustion analysis

For safe and economic operation of the plant flue gas
measurements are essential when commissioning.
The maximum CO2 content for the various gases can be
obtained from the gas suppliers (refer to table).
Example:
with 15% excess air (=1.15) and 12% CO2 max. a test
value
Determination of flue gas losses
The oxygen content of the flue gas and the difference
between flue gas and combustion air temperature must be
determined. The oxygen content and the flue gas
temperature must be measured at the same time at one
point. Instead of oxygen content the carbon dioxide of the
flue gas can also be measured. The combustion air
temperature is measured in the proximity of the burner air
intake.

12 The flue gas losses are calculated when measuring the

of CO2 gem ~ = 10.4 % should be reached. oxygen content according to the equation:
1.15
A2
The CO content must not be more than 0.005 Vol. %
qA = (tA tL) ( + B)
(50 ppm)
21 O2
Flue gas temperature for full load (nominal load) is the
If the carbon dioxide content is measured instead of the
result of burner setting at nominal loading.
oxygen content, the calculation is carried out according to
the equation:
Flue gas temperature for partial load is the result of
the control range adjustment.
A1
qA = (tA tL) ( + B)
The instructions of the manufacturer are to be followed
CO2
closely on hot water boiler installations. Normally a
partial load of 50 - 60% of the nominal load is set
whereby:
(some of the data may be on the boiler rating plate).
qA = flue gas losses in %
tA = flue gas temperature in C
On air heater installations the partial load is normally
tL = combustion air temperature in C
even higher. Again, the instructions of the
CO2 = volume of carbon dioxide content in dry flue
manufacturer should be closely followed.
gas %
O2 = volume of oxygen content in dry flue gas %
The flue gas installation should also be set out to
protect against damage through condensation
Oil Natural Towns Coke Liquid
(excluding acid proof chimneys).
Gas Gas Gas Petroleum
Gas and
Limitation of flue gas losses
LPG/Air
We recommend that oil and gas combustion systems are
mixture
so operated that the limits given in the table below for flue
gas losses are not exceeded.
A1 = 0.50 0.37 0.35 0.29 0.42
A2 = 0.68 0.66 0.63 0.60 0.63
Nominal Limits for flue gas losses % from
B = 0.007 0.009 0.011 0.011 0.008
thermal oil and gas combustion systems
output installed installed installed installed
up to after from from
31.12.82 1.1.83 1.10.88 1.1.98
kW 3.10.90
4 to 25 15 14 12 11
25 to 50 14 13 11 10
over 50 13 12 10 9

Calorific value of various types of gases and max. CO2:

Gas type Calorific value Hi Max. CO2

MJ/m3 kWh/m3n

2. Gas type
Group LL (Natural Gas) 28.48 to 36.40 7.91 to 10.11 11.5 to 11.7
Group E (Natural Gas) 33.91 to 42.70 9.42 to 11.86 11.8 to 12.5

3. Gas type
Propane P 93.21 25.99 13.8
Butane B 123.81 34.30 14.1
13
3. Technical information
3.1 Combustion head
Burner type Flame tube Diffuser Nozzle element Distribution star
mm mm mm Orifice mm mm
type d1 d2 outer inner a1 b c d e

WG10N/1-A WG10/1 90 68 74 24 4x7.5 58 4 x 1.3 63.5 4.5

WG10F/1-A WG10/1 90 68 74 24 4x7.5 58 4 x 1.3 63.5 4.5

WG20N/0-A WG20/0 108 85 90 36 4x8 69 4 x 2.1 79 5

WG20F/0-A WG20/0 108 85 90 36 4x8 69 4 x 2.1 79 5
WG20N/1-A WG20/1 120 88 95 36 4x11 68 4 x 2.1 86 7
WG20F/1-A WG20/1 120 88 95 36 4x11 68 4 x 2.1 86 7

Note: Mixing head and distribution star on LPG burners are equipped with a restricting distributor.

a1 a c

d2 d1 b b1 d

3.2 Mixing head installation

Push combustion head through the carrier into the cover.

L
Turn screw to scale setting 0. Note dimension X.

