Installation and Operating Instruction: Dual Fuel Burner WM - GL30/3-A / ZM-R (W-FM 54)

Installation and operating instruction
Dual fuel burner WM - GL30/3-A / ZM-R (W-FM 54) 83263302 • 2/2014-12

Conformity certification
Sprachschlüssel 2183000002
Manufacturer: Max Weishaupt GmbH
Address: Max-Weishaupt-Straße
D-88475 Schwendi
Product: Dual fuel burner type
WM-GL 30/3-A
(W-FM 54)
The product described above conforms with
the regulations of directives:
GAD 2009 / 142 / EC

MD 2006 / 42 / EC
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
This product is labelled as follows:
CE-0085
Schwendi, 21.02.2014
ppa. ppa.
Dr. Schloen Denkinger
Manager Research Manager Production and

and Development Quality Management
Dual fuel burner WM - GL30/3-A / ZM-R (W-FM 54)
1 User instructions ..................................................................................................................... 6

1.1 User guide ............................................................................................................. 6
1.1.1 Symbols ................................................................................................................. 6
1.1.2 Target group ......................................................................................................... 6
1.2 Guarantee and Liability ....................................................................................... 7
2 Safety ............................................................................................................................................ 8
2.1 Designated application ....................................................................................... 8
2.2 When gas can be smelled ................................................................................. 8
2.3 Safety measures .................................................................................................. 8
2.3.1 Normal operation ................................................................................................. 8
2.3.2 Electrical connection ........................................................................................... 8
2.3.3 Gas supply ............................................................................................................ 9
2.4 Alterations to the construction of the equipment ......................................... 9
2.5 Noise emission ..................................................................................................... 9
2.6 Disposal ................................................................................................................. 9
3 Product description ............................................................................................................. 10

3.1 Type key .............................................................................................................. 10
3.2 Serial number ..................................................................................................... 10
3.3 Function .............................................................................................................. 11
3.3.1 Air supply ............................................................................................................ 11
3.3.2 Gas supply ......................................................................................................... 12
3.3.3 Oil supply ............................................................................................................ 14
3.3.4 Electrical components ..................................................................................... 16
3.4 Technical data ................................................................................................... 17
3.4.1 Approval data ..................................................................................................... 17
3.4.2 Electrical data .................................................................................................... 17
3.4.3 Ambient conditions ........................................................................................... 17
3.4.4 Permissible fuels ............................................................................................... 17
3.4.5 Emissions ............................................................................................................ 18
3.4.6 Rating .................................................................................................................. 19
3.4.7 Dimensions ......................................................................................................... 20
3.4.8 Weight ................................................................................................................. 21
4 Installation ................................................................................................................................ 22
4.1 Installation conditions ...................................................................................... 22
4.2 Check rating ....................................................................................................... 23
4.3 Set mixing head ................................................................................................. 24
4.3.1 Setting diagram ................................................................................................. 24
4.3.2 Set flame tube ................................................................................................... 25
4.3.3 Adjust combustion head extension (optional) ............................................ 25
4.4 Burner installation ............................................................................................. 26
5 Installation ................................................................................................................................ 28
5.1 Gas supply ......................................................................................................... 28
5.1.1 Screwed valve train .......................................................................................... 29
5.1.2 Flanged valve train ............................................................................................ 30
5.1.3 Fitting gas pressure switch ............................................................................ 32
5.1.4 Carry out soundness test of gas supply line and vent ............................. 33
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5.2 Oil supply ............................................................................................................ 34

5.3 Electrical connection ........................................................................................ 36
6 Operation .................................................................................................................................. 38
6.1 Operating panel ................................................................................................ 38
6.2 Display ................................................................................................................. 39
7 Commissioning ...................................................................................................................... 40
7.1 Prerequisite ........................................................................................................ 40
7.1.1 Connect measuring devices .......................................................................... 41
7.1.2 Check gas connection pressure ................................................................... 43
7.1.3 Check soundness of gas valve train ............................................................. 44
7.1.4 Check high pressure regulator type 06/1 … 09/1 and 1/1 … 5/1
................................................................................................................................ 46
7.1.5 Check high pressure regulator type 5/1-25/50 … 9/1-100/150 ........ 47
7.1.6 Venting the gas valve train .............................................................................. 48
7.1.7 Preset pressure regulator ............................................................................... 49
7.1.8 Preset gas and air pressure switch .............................................................. 51
7.2 Adjusting the burner ......................................................................................... 52
7.2.1 Adjusting gas side ............................................................................................ 52
7.2.2 Adjusting oil side ............................................................................................... 64
7.3 Set pressure switches ..................................................................................... 76
7.3.1 Set oil pressure switch .................................................................................... 76
7.3.2 Set gas pressure switch ................................................................................. 77
7.3.3 Set air pressure switches ............................................................................... 78
7.4 Concluding work ............................................................................................... 79
7.5 Check combustion ........................................................................................... 80
7.6 Calculate gas throughput ............................................................................... 81
7.7 Subsequent optimisation of operating points ............................................ 82
8 Shutdown .................................................................................................................................. 83
9 Servicing .................................................................................................................................... 84
9.1 Notes on servicing ............................................................................................ 84
9.2 Service plan ....................................................................................................... 86
9.3 Hinge open the burner .................................................................................... 87
9.4 Removing and refitting nozzle assembly ...................................................... 88
9.5 Set nozzle distance .......................................................................................... 89
9.6 Removing the mixing head .............................................................................. 89
9.7 Set ignition electrodes ..................................................................................... 90
9.7.1 Set ignition electrodes nozzle assembly ..................................................... 90
9.7.2 Set ignition electrode diffuser ........................................................................ 90
9.8 Set nozzle tubes ................................................................................................ 91
9.9 Replacing the nozzle ........................................................................................ 91
9.10 Removing and refitting air damper stepping motor .................................. 92
9.11 Removing air regulator ..................................................................................... 93
9.12 Set air regulator ................................................................................................. 94
9.13 Removing and refitting gas butterfly stepping motor ............................... 95
9.14 Removing and refitting oil quantity regulator stepping motor ............... 96
9.15 Set pump coupling .......................................................................................... 97
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9.16 Set magnetic coupling ..................................................................................... 97

9.17 Removing fan wheel ......................................................................................... 98
9.18 Check position of inlet nozzle ........................................................................ 98
9.19 Replace spring on pressure regulator ......................................................... 99
9.20 Service position switch unit AGM .............................................................. 100
10 Troubleshooting ................................................................................................................. 101

10.1 Procedures for fault conditions ................................................................... 101
10.2 Rectifying faults ............................................................................................... 102
11 Spares ...................................................................................................................................... 104
12 Technical documentation .............................................................................................. 120

12.1 Appliance categories ..................................................................................... 120
13 Project planning .................................................................................................................. 124

13.1 Oil supply .......................................................................................................... 124
13.1.1 Single pipe oil supply ..................................................................................... 125
13.1.2 Ring main operation ....................................................................................... 125
13.1.3 Oil circulation unit ........................................................................................... 125
13.2 Flue gas system .............................................................................................. 125
14 Notes ........................................................................................................................................ 126
15 Key word index ................................................................................................................... 128
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1 User instructions
1 User instructions
These installation and operating instructions form part of the equipment and must be
Translation of original kept on site. They are supplemented by the installation and operating instructions
operating instructions Combustion Manager W-FM 54.
1.1 User guide
1.1.1 Symbols
Immediate danger with high risk.

Non observance can lead to serious injury or death.
DANGER
Danger with medium risk.

Non observance can lead to environmental damage,
serious injury or death.
WARNING
Danger with low risk.

Non observance can cause damage to the equipment
and injury to personnel.
CAUTION
Important information
Requires direct action
Result after an action
Itemisation
Range of values
1.1.2 Target group

These installation and operating instructions are intended for the operator and quali-
fied personnel. They should be observed by all personnel working on the unit.
Work on the unit must only be carried out by personnel who have the relevant training
and instruction.
Persons with limited physical, sensory or mental capabilities may only work on the unit
if they are supervised or have been trained by an authorised person.
Children must not play near or on the unit.
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1 User instructions
1.2 Guarantee and Liability

Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
▪ Non approved application,
▪ non-observance of the installation and operating instruction,
▪ operation with faulty safety equipment,
▪ continual operation despite a fault,
▪ improper installation, commissioning, operation and service,
▪ unauthorised modifications made to the unit,
▪ the installation of additional components, which have not been tested with the unit,
▪ the installation of combustion chamber inserts, which impede full flame formation,
▪ repairs, which have been carried out incorrectly,
▪ the use of non original Weishaupt parts,
▪ unsuitable fuels,
▪ defects in the inlet lines,
▪ acts of God.
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2 Safety
2 Safety
2.1 Designated application

The burner is suitable for operation on heat exchangers to EN 303, EN 267 and EN
676.
If the burner is not used on combustion chambers to EN 303, EN 267 and EN 676,
a safety assessment of combustion and flame stability during individual process con-
ditions and of the shutdown limits of the combustion plant has to be carried out and
documented.
The combustion air must be free from aggressive compounds (e.g. Halogens). If the
combustion air in the boiler room is contaminated, increased cleaning and servicing
will be required. In this case ducted air intake is recommended.
The burner should only be used in enclosed rooms.
Improper use could:
▪ endanger the health and safety of the user or third parties,
▪ cause damage to the appliance or other material assets.
2.2 When gas can be smelled

Avoid open flames and spark generation, for example:
▪ do not operate light switches,
▪ do not operate electronic equipment,
▪ do not use mobile telephones.
▶ Open doors and windows.
▶ Close gas isolating valve.
▶ Warn the inhabitants (do not ring door bells).
▶ Leave the building.
▶ Inform the heating contractor or gas supplier from outside of the building.
2.3 Safety measures

Safety relevant fault conditions must be eliminated immediately.
Components, which show increased wear and tear or whose design lifespan is or will
be exceeded prior to the next service should be replaced as a precaution (see Ch.
9.2).
2.3.1 Normal operation

▪ All labels on the unit must be kept in a legible condition,
▪ the unit should only be operated with its cover in the closed position,
▪ do not touch moving parts during operation,
▪ stipulated settings, service and inspection work should be carried out at regular
intervals.
2.3.2 Electrical connection

