Weishaupt WL40Z-A 1LN Manual Download Page 36 | Manualshive

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Installation and operating instruction
Oil burner WL40Z-A 1LN

7 Commissioning

83298902 2/2019-05 La

36-112

7 Commissioning

7.1 Prerequisite

Commissioning must only be carried out by qualified personnel.

Only correctly carried out commissioning ensures the operational safety.

Prior to commissioning ensure that:

all assembly and installation work has been carried out correctly,
sufficient combustion air is available, if necessary install ducted air intake
the annulus between 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 instructions of the heat exchanger are complied with
a heat demand is available

Additional system-related tests could be necessary. Please observe the operating
guidelines for the individual components.

On installations with process equipment, the conditions for safe operation and
commissioning must be met, see worksheet 8-1 (Print No. 831880xx).

7.1.1 Connect measuring devices

Pressure measuring device for mixing pressure

Open pressure test point for mixing pressure

1

and connect pressure measur-

ing device.

1

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Summary of Contents for WL40Z-A 1LN

Page 1: ...Installation and operating instruction Oil burner WL40Z A 1LN 83298902 2 2019 05 ...

Page 2: ... 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 a nozzle 20 4 3 Burner inst...

Page 3: ... refitting nozzle shut off 64 9 6 Set ignition electrodes 65 9 7 Removing the mixing head 66 9 8 Set mixing head 67 9 9 Service position 68 9 10 Removing and refitting oil pump 69 9 11 Removing and refitting fan wheel 70 9 12 Remove burner motor 70 9 13 Removing and refitting oil pump filter 71 9 14 Removing and refitting air damper actuator 72 9 15 Removing and refitting angle drive 73 9 16 Repla...

Page 4: ...Installation and operating instruction Oil burner WL40Z A 1LN 83298902 2 2019 05 La 4 112 13 Spares 92 14 Notes 106 15 Key word index 108 ...

Page 5: ... carried 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 ...

Page 6: ...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 installat...

Page 7: ... 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 Normal operation All labels on the unit must be kept in a legible condition Sti...

Page 8: ...f 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 Disposal Dispose of all materials and components in a safe and environmentally friendly way at an authorised location Observe local regulations ...

Page 9: ...a 9 112 3 Product description 3 1 Type key WL40Z A 1LN W Type W burner L Fuel Oil EL 40 Size Z Version two stage A Construction 1LN Version LowNOX 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: ...e 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...

Page 11: ...at demand Minimum oil pressure switch optional Depending on the burner application optional equipment may be required for op timum operation ch 12 2 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 prevent...

Page 12: ...splay 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 initiated 4 Pre purge The remaining p...

Page 13: ... 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 purge ...

Page 14: ...panel L A Air damper actuator G Coded plug black 1 Slot 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 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 switch...

Page 15: ...s frequency 230 V 50 Hz Consumption at start max 901 W Consumption during operation 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 1 with the relevant suitable fuel oil and layout of oil supply 3 4 4 Fuels...

Page 16: ...fuel combustion air temperature and humidity medium temperature Sound levels Dual number noise emission values Measured sound power level LWA re 1 pW Uncertainty value KWA 77 4 dB A 1 dB A Measured sound pressure level LpA re 20 μPa Uncertainty value KpA 71 4 dB A 2 dB A 1 Determined to ISO 9614 2 2 Determined at 1 metre distance from the front of the burner The measured noise levels plus uncertai...

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 14 16 18 20 22 24 26 28 30 2 100 360 380 340 320 300 280 260 240 220 200 180 160 140 120 1 0 1 ...

Page 18: ... Product description 83298902 2 2019 05 La 18 112 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 19: ...rude 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 refract...

Page 20: ...ifferent distribution may be necessary Example Burner capacity required approx 335 kW 65 of burner capacity required 335 kW 0 65 218 KW Nozzle size 5 00 gph see nozzle selection table Stage 1 10 bar 226 1 kW Stage 2 22 bar 335 6 kW Recommended nozzles Make Characteristics Fluidics 45 HF Fluidics 60 HF 1 Steinen 60 PH 1 1 Alternative for short combustion chambers of if the flame in unstable Pump pr...

Page 21: ... 50 119 124 2 75 124 131 136 3 00 136 143 149 3 50 158 165 174 4 00 181 189 199 4 50 204 213 223 5 00 226 237 248 5 50 249 261 272 Stage 2 Burner capacity kW at pump pressure Nozzle size gph 20 bar 22 bar 24 bar 2 50 160 169 176 2 75 175 183 190 3 00 192 201 211 3 50 224 234 245 4 00 256 267 280 4 50 287 301 314 5 00 320 336 351 5 50 351 368 Conversion of burner capacity to oil throughput see form...

