Weishaupt WL30Z-C Manual Download

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Installation and operating instruction

Oil burner WL30Z-C

83297902 3/2019-11

Summary of Contents for WL30Z-C

Page 1: ...Installation and operating instruction Oil burner WL30Z C 83297902 3 2019 11 ...

Page 2: ...l number 9 3 3 Function 10 3 3 1 Air supply 10 3 3 2 Oil supply 11 3 3 3 Electrical components 12 3 3 4 Program sequence 12 3 3 5 Inputs and outputs 14 3 4 Technical data 15 3 4 1 Approval data 15 3 4 2 Electrical data 15 3 4 3 Ambient conditions 15 3 4 4 Fuels 15 3 4 5 Emissions 16 3 4 6 Rating 17 3 4 7 Dimensions 18 3 4 8 Weight 18 4 Installation 19 4 1 Installation conditions 19 4 2 Selecting t...

Page 3: ...e burner 63 9 4 Replace nozzles 64 9 5 Set ignition electrodes 65 9 6 Removing the mixing head 66 9 7 Set mixing head 67 9 8 Service position 68 9 9 Removing and refitting oil pump 69 9 10 Removing and refitting fan wheel 70 9 11 Remove burner motor 70 9 12 Removing and refitting oil pump filter 71 9 13 Removing and refitting air damper actuator 72 9 14 Removing and refitting angle drive 73 9 15 R...

Page 4: ...g instruction Oil burner WL30Z C 83297902 3 2019 11 La 4 112 12 Project planning 88 12 1 Oil supply 88 12 2 Continuous running fan or post purge 90 12 3 Additional requirements 91 13 Spares 92 14 Notes 106 15 Key word index 108 ...

Page 5: ...arried out by personnel who have the relevant train ing and instruction Persons with limited physical sensory or mental capabilities may only work on the unit if they are supervised or have been trained by an authorised person Children must not play with the unit 1 2 Symbols DANGER Immediate danger with high risk Non observance can lead to serious injury or death WARNING Danger with medium risk No...

Page 6: ...servance of the manual operation with faulty safety equipment continual operation despite a fault improper installation commissioning operation and service repairs which have been carried out incorrectly the use of non original Weishaupt parts force majeure unauthorised modifications made to the unit the installation of additional components which have not been tested with the unit the installatio...

Page 7: ...assets 2 2 Safety measures Safety relevant fault conditions must be eliminated immediately Components which show increased wear and tear or whose design lifespan is or will be exceeded prior to the next service should be replaced as a precaution The design lifespan of the components is listed in the service plan ch 9 2 2 2 1 Personal protective equipment PPE Use the necessary personal protective e...

Page 8: ...erts which hinder flame burnout Use only original Weishaupt replacement parts 2 4 Noise emission The noise emissions are determined by the acoustic behaviour of all components fitted to the combustion system Prolonged exposure to high noise levels can lead to loss of hearing Provide oper ating personnel with protective equipment Noise emissions can further be reduced with a sound attenuator 2 5 Di...

Page 9: ... 9 112 3 Product description 3 1 Type key WL30Z C Type W Series Compact burner L Fuel Oil EL 30 Size Z Type of control two stage C Construction 3 2 Serial number The serial number on the name plate identifies the product This is required by Weishaupt s customer service department 1 1 Name plate Ser No ...

Page 10: ...air dampers close automatically Fan wheel The fan wheel supplies the air from the air intake housing to the combustion head Diffuser The air gap between flame tube and diffuser is adjusted by positioning the diffuser This adjusts the mixing pressure and the air quantity required for combustion Air pressure switch optional Depending on the burner application optional equipment may be required for o...

Page 11: ...Minimum oil pressure switch optional Depending on the burner application optional equipment may be required for op timum operation ch 12 3 The minimum oil pressure switch monitors the pump pressure in the supply If the preset pressure is not achieved the combustion manager initiates a lockout Sequence diagram Standard Continuous operation with oil pressure switch P 1 2 3 7 4 5 1 2 3 4 5 1 3 2 6 4 ...

Page 12: ...the burner are shown on the display Phase Function TEST After the power supply has been switched on the combustion manager performs a self test L At heat demand the air damper actuator drives to the reference point 1 The combustion manager monitors for extraneous light 2 The air damper actuator drives to pre purge to air damper setting stage 2 operating point P9 3 Ignition and pre purge is initiat...

Page 13: ...ing point P1 stage 1 B16 Temperature or pressure regulator stage 2 3 Operating point P2 solenoid valve stage 2 F2 Temperature or pressure limiter 4 Operating point P9 stage 2 K11 Stage 1 solenoid valve 5 Operating phase K13 Stage 2 solenoid valve TI Initialisation time Test 3 s M1 Burner motor TN Post purge time 2 ch 6 2 3 M20 Air damper actuator TS Safety time 3 s P11 Control lamp operation optio...

Page 14: ...Slot for analogue module EM3 3 or fieldbus module EM3 2 2 W FM cover 1 Stage 1 solenoid valve K11 3C Burner motor or frequency converter for continuous running fan voltage supply flame sensor LFS1 continuous operation 3N Burner motor or frequency converter 4 Ignition unit 5 not used 6 Stage 2 solenoid valve K13 7 Bridging plug No 7 8 Oil meter impulse generator 11 Air pressure switch 12 Oil pressu...