For work carried out on live parts:
▪ Observe the accident prevention instructions BGV A3 and adhere to local direc-
tives,
▪ tools in accordance with EN 60900 should be used.
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2 Safety
2.3.3 Gas supply

▪ Only the gas supply company or an approved agent may carry out installation,
alteration and maintenance work on gas appliances in buildings and properties.
▪ Pipe work must be subject to a combined load and valve proving test and usability
testing relative to the pressure range intended (e.g.
DVGW-TRGI, work sheet G 600).
▪ Inform the gas supply company about the type and size of plant prior to installation.
▪ Local regulations and guidelines must be observed during installation (e. g.
DVGW-TRGI, work sheet G 600; TRF Band 1 and Band 2).
▪ The gas supply pipe work should be suitable for the type and quality of gas and
should be designed in such a way that it is not possible for liquids to form (e. g. con-
densate). Observe vaporisation pressure and vaporisation temperature of liquid
petroleum gas.
▪ Use only tested and approved sealing materials, whilst observing all process in-
formation.
▪ Re-commission the appliance when changing to a different type of gas.
▪ Carry out soundness test after each service and fault rectification.
2.4 Alterations to the construction of the equipment

All conversions require written approval from Max Weishaupt GmbH.
▪ No additional components may be fitted, which have not been tested for use with
the equipment,
▪ do not use combustion chamber inserts, which hinder flame burnout,
▪ use only original Weishaupt replacement parts.
2.5 Noise emission

The noise emissions are determined by the acoustic behaviour of all components fitted
to the combustion system.
Prolonged exposure to high noise levels can lead to loss of hearing. Provide operating
personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.
2.6 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.
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3 Product description
3.1 Type key

WM - GL30/3-A / ZM-R
WM Type: Weishaupt Monarch
-G Fuel: Gas
L Fuel: Fuel oil EL
30 Size
/3 Ratings size
-A Construction
/ ZM Version: sliding two stage or modulating (Gas)
-R Version: sliding two stage or modulating (Oil)
3.2 Serial number

The serial number on the name plate identifies the product. This is required by Weish-
aupt's customer service department.
1 Name plate
Serial-No.
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3.3 Function
3.3.1 Air supply
Air dampers
The air dampers regulate the air quantity required for combustion. The combustion
manager controls the air dampers via stepping motor. At burner shutdown the air
dampers close automatically. This reduces heat loss in the heat exchanger.
Fan wheel
The fan wheel supplies the air from the air intake housing to the combustion head.
Flame tube
The air gap between flame tube and diffuser is adjusted by positioning the flame tube.
This adjusts the mixing pressure and the air quantity required for combustion.
Air pressure switch

The air pressure switch monitors the fan pressure. If the fan pressure is insufficient,
the combustion manager initiates a lockout.
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3.3.2 Gas supply
Double gas valve 1

The double gas valve opens and shuts off the gas supply.
Gas filter 2
The gas filter protects the subsequent valve train components from foreign particles.
Gas isolating valve 3

The gas isolating valve shuts off the gas supply.
Pressure regulator 4
The pressure regulator reduces the connection pressure and ensures a constant set-
ting pressure.
High gas pressure switch 5 (optional)

The high gas pressure switch monitors the setting pressure. If the gas pressure ex-
ceeds the value set, the combustion manager initiates a controlled safety shut-
down.
The combustion manager delays the operation of the high gas pressure switch during
the start-up of the burner. During this time any possible back pressure is reduced.
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Low / valve proving gas pressure switch 6

If the gas pressure is lower than the value set, the low gas pressure switch initiates
a controlled shutdown at the combustion manager.
The gas pressure switch also checks, if the valves are tight. It signals the combustion
manager if the pressure increases or decreases to an impermissible level during valve
proving.
Valve proving is carried out automatically by the combustion manager:
▪ after every controlled shutdown,
▪ prior to burner start following lockout or power outage.
1. Test phase (function sequence for valve proving valve 1):
▪ valve 1 closes,
▪ valve 2 closes after a delay,
▪ the gas escapes and the pressure between valve 1 and valve 2 reduces,
▪ both valves remain closed for 10 seconds.
If the gas pressure increases to above the set value during these 10 seconds, valve
1 is leaking. The combustion manager initiates a controlled shutdown.
2. Test phase (function sequence for valve proving valve 2):
▪ valve 1 opens, valve 2 remains closed,
▪ the gas pressure between valve 1 and valve 2 increases,
▪ valve 1 closes again,
▪ both valves remain closed for 10 seconds.
If the gas pressure decreases to below the set value during these 10 seconds, valve
2 is leaking. The combustion manager initiates a controlled shutdown.
Gas butterfly valve 7

The gas butterfly valve regulates the gas quantity depending on the rating required.
The combustion manager drives the gas butterfly valve via stepping motor.
V2 V1
P P
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3.3.3 Oil supply
Oil pump
The pump draws the oil through the supply line and carries it under pressure to the
oil nozzle. The pressure regulating valve keeps the oil pressure constant.
Solenoid valves
The solenoid valves open and close the oil supply.
Nozzle assembly
The pump pumps the oil through the solenoid valves and the pressure lines to the
nozzle head, where the oil is atomised by the nozzle. The integrated nozzle shut off
opens or closes the oil supply directly at the oil nozzle.
Oil quantity regulator

The oil quantity regulator is driven by the combustion manager via stepping motor. An
oil metering vee slot in the oil quantity regulator changes the spill back quantity of the
fuel and thus the atomised quantity of the oil at the nozzle. The oil quantity regulator
has two metering slots. Each metering slot is matched with a specific oil throughput.
Two identity code numbers are located on the shaft of the oil quantity regulator, which
denote the oil throughput set.
1
2 2
1
Identity code Oil throughput

1 up to 280 kg/h
2 greater than 280 kg/h
Factory setting see burner data sheet.
Max. oil pressure switch

The maximum oil pressure switch monitors the pressure in the return. If the value set
is exceeded, the burner switches off.
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Sequence of operation
During the pre-purge time all shut off devices are closed. For burner ignition, the
combustion manager opens solenoid valves 3 and 7, as well as the shut off device
4 in the nozzle head. The oil quantity regulator 5 is in the open position (ignition
load position). Due to the low resistance of the oil quantity regulator in the return only
a small quantity of oil is atomised at the nozzle, the larger quantity flows to the pump
return. If the load increases, the metering slot in the oil quantity regulator is decreased,
this reduces the oil flow in the return and thus increases the oil quantity at the nozzle
outlet.
P M
1 Oil pump
2 Strainers
3 Solenoid valve supply (fitted in flow direction)
4 Nozzle head with shut off device
5 Oil quantity regulator
6 Maximum oil pressure switch
7 Solenoid valve return (fitted against flow direction)
The solenoid valve in the supply is always switched electrically in series with the
solenoid valve in the return. The voltage of the solenoid coil is therefore 115 V at
230 V/50 Hz mains voltage.
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3.3.4 Electrical components
Combustion Manager
The combustion manager W-FM is the central control unit of the burner. It controls
the sequence of operation, monitors the flame and communicates with all compo-
nents.
Display and operating unit (ABE)

The ABE is used to display and alter the operational values and parameters of the
combustion manager. It is connected by connection cable and can be remove from
the burner, e. g. when commissioning.
Burner motor
The burner motor drives the fan wheel and the oil pump.
On burners without speed control the combustion manager controls a star delta
combination.
On burners with speed control a frequency converter is connected in series.
Magnetic coupling
During gas operation, the magnetic coupling decouples the oil pump from the burner
motor.
Ignition unit
The electronic ignition unit creates a spark at the electrodes, which ignites the
fuel/air mixture.
Flame sensor
The combustion manager monitors the flame signal via the flame sensor. If the flame
signal becomes too weak, the combustion manager initiates a controlled shutdown.
See installation and operating manual Combustion Manager W-FM for flame signal
required.
Limit switch
The limit switch in the hinged flange stops the burner from operating in the open
position.
Fuel selection switch

The relevant fuel is preselected using the fuel selection switch. If the fuel selection
switch is set to EXTERNAL, fuel selection via building management system or external
fuel selection switch is possible.
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3.4 Technical data
3.4.1 Approval data

PIN 2009/142/EC CE-0085 BU 0360
PIN 97/23/EG Z-IS-TAF-MUC-10-05-376456-019
DIN CERTCO 5G1044/10M
Basic standards EN 267: 2011
EN 676: 2008
EN 60335-2-102 and EN 60335-1
EN 61000-6-2 and EN 61000-6-4
3.4.2 Electrical data
Burner control
Supply voltage / frequency 230 V/50 Hz
Consumption at start max 430 W
Consumption during operation max 120 W
Internal unit fuse 6.3 AT
External fuse max 16 AT
Burner motor WM-D132/210-2/14K0

Mains voltage/Mains frequency 380 … 415 V/50 Hz
Consumption max 15.5 kW
Power consumption max 28 A
Speed min 2920 rpm
External fuse 50 A (YΔ start)
3.4.3 Ambient conditions

Temperature in operation -15 … +40 °C (Gas)
-10(1 … +40 °C (Oil)
Temperature during transport / storage -20 … +70 °C
Relative humidity max 80 %, no dew point
(1
with the relevant suitable fuel oil and layout of oil supply.
3.4.4 Permissible fuels

▪ Natural Gas E/LL,
▪ Liquid Petroleum Gas B/P,
▪ Fuel oil EL to DIN 51603-1,
▪ Fuel oil EL A Bio 10 to DIN 51603-6
▪ Fuel oil EL to ÖNORM-C1109 (Austria)
▪ Fuel oil EL to SN 181 160-2 (Switzerland).
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3.4.5 Emissions
Flue gas
▪ Emission Class 2 on fuel oil EL to EN 267,
▪ Emission Class 2 on Gas to EN 676.
The NOx values are influenced by:
▪ combustion chamber dimensions
▪ flue gas system
▪ fuel
▪ combustion air (temperature and humidity)
▪ medium temperature
For combustion chamber dimensions see leaflet "Conditions for attaining the NOx
emission values for Weishaupt burners (Print No. 1539 and 972)".
Sound levels
Dyad noise emission values to ISO 4871
Measured sound power level LWA (re 1 pW) 93 dB(A)(1
Uncertainty value KWA 4 dB(A)
Measured sound pressure level LpA (re 20 µPa) 85 dB(A)(2
Uncertainty value KpA 4 dB(A)
(1
Determined to noise level measurement standard ISO 9614-2.
(2
Determined at 1 metre distance in front of the burner.
The measured noise levels plus uncertainty values form the upper limit value, which
could occur when measuring.
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3.4.6 Rating
Combustion heat rating

