WG1-WG11 Dual Fuel Burners Instalation Manual An

Installation and operating instructions
Weishaupt dual fuel burners

Sizes 1 to 11
83041902 1/98
2
Conformity certification
We hereby confirm that Weishaupt gas and dual fuel
burners conform to the basic requirements of the
following EC guidelines:
90/396/ EEC Gas Equipment Guideline
89/336/ EEC Electromagnetic Compatibility
73/23/ EEC Low Voltage Guideline
Therefore the burner carries the CE/0085 Label.
The product conforms to the type test
0085 of the Notified Body.
Extensive quality assurance is guaranteed by a certified
Quality Management System to DIN EN ISO 9001.
Max Weishaupt GmbH
Burner and Heating Systems
D-88475 Schwendi
0085
Contents
Title Page
1. General instructions 3
2. Burner installation 5
3. Burner fuel system for gas 7
4. Description of valve trains 8
4.1 Solenoid valves 8
4.2 Pressure regulator type FRS 10
4.3 Valve proving VPS 504 11
4.4 Valve proving type W-DK 3/01 14
5. Installation of valve trains 15
5.1 Safety information 15
5.2 Installation example 16
6. Soundness test of valve trains 18
7. Sequence test of operation 18
8. Preparation for first commissioning 19
8.1 Testing gas supply pressure 19
8.2 Purging gas supply line 19
9. Commissioning the gas part 19
9.1 Checks prior to first commissioning 19
9.2 Flame monitoring 19
9.3 Adjusting gas part 20
9.4 Set gas pressure switch 22
9.5 Set air pressure switch 22
9.6 Combustion analysis 23
9.7 Setting pressure and minimum
connection pressure 24
10. Setting the mixing head 29
11. Capacity graphs 30
12. Oil supply 33
13. Oil Pump 34
14. Fan wheel attachment 36
15. Fuel system for oil 37
16. Regulating systems 38
16.1 RGL3 to RGL 7 38
16.2 RGL8 to RGL11 39
16.3 Oil meter and oil regulator 40
17. Nozzle selection 41
17.1 Two and three stage burners 41
17.2 Regulating burner 42
18. Removal of mixing head -
ignition electrode setting 44
19. Commissioning the oil part 45
19.1 Tests prior to first commissioning 45
19.2 Adjusting the oil part 45
20. Sequence of operation 47
20.1 Pre-requisite for burner start 48
20.2 Symbols on the fault position indicator 48
20.3 Basic wiring diagram for LFL 1.../ LGK16... 49
20.4 Switching times 50
20.5 Sensor line between LGK 16... and
QRA 53 / QRA 55 or sensor electrode 51
20.6 Technical data 52
21. Cam setting of limit and auxiliary
switches in the servo-motor 53
21.1 Dual fuel burners, two stage 53
21.2 Dual fuel burners, sliding two stage 54
22. Throughput determination, conversion
from normal to operating condition 55
23. Fault conditions and procedures 57
3
1. General instructions
Safety
To ensure safe burner operation, the burner has to be
installed and commissioned by qualified personnel
and all guidelines in these operating instructions have
to be followed.
Special attention should be paid to the relevant
installation and safety guidelines given (i.e. local
Codes of Practice).
Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
commissioned, and may only be replaced by, the
manufacturer or the authorised agent.
Failure to comply can lead to serious injury or death
and can cause considerable damage to the plant.
Qualified personnel according to this operating
manual are persons who are familiar with the
installation, mounting, setting and commissioning of
the product and which have the necessary
qualifications such as:-
Training, instruction or authorisation to switch
electrical circuits and electrical devices on and off, to
earth them and to mark them in accordance with the
safety standards.
Training, instruction or authorisation to carry out
installation, alteration and maintenance work on gas
installations in buildings and on site.
Operating instructions
The installation and operating instructions included with
each burner must be displayed clearly in the plant room.
We refer to DIN 4755, point 5. The address of the nearest
service centre must be entered on the reverse of the
instructions.
Instruction of personnel
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with
regard to the operation of the burner. With frequently
occurring burner faults, the nearest service centre must be
notified.
Installation
The installation of oil fired equipment must be carried out
to extensive guidelines and regulations. It is the duty of the
installer to familiarise himself with all regulations.
Installation, commissioning and maintenance must be
carried out with care. Fuel oils to DIN 51 603 EL should
be used.
Electrical wiring
Each burner is supplied with a wiring diagram and burner
connection diagram as standard.
Maintenance and service
In accordance with DIN 4756, the whole installation
including the burner should be inspected by a qualified
engineer of the supplier at least once a year. The
combustion figures should be checked after each service
and each time an error has been rectified. If, during
maintenance, control seal joints have to be opened, these
have to be thoroughly cleaned and new seals fitted when
re-assembling.
Abbreviated instructions
The following table gives an overview of the procedures for
installation and commissioning.
To ensure safe installation and commissioning
all instructions given in these installation and
operating instructions must be followed.
Step Action Chapter
1 Burner installation 2
2 Installation of oil supply 12 to 16
3 Installation of gas valve trains 5
4 Soundness test of valve train 6
5 Testing gas supply pressure 8.1
6 Purging the gas supply line 8.2
7 Testing sequence of operation 7
8 Nozzle selection 17
9 Testing the mixing head 10 and 18
10 Testing the plant 9.1 and
19.1
On two and three stage burners:
11 Commissioning gas part 9
12 Commissioning oil part 19
On regulating burners:
11 Commissioning oil part 19
12 Commissioning gas part 9
DANGER
4
Installation conditions
Material, construction and type of protection of the
burners and gas valve trains in their standard version are
designed for use indoors. Permitted ambient temperature
is - 15C to + 40C.
Electrical installation
When installing the electrical connection cables ensure
that these are long enough to allow the burner and boiler
door to be hinged open.
Control circuits, which are taken from one of the supply
phases, must only be connected with an earthed neutral
conductor.
On a mains supply which is not earthed the control voltage
must be supplied via an isolating transformer.
The pole of the transformer, which is to be used as the
neutral conductor must be earthed.
The control circuit phase and neutral conductors must
be connected correctly.
Ensure the correct fuse ratings are not exceeded. Earthing
and neutral conductors must conform to local regulations.
General information for gas operation
When installing a gas combustion system, local
regulations and guidelines must be observed.
The subcontractor responsible for the installation or
changes of the gas system must inform the gas supplier of
the type and extent of the installation planned and the
intended work. The subcontractor must ascertain that an
adequate gas supply to the installation is ensured.
Installation, alteration and maintenance work on gas
systems in buildings and on process sites, must only be
carried out by installers who have a contract with the gas
supplier.
Gas characteristics
The following information must be obtained from the gas
supplier:
Type of gas, calorific value in kW/hm
3
, max. CO
2
content of
flue gas, gas supply pressure.
Gas line
The gas pipework must be subject to a preliminary and
main test or the combined loading test and soundness
test, according to the pressure range intended. The air or
purge gas required for the test must be expelled from the
pipework.
The determination of the pipework diameter usually gives a
diameter, which is at least one diameter larger than the
size of the burner valve train.
Gas valve train
Observe the sequence and flow direction. The distance
between burner and DMV valve should be as small as
possible in order to guarantee trouble free start.
Pipe thread connection
Only tested and approved sealing material should be
used. Please observe individual user instructions!
Soundness test
Brush connection points with foam forming agents or
similar, non-corroding materials.
Gas types
The burner must only be operated with the type of gas
stipulated on its name plate. When converting to other
types of gas re-commissioning is required. A conversion kit
may also be needed.
Valve train installation
The valve train must be fixed and supported securely.
Standard connection is from the right.
Gas meter
The siting, size and type of gas meter are the responsibility
of the gas supplier. Only those meters, which have been
approved, should be used. If no gas meter is fitted, as for
instance on liquid petroleum gas installations, the operator
has to be made aware that the burner can not be set to its
optimum, because basic testing is not possible without a
meter installation.
Plant room regulations
Local regulations regarding the design of plant rooms
must be observed and the installation of an emergency
switch and a mains gas shut off system should be
considered. Attention should also be paid that sufficient
ventilation is available in the plant room. Any shortcoming
should be noted in the commissioning report.
The commissioning report must be completed by the
service engineer and signed by the plant operator or his
authorised agent. The operator should be instructed in the
correct operation of the burner and control panel. The
operating instructions included with each burner must be
displayed clearly in the plant room.
Thermal / manual shut off system
If a thermal / manual shut off system is required, this
should be fitted in front of the burner fuel isolation valve(s).
This installation must conform to local regulations.
5
2. Burner Mounting
Mounting to the heat exchanger
Installation example for heat exchanger with refractory
Drilling dimensions of the burner plate
Size 1 to 10 Size 11
Size Combustion Dimensions in mm
head type l1 d1 d2 d3 d4 d5
1 G1/2a 112 130 160 160-170 135 M8
3 G3/1a 157 160 190 186 165 M10
5 G5/1a 200 200 240 235 210 M10
7 G7/1a 230 250 290 298 270 M12
8 G7/2a 230 265 300 298 270 M12
9-10 UG2/1a 233 325 360 330 305 M12
11 UG3/1a 280 380 420 400 385/360* M12
* The burner can only be removed with the boiler plate
d5
d4
d3
d5
d4
d3
6
0
3
0
The gap between combustion head

