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Installation and operating instruction

Oil burner WL40Z-A

83298002 3/2019-11

Summary of Contents for WL40Z-A

Page 1: ...Installation and operating instruction Oil burner WL40Z A 83298002 3 2019 11...

Page 2: ...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...

Page 3: ...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...

Page 4: ...instruction Oil burner WL40Z A 83298002 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...

Page 5: ...rried 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 traine...

Page 6: ...ervance 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 incorrect...

Page 7: ...ssets 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 nex...

Page 8: ...rts 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...

Page 9: ...9 112 3 Product description 3 1 Type key WL40Z A Type W Series Compact burner L Fuel Oil EL 40 Size Z Type of control two stage A Construction 3 2 Serial number The serial number on the name plate ide...

Page 10: ...ir 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 positioni...

Page 11: ...epending on heat demand 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 monit...

Page 12: ...ay 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 m...

Page 13: ...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 Operatin...

Page 14: ...r 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...

Page 15: ...on 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 2...

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 lev...

Page 17: ...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 o...

Page 18: ...002 3 2019 11 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 1 235 mm without combustion head extension 335 mm with combustion head ext...

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 instruct...

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 capaci...

Page 21: ...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...

Page 22: ...res 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 insu...

Page 23: ...re hose 6 Remove oil pump 7 and install rotated by 180 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 Clo...

Page 24: ...ax 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 CA...

Page 25: ...ension 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...

Page 26: ...onverter 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...

Page 27: ...tion 83298002 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 co...

Page 28: ...ble 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 1...

Page 29: ...o 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 VisionB...

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 Unp...

Page 31: ...aneously 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...

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...

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...

Page 34: ...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...

Page 35: ...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 oper...

Page 36: ...lled 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...

Page 37: ...re 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 p...

Page 38: ...002 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 sens...

Page 39: ...83298002 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 mi...

Page 40: ...air damper setting required from the diagram and note down Example Burner capacity stage 2 stage 1 required 450 kW 247 5 kW Diffuser setting dimension X 21 8 mm Air damper setting stage 2 stage 1 78 3...

Page 41: ...on 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 3 4 5 6 7 8 9 10 12 13 11 150...

Page 42: ...k 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 manage...

Page 43: ...nt 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 wh...

Page 44: ...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 The pump pressure mus...

Page 45: ...bustion 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 t...

Page 46: ...ning 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...

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 posit...

Page 48: ...p 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 simulta...

Page 49: ...ld 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 p...

Page 50: ...d 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 poin...

Page 51: ...s 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 carri...

Page 52: ...re 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...

Page 53: ...y 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...

Page 54: ...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 depend...

Page 55: ...ment 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 pres...

Page 56: ...nd 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 operatin...

Page 57: ...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...

Page 58: ...ager 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 co...

Page 59: ...Installation and operating instruction Oil burner WL40Z A 8 Shutdown 83298002 3 2019 11 La 59 112 8 Shutdown For breaks in operation Switch off burner Close fuel shut off devices...

Page 60: ...icing 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...

Page 61: ...ch 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 d...

Page 62: ...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 le...

Page 63: ...icing 83298002 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 Re...

Page 64: ...zles 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 n...

Page 65: ...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 nece...

Page 66: ...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...

Page 67: ...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...

Page 68: ...19 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 ho...

Page 69: ...move 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 retu...

Page 70: ...t 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 se...

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...

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...

Page 73: ...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 it...

Page 74: ...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 Pr...

Page 75: ...mittent 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...

Page 76: ...Te ch nik er l be tri eb Pu nk t L A n P0 P1 P2 P3 P9 Brennereinstellungen Datum Ma X mm ldruck Gro last bar Voreinstellung Luftklappe bei Gro last P9 Techniker lbetrieb Punkt L A n P0 P1 P2 P3 P9 1...

Page 77: ...bserve 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 continuo...

Page 78: ...itch 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 trigger...

Page 79: ...ashing 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 personn...

Page 80: ...e 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...

Page 81: ...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 combusti...

Page 82: ...cond 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 co...

Page 83: ...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 conv...

Page 84: ...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...

Page 85: ...t 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 pulsat...

Page 86: ...n 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...

Page 87: ...ocumentation 83298002 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...

Page 88: ...sistance 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 o...

Page 89: ...ply 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 s...

Page 90: ...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...

Page 91: ...ion 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 swi...

Page 92: ...Oil burner WL40Z A 13 Spares 83298002 3 2019 11 La 92 112 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...

Page 93: ...3 441 033 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 2...

Page 94: ...n and operating instruction Oil burner WL40Z A 13 Spares 83298002 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 0...

Page 95: ...00 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...

Page 96: ...d operating instruction Oil burner WL40Z A 13 Spares 83298002 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...

Page 97: ...t 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 a...

Page 98: ...tion and operating instruction Oil burner WL40Z A 13 Spares 83298002 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 11 4 10 4 10 4 11 4 10 4 08 4 05 4 04 4 06 4 09 4 09 4 13 4 14 4...

Page 99: ...06 067 4 05 Sealing ring 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...

Page 100: ...on Oil burner WL40Z A 13 Spares 83298002 3 2019 11 La 100 112 5 01 5 05 5 08 5 06 5 12 5 10 5 12 5 09 5 11 5 16 5 17 5 24 5 23 5 18 5 15 5 15 5 29 5 31 5 19 5 22 5 20 5 21 5 14 5 27 5 25 5 26 5 04 5 0...

Page 101: ...ion 240 310 11 092 900mm for 200 mm extension 240 310 11 102 5 06 Guide tube Standard 241 400 10 012 extended by 100 mm 240 400 10 012 extended by 200 mm 240 400 10 032 5 07 Screw M4 x 8 Torx Plus 20I...

Page 102: ...on Oil burner WL40Z A 13 Spares 83298002 3 2019 11 La 102 112 5 01 5 05 5 08 5 06 5 12 5 10 5 12 5 09 5 11 5 16 5 17 5 24 5 23 5 18 5 15 5 15 5 29 5 31 5 19 5 22 5 20 5 21 5 14 5 27 5 25 5 26 5 04 5 0...

Page 103: ...2 5 00 gph 60 SS Steinen 612 223 5 50 gph 60 SS Steinen 612 224 6 00 gph 60 SS Steinen 612 225 5 13 Adjusting lever top part 241 400 10 077 5 14 Adjusting lever bottom part 241 400 10 067 5 15 Screw M...

Page 104: ...lation and operating instruction Oil burner WL40Z A 13 Spares 83298002 3 2019 11 La 104 112 6 23 6 22 6 18 6 03 6 01 6 02 6 19 6 12 6 13 6 14 6 04 6 17 6 09 6 08 6 07 6 05 6 06 6 15 6 16 6 21 6 20 6 1...

Page 105: ...lug 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 1...

Page 106: ...Installation and operating instruction Oil burner WL40Z A 14 Notes 83298002 3 2019 11 La 106 112 14 Notes...

Page 107: ...Installation and operating instruction Oil burner WL40Z A 14 Notes 83298002 3 2019 11 La 107 112...

Page 108: ...tor 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 setti...

Page 109: ...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...

Page 110: ...s 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...

Page 111: ...83298002 3 2019 11 La...

Page 112: ...eishaupt 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 T...

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