Natural Gas 600 … 5700 kW
Liquid Petroleum Gas 900 … 5700 kW
Fuel oil 1100 … 5700 kW
92.4 … 479.0 kg/h(1
Combustion head WM-G(L) 30/3
(1
The oil throughput data relates to a calorific value of 11.9 kWh/kg for fuel oil EL.
Capacity graph
Capacity graph to EN 267 and EN 676.
The ratings data given relates to an installation elevation of 0 m above sea level. For
installation elevations above 0 m a ratings reduction of approx. 1 % per 100 m applies.
A limited capacity graph is valid for ducted air intake.
Combustion heat rating at combustion head setting:
Fuel oil Natural Gas Liquid Petroleum
Gas
Combustion head 3 5 7
OPEN
Combustion head 4 6 8
CLOSED
20
18
16
14
12
10
8
6
4
2
0
-2
-4
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
0 50 100 150 200 250 300 350 400 450 500
1 Combustion heat rating [kW] or [kg/h]

2 Combustion chamber pressure [mbar]
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3.4.7 Dimensions
Burner
367 mm
232 mm
730 mm
505 mm
148 mm
256 mm
268 mm
625 mm
261 mm
mm
0 59
1
348 mm
450 mm
11
37
mm
548 mm
8 mm
319 mm
1166 mm
1 349 … 389 mm without combustion head extension

499 … 539 mm with combustion head extension (150 mm)
649 … 689 mm with combustion head extension (300 mm)
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Mixing head
310 mm
260 mm
62 mm
3.4.8 Weight
Burner
approx. 202 kg
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4 Installation
4 Installation
4.1 Installation conditions
Burner type and capacity graph

Burner and heat exchanger must be matched.
▶ Check burner type and burner rating.
Installation location
▶ Prior to installation ensure that:
▪ the space for the burner hinging range is sufficient (see Ch. 3.4.7),
▪ sufficient combustion air is available, if necessary install ducted air intake.
Prepare heat exchanger
The refractory 3 must not protrude beyond the front edge of the combustion head,
it can, however, take a conical shape (min 60°).
Refractory may not be required on boilers with water-cooled front, unless the manu-
facturer gives other instructions.
Following installation, the aperture 4 between flame tube and refractory should be
filled with flame-proof, resilient insulating material (do not make solid).
Boiler constructions with deep refractories or thick doors, or boilers with reverse flame
combustion chambers may require a combustion head extension. Head extensions
of 150 and 300 mm are available. Dimension 2 then changes according to the head
extension used.
The burner has to be hinged open by approx. 70 … 80° to allow removal of the mixing
head.
M12
60° 60°
30°
420 mm
367 mm
375 mm
400 mm
1 Flange gasket
2 min 349 mm (combustion head OPEN)
max 389 mm (combustion head CLOSED)
3 Refractory
4 Aperture
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4 Installation
4.2 Check rating

The burner as delivered is equipped with an oil nozzle type -w- S5 50°V. It has been
factory pre-sized for a specific oil throughput (factory presetting see burner data
sheet).
Alternatively an oil nozzle type W S4 50° can be used.
Pump pressure setting

20 … 30
Spray characteristic and spray angle varies depending on pump pressure.
Determine exact oil throughput at oil meter or by weighing.
Nozzle selection table -w- S5 50°V

20 bar 22 bar 24 bar 26 bar 28 bar 30 bar
Nozzle size kW(1 kW(1 kW(1 kW(1 kW(1 kW(1
225 kg/h 2041 2136 2231 2327 2422 2517
250 kg/h 2273 2378 2483 2587 2692 2797
275 kg/h 2487 2601 2715 2830 2944 3058
300 kg/h 2725 2850 2975 3100 3225 3350
330 kg/h 3011 3150 3289 3429 3568 3707
360 kg/h 3308 3459 3610 3762 3913 4064
390 kg/h 3606 3770 3934 4099 4263 4427
420 kg/h 3915 4095 4275 4454 4634 4814
460 kg/h 4320 4517 4714 4912 5110 5307
500 kg/h 4718 4933 5149 5364 5580 5795
550 kg/h 5194 5431 5668 5904 6141 6378
(1
Guaranteed minimum rating of the relevant nozzle at an oil regulator setting of 90°.
Nozzle selection diagram -w- S4 50°

20 bar 22 bar 24 bar 26 bar 28 bar 30 bar
Nozzle size kW(1 kW(1 kW(1 kW(1 kW(1 kW(1
225 kg/h 2118 2217 2316 2414 2513 2612
250 kg/h 2344 2452 2561 2669 2778 2886
275 kg/h 2570 2688 2806 2923 3041 3159
300 kg/h 2862 2994 3126 3258 3390 3522
330 kg/h 3142 3286 3430 3574 3718 3862
360 kg/h 3421 3578 3735 3893 4050 4207
390 kg/h 3707 3877 4047 4218 4388 4558
420 kg/h 4082 4269 4456 4642 4829 5016
460 kg/h 4415 4616 4817 5018 5219 5420
500 kg/h 4766 4984 5202 5419 5637 5855
550 kg/h 5248 5487 5726 5966 6205 6444
(1
Guaranteed minimum rating of the relevant nozzle at an oil regulator setting of 90°.
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4 Installation
4.3 Set mixing head
4.3.1 Setting diagram
Determine flame tube and air damper setting

Set mixing head relative to the combustion heat rating required. Therefore the flame
tube setting and air damper setting are matched.
Do not operate the burner outside of its capacity graph.
▶ Determine the required flame tube setting (dimension S1) and air damper setting
from diagram and note down.
Example Example 7 Example 8
Burner rating required 2750 kW 4250 kW
Combustion chamber pres-
7.0 mbar 11.0 mbar
sure
Flame tube setting
115 mm 86 mm
dimension S1
(279 mm) (250 mm)
(auxiliary dimension E)
Air damper setting 59° > 80°
20
70°
18
60°
16
50°
14
12 40°
10
8 30°
6
20°
4
10°
2
0 75
(239)
-2
115 105 95 85
-4 (279) (269) (259) (249)
-6
-7
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
1 Combustion heat rating in kW

2 Combustion chamber pressure in mbar
3 Air damper setting in ° (1
4 Flame tube setting dimension S1 in mm (1
(Auxiliary dimension E in mm) (1
5 Setting range of the air dampers with flame tube setting CLOSED (115 mm)
6 Setting range for flame tube with air damper setting > 80°
(1
Different settings may be required depending on site conditions.
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4 Installation
4.3.2 Set flame tube

▶ Hinge open the burner (see Ch. 9.3).
▶ Remove nozzle assembly (see Ch. 9.4).
▶ Remove mixing head (see Ch. 9.6).
▶ If necessary, adjust to optimum combustion head extension position
(see Ch. 4.3.3).
▶ Undo screws 1.
▶ Adjust flame tube until the flame tube setting determined is reached at auxiliary
dimension E.
▶ Centralise flame tube whilst checking the distance at a minimum of 3 positions
(each offset by 120°).
▶ Re-tighten screws.
▶ Fit mixing head.
E S1
4.3.3 Adjust combustion head extension (optional)
Check flame tube length.

▶ Check total length of flame tube, dimension 2, and adjust if necessary.
Extension 150 mm 300 mm
Total length 528 mm (±1) 678 mm (±1)
▶ Undo hexagonal nuts 1 on flame tube.

▶ Adjust flame tube until total length has been reached at dimension 2.
▶ Centralise flame tube whilst checking the distance at a minimum of 3 positions
(each offset by 120°).
▶ Re-tighten hexagonal nuts 1, counter-holding at the screws.
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4 Installation
4.4 Burner installation

Risk of electric shock
Working on the device when voltage is applied can lead to electric shock.
▶ Isolate the device from the power supply prior to starting any work.
DANGER ▶ Safeguard against accidental re-start.
Only valid in Switzerland

When installing and operating in Switzerland the regulations of SVGW, VKF, local
and Cantonal regulations and the EKAS guideline (LPG Guideline Part 2) must be
observed.
▶ Screw studs 4 to boiler plate.

▶ Attach hinge flange 2 with flange gasket 3 to studs.
▶ Secure hinge flange to boiler plate with nuts 1.
▶ The aperture between flame tube and refractory should be filled with flame-proof,
resilient insulating material (do not make solid).
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4 Installation
▶ Using suitable lifting equipment lift burner and, using hinge pins 4, fit into hinged
flange. Observe hinging direction.
▶ Check nozzle distance and adjust if necessary (see Ch. 9.5).
▶ Connect pressure hoses ensuring correct allocation.
▶ Place ignition cables into the burner housing, close the burner and secure with
dome nut 3.
1 Supply
2 Return
▶ Open view port cover.