and refractory must be filled with
flexible insulating material . Do not
make solid.
Hinging the burner
Remove gas butterfly rod.
Electrical connection
A wiring diagram is enclosed with each burner delivery.
Interlock switch
The interlock switch is arranged in such a manner that the
circuit is closed in the burner closed position. In the burner
open position, the circuit is interrupted by the release of
the tripping pin in the interlock switch.
Transport weight
Burner type Weight (without valve train)
GL 1 42 kg
GL 3 47 kg
RGL 3 47 kg
GL 5 55 kg
RGL 5 55 kg
GL 7 82 kg
RGL 7 82 kg
GL 8 91 kg
RGL 8 91 kg
GL 9 136 kg
RGL 9 136 kg
RGL 10 137 kg
RGL 11 167 kg
6
Combustion head extension
Combustion head extensions are required on appliances
with very thick doors and boilers with a flame reversal fire
tube.
For easy removal of the burner internal head assembly,
particularly those with head extensions, it is important, that
the burner body is able to swing through approx. 90.
To enable installation and service work to be carried out,
the refractory should not be longer than dimension l 1.
Only valid for standard boiler arrangements, not for special
combustion chambers, ovens etc.
Installation example
Refractory
Burner plate
Flange gasket
Burner flange
flexible insulating material
Combustion head
Extension
Burner Extension Dimension in mm
size mm l1 d1 d2 d3
1 100 212 120 130 170
1 200 312 120 130 170
1 300 412 120 130 170
3 100 257 140 160 200
3 200 357 140 160 200
3 300 457 140 160 200
5 100 300 180 200 240
5 200 400 180 200 240
5 300 500 180 200 240
7 100 330 220 250 290
7 200 430 220 250 290
7 300 530 220 250 290
8 200 430 220 265 305
8 300 530 220 265 305
9-10 200 433 280 325 365
9-10 300 533 280 325 365
11 200 480 325 380 420
11 300 580 325 380 420
7
P
4a 1
P
4 5a 6
9 5b
2 3
P
12
7 10 11
P
4a
P
5b
4 5 6
9 7
1 2 3 8
3. Burner fuel system for gas
With DMV valve and valve proving system VPS
With 2 solenoid valves and valve proving system W-DK 3/01
Valve trains
In accordance with EN 676 burners must be fitted with
Group A solenoid valves.
Weishaupt gas and dual fuel burners are supplied as
standard with two solenoid valves (on DN 150 with two
single solenoid valves).
Weishaupt also recommend the use of a valve proving
system. In accordance with EN 676 the use of a valve
proving system is required for installations from 1.200 kW.
This and other valve train components, such as gas filter
and gas governor can be found in the Weishaupt
accessories list.
Legend
1 Ball valve
2 Gas filter
3 Pressure regulator
4 Gas pressure switch, min.
5 Double solenoid valve (DMV)
5a Single solenoid valve
5b Ignition gas solenoid valve
6 Gas butterfly valve
7 Pressure gauge with push button valve
8 VPS valve proving
9 Burner
10 Valve leakage indicator
11 Vent valve
12 Gas pressure switch for valve proving W-DK 3/01
8
1
2
3
6
4
7
5
4. Description of valve trains
Function
DMV-D/ 11
Two single solenoid valves normally closed, fast opening,
fast closing, manual limiting of gas throughput is possible
by adjusting main flow at valve 1 (V1).
Technical data
Max. operating pressure 500 mbar
Voltage/frequency ~(AC) 230 V - 15 %...
to 240 V + 10 % 50/60 Hz
or ~(AC) 110 V 50/60 Hz
Ambient temperature -15 C ... +60 C
Installation Horizontal or vertical
L1 N
2 1 3
V1 V2
L2
Electrical connection Pressure test point
Legend
1 Pressure into V1
2 Pressure between V1 and V2
3 Pressure after V2
4 Inlet flange connection
5 Outlet flange connection
3
L2
3
1
L1 N
2
DMV-D 5040/11 - 5125/11
2
3 1
5 4
Legend
1, 2 Pressure into V1
3 Pressure between V1 and V2
4 Ignition gas outlet
5 Pressure after V2
6 Inlet flange connection
7 Outlet flange connection
1
2
3
4
2
c
m
4
4
V1 V2
2 3 5
2 3 5
1
1
6 7
4
4
V1 V2
1 2 3
1 2 3
DMV and GW plug
DMV-D 507/11 - 520/11
MVD 507/5
DN 3/4 with
socket connection
DN150 with
flange connection
DIN 2633 PN16
MV 5150/5-S
R 1/4 both sides
R 3/4"
R1/4 both sides
4.1 Solenoid valves
9
1. Switch off and isolate installation
2. Remove connection plug
3. Remove paint seal from screw A
4. Remove counter sunk screw A
5. Remove cheese head screw B
6. Remove cap (C) and metal plate (D)
7. Change solenoid, checking new unit is correct
type/voltage
8. Refit metal plate (D) and cap (C)
9. Refit screws A and B
10. Do a gas tightness test at test point 2 and 3:
p
min
= 100 - 150 mbar
11. Carry out function test
12. Switch on supplies and test burner
Changing solenoid valve DMV
A
B
C
D
E
F
Gas throughput adjustment
DMV 507-5125 DMV 507 - 520/11 Throughput adjustment on V1 via
covered adjusting screw.
One turn = 0.5 mm stroke
adjustment, anti-clockwise to in-
crease flow , and vice-versa.
DMV 5040 - 5125 Throughput adjustment on V1 via
covered adjusting screw.
One turn = 1 mm stroke
adjustment, anti-clockwise to in-
crease flow , and vice-versa.
Factory pre-set: maximum stroke
V1
min max
Connection of gas pressure switch to DMV
Fit gas pressure switch
10
4.2 Pressure regulator type FRS
Outlet pressure adjustment (set value) 1. Remove cap A
2. To increase outlet pressure (set value), turn screw B
clockwise.
or
3. To reduce outlet pressure (set value), turn screw B anti-
clockwise.
4. Prove the adjustment is correct.
5. Replace cap A
Changing the spring
1. Remove cap A. Turn screw B totally anti-clockwise.
2. Remove spring retainer C, and remove the spring D.
3. Fit new spring D.
4. Re-fit spring retainer C, and by turning screw B set the
required outlet pressure.
5 Prove adjustment is correct and re-fit cap A, and new
range label.
Type of spring / colour Outlet pressure range
mbar
orange 5 20
blue 10 30
red 25 55
yellow 30 70
black 60 110
pink 100 150
B
A
C
A
B
D
Gas pressure swith on DMV-screwed version
11
4.3 Valve proving system VPS 504
Operation
The valve proving system type VPS 504 operates to the
pressure build up principle. The prog. is activated at heat
request. Valve proving is carried out after every burner start.
The VPS 504 carries out a self-test during the switching
sequence. If a fault occur release is prohibited and an error
message is displayed.
Technical data
Max. operating pressure 500 mbar
Test volume 4,0 l
Pressure increase via
motor pump 20 mbar
Voltage/frequency ~(AC) 230 V - 15 %...
to 240 V + 10 % / 50 Hz
or ~(AC) 110 V / 50 Hz
Type of protection/
switching duration
Series 04 IP 54 / 100 % Ed
Pre-fusing (by others) 10 A F oder 6.3 A T
Fusing fitted to
housing T6,3 L 250 V
Switching current operating output max. 1A
lockout output max. 1A
Release time 10 26 s
max. number of test cycles 20 /h
Ambient temperature -15 C ... +60 C
Installation vertical or horizontal
Pressure reduction
1 Connection p
e
, p
1
2 Connection p
a
, p
2
3, 4 Test points
III III
III
III
I I I
III
III
I I I
I I I I I I I I I
pa
p2
pe
p1
pa
p2
pe
p1
3
2
1
VPS 504
p2
pa
p1
pe
p2
pa
p1
pe
1 2
3 4
DMV-.
MB-
Series 04
12
Sequence of operation
V1 V2
VPS 504
p2
pa
p1
pe
p2
pa
p1
pe
A
p
e
A
p + 20 mbar
e
V1 V2
VPS 504
p2
pa
p1
pe
p2
pa
p1
pe
p
e
A
V1 V2
VPS 504
p2
pa
p1
pe
p2
pa
p1
pe
p
e
p
e
p
e
A
Programme sequence Shut down condition: Valve 1 and valve 2 are closed.
Pressure build-up: The internal motor pump increases the
gas pressure in the test section by approx. 20 mbar when
compared to the pressure p
e
on the inlet side of valve 1.
During the test phase the inbuilt differential pressure
switch checks the test section for soundness. Once the
test pressure has been reached the motor pump is
switched off (end of test phase). The release time (10 to
26 secs) depends on the test volume (max. 4.0 l).
If the test section is sound, the contact to the burner
control is released after max. 26 secs. The yellow signalling
lamp is illuminated.
If the test section is not sound or if the pressure increase of
+ 20 mbar is not reached during the test phase (max
26secs.), the VPS 504 goes to lockout. The red signalling
lamp is illuminated as long as contact is made by the
regulator (heat request).
An automatic restart is carried out following short term
voltage loss during the test phase or during burner
operation.
0 5 10 15 20 25 [s] 30
VPS 504 "DICHT" VPrf = 0,3 l
VPS 504 "DICHT" VPrf = 4,0 l
VPS 504 "UNDICHT"
Regulator
Pump motor
Solenoid valve
Diff. pres. switch
Release signal
Regulator
Pump motor
Solenoid valve
Diff. pressure switch
Release signal
Regulator
Pump motor
Solenoid valve
Diff. pressure switch
Release signal
Lockout signal
A=Programmer
Shutdown Pressure build-up
Operation
Installation
VPS on DMV screwed VPS on DMV flanged
Note:
Remove closing plug prior to installation
Properly tighten cover screw and connecting screw,
avoiding over-tightening!
Protect flange surface. Tighten screws in diagonally
opposite sequence.
The unit must not be used as a lever.
When work in on the VPS 504 is complete carry out
valve proving and function test.
Ensure tight sealing when changing parts.
Remove closing
plug
VPS "Sound" Vtest = 0.3 l
VPS "Sound" Vtest = 4.0 l
VPS "Not Sound"
13
Electrical connection VPS 504 series 04
With cable gland PG 13.5 and connection to screw
terminals.
Potential free relay contacts must only be used for
signalling and never for burner control circuit!
Release time tF
Time required by the VPS 504 to carry out a complete test
cycle. The release time of the VPS 504 depends on the
test volume and inlet pressure:
V
test
< 1.5 l V
test
> 1.5 l
p
e
> 20 - 500 mbar p
e
> 20 mbar
t
F
10 s t
F
> 10 s
t
F max / VPS 504
26 s
Test time P
t
Pump time of the motor pump.
Test volume V
test
Volume between V1 on the outlet side and V2 on the
inlet side.
V
test max. / VPS 504
= 4 l.
Test volume of the multiple settings units
Type Rp/ DN Test volume
DMV-D(LE) 503/ 11 Rp 3/8 0.09 l
DMV-D(LE) 507/ 11 Rp 3/4 0.09 l
DMV-D(LE) 512/ 11 Rp 1 1/4 0.25 l
DMV-D(LE) 520/ 11 Rp 2 0.25 l
DMV-D(LE) 5040/ 11 DN 40 0.36 l
DMV-D(LE) 5050/ 11 DN 50 0.36 l
DMV-D(LE) 5065/ 11 DN 65 0.60 l
DMV-D(LE) 5080/ 11 DN 80 1.70 l
DMV-D(LE) 5100/ 11 DN 100 2.30 l
DMV-D(LE) 5125/ 11 DN 125 3.75 l

9
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Sicherung eingebaut, auswechselbar
Fuse built into housing, exchangeable
Fusibile integr dans la couvercle du botier
interchangeable
Typ/Type/Type/Tipo T 6,3 L 250 V
Betriebsanleitung beachten!
Please comply with the operating instructions!
Suivre les instructions de la notice d'utilisation!
Seguire le istruzioni!
Standard:
Kabeldurch-
fhrung
PG 13,5
Zustzlich
Kabeldurchfhrung
PG 11 mglich
pe
Mestutzen
pa
Mestutzen
Sauganschlu (Gaseingang)
Druckanschlu (zur Prfstrecke)
1
NC
VPS 504
Serie 04
intern
2
COM
3
NO
4 5
B
6
L1
7
N
8
potentialfreies Strsignal
(Leitwartensignal)
Betriebsspannung ~(AC) 230 V 50 Hz
}
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r
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dicht
undicht
V3
P
Interchangeable
fuses:
T 6.3 L 230V
to ICE 127 2/ III
(DIN 41662)
D5 x 20
1 2 3 4
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
p
=
3
0
0
m
b
a
r
e
p
=
1
0
0
m
b
a
r
e
p
=
2
0
m
b
a
r
e
p
=
5
0
0
m
b
a
r
e
t
10 s
V
1,5 l
Anwendungsbereich
F
Prf
t [s]
F
V [l]
Prf
Installation dimensions S04/ S04
VPS 504 Series 04
VPS 504
Series 04
internal
Potential free lockout signal
Operating voltage
R
e
l
e
a
s
e