Page 22: ...h 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 electrodes c...

Page 23: ...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 2...

Page 24: ...e 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 h...

Page 25: ...l 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: ...y 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 ...

Page 27: ...llation 83298902 2 2019 05 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: ...riable 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 conjuncti...

Page 29: ...ring troubleshooting ch 11 1 Press and hold and simultaneously for approx 3 seconds The combustion manager changes 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 If the VisionBox Software is connected change over to the access level must be confirmed via the operating ...

Page 30: ...or 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 mem...

Page 31: ...ultaneously 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...

Page 32: ...ator 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 keys simultaneously Repetition counter Press key G 19 Flame Signal Left display 1 Alternating value Rig...

Page 33: ... 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 for oil c...

Page 34: ...ess 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 param...

Page 35: ... 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 2 flame sensor QRB4 or flame sensor for continuous operation E3 Fan configuration 0 Off 1 fa...

Page 36: ...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 are complied with a heat demand is available Additional system related tests could...

Page 37: ...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 plug on the pump Connect vacuum gauge 1 and pressure gauge 2 1 9 2 1 7 1 2 Set minimum oil pressure switch optional Depending on the burner application optional equipment may be required for op timu...

Page 38: ...e diffuser setting dimension X and air damper setting required from the diagram and note down Example Burner capacity stage 2 stage 1 required 335 kW 226 kW Diffuser setting dimension X 13 8 mm Air damper setting stage 2 stage 1 57 32 Diffuser default settings 100 360 380 340 320 300 280 260 240 220 200 180 160 140 120 4 6 8 10 12 14 16 2 1 1 Combustion heat rating kW 2 Diffuser settings dimension...

Page 39: ...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 4 100 360 380 340 320 300 280 260 240 220 200 180 160 140 120 6 8 10 12 14 16 2 1 3 4 1 Combustion heat rating kW 2 Mixing pressure mbar 3 Stage 1 4 Stage 2 Guide values which could vary depend on comb chamber re...

Page 40: ...heck 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 Fa...

Page 41: ...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 displ...

Page 42: ...ng 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 an...

Page 43: ...ump 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 dam...

Page 44: ...o 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 Press key Burner drives to stage 1 P1 Press key Burner drives to stage 2 P9 ...

Page 45: ...ess 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 ov...

Page 46: ...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 disp...

Page 47: ... 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 48: ... 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 Pres...

Page 49: ...ress 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 w...

Page 50: ... 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 press...

Page 51: ...ion 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 10 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 L ...

Page 52: ...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 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 53: ...e 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...

Page 54: ...urement 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 Sit...

Page 55: ...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 a...

Page 56: ...k 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 provi...

Page 57: ...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 sim...

Page 58: ...Installation and operating instruction Oil burner WL40Z A 1LN 8 Shutdown 83298902 2 2019 05 La 58 112 8 Shutdown For breaks in operation Switch off burner Close fuel shut off devices ...

Page 59: ...cool 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...

Page 60: ...touch 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 ...

Page 61: ...50 000 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 years Replace Oil solenoid valve Soundness 250 000 bur...

Page 62: ...Installation and operating instruction Oil burner WL40Z A 1LN 9 Servicing 83298902 2 2019 05 La 62 112 9 3 Hinge open the burner Observe notes on servicing ch 9 1 Remove screws 1 Hinge open the burner 1 ...

Page 63: ...es 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 64: ... 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 65: ...La 65 112 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 66: ...g 83298902 2 2019 05 La 66 112 9 7 Removing the mixing head Observe notes on servicing ch 9 1 Remove flame sensor 5 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 67: ...ten 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 set...

Page 68: ... 2019 05 La 68 112 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 69: ...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 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 retu...

Page 70: ...fit 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 12 Remove 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 s...

Page 71: ...02 2 2019 05 La 71 112 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 72: ...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 dampe...

Page 73: ...2 2 2019 05 La 73 112 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 74: ...ion 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 ...

Page 75: ...termittent operation Standard 1 continuous operation Press E2 is displayed Set value 2 flame sensor QRB4 or flame sensor for continuous operation using Enter and key 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 necess...

Page 76: ...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 seconds The parameter level is activated Press Press Enter key until para...

Page 77: ...struction Oil burner WL40Z A 1LN 9 Servicing 83298902 2 2019 05 La 77 112 9 17 Replacing the fuse 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 ...

Page 78: ... 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 following...

Page 79: ... flashing 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 m...