▶ Plug diffuser ignition cable 1 into the left socket.
▶ Plug nozzle assembly ignition cables 4 into the two sockets on the right.
▶ Fit solenoid coil plug 2.
▶ Close view port cover.
▶ Plug in plug 3 on gas butterfly valve stepping motor.
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5 Installation
5 Installation
5.1 Gas supply

Risk of explosion due to leaking gas
Gas leaks can lead to a build-up of explosive gas/air mixture. With an ignition source
present this can result in an explosion.
DANGER ▶ Install gas supply with care.
▶ Observe all safety instructions.
Only an approved gas installer may carry out the gas side connection. Observe local
regulations.
The following should be obtained from the gas supply company:
▪ Type of gas
▪ Gas connection pressure.
▪ Maximum CO2 content in the flue gas.
▪ Calorific value in normal condition [kWh/m3].
Observe maximum permissible pressure of all components of the gas valve train.
▶ Close all fuel shut off devices prior to commencing work and protect from acci-
dental re-opening.
Observe general installation instructions

▪ The stepping motor of the gas butterfly valve must be located on the opposite side
to the gas valve train, if necessary rotate gas butterfly valve by 180°.
▪ Install manually operated shut off valve (gas isolating valve) in the supply.
▪ Ensure correct mounting alignment and cleanliness of sealing surfaces.
▪ Mount valve train free of vibration. It must not be allowed to swing. Suitable sup-
ports should be fitted.
▪ Mount valve train free of tension, if necessary fit compensator parallel to the burner
shaft.
▪ The distance between burner and double gas valve should be as small as possible.
If the distance is too great it could influence the burner start.
▪ The distance between pressure regulator and double gas valve should be as small
as possible. If the distance is too great, the function of the optional high gas pres-
sure switch cannot be guaranteed.
▪ Observe sequence and flow direction of gas valve train.
▪ If necessary fit high pressure regulator (see installation and operating manual Pres-
sure regulating devices).
Breather and vent lines for high pressure regulators without safety diaphragm
should be discharged to atmosphere.
▪ If necessary, fit thermal shut off device (TAE) in front of the gas isolating valve.
Installation position
Double gas valve and pressure regulator can be positioned with the actuator axis
angled from standing vertical to lying horizontal.
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5 Installation
5.1.1 Screwed valve train

▶ Mount gas valve train free of stresses.
▶ Install disconnecting point between double gas valve and isolating valve.
✓ Boiler door can still be hinged open with valve train installed.
Installation examples
1 Double gas valve

2 High gas pressure switch (optional)
3 Gas filter
4 Gas isolating valve
5 Pressure regulators
6 Low / valve proving gas pressure switch
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5 Installation
5.1.2 Flanged valve train
Installation location VGD (from DN 125)

▶ Install stepping motors (connection to the front).
▶ Fit intermediate plug.
✓ Plug socket 1 must be plugged into stepping motor valve 1 (inlet side).
▶ For installation to the right, change over ignition gas plate 2 and pressure switch
plate 3.
Mount gas valve train

▶ Mount gas valve train free of stresses. Do not compensate for installation errors by
over-tightening the flange screws.
▶ Ensure correct alignment of flange seals.
▶ Tighten screws evenly diagonally across.
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5 Installation
Installation examples
1 Double gas valve

2 High gas pressure switch (optional)
3 Gas filter
4 Gas isolating valve
5 Pressure regulators
6 Low / valve proving gas pressure switch
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5 Installation
5.1.3 Fitting gas pressure switch

▶ Remove closing plug of test point 1.
▶ Fit sealing rings 2 supplied to the low gas pressure switch / valve proving 3,
ensuring all sealing surfaces are clean.
▶ Fix gas pressure switch to the double gas valve with the screws supplied.
W-MF DMV VGD
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5 Installation
5.1.4 Carry out soundness test of gas supply line and vent
Only the gas supply company or a contract installation company may carry out a
soundness test and vent the gas line.
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5 Installation
5.2 Oil supply

Observe EN 12514-2, DIN 4755, TRÖI and local regulations.
Check conditions for oil pump

Suction resistance max 0.4 bar(1
Supply pressure max 5 bar(1
Supply temperature max 140 °C(1
(1
Measured at the pump.
Check conditions for oil hoses

Length 1300 mm
Oil hose connection M38 x 1.5
Threaded socket connection M38 x 1.5 x G1"
Nominal pressure 10 bar
Thermal load max 100 °C
Connect oil supply
Damage to the oil pump due to incorrect connection

Mixing up supply and return can damage the oil pump.
▶ Ensure correct connection of oil hoses to the supply and return of the pump.
CAUTION
1 Supply
2 Return
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5 Installation
▶ Connect oil supply and observe:

▪ Do not twist oil hoses,
▪ avoid mechanical tension,
▪ ensure sufficient hose length for the burner hinge range
▪ do not kink oil hoses (curve radius 1 of 165 mm must be maintained).
If these conditions for connection cannot be met:
▶ Adapt oil supply on site.
Purge oil supply and ensure it is tight
Damage to oil meter in oil circulating device resulting from purging

If an oil circulating device is fitted, the purging process could damage the integrated
oil meter.
CAUTION ▶ Replace oil meter with adapter during purging.
Oil pump seized due to running dry

The pump could be damaged.
▶ Fill oil supply with oil and purge.
CAUTION
▶ Check oil supply is tight.
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5 Installation
5.3 Electrical connection

Electric shock caused by frequency converter despite disconnection from the

voltage supply
It is possible that electrical components on burners with frequency converters con-
WARNING tinue to carry voltage and cause electric shock even after the voltage supply has been
disconnected.
▶ Wait approx. 5 minutes before commencing work.
✓ Electric voltage has dissipated.
The electrical connection must only be carried out by qualified electricians. Observe
local regulations.
Carry out electrical connection in such a way that the burner can still be hinged open.
Connect combustion manager

▶ Use cable entry grommets on the housing.
▶ Connect wiring to wiring diagram enclosed.
Control circuits, which are taken directly via a 16 AT pre-fuse from a 3 phase or
single phase alternating current supply, must only be connected between a phase
conductor and earth potential neutral conductor.
On mains supply, which does not have a neutral, 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.
Phase L must not be mixed up with the neutral conductor N. Contact protection will
otherwise no longer be given. Malfunctions, which endanger operational safety could
occur.
The cable cross section of the voltage supply must be suitable for the nominal current
of the pre-fusing (maximum 16 AT).
All other cable connections must be suitable for the relevant internal unit fuse
(6.3 AT).
Earthing and neutral conductor must conform to local regulations.
The following applies for cable length:
▪ Display and operating unit, load controller, safety interlock circuit, burner flange,
reset key - maximum 20 m (100 pF/m).
▪ BCI interface - maximum 20 m (100 pF/m).
Connect gas valve train
Observe wiring diagram enclosed.
▶ Connect double gas valve (plug K32 / Y2):
▪ Solenoid coil on W-MF or DMV
▪ Stepping motor on VGD (see Ch. 5.1.2)
▶ Connect low / valve proving gas pressure switch (plug B31 / F11).
▶ If required, connect high gas pressure switch (plug B33 / F33).
Connect burner motor
The motor must be protected against thermal overload and short circuit. The use of
a motor protection switch is recommended.
▶ Open terminal box on motor.
▶ Connect voltage supply to wiring diagram enclosed, observe motor rotation.
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5 Installation
Speed control (optional)

If the frequency converter is located on the motor, the cable to the frequency converter
is not screened.
If the frequency converter is separate the control line and the motor connection must
be screened:
▶ Apply screen to the designated screen clamp on frequency converter.
▶ Use screen cable glands (metal) on the burner.
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6 Operation
6 Operation
6.1 Operating panel

For further instruction see installation and operating manual Combustion Manag-
er W-FM 54.
Display and operating unit (ABE)
S
P
i
V h min s % info
VSD esc
F A - +
No. Key Function

1 [ENTER] back-up of value changes;
entry to parameter and values
[info] press approx. 3 seconds = Info level;
press approx. 5 seconds = Service level
2 [+] navigation through parameter structure;
3 [–] changing the setting values
2 and 3 [+] and [–] simulta- cancel/return
neously (esc)(1
4 [A] (Air) selects the actuator of the the air dampers
5 [F] (Fuel) selects the fuel supply
4 and 5 [A] and [F] simulta- selects the frequency converter (optional)
neously (VSD)(2
(1
Escape
(2
Variable Speed Drive
OFF function
▶ Press [ENTER] key and any other key simultaneously.
✓ Immediate lockout.
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6 Operation
6.2 Display
The black cursor in the display shows the status of the inputs and outputs, the unit of
values and the active level.
S
P
i
V h min s %
1 Heat demand by the boiler control (start)

2 Burner motor
3 Ignition
4 Fuel valves
5 Flame signal on
6 Flame failure or lockout
7 Degree of angle setting
8 Percentage value
9 Second
0 Minute
q Hour (together with volume = V/h)
w Volume (m³, l, ft³, gal)
e Stepping motor OPEN
r Stepping motor CLOSED
t Service level
z Info level
u Parameter level (heating engineer level)
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7 Commissioning
7 Commissioning
7.1 Prerequisite
Commissioning must only be carried out by qualified personnel.
Only correctly carried out commissioning ensures the operational safety of the burner.
▶ Prior to commissioning ensure that:
▪ all assembly and installation work has been carried out correctly
▪ sufficient combustion air is available, if necessary install ducted air intake
▪ the annulus between flame tube and heat exchanger is filled
▪ the heat exchanger is filled with medium
▪ all regulating, control and safety devices are functioning and set correctly
▪ the flue gas ducts are unimpeded
▪ a measuring point conforming to standards is available to measure the flue gas
▪ the heat exchanger and flue gas ducting up to the test point are sound (extra-
neous air influences the test results)
▪ the operating instructions of the heat exchanger are complied with
▪ a heat demand is available
Additional system-related tests could be necessary. Please observe the operating
guidelines for the individual components.
On installations with process equipment, the conditions for safe operation and com-
missioning as detailed in worksheet 8-1 (Print No. 1880) must be met.
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7 Commissioning
7.1.1 Connect measuring devices
Pressure measuring device for mixing pressure

▶ Open pressure test point in front of the mixing head 1 and connect pressure
measuring device.
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7 Commissioning
Oil pressure measuring devices on oil pump
Oil leakage from oil pressure measuring devices due to constant load
Oil pressure measuring devices could be damaged and cause environmental pollution
through leakage.
WARNING ▶ Close or remove oil pressure measuring devices once commissioning is complete.
▪ Vacuum gauge for suction resistance/supply pressure.
▪ Pressure gauge for pump pressure.
▶ Close fuel shut off devices.
▶ Remove closing plug on the pump.
▶ Connect vacuum gauge 1 and pressure gauge 2.
-1 9
Oil pressure measuring device connected to the return line
through leakage.
Pressure gauge for return pressure.
▶ Remove bypass plug from the return line for pressure gauge 1.
▶ Connect pressure gauge.
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7 Commissioning
7.1.2 Check gas connection pressure
Minimum connection pressure
Add the combustion chamber pressure in mbar to the minimum connection pressure.
The connection pressure should not fall below 15 mbar.
▶ Determine minimum connection pressure for low pressure installations from table
(see Ch. 7.1.7).
Maximum connection pressure

With low pressure supplies, pressure regulators to EN 88-1 with safety diaphragm
are used. Maximum connection pressure into isolating valve is 300 mbar.
With high pressure supplies high pressure regulators with safety assemblies are se-
lected from the following brochures:
▪ Pressure regulators up to 4 bar, Print No. 12
▪ Pressure regulators with safety devices, Print No. 1979.
Maximum connection pressure on high pressure installations see name plate.
Check connection pressure
Risk of explosion due to excess gas pressure