s
i
g
n
a
l
O
p
e
r
a
t
i
n
g
v
o
l
t
a
g
e
N
e
u
t
r
a
l
c
o
n
d
.
E
a
r
t
h
not sound
sound
V
test.
1,5 l
V
test
Application range
Replacement fuse
Additional cable
entry
PG11
p
e
test point
Suction connection
(gas inlet)
Pressure connection
(to the test section)
p
a
test point
Standard
cable entry
PG 13.5
14
1 Solenoid valve 1
2 Solenoid valve 2
3 Leakage indicator unit
4 Vent valve
5 Gas pressure switch
6 Programmer fitted into
control panel
150
5 5
75
100
1
3
3
2
3
II
II
Fitting dimension
Plug-in unit
Sub- base
cable entry
3 1 4 2 5 6
4.4 Valve proving system type W-DK 3/ 01
Construction
The valve proving system W-DK 3/01 consists of four main
parts:
I Programmer fitted into the control panel of plant
IGas pressure switch fitted to the test section between
the solenoid valves
I Vent valve (normally open) fitted into the vent line
I Leakage indicator unit fitted into the vent line
Function
The tightness of the solenoid valves in the gas valve train is
checked prior to each burner start.
Operation
1. Test phase: During pre-purge all solenoid valves are
closed. If pressure builds up due to possibly leaking first
valve, the pressure increase is detected by the gas
pressure switch.
2. Test phase: If the first solenoid valve is gas-tight, it is
opened momentarily , but the vent valve remains closed.
Gas pressure is now in the section between the
solenoid valves. It is tested for a reduction in pressure in
test section. The test is controlled by the programmer.
Gas valve train with Weishaupt valve proving system W-DK 3/01
Technical data
Weishaupt valve proving system Type W-DK 3/01
Mains voltage/ Frequency V / Hz 220 15% / 50 or 60
Fusing A in accordance with the
pre-fusing of the burner
control
Perm. ambient temperature C 10+ 60
Programmer Test times
Pressure switch test
without pressure secs. 8
Fill test section secs. 2
Test time with test pressure secs. 9
Type of protection IP40
Consumption VA approx. 4
Installation as required
Weight kg 0.734
Pressure switch GW50 A4 Setting range mbar 2.550
Pressure switch GW150 A4 Setting range mbar 30150
Vent valve LGV 507/5 Nominal diameter R 3/4
Leakage indicator
(without glycerine) Nominal diameter R 3/4
Programmer
Test result
If a pressure increase (phase 1) or pressure decrease
(phase 2) is detected, the burner start is inhibited.
Otherwise the solenoid valves seats are gas tight and the
burner starts.
Pressure switch setting
1/2 flow pressure
15
5. Installation of valve trains
5.1 Safety notice
Risk of explosion!
If the valve trains are not installed correctly, their
soundness cannot be ensured.
To avoid deadly accidents, the following safety
instructions must be observed during
installation:
GObserve the maximum permitted gas pressure in the
valve train. Contact your local gas supplier to obtain the
connection pressure of the gas mains supply.
The connection pressure must not exceed the maximum
pressure recorded on the name plate.
GValve trains must be installed securely to avoid vibration
during operation.
Suitable supports should be used (available as
Weishaupt accessory).
The supports must be fitted to the specific site
requirements when mounting the valve trains.
GValve trains must be installed tension free. Never
compensate for mistakes made during installation by
over tightening the flange screws.
GFlange screws should be tightened diagonally opposite.
GEnsure flange gaskets are clean and fitted correctly.
GOnly gas board approved sealing material should be
used. If a connection needs to be loosened often, flange
connections with inlaid gasket should be used.
Other installation information:
On installations, which are subject to special regulations
for steam boilers, the valve trains can be vented with a test
burner. The first solenoid is fitted with a connection point
for this test burner.
To allow the appliance door to be hinged open, a flange
connection point, if possible at door level, should be fitted
(compensator see drawings, chapter 5.2).
To achieve better start conditions, the distance between
burner and solenoid valves (ignition and mains gas) should
be as small as possible.
Observe sequence and flow direction of valve train.
If a thermal shut off device TAE is required, this must be
fitted in front of the ball valve.
DANGER
Danger
16
Low pressure supply with DMV flanged
11 10 9
8 7 6
5a 4 3 1 2a
1 3 4
9
6 7 8 5b
11 10
2a
5.2 Installation example
High pressure supply with DMV flanged
17
Low pressure supply with single valves (only for nominal diameter DN 150)
1 Solenoid valve for ignition gas
2a Double solenoid valve DMV
2b Single valve
3 Test burner
4 Gas pressure switch, max. (on TRD)
5a High pressure regulator
5b Low pressure regulator
6 Filter
7 Pressure gauge with push button valve
8 Ball valve
9 Compensator
10 Gas pressure switch, min.
11 Valve proving system VPS
12 Pressure switch for valve proving system W-DK 3/01
1 3 4 6 7 8
11 10
5b 2a
1 2b 2b 3 4 5b 6 7 8
12 10 9
Low pressure supply with DMV screwed
18
6. Soundness test of valve trains
Soundness test of the gas train must be carried out with
the main isolating cock and DMV valves closed. Proceed
as follows:
1. Test phase: ball cock up to 1st valve seat (V1)
The test assembly is connected to the gas filter and DMV
inlet. During pressure testing, the test point 2 between
DMV valve seats V1 and V2 has to be open.
2. Test phase: volume between 1st and 2nd valve seat
The test assembly is fitted to the DMV test point 2.
Test pressure in the valve train should be between 100 and
150 mbar.
Wait 5 minutes for pressure equalisation.
The valve train is not leaking if the pressure drop is no
more than 1 mbar after the test period of 5 minutes has
elapsed
3. Test phase: Valve train connection parts and gas
butterfly valve
The third test phase can only be carried out during
operation and by using a leak detection solution.
Results of the pressure test must be recorded on the
service/commissioning report.
Attention!
After all maintenance and commissioning work on gas
supplying components a soundness test must be
carried out.
1 Rubber hose with T piece
2 Aspirator
3 U-tube manometer or electronic manometer
1
2
3
7. Sequence test of operation
Wiring connection check
Check that the wiring to all parts, especially the valve train,
is carried out in accordance with the wiring diagram
supplied with the burner.
Testing the burner
Check the rotation of burner motor.
Disengage servomotor. It must be possible to turn the
servomotor by hand. Re-engage servomotor.
Sequence test gas operation (without gas)
The ball valve must be closed. Air is pumped into the valve
train by means of the hand pump still connected from the
soundness test. The pressure must be at least as high as
the subsequent gas operating pressure.
The burner is switched on and the following programme
should take place:
Versions with DMV and valve proving system VPS
Burner motor starts following successful valve proving.
The servomotor opens the air damper in approx. 40 (20)
seconds.
The full load pre-purge period is 30 seconds.
The servomotor closes the air damper to the ignition
position in approx. 35 (17) seconds.
The pre-purge time of approx. 4 seconds begins.
Gas solenoid valves are opened.
Pressure in the valve train falls.
Gas pressure switch shuts down the burner.
Gas solenoid valves are closed.
If the gas pressure switch does not shut down after the
safety time of 2 seconds has elapsed, then the burner
control locks out.
Version with two solenoid valves and valve proving
system W-DK 3/ 01
Burner motor starts.
The servomotor opens the air damper in approx. 40 (20)
seconds.
The full load pre-purge period is 30 seconds.
Valve proving is carried out in accordance with the
sequence of operation (see chapter 13).
The servomotor closes the air damper to the ignition
position in approx. 35 (17) seconds.
The pre-purge time of approx. 4 seconds begins.
Gas solenoid valves are opened.
Pressure in the valve train falls.
Gas pressure switch shuts down the burner.
Gas solenoid valves are closed.
If a fault occurs during the sequence of operation see
description of burner control LFL1... and the additional
information.
First test phase Second test phase
V1 V2
19
Risk of explosion!
The mains gas pressure must not exceed the
max. permitted pressure of the valve trains listed
on the burner name plate. The mains gas
pressure must be checked prior to first
commissioning.
1. Connect manometer to filter.
2. Slowly open the ball valve monitoring the manometer at
all times.
3. Close the ball valve immediately if the mains gas
pressure exceed the max. permitted pressure of the
valve train. The burner must not be started.
4. Contact your nearest Weishaupt branch office.
8. Preparation for first commissioning
8.1 Testing the gas supply pressure
DANGER
8.2 Purging the gas supply line
Purging
The valve train must be purged prior to first
commissioning.
A hose leading into the open is connected to the test point
on the gas solenoid valve to discharge the air.
The ball valve is opened. The gas in the valve trains
escapes into the open via the hose.
After purging, the test manometer or gauge is
reconnected at the test point on the solenoid valve.
If a test burner is installed, this must be used to ensure
that no air is present in the equipment.
Any air or inert gas in the distribution lines must also
be expelled from the pipework. This work is usually
carried out by the local gas authority.
When work on the valve train involves changing
components, the valve train must be purged and
undergo a valve proving test before the burner is
switched on again.
9. Commissioning
9.1 Checks prior to first commissioning
The whole installation must be checked prior to the
first commissioning.
GHas the heat exchanger been installed ready for
operation?
GAre heat exchanger and system filled sufficiently with
heating medium?
GAre movable explosion flaps fitted?
GIs the flue gas damper open?
GAre the flue gas ways free?
GAre the fans of air heaters operating correctly?
GIs the ventilation to the plant sufficient?
GHas the whole installation been wired correctly?
GHave temperature switch, pressure switch and safety
limiting systems been set to operating requirements?
GIs sufficient load available?
GHas the low water safety interlock been adjusted
correctly?
GHave all fuel carrying parts been vented (free of air)?
GCheck rotation of burner motor.
GHas the valve train leakage test been carried out?
GIs the gas supply pressure correct?
It is possible that other site-specific tests will have to be
carried out. Refer to the operating instructions of individual
site components.
9.2 Flame monitoring
Test for flame sensor
Ionisation electrode: By separating the plug connections
in the vicinity of the terminal strip.
UV cell: By withdrawal from the holder on the burner
flange.
Note: With the LGK 16... burner control and UV sensor
QRA 53/55, it is only possible to measure the sensor
current by means of the special sensor current measuring
instrument type KF8832.
UV detector QRA2 and LFL
Microammeter
(range 0 ... 600 A
or 0 ... 1 mA)
22
23
Danger
20
9.3 Adjusting gas part
On two and three stage burners GL30/ 40 the gas part
is commissioned prior to the oil part. On regulating
burners the oil part must be commissioned prior to the
gas part.
Switch on procedure
Set operating switch to gas.
Open ball valve.
Release gas pressure regulating spring (see chapter
4.2).
Set selector switch in control panel to Stop.
Reset installation.
Switch on burner operating switch.
Ignition
After the pre-purge time has elapsed, wait for flame
formation. If ignition problems occur check the pre-setting
of the gas butterfly valve (nominal approx. 5 - 10Open
on the gas butterfly scale), as well as the position of the
ignition load switch in the servomotor (ZM: No. IV) and if
necessary increase slightly. Check sensor current with
microammeter.
Intermediate testing (partial load to full load):
After approx. 20 secs. the servomotor runs from ignition to
partial load position.
Set gas pressure to table in chapter 9.7
(Setting pressure into solenoid valve).
Carry out CO test.
Version Z:
Switch off servomotor with toggle switch
Adjust regulating cam step by step with servomotor
dis-eneaged
Re-engage servomotor.
Carry out CO tests at each cam setting up to full load
setting.
GL burners:
Make the necessary corrections to the pressure
settings.
Version ZM:
Disengage servomotor
Turn gas regulating cam step by step by hand and re-
engage servomotor.
Carry out CO tests at each cam setting up to full load
setting.
GL burners:
Make the necessary corrections to the pressure
settings.
RGL burners:
Make the necessary corrections by adjusting the gas
curve band.
Full load setting:
Drive up servomotor electrically towards full load:
Version Z:
Switch toggle switch in servomotor to On
Set selector switch in the control panel to full load
Version ZM:
Disengage servomotor
Return gas regulating cam to its intermediate position
and re-engage servomotor.
Set selector switch in control panel to full load.
Butterfly valve pre-setting
Disengaging servomotor SQM
Disengaging servomotor 1055/80
Setting combustion air
The required amount of gas for full load must be set and
measured at the gas meter (the gas pressures given in the
table chapter 9.7 are only an aid for setting and adjusting).
21
Combustion test:
GL burners:
Regulate the amount of gas by adjusting the gas
setting pressure. Regulate the combustion values by
adjusting the curve band of the air regulating cam and
positioning of the regulating sleeve so that best
possible values and good flame stability are achieved
with fully opened air damper.
RGL burners:
The oil side settings of the air curve band and the
mixing head must not be altered. Match gas quantity to
the existing conditions by adjusting the gas curve
band and if necessary by correcting the gas pressure
on the regulator.
The gas pressure set for full load must not be altered.
Intermediate check (full load to partial load).
Version Z:
As the burner rating changes between full and partial
load (high and low fire) occur quickly, it is only
necessary to do spot checks at the intermediate
ratings for CO.
Start cams step by step electrically, (trip switch off,
selector switch stage 1), start points with trip switch.
Version ZM
After the burner operating range between high fire
and low fire has been determined with good
combustion quality, it is necessary to adjust the
intermediate firing rate combustion qualities. Set the
modulation selector switch to Stop, disengage
servomotor drive, and set each cam band adjuster for
good combustion quality. Re-engage servomotor
drive and set the modulation selector switch to
Automatic.
GL Burners:
Adjust the combustion quality by means of the air cam
band.
RGL Burners:
Adjust the combustion quality by means of the gas
cam band.
It is important that the cam bands scribe a smooth arc.
Partial load setting
Set selector switch on control panel to Stage 1 or
Partial load. Set the required gas volume (throughput) by
means of the auxiliary switch in the servomotor (Z: No 11,
ZM: No.V1) and measure volume at the gas meter.
Pay attention to the minimum limits of the capacity graphs,
flue gas temperatures and instructions of the boiler
manufacturer.
Completing commissioning
Check ignition load setting once burner has been
commissioned, if needed adjust at the auxiliary switch in
the servomotor (Z: No.V,ZM:No.IV). The ignition load
setting needs to be reliable and free of ignition impact,
regard must be taken of local requirements covering
ignition firing rate limitations. An ignition test needs to be
made with the gas pipework downstream of the safety
valve and the head of the burner devoid of gas. The
required measurements can be made by holding the
burner in the start gas phase (Z: toggle switch in
servomotor, ZM: interrupt servomotor neutral at ignition
load position).
Check the CO limit by setting burner from low fire (partial
load) to high fire (full load) and high fire to low fire.
With the installation operating, test the function and
setting of safety equipment, i.e. gas and air pressure
switches, plant temperature/pressure limit switches,
interlocks.
Documentation:
The following setting values have to be noted on the
commissioning report.
At ignition load: At full and partial load:
Gas throughput Gas throughput
Sensor current Gas pressure into ball valve
CO Gas pressure after ball valve
CO
2
CO
With liquid petroleum gas: Exhaust gas temperature
take smoke measurements Fan pressure
Suction/pressure in
combustion chamber
Sensor current
22
9.4 Set gas pressure switch
Gas pressure switch type GW50A2
Gas pressure switch, min.
To set a pressure switch for gas, a pressure measuring unit
has to be fitted to test point 1 of the DMV and the
microammeter for measuring of the ionisation current.
When determining the switch point, pay attention that this
is not below half the regulated pressure, that the ionisation
current is a minimum of 5 A and that combustion is CO
< 1000 ppm (CO increase due to excess air).
Setting is carried out in the following manner:
1. Burner is operating (full load)
2. Gradually close ball valve so that the pressure at the
pressure test unit slowly decreases.
3. Setting pressure has been reached when
CO increases
sensor current does not drop below the minimum
permitted value
or when half the regulated gas pressure has been
reached
4. Slowly turn the setting cam of the gas pressure switch
to the right until the burner carries out a controlled
shutdown.
5. Control - the burner is restarted with open ball valve. If
the ball valve is closed again, the shut down pressure can
be tested. The burner control must not go to lockout.
High gas pressure switch, max. (to TRD/ I M30)
must be set to 1.3 x p
max
.
3
0
3
5
4
0
4
5
5
0
25 20
1
5
1
0
5
2
, 5
m b a r
G
W
5
0
A
2
9.5 Set air pressure switch
The air pressure switch is pre-set. The switch point
must be checked and adjusted during commissioning.
For this a differential pressure measurement between
points and is required. Pressure behaviour is