Page 15: ...on max 450 W Power consumption max 3 1 A Internal unit fuse T6 3H IEC 127 2 5 External fuse max 16 AB 3 4 3 Ambient conditions Temperature in operation 10 1 40 C Temperature during transport storage 20 70 C relative humidity max 80 no dew point Installation elevation max 2000 m 2 1 With the relevant suitable fuel oil and layout of oil supply 2 Consultation with Weishaupt is required for higher ins...

Page 16: ...stion chamber dimensions see Weishaupt Partner Portal Documents and Applications Online Applications NOX calculation for burners Sound levels Dual number noise emission values Measured sound power level LWA re 1 pW Uncertainty value KWA 76 4 dB A 1 dB A Measured sound pressure level LpA re 20 μPa Uncertainty value KpA 72 4 dB A 2 dB A 1 Determined to ISO 9614 2 2 Determined at 1 metre distance fro...

Page 17: ... 9 kWh kg for fuel oil EL Capacity graph Capacity graph to EN 267 The capacity data given relates to an installation elevation of 500 m above sea level For installation elevations above 500 m a capacity reduction of approx 1 per 100 m applies A limited capacity graph is valid for ducted air intake 10 12 5 15 17 5 20 22 5 25 27 5 7 5 5 2 3 50 75 100 125 150 175 200 225 250 275 300 325 350 1 0 1 2 3...

Page 18: ...12 3 4 7 Dimensions Burner 420 mm 480 mm 460 mm 127 mm 342 mm 62 mm 226 mm 620 mm 460 mm 5 1 0 m m 158 1 1 169 mm without combustion head extension 269 mm with combustion head extension 100 mm 369 mm with combustion head extension 200 mm 469 mm with combustion head extension 300 mm 3 4 8 Weight approx 28 kg ...

Page 19: ...ond the front edge of the combustion head The refractory can take a conical shape min 60 Refractory may not be required on boilers with water cooled front unless the man ufacturer gives other instructions Following installation the aperture 4 between flame tube and refractory should be filled with flame proof resilient insulating material Do not make solid Heat exchangers with deep refractories or...

Page 20: ... gas temperature boiler chimney observe heat demand observe start behaviour of burner Typical distribution of load a different distribution may be required Nozzle 1 55 Nozzle 2 45 Example Burner capacity required approx 250 kW 55 of burner capacity required 250 kW 0 55 137 5 KW 45 of burner capacity required 250 kW 0 45 112 5 kW Nozzle size at 12 bar see nozzle selection table Nozzle 1 135 7 kW 2 ...

Page 21: ...2 4 54 7 57 1 58 3 1 25 55 9 59 5 61 9 64 3 66 6 1 35 60 7 64 3 66 6 69 0 72 6 1 50 67 8 71 4 73 8 77 4 79 7 1 65 75 0 78 5 82 1 85 7 88 1 1 75 78 5 83 3 86 9 90 4 94 0 2 00 90 4 95 2 98 8 102 3 107 1 2 25 101 2 107 1 111 9 116 6 120 2 2 50 113 1 119 0 123 8 128 5 133 3 2 75 123 8 130 9 135 7 141 6 146 4 3 00 135 7 142 8 148 8 154 7 159 5 3 50 158 3 165 4 173 7 180 9 186 8 4 00 180 9 189 2 198 7 2...

Page 22: ...ires conversion measures ch 4 3 1 Fit flange gasket 5 and burner flange 3 to the boiler using screws The aperture between combustion head and refractory should be filled with flame proof resilient insulating material Do not make solid Unplug ignition cables 6 Undo screw 2 and remove diffuser Fit nozzles ch 9 4 Re fit diffuser and ignition cables Set ignition electrodes ch 9 5 Check nozzle distance...

Page 23: ...hose 6 Remove oil pump 7 and install rotated clockwise by 90 ch 9 9 Remove mixing head 4 see ch 9 6 Remove ignition cable 5 including grommet and guide it through the cable grommet opposite on the cover Close open cable grommet with shut off grommet Fit mixing head rotated by 180 Connect pressure hose Wedge profile flange gasket required Order No 240 310 00 047 Rotate burner flange 2 180 and mount...

Page 24: ...max 2 bar 1 Supply temperature max 60 C 1 1 Measured at the pump Check conditions for oil hoses Length 1200 mm Oil hose connection G Nominal pressure 10 bar Thermal load max 100 C Connect oil supply CAUTION Damage to the oil pump caused by incorrect connection Mixing up supply and return can damage the oil pump Ensure correct connection of oil hoses to the supply and return of the pump Fit oil hos...

Page 25: ...tension consider length of hose required for the service position do not kink oil hoses curve radius 1 of 75 mm must be maintained If these conditions for connection can not be met Adapt oil supply on site 1 Purge oil supply and ensure it is tight CAUTION Oil pump seized due to running dry Pump could be damaged Fill oil supply with oil and purge Ensure oil supply is tight ...

Page 26: ...converter It is possible that electrical components continue to carry voltage and cause elec tric shock even after the voltage supply has been disconnected Wait approx 5 minutes before commencing work Electric voltage has dissipated The electrical connection must only be carried out by qualified electricians Ob serve local regulations Observe wiring diagram supplied Check polarity and wiring of 7 ...

Page 27: ...ation 83297902 3 2019 11 La 27 112 Separate supply line for burner motor not with variable speed drive Observe wiring diagram supplied Plug supply line for burner motor into connection plug 1 of the contactor 1 External fuse of separate supply line min 10 AT max 16 AT ...