Exceeding the maximum connection pressure (see name plate) can damage the gas
valve train and lead to an explosion.
DANGER ▶ Check gas connection pressure.
▶ Fit pressure measuring device to gas filter (with high pressure supplies the inlet of
the pressure regulator is already equipped with a pressure measuring device).
▶ Slowly open isolating valve whilst checking the pressure increase.
If the measured connection pressure exceeds the maximum connection pressure:
▶ Immediately close isolating valve.
▶ Do not start plant.
▶ Inform system operator.
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7 Commissioning
7.1.3 Check soundness of gas valve train
Soundness test
▶ Carry out soundness test:
▪ prior to commissioning,
▪ after servicing.
Valid for all test phases:
Test pressure 100 … 150 mbar
Waiting time for pressure equalisation 5 minutes
Test time 5 minutes
Permissible pressure loss max 1 mbar
First test phase

In the first phase the valve train section from the gas isolating valve up to the first valve
of the double gas valve is tested.
▶ Switch off burner.
▶ Connect test gauges to gas filter and inlet to valve 1 (double gas valve).
▶ Open test point between valve 1 and valve 2.
▶ Carry out soundness test.
With high pressure regulators it is possible that the safety vent valve (SBV) responds
prior to the test pressure being achieved.
▶ Close vent line for soundness test.
▶ It is important to re-open vent line after commissioning.
Second test phase
In the second phase the interspace in the double gas valve is tested.
▶ Connect test gauge to test point between valve 1 and valve 2
(double gas valve).
▶ Carry out soundness test.
▶ Close all test points.
1 First test phase

2 Second test phase
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7 Commissioning
Third test phase

In the third test phase, the valve train section from outlet of double gas valve to the
seal point between gas butterfly valve and hinge flange is checked. Carry out test
phase with the burner operating in partial and full load. Use an approved leak detecting
spray or gas detector for testing.
Use only leak detecting foam solutions, which do not cause corrosion (see
DVGW-TRGI, work sheet G 600).
▶ Check all components, intersections and test points of the valve train between
double gas valve and hinge flange.
▶ Document result of the soundness test on the engineers report.
Test points
W-MF 5xx DMV 525 DMV 5065 ... 5100 VGD 40
1 Pressure into valve 1

2 Pressure between valve 1 and valve 2
3 Pressure after valve 2
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7 Commissioning
7.1.4 Check high pressure regulator type 06/1 … 09/1 and 1/1 …
5/1
The setting and function of the safety valves of the pressure regulating device must
be checked.
For detailed information see leaflet:
1. Check function of safety shut off valve (SAV)
▶ Seal vent line with sealing washer.
▶ Connect test equipment.
▶ Increase pressure to 350 mbar.
✓ SAV must respond.
If the SAV does not respond:
▶ De-energise spring until the SAV responds.
2. Check soundness of safety shut off valve (SAV)
The SAV has responded.
▶ Open and close isolating valve.
▶ Open test point between high pressure regulator and double gas valve.
The pressure enclosed between the gas isolating valve and the high pressure regu-
lator must not decrease.
▶ Close test point.
3. Check function of safety vent valve (SBV)
▶ Reset SAV.
▶ Remove sealing washer from vent line.
▶ Increase pressure.
✓ SBV must open, before SAV responds.
4. Check zero shut off
▶ Open isolating valve and wait, until the output pressure of the regulator is constant.
The pressure difference between input and output pressure of the regulator must
remain constant.
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7 Commissioning
7.1.5 Check high pressure regulator type 5/1-25/50 …

9/1-100/150
The setting and function of the safety valves of the pressure regulating device must
be checked.
1. Check function of safety shut off valve (SAV)
To be able to check the SAV, the vent pressure of the safety vent valve (SBV) must
be higher than the release pressure of the SAV.
▶ Energise spring on safety vent valve.
▶ Connect test equipment.
▶ Increase pressure to 350 mbar.
✓ SAV must respond.
If the SAV does not respond:
▶ De-energise spring until the SAV responds.
2. Set safety vent valve (SBV)
▶ De-energise spring on SBV to 300 mbar vent pressure.
3. Check soundness of safety shut off valve (SAV)
The SAV has responded.
▶ Open and close isolating valve.
▶ Open test point between high pressure regulator and double gas valve.
The pressure enclosed between the gas isolating valve and the high pressure regu-
lator must not decrease.
▶ Close test point.
▶ Reset SAV.
4. Check zero shut off
▶ Open isolating valve and wait, until the output pressure of the regulator is constant.
The pressure difference between input and output pressure of the regulator must
remain constant.
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7 Commissioning
7.1.6 Venting the gas valve train

The test burner must not be used to vent the gas valve train.
▶ If necessary, fit test nipple in front of valve 1 (see Ch. 7.1.3).

▶ Open test nipple and connect an approved vent hose.
▶ Vent hose must lead to atmosphere.
▶ Open gas isolating valve.
✓ The gas/air mixture in the valve train vents via the hose to safe atmosphere.
▶ Remove vent hose and immediately close test point.
▶ Use a test burner to ensure no air is present in the valve train.
✓ The line must be completely vented.
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7 Commissioning
7.1.7 Preset pressure regulator
Determine setting pressure
Add the combustion chamber pressure in mbar to the setting pressure into double
gas valve.
▶ Determine setting pressure from the table and note down.

The details given for calorific value Hi relate to 0 °C and 1013 mbar.
The table values have been calculated under ideal conditions. The values are therefore
guide values for basic settings.
Full load in kW Min. connection pressure into isolat- Setting pressure into double gas valve
ing valve in mbar (low pressure supply) in mbar
Nominal diameter valve 1½” 2” DN DN DN DN DN 1½” 2” DN DN DN DN DN
train 65 80 100 125 150 65 80 100 125 150
Natural Gas E (N); Hi = 37.26 MJ/m3 (10.35 kWh/m3); d = 0.606
2500 227 78 40 25 18 15 14 118 37 20 15 12 11 11
2900 - 104 53 33 22 19 17 158 49 27 20 16 14 14
3300 - 133 67 41 27 23 21 - 63 34 25 19 18 17
3800 - 174 86 53 34 28 26 - 82 44 32 24 22 21
4300 - 218 106 63 40 32 29 - 102 53 38 28 25 24
4800 - 268 129 75 46 36 32 - 124 63 44 31 28 27
5300 - - 153 88 52 41 35 - 148 73 51 35 31 29
5700 - - 175 98 57 44 38 - 169 82 56 38 33 32
Natural Gas LL (N); Hi = 31.79 MJ/m3 (8.83 kWh/m3); d = 0.641
2500 - 109 54 33 22 18 16 168 51 27 19 14 13 13
2900 - 146 72 43 28 23 21 - 68 36 26 19 17 17
3300 - 187 92 55 35 28 25 - 88 46 33 24 22 21
3800 - 246 119 70 43 35 31 - 115 59 42 30 27 26
4300 - - 148 85 51 40 35 - 143 72 50 35 31 30
4800 - - 181 102 60 46 40 - 175 86 59 40 35 33
5300 - - 216 120 69 52 44 - - 101 68 45 39 37
5700 - - 247 136 76 57 48 - - 114 76 50 43 40
Liquid Petroleum Gas(1; Hi = 25.89 kWh/m3; d = 1.555
2500 97 36 20 14 11 10 9 51 17 11 9 7 7 7
2900 129 47 26 18 14 12 12 68 23 14 11 9 9 9
3300 166 60 33 22 17 15 14 88 30 18 14 12 11 11
3800 219 78 42 28 20 18 17 115 39 23 18 15 14 14
4300 278 97 51 33 24 21 19 146 48 28 22 17 16 16
4800 - 118 61 39 27 23 21 179 57 32 24 19 18 17
5300 - 141 71 44 30 25 23 - 68 37 28 21 19 19
5700 - 161 80 49 32 27 24 - 76 41 30 23 21 20
(1
The selection for Liquid Petroleum Gas is calculated for Propane, it can however, also be used for Butane.
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7 Commissioning
Preset setting pressure

▶ Check setting pressure range of spring fitted.
▶ If necessary replace spring (see Ch. 9.19).
▶ Close isolating valve 2.
▶ Remove end cap 1 and de-energise pressure regulator.
▶ Open test point into valve 1 and connect test gauge 4.
▶ Slowly open isolating valve and using the test burner 3 vent back pressure into
valve 1.
▶ Energise regulator and pre-set setting pressure determined:
▪ Clockwise rotation (+) = increase pressure
▪ Anticlockwise rotation (-) = decrease pressure
▶ Refit end cap.
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7 Commissioning
7.1.8 Preset gas and air pressure switch

The presetting of the pressure switches is only valid during commissioning. Once
commissioning has been completed the pressure switches must be set correctly
(see Ch. 7.3).
Air pressure switch
without speed control approx. 15 mbar
with speed control approx. 3 mbar
Low / valve proving gas pressure switch approx. ½ control pressure(1
High gas pressure switch approx. twice control pres-
sure
(1
The value must be greater than the maximum mixing pressure present during pre-
purge and less than the static pressure present.
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7 Commissioning
7.2 Adjusting the burner

In addition to this chapter, the installation and operating manual Combustion Manager
W-FM 54 should be observed. This document contains detailed information about:
▪ menu structure and navigation,
▪ parameter settings,
▪ editing of load points,
▪ function, etc.
7.2.1 Adjusting gas side
Prerequisite
✓ Gas pressure in gas valve train increases.
▶ Close isolating valve.
▶ Set fuel selection switch on burner housing to gas.
▶ Switch on voltage supply.
✓ The display shows either OFF UPr0 or OFF GAS0.
OFF UPr0 burner off and not programmed
OFF GAS0 burner off
S S
P P
i i
V h min s % V h min s %
1. Enter password
▶ Press keys [F] and [A] simultaneously.
✓ The display shows CodE.
▶ Enter the first digit using [+] or [–] and confirm with [ENTER].
▶ Repeat procedure until the password has been entered.
▶ Exit password entry using [ENTER].
✓ The display shows PArA (parameter level) for a short time and then changes over
to 400: SEt (Setup).
S
P
i
S S
V h min s %P P
i i
S
V h min s % V h min s %P
i
V h min s %
2. Switch on burner
▶ Ensure there is a demand for heat.
✓ A black dash appears below the S symbol (start).
For the duration of the commissioning a heat dem,and is required from the appliance
controller, that means signal on input X5-03/1.
S
P
i
V h min s %
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7 Commissioning
3. Start setup
▶ Press [ENTER] key.
If the combustion manager has been pre-programmed, the display
shows run GAS0 1.
▶ Select type of setting (from step 8).
If the combustion manager has not been programmed, the display shows parameter
201 2.
▶ Define parameter 201, 542 and 641 and set P0 (from step 4).
▪ 201 = Type of operation
▪ 542 = Activation of frequency converter
▪ 641 = Speed standardisation
S
P
i
S V h min s %
P
i
V h min s % S
P
i
V h min s %
4. Set type of operation
The following steps must only be carried out if the combustion manager is not pro-
grammed. If the combustion manager has been pre-programmed, proceed with step
8.