monitored throughout the set range of the burner by the
manometer (i.e. U tube). The lowest differential pressure
value is used for the determination of switch point. The
switch point is set to > 80% of this value. To do this, the
protective cap of the LGW is removed and the calculated
value is set at the setting wheel.
Example:
Reduced differential 20 mbar
Switch point air pressure switch 20 x 0.8 = 16 mbar
Installation dependant influences, such as flue gas
recirculation, heat exchanger, installation or air supply, on
the air pressure switch and the settings may result in
adjustments having to be made.
Differential pressure test
3
0
3
5
4
0
4
5
5 0
25 20
1
5
1
0
5
2
, 5
m b a
Pressure switch for air type LGW50A2
23
Calorific value of various types of gas and max. CO
2
Type of gas Calorific value H
i
, CO
2
max.
MJ/m
3
kWh/m
3
1. Gas family
Group A (Towns Gas) 15.1217.64 4.204.90 1213
Group B (Grid Gas) 15.9118.83 4.425.23 10
2. Gas family
Group LL (Natural Gas) 28.4836.40 7.9110.11 11.511.7
Group E (Natural Gas) 33.9142.70 9.4211.86 11.812.5
3. Gas family
Propane P 93.21 25.99 13.8
Butane B 123.81 34.30 14.1
To ensure efficient and problem free operation of the
installation, flue gas measurements must be taken.
The various maximum CO
2
contents can be obtained from
the local gas board (guide values see table).
Excess air should not exceed 10 to 20 % at full load
and 30% at partial load.
Excess air
CO
2
max.
CO
2
measured
The CO content must not be more than 0.005 Vol. %
(50 ppm)
Flue gas temperature for full load (nominal load) is the
result of burner setting at nominal loading.
Flue gas temperature for partial load is the result of
the control range adjustment.
The instructions of the manufacturer are to be
followed closely on hot water boiler installations.
Normally a partial load of 50 - 65% of the nominal load
is set (some of the data may be on the boiler rating
plate).
On air heater installations the partial load is normally
even higher. Again, the instructions of the
manufacturer should be closely followed.
The flue gas installation should also be set out to
protect against damage through condensation
(excluding acid proof chimneys).
9.6 Combustion analysis
24
9.7 Setting pressure and minimum connection pressure
The results of the following tables have been calculated on
flame tubes under idealised conditions. The values are
therefore guidelines for basic settings. Small variations
may occur when commissioning depending on individual
installations.
* The data given for DN40 is also valid for 1 1/2 and
those for DN50 for 2 valve trains.
The combustion chamber pressure in mbar must be added
to the minimum gas pressure determined.
Selection of nominal diameter for valve trains for towns gas
see separate worksheet, print No. 900.
With low pressure supplies with double solenoid valves
(DMV) pressure regulators to EN 88 with safety
diaphragm are used. Maximum permissible connection
pressure into isolating valve is 300 mbar on low pressure
installations.
With high pressure supplies high pressure regulators to
DIN 3380 are selected from the technical brochure
Pressure regulating and safety assemblies for Weishaupt
gas and dual fuel burners.
High pressure regulators for connection pressure up to 4
bar are detailed in this brochure.
Max. supply pressure see burner name plate.
The data given for calorific value H
i
relate to 0C and
1013.25 mbar.
Size 1
Burner Low pressure supply (gas pressure in mbar High pressure supply
rating into isolating valve, p
e,max
= 300 mbar) (setting pressure in mbar into double solenoid valve)
kW Nominal diameter of valve trains Nominal diameter of valve trains
3/ 4 1 40* 50* 65 3/ 4 1 40 50 65
Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve
25 25 25 25 25 25 25 25 25 25
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
150 14 7
200 21 10 11
220 25 11 13
250 31 13 8 16 6
280 37 15 9 8 20 7 5 5
300 42 17 10 9 23 7 6 6 5
320 47 18 11 9 8 25 8 6 6 5
340 52 20 12 10 9 28 9 7 6 6
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
150 18 9 9
200 28 12 15 5
220 33 14 9 18 6
250 42 16 10 8 22 7 5 5
280 51 19 11 9 8 27 8 6 6 5
300 58 22 12 10 9 31 9 7 6 6
320 65 24 13 10 9 35 10 7 7 6
340 73 26 14 11 9 39 11 8 7 6
Liquid Petroleum Gas B/ P, H
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
150
200 11 6
220 13 7
250 16 8 8
280 18 9 10
300 20 10 11
320 23 11 12 5
340 25 12 8 14 6
* The data given for DN40 is also valid for 1 1/2 and those for DN50 for 2 valve trains.
25
Size 3
e,max
3/ 4 1 40* 50* 65 80 3/ 4 1 40 50 65 80
25 25 40 40 40 40 25 25 40 40 40 40
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
300 41 16 9 22 6
350 54 20 10 8 29 8 5
400 69 25 12 9 37 10 6 6
450 86 30 14 11 9 46 12 7 7 6 5
500 105 36 16 12 9 9 56 14 8 8 6 6
550 126 42 18 13 10 9 68 17 9 9 7 6
600 149 49 21 15 11 10 80 19 10 10 8 7
650 174 56 23 16 12 11 93 22 11 11 9 8
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
300 57 21 10 8 30 8
350 76 26 12 10 40 10 6 6
400 98 33 15 11 9 52 13 7 7 6 5
450 123 40 18 13 10 9 65 16 8 8 6 6
500 150 49 20 14 11 9 80 19 10 9 7 6
550 181 58 23 16 12 10 96 22 11 10 8 7
600 214 68 27 18 13 11 114 26 13 12 9 8
650 250 78 30 20 14 12 133 29 14 13 10 9
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
300 19 9 10
350 25 11 13
400 32 13 8 17 6
450 39 16 9 21 7
500 47 19 11 9 26 8 6 6 5
550 56 21 12 10 8 8 30 40 6 6 6 5
600 66 25 13 11 9 9 36 11 7 7 6 6
650 76 28 14 12 10 9 42 12 8 8 7 7
Size 5
e,max
3/ 4 1 40* 50* 65 80 100 3/ 4 1 40* 50* 65 80 100
25 25 40 50 50 50 50 25 25 40 50 50 50 50
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
500 105 35 16 11 9 56 14 8 7 5
550 126 42 18 12 9 8 67 16 9 8 6 5 5
600 149 49 20 14 10 9 8 79 19 10 9 7 6 6
650 174 56 23 15 11 9 9 93 22 11 10 7 6 6
700 201 64 26 17 12 10 9 107 25 12 11 8 7 7
800 261 82 32 20 14 11 10 139 31 15 13 10 8 8
900 102 39 24 16 13 12 38 18 15 11 9 9
940 111 42 25 17 13 12 41 19 16 12 10 9
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
500 150 48 20 13 10 8 80 18 9 8 6 5 5
550 180 58 23 15 11 9 8 96 22 11 9 7 6 6
600 214 67 27 17 12 10 9 113 25 12 11 8 7 6
650 250 78 30 19 13 11 10 133 29 14 12 9 7 7
700 289 90 34 21 14 11 10 33 16 13 10 8 7
800 115 43 25 16 13 12 43 19 16 11 9 9
900 144 52 30 19 15 13 53 23 20 13 11 10
940 157 57 33 20 15 13 57 25 21 14 11 10
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
500 46 18 10 25 7
550 55 20 11 8 29 9 5 5
600 65 23 12 9 35 10 6 6
650 75 27 13 10 8 40 11 7 6 5
700 86 30 15 11 9 8 46 13 8 7 6 5 5
800 111 38 17 13 10 9 9 60 16 9 8 7 6 6
900 139 46 21 14 11 10 9 75 19 11 9 8 7 7
940 151 50 22 15 12 10 10 81 20 11 10 8 7 7
26
Size 7
e,max
3/ 4 1 40* 50* 65 80 100 125 3/ 4 1 40* 50* 65 80 100 125
40 40 40 50 65 65 65 65 40 40 40 50 65 65 65 65
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
800 256 77 30 18 12 9 8 134 26 13 11 7 6 5 5
900 96 37 22 13 10 9 9 32 16 13 9 7 6 6
1000 117 44 26 15 12 10 9 39 19 16 10 8 7 7
1100 141 52 30 17 13 11 10 46 22 19 11 9 8 7
1200 166 61 34 19 14 12 11 55 26 21 13 10 9 8
1400 224 81 44 24 17 14 12 73 34 28 16 12 10 9
1600 290 103 55 29 20 16 14 94 43 35 19 14 12 11
1750 122 65 33 22 17 15 111 50 40 22 16 13 12
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
800 109 41 24 14 11 9 8 36 17 14 9 7 6 6
900 136 50 28 16 12 10 9 45 21 17 11 8 7 7
1000 167 61 34 19 13 11 10 54 26 21 12 9 8 7
1100 201 72 40 21 15 12 11 65 30 24 14 10 9 8
1200 237 85 46 24 16 13 12 77 35 28 16 11 10 9
1400 113 60 30 20 15 14 103 46 37 20 14 12 10
1600 145 76 37 24 18 15 133 59 47 25 17 13 12
1750 172 89 43 27 20 17 69 55 28 19 15 13
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
800 108 35 16 11 8 57 13 7 7
900 136 43 19 13 9 71 15 9 8 6
1000 166 52 22 14 10 9 87 18 10 9 6 6 5 5
1100 200 62 26 16 11 9 9 8 105 22 12 10 7 6 6 6
1200 237 72 29 18 12 10 9 9 125 25 14 12 8 7 6 6
1400 97 38 23 15 12 10 10 33 17 15 10 8 8 7
1600 124 48 28 17 13 12 11 42 21 18 12 10 9 8
1750 147 56 32 19 15 13 12 50 25 21 13 11 10 9
Size 8
e,max
40* 50* 65 80 100 125 40* 50* 65 80 100 125
40 50 65 65 65 65 40 50 65 65 65 65
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
1100 51 28 16 11 10 9 21 17 10 8 7 6
1200 60 33 18 13 10 9 25 20 12 8 7 7
1300 69 38 20 14 11 10 28 23 13 9 8 7
1400 79 43 22 15 12 11 32 26 14 10 9 8
1600 101 54 27 18 14 12 41 33 18 12 10 9
1800 127 66 33 21 16 14 51 40 21 14 11 10
2000 154 80 39 24 18 15 62 49 25 16 13 11
2250 193 99 47 28 20 17 77 60 30 19 15 13
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
1100 71 38 20 14 11 10 29 23 13 9 7 7
1200 83 44 23 15 12 10 34 27 15 10 8 7
1300 97 51 26 17 13 11 39 31 16 11 9 8
1400 111 58 29 18 14 12 45 35 18 12 10 9
1600 143 74 36 22 16 14 57 45 23 15 12 10
1800 179 92 43 25 18 15 71 55 28 17 13 11
2000 220 111 51 30 21 17 86 67 33 20 15 13
2250 276 138 63 35 24 19 107 83 40 24 18 15
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
1100 25 15 10 8 11 9 6 5
1200 28 17 11 9 8 13 11 7 6 5 5
1300 32 20 12 10 9 8 14 12 8 6 6 6
1400 37 22 14 11 9 9 16 14 9 7 6 6
1600 46 27 16 12 10 10 20 17 11 8 7 7
1800 57 32 19 14 12 11 25 20 12 10 8 8
2000 69 38 21 15 13 12 29 24 14 11 9 9
2250 85 47 25 18 14 13 36 29 17 13 11 10
27
Size 9
rating into isolating valve. p
e.max
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
50 50 65 80 80 80 80 50 50 65 80 80 80 80
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
1600 96 53 27 17 13 11 10 36 32 17 11 9 8 8
1800 120 65 32 20 15 12 11 44 40 20 13 10 9 9
2000 146 79 38 23 16 14 12 54 48 24 15 12 10 10
2200 176 94 44 26 18 15 13 64 57 28 17 13 11 11
2400 208 111 51 29 20 16 14 75 67 33 20 15 13 12
2800 279 147 67 37 25 19 17 100 89 42 24 18 15 14
3200 190 84 45 29 22 19 129 114 53 30 21 17 16
3500 225 99 52 33 25 21 135 62 34 24 19 18
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
1600 136 73 35 21 15 12 11 49 44 22 14 10 9 8
1800 170 91 42 24 17 14 12 61 55 27 16 12 10 10
2000 208 110 50 28 19 15 13 75 66 32 19 14 11 11
2200 250 132 59 33 22 17 15 89 79 38 21 16 13 12
2400 296 156 69 37 24 19 16 105 93 44 24 17 14 13
2800 208 91 47 30 22 19 124 57 31 21 17 15
3200 269 116 59 36 26 22 72 38 26 20 18
3500 136 68 41 29 24 85 44 29 22 20
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
1600 44 26 15 11 10 9 8 18 16 10 7 7 6 6
1800 54 32 18 13 11 10 9 21 20 12 9 8 7 7
2000 65 38 21 14 12 11 10 26 23 14 10 8 8 8
2200 77 44 24 16 13 12 11 30 27 16 11 9 9 8
2400 91 51 27 18 14 13 11 35 32 18 12 10 9 9
2800 121 67 34 22 17 15 13 46 41 22 15 12 11 11
3200 156 85 42 26 19 17 15 59 52 28 18 15 13 12
3500 185 100 48 29 21 18 16 69 62 32 20 16 14 14
Size 10
e,max
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
50 50 65 80 80 80 80 50 50 65 65 65 65 80
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
2000 146 78 37 22 16 13 11 53 47 24 14 11 10 9
2200 175 93 43 25 17 14 13 63 56 28 17 13 11 10
2400 207 110 50 28 19 16 14 74 66 32 19 14 12 11
2600 241 127 58 32 21 17 15 86 76 37 21 15 13 12
2800 278 146 66 36 24 18 16 99 88 41 24 17 14 13
3200 189 83 44 28 21 18 128 113 52 29 20 16 15
3600 102 53 33 24 20 64 34 24 19 17
3950 121 61 37 27 23 76 40 27 21 19
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
2000 208 110 50 28 19 15 13 74 66 31 18 13 11 10
2200 250 131 59 32 21 16 14 89 78 37 21 15 12 11
2400 296 155 68 36 23 18 15 105 92 43 24 17 13 12
2600 180 79 41 26 20 17 122 107 49 27 19 15 13
2800 208 90 46 29 21 18 123 56 30 21 16 14
3200 115 58 35 25 21 71 37 25 19 17
3600 142 70 41 29 23 88 45 29 22 19
3950 169 82 47 33 26 104 52 33 24 21
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
2000 65 37 20 14 11 10 9 25 23 13 9 8 7 7
2200 77 43 23 15 12 11 10 30 27 15 10 9 8 8
2400 90 50 26 17 13 12 11 34 31 17 12 10 9 8
2600 105 58 29 19 15 13 12 40 36 19 13 11 10 9
2800 120 66 33 21 16 14 12 45 41 22 14 12 10 10
3200 155 84 41 25 18 16 14 58 52 27 17 14 12 11
3600 194 104 49 29 21 17 16 71 64 32 20 16 14 13
3950 231 124 58 33 23 19 17 85 75 38 23 18 15 14
28
Size 11
e,max
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
65 65 65 80 100 100 100 65 65 65 80 100 100 100
Natural Gas E, H
i
= 37.26 MJ/ m
3
(10.35 kWh/ m
3
), d = 0.606
3200 182 82 43 26 20 16 121 106 51 27 19 14 13
3400 204 91 47 29 21 17 136 119 57 30 20 16 14
3600 228 101 51 31 22 18 132 63 33 22 17 15
3800 112 56 33 24 20 69 36 24 18 16
4000 123 61 36 26 21 76 39 25 19 17
4400 146 72 41 29 23 90 46 29 21 19
4800 172 84 47 32 25 106 53 33 24 21
5100 193 93 52 35 27 118 59 36 26 22
Natural Gas LL, H
i
= 31.79 MJ/ m
3
(8.83 kWh/ m
3
), d = 0.641
3200 113 56 33 23 19 70 36 23 17 15
3400 127 63 36 25 20 78 39 25 18 16
3600 141 69 39 27 21 87 43 27 19 17
3800 156 76 42 29 23 96 47 29 21 18
4000 172 83 46 31 24 105 52 31 22 19
4400 205 98 53 35 27 125 61 36 25 21
4800 114 61 39 30 71 41 28 24
5100 127 67 43 32 78 45 30 25
i
= 93.20 MJ/ m
3
(25.89 kWh/ m
3
), d = 0.555
3200 151 81 40 24 17 14 12 54 48 25 16 12 11 10
3400 170 90 44 26 18 15 13 61 54 28 17 13 11 11
3600 189 100 48 28 19 16 14 67 59 31 19 14 12 11
3800 210 111 53 30 21 17 15 74 66 34 20 15 13 12
4000 232 122 58 32 22 18 15 82 72 37 22 16 14 13
4400 279 145 68 37 25 20 17 98 86 43 25 18 15 14
4800 171 79 43 28 22 19 115 101 50 29 20 17 15
5100 192 88 47 30 23 20 129 113 56 31 22 18 16
29
Combustion head dual fuel burners sizes 1 to 3 Combustion head dual fuel burners sizes 5 to 11
Flame tube setting
Nozzle star
Perforated diffuser
Conical diffuser
Perforated diffuser
Conical diffuser
10. Setting the mixing head
Burner Flame tube Perforated Diffuser Diffuser Nozzle Flame tube
type mm diffuser mm mm distances mm distances setting mm
type outer inner outer inner a b c d e
GL1/ 1-E G1/2a 130 115 80 95 40 15 13 5 8 139 - 154
GL3/ 1-E G3/1a 160 133 90 100 40 15 18 5 8 158 - 178
RGL3/ 1-E
GL5/ 1-D G5/1a 200 173 100 100(125)* 50(50)* 5 13 8 8 168 - 193
RGL5/ 1-D
GL7/ 1-D G7/1a 250 213 110 110(135)* 50(50)* 5 23 8 8 193 - 218
RGL7/ 1-D
GL8/ 1-D G7/2a 265 213 120 120(155)* 50(50)* 5 30 8 8 193 - 218
RGL8/ 1-D
GL9/ 1-D UG2/1a 325 270 130 130 70 5 33 8 10 217 - 247
RGL9/ 1-D
RGL10/ 1-D UG2/1a 325 270 130 130 70 5 33 8 10 217 - 247
RGL11/ 1-D UG3/1a 380 315 155 155 70 5 43 8 10 274 - 304
* Diffuser special version, see spares list
30
11. Capacity graphs
The ratings depending on pressure in the combustion
chamber are limit values, which have been measured
on idealised test flame tubes to DI N 4788, part 1 or EN
267 and DI N 4788, Part 2 or EN 676. All ratings data
given relate to an air temperature of 20C and an
installation elevation of 500 m.
The oil throughput information refers to calorific values
of 11.91 kWh/ kg for distillate oil EL and 11.24 kWh/ kg
for residual oil S.
Modulating burners
The modulating burner is based on the sliding two stage
burner. The modulating characteristic is obtained with a
special regulating controller, which is fitted in the control
panel. A servomotor with 42 seconds running time is also
used.
The burner types shown are type tested for the following
fuels:
Natural Gas _______________________________E and LL
Liquid Petroleum Gas ___________________________B/ P
Fuel oil ________________________________________EL
Burners with speed control or electronic compound
regulation
There is no reduction in the rating when using speed
control or electronic compound regulation, even when
combined with O
2
regulation. On burners with speed
control and electronic compound regulation and FGR as
well as with or without O
2
regulation a reduction of 5 %
occurs.
Burners with flue gas recirculation (FGR) and / or O
2
regulation
If a flue gas recirculation system or O
2
regulation is
provided, then the maximum burner capacity graphs are
reduced by the following values:
Reduction approx. % System
5 % ARF or O
2
regulation
10 % ARF withO
2
regulation
With flue gas recirculation it must also be noted that the
combustion chamber resistance increases by the factor
1.3. The exact value can be obtained from the planning
documents for flue gas recirculation, print No. 1025.
Please also check if combustion head extensions are
needed with FGR (see Special Equipment). On burners
with flue gas recirculation, only sound absorbers of special
execution may be fitted.
For towns and sewage gas the maximum burner
ratings in the graphs must be reduced by 10%.
Range of regulation on oil operation
Dual fuel burners with spill type nozzles have a maximum
turndown ratio on oil operation of approx. 3 : 1. It should be
noted that the lower operating point must lie within the
capacity graph.
Combustion head Open
Combustion head Closed
(see dimension e, chapter 10)
6
5
4
3
2
1
0
-1
-2
-3
-4
kW 0 50 100 150 200 250 300 350
kg/h 5 10 15 20 25 0
mbar Burner type GL1/ 1-E
Type of combustion head G 1/2a, 115x95K
Rating kW, Natural Gas/ LPG 60-335
kg/h Distillate oil EL 10-28,1
Size 1
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
O
i
l
0
-2
-4
kW 0 100 200 300
kg/h 10 20 30 40 50 0
400 500
2
4
6
8
10
12
60 70 80
600 700 800 900 1000
mbar Burner type GL3/ 1-E RGL 3/ 1-E
Type of combustion head G 3/1a, 133x100K G 3/1a, 133x100K
Rating kW, Natural Gas/ LPG 90-630 90-630
kg/h Distillate oil EL 16-52,9 16-52,9
Size 3
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
O
i
l
0
-2
-4
kW 0 100 200 300
kg/h 10 20 30 40 50 0
400 500
2
4
6
8
10
12
60 70 80
600 700 800 900 1000
mbar Burner type GL5/ 1-D RGL 5/ 1-D
Type of combustion head G 5/1a, 173x100 G 5/1a, 173x100
Rating kW, Natural Gas/ LPG 200-940 200-940
kg/h Distillate oil EL 20-79 20-79
Size 5
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
O
i
l
31
0
-2
-4
kW 0 400
kg/h 40 80 120 0
800
2
4
6
8
10
12
160 200
1200 1600 2000
14
16
2400
mbar Burner type GL7/ 1-D
Type of combustion head G 7/1a, 213x110
kg/h Distillate oil EL 32-147
Size 7
Size 8
H
e
i
z
l
N
a
t
u
r
a
l
G
a
s
/
L
P
G
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
0
-2
-4
kW 0 400
kg/h 40 80 120 0
800
2
4
6
8
10
12
160 200
1200 1600 2000
14
16
2400
mbar Burner type GL8/ 1-D TMD
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
O
i
l
0
-2
-4
kW 0 400
kg/h 40 80 120 0
800
2
4
6
8
10
12
160 200
1200 1600 2000
14
16
2400
mbar Burner type RGL7/ 1-D
H
e
i
z
l
O
i
l
N
a
t
u
r
a
l
G
a
s
/
L
P
G
N
a
t
u
r
a
l