Secure the carrier after setting the length L with fixing

screws. L
Combustion head Length L Dimension X X
mm mm

WG10/1 267 12
WG20/0 327 10
WG20/1 325 12

3.3 Ignition and sensor electrode setting

After the combustion head has been adjusted, check the

arrangement of the ignition electrode and the ionisation
electrode. Setting dimensions as pictured.

The burner has a single pole ignition. For some special

cases, placing of the electrode tip may be favourable in a
different position.
Ignition
The sensor electrode can be set as shown on the left. In electrode
special cases it may be better to place the electrode in a
different position (turn or increase spacing).
11.,55 22
- 5 --
22 1,.5

Ignition electrode 4 mm diameter

Sensor electrode 6.3 mm diameter
14
3.4 Burner equipment

Burner Burner control Motor Servomotor Fan Ignition unit Air pressure Weight -
type with console switch Burner / valve train (with FRS and DMV)

ECK 01-2
MMI962.1 230V, 50 Hz SQN 90.350 A 2790
WG10/1 with AK820.01 S03 2600 rpm 220-240V, 50-60 Hz 120 x 30 W-ZG01 LGW 3A1 12.3 kg (3/8") 3.0 kg
220-240V, 50/60 Hz 0.025 kW 0.25 A 10 s run time (1/2") 4.0 kg
Cond. 1.2F

ECK 03-2
MMI962.1 230V, 50 Hz SQN 90.350 A 2790
WG20/0 with AK820.01 S03 2800 rpm 220-240V, 50-60 Hz 146 x 40 W-ZG01 LGW 10A1 16.8 kg (3/8") 3.0 kg
220-240V, 50/60 Hz 0.055 kW 0.55 A 10 s run time (1/2") 4.0 kg
Cond. 4F (3/4") 4.6 kg

ECK 03-2
MMI962.1 230V, 50 Hz SQN 90.350 A 2790 (1/2") 4.0 kg
WG20/1 with AK820.01 S03 2800 rpm 220-240V. 50-60 Hz 146 x 40 W-ZG01 LGW 10A1 17.5 kg (3/4") 4.6 kg
220-240V, 50/60 Hz 0.1 kW 0.88 A 10 s run time (1") 6.7 kg
Cond. 4F

On two stage operation with servomotor SQN 90.200.

3.5 Burner dimensions

on WG10/WG20:
3/8: 80 or 190 mm
1/2: 80 or 190 mm
3/4: 85 or 195 mm
1: 90 or 200 mm

on WG10 3/8: 287 mm

1/2: 304 mm
on WG20 3/8: 311 mm
Heat exchanger 1/2: 326 mm
connection dimensions 3/4: 326 mm
1: 367 mm
to EN 226

Dims. approx. mm l1 l2 l3 l4 l5 b1 b2 b3 h1 h2 h3 h4 h5 d1 d2 d3 d4 d5
WG10../1-A 229 131 73 100 55 300 150 240 320 95 72 140 146 90 M8 130-150 95 70 45
WG20../0-A 305 145 100 121 73 370 195 300 390 115 92 155 176 108 M8 150-170 110 100 45
WG20../1-A 305 145 100 121 73 370 195 300 390 115 92 155 176 120 M8 150-170 130 100 45

15
3.6 Gas valve train dimensions
Item a Valve train flange
b Double nipple
c DMV flange
d DMV
a e DMV flange
b f Double nipple
g Elbow
h Double nipple
c on WG10/WG20:
3/8: 80 or 190 mm
f h d 1/2: 80 or 190 mm
g 3/4: 85 or 195 mm
1: 90 or 200 mm
e on WG10 3/8: 287 mm
1/2: 304 mm
h f on WG20 3/8: 311 mm
g 1/2: 326 mm
3/4: 326 mm
1: 367 mm
1" : 373 mm

Valve train parts

R Pos. a Pos. b Pos.c Pos. d Pos. e Pos. f Pos. g Pos. h

WG10/1 3/8 WG10-1/2 1/2x180 503-1/2 503/11 503-3/8 3/8x100 W3/8 3/8x50
1/2 WG10-1/2 1/2x180 507-1/2 507/11 507-1/2 1/2x100 W1/2 1/2x50

WG20 3/8 WG20-3/4 1/2x200 1) 503-1/2 503/11 507-3/8 3/8x160 W3/8 3/8x50
1/2 WG20-3/4 3/4x200 507-3/4 507/11 507-1/2 1/2x150 W1/2 1/2x50
3/4 WG20-3/4 3/4x200 507-3/4 507/11 507-3/4 3/4x160 W3/4 3/4x50
1 WG20-3/4 3/4x200 512-1 2) 512/11 512-1 1x160 W1 1x50

1) Reducing nipple 3/4 x 1/2

2) Reducing nipple 1 x 3/4

3.7 Electrical data

Mains voltage max. pre fuse max. internal fuse Consumption
Start/ Operation

WG10/1-A, LN 230V; 50 Hz 10A gl T 6.3A / 250V 220 / 100W

WG20/0-A, LN 230V; 50 Hz 10A gl T 6.3A / 250V 310 / 170W
WG20/1-A, LN 230V; 50 Hz 10A gl T 6.3A / 250V 310 / 250W

3.8 Permitted ambient conditions

Temperature Humidity Requirements
EMV Low voltage guideline

In operation max. 80% rel. EC directive 89/336/EEC EN 60335

0 to +60C humidity
Transport/storage EN 50081-1
-20 to +70C EN 50082-1

16
4. Description of valve train
4.1 Schematic of gas valve train

Legend
1 Ball valve 6 Gas quantity regulation Layout of valve train
2 Gas filter 7 Valve proving VPS504 5 6
3 Pressure regulator (FRS) (special equipment)
4 Gas pressure switch
5 Double solenoid valve (DMV)

1 2 3 4 7

4.2 Double solenoid valve type DMV

Operation Technical data

DMV-D/11 Max. operating pressure 500 mbar
Two single stage solenoid valves normally closed, fast Voltage/frequency ~(AC) 230 V - 15 %
opening and closing, manual limit of gas flow possible by to 240 V + 10 % 50/60 Hz
main flow adjustment at valve 1 (V1). or ~(AC) 110 V 50/60 Hz
Installation Horizontal gas train -
solenoid vertical
Vertical gas train -
solenoid horizontal
Pressure test point Electrical connection
DMV-D 503/11 - 520/11 1 2 3

L1 N L2
V1 V2
2 1 3
1 2
4 5 1 2 3
N L1
Legend
2 1 Pressure in front of V1 33
2 Pressure between V1 and V2
1 3
3 Pressure after V2
L2 V1 V2
4 Inlet flange connection
5 Outlet flange connection

DMV and GW plug

Plug connection can be 4
turned if required

4 2c
m

2
4 3

17
Changing solenoid

1. Switch off and isolate installation A

2. Remove paint seal from screw A B

3. Remove counter sunk screw A
4. Remove cheese head screw B C

5. Change solenoid, checking new unit is correct

D
type/voltage
6. Refit screws A and B
7. Do a gas tightness test at test point 2 and 3:
E
pmin = 100 - 150 mbar
8. Carry out function test
9. Switch on supplies and test burner.

Gas throughput adjustment

DMV 503/11 Throughput adjustment on V2 DMV 503 DMV 507-5125

loosen locking screw and turn
the adjuster. One turn = 0.5 mm V2
of adjustment max min max min
V1
DMV 507 - 520/11 Throughput adjustment on V1
One turn = 0.5 mm of
adjustment

4.3 Pressure regulator type FRS

Outlet pressure adjustment (set point setting)

Factory setting: standard spring 5 - 20 mbar

1. Remove cap A A
2. To increase, turn screw B clockwise
= increase of outlet pressure (set point)
B
or

3. To reduce, turn screw B anti-clockwise

= reduction of outlet pressure (set point)
4. Check the adjustment is correct.
5. Replace cap A.

Changing the spring

1. Remove cap A. Turn screw B totally anti-clockwise.

2. Remove spring retainer C, and remove the spring D.
3. Fit new spring D. A
4. Re-fit spring retainer C, and by turning screw B set the B
required outlet pressure.
5. Check adjustment is correct and re-fit cap A. Stick C
label for new spring onto name plate. D

Type of spring / colour Outlet pressure range

mbar

orange 5 - 20
blue 10 - 30
red 25 - 55
yellow 30 - 70
black 60 - 110
pink 100 - 150
18
4.4 Setting gas pressure switch
To set a pressure switch for gas, a pressure measuring unit Gas pressure switch type GW50A5
has to be fitted to test point 1 of the DMV and the
microammeter for measuring of the ionisation current.
When determining the switch point, pay attention that this
is not below half the regulated pressure, that the ionisation
current is a minimum of 5 uA and that combustion is
CO < 1000 ppm.
Setting is carried out in the following manner:
1. Burner is operating
2. Gradually close ball valve so that the pressure at the
pressure test unit slowly decreases.
3. Setting pressure has been reached when
CO increases
sensor current is only 5 A
or when half the regulated gas pressure has been
reached.
4. Slowly turn the setting cam of the gas pressure switch
to the right until the burner carries out a controlled
shutdown.
5. Control - the burner is restarted with open ball valve. If
the ball valve is closed again, the shut down pressure
can be tested. The burner control must not go to
lockout.

4.5 Setting air pressure switch

Factory settings LGW 3 : 1.2 mbar Air pressure switch
LGW10 : 5.5 mbar
The switch point must be checked and if necessary adjusted
when first commissioning. For this a differential pressure
measurement between points and is required.
1. Connect pressure gauge as shown in diagram.
2. Start burner.
3. Drive through the setting range of the burner whilst
monitoring the pressure at the pressure test unit.
4. Determine the value of the lowest differential pressure.
5. turn the setting screw towards + until the air pressure
switches and the burner locks out.
6. Set the switch point to 20% below the lockout point just
reached
Differential pressure test
Example WG10:
Lowest differential pressure: : 2.9 mbar
Switch point of air pressure switch: : 2.9 x 0.8 = 2.4 mbar Air pressure switch
Switch point difference: : 0.5 mbar
Alteration to switch point on LGW3: : 0.5 mbar
One turn of setting screw towards -
1
Altering the switch point:
Each turn of the setting screw LGW 3 : 0.5 mbar
LGW10 : 1.5 mbar
Note:
Installation specific influences, i.e. by flue gas installations, heat
exchangers, location or air supply to the air pressure switch and
the setting, may require a different setting.

2

4.6 Flame monitoring

A microammeter or multimeter is used for measuring the
ionisation current.

A plug connection fitted in the ionisation cable is provided

to interconnect the microammeter. For trouble free
operation the sensor current should be adequately high.
The minimum response of the monitoring device is about 1
micro amp. Therefore an ionisation current of 5 micro
amps minimum should be measured during burner
operation (possibly adjust the sensor electrode position).

A negative movement of the microammeter during post

ignition does not usually affect trouble free operation.

19
20
AK 820 . 01S03

MMI 962
A1 8 B 6 C 4 7 3 2 A 1 9 5

F11

X 3:7
X 3:1
X 3:2
X 3:9
X 3:3
X 3:11
X 3:4
X 3:13
X 3:14
X 3:8
X 3:10
X 3:12
X 3:5
X 3:6

X4 6 5 4 3 2 1
L N T1 T2 S3 B4 X8 N L1 L2 N L1 L2 X9
X6 H11 1 2 3 1 2 3
K1 K2 M1
Single stage version and servomotor

M P
h
K2
P
P11
C1 S10 T1 B1 S11 Y1
P
K1 M Y6

SQN90 350
5. Electrical connection and operation

A2

VPS 504 S03

L N T1 T2 S3 B4
X6

L N T1 T2 S3 B4 Burner controls are safety devices! Do not open!

X6
Unauthorised intervention can have unforeseen consequences!
H2 H2
Legend
/P /P /P /P S1 Mains switch
F2 F3 h S2 F2 F3 h A1 Burner control box S2 Reset button
A2 Valve proving S10 Pressure switch for air
H1 P1 H1 P1 S11 Pressure switch for gas
B1 Flame sensor
with valve proving without valve proving T1 Ignition transformer
S1 S1 C1 Motor condensor
F1 F1 X3 Plug console
F1, F11 Fuse X4 Terminals on servomotor
F2 Temperature or pressure X6 Burner connection plug
L PE N L PE N regulator X8, X9 Gas valve train connection
230V 1 , N , PE 50/60HZ F3 Temperature or pressure plug
regulator
H1 Fault indicator lamp Y1 DMV gas valve train
H2/H11 Indicator lamp operation Y6 Servomotor

M1 Burner motor I Limit switch full load

II Limit switch Closed
P1/P11 Hour counter/imp. coun. (opt.)
 AK 820 . 01S03

MMI 962 62162/000180

A1 8 B 6 C 4 7 3 2 A 1 9 5

X 3:7
X 3:1
X 3:2
F11

X 3:9
X 3:3
X 3:11
X 3:4
X 3:13
X 3:14
X 3:8
X 3:10
X 3:12
X 3:5
X 3:6

X4 9 6 8 10 2 1 7 3
X8 N L1 L2 N L1 L2 X9
L N T1 T2 S3 B4 B1 T6 T7 T8
X6 K2 H11 1 2 3 1 2 3
X7 M1
K1 M P
/P h

S2 F4 K2
P
K2 P11
S11 Y1
Sliding two stage or modulating version

C1 S10 T1 B1

K1 M Y6

SQN90 220
P

VPS 504 S03

A2
L N T1 T2 S3 B4 L N T1 T2 S3 B4
X6 X6 Burner controls are safety devices! Do not open!
Unauthorised intervention can have unforeseen consequences!
H2 H2
P P /P /P Legend
/ / h h
F2 F3 F2 F3 A1 Burner control box S1 Mains switch
H1 P1 H1 P1 A2 Valve proving S2 Reset button
B1 Flame sensor S10 Pressure switch for air
with valve proving without valve proving C1 Motor condensor S11 Pressure switch for gas
S1 S1 F1, F11 Fuse T1 Ignition transformer
F1 F1 F2 Temperature or pressure X3 Plug console
regulator X4 Terminals on servomotor
L PE N L PE N F3 Temperature or pressure X6,X7 Burner connection plug
230V 1 , N , PE 50/60HZ regulator X8,X9 Gas valve train connection plug
F4 Temperature or pressure Y1 DMV gas valve train
regulator full load Y6 Servomotor
H1 Fault indicator lamp
H2/H11Indicator lamp operation I Limit switch full load
M1 Burner motor II Limit switch Closed
P1/P11 Hour count./imp. counter (opti.) III Auxiliary switch partial load

21
Sequence of operation Fault position indicator

A1 MMI 962
1 9 8 4 3 7 5 C 6 B 2

/P
F3
/P P
F2 S10
P
S11 B1
M M
1
S1
M1 T1 Y1 Y6 H1
F1
L N
220V 1,N 50HZ

Function diagrams:
Start with flame formation Fault position
TW indicator
Burner On White
blue
T VV red
blue
TV
T VZ
orange
Operating yellow
position TS red

green
Burner Off

Function diagram
blue pre purge
Start without flame formation Fault position
indicator:
Burner On White red air pressure-
blue
red switch check
blue
white return to
orange
yellow start position
Fault red
green programme
sequence stop
Flame failure during operation
red burner operation
Burner On White
blue
red
blue yellow safety time
Operating orange
gelb
position red
orange pre-ignition
green
Fault

Flame signal at start Function

Burner On White
Fault
The programme indicator can be read through the cover of
the control box. If a fault shutdown occurs the programme
controller stops and indicates the type of fault shutdown.
Function diagrams (air pressure switch)
On all fault shutdowns the fuel supply is immediately
Air pressure switch closed at start Fault position
interrupt. One cause of this may be a premature or non-
Burner On indicator:
White existing flame signal or the air pressure switch has
blue
red switched at the wrong moment.
Continuous
non-function
programme
run

Air pressure switch does not close

Burner On White
blue
Fault red

Air pressure switch stays open

Burner On White
blue
red
Fault blue

Solenoid connection interrupted

Burner On White
blue
red
Fault blue

Voltage present Current flow

Test phase S10 and Y1 Flame present

22
Technical data burner control MMI 962 Switching time MMI 962 Mod. 23

Operating voltage __________220V15% to 240V+10% Total cycle time of program control 80 s.

Main frequency ___________________(50 60 Hz) 50 Hz Total pre-purge time
Max pre-fuse ______________________ 10A fast, 6A slow (full load purge time) TV (TVV) 45 s
Max. contact loading ____________________________4 A (21 s)
Total loading ______________________________max. 6 A with servomotor run time 12 s.
Sensitivity of flame sensor ______________1 microampere Pre-ignition TVZ 3s
Min recommended ionisation current ____5 microamperes Safety time TS max 3 s
Max sensor line length _________________________20 m Waiting time TW 8s
Max reaction time for air
pressure switch 15 s

Sequence diagram with MMI 962 - single stage with servomotor

(I,II = switch points of servomotor Con- Nominal load pre-purge Ignition and Nominal load Con-
auxiliary switches) troller fuel release troller
ON Off
Full load
Air
Ignition position = CLOSED
Fuel control

Full load
Gas
Ignition load

yel-
white blue red blue orange low red green white
MM I 962 position indicator

Control circuit 1/9

Burner Control time
sequence diagram

Servomotor C
Burner fan (4)

Ignition 3
Fuel release 7/5

Programme sequence with MMI 962 - sliding two stage or modulating

(I,II = switch points of servomotor Con- Nominal load pre-purge Ignition and Nominal load Control-
auxiliary switches) troller fuel release ler Off
ON
Full load
Ignition position =
Air Partial load
CLOSED

Full load
Fuel control

Partial load =
ignition load
Gas

yel-
white blue red blue orange low red green white

MMI 962 position indicator

1/9
Burner Control time

Control circuit C
sequence diagram

Servomotor 6
Burner fan (4)

Ignition 3

Fuel release 7/5

23
Programme sequence single stage with servomotor

Start conditions:
power supply available
boiler limit control
boiler controller closed
burner control in start position
(white field on position indicator)

Neutral on terminal N from connection plug X6

Voltage on L via F 11 to T1, via regulator F3 to T2
from connection plug X6

Gas pressure switch S11 is activated, voltages on A1: Burner control programme cannot start
terminal 9. Via bridge plug X3:10 voltage No
on terminal 1 of burner control.

Yes
Fault shutdown at start of blue field Sensor current already present
of fault position indicator Yes Extraneous light Control faulty

No
Servomotor runs open Continual non-functioning programme run
No Air pressure switch S10 is actuated before start
Bridging plug X3:10 is missing
Yes
Fault shutdown on red line
Check voltage on terminal 3 and 1 and terminal 5 and neutral on terminal 6 of
servomotor (X4)
Check servomotor function

Limit switch I in servomotor is actuated in full Fault shutdown on red line

load position, burner motor starts No Check open signal from servomotor to terminal X4:14
voltage on terminal 4 of X4, X3:2 and X3:3 Check voltage and neutral on plug X3:3
Check motor for function check capacitor C1
Yes

Fault shutdown on red line Air pressure switch S10 not functioning
Yes Using a multi-meter check if S10 is activated after burner start
Check connection in sequence S10, Y1 (and Y1 for electrical passage)
Check air pressure switch function

No
Fault shutdown in blue field of fault position indicator
No
Servomotor is reset into the CLOSED (ignition) position
35 s after start
Yes
Ignition switches on (orange field)
the ignition spark can be heard
Yes
Solenoid valve opens (start of yellow field)
The gas pressure falls on the connected U tube manometer
Yes
Flame forms, sensor current can be measured
to an adequate value (>5 A ) after ignition has shutdown.
Reset air pressure switch to off position
Yes
Check servomotor connection on X4:2 and X4:5
No
Fault shutdown in yellow field (after safety time)
No Check primary connection of ignition transformer T1 on plug X3:4
Check ignition transformer for function
Fault shutdown in yellow field (after safety time)
No No fuel release Check solenoid valve function
Fault shutdown in yellow field (after safety time)
No No sensor current
check ionisation line and sensor electrode sensor current too low
check air and gas setting
check correct polarity of burner connection

Yes
Burner shutdown with immediate restart Gas pressure switch contact is opened by falling gas pressure
Yes check pressure switch setting
check gas filler for contamination
No
Ignition shutdown after 2 s, burner operation ignition load
position indicator in red field

After the solenoid valve has opened servomotor runs Check voltage on terminal C from control to terminal X4.5
to full load after short delay time No from servomotor
Yes
Burner shutdown with immediate restart Gas pressure switch contact is opened by falling gas pressure
Yes check pressure switch setting
check gas filter for contamination
No
Burner Operation
fault position indicator at the end of green field
24
Programme sequence two stage or modulating

Start conditions:
power supply available
boiler limit control
boiler controller closed
burner control in start position
(white field on position indicator)

Neutral on terminal N from connection plug X6

Voltage on L via F 11 to T1, via regulator F3 to T2
from connection plug X6

Gas pressure switch S11 is activated, voltages on A1: Burner control programme cannot start
terminal 9. Via bridge plug X3:10 voltage No
on terminal 1 of burner control.
Yes
Fault shutdown at start of blue field Sensor current already present
of fault position indicator Yes Extraneous light Control faulty
No
Servomotor runs open Continual non-functioning programme run
No Air pressure switch S10 is actuated before start
Bridging plug X3:10 is missing

Fault shutdown on red line

Check voltage on terminal 2 and 8 and neutral on terminal 6
of servomotor (X4)
Check servomotor function

Limit switch I in servomotor is actuated in full load Fault shutdown on red line
position, burner motor starts No Check open signal from servomotor to terminal X4:10
voltage on terminal 10 of X4, X3:2 and X3:3 Check motor for function check capacitor C1
Yes
Fault shutdown on red line Air pressure switch S10 not functioning
(25 s after start) Yes Using a multi-meter check if S10 is activated after burner start
Check connection in sequence S10, Y1 (and Y1 for electrical passage)
Check air pressure switch function

No
Fault shutdown in blue field of fault position indicator Reset air pressure switch to off position
Yes
No
Servomotor is reset into the partial load (ignition) position Check servomotor connection on X4:7
No switch III should be set to partial load setting
Yes
Ignition switches on (orange field) Fault shutdown in yellow field (after safety time)
ignition spark is audible No Check primary connection of ignition transformer T1 on plug X3:4
Check ignition transformer for function
Yes
Solenoid valve opens at start of yellow field Fault shutdown in yellow field (after safety time)
The gas pressure falls on the connected U tube manometer No No fuel release Check solenoid valve function
Yes
Flame forms, sensor current can be measured Fault shutdown in yellow field (after safety time)
to an adequate value (>5 A ) after ignition has shutdown. No No sensor current
check ionisation line and sensor electrode
sensor current too low
check air and gas setting
check correct polarity of burner connection
Yes
Burner shutdown with immediate restart Gas pressure switch contact is opened by falling gas pressure
Yes check pressure switch setting
check gas filter for contamination
No
Ignition switches off, burner operation partial load
position indicator in red field

Servomotor regulation of stage 2 is released after a short delay time

Servomotor runs to full load when stage 2 is requested. Check voltage on terminal 6 from the motor to terminal rail X4:9
No Plug X7:T6/T8 and X4:1 of servomotor
Check connection and function of stage 2 regulator
(T6-T8 servomotor open - T6T7 servomotor closed)
Yes
Burner shutdown with immediate restart Gas pressure switch contact is opened by falling gas pressure
Yes check pressure switch setting
No check gas filter for contamination

Burner Operation
fault position indicator at the end of green field

25
6. Cause and rectification of faults
If faults occur the basic requirements for correct operation
must first be examined

1. Check the electric supply

2. Check that the gas supply is correct and that manual valves are open
3. Check that all controls e.g. thermostats, pressure switches, water level
interlocks, limit and time switches are correctly set
4. Ensure that the burner air or gas settings have not been altered

When it is established that the fault is not due to external conditions,

the burners must be tested.

Reset the burner lockout and switch on burner. By careful observation of the
sequence of operations the cause can be recognised and remedied.
The use of a micrometer as an instrument to measure the flame sensor signal is
essential.

Condition Cause Remedy

General faults

Burner motor does not start No electric supply Close circuit

Reset safety limit control

Fuse faulty Replace

Neutral circuit open Repair

Motor faulty Replace

Capacity faulty Replace

Control circuit open look for contact break, switch on or reset

regulator or detector

Gas supply interrupted isolating Open isolating valve inform gas authority
valve closed if no gas for a prolonged period

Burner control faulty Replace

Lack of air

Burner motor starts, after Air pressure switch faulty Replace

or during pre-purge lockout
occurs

Pressure tube faulty Replace

Pressure switch contact drops Set air pressure correctly

(air pressure too low) If necessary replace

Fan dirty Clean

26
Condition Cause Remedy

No ignition

Burner motor starts. voltage Ignition electrode gas too wide Adjust
on plug X3:4 (burner control)

No ignition after a short Ignition electrodes of ignition line Correct earth fault replace damaged
time lockout occurs have earth fault, insulator faulty electrodes or cables

Ignition transformer faulty Replace ignition transformer

Shortage of gas

Motor starts, ignition is in order, Solenoid valves do not open, as Replace solenoid valve and correct
after short time lock-out occurs solenoid valve is faulty or cables interruption to supply
(check voltage to interruptedterminal 5)

Burner motor starts, ignition Gas pressure drop when solenoid Clean insert or replace
in order, after a short time valve opens due to blocked filter
shutdown occurs (no fault)

Flame monitoring fault

Ionisation monitoring

Burner motor starts, ignition Ignition affects ionisation current Change phase and neutral on ignition
is audible, normal flame too much transformer primary side
establishment then fault shutdown Reduce spark gap

Ionisation current fluctuates, too low Alter position of ionisation electrode,

correct possible high resistance in
ionisation line and terminals (tighten
terminals)

Ionisation current not present or For main which are not earthed
too low the pole used earth must earthed

Gas/air mixture setting not correct Re-adjust (see commissioning)

27
Weishaupt products Max Weishaupt GmbH, D-88475 Schwendi
Tel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58
Print No. 458 GB, October 99

and service Printed in Germany. All rights reserved

Oil, gas and dual fuel burners types W and WG/WGL

up to 570 kW
They are used mainly in houses and small buildings.
Advantages: fully automatic, reliable operation, individual
components easily accessible, easy to service, quiet operation.

Oil, gas and dual fuel burners types Monarch

R, G, GL, RGL up to 10.900 kW
These are used on all types and sizes of central heating
plant. The basic model which has proved successful over
many years is the basis for a variety of versions. These
burners have founded the outstanding reputation of
Weishaupt products.

Oil, gas and dual fuel burners types WK

up to 17.500 kW
WK types are decidedly industrial burners.
Advantages: Built to the modular system, load dependent
variable combustion head, sliding two stage or modulating
operation, easy to service.

Weishaupt control panels, the proven complement to

Weishaupt burners
Weishaupt burners and Weishaupt control panels form
the ideal unit, a combination which has already proved
successful in hundreds of thousands of combustion
installations. The advantages: Cost saving during planning,
installation, servicing and guarantee work. The responsibility
belongs to one manufacturer.

Weishaupt Thermo Unit / Weishaupt Thermo Gas.

These Units combine the technical innovations and operating
efficiencies developed from over 1 million installations.
Weishaupt Thermo Gas and Weishaupt Thermo Unit
provide the ideals of complete heating centres for houses
and appartments.

Product and service are the complete

Weishaupt achievement
An extensive service organisation guarantees Weishaupt
customers the greatest possible reliability. In addition
our customers are looked after by heating firms who have
been working with Weishaupt for many years.