✓ The display shows only the parameter value.
▶ Using [+] or [–] set type of operation 1 (direct ignition) and confirm with [ENTER].
▶ Exit entry using [esc].
✓ The display shows parameter 201 with the current type of operation.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
5. Activate/deactivate frequency converter

▶ Press [+] key.
✓ The display shows parameter 542.
▶ Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
▪ 0 = without frequency converter
▪ 1 = with frequency converter
✓ The display shows parameter 542 with the current setting.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
6. Carry out speed standardisation
If there is no frequency converter fitted or has already been standardised with the
other fuel,skip speed standardisation 641 using the [+] key and continue with step 7.
▶ Press [+] key.

▶ Set value to 1 using the [+] key and start speed standardisation by pressing [EN-
TER].
▶ Check rotation direction of burner motor.
✓ The fan motor starts with the air dampers open. Once standardisation is complete,
the display changes from 1 to 0.
▶ Exit speed standardisation using [esc].
✓ The standardised speed can be selected in parameter 642.
S S S
P P P
i i i
S S
V h min s % P % P % m 3 m 3/h l l/h
i i
S
P
i
V h min s %
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7 Commissioning
7. Preset ignition and full load points

▶ Press [+] key.
✓ The display shows the ignition load point P0.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting 4.0 … 6.0°.
▶ Press and hold [F] key and using [+]/[–] enter gas butterfly position of 8.0 … 13.0°.
Only in conjunction with frequency converter
▶ Press and hold [A] and [F] (VSD) keys simultaneously and enter speed using [+]/
[–] keys.
✓ The ignition speed should not be less than 70 %.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
h min s %
S
P
i
V h min s %
▶ Press [+] key.

✓ The display shows the full load point P9.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting from setting di-
agram.
▶ Press and hold [F] key and using [+]/[–] enter gas butterfly position of 45.0 …
50.0°.

▶ Press and hold [A] and [F] (VSD) keys simultaneously and set speed to 100 %
using [+]/[–] keys.
▶ Press [+] key.

✓ Exit pre-setting.
The display changes to run GAS0.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
8. Select type of setting

The following can be selected as type of setting:
▪ Adjustment with flame,
▪ Pre-setting without flame.
Pre-setting without flame is only used, if the operating points are already known (for
example if the combustion manager is exchanged).
Adjustment with flame 1

✓ The burner starts pre-purge Ph12 and stops in ignition position Ph36 without flame
formation.
The display shows the ignition load point P0.
▶ Set mixing pressure in ignition position (from step 10).
Pre-setting without flame 2

▶ Briefly press [esc] key.
✓ The display shows the operating point P0.
The black dash below the S symbol disappears.
▶ Pre-set operating points without flame (from step 9).
S S
P P
i i
S V h min s % S %
P P
i i
V h min s % S V h min s %
P
i
V h min s %
9. Pre-set points without flame

This step must only be carried out, if the type of setting without flame has been se-
lected previously. The adjustment with flame (from step 10) is not replaced by this
process.
▶ Press [+] key.
▶ Press and hold the [A] key and preset air damper setting using [+]/[–] keys.
▶ Press and hold [F] key and using [+]/[–] pre-set gas butterfly valve position.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and pre-set speed using [+]/
[–] keys.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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7 Commissioning
▶ Press [+] key.

✓ The display shows CALC.
The combustion manager starts the calculation.
The display then shows the operating point P2.
▶ Set position Air dampers [A] and gas butterfly valve [F] or speed [A] and [F] (VSD).
▶ Using [+] key select and pre-set points P3 to P9 in sequence.
S
P
i
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
▶ Exit pre-setting using [esc].

✓ The display shows 400 SEt.
✓ The display shows run GAS0.
✓ The burner starts pre-purge and stops in ignition position without flame forma-
tion.
S
P
i
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
10. Check mixing pressure in ignition position

The mixing pressure in ignition position must be between 0.5 and 2.0 mbar.
▶ If necessary, adjust mixing pressure via air damper setting.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and enter speed using [+]/
[–] keys.
✓ The ignition speed should not be less than 70 %.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
11. Check gas valves

▶ Press [+] key and ensure that the valves open and close correctly.
✓ The burner tries to ignite.
The low gas pressure switch is activated.
The display then shows OFF UPr0.
▶ Press [ENTER] key, until the burner starts again.
✓ The display shows P0 again with the values already set for mixing pressure in ig-
nition position.
12. Igniting the burner

▶ Press [+] key.
✓ The burner ignites and the stepping motors stop in the ignition position.
The display shows the following operating phases.
▪ Ph 38 = Ignition ON
▪ Ph 39 = Test low gas pressure switch (fuel valve 1 opens)
▪ Ph 40 = Fuel valve
▪ Ph 42 = Ignition OFF
▪ Ph 44 = Flame in ignition position
S
P S
i
P S
i P
V h % S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %
V h min s %
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7 Commissioning
13. Adjust setting pressure on pressure regulator

Check the setting pressure at the pressure regulator and if necessary adjust
(see Ch. 7.1.7).
14. Check combustion

▶ Determine combustion values at ignition position.
▶ Set O2 content of approx. 4 … 5 % via gas butterfly valve position.
15. Pre-set operating point P1
▶ Press [+] key.
▶ Pre-set gas throughput [F] and air quantity [A] whilst observing combustion values.
✓ The operating point P1 must lie below the partial load required and within the ca-
pacity graph (see Ch. 3.4.6).

A minimum speed of 50% should be aimed for in operating point P1.
▶ Slowly reduce speed using [F] and [A] (VSD) keys, whilst opening Air dampers
alternately using the [A] key.
▶ Press [+] key.

If no other points have been defined, the combustion manager carries out a cal-
culation and calculates all missing points up to P9, the display briefly shows
CALC.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P m
i
V h min s %
S
P
i S
P m l l/h
i
V h min s %
V h min s %
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7 Commissioning
16. Drive to full load

▶ Using the [+] key, drive to the points in sequence up to P9.
▶ Check combustion values at each point and if necessary correct via the gas but-
terfly valve position [F].
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
17. Adjust full load

When adjusting full load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner must be observed (see Ch. 3.4.6).
▶ Calculate gas throughput (operating volume VB) to be set (see Ch. 7.6).
▶ Set the gas butterfly position [F] in full load to approx. 60 … 70°.
Select the lowest possible fan speed, however this should not be less than 80 %.
Observe NOX values and flame stability.
▶ Adjust setting pressure at the pressure regulator until gas throughput (VB) is ach-
ieved.
▶ Check combustion values.
▶ Determine combustion limit and set excess air (see Ch. 7.5).
▶ Re-determine gas throughput.
▶ If necessary adjust setting pressure at pressure regulator and reset excess air.
The setting pressure must not be altered once this work has been completed.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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7 Commissioning
18. Initiate a calculation

To achieve a constant operating behaviour, it is necessary to initiate a calculation from
P9 to P1.
▶ Press [–] key for approx. 4 seconds.
▶ Release [–] key.
✓ The combustion manager starts the calculation.
S S
P P
i i
S
P
i
V h min s %
19. Adjusting the operating points
If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
▶ Briefly press [–] key, to ensure points already calculated or set are not overwritten.
The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control and/
or speed control.
▶ Check combustion values
▶ Press and hold [F] key and using [+]/[–] optimise combustion values.
▶ Optimise combustion values at each operating point, until P1 has been reached.
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
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7 Commissioning
20. Define upper load limit (full load)

Full load can be limited via parameter 546.
▶ Exit setting mode using [esc].
✓ The display shows 546 – – – –.
Full load has not been defined, that means full load ≙ P9 (100 % load assignment).
Continue with step 21, if the full load is not to be limited.
▶ Set load limit using [+] or [–] and confirm with [ENTER].
✓ Burner drives to value set.
✓ The display shows 546 with the current upper load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
21. Define lower load limit (partial load)

Partial load can be limited using parameter 545.
When adjusting partial load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner should be observed.
▶ Press [+] key.
Partial load has not been defined, that means partial load ≙ P1.
▶ Determine fuel throughput and if necessary adjust load limit.
✓ The display shows 545 with the current lower load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
22. Save points

✓ The display shows oP (Operate) with the current rating.
S S S
P P P
i i i
V h min s % V h min s % V h min s %
23. Adjust air damper setting pre-purge position

To support the switch behaviour of the gas pressure switch during valve proving, the
air damper setting in pre-purge position must be the same as the air damper setting
in operating point P9 (full load).
✓ The display shows 400: SEt.
▶ Press [+] key.
✓ The display shows 500: PArA.
▶ Using [+] key select 502.00 and confirm with [ENTER].
▶ Using [+] key select 502.01 and confirm with [ENTER].
▶ Using [-] key, set air damper setting to the value of operating point P9 and confirm
with [ENTER].
▶ Exit level using [esc].
24. Check start behaviour
▶ Switch off and restart burner.
▶ Check start behaviour and if necessary correct ignition load setting.
If the ignition load setting has been changed:
▶ Re-check start behaviour.
25. Data backup
▶ Select 000: Int using [-] key and confirm with [ENTER].
✓ The display shows parameter 050.00: 0
✓ The display shows bAC_up.
▶ Set 1 using [+] key and confirm with [ENTER].
✓ Following successful data back-up, the display is reset to 0.
The values have been backed up from the combustion manager to the ABE.
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7 Commissioning
7.2.2 Adjusting oil side
Prerequisite
▶ Set fuel selection switch on burner housing to Oil.
▶ Open oil shut off devices.
▶ Switch on voltage supply.
✓ The display shows either OFF UPr1 or OFF OIL1.
OFF UPr1 burner off and not programmed
OFF OIL1 burner off
S S
P P
i i
1. Enter password
S
P
i
S S
V h min s %P P
i i
S
i
V h min s %
2. Switch on burner
▶ Ensure there is a demand for heat.
✓ A black dash appears below the S symbol (start).
For the duration of the commissioning a heat dem,and is required from the appliance
controller, that means signal on input X5-03/1.
S
P
i
V h min s %
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7 Commissioning
3. Start setup
If the combustion manager has been pre-programmed, the display
shows run OIL1 1.
▶ Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
301 2.
▶ Define parameter 301, 542 and 641 and set P0 (from step 4).
▪ 301 = Type of operation
▪ 542 = Activation of frequency converter
▪ 641 = Speed standardisation
S
P
i
S V h min s %
P
i
V h min s % S
P
i
V h min s %
4. Set type of operation
The following steps must only be carried out if the combustion manager is not pro-
grammed. If the combustion manager has been pre-programmed, proceed with
step 9.

▶ Using [+] or [–] set type of operation 12 (oil modulating) and confirm with [ENTER].
✓ The display shows parameter 301 with the current type of operation.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
5. Activate/deactivate frequency converter

▶ Press [+] key.
▶ Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
▪ 0 = without frequency converter
▪ 1 = with frequency converter
✓ The display shows parameter 542 with the current setting.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
6. Carry out speed standardisation
If there is no frequency converter fitted or has already been standardised with the
other fuel,skip speed standardisation 641 using the [+] key and continue with step 7.
▶ Press [+] key.

▶ Set value to 1 using the [+] key and start speed standardisation by pressing [EN-
TER].
✓ The fan motor starts with the air dampers open. Once standardisation is complete,
the display changes from 1 to 0.
▶ Exit speed standardisation using [esc].
✓ The standardised speed can be selected in parameter 642.
S S S
P P P
i i i
S S
V h min s % P % P % m 3 m 3/h l l/h
i i
S
P
i
V h min s %
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7 Commissioning
7. Take over or preset ignition load point

▶ Press [+] key.
✓ The display shows the ignition load point P0.
The ignition load point P0 is factory preset (see burner data sheet). If values are avail-
able continue with step 8. If the combustion manager has not been programmed (e. g.
if the unit has been replaced) the air damper setting and the position of the oil quantity
regulator have to be entered.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting 20 … 30°.
▶ Press and hold [F] key and using [+]/[–] key enter position of oil quantity regulator
31 … 47°.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
8. Preset full load point

▶ Press [+] key.
✓ The display shows the full load point P9.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting from setting
diagram (see Ch. 4.3.1).
▶ Determine the position of the oil quantity regulator from the burner data sheet.
▶ Press and hold [F] key and enter the value using [+]/[–] key.
▶ Press [+] key.
✓ Exit pre-setting.
The display changes to run OIL 1.
S
P
i
S
V h P %
i
V h min s %
S
P
i
S S h min s %
P P m3 m
i i
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7 Commissioning
9. Select type of setting

The following can be selected as type of setting:
▪ Adjustment with flame,
▪ Pre-setting without flame.
Pre-setting without flame is only used, if the operating points are already known (for
example if the combustion manager is exchanged).
Adjustment with flame 1

✓ The burner starts pre-purge Ph12 and stops in ignition position Ph36 without flame
formation.
▶ Set mixing pressure in ignition position (from step 11).
Pre-setting without flame 2

▶ Briefly press [esc] key.
The black dash below the S symbol disappears.
▶ Pre-set operating points without flame (from step 10).
S S
P P
i i
S V h min s % S %
P P
i i
V h min s % S V h min s %
P
i
V h min s %
10. Pre-set points without flame

This step must only be carried out, if the type of setting without flame has been se-
lected previously. The adjustment with flame (from step 11) is not replaced by this
process.
▶ Press [+] key.
▶ Press and hold the [A] key and preset air damper setting using [+]/[–] keys.
▶ Press and hold [F] key and using [+]/[–] key preset position of oil quantity regulator.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and pre-set speed using [+]/
[–] keys.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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7 Commissioning
▶ Press [+] key.

The combustion manager starts the calculation.
▶ Set position Air dampers [A] and oil quantity regulator [F] or speed control [A]
and [F] (VSD).
▶ Using the [+] key select and pre-set points P3 to P9 in sequence.
S
P
i
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
▶ Exit pre-setting using [esc].

✓ The display shows run OIL1.
✓ The burner starts pre-purge and stops in ignition position without flame forma-
tion.
S
P
i
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
11. Check mixing pressure in ignition position

The mixing pressure in ignition position must be between 2 … 4 mbar.
▶ If necessary, adjust mixing pressure via air damper setting.
In oil operation, the ignition speed should be 100 %.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and set speed to 100 %
using [+]/[–] keys.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
12. Check pump pressure

The pressure in ignition position must be 28 … 30 bar, adjust if required.
▶ Check pressure at the pressure gauge.
▶ Remove end cap 1.
▶ Undo locknut 2.
▶ Set pressure using pressure regulating screw.
▪ Clockwise rotation = increase pressure
▪ Anticlockwise rotation = decrease pressure
13. Igniting the burner

▶ Press [+] key.
✓ The burner ignites and the stepping motors stop in the ignition position.
The display shows the following operating phases.
▪ Ph 38 = Ignition ON
▪ Ph 40 = Fuel valve
▪ Ph 42 = Ignition OFF
▪ Ph 44 = Flame in ignition position
S
P S
i P S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %
V h min s %
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7 Commissioning
14. Check combustion

▶ Determine combustion values at ignition position P0.
▶ Set O2 content of approx. 4 … 5 % by positioning the oil quantity regulator [F],
whilst observing the return pressure and maintaining 8 bar.
15. Pre-set operating point P1

In oil operation, the speed should only be reduced so far, that the pump pressure set
at full load does not fall by more than 15 %.
▶ Press [+] key.

▶ Check combustion values and correct if necessary.
▶ Press [+] key.
If no other points have been defined, the combustion manager carries out a cal-
culation and calculates all missing points up to P9, the display briefly shows
CALC.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P m
i
V h min s %
S
P
i S
P m l l/h
i
V h min s %
V h min s %
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7 Commissioning
16. Drive to full load

▶ Using the [+] key, drive to points P2 to P9 in sequence.
▶ Check combustion values at each point and correct via the position of the oil
quantity regulator [F].
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
17. Adjust full load

When adjusting full load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner should be observed (see Ch. 3.4.6).
The burner has been factory pre-sized for a specific oil throughput (see burner data
sheet).
▶ pump pressure and oil quantity regulator position to the data given on the burner
data sheet.
▶ Determine oil throughput, if necessary adjust position of oil quantity regulator [F]
until the oil throughput required is achieved.
▶ Check combustion values.
▶ Determine combustion limit and set excess air (see Ch. 7.5).
The pump pressure must not be altered once this work has been completed.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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7 Commissioning
18. Initiate a calculation

To achieve a constant operating behaviour, it is necessary to initiate a calculation from
P9 to P1.
▶ Press [–] key for approx. 4 seconds.
▶ Release [–] key.
✓ The combustion manager starts the calculation.
S S
P P
i i
S
P
i
V h min s %
19. Adjusting the operating points
If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
▶ Briefly press [–] key, to ensure points already calculated or set are not overwritten.
The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control.
▶ Check combustion.
▶ Press and hold [F] key and using [+]/[–] optimise combustion values.
▶ Optimise combustion values at each operating point, until P1 has been reached.
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
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7 Commissioning
20. Define upper load limit (full load)

Full load can be limited via parameter 566.
▶ Exit setting mode using [esc].
Full load has not been defined, that means full load ≙ P9 (100 % load assignment)
Continue with step 21, if the full load is not to be limited.
✓ The display shows 566 with the current upper load limit.
S
P
i
V h min s %
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
21. Define lower load limit (partial load)

Partial load can be limited using parameter 565.
When adjusting partial load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner should be observed.
▶ Press [+] key.
Partial load has not been defined, that means partial load ≙ P1.
▶ Determine fuel throughput and if necessary adjust load limit.
✓ The display shows 565 with the current lower load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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7 Commissioning
22. Save points

✓ The display shows oP (Operate) with the current rating.
S S S
P P P
i i i
V h min s % V h min s % V h min s %
23. Check start behaviour

▶ Switch off and restart burner.
▶ Check start behaviour and if necessary correct ignition load setting.
If the ignition load setting has been changed:
▶ Re-check start behaviour.
24. Data backup
▶ Select 000: Int using [-] key and confirm with [ENTER].
✓ The display shows parameter 050.00: 0
✓ The display shows bAC_up.
▶ Set 1 using [+] key and confirm with [ENTER].
✓ Following successful data back-up, the display is reset to 0.
The values have been backed up from the combustion manager to the ABE.
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7 Commissioning
7.3 Set pressure switches
7.3.1 Set oil pressure switch
Maximum oil pressure switch in the return

▶ Remove end cap.
▶ Set max. oil pressure switch in the return to 5 bar, or for ring main operation set to
5 bar above the ring main pressure.
▶ Refit end cap.
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7 Commissioning
7.3.2 Set gas pressure switch
Set low / valve proving gas pressure switch

Two setting criteria need to be met:
1. Criterion (monitoring gas connection pressure)

▶ Connect pressure measuring device to test point 3 of the gas pressure switch.
▶ Start burner and drive to full load.
▶ Slowly close gas isolating valve until either:
▪ the O2 content in the flue gas increases to above 7 %,
▪ the flame stability considerably worsens,
▪ the CO content increases,
▪ or the gas pressure drops to 70 %.
▶ Determine gas pressure and note down.
2. Criterion (valve proving)
Setting pressure ▶ Open gas isolating valve.
▶ Use test burner 2 to reduce static pressure.
▶ Determine static pressure (PR) into valve 1 1.
▶ Switch on burner.
▶ Determine maximum pressure during pre-purge (PV) after valve 2 5.
▶ Calculate setting pressure using formula on the left and note down.
Set and check switch point

The higher pressure from the two criteria is set at the gas pressure switch.
▶ Set gas pressure switch at the setting dial 4.
▶ Drive burner to 40 … 50 % of the rating.
✓ The gas pressure drops.
If the low gas programme starts, the gas pressure switch has been set correctly.
If the combustion manager initiates a controlled shutdown, the low gas pressure
switch operates too late. In this case:
▶ Increase switch point at setting cam 4.
▶ Re-check switch point.
20
30
150
50
130
70
11
0
90
Set high gas pressure switch (optional)

▶ Set high gas pressure switch to 1.3 × PF (flow pressure at full load).
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7 Commissioning
7.3.3 Set air pressure switches

The switch point must be checked and if necessary adjusted during commissioning.
▶ Remove closing cap 4 from air pressure switch.
▶ Connect pressure inlet of pressure measuring device 2 to the air pressure switch.
▶ Connect low pressure hose 1 to pressure measuring device using a T piece.
▶ Start the burner.
▶ Carry out differential pressure measurement across the whole ratings range and
determine the lowest differential pressure.
▶ Set 80 % of the determined differential pressure at the setting cam 3.
Example Lowest differential pressure 32 mbar
Switch point air pressure switch (80 %) 32 mbar × 0.8 = 25.6 mbar
Site specific influences on the air pressure (e.g. by the flue gas system, heat ex-
changer, installation location or air supply), may make it necessary to vary the setting
of the air pressure switch.
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7 Commissioning
7.4 Concluding work

through leakage.
▶ Check and adjust the function of all regulating, control and safety devices of the
installation during operation.
▶ Remove gas pressure measuring devices and close all test points.
▶ Conclude valve proving of gas valve train (third test phase) (see Ch. 7.1.3).
▶ Check tightness of oil carrying components.
▶ Enter combustion values and settings in the commissioning record and/or test
sheet.
▶ Inform the operator about the use of the equipment.
▶ Hand the installation and operating manual to the operator and inform him that this
should be kept with the appliance.
▶ Point out to operator that the installation should be serviced annually.
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7 Commissioning
7.5 Check combustion

Carry out flue gas measurements to ensure environmentally friendly, economical and
reliable operation of the installation.
Determine excess air

▶ Slowly close the air damper in the relevant operating point, until combustion limit
is reached (CO content approx. 100 ppm or soot number approx. 1).
▶ Measure and document O2 content.
▶ Read air number (λ).
Increase air number to ensure sufficient excess air.
▪ by 0.15 … 0.2 (equates to 15 … 20 % excess air),
▪ by more than 0.2 for more difficult conditions, such as:
- dirty intake air,
- fluctuating intake temperature,
- fluctuating chimney draught.
Example
▶ Set air number (λ*), do not exceed CO content of 50 ppm.

▶ Measure and document O2 content.
Check flue gas temperature
▶ Check flue gas temperature
▶ Ensure that the flue gas temperature complies with the data supplied by the boiler
manufacturer.
▶ If necessary adjust flue gas temperature, e g.:
▪ Increase burner rating in partial load to avoid condensation in the flue gas ducts
(except on condensing units).
▪ Reduce burner rating in full load to improve efficiency.
▪ Adjust heat exchanger to the data supplied by the manufacturer.
Determine flue gas losses
▶ Drive to full load.
▶ Measure combustion air temperature (tL) near the air damper(s).
▶ Measure oxygen content (O2) and flue gas temperature (tA) at the same time at one
point.
▶ Determine flue gas losses using the following formula:
qA Flue gas losses [%]

tA Flue gas temperature [°C]
tL Combustion air temperature [°C]
O2 Volumetric content of oxygen in dry flue gas [%]
Fuel factors Natural Gas Liquid Petroleum Fuel oil
Gas
A2 0.66 0.63 0.68
B 0.009 0.008 0.007
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7 Commissioning
7.6 Calculate gas throughput

Formula symbol Explanation Example values
VB Operating volume [m3/h]. -
Volume measured at gas meter at current pressure and tempera-
ture (gas throughput)
VN Standard volume [m3/h] -
Volume gained by gas at 1013 mbar and 0 °C
f Conversion factor -
QN Heat rating [kW] 560 kW
Boiler efficiency (e. g. 92 % ≙ 0.92) 0.92
Hi Calorific value [kWh/m3] (at 0 °C and 1013 mbar) 10.35 kW/m3 (Natural Gas
E)
tGas Gas temperature at gas meter [°C] 10 °C
PGas Gas pressure at gas meter [mbar] 30 mbar
PBaro Barometric air pressure [mbar] (see table) 500 m ≙ 955 mbar
VG Gas throughput determined at gas meter 2 m3
TM Time measured during gas throughput (VG) 117 seconds
Determine the normal volume

▶ Calculate the normal volume (VN) using the following formula.
.
. .
Calculate conversion factor

▶ Determine gas temperature (tGas) and gas pressure (PGas) at gas meter.
▶ Determine air pressure (PBaro) from the table.
Height 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
above sea
level [m]
PBaro 1013 1001 990 978 966 955 943 932 921 910 899 888 877 866
[mbar]
▶ Calculate conversion factor (f) using the following formula.
Determine operating volume (gas throughput) required
.
.
.
Measure current operating volume (gas throughput)

▶ Measure gas throughput (VG) at gas meter, measuring time (TM) should be a min-
imum of 60 seconds.
▶ Calculate operating volume (VB) using the following formula.
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7 Commissioning
7.7 Subsequent optimisation of operating points

If necessary, the combustion values can subsequently be corrected.
▶ Start the burner.
▶ Press keys [F] and [A] simultaneously, to enter the password.
✓ The display shows run GAS0 or run OIL1.
S
P
i
S S
V h min s %P P
i i
S
i
V h min s %
S
P
i
V h min s %

✓ Point P1 is selected and is displayed flashing once the position is reached.
▶ If necessary optimise combustion:
▪ Press and hold [A] key and using [+]/[–] adjust air damper position.
▪ Press and hold [F] key and using [+]/[–] adjust position of gas butterfly valve or
oil quantity regulator.
▶ Initiate the other operating points using the [+] key or the [-] key and optimise as
necessary.
S
P
i
S V h min s %
P
i
V h min s % S S
P P
i i
▶ Press [esc] key 3 times to return to the operating level.

▶ Carry out data backup.
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8 Shutdown
8 Shutdown
For breaks in operation:
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9 Servicing
9 Servicing
9.1 Notes on servicing

Risk of explosion due to leaking gas
Improper service work can lead to escaping gas and explosion.
▶ Close fuel shut off devices prior to starting work.
DANGER ▶ Care should be taken when dismantling and assembling gas carrying system com-
ponents.
▶ Tightly close the screws on the test points ensuring the tests points are sealed.

Danger of getting burned on hot components

Hot components can lead to burns.
▶ Allow components to cool.
WARNING
Servicing must only be carried out by qualified personnel. The combustion plant
should be serviced annually. Depending on site conditions more frequent checks may
be required.
Components, which show increased wear and tear or whose design lifespan is or will
be exceeded prior to the next service should be replaced as a precaution (see Ch.
9.2).
Weishaupt recommends a service contract is entered into to ensure regular inspec-

tions.
The following components must only be replaced and must not be repaired in any
way:
▪ combustion manager
▪ flame sensor
▪ actuators (stepping motors)
▪ oil solenoid valves
▪ gas valves
▪ pressure regulator
▪ pressure switch.
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9 Servicing
Prior to every servicing

▶ Inform the operator about the extent of service work to be carried out.
▶ Switch off mains switch of installation and safeguard against accidental reactiva-
tion.
Following servicing
▶ Check tightness of oil and gas carrying components.
▶ Check function of:
▪ ignition,
▪ flame monitoring,
▪ oil pump (pump pressure and suction resistance),
▪ gas carrying components (gas inlet and outlet pressure),
▪ pressure switch
▪ safety interlock circuit.
▶ Check combustion values, if necessary re-adjust the burner.
▶ Enter combustion values and settings in the commissioning record and/or test
sheet.
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9 Servicing
9.2 Service plan

Components Criteria Service procedure
Fan wheel Soiling ▶ Clean
Damage ▶ Replace
Coupling cross on coupling Wear ▶ Replace
centre piece Recommendation: at least every 2 years
Air duct Soiling ▶ Clean
Air dampers Soiling ▶ Clean
Distance to housing 0.5 mm ±0.1 ▶ Adjust air dampers
Sleeve bearing air damper shaft Has play > 0.2 mm ▶ Replace
Foam parts of air regulator Damage/brittleness/soiling ▶ Replace
View port cover Air escaping ▶ Replace
Ignition cable Damage ▶ Replace
Ignition electrodes Soiling ▶ Clean
Damage/wear ▶ Replace
Combustion Manager 250 000 start-ups reached ▶ Recommendation: replace
(equal to approx. 10 years)
Flame sensor Soiling ▶ Clean
Damage ▶ Replace
Pressure switch Switch point ▶ Check
Flame tube/diffuser Soiling ▶ Clean
Damage ▶ Replace
Oil nozzle Soiling/wear ▶ Replace
Recommendation: at least every 5 years
Oil hoses Damage/oil escaping ▶ Replace
Pressure hoses nozzle assembly Damage/oil escaping ▶ Replace
Oil regulator Excess air due to wear ▶ Adjust burner
Hysteresis behaviour/damage/oil escap- ▶ Replace
ing
Oil solenoid valves Soundness ▶ Replace
Recommendation: at least every 10
years
Double gas valve/multifunction Damage/soundness ▶ Replace
assembly
Gas pressure regulator Control pressure ▶ Check
Damage/soundness ▶ Replace
Filter insert multifunction as- Soiling ▶ Replace
sembly/gas filter
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9 Servicing
9.3 Hinge open the burner

Observe notes on servicing (see Ch. 9.1).
Damage to oil hoses due to mechanical strain

If oil hoses are leaking, oil can escape and lead to environmental damage.
▶ Avoid mechanical strain on the oil hoses when hinging open the burner.
WARNING
▶ Check hinge pin 1 on burner flange is fitted correctly.

▶ Remove view port cover.
▶ Unplug ignition cables 2.
▶ Remove plug from solenoid coil 3.
▶ Remove dome nut.
▶ Carefully hinge open the burner.
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9 Servicing
9.4 Removing and refitting nozzle assembly

Removing
▶ Hinge open the burner.
▶ Undo screw 1, until it is flush with the mixing tube 2.
▶ Pull out nozzle assembly.
If the hinge range of the burner is limited:
▶ Place nozzle assembly into burