Weishaupt WL40/1-A Z-1LN-A Installation And Operating Instruction Download

Page: 87 / 116

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A

10 Troubleshooting

83319702 1/2020-10 La

87-116

10.2 Rectifying faults

The following faults must only be rectified by qualified personnel:

Fault codes Cause

Rectification

01h

…

02h

05h

…

0bh

0Eh

…

10h

13h

…

15h

17h

19h

…

1Ch

1Eh

43h

45h

50h

56h

69h

…

A0h

A4h

…

A5h

ACh

b0h

…

b2h

b9h

Internal unit fault

Interrupt the voltage supply temporarily
Reset the burner, if fault reoccurs replace the
combustion manager [ch. 9.16]

The following faults must only be rectified by qualified personnel:

Fault codes Cause

Rectification

03h

First detailed fault code:

09h

Ambient temperature too high

Interrupt the voltage supply temporarily
Check ambient temperature [ch. 3.4.3]
Reset the burner, if fault reoccurs replace the
combustion manager [ch. 9.16]

Internal unit fault

Interrupt the voltage supply temporarily
Reset the burner, if fault reoccurs replace the
combustion manager [ch. 9.16]

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
Check values in parameter level [ch. 6.2.3]
Check parameter E0 … E4 [ch. 6.2.4]

Pre-purge phase less than 5 seconds
(sum from parameters 60 and 61).

Increase pre-purge phase (only possible with
VisionBox).

11h

Low voltage

Check voltage supply

12h

Voltage supply was temporarily interrupted

Check voltage supply

16h

Communication with TWI interface (VisionBox)
incorrect

Plug in and unplug participants on the TWI Bus
only when de-energised
Reduce the number of participants on the TWI
Bus
Reduce cable length

Summary of Contents for WL40/1-A Z-1LN-A

Page 1: ...Installation and operating instruction Oil burner WL40 1 A Z 1LN A 83319702 1 2020 10 ...

Page 2: ...Serial number 10 3 3 Function 11 3 3 1 Air supply 11 3 3 2 Oil supply 12 3 3 3 Electrical components 13 3 3 4 Program sequence 14 3 3 5 Inputs and outputs 16 3 4 Technical data 17 3 4 1 Approval data 17 3 4 2 Electrical data 17 3 4 3 Ambient conditions 17 3 4 4 Fuels 17 3 4 5 Emissions 18 3 4 6 Rating 19 3 4 7 Dimensions 20 3 4 8 Weight 20 4 Installation 21 4 1 Installation conditions 21 4 2 Selec...

Page 3: ...lace nozzle 68 9 5 Removing and refitting nozzle shut off 69 9 6 Set ignition electrodes 70 9 7 Removing the mixing head 71 9 8 Set mixing head 72 9 9 Service position 73 9 10 Removing and refitting oil pump 74 9 11 Removing and refitting fan wheel 75 9 12 Remove burner motor 76 9 13 Removing and refitting oil pump filter 77 9 14 Removing and refitting air damper actuator 78 9 15 Removing and refi...

Page 4: ...truction Oil burner WL40 1 A Z 1LN A 83319702 1 2020 10 La 4 116 12 Project planning 94 12 1 Oil supply 94 12 2 Continuous running fan or post purge 96 12 3 Additional requirements 97 13 Spares 98 14 Notes 112 15 Key word index 113 ...

Page 5: ...ut by personnel who have had the relevant training 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 Danger with high risk Non observance can lead to serious injury or death WARNING Danger with medium risk Non observance ca...

Page 6: ...n observance 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 install...

Page 7: ...ial 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 protecti...

Page 8: ... inserts 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 ...

Page 9: ... A 3 Product description 83319702 1 2020 10 La 9 116 3 Product description 3 1 Type key WL40 1 A Z 1LN A Type W Series Compact burner L Fuel Oil EL 40 Size 1 Ratings size A Construction Version Z Type of control two stage 1LN Mixing head LowNOX A Mixing head version ...

Page 10: ...n Oil burner WL40 1 A Z 1LN A 3 Product description 83319702 1 2020 10 La 10 116 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 11: ...eat loss in the heat exchanger 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 op...

Page 12: ...itch 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 Nozzle head with nozzle shut off The nozzle shut off is integrated in the nozzle head It prevents oil leaks after shut down Seque...

Page 13: ...nd parameters of the combustion manager can be displayed and changed at the operating panel Burner motor The burner motor drives the fan wheel and the oil pump With variable speed drive a frequency converter is connected upstream Ignition unit The electronic ignition unit creates a spark at the electrode which ignites the fuel air mixture Flame sensor The combustion manager monitors the flame sign...

Page 14: ...rge is initiated 4 Pre purge The remaining pre purge time is displayed 5 The air damper actuator drives to ignition position operating point P0 6 Waiting time in ignition position 7 Stage 1 solenoid valve and the safety valve open The fuel is released The safety time begins The dis play shows symbol 8 Post ignition time starts this aids flame stabilisation 9 The air damper actuator drives to air d...

Page 15: ...nt 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 K14 Safety solenoid valve TN Post purge time 2 s ch 6 2 3 M1 Burner motor TS Safety time 3 s M20 Air damper actuator TV Pre purg...

Page 16: ...ot for analogue module EM3 3 or fieldbus module EM3 2 2 W FM cover 1 Safety solenoid valve K14 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 Stage 1 solenoid valve K11 6 Stage 2 solenoid valve K13 7 Bridging plug No 7 8 Oil meter impulse generator 11 Air pressure switc...

Page 17: ...eration max 801 W Power consumption max 4 0 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 highe...

Page 18: ...Combustion 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 78 4 dB A 1 dB A Measured sound pressure level LpA re 20 μPa Uncertainty value KpA 73 4 dB A 2 dB A 1 Determined to ISO 9614 2 2 Determined at 1 metre distanc...

Page 19: ... 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 30 32 5 35 37 5 40 42 5 2 100 425 450 475 500 525 400 375 350 325 300 275 250 225 200 175 150 125 1 0 1 2 3 4 5 6 7 2 1 3 4 1 Combustion heat rating kW ...

Page 20: ... 3 Product description 83319702 1 2020 10 La 20 116 3 4 7 Dimensions Burner 450 mm 577 mm 480 mm 151 mm 360 mm 72 mm 245 mm 615 mm 480 mm 5 7 0 m m 185 1 1 231 mm without combustion head extension 331 mm with combustion head extension 100 mm 3 4 8 Weight approx 37 kg ...

Page 21: ...otrude beyond 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 refra...

Page 22: ...hroughput a different distribution may be necessary Example Burner capacity required approx 415 kW 65 of burner capacity required 415 kW 0 65 270 KW Nozzle size 6 50 gph see nozzle selection table Stage 1 10 bar 291 kW Stage 2 20 bar 415 kW Recommended nozzles Make Characteristics Fluidics 45 HF Fluidics 60 HF 1 1 Alternative for short combustion chambers of if the flame in unstable Pump pressure ...

Page 23: ... 248 5 50 235 249 261 273 6 00 257 271 284 298 6 50 278 291 308 321 7 00 299 317 332 346 7 50 320 338 355 370 8 00 343 361 380 395 Stage 2 Burner capacity kW at pump pressure Nozzle size gph 17 bar 18 bar 20 bar 22 bar 3 00 176 181 192 201 3 50 206 211 224 234 4 00 235 241 256 267 4 50 264 271 287 301 5 00 293 301 320 336 5 50 322 331 351 368 6 00 351 361 382 401 6 50 380 393 415 435 7 00 411 421 ...

Page 24: ...es 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 Remove screw 7 and remove diffuser 8 Undo screw 2 and remove ignition electrode holder Fit nozzle ch 9 4 Re fit diffuser and ignition cables Set ignition electrod...

Page 25: ...6 Remove oil pump 7 and install rotated by 180 ch 9 10 Remove mixing head 4 see ch 9 7 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 hoses ensuring correct allocation Wedge profile flange gasket required Order No 240 410 00 017 Rotate burner flange...

Page 26: ...sure 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 NOTICE 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...

Page 27: ...ical 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 NOTICE Oil pump seized due to running dry Pump could be damaged Fill oil supply with oil and purge Ensure oil supply is tight ...

Page 28: ...ncy 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 o...

Page 29: ...stallation 83319702 1 2020 10 La 29 116 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 30: ... variable 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 conjun...

Page 31: ...ges 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 c...

Page 32: ...uator 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 ...

Page 33: ...imultaneously 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 E...

Page 34: ...ating 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...

Page 35: ...n the 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 Fact...

Page 36: ... Press 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 pa...

Page 37: ...ing or 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 cont...

Page 38: ...en flame tube and heat exchanger is filled 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...

Page 39: ... 1 Oil pressure measuring devices on oil pump Vacuum gauge for suction resistance supply pressure Pressure gauge for pump pressure NOTICE 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...

Page 40: ...83319702 1 2020 10 La 40 116 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 12 μA 1 ...

Page 41: ...ioning 83319702 1 2020 10 La 41 116 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 42: ...tting Do not operate the burner outside of the capacity graph ch 3 4 6 Determine the diffuser setting dimension X and air damper setting required from the diagram and note down Example Burner capacity stage 2 stage 1 required 415 kW 270 kW Diffuser setting dimension X 26 0 mm Air damper setting stage 2 stage 1 65 38 Diffuser default settings 100 425 450 475 500 525 400 375 350 325 300 275 250 225 ...

Page 43: ...t diffuser With dimension X 0mm the indicating bolt is flush with nozzle assembly cover Turn screw 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 100 425 450 475 500 525 400 375 350 325 300 275 250 225 200 175 150 125 2 4 6 8 10 12 14 16 2 1 4 3 1 Combustion he...

Page 44: ...g check 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...

Page 45: ...ng point 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 di...

Page 46: ...tting 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 for stage 1 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...

Page 47: ...k pump pressure at pressure gauge Set pressure using pressure regulating screw 1 increase pressure clockwise rotation decrease pressure anticlockwise rotation 1 Adjust P9 Check combustion values Determine combustion limit ch 7 5 Set excess air via air damper setting L A Adjust P1 Press key Burner drives to stage 1 P1 Check combustion values Determine combustion limit ch 7 5 Set excess air via air ...

Page 48: ... 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 3 0 5 0 mbar If necessary adjust mixing pressure via air damper setting L A Press key Burner drives to stage 1 P1 Press key Burner drives to stage 2 P9 ...

Page 49: ... 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 air phase CO content prior to switch...

Page 50: ...l 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 Factory setting operating point P9 stage 2 is di...

Page 51: ...and hold 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 52: ...ss and 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 Pr...

Page 53: ...y Press 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 accordanc...

Page 54: ...ng pressure 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 Set pump pressure for stage 2 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 pre...

Page 55: ...ustion limit ch 7 5 Set excess air via air damper setting and speed Adjust P1 Press key Burner drives to stage 1 P1 Reduce speed only so far as to ensure safe operating behaviour whilst maintaining speed of 55 maintaining pump pressure of 9 bar and not operating burner outside of the capacity graph Slowly reduce speed using L A and ENTER key whilst opening air damper setting alternately using the ...

Page 56: ...e 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 3 0 5 0 mbar If necessary adjust mixing pressure via air damper setting L A Press key Burner drives to stage 1 P1 Press key Burner drives to stage 2 P9 ...

Page 57: ...splayed Set switch off point stage 2 when running 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 oper...

Page 58: ... and 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 59: ...easurement 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 ...

Page 60: ...d or 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...

Page 61: ...Check 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 p...

Page 62: ...on manager 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 ...

Page 63: ...Installation and operating instruction Oil burner WL40 1 A Z 1LN A 8 Shutdown 83319702 1 2020 10 La 63 116 8 Shutdown For breaks in operation Switch off burner Close fuel shut off devices ...

Page 64: ...l Servicing 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...

Page 65: ...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 pressure switch 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 stick...

Page 66: ...ner 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 Nozzle shut off Soundness Replace Oil pump filter Soiling Replace Oil hose Damage oil escaping Replace Recommendation every 5 years Pressure hose nozzle assembly Damage oil escaping 5 ye...

Page 67: ...tallation and operating instruction Oil burner WL40 1 A Z 1LN A 9 Servicing 83319702 1 2020 10 La 67 116 9 3 Hinge open the burner Observe notes on servicing ch 9 1 Remove screws 1 Hinge open the burner 1 ...

Page 68: ...zles always fit new nozzles Hinge open the burner ch 9 3 Unplug ignition cable 4 Undo screw 1 and remove diffuser Undo screw 5 and remove ignition electrode holder Counter hold on the nozzle body 3 using a spanner and remove nozzle 2 Fit new nozzle ensuring it is seated tightly Refit diffuser in reverse order Set nozzle distance ch 9 8 Set ignition electrodes ch 9 6 2 5 1 3 4 ...

Page 69: ...ng Remove nozzle ch 9 4 Counter hold the nozzle assembly 4 using a spanner and remove nozzle holder 1 Remove valve piston 2 and compression spring 3 using a suitable tool e g pliers do not damage valve piston and O ring 1 2 3 4 Refitting Do not refit damaged valve pistons replace as necessary Refit nozzle shut off in reverse order Check nozzle distance ch 9 8 Set ignition electrodes ch 9 6 ...

Page 70: ...0 La 70 116 9 6 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 3 0 mm 2 0 2 5 m m 2 5 3 0 mm ...

Page 71: ...20 10 La 71 116 9 7 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 hoses 4 Undo screws 3 Turn mixing head to the left up to the recess and remove 1 2 5 4 3 ...

Page 72: ...ighten 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 7 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 ...

Page 73: ...2 1 2020 10 La 73 116 9 9 Service position Observe notes on servicing ch 9 1 Remove mixing head ch 9 7 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 74: ...ug 1 Remove oil hoses 5 and pressure hoses 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 NOTICE 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 re...

Page 75: ...nd refitting fan wheel Observe notes on servicing ch 9 1 Removing Place housing cover into service position ch 9 9 Remove grub screw 1 and remove fan wheel Refitting Refit 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 ...

Page 76: ...e burner motor Observe notes on servicing ch 9 1 Remove the oil pump ch 9 10 Remove fan wheel ch 9 11 Unplug plug 1 Hold motor and remove screws 2 Remove motor Only in conjunction with variable speed drive The variable speed drive sensor is fitted to the burner motor If necessary remove variable speed drive sensor 1 2 ...

Page 77: ...9702 1 2020 10 La 77 116 9 13 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 78: ...e to 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 dam...

Page 79: ...9702 1 2020 10 La 79 116 9 15 Removing and refitting angle drive Observe notes on servicing ch 9 1 Removing Remove air damper actuator ch 9 14 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 80: ... 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 1 see ch 6 2 3 It is pre...

Page 81: ...Press E1 is displayed The value of parameter E1 can not be altered 0 intermittent 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...

Page 82: ... s t b a r V o re in s te ll u n g L u ft k la p p e b e i G ro ß la s t 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 se...

Page 83: ...use 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 18 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 84: ...ing switch 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 follow...

Page 85: ...yed flashing Read error code e g A7h Rectify cause of fault ch 10 2 Resetting NOTICE 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...

Page 86: ...wn the 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 87: ...ature ch 3 4 3 Reset the burner if fault reoccurs replace the combustion manager ch 9 16 Internal unit fault Interrupt the voltage supply temporarily Reset the burner if fault reoccurs replace the combustion manager ch 9 16 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 ...

Page 88: ... 16 Second 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 ...

Page 89: ...de 05h Tolerance fault air actuator Check freedom of movement of air damper and or angle drive Replace actuator ch 9 14 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 P...

Page 90: ...dh Air 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 combust...

Page 91: ...stion air quantity Adjust burner Boiler room ventilated insufficient Ensure sufficient boiler room ventila tion Wrong oil nozzle Check nozzle type ch 4 2 Combustion pulsating or burner booming Mixing head set incorrectly Set mixing head ch 9 8 Incorrect combustion air quantity Adjust burner Wrong oil nozzle Check nozzle type ch 4 2 CO content too high Nozzle distance too big Check nozzle distance ...

Page 92: ...isation 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 Se...

Page 93: ...cal documentation 83319702 1 2020 10 La 93 116 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 94: ...ion 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 supp...

Page 95: ...p supply 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 bu...

Page 96: ...r fan 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 compres...

Page 97: ...mbustion 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...

Page 98: ... burner WL40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 98 116 13 Spares 1 27 1 26 1 04 1 02 1 01 1 07 1 23 1 16 1 20 1 17 1 22 1 24 1 25 1 19 1 15 1 11 1 05 1 14 1 14 1 11 1 05 1 12 1 13 1 03 1 19 1 08 1 06 1 13 1 09 1 18 1 19 1 10 1 24 1 21 ...

Page 99: ...0 x 13 5 x 1 5 DIN 7603 441 033 1 15 Bracket for oil hose 241 400 01 367 1 16 Intermediate flange 241 400 01 427 1 17 Threaded socket R WES6 453 010 1 18 Protective cap DN 6 SELF 50 2 CF 232 300 01 047 1 19 Pin M12 x 118 241 400 01 267 1 20 Joint 80 x 64 75 241 400 01 067 1 21 Joint 106 9 x 120 241 400 01 077 1 22 Burner flange 241 400 01 437 Screw M10 x 35 DIN 912 402 600 Washer A10 5 DIN 125 430...

Page 100: ...ction Oil burner WL40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 100 116 Burner without variable speed drive 2 19 2 21 2 22 2 24 2 20 2 23 2 23 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 101: ...aring left 241 400 02 037 2 10 Bearing right with bearing bush 241 210 02 032 2 11 Shaft air damper angle drive 241 400 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 241 400 02 222 2 16 Screw M4 x 10 Torx Plus 20IP 409 236 2 17 Guide sleeve 241 400 02 207 2 18 Shaft angle drive actuator 241 400 02 157 2 1...

Page 102: ...erating instruction Oil burner WL40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 102 116 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 103: ...ann cut edge Tuflok 420 550 3 07 Air guide 241 310 01 307 3 08 Air damper complete 241 400 02 012 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 241 400 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 T...

Page 104: ...L40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 104 116 1 4 13 2 1 2 4 21 4 18 4 17 4 19 4 20 4 12 4 14 4 26 4 15 4 11 4 03 4 25 4 22 4 24 4 23 4 02 4 03 4 25 4 12 4 14 4 14 4 12 4 13 4 12 4 09 4 10 4 08 4 06 4 05 4 07 4 15 4 01 4 05 4 04 4 16 4 16 4 16 ...

Page 105: ...e screw HS TN WEISH XCF 452 877 4 12 Sealing ring A10 x 13 5 x 1 DIN 7603 Cu 440 027 4 13 Solenoid valve 121Z2323 230V50Hz 240V60Hz 604 480 Solenoid coil 483764 T1 230V50Hz 240V60Hz 604 453 4 14 Screwed union 24 SDSX LL06 G A ST CH60 452 291 4 15 Screwed union 24 EX LL06 P ST 452 050 4 16 Grub screw M6 x 10 DIN 914 420 630 4 17 Pressure switch DSF 158 F001 0 25 bar 640 109 4 18 Sealing ring C6 2 x...

Page 106: ...WL40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 106 116 5 12 5 02 5 01 5 03 5 09 5 10 5 04 5 11 5 15 5 17 5 13 5 14 5 16 5 21 5 20 5 20 5 24 5 27 5 25 5 26 5 19 5 08 5 06 5 07 5 05 5 22 5 29 5 31 5 28 5 23 5 34 5 36 5 32 5 30 5 33 5 31 5 34 5 35 5 18 ...

Page 107: ...409 362 5 13 Nozzle head with nozzle shut off Standard 241 400 10 212 extended by 100 mm 240 400 10 082 5 14 Nozzle shut off set 240 100 10 042 5 15 Oil nozzle 3 00 gph 45 HF Fluidics 602 687 3 50 gph 45 HF Fluidics 602 688 4 00 gph 45 HF Fluidics 602 689 4 50 gph 45 HF Fluidics 602 690 5 00 gph 45 HF Fluidics 602 692 5 50 gph 45 HF Fluidics 602 691 6 00 gph 45 HF Fluidics 602 693 6 50 gph 45 HF F...

Page 108: ...WL40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 108 116 5 12 5 02 5 01 5 03 5 09 5 10 5 04 5 11 5 15 5 17 5 13 5 14 5 16 5 21 5 20 5 20 5 24 5 27 5 25 5 26 5 19 5 08 5 06 5 07 5 05 5 22 5 29 5 31 5 28 5 23 5 34 5 36 5 32 5 30 5 33 5 31 5 34 5 35 5 18 ...

Page 109: ... 087 5 23 Adjusting screw M6 x 88 241 400 10 097 5 24 Spring washer A6 DIN 137 431 615 5 25 Hexagonal nut M6 DIN 934 411 301 5 26 Hexagonal nut M6 DIN 985 411 302 5 27 Guide foil 7 8 x 134 8 241 300 01 027 5 28 Nozzle assembly cover complete QRB4 241 400 01 142 5 29 View port glass 241 400 01 377 5 30 O ring 33 5 x 3 55 NBR70 ISO 3601 445 177 5 31 Bracket for oil lines 241 310 14 067 5 32 Shut off...

Page 110: ...rating instruction Oil burner WL40 1 A Z 1LN A 13 Spares 83319702 1 2020 10 La 110 116 6 24 6 25 6 26 6 27 6 22 6 21 6 17 6 03 6 01 6 02 6 18 6 13 6 04 6 16 6 09 6 08 6 07 6 05 6 06 6 14 6 15 6 23 6 20 6 19 6 12 6 11 6 10 ...

Page 111: ...lenoid valve 241 400 12 062 6 13 Plug cable No 1 safety solenoid valve 241 400 12 052 No 6 stage 2 solenoid valve 241 400 12 142 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 unit ST18 3 716 543 6 17 Fixing bracket 241 400 12 017 6 18 ABE for W FM 20 25 with 0 58 m cable 600 481 6 19 Ignition unit type W ZG01 230 V 100 VA 603 229 6...

Page 112: ...Installation and operating instruction Oil burner WL40 1 A Z 1LN A 14 Notes 83319702 1 2020 10 La 112 116 14 Notes ...

Page 113: ...Contactor 29 Control unit 80 Conversion table 93 Corrections 62 Current measuring device 40 D Default settings 42 Design lifespan 7 64 Detailed fault codes 86 Device fuse 83 Diffuser 11 42 43 Diffuser setting 42 Dimensions 20 Display 30 31 32 Display and operating unit 30 Disposal 8 Drilling diagram 21 Ducted air intake 7 19 E Electrical connection 28 Electrical data 17 Electrodes 70 Electrostatic...

Page 114: ...r 77 Oil supply 26 94 Oil temperature 94 Operating level 30 Operating panel 13 84 Operating problems 91 Operating status 31 86 92 Outputs 16 P Pa 93 Parameter level 35 Pascal 93 Personal protective equipment 7 Post purge time 15 PPE 7 Pre filter 94 Pre purge time 15 Pressure gauge 39 Pressure measuring device 39 Pressure regulating screw 46 47 54 Pressure switch 11 12 59 Program sequence 14 92 Pro...

Page 115: ...ts 33 Sticker 82 Storage 17 Suction resistance 26 94 Supply 26 Supply pressure 26 39 94 Supply temperature 26 T Temperature 17 Transport 17 Troubleshooting 91 Two pipe system 95 Type key 9 U Unit 93 Unit of pressure 93 V Vacuum 94 Vacuum gauge 39 Variable speed drive 13 Variable speed drive sensor 76 VisionBox 31 Voltage supply 17 W Weight 20 ...

Page 116: ...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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Weishaupt WL40/1-A Z-1LN-A, Installation And Operating Instruction

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