Page 80: ... 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 81: ...ure 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 Ch...

Page 82: ... 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 for...

Page 83: ...irst detailed fault code 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 s...

Page 84: ...ssure switch and cable if neces sary replace Check burner motor and cable replace if necessary ch 9 12 Cdh 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...

Page 85: ...ch 9 4 Nozzle worn Flame tube diffuser has heavy soot deposit Oil nozzle defective Replace nozzle ch 9 4 Mixing head set incorrectly Set mixing head ch 9 8 Incorrect combustion 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 mixi...

Page 86: ...tion 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 Secon...

Page 87: ...l documentation 83298902 2 2019 05 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: ...n 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...

Page 89: ...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 burn...

Page 90: ...nt X Burner control combustion 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 Minimum oil pressure switch X X X Maximum fuel pressure monitor ing device Max oil pressure...

Page 91: ...Installation and operating instruction Oil burner WL40Z A 1LN 12 Project planning 83298902 2 2019 05 La 91 112 ...

Page 92: ...tion Oil burner WL40Z A 1LN 13 Spares 83298902 2 2019 05 La 92 112 13 Spares 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 93: ...457 1 13 Screw G A DIN 908 409 004 1 14 Sealing ring 10 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 S...

Page 94: ... and operating instruction Oil burner WL40Z A 1LN 13 Spares 83298902 2 2019 05 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: ...1 400 08 032 2 06 Grub screw M8x8 w ann cut edge Tuflok 420 550 2 07 Air guide 241 310 01 307 2 08 Air damper complete 241 400 02 012 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 241 400 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...

Page 96: ... operating instruction Oil burner WL40Z A 1LN 13 Spares 83298902 2 2019 05 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 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 Torx...

Page 98: ...stallation and operating instruction Oil burner WL40Z A 1LN 13 Spares 83298902 2 2019 05 La 98 112 4 11 4 03 4 02 4 03 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 99: ...5 DIN 7603 Cu 440 010 4 06 Swivel screw G x M12 x 1 241 400 06 097 4 07 Sealing ring A14 x 20 x 1 5 DIN 7603 Cu 440 041 4 08 Pressure hose DN 4 410 mm Ermeto 6LL 491 248 4 09 Pressure hose DN 4 380 mm 6 LL M10 x 1 491 130 4 10 Screwed union 24 BSEX LL06 G B ST 452 618 4 11 Hollow core screw HS TNWEISHXCF 452 877 4 12 Sealing ring A10 x 13 5 x 1 DIN 7603 Cu 440 027 4 13 Solenoid valve 121Z2323 230V...

Page 100: ...er WL40Z A 1LN 13 Spares 83298902 2 2019 05 La 100 112 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 101: ...t 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 2 50 gph 45 HF Fluidics 602 685 2 75 gph 45 HF Fluidics 602 686 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 2 50 gph 60 HF Fluidics ...

Page 102: ...er WL40Z A 1LN 13 Spares 83298902 2 2019 05 La 102 112 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 103: ...87 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 g...

Page 104: ...Installation and operating instruction Oil burner WL40Z A 1LN 13 Spares 83298902 2 2019 05 La 104 112 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 20 6 19 6 12 6 11 6 10 ...

Page 105: ...ck 716 190 6 08 Bridging plug 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 5 stage 1 solenoid 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 rese...

Page 106: ...Installation and operating instruction Oil burner WL40Z A 1LN 14 Notes 83298902 2 2019 05 La 106 112 14 Notes ...

Page 107: ...Installation and operating instruction Oil burner WL40Z A 1LN 14 Notes 83298902 2 2019 05 La 107 112 ...

Page 108: ...tactor 27 Control unit 74 Conversion table 87 Corrections 57 D Default settings 38 Design lifespan 7 59 Detailed fault codes 80 Device fuse 77 Diffuser 10 38 39 Diffuser setting 38 Dimensions 18 Display 28 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 Emission 16 Emission class 16 Excess air 56 F F...

Page 109: ...el 12 78 Operating problems 85 Operating status 29 80 86 Outputs 14 P Pa 87 Parameter level 33 Pascal 87 Post purge time 13 Pre filter 88 Pre purge time 13 Pressure gauge 37 Pressure measuring device 36 37 Pressure regulating screw 42 43 50 Pressure switch 10 11 54 Program sequence 12 86 Pulsating 85 Pump 11 24 37 69 89 Pump filter 71 Pump pressure 20 37 42 43 50 R Recommended nozzles 20 Refractor...

Page 110: ...a 110 112 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: ...83298902 2 2019 05 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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