G
a
s
/
L
P
G
0
-2
-4
kW 0 400
kg/h 40 80 120 0
800
2
4
6
8
10
12
160 200
1200 1600 2000
14
16
2400
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
O
i
l
0
-2
-4
kW 0 400
kg/h 40 80 120 0
800
2
4
6
8
10
12
160 200
1200 1600 2000
14
16
2400
mbar Burner type GL8/ 1-D ZD-ZMD
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
O
i
l
0
-2
-4
kW 0 400
kg/h 40 80 120 0
800
2
4
6
8
10
12
160 200
1200 1600 2000
14
16
2400
N
a
t
u
r
a
l
G
a
s
/
L
P
G
O
i
l
32
Size 9
6
4
2
0
-2
-4
kW 0 1000 2000 3000
kg/h 50 100 150 200 250 0
4000
8
10
12
14
16
300 350 400
500 1500 2500 3500 4500
Type of combustion head UG 2/1a, 270x130
Rating kW, Natural Gas 500-3600
LPG 600-3600
N
a
t
u
r
a
l

G
a
s
N
a
t
u
r
a
l

G
a
s
L
P
G
O
i
l
L
P
G
O
i
l
6
4
2
0
-2
-4
kW 0 1000 2000 3000
kg/h 50 100 150 200 250 0
4000
8
10
12
14
16
300 350 400
500 1500 2500 3500 4500
LPG 600-3600
N
a
t
u
r
a
l

G
a
s
N
a
t
u
r
a
l

G
a
s
L
P
G
O
i
l
L
P
G
O
i
l
Size 10 Size 11
6
4
2
0
-2
-4
kW 0 1000 2000 3000
kg/h 50 100 150 200 250 0
4000
8
10
12
14
16
300 350 400
500 1500 2500 3500 4500
LPG 750-4100
N
a
t
u
r
a
l

G
a
s
N
a
t
u
r
a
l

G
a
s
L
P
G
O
i
l
L
P
G
O
i
l
6
4
2
0
-2
-4
kW 0 1000 2000 3000
kg/h 50 100 150 200 250 0
4000 5000
8
10
12
14
16
18
20
22
24
26
28
300 350 400
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
N
a
t
u
r
a
l

G
a
s
/
L
P
G
O
i
l
33
12. Oil supply
Reliable operation to a large extend depends on the oil
supply. The pipe system and sizing can be obtained from
out technical worksheets.
Ring main system
The use of a ring main oil system is recommended and
often essential.
Note
The installation dependent ring main pressure increases
the factory pre-set burner pump pressure.
Single pipe installation on request.
Suction lift operation
Suction lift operation is possible for individual burners
operating on distillate oil EL. For installation and functional
diagrams for ring main and suction lift operation, see
technical work sheet 5...
Ring main with oil filter
Large installations (industrial or district heating) should, if
at all possible, be operated without interruptions. We
therefore recommend the use of a double pump
aggregate, which can operate with one or the other pump.
Both pumps are fitted with oil filters, so that it is possible
to clean one pump or its filter during burner operation. The
supply quantity must be at least twice the nozzle capacity
of all burners connected to the ring main. Pre-requisite is
the installation of a gas / air separator or circulation tank.
Strainer
A strainer is fitted in the burner oil pipe work (flow), to
prevent debris, such as loosened particles from the
welded joints for example from reaching the solenoid
valves. The filter should be cleaned periodically,
particularly at the early stage of operation.
Air / gas separator
A Weishaupt air/gas separators should be fitted at the
point at which the burner is connected to the two pipe
system. The air/gas separator should be fitted as close to
the burner as possible (see technical work sheets). It is
particularly important to use a separator on residual fuel oil
installations. When installing the air / gas separators,
please observe the instruction label of the unit.
Filter
Between the ring main and burner pump connection a fine
filter must be fitted. This filter prevents dirt particles from
the oil and pipework from reaching the burner.
Operating without filter can have the following
consequences:
GSeizing of pump gearing
GBlocking of solenoid valve and nozzle
Oil supply line to the burner
Termination of the oil supply pipes must allow tension free
connection of the flexible oil hoses. Both oil and electrical
connections must allow the burner to swing open.
Prerssure regulating valve in the ring main
Setting for distillate oil EL
Ring main pressure 1 ... 1.5 bar
Note
Isolating devices in the return flow line must be
protected from unintentional closure (e.g. ball valves
with mechanical connection or burner interlock
switch).
Attention!
If the shut off combination is used to test the operation
of the end position switch, the manual lever may only
be closed until the end position switch has responded.
The combination can only be shut completely when
the burner pump has shut off. Otherwise pressure
surges and cavitations can damage the pump.
The installation of non return valves is not permitted
on burners with return flow nozzles.
Residual oil installation must have adequate heating of
the pipework.
The gas/ air separators should be fitted as close as
possible to the burner.
Single pipe installation on request.
On dual fuel burners without electromagnetic coupling
the oil isolating combination must not be closed
during gas operation.
34
The pumps are suitable for installation and operation in
the two pipe system.
The pumps are fitted with a pressure regulating device
and a quick action valve. The pressure regulating valve
keeps the pressure constant.
Setting
GThe suction line must be filled with fuel oil before
commissioning and the pump vented. If this is not
done, the pumps will be damaged, due to running dry.
GTo test the vacuum or supply pressure on the suction
side of the pump, screw in a vacuum or pressure
gauge into the connection point (6).
GFor pump pressure testing a manometer must be
screwed into connection point (5).
GTo adjust the pressure, remove nut and set the
required pump pressure.
Rotation to right = Pressure increase
Rotation to left = Pressure reduction
GThe suction resistance should not exceed 0.4 bar.
GMax supply pressure for pumps
Types AE, AJ, J ____________________________ 2,0 bar
for pumps types E and TA ___________________ 5,0 bar
(measured at the pump).
Filter for pump types AE, AJ, J and E
The strainer fitted between the filter and the pump in the
oil flow keeps foreign particles away from the pump gear.
The pumps are fitted with two different strainer sizes.
The mesh of the strainer for E pumps is coarser.
This strainer has to be cleaned periodically depending
on the degree of soiling. If the mesh is heavily soiled, the
vacuum on the suction side increases. The mesh can be
reached for cleaning by unscrewing eight screws (12)
on the pump cover.
After fitting the strainer, check the pump gear cover for
tightness.
Single pipe operation
In certain cases the pumps J, AE, AJ and TA may be used
in single pipe installations.
The following must be observed:
As the pump in a single pipe system does not pull a
vacuum, continual oil supply to the pump must be
ensured.
The bypass plug must be removed and the return line
closed.
On single pipe systems the supply line must be vented
into a container until all the air is expelled, reconnected
to the pump and the pump vented via the pressure
gauge port.
Pump J6 + J7
6
1 7 4 5 3 2 12
Pump TA2, TA3, TA4
6
5
1 7 4
2
2a 3
6
6 3 12
1 7 4 2 5
5
3
1 2
6
4
2a
Pump E6, E7
Pump AJ6
1 Suction connection
2 Return connection
2a Return connection oil regulator
3 Nozzle supply line
4 Pressure regulating screw
5 Pressure gauge connection
6 Vacuum gauge connection
7 Dome nut
12 Cover screw
13. Oil pump
35
Pump coupling
Between fan wheel and pump (motor shaft) a flexible
rubber coupling is fitted. When exchanging the pump or
coupling please ensure that axial misalignment does not
exceed 1.5 mm.
Solenoid coupling on burner sizes 1 to 3
Distance 0,3 0,5 mm
Distance 0,3 0,5 mm
Solenoid coupling on burner sizes 5 to 11
Pump coupling
8 9 10 11
8 Centre section of coupling
9 Axial play 1.5 mm
10 Socket head screw
11 Pump coupling
5
3
1 2
6
4
Pump AE
Magnetic coupling
On oil operation, a new type of frictionless magnetic
coupling drives the connection between burner motor and
pump. On gas operation, the pump is disengaged to
reduce wear and tear. Distance between the coupling
discs when switched off is between 0.3mm and 0.5mm.
The coupling requires an operating voltage of 24V DC.
A transformer and rectifier for this is fitted to the burner.
1 Suction connection
2 Return connection
2a Return connection oil regulator
3 Nozzle supply line
4 Pressure regulating screw
5 Pressure gauge connection
6 Vacuum gauge connection
36
14. Fan wheel attachment
Burner sizes 1 and 3
The fan fits onto a cylindrical shaft. Power is transmitted
via a shaft key. The fan is secured by an M8 set screw and
the shaft key.
Burner size 5
The fan fits onto a cylindrical shaft. Power is transmitted
via a shaft key. The fan is fixed to the motor shaft by an M6
x 25 screw with washer.
Burner sizes 7-8
On burner sizes 7-8 the fan fits onto a cylindrical shaft.
Power is transmitted by a shaft key. The fan is fixed to the
motor shaft by an M8 countersunk screw and washer.
Burner sizes 9-11
On burner sizes 9-11 the fan fits onto a self locking cone
shaft which transmits the power from the motor. The
coupling piece is connected to the fan with two cylindrical
pins. An M10 x 40 left hand threaded screw secures the
coupling piece to the motor shaft.
Removing the fan
Burner sizes 1 and 3
The extractor, Part No. 111 111 00 0122, can be applied
to the two M6 threaded holes and the fan removed.
Burner sizes 5-8
The extractor, Part No. 111 111 00 01/2, can be applied
to the two M6 threaded holes and the fan removed.
Burner sizes 9-11
To remove the fan the extractor, Part No. 121 362 0013/2
is applied to the two M10 threaded holes.
Burner sizes 1 and 3 Burner size 5 Burner sizes 7 and 8 Burner sizes 9 to 11
37
15. Fuel system for oil
Installation of oil meter
When oil meters are fitted in the flow and return lines, the
system must be protected by a safety valve in the return
line (see fuel system schematic in our work sheets).
A blocked oil meter can lead to the following damage:
Bursting of oil hoses.
Pump damage (the glands on the pump will leak).
Changes in oil throughput without changes to combustion
air. Changes in oil throughput occur if the meter is blocked
during burner operation. The back pressure, which occurs,
renders the oil regulation ineffective. Deflagration may
occur on restart.
In accordance with DI N 4787 and TRD 411 a pressure
switch is required in the supply line if a separate pump
unit is used.
GL1 - GL8 (oil part two stage),
GL8 - GL9 (oil part three stage)
2
2 5 1 8
P
M
1 12 6
115 V
7
115 V
17 15
14 3 13
4
RGL8 to RGL11
RGL3 to RGL 7
P M
1 10 5
15 3 17 5
3
115 V 115 V
115 V 115 V
1 Pump, without solenoid valve fitted
2 Solenoid valve type 121 C2323 Coil 9 Watt
(normally closed) Rp 1/8* from size 7
solenoid valve type 121 K2423 Coil 9 Watt
(normally closed) Rp 1/8*
3 Solenoid valve type 121 K2423 Coil 19 Watt
(normally open) Rp 1/8*
6 Solenoid valve type 321 H2322 Coil 20 Watt
7 Solenoid valve type 121 G2320 Coil 20 Watt
8 Nozzle head EL two or three stage
(without inbuilt shut off device)
10 Nozzle head R (without inbuilt shut off device)
12 Nozzle head R (with inbuilt shut off
device in supply and return)
13 Butterfly
14 Filter
15 Oil regulator
17 Pressure switch 0 - 10 bar return (on EL set to 5 bar)
G Burner type RGL5 - RGL7
The shut off devices (solenoid valves) (3) (5) are swit-
ched electrically in series. The voltage of the solenoid
coil is therefore 115V at 230 V AC; 50 Hz mains vol-
tage.
G Burner type RGL8 - RGL11
The shut off devices (solenoid valves) (6) (7) are swit-
ched electrically in series. The voltage of the solenoid
coil is therefore 115V at 230 V AC; 50 Hz mains vol-
tage.
The voltages given relate to a control voltage of 230 V.
* Rp = Whitworth pipe threads (internal) DIN 2999.
38
16.1 RGL3 to RGL7
16. Regulating systems
This regulating system does not have a nozzle closure
valve. The solenoid valves carry out the isolating
function.
Operation
During pre purge solenoid valves (3) and (5) are closed.
Oil is supplied via the pump pressure side to the closed
solenoid valve (5) in the supply line. Solenoid valves (3)
and (5) are electrically connected in series.
System diagram 1
After the pre purge period has elapsed, the solenoid valves
(3) and (5) open. Oil flows via the nozzle supply line to the
nozzle and via the return line to the oil regulator (15). The
oil regulator is now open (ignition load) position. Due to
lower flow pressure, less oil leaves the nozzle. The greater
oil quantity flows via the nozzle return line to the oil
regulator or pump return line. The return flow pressure is
approx. 10 bar at partial load position.
The oil pressure switch (17) shuts down the burner if the
pressure increases to an excessive level.
System diagram 2
Full load operation is obtained by reducing the metering
slot. This is done by a rotary movement of the oil regulator
(direction of rotation to the right seen from the shaft). This
throttles the flow of oil in the return line and the oil quantity
increases at the nozzle outlet. On controlled shutdown the
solenoid valves close and shut off the flow of oil to the
nozzle and from the oil supply.
Legend and notes for switching and installation of the
solenoid valves see chapter 15. Fuel systems for oil.
Nozzle head RGL3 to RGL7
System diagram 1
System diagram 2
Nozzle supply
Nozzle return
Regulating nozzle
39
16.2 Regulating system RGL8 to RGL 11
Operation
System diagram 1
During burner shutdown and pre purge shut off devices
(6), (3) and (7) are closed and the shut off device (4) is
open.
The ring main pressure during burner shut down or the
pump pressure during pre-purge is present at shut off
device (6) and (7).
System diagram 2
After the pre-purge period has elapsed (the servomotor is
in ignition position) shut off devices (6), (3) and (7) open
and shut off device (4) closes. The fuel oil is now released
for combustion.
The pressure switch (17) checks the pressure in the
return. If the pressure increases to an excessive level, the
burner shuts down. Shut off devices (6), (3) and (7) close
and simultaneously shut off device (4) opens.
Attention!
Shut off devices (solenoid valves) (6) and (7) are
electrically connected in series. The voltage of the
solenoid coils is therefore 110V with 220V mains voltage.
On shut off device (solenoid valve) (7), the directional
arrow on the solenoid valve must point towards the nozzle.
This means that the solenoid valve in the nozzle return is
fitted against the flow direction (during burner operation).
The shut off device in the nozzle head (nozzle shut off
valve) is effective as one safety shut off device in the return
line and one in the supply line.
Together with the safety shut off devices (6) and (7) and
the safety shut off device in the nozzle head, the
requirement for two shut off devices in both the supply and
return is fulfilled.
Legend and notes for switching and installation of the
solenoid valves see chapter 15. Fuel systems for oil.
Nozzle head RL and RMS burners
System diagram 1 System diagram 2
Control circuit supply Supply Nozzle closing
needle
Nozzle
plate
Control circuit return Return Regulating nozzle type W
Swirl plate
40
16.3 Oil meter and oil regulator
Installing an oil meter
When installing oil meters in the supply and return lines,
the meter in the return line must be fitted with a safety
valve (see pipe line schematic in our worksheets).
A seized oil meter can cause the following faults:
Bursting of oil hoses
Pump damage (pump seals start to leak)
Load changes without combustion air changes. Load
changes occur if the oil meter seizes during burner
operation. The spill back pressure will render the oil
regulator useless. A re-start can lead to an explosion.
Shut off devices in the return line must be protected
against unintentional closure (i.e. ball valves by mechanical
connection). Fitting of none return valves is not permitted.
Oil regulator RGL3 to RGL 11
The oil regulator is driven by the servomotor. By means of a
vee slot metering groove it regulates the variable oil
quantity.
Each regulator has two regulating grooves, which can be
interchanged. Two identification numbers have been
embossed on the shaft of each regulator, e.g. 00-0 (see
picture).
Each groove depth is designated to an identification
number. The following table shows the designation to the
oil throughput.
Oil regulator Use
identification number oil throughput kg/h
00 0 - 50
0 51 - 70
1 71 - 120
2 121 - 280
3 281 - 380
4 381 - 420
To ensure that the oil volume is regulated by the
correct metering grove, the adjusting spring of the
relevant number has to be used.
Setting example : adjusting spring at number 00
Basic setting
identification number
oil regulating groove
Cam
identification
i.e cam 6
Full load setting
Adjusting spring
Basic setting
regulating cam
cam1
The oil
regulating
groove
selected can
be seen from
the top in the
basic setting
cam 1.
41
17. Nozzle selection
17.1 Two and three stage burners GL
It is recommended that solid or semi solid nozzles are used
with a spray angle of 60and 45respectively. Due to the
various configurations of combustion zones encountered,
no binding information can be given.
Nozzle spray angles and patterns alter depending on the
atomising pressure. The data marked on the nozzle only
applies at a pressure of 7 bar.
On two stage burners the total burner capacity must be
divided between two nozzles. Usually nozzle 1 is sized to
have sufficient capacity for the basic load at approximately
2/3 of the total load. At peak demands nozzle 2 is added to
the throughput. A different nozzle ratio may be required,
depending upon the heat demand and the appliance flue
gas pressure loss.
The charts are compiled using distillate oil with a viscosity
of 4 mm
2
/sec (cSt.) at 20C.
Removing and replacing nozzles
When removing and replacing the nozzle, the nozzle head
must be held with a suitable spanner. Before fitting nozzles
ensure that the insert is firmly seated.
Nozzle cleaning
Nozzle cleaning is not recommended. A new nozzle should
be fitted.
Atomisation pressure
Burner type Pressure
GL 10 14 bar
Spray characteristic
Hollow spray Semi solid spray Solid spray
Spray angle
Nozzle selection diagram GL1 to GL9
Nozzle selection diagrams
The diagrams are based on information given by the nozzle
manufacturer. Variations in viscosity and manufacturing
tolerances result in a throughput variations of approx. 10%.
Because oil pressure is lost via the preheater and burner
fuel system, the precise oil throughput can only be
determined by weighing.
P
r
e
s
s
u
r
e

[
b
a
r
]

(
m
e
a
s
u
r
e
d

a
t

t
h
e

n
o
z
z
l
e
)
Oil throughput
P
r
e
s
s
u
r
e

[
b
a
r
]

(
m
e
a
s
u
r
e
d

a
t

t
h
e

n
o
z
z
l
e
)
Oil throughput
P
r
e
s
s
u
r
e

[
b
a
r
]

(
m
e
a
s
u
r
e
d

a
t

t
h
e

n
o
z
z
l
e
)
Oil throughput
Distillate oil = 0,84 [ kg/dm
3
]
3
]
3
]
kg/h
l/h
kg/h
l/h
kg/h
l/h
42
17.2 Regulating burners
The diagrams show the flow rate of the regulator nozzles
depending on supply pressure. For RGL burners a pump
pressure between 20 and 30 bar should be selected.
Care must be taken that the minimum pump pressure
does not fall below 20 bar, even at the lowest oil
regulator position.
Nozzle return pressure spill back nozzle WB3/ K3
When commissioning the nozzle return pressure must be
measured. This must not be less than 10 bar for partial
load.
The solenoid valve is fitted with a T piece for the test point.
Regulating nozzle W, series 4
When commissioning the nozzle return pressure must be
measured. This must not be less than 8 bar for partial load.
The test point is on the distribution piece
Nozzle cleaning
The nozzle has to be taken apart and each part cleaned in
petrol or paraffin. The filter sieve must be replaced. If other
parts are defective or worn the nozzle must be replaced.
Regulator nozzles
Burner size 3 to 7 Burner size 8 to 11
Type WB3/ K3 Type W
Atomising pressure
Burner type Atomising pressure
RGL 20 30
Test point
return
Test point nozzle return pres. spill back nozzle WB3/ K3
43
20 25 30
30
35
40
45
50
55
60
65
70
80
90
100
110
120
130
140
150
30
35
40
45
50
55
60
65
70
80
90
100
110
120
130
140
150
160
180
170
20 25 30
20
40
60
80
100
140
160
180
200
220
240
260
300
320
340
360
380
W 40
120
280
400
420
440
460
W 45
W 50
W 55
W 60
W 70
W 80
W 90
W 100
W 110
W 125
W 140
W 160
W 180
W 200
W 225
W 250
W 275
W 300
W 330
W 360
W 390
W 420
W 460
Nozzle selection diagram type WB3/ K3
Regulator nozzle type WB3 to 70 kg/h
type K3 80 ... 180 kg/h
Spray angle 50
Supply pressure [bar]
(measured at the pump)
Example nozzle selection type WB3
Oil throughput required: _____________________ 50 kg/h
Nozzle size to diagram: __________________________ 55
Supply pressure to diagram: ___________________ 24 bar
Supply pressure [bar]
Example nozzle selection type W
Oil throughput required: ____________________ 160 kg/h
Nozzle size to diagram: _______________________ W180
Supply pressure to diagram: ___________________ 25 bar
Nozzle selection diagram type W, series 4
Regulator nozzle type W, series 4
Spray angle 50
N
o
z
z
l
e

t
y
p
e

K
3
N
o
z
z
l
e

t
y
p
e

W
B
3
N
o
z
z
l
e

s
i
z
e

r
e
l
a
t
i
n
g

t
o

3
0

b
a
r
N
o
z
z
l
e

s
i
z
e

r
e
l
a
t
i
n
g

t
o

3
0

b
a
r
O
i
l

t
h
r
o
u
g
h
p
u
t

[
k
g
/
h
]
O
i
l

t
h
r
o
u
g
h
p
u
t

[
k
g
/
h
]
44
18. Removal of mixing head - ignition electrode setting
Flexible oil pressure hoses
Removal mixing head
Ignition electrode setting GL1 to GL 9 (two/three stage)
Ignition electrode setting RGL3 to RGL 7
Ignition electrode setting RGL8 to RGL 11
Notes on oil pressure hoses
The oil and pressure hoses are corrugated high grade
steel with a high grade steel woven wire sleeve cover.
The oil and pressure hoses should be protected from
external mechanical damage.
When fitting, care must be taken to ensure the hose is not
twisted. It must not during fitting, or during later movement,
receive torsional strain.
A spanner should be used to counter hold when
tightening.
Before hinging the burner open, the gas butterfly valve
rod must be removed. See reference plate on burner.
Before recommissioning, check that the burner valve
rod has been reconnected.
Removal of nozzle head or electrode holder
45
19. Commissioning the oil part
19.1 Tests prior to initial commissioning
Before commissioning can commence, the entire plant
must check.
GHas the heat exchanger been mounted ready for
operation?
GAre heat exchanger and system filled sufficiently with
heating medium?
GAre the flue gas passages free from obstruction?
GHave explosion flaps been fitted?
GIs the flue gas damper open?
GIs sufficient air supply ensured?
GHave the operating instructions of the heat exchanger
been followed?
GHas the whole installation been wired correctly?
GHave temperature regulator, pressure regulator and
safety limit controls been set correctly and place into the
operation position?
GIs load available?
GHas the low water safety interlock been set correctly?
GHave all fuel carrying pipe lines been purged of air?
GIs the rotation of the burner motor correct?
GIs sufficient fuel oil in the tank?
GHave a soundness tests of the oil hydraulic been carried
out?
GAre the oil supply pumps (if fitted) switched on?
GAre the oil shut off devices open?
GAre oil-supply lines and pump filled with oil?
GIs the correct oil nozzle fitted?
Other installation specific tests may be required. See
operating instructions of individual components.
19.2 Adjusting the oil part
On regulating burners the oil part is commissioned
prior to the gas part. On GL burners the gas part is
commissioned first and the oil part is matched by the
relevant nozzle selection. This results in different
procedures when commissioning.
Switch on procedure
Set operating switch to oil.
Open shut off valve (shut off assemblies) in the oil
supply.
Set selector switch in the control panel to stop.
Reset installation.
Switch on burner operating switch.
Ignition
Once pre-purge is complete await flame formation.
If ignition problems occur:
GL burners:
Check nozzle size of stage 1; if necessary select
different nozzle
RGL burners:
Check position of ignition load switch on the
servomotor (No. III), if necessary adjust setting.
Test sensor current on the microammeter.
Full load setting
After approx. 20 secs, the servomotor runs from ignition to
full load. (Ensure this is carried out with excess air by
previously reducing the required oil pressure). For full load
the required oil throughput must be set and measured
(nozzle selection diagrams are only an aid for setting and
checking).
Carry out combustion analysis:
RGL burners:
Set oil throughput by adjusting pump pressure
(20 to 30 bar).
Set combustion values by adjusting the air curve
band and positioning of the regulating sleeve so
that with fully opened air damper a smoke number
<1 and CO2> 13 Vol. - % with good flame stability
can be achieved.
Setting limit and auxiliary switches
Disengaging the servomotor
46
GL burners:
The gas side settings of the air curve band and the
mixing head positions must not be altered. The oil
throughput is matched by adjusting the pump
pressure (10 to 14 bar), if necessary select different
nozzle size.
The pump pressure and the position of mixing head set on
full load must not be adjusted.
Intermediate testing (full load to partial load)
RGL Burners:
A point by point combustion check is necessary at
the adjusting cam.
Adjust cams manually step by step in the direction
of ignition load (selector switch Stop, disengage
servomotor, adjust, re-engage).
Regulate combustion values by adjusting the air
curve bands. Ensure the curve bands have an even
profile.
GL burners:
The air curve band setting for must not be altered.
The transition switching points of the servomotor for
the second (third) stage nozzles (Z: No.I; ZM: V or V
and III) must be set so that the excess air phase,
prior to switch over is not too long, and the flame
extinguishes, but on the other hand that any smoke
period after switch over is as short as possible.
Partial load setting
Set selector switch in the control panel to stage 1 or
Partial load.
RGL burners:
Set and measure the required oil throughput for
partial load with the auxiliary switch in the
servomotor (No. VII).
GL burner, version ZM:
Match excess air to the oil throughput required for
the nozzle selected for partial load with the auxiliary
switch (No. VII).
Measure oil throughput, if necessary select a
different nozzle.
The intermediate setting on three stage burners is
carried out the same way.
GL burners, version Z:
Carry out combustion test in partial load setting
(same auxiliary switch for gas and oil) with the
selected nozzle.
Measure oil throughput, if necessary select a
different nozzle.
If changing the nozzle on partial load (GL burners) the full
load setting has to be re-checked and if necessary re-
adjusted. For partial load setting, the lower ratings limits of
the capacity graphs, the flue gas temperature and
instructions from the boiler manufacturer have to be
observed.
Concluding work:
Check ignition load setting when the burner has been
commissioned:
RGL burner:
If necessary correct at auxiliary switch (No. III) on
the servomotor.
GL burners:
If necessary select new nozzle. Full and partial load
setting will then have to be repeated.
Setting is correct if the burner starts without start impact.
Check and adjust operation of safety equipment (i.e. air
pressure switch, thermostat, pressure stat etc.) whilst
installation is in operation.
Documentation
The following setting values must be recorded on the
report sheet or test sheet.
On full and partial load:
oil throughput
nozzle type
pump pressure
supply and return pressure (on RGL burners)
CO
2
smoke number
flue gas temperature
fan pressure
draught or pressure in the combustion chamber
sensor current
Setting the curve band
47
Oil operation version ZM
Sequence diagram for air
Time sequence diagram
for servomotor
Sequence diagram
for oil
Time sequence
diagram for ignition
and fuel release
Position indicator on
burner control
Regulator
On
Nominal load
pre-purge
Ignition and
fuel release
Ratings regulation Regulator Off
Full load
Terminal on LFL/ LGK
Control circuit
Partial load
Ignition load
Closed
* Programme interruption on resi-
dual oil burners for oil circulation
to nozzle head (to DIN 4787
max. 45 secs.)
20. Sequence of operation
Gas operation version ZM
Sequence diagram for air
Regulator On Nominal load
pre-purge
Ignition and fuel
release
Ratings
regulation
Regulator Off
Full load
Partial load
Ignition load
Terminal on LFL/ LGK Closed
Control circuit
Time sequence diagram
for servomotor
Sequence diagram for gas
Time sequence diagram for
ignition and fuel release
Position indicator on burner
control
The LFL1... burner control units are designed to provide
control and supervision of multistage and modulating
burners. They are only suitable for burners with intermittent
burner operation. The fail safe burner control LGK16... is
used for burners with continuous operation.
Full load
Partial load
Ignition load
Closed
* on sizes 8 to 11, ** on sizes 1 to 7
48
In the event of a fault condition the fuel supply is always
interrupted immediately. Simultaneously the sequence
switch stops and thus lockout is indicated. The symbol
appearing above the reading mark indicates the kind of
fault.
No start e.g. because the closed signal has not been
supplied to terminal 8 by the limit switch/auxiliary
switch or because a contact has not been closed bet-
ween terminals 12 and 4 or 4 and 5.
Controlled shut down because the open signal has
not been supplied to terminal 8 by the limit switch.
P Lockout because the air pressure signal has not been
received by the start of the air pressure check. Air
pressure failure after this point also causes the
control to go to lockout.
I Lockout due to a fault in the flame supervision circuit.
Controlled shutdown because the position signal for
the low flame position has not been supplied to termi-
nal 8 by the auxiliary switch.
1 Lockout because no flame signal has been received on
completion of the first safety time. Any flame signal
failure after completion of the first safety time also
causes the control to go to lockout.
2 Lockout because no flame signal has been received on
completion of the second safety time (flame signal of
the main flame with interrupted pilot burners).
I
Lockout because the flame signal has been lost during
operation or air pressure failure has occurred.
Lockout on completion of control programme se-
quence due to extraneous light (e.g. flame not extin-
guished, leaking fuel valves) or due to a faulty flame sig-
nal (e.g. aged UV tube, fault in flame supervision circuit
or similar).
If lockout occurs at any other point between start and pre-
ignition, which is not marked by a symbol, there is normally
a premature and thus faulty flame signal.
a b Start up sequence
b b With some time variants: idle steps of the se-
quence switch up to the self shut down after
burner start up (b = operating position of the
sequence switch).
b(b) a Post purge sequence after controlled shut
down. In start position a the sequence switch
switches itself off automatically or immediately
initiates another burner start, e.g. after a fault
has been corrected.
G Duration of safety time with expanding flame
burners.
GG Duration of safety time with interrupted pilot
burners.
20.1 Pre-requisite for burner start
Reset control unit
Air damper closed. The limit switch for the CLOSED
position must supply voltage from terminal 11 to terminal
8.
The control contacts for the CLOSED position of fuel
valves or other contacts between terminal 12 and S10
with similar control functions must be closed.
The normally closed contact of the air pressure monitor
must be closed (LP test), i.e. terminal 4 must be under
voltage.
The contacts of the gas pressure switch S11 and the
temperature or pressure switch F4, F5 must also be
closed.
20.2 Symbols on the fault position indicator
aus
42
49
M
SM
N
M
L
S1
F4
F
br1
1
a b
a b
4 12 6
I
ar1
ar2
K1 K1
7
M1
N
5 13 14
1
5 4
22 15 24
3
2
22
23
23 24
22 23 24
fr1 fr3 fr2
B1
QRA5..
N
B1
uv
UV
QRA2
B1
V
FR
NTC
XII
XIII
XI
AR
XIV
VII
ar3
S
H
br2
V
VIII X
BR
S3
a
b
a b b a
a b
M E
a b a b
3 21 2 16 17 18 19 20 9 11 10 8
III I II IV
1
Y2
H6
T1 Y1 Y4
LK
F
5
S10
b
A
+
II
F6
b b
b
b
b
a a
a
a
a
III
IV
M
S
1
1
M1
VI
F3
a
Y6
N N
LGK...
LFL/ LGK
LFL...
20.3 Basic wiring diagram for burner control LFL1... / LGK 16...
Legend:
AR Load relay (main relay) with contacts ar
B1 Flame sensor
BR Lockout relay
F Fuse in burner control
F3 Steuersicherung
F4 Temperature or pressure switch
F5 Temperature or pressure regulator
F6 Temperature or pressure regulator FULL LOAD
FR Flame relay
H Control lamp Lockout
H6 Remote indication for lockout
K1 Motor contactor
LK Air damper
M1 Fan or burner motor
S Reset key
S1 Brenner ein
S3 Fernentstrung
S10 Air pressure switch
S11 Gas pressure switch
T1 Ignition transformer
Y1 Solenoid valve ignition gas
Y2 Solenoid valve main gas
Y4 Additional solenoid valve
Y6 Servomotor
Y12 Solenoid valve
s
9
50
t1 Pre purge time
t2 Safety time
t3 Pre-ignition time
t4 Interval between voltage on terminals 18 and 19
t5 Interval between voltage on terminals 19 and 20
t6 Post purge time
t7 Interval to voltage on terminal 7
t8 Duration of start up sequence
t9 Second safety time *
t10 Interval to start of air pressure control
t11 Run time of air damper (Open)
t12 Run time of air damper (min.)
t13 Permissible after burn time
t16 Interval up to OPEN command for air damper
t20 Interval up to self shut down of the sequence switch
(not on all controls)
* Programme for interrupted pilot burners.
Positions of lockout indicator
C
o
n
t
r
o
l

o
u
t
p
u
t
s

o
f

c
o
n
t
a
c
t
s
:
Legend for diagram of sequence switch
LFL1... / LGK16
20.4 Switching times
Switching times in seconds * in start up sequence
The figures in brackets apply to burners with interrupted pilot.
LFL 1.122 LFL 1.322 LFL 1.622
LGK 1.122 LGK 1.322 LGK 1.622
t7 Start delay for burner motor 2 2 2
t16 Interval from start up to OPEN command of air damper 4 4 4
t11 Run time of air damper in OPEN position optional optional optional
t10 Interval from start up to commenc. of air pressure check 6 8 8
t1 Pre-purge time with air damper open 10 36 66
t12 Run time of air damper to ignition position optional optional optional
t3 Pre-ignition period 4 4 4
t2 First safety period 2 2 2
t4 Interval between start of t2 and release
of valve at terminal 19 6 10 10
(t9)Second safety period (2) (2) (2)
t5 Interval between end of t4 and release of load
controller or valve at terminal 20 4 10 10
Duration of start up (without t11 and t12) 30 60 96
t6 Post purge time 10 12 12
t13 Permissible after burn time 10 12 12
* Valid for frequency 50 Hz. For 60 Hz frequency switching times are reduced by approx. 20%.
51
1
1
2
5
3
4
1
2
5
3
4
1
2
5
3
4
2
22
23
15
QRA5...
Burner control
LGK...
Terminal
socket
Terminal in
control panel
Mains cable 3 x 1.5 mm
2
Single core coaxial cable
Screening
max. 60 m
Burner
Burner connection
terminal
Cable
AGM 1
20.5 Sensor line between LGK16... and QRA53 / QPA 55 or sensor electrode
Fitting the senor line
GThe connections between burner control terminal 23,
and UV cell terminal 3, as well as burner control terminal
15 and UV cell terminal 4, have to be fitted as separate
single core coaxial cables with a capacitance of max
45pF/m. The coaxial cable used can be of types RG-62
A/ U or RG-71 B/ U. The screening of these coaxial
cables must be earthed on both cable ends.
GFor the connection between the burner control terminals
1, 2, 22 and the matching terminals of the UV cell
terminals 1, 2 and 5 a normal three core, 1.5mm2 PVC
cable can be used. The line length is unlimited.
GThe coaxial cable and the three core cable may be fitted
in the same cable duct as other mains voltage lines
(control lines and motor lines).
GMaximum line length for the coaxial cable is 60m. The
connection to the burner terminal rail and the control
panel terminal rail must be carried out according to the
wiring diagram. It is important that terminal 22 on the
LGK terminal sub-base is earthed.
Test possibilities of the detector cable
Due to the capacitance of the detector cable connected to
terminal 15 and 23 of the LGK burner control a voltage
reduction in the sensor circuit occurs due to the
capacitance loading. To obtain a reading, the voltage can
be measured at the connection terminals 22 and 23
without detector cable connected and subsequently with
detector cable connected, providing the line length is
within the stipulated limits. The voltage difference must not
be higher than 22 VAC. A higher voltage reduction
indicates the danger of unsafe monitoring.
Wiring diagram
52
20.6 Technical data
Mains voltage ____________220 V - 15% 240 V + 10%
Frequency__________________50 Hz - 6% 60 Hz + 6%
Consumption________________________________3,5 VA
Fuse (inbuilt)________________ M6.3/250 E semi time lag
according to DIN41571, sheet 2).
External fuse______________________________max. 10 A
Permissible input current at terminal 1 ____5 A continuous,
peaks of up to 20A
Permissible load of ____________4A continuous; peaks of
control terminals ______________up to 20A, total max. 5A
Required switching capacity of switching devices
between terminals 4 & 5 ________________________1 A
between terminals 4 & 12_______________________1 A
between terminals 4 & 14 _____________1A continuous,
peaks of up to 20A
Mounting position ___________________________optional
Protection standard ___________________________IP 40
Permissible ambient temperature__-20 + 60C at 220 V
UV supervision with LFL1 ...
Supply voltage _______________ operation 330 V 10 %
test 380 V 10 %
Min. required sensor current ____________________70 A
Max. sensor current _____operation 630 A, test 1300 A
Max. permissible cable length to detector on LFL1 ...
normal cable, wired separately ________________100 m
UV supervision with LGK 16 ...
Supply voltage __280V ~ 10 % (without sensor current)
Max. permitted length
Of sensor line (wired separately) _______ see chapter 20.5
53
21. Cam setting of limit and auxiliary switches
21.1 Dual fuel burners, two stage (servomotor 1055/ 80)
Description
By disengaging the cam from the drive wheel, the cam can
be moved to check the correct actuation of the limit and
auxiliary switches by the switch cams.
The cam is brought into the basic position (scale position
0) and then slowly turned clockwise to the right (when
viewed from the direction, servomotor to cam). Switch III
must be actuated by the third cam to supply the auxiliary
winding open. After some rotational movement, limit
switch IV is no longer actuated by the fourth cam.
The switch points of the limit switches open and closed
are set on delivery to a total angle of rotation of 90.
Limit switch adjustment
Via an indicator on the drive axis the position of the air
damper is shown on a scale 0- 90.
Between the switch or cams there is an adjustment scale.
The adjustment of the cam switch is shown on this scale
by a small indicator and gives the switching point of the
appropriate switch in relation to the actual air damper
position. The limit switch and cam switches are marked on
all wiring diagrams with I, II, III, IV, V and have the function
as shown in the connection diagram.
The diagram is also shown on the servomotor cover.
Switch for burner adjustment
This switch offers the facility of stopping the servomotor
electric operation.
Therefore, by also disengaging the drive mechanically, the
regulating cam can be placed at any position between
partial and full load.
After the setting work is complete, the drive mechanism
should be re-engaged and the switch reset to the normal
operating position.
I full load oil
II partial load 50
III open 90
IV closed 0
V ignition load 10
VI free
These switch points need
to be adjusted to match
plant conditions
0
90
M
g
r
a
u

-

g
r
e
y

-

g
r
i
s
g
r
n

-
g
r
e
e
n

-

v
e
r
t
s
c
h
w
a
r
z

-

b
l
a
c
k

-

n
o
i
r
VI
V
II
I
III
IV
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Servomotor type 1055/80 with inbuilt cam switches I - VI Connection diagram
Servomotor
Switch
identification
Control cam aid
Air damper
position indicator
Socket pin (must
be removed
when changing
printed circuit
board)
Fixing for air
damper shaft
Terminal rail
Printed circuit
board cover
Bottom of housing
Switch position
indicator
Gear wheel (may be
uncoupled for manual
adjustment)
Control cams:
auxiliary switch VI,
valve stage 3
Auxiliary switch V,
intermediate load /
partial load
Auxiliary switch II,
partial load
Auxiliary switch I,
valve stage 2
Limit switch III,
full load
Limit switch IV, Closed
54
21.2 Dual fuel burners, sliding two stage and modulating (servomotor SQM)
Description
The limit and auxiliary switches are set manually on the
adjustable cams. The cams have a small pointer, which
indicates the appropriate switching point on a scale
between the cams.
The servomotors are supplied with the following standard
switch settings:
I - Open 120
II - Closed 0
III - Ignition load oil 30
IV - Ignition load gas 20
V - Stage 2 oil switch (GL) 100
VI - Partial load gas 45
VII - Partial load oil 50
The switch settings must be reset when commissioning to
the requirements of the installation.
The outer scale on the end of the cam shaft serves as a
position indicator. With the lever fitted on the gearbox the
cam switches can be disengaged from the drive. This
makes it possible, manually, to turn the cam to any position
required. When the lever is in the vertical position the drive
is engaged.
Connection diagram
* On GL... TMD burners the auxiliary
switch III is used for the intermedi-
ate load on oil operation.
N
I
21 1 11
II
22 2 12
III
23 3 13
V
25 5 15
IV
24 4 14
VI
26 6 16
VII
27 7 11 a b c
M
~
Setting limit and auxiliary switches Disengaging the servomotor
I Limit switch full load
II Limit switched closed
III* Limit switch ignition load oil
IV Auxiliary switch ignition load gas
V Auxiliary switch stage 2 oil
VI Auxiliary switch partial load gas
VII Auxiliary switch partial load oil
55
22. Throughput determination, conversion from normal to operating conditions
To obtain a given burner heat input rate, the gas quantity
must be calculated.
Example:
Boiler nominal rating: 5000 kW
Efficiency (in advance): 92%
Natural gas LL (calorific value) H
i
= 8.83 kWh/m
3
Boiler loading =
5000
= 5435 kW
0.92
Gas throughput: V
n
=
5435
= 616 m
3
/h
8.83
As the gas volume is altered considerably by pressure and
temperature, the gas quantity must be calculated to the
appropriate operating condition.
Operating condition for above example:
mbar
P
o
= Barometer level 960
P
G
= Gas pressure* 500
Total pressure 1460
t
G
= Gas temperature 10C
* Read gas pressure and gas temperature from gas meter.
See table: 960 + 500 = 1460 mbar gives the factor 1.391
In order to obtain the correct loading for the example, the
gas throughput calculated must be divided by the factor
read off.
Gas throughput in operating conditions:
V
n
616
VB = = 42.8 m
3
/h
f 1.391
With other gas pressures and gas temperatures the
conversion factor can be determined according to the
following formula.
P
o
+ P
G
273
f =
1 013 273 + t
G
The humidity content of the gas is small and is therefore
not taken into account in the table figures or conversion
factor.
Average yearly air pressure at various height sectors
Average geodetic Average yearly air pressure in mbar at
height of supply area a relative humidity of 75% and an
above sea level. average temperature at sea level of
10C.
Northern Southern
Germany Germany
mbar mbar
0 1015 1017
1 50 1012 1014
51100 1006 1008
101150 1000 1002
151200 994 996
201250 988 990
251300 982 984
301350 976 978
351400 970 972
401450 964 966
451500 958 960
501550 952 954
551600 946 949
601650 941 943
651700 935 937
701750 929 931
1)
1 mbar = 0,750 Torr = 10,20 mm VS
1 Torr = 1,333 mbar = 13,6 mm VS
1 mm VS = 0,0735 Torr = 0,0981 mbar
Total pressure P
o
+ P
G
Conversion factor f
in Gas temperature t
G
in C
mbar
1)
Torr 0 5 10 15 20 25
900 675 0.888 0.872 0.857 0.842 0.828 0.813
920 690 0.908 0.892 0.876 0.861 0.846 0.832
940 705 0.928 0.911 0.895 0.880 0.865 0.850
960 720 0.948 0.931 0.915 0.899 0.884 0.868
980 735 0.967 0.950 0.933 0.917 0.901 0.886
1000 750 0.987 0.969 0.952 0.936 0.920 0.904
1020 765 1.007 0.989 0.972 0.955 0.939 0.922
1040 780 1.027 1.009 0.991 0.974 0.957 0.941
1060 795 1.046 1.027 1.009 0.992 0.975 0.958
1080 810 1.066 1.047 1.029 1.011 0.994 0.976
1100 825 1.086 1.066 1.048 1.030 1.012 0.995
1120 840 1.106 1.086 1.067 1.048 1.031 1.013
1140 855 1.125 1.105 1.086 1.067 1.049 1.031
1160 870 1.145 1.124 1.105 1.085 1.067 1.049
1180 885 1.165 1.144 1.124 1.104 1.086 1.067
56
Total pressure P
o
+ P
G
Conversion factor f
in Gas temperature t
G
in C
mbar
1)
Torr 0 5 10 15 20 25
1200 900 1,185 1,164 1,144 1,123 1,104 1,085
1220 915 1,204 1,182 1,162 1,141 1,122 1,103
1240 930 1,224 1,202 1,181 1,160 1,141 1,121
1260 945 1,244 1,222 1,200 1,179 1,159 1,140
1280 960 1,264 1,241 1,220 1,198 1,178 1,158
1300 975 1,283 1,260 1,238 1,216 1,196 1,175
1320 990 1,303 1,280 1,257 1,235 1,214 1,194
1340 1005 1,323 1,299 1,277 2,254 1,233 1,212
1360 1020 1,343 1,319 1,296 1,273 1,252 1,230
1380 1035 1,362 1,338 1,314 1,291 1,269 1,248
1400 1050 1,382 1,357 1,334 1,310 1,288 1,266
1420 1065 1,402 1,377 1,353 1,329 1,307 1,284
1440 1080 1,422 1,396 1,372 1,348 1,325 1,303
1460 1095 1,441 1,415 1,391 1,366 1,342 1,320
1480 1110 1,461 1,435 1,410 1,385 1,362 1,338
1500 1125 1,481 1,454 1,429 1,404 1,380 1,357
1520 1140 1,500 1,473 1,448 1,422 1,398 1,374
1540 1155 1,520 1,493 1,467 1,441 1,417 1,392
1560 1170 1,540 1,512 1,486 1,460 1,435 1,411
1580 1185 1,560 1,532 1,505 1,479 1,454 1,429
1600 1200 1,579 1,551 1,524 1,497 1,472 1,446
1620 1215 1,599 1,570 1,543 1,516 1,490 1,465
1640 1230 1,619 1,590 1,562 1,535 1,509 1,483
1660 1245 1,639 1,610 1,582 1,554 1,528 1,501
1680 1260 1,658 1,628 1,600 1,572 1,545 1,519
1700 1275 1,678 1,648 1,619 1,591 1,564 1,537
1720 1290 1,698 1,667 1,639 1,610 1,583 1,555
1740 1305 1,718 1,687 1,658 1,629 1,601 1,574
1760 1320 1,737 1,706 1,676 1,647 1,619 1,591
1780 1335 1,757 1,725 1,696 1,666 1,638 1,609
1800 1350 1,777 1,745 1,715 1,685 1,656 1,628
1820 1365 1,797 1,765 1,734 1,704 1,675 1,646
1840 1380 1,816 1,783 1,752 1,722 1,693 1,663
1860 1395 1,836 1,803 1,772 1,741 1,711 1,682
1880 1410 1,856 1,823 1,791 1,759 1,730 1,700
1900 1425 1,876 1,842 1,810 1,778 1,748 1,718
1920 1440 1,895 1,861 1,829 1,796 1,766 1,736
1940 1455 1,915 1,881 1,848 1,815 1,785 1,754
1960 1470 1,935 1,900 1,867 1,834 1,803 1,772
1980 1485 1,955 1,920 1,887 1,853 1,822 1,791
2000 1500 1,974 1,938 1,905 1,871 1,840 1,802
2050 1538 2,024 1,988 1,953 1,919 1,886 1,854
2100 1575 2,073 2,036 2,000 1,965 1,932 1,899
2150 1613 2,122 2,084 2,048 2,012 1,978 1,944
2200 1650 2,172 2,133 2,096 2,059 2,024 1,990
2250 1688 2,221 2,181 2,143 2,106 2,070 2,034
2300 1725 2,270 2,229 2,191 2,152 2,116 2,079
2350 1763 2,320 2,278 2,239 2,199 2,162 2,125
2400 1800 2,369 2,326 2,286 2,246 2,208 2,170
2450 1838 2,419 2,375 2,334 2,293 2,255 2,216
2500 1875 2,468 2,424 2,382 2,340 2,300 2,261
2550 1913 2,517 2,472 2,429 2,386 2,346 2,306
2600 1950 2,567 2,521 2,477 2,434 2,392 2,351
2650 1988 2,616 2,569 2,524 2,480 2,438 2,396
2700 2025 2,665 2,617 2,572 2,526 2,448 2,441
2750 2063 2,715 2,666 2,620 2,574 2,530 2,487
2800 2100 2,764 2,714 2,667 2,620 2,576 2,532
2850 2138 2,813 2,762 2,715 2,667 2,662 2,577
2900 2175 2,863 2,812 2,763 2,714 2,668 2,623
2950 2213 2,912 2,860 2,810 2,761 2,714 2,667
3000 2250 2,962 2,909 2,858 2,808 2,761 2,713
3100 2325 3,060 3,005 2,953 2,901 2,852 2,803
3200 2400 3,159 3,102 3,048 2,995 2,944 2,894
3300 2475 3,258 3,199 3,144 3,089 3,036 2,984
3400 2550 3,356 3,296 3,239 3,181 3,128 3,074
3500 2625 3,455 3,393 3,334 3,275 3,220 3,165
3600 2700 3,554 3,490 3,430 3,369 3,312 3,255
3700 2775 3,653 3,587 3,525 3,463 3,405 3,346
3800 2850 3,751 3,684 3,620 3,556 3,496 3,436
3900 2924 3,850 3,781 3,715 3,650 3,588 3,527
4000 3000 3,949 3,878 3,811 3,744 3,680 3,617
57
23. Fault conditions and procedures
If faults occur the basis requirements for correct operation
must first be examined.
1. Check the electric supply.
2. Check that the gas supply is correct and that manual
valves are open.
3. Ensure that an oil supply is available
(dual fuel burners only).
4. Check that all controls e.g. thermostats, pressure
switches, water level interlocks, limit and time switches
are correctly set.
5. Ensure that the burner air or gas settings have not been
altered.
When it is established that the fault is not due to external
conditions, the burner must be tested. Reset the burner
lockout and switch on burner, by careful observation of the
sequence of operations the cause can be recognised and
remedied. When checking, a microammeter and a U tube
manometer must be used.
General faults
Burner motor does not start No electric supply Close circuit
Fuse blown Replace
Neutral open circuit Repair
Motor faulty Replace
Control circuit open Look for contact break, switch on
or reset regulator or detector
Gas supply interrupted Open isolating valve, inform gas
isolating valve closed authority if no gas for a prolonged
period.
Burner control fault Replace
Lack of air
Burner motor starts, after full Air pressure switch faulty Replace
load pre-purge lockout occurs
Burner motor starts, lockout after Solenoid valve leaking indication on Repair leak
approx. 20 secs. (only on versions valve proving programme if burner
with valve proving) control in start position
Burner motor starts, lockout Pressure switch contact does Set pressure switch correctly,
after 10 secs of full load pre-purge not switch in operating position if necessary replace
(air pressure too low)
Fan contaminated Clean
Burner motor rotation incorrect Correct rotation
Ignition failure
Burner motor starts, voltage on Ignition electrode gap too wide Adjust setting (see chapter 22)
terminal 16 of burner control, no
ignition, after a short time lockout occurs
Ignition electrodes or ignition line have Remove earth connection, replace
earth connection, insulating body fault damaged electrodes or cables.
Ignition transformer faulty Replace ignition transformer
No flame establishment
Motor starts, ignition in order, after short Solenoid valve does not open, as Replace solenoid valve correct
time lockout occurs solenoid valve coil is faulty or cables interruption to electric supply,
interrupted. check voltage to terminal 17.
Condition Cause Remedy
58
Lockout after flame establishment
Ignition flame forms. Lockout Blocked filter Clean filter
occurs when running at normal load
Pressure regulating control sluggish Check breather orifice
Gas meter faulty or water in lower Inform gas authority
lying lines.
Flame monitoring fault
Burner motor starts, ignition is audible, Gas/air mixture setting not correct Re-adjust (see commissioning)
normal flame establishment then fault
shutdown
Flame sensor (UV cell) UV cell dirty Clean (remove oil and grease
traces)
Illumination too weak Check combustion setting
UV cell defective Replace
Pump
Supplies no oil Pump faulty Replace
Capacity decreases Replace pump
Suction valve leaking Remove suction valve and clean or
replace
Suction line leaking Seal lines
Isolating valves closed Open
Filter blocked Clean
Filter leaking Replace
Oil lines leaking Tighten unions, vent.
Severe mechanical noise Pump sucks air Tighten unions, vent
Vacuum in oil line too high Clean filter, open valves fully.
Nozzle
Uneven atomisation Nozzle dirty or damaged Clean nozzle or replace
Condition Cause Remedy
Regular maintenance saves energy and protects the environment
We recommend regular maintenance of combustion
equipment to all plant operators. It saves fuel and
ensures constantly good combustion results.
Excellent combustion quality is a pre-requisite for
environmentally friendly operation.
Weishaupt products
and service
Oil, gas and dual fuel burners types W and WG/ WGL
up to 570 kW
They are used mainly in houses and small buildings.
Advantages: fully automatic, reliable operation, individual
components easily accessible, easy to service, quiet operation.
Oil, gas and dual fuel burners types Monarch
R, G, GL, RGL up to 10.900 kW
These are used on all types and sizes of central heating
plant. The basic model which has proved successful over
many years is the basis for a variety of versions. These
burners have founded the outstanding reputation of
Weishaupt products.
Oil, gas and dual fuel burners types WK
up to 17.500 kW
WK types are decidedly industrial burners.
Advantages: Built to the modular system, load dependent
variable combustion head, sliding two stage or modulating
operation, easy to service.
Weishaupt control panels, the proven complement to
Weishaupt burners
Weishaupt burners and Weishaupt control panels form
the ideal unit, a combination which has already proved
successful in hundreds of thousands of combustion
installations. The advantages: Cost saving during planning,
installation, servicing and guarantee work. The responsibility
belongs to one manufacturer.
Weishaupt Thermo Unit / Weishaupt Thermo Gas.
These Units combine the technical innovations and operating
efficiencies developed from over 1 million installations.
Weishaupt Thermo Gas and Weishaupt Thermo Unit
provide the ideals of complete heating centres for houses
and appartments.
Product and service are the complete
Weishaupt achievement
An extensive service organisation guarantees Weishaupt
customers the greatest possible reliability. In addition
our customers are looked after by heating firms who have
been working with Weishaupt for many years.
Max Weishaupt GmbH, D-88475 Schwendi
Tel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58
Print No. 419 GB, August 98
Printed in Germany. All rights reserved

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Installation and operating instructions

Weishaupt dual fuel burners

The gap between combustion head

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