Weishaupt W-ZG 02 Ignition Transformer

Weishaupt W-ZG 02 High-Voltage Ignition Transformer Unit

The Weishaupt W-ZG 02 (also designated under OEM references 603226, 603203, and Beru/Termal 507 02 22 01) is a heavy-duty, continuous-duty rated (100% ED) electronic ignition transformer. Engineered specifically for forced-draft gas, light oil, heavy fuel oil (HFO), and dual-fuel industrial and marine combustion systems, the W-ZG 02 delivers stable mid-point grounded high-voltage discharge across dual ignition electrodes.

Designed to withstand rigorous marine boiler operating profiles, high ambient vibration, and severe thermal cycles up to 60°C ambient, the W-ZG 02 converts single-phase 230V AC line power into a 2 × 9 kV peak (18 KV differential) breakdown potential at a continuous 20 mA RMS secondary current. This ensures rapid, flicker-free arc generation capable of vaporizing and igniting atomized fuel oil or gaseous fuel-air mixtures under pressurized combustion chamber conditions.

Model Details

• Primary Manufacturer Part Numbers:
  • 603203 (Standard 230V, 50/60Hz)
  • 603226 (Latest 230V revision with upgraded suppression)
  • 603204 / 603184 / 603185 (110V / 120V US/Marine Grid models)
• OEM / Factory Reference: BERU 507 02 22 01, BERU 0 040 401 022
• Direct Legacy Replacements: Replaces legacy units 603196, 603184, 603139, 603137, and 603203.

Key Features

1. Continuous-Duty Cycle (100% ED @ 60°C): Engineered for full 100% duty cycle rating up to 60°C ambient, preventing thermal cut-out during repeated purge-and-relight sequences.
2. High-Output Discharge (2 × 9 kVp): Delivers an 18 KV peak arc potential across symmetrical secondary poles with a 20 mA RMS short-circuit current to penetrate high-pressure combustion heads.
3. Solid-State Encapsulation: Vacuum-potted in thermoset polyurethane resin inside an impact-resistant polybutylene terephthalate (PBT) enclosure, delivering IP40 protection, dielectric breakdown immunity, and vibration damping.
4. Integrated Secondary EMC Suppression: Features built-in low-noise attenuation circuitry to protect microprocessor-based burner management controllers (e.g., Weishaupt W-FM 50, W-FM 100, W-FM 200) from back-EMF spikes.
5. Standard 4 mm Terminal Integration: Symmetrical high-voltage pin connections designed for 4 mm brass connector plugs (BERU C6 / C6/A SAE fittings) ensure rapid field swap-outs without rewiring.

Applications

• Marine Auxiliary & Exhaust Boilers: Heavy fuel oil and marine gas oil (MGO) ignition for Alfa Laval Aalborg and KangRim steam plants aboard commercial cargo, container, and tanker vessels.
• Offshore Rig Firing Systems: Inert gas generators, deck thermal oil heaters, and offshore marine waste incinerator units requiring certified ignition sources.
• Industrial Steam & Hot Water Generation: Food processing boilers, district heating networks, and pharmaceutical clean-steam generation systems running continuous shifts.
• Process Combustion & Rotary Kilns: Asphalt plants, drying ovens, paint curing booths, and high-temperature thermal oxidizers.

Frequently Asked Questions

What is the primary difference between the Weishaupt W-ZG 01 and W-ZG 02?

The W-ZG 01 is an intermittent-rated ignition device (typically 33% ED over 3 minutes), whereas the W-ZG 02 is a 100% ED continuous-rated unit. The W-ZG 02 provides superior arc stability and higher thermal limits making it the mandatory standard for heavy oil systems, modulating burners, and automated marine steam plants.

Why does my burner suffer flame lockout immediately following the ignition cycle?

If the ignition arc creates electromagnetic interference, it can disrupt the flame sensor signal (flame rod ionization or UV/photocell input) sent to the burner management controller (W-FM relay). Verify that the primary protective earth (PE) lead is tightly bonded to the burner chassis, that ignition cables do not run parallel to flame sensor wiring, and that the electrode gap does not exceed 4.0 mm.

Does the secondary output polarity matter when connecting the two ignition electrodes?

No. The W-ZG 02 secondary stage produces a symmetrical, center-grounded alternating high-voltage output 2 9 kVp. The spark discharges across the differential between the two electrodes regardless of which 4 mm socket connects to the left or right electrode plug.