Page 28: ...able speed drive Various actions are only triggered when the key is released for example changing the display reset OFF function Press ENTER L A and G keys simultaneously Immediate lockout with error 18h Operating level The current air damper setting and or the fan speed can be displayed in the operat ing level 10 Displaying air damper setting Press key L A Displaying fan speed only in conjunction...

Page 29: ...to operating display The display shows cur rent operating status with a number Back to standard display Press and hold and simultaneously for approx 3 seconds VisionBox Software optional If the VisionBox Software is connected change over to the access level must be confirmed via the operating panel Press Software changes to the access level Flame sensor LFS1 optional Only in conjunction with conti...

Page 30: ... runs CLOSED 5 Actuator runs OPEN 6 Burner in operation 7 Lockout 8 Service level activated Combustion manager performs self test ch 3 3 4 Standby no heat demand Shutdown via contact X3 7 plug No 7 Unprogrammed condition or programming not completed Standby no heat demand shutdown via fieldbus module Current operating phase ch 3 3 4 Under voltage in standby or internal device error see error memor...

Page 31: ...taneously for approx 2 seconds 1 Hours run stage 1 2 Hours run stage 2 3 Burner starts 4 Device item number 5 Index of device item number 6 Device number 7 Production date DDMMYY 8 Fieldbus address 10 Oil pressure switch function 11 Current fan speed only in conjunction with variable speed drive Display of standardised speed Press key L A 12 Current oil consumption 0 1 l h 13 Analogue module EM3 3...

Page 32: ... point P1 2 Actuator position in operating point P2 switch off point stage 2 when running closed 3 Actuator position in operating point P3 switch on point stage 2 when running open 9 Actuator position in operating point P9 10 18 Fault memory most recent fault ninth last occurred fault Display additional information 1 Detailed error codes operating status Press key 2 Detailed error codes Press and ...

Page 33: ... module used Setting range of parameters see installation and operating manual of module Fieldbus module response to heat demand 2 Bus default and control circuit T1 T2 activated Analogue module 2 DIP switches activated 2 4 Post purge time 0 4095 s 2 5 Fault memory 0 fault memory is empty 1 fault memory contains data Delete fault memory Press L A and simultaneously for approx 2 seconds 6 Factor fo...

Page 34: ...s Enter and L A simultaneously and press or 50 0 L Load shutdown 0 0 4095 seconds If there is no longer a demand for heat the W FM reduces the burner capacity and closes the fuel valves after the time set has elapsed If partial load is reached before the time has elapsed the fuel valves close immediately 0 o Operating mode O2 trim only in conjunction with O2 trim 0 not activated Additional paramet...

Page 35: ...r Press to reach the next parameter Parameters Information Setting range E0 Burner type 0 single fuel burner 1 dual fue burner E1 Operating mode display only no adjust ment possible 0 intermittent operation 1 continuous operation E2 Flame sensor type 0 ionisation electrode or flame sensor FLW 1 switch input X3 14 flame sensor LFS1 RAR9 2 flame sensor QRB4 E3 Fan configuration 0 Off 1 fan control 2...

Page 36: ...illed the heat exchanger is filled with medium the regulating control and safety devices are functioning and set correctly the flue gas ducts are unimpeded a measuring point conforming to standards is available to measure the flue gas the heat exchanger and flue gas ducting up to the test point are sound ex traneous air influences the test results the operating instructions of the heat exchanger a...

Page 37: ...ure measuring devices on oil pump Vacuum gauge for suction resistance supply pressure Pressure gauge for pump pressure WARNING Oil leakage from oil pressure measuring devices due to constant load Oil pressure measuring devices could be damaged and cause environmental pollu tion through leakage Remove oil measuring devices once commissioning is complete Close fuel shut off devices Remove closing pl...

Page 38: ...902 3 2019 11 La 38 112 Measuring device for sensor current continuous operation only Disconnect plug coupling on flame sensor LFS1 Connect current measuring device 1 in series Flame signal flame sensor LFS1 RAR9 Extraneous light detection from 6 5 μA Minimum flame signal 13 μA 1 ...

Page 39: ...g 83297902 3 2019 11 La 39 112 7 1 2 Set minimum oil pressure switch optional Depending on the burner application optional equipment may be required for op timum operation ch 12 3 Remove end cap Set minimum oil pressure switch to 8 bar using the setting screw Refit end cap ...

Page 40: ...fuser setting dimension X and air damper setting required from the diagram and note down Example Burner capacity stage 2 stage 1 required 250 kW 137 5 kW Diffuser setting dimension X 16 2 mm Air damper setting stage 2 stage 1 65 28 Diffuser default settings 2 1 10 12 14 16 18 20 22 24 8 6 4 50 75 100 125 150 225 175 250 275 300 325 350 200 1 Combustion heat rating kW 2 Diffuser settings dimension ...

Page 41: ...w 1 until dimension X equals the value determined X 1 Determine mixing pressure Determine the mixing pressure required for the preset combustion heat rating from the diagram and note down 2 1 3 4 5 6 7 8 9 10 11 100 50 75 125 175 225 275 325 150 200 250 300 350 4 3 2 1 1 Combustion heat rating kW 2 Mixing pressure mbar 3 Stage 1 4 Stage 2 Guide values which could vary depend on comb chamber resist...

Page 42: ...ck suction resistance or flow pressure of oil pump ch 5 1 mixing pressure ch 7 1 1 1 Preset combustion manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply Combustion manager drives to Standby Press G and L A keys simultaneously Combustion manager changes to access level Press key Combustion manager changes into the setting level for step points Preset P9 Press key Fact...

Page 43: ...int P0 ignition position is displayed Press and hold L A key and set the same values as for P1 using the or key Preset P2 and P3 Press key Factory setting operating point P2 switch off point stage 2 when running closed is displayed Press and hold L A key and set P2 approx 3 8 above P1 using the or key Press key Factory setting operating point P3 switch on point stage 2 when running open is display...

Page 44: ...etting level Plug in bridging plug No 7 on combustion manager Burner starts in accordance with program sequence and stops in operating point P0 ignition position Set pump pressure The pump pressure must be set according to the nozzle selected ch 4 2 Check pump pressure at pressure gauge Set pressure using pressure regulating screw 1 increase pressure clockwise rotation decrease pressure anticlockw...

Page 45: ...mbustion values Determine combustion limit ch 7 5 Set excess air via air damper setting L A Adjust P0 Press key Burner drives to operating point P0 ignition position Press and hold L A key and set P0 to the same value as P1 using the or key Check mixing pressure The mixing pressure in ignition position must be between 2 0 4 5 mbar If necessary adjust mixing pressure via air damper setting L A Pres...

Page 46: ...nning closed P2 to approx 1 3 of the setting movement between P1 and P9 Formula P2 P9 P1 0 33 P1 Press and hold L A key and set P2 using or key Press key Switch on point stage 2 when running open P3 is displayed Press and hold L A key and set the same values as for P2 using the or key Press G and L A keys simultaneously Combustion manager changes to operating level 10 depending on heat de mand sta...

Page 47: ... restart burner Check start behaviour Check on and off switch point stage 2 excess air phase CO content prior to switch over must not be too long flame must not fail If necessary correct ignition position P0 If necessary correct switch on point P3 and switch off point P2 If the existing settings have been changed re check start behaviour and on and off switch points ...

Page 48: ...mp ch 5 1 mixing pressure ch 7 1 1 1 Preset combustion manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply Combustion manager drives to Standby Press G and L A keys simultaneously Combustion manager changes to access level Press key Combustion manager changes into the setting level for step points Preset P9 Press key Factory setting operating point P9 stage 2 is displa...

Page 49: ...old L A key and set air damper setting determined using the or key ch 7 1 3 Press Enter and L A simultaneously Factory setting fan speed 100 is displayed Preset P0 Press key Factory setting operating point P0 ignition position is displayed Press and hold L A key and set the same values as for P1 using the or key Press Enter and L A simultaneously Factory setting fan speed 100 is displayed ...

Page 50: ...nd hold L A key and set P2 approx 3 8 above P1 using the or key Press Enter and L A simultaneously Factory setting fan speed 100 is displayed Press key Factory setting operating point P3 switch on point stage 2 when running open is displayed Press and hold L A key and set the same values as for P2 using the or key Press Enter and L A simultaneously Factory setting fan speed 100 is displayed Press ...

Page 51: ...ss key Combustion manager changes to setting level Plug in bridging plug No 7 on combustion manager Burner starts Speed standardisation starts Press key within 20 seconds Speed standardisation is carried out U and the current fan speed are displayed Wait approx 5 seconds until the fan speed has stabilised Press key within 15 seconds Speed standardisation is complete Burner starts in accordance wit...

Page 52: ...ure regulating screw 1 increase pressure clockwise rotation decrease pressure anticlockwise rotation 1 Press key Burner drives to operating point P1 Press key Burner drives to operating point P9 Adjust P9 Select speed at full load as low as possible but not less than 80 In doing so observe flame stability maintain mixing pressure required ch 7 1 3 Check combustion values Determine combustion limit...

Page 53: ...ly reduce speed using L A and ENTER key whilst opening air damper setting alternately using the L A key Check combustion values Determine combustion limit ch 7 5 Set excess air via air damper setting L A Adjust P0 The ignition speed should be 100 Press key Burner drives to operating point P0 ignition position Check mixing pressure The mixing pressure in ignition position must be between 2 0 4 5 mb...

Page 54: ...2 when running open P3 is displayed Press and hold L A key and set the same values as for P2 using the or key Press G and L A keys simultaneously Combustion manager changes to operating level 10 depending on heat de mand stage 1 or stage 2 is displayed 3 Check start behaviour and on off switch points Switch off and restart burner Check start behaviour Check on and off switch point stage 2 excess a...

Page 55: ...ement Start the burner Carry out differential pressure measurement across the whole capacity range of the burner and determine the lowest differential pressure Calculate switch point 80 of release pressure or lowest differential pressure Set the switch point determined at the setting cam 1 Example Lowest differential pressure 6 3 mbar Switch point air pressure switch 80 6 3 mbar 0 8 5 0 mbar Site ...

Page 56: ... test sheet Enter setting values on the sticker 1 supplied Adhere sticker to the burner Mount cover on burner Inform the operator about the use of the equipment Hand the installation and operating manual to the operator and inform him that this should be kept with the appliance Point out to operator that the installation should be serviced annually B re n n e re in s te ll u n g e n D a tu m M a ß...

Page 57: ...flue gas temperature Check flue gas temperature Ensure that the flue gas temperature complies with the data provided by the boiler manufacturer If necessary adjust flue gas temperature e g Increase burner capacity in partial load to avoid condensation in the flue gas ducts except on condensing units Reduce burner capacity in full load to improve efficiency Adjust heat exchanger to the data provide...

Page 58: ...nager Combustion manager drives to Standby Briefly press and simultaneously Combustion manager changes to access level Press Combustion manager changes to setting level Plug in bridging plug No 7 on combustion manager Burner starts and stops in operating point P0 ignition position Initiate the other operating points using the or key and optimise if required Exit setting level Press G and L A simul...

Page 59: ...Installation and operating instruction Oil burner WL30Z C 8 Shutdown 83297902 3 2019 11 La 59 112 8 Shutdown For breaks in operation Switch off burner Close fuel shut off devices ...

Page 60: ...vicing must only be carried out by qualified personnel The combustion plant should be serviced annually Depending on site conditions more frequent checks may be required Components which show increased wear and tear or whose design lifespan is or will be exceeded prior to the next service should be replaced as a precaution The design lifespan of the components is listed in the service plan ch 9 2 ...

Page 61: ...uch ignition device during the ignition process Check tightness of oil carrying components Check function of ignition flame monitoring oil pump pump pressure and suction resistance control and safety devices Check combustion values if necessary re adjust the burner Enter combustion values and settings in the commissioning record Enter setting values on the sticker supplied Adhere sticker to the bu...

Page 62: ...0 burner starts or 10 years 2 Replace Flame sensor LFS1 250 000 burner starts or 10 years 2 Replace Flame tube diffuser Soiling Clean Damage Replace Oil nozzle Soiling wear Replace Recommendation at least every 2 years Oil pump filter Soiling Replace Oil hose Damage oil escaping Replace Recommendation every 5 years Pressure hose nozzle assembly Damage oil escaping 5 years Replace Oil solenoid valv...

Page 63: ...vicing 83297902 3 2019 11 La 63 112 9 3 Hinge open the burner Observe notes on servicing ch 9 1 Without combustion head extension Remove screws 1 Hinge open the burner With combustion head extension Remove mixing head ch 9 6 Remove screws 1 Hinge open the burner 1 ...

Page 64: ...zzles always fit new nozzles Hinge open the burner ch 9 3 Unplug ignition cable 5 Undo screw 4 and remove diffuser Counter hold on the nozzle assembly 3 using a spanner and remove the nozzles Fit new nozzle ensuring it is seated tightly Refit diffuser in reverse order Set nozzle distance ch 9 7 Set ignition electrodes ch 9 5 1 2 4 3 5 1 Stage 1 nozzle 2 Stage 2 nozzle ...

Page 65: ...9 5 Set ignition electrodes Observe notes on servicing ch 9 1 The ignition electrodes must not touch the nozzle s atomising cone Hinge open the burner ch 9 3 Check distance of ignition electrodes If necessary adjust ignition electrodes by slightly bending 2 0 3 0 mm 2 0 mm 2 0 m m 1 1 Stage 1 nozzle ...

Page 66: ...1 La 66 112 9 6 Removing the mixing head Observe notes on servicing ch 9 1 Remove flame sensor QRB4 5 or flame sensor RAR9 optional Remove solenoid valve plug 1 Unplug ignition cable 2 Remove pressure hose 4 Undo screws 3 Turn mixing head to the left up to the recess and remove 1 2 5 4 3 ...

Page 67: ...en screw 1 A 5 6 mm 2 1 Check basic setting Dimension S1 can only be checked when the burner is mounted to a boiler door which is hinged open Hinge open boiler door or if necessary remove mixing head ch 9 6 Turn setting screw 1 until the indicating bolt 2 is flush with the nozzle as sembly cover dimension X 0 mm Check dimension S1 and or dimension Lx Set dimension S1 and or dimension Lx using sett...

Page 68: ...019 11 La 68 112 9 8 Service position Observe notes on servicing ch 9 1 Remove mixing head ch 9 6 Unplug plug 4 from ignition unit Remove cover 2 and remove plugs Remove support 3 for oil hoses Hold housing cover and remove screws 1 Place housing cover onto hanging bolts 5 1 2 3 4 5 ...

Page 69: ...emove oil hoses 5 and pressure hose 4 Undo screws 2 and remove oil pump Refitting Install oil pump in reverse order and ensure correct alignment of coupling 3 ensure correct allocation of flow and return of the oil hoses CAUTION Damage to the oil pump caused by incorrect connection Mixing up supply and return can damage the oil pump Ensure correct connection of oil hoses to the supply and return o...

Page 70: ...it fan wheel in reverse order and ensure correct alignment of the spring washer 2 screw in new grub screw 1 turn fan wheel to ensure it moves freely 1 2 1 2 9 11 Remove burner motor Observe notes on servicing ch 9 1 Remove the oil pump ch 9 9 Remove fan wheel ch 9 10 Unplug plug 1 Hold motor and remove screws 2 Remove motor Only in conjunction with variable speed drive The variable speed drive sen...

Page 71: ... 3 2019 11 La 71 112 9 12 Removing and refitting oil pump filter Observe notes on servicing ch 9 1 Removing Close fuel shut off devices Remove bolts 1 Remove pump cover Replace filter 3 and gasket 2 2 3 1 Refitting Refit filter in reverse order ensuring sealing surfaces are clean ...

Page 72: ... the actuator caused by turning the hub Actuator could be damaged Do not turn hub manually or with tool Plug in actuator plug 4 at the combustion manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply The combustion manager checks the actuator and drives to the reference point Interrupt voltage supply Fit shaft 2 to actuator Set indicator 1 on angle drive to 0 air damper ...

Page 73: ...3 2019 11 La 73 112 9 14 Removing and refitting angle drive Observe notes on servicing ch 9 1 Removing Remove air damper actuator ch 9 13 Remove screws 2 Remove angle drive Refitting Turn shaft 1 to its stop air damper Open and hold Fit angle drive to shaft Secure angle drive 1 2 ...

Page 74: ...n manager Unplug bridging plug No 7 on combustion manager Switch on voltage supply The unprogrammed condition of the combustion manager is indicated by a flash ing display The burner goes to lockout Press ENTER Burner has been reset Combustion manager drives to Standby If an oil pressure switch is fitted set parameter 7 and 8 to 1 see ch 6 2 3 If an air pressure switch is fitted set parameter 8 to...

Page 75: ...rmittent operation Standard 1 continuous operation Press E2 is displayed Set value using Enter and 1 switch input X3 14 flame sensor LFS1 RAR9 2 flame sensor QRB4 Press E3 is displayed If required set value using ENTER and keys 1 fan control burner without variable speed drive 3 variable speed drive burner with variable speed drive Press E4 is displayed Adopt value 0 no ignition delay if necessary...

Page 76: ...P 9 Te ch nik er Öl be tri eb Pu nk t L A n P0 P1 P2 P3 P9 Brennereinstellungen Datum Maß X mm Öldruck Großlast bar Voreinstellung Luftklappe bei Großlast P9 Techniker Ölbetrieb Punkt L A n P0 P1 P2 P3 P9 1 Deactivate E Parameters Following commissioning set parameter E to 0 Press Enter and keys simultaneously for approx 2 seconds The parameter level is activated Press Press Enter key until parame...

Page 77: ...Observe notes on servicing ch 9 1 Unplug connection plug from combustion manager Replace fuse T6 3H IEC 127 2 5 1 1 Replacement fuse 9 17 Set flame senor RAR9 optional Only in conjunction with continuous operation Observe notes on servicing ch 9 1 Remove flame sensor Undo screw 1 Set flame sensor 2 Tighten screw 1 1 2 95 mm ...

Page 78: ...witch Temperature limiter or pressure limiter on heat exchanger has triggered 1 Reset temperature limiter or pressure limiter on heat exchanger Low water safety interlock on heat ex changer has triggered 1 Top up water Reset low water safety interlock on heat exchanger 1 Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly 10 1 2 Display OFF The following f...

Page 79: ...lashing Read error code e g A7h Rectify cause of fault ch 10 2 Resetting WARNING Damage resulting from incorrect fault repair Incorrect fault repair can cause damage to the equipment and injure personnel Do not carry out more than 2 lockout resets successively Faults must be rectified by qualified personnel Press ENTER Burner has been reset Fault memory The last 9 faults are saved in the fault mem...

Page 80: ...he error in more detail can be dis played by pressing a button The first detailed fault code and the second detailed fault code are only relevant for the following faults 03h 18h 41h 65h First detailed fault code operating status Press key 1 2 1 First detailed fault code 2 Operating status Second detailed fault code Press and keys simultaneously Repetition counter Press key G ...

Page 81: ...e ch 3 4 3 Reset the burner if fault reoccurs replace the combustion manager ch 9 15 Internal unit fault Interrupt the voltage supply temporarily Reset the burner if fault reoccurs replace the combustion manager ch 9 15 04h More than 5 resets in the last 15 minutes Press and hold reset key for 5 seconds Display flashes Reset burner 0Ch Burner configuration incorrect Check burner configuration Chec...

Page 82: ...econd detailed fault code E1h E7h Calibration values in EEPROM incorrect Second detailed fault code EEh Communication to W FM 25 failed Second detailed fault code EFh Extension module to W FM 25 not compatible Check version 1dh EMC interference Optimise EMC measures 40h Speed standardisation outside of limits set Carry out speed standardisation 41h First detailed fault code 01h Speed differs for t...

Page 83: ...h Tolerance fault air actuator Check freedom of movement of air damper and or angle drive Replace actuator ch 9 13 First detailed fault code 06h Tolerance fault frequency converter Check frequency converter or fan replace if ne cessary First detailed fault code 07h Time run out during speed standardisation Time in setting mode run out Press key within 20 seconds during speed standardisation Press ...

Page 84: ...r pressure switch 2 does not react Check air pressure switch setting Check hoses on air pressure switch Check air pressure switch and cable replace if necessary CEh Bridging plug No 15 is missing Plug in bridging plug CFh No start release X3 14 Check start release d1h Connection to actuator faulty Rectify the fault using the following procedure Interrupt voltage supply Plug in plug on combustion m...

Page 85: ...et mixing head ch 9 7 Incorrect combustion air quantity Adjust burner Boiler room ventilated insufficient Ensure sufficient boiler room ventila tion Wrong oil nozzle Check nozzle type Combustion pulsating or burner booming Mixing head set incorrectly Set mixing head ch 9 7 Incorrect combustion air quantity Adjust burner Wrong oil nozzle Check nozzle type CO content too high Nozzle distance too big...

Page 86: ...on confirmation 10 Start burner motor and ignition oil operation 11 Waiting for air pressure 4 12 Pre purge 13 Internal sequence 5 14 Driving to ignition position 6 15 Waiting time in ignition position 16 Waiting time in ignition position 7 17 First safety time fuel release 18 First safety time flame detection 8 19 First stabilisation time 20 Stop setting mode P0 A 21 Second safety time 22 Second ...

Page 87: ...documentation 83297902 3 2019 11 La 87 112 11 2 Conversion table unit of pressure Bar Pascal Pa hPa kPa MPa 0 1 mbar 10 0 1 0 01 0 00001 1 mbar 100 1 0 1 0 0001 10 mbar 1 000 10 1 0 001 100 mbar 10 000 100 10 0 01 1 bar 100 000 1 000 100 0 1 10 bar 1 000 000 10 000 1 000 1 ...

Page 88: ...resistance or install oil supply pump or suction unit whilst observing the maximum supply pressure at the oil filter The suction resistance depends on suction line length and diameter pressure loss of oil filter and other components lowest oil level in the oil storage tank max 3 5 m below the oil pump If an oil feeder pump is installed max 1 5 bar supply pressure at oil filter max 0 7 bar supply p...

Page 89: ...pply and return can damage the oil pump Ensure correct connection of oil hoses to the supply and return of the pump If the oil is supplied via a single pipe system and automatic de aerator must be in stalled in front of the oil pump Two pipe system In a two pipe system the oil pump is vented automatically Ring main operation Weishaupt recommends the use of a ring main when operating several burner...

Page 90: ...n e g due to a power failure or defective motor during operation with continuous running fan or increased post purge may result in back radiation or hot flue gases flowing back into the burner housing This could cause a fire If fail safe continuous ventilation or post purge is required take appropriate meas ures such as installing compressed air flushing on site with sufficiently large compressed ...

Page 91: ...tion manager Designed for continuous opera tion greater than 1200 kW X Flame monitor flame sensor self checking X Control device air fuel ratio ISO 23552 1 X X X Air monitoring device air pres sure switch Min pressure switch to EN 1854 X X X Minimum fuel pressure monitor ing device Min oil pressure switch 2 X X X Maximum fuel pressure monitor ing device Max oil pressure switch 1 X Oil solenoid val...

Page 92: ...ion Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 92 112 13 Spares 1 04 1 02 1 01 1 07 1 22 1 15 1 19 1 16 1 26 1 25 1 21 1 23 1 24 1 18 1 14 1 10 1 05 1 13 1 13 1 10 1 05 1 11 1 12 1 03 1 18 1 08 1 06 1 12 1 09 1 17 1 18 1 23 1 20 ...

Page 93: ...e 241 400 01 367 1 15 Intermediate flange 241 310 01 047 1 16 Threaded socket R WES6 453 010 1 17 Protective cap DN 6 SELF 50 2 CF 232 300 01 047 1 18 Pin M12 x 110 241 310 01 267 1 19 Joint 70 x 59 75 241 310 01 067 1 20 Joint 87 9 x 110 241 310 01 077 1 21 Burner flange 241 310 01 057 Screw M8 x 30 DIN 912 402 517 Washer A8 4 DIN 125 430 506 1 22 Flange gasket 8 x 219 5 x 219 5 Standard 241 310 ...

Page 94: ...on and operating instruction Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 94 112 Burner without variable speed drive 2 01 2 11 2 12 2 18 2 17 2 14 2 16 2 06 2 04 2 13 2 15 2 09 2 08 2 10 2 03 2 02 2 05 2 07 ...

Page 95: ...310 08 022 2 06 Grub screw M8x8 w ann cut edge Tuflok 420 550 2 07 Air guide 232 400 01 047 2 08 Air damper complete 241 310 02 162 2 09 Bearing left 241 400 02 037 2 10 Bearing right with bearing bush 241 210 02 032 2 11 Shaft air damper angle drive 241 310 02 147 2 12 Angle drive 241 110 02 062 2 13 Air actuator STE 4 5 24 V 651 103 2 14 Screw M4 x 30 Torx Plus metric 409 245 2 15 Fixing plate 2...

Page 96: ...nd operating instruction Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 96 112 Burner with variable speed drive 3 20 3 19 3 06 3 01 3 03 3 02 3 04 3 05 3 07 3 11 3 12 3 18 3 17 3 14 3 16 3 13 3 15 3 09 3 08 3 10 ...

Page 97: ...cut edge Tuflok 420 550 3 07 Air guide 232 400 01 047 3 08 Air damper complete 241 310 02 162 3 09 Bearing left 241 400 02 037 3 10 Bearing right with bearing bush 241 210 02 032 3 11 Shaft air damper angle drive 241 310 02 147 3 12 Angle drive 241 110 02 062 3 13 Air actuator STE 4 5 24 V 651 103 3 14 Screw M4 x 30 Torx Plus metric 409 245 3 15 Fixing plate 241 400 02 222 3 16 Screw M4 x 10 Torx ...

Page 98: ...Installation and operating instruction Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 98 112 4 04 4 03 4 07 4 14 4 02 4 03 4 14 4 12 4 10 4 10 4 08 4 05 4 04 4 06 4 09 4 13 4 14 4 05 4 01 4 11 ...

Page 99: ...ng A13 5 x 17 x 1 5 DIN 7603 Cu 440 010 4 06 Pressure hose DN 4 380 mm 6 LL M10 x 1 491 130 4 07 Screwed union 24 TX LL06 P ST 452 104 4 08 Threaded socket 6 x G x 35 111 351 85 377 4 09 Solenoid valve 121Z2323 230V 50Hz 240V 60Hz 604 480 Solenoid coil 483764 T1 604 453 4 10 Sealing ring A10 x 13 5 x 1 DIN 7603 Cu 440 027 4 11 Screwed union M10 x 1 x 57 241 310 13 017 4 12 Screwed union XGE G1 8A ...

Page 100: ...ion Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 100 112 5 01 5 05 5 08 5 06 5 31 5 10 5 31 5 09 5 11 5 15 5 16 5 23 5 22 5 17 5 14 5 14 5 28 5 30 5 18 5 21 5 19 5 20 5 13 5 26 5 24 5 25 5 04 5 07 5 27 5 25 5 02 5 03 5 28 5 29 5 12 ...

Page 101: ...e 241 110 00 017 5 11 Nozzle assembly complete Standard 241 313 10 010 extended by 100 mm 240 310 10 010 extended by 200 mm 240 310 10 040 extended by 300 mm 240 310 10 050 5 12 Adjusting lever top part 241 400 10 077 5 13 Adjusting lever bottom part 241 400 10 067 5 14 Screw M4 x 12 Torx Plus 20IP 409 237 5 15 Indicating bolt M6 x 90 241 110 10 097 5 16 Cap 5 25 natural 241 110 10 087 5 17 Adjust...

Page 102: ...ion Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 102 112 5 01 5 05 5 08 5 06 5 31 5 10 5 31 5 09 5 11 5 15 5 16 5 23 5 22 5 17 5 14 5 14 5 28 5 30 5 18 5 21 5 19 5 20 5 13 5 26 5 24 5 25 5 04 5 07 5 27 5 25 5 02 5 03 5 28 5 29 5 12 ...

Page 103: ...cs 602 078 2 00 gph 60 SF Fluidics 602 079 2 25 gph 60 SF Fluidics 602 080 2 50 gph 60 SF Fluidics 602 081 0 75 gph 60 S Steinen 612 205 0 85 gph 60 S Steinen 612 206 1 00 gph 60 S Steinen 612 207 1 10 gph 60 S Steinen 612 208 1 25 gph 60 S Steinen 612 210 1 35 gph 60 S Steinen 612 211 1 50 gph 60 S Steinen 612 212 1 65 gph 60 S Steinen 612 213 1 75 gph 60 S Steinen 612 214 2 00 gph 60 S Steinen 6...

Page 104: ...tallation and operating instruction Oil burner WL30Z C 13 Spares 83297902 3 2019 11 La 104 112 6 22 6 21 6 17 6 03 6 01 6 02 6 18 6 12 6 13 6 04 6 16 6 09 6 08 6 07 6 05 6 06 6 14 6 15 6 20 6 19 6 11 6 10 ...

Page 105: ...lug No 7 241 400 12 042 6 09 Plug cable No 3 motor 241 050 12 062 6 10 Plug cable No 3 N frequency converter 230 310 12 122 6 11 Plug cable No 3 motor supply VSD 230 310 12 142 6 12 Plug cable No 6 stage 2 solenoid valve 241 400 12 072 6 13 Plug cable No 1 solenoid valve 241 400 12 052 6 14 Plug cable No 14 for remote reset 230 110 12 362 6 15 Contactor 230 V with bracket 230 310 12 512 6 16 Plug ...

Page 106: ...Installation and operating instruction Oil burner WL30Z C 14 Notes 83297902 3 2019 11 La 106 112 14 Notes ...

Page 107: ...Installation and operating instruction Oil burner WL30Z C 14 Notes 83297902 3 2019 11 La 107 112 ...

Page 108: ...ctor 27 Control unit 74 Conversion table 87 Corrections 58 Current measuring device 38 D Default settings 40 Design lifespan 7 60 Detailed fault codes 80 Device fuse 77 Diffuser 10 40 41 Diffuser setting 40 Dimensions 18 Display 28 29 30 Display and operating unit 28 Disposal 8 Drilling diagram 19 Ducted air intake 7 17 E Electrical connection 26 Electrical data 15 Electrodes 65 Electrostatic disc...

Page 109: ...8 Oil temperature 88 Operating level 28 Operating panel 12 78 Operating problems 85 Operating status 29 80 86 Outputs 14 P Pa 87 Parameter level 33 Pascal 87 Personal protective equipment 7 Post purge time 13 PPE 7 Pre filter 88 Pre purge time 13 Pressure gauge 37 Pressure measuring device 37 Pressure regulating screw 44 52 Pressure switch 10 11 55 Program sequence 12 86 Protective equipment 7 Pul...

Page 110: ...ds 15 Starts 31 Sticker 76 Storage 15 Suction resistance 24 88 Supply 24 Supply pressure 24 37 88 Supply temperature 24 T Temperature 15 Transport 15 Troubleshooting 85 Two pipe system 89 Type key 9 U Unit 87 Unit of pressure 87 V Vacuum 88 Vacuum gauge 37 Variable speed drive 12 Variable speed drive sensor 70 VisionBox 29 Voltage supply 15 W Weight 18 ...

Page 111: ...83297902 3 2019 11 La ...

Page 112: ...Weishaupt GmbH 88475 Schwendi Weishaupt close by Addresses telephone numbers etc can be found at www weishaupt de We reserve the right to make changes All rights reserved Water heaters Energy storage The diverse program of potable water and energy storage for various heat sources includes storage volumes of 70 to 3 000 litres In order to minimize storage losses potable water cylinders from 140 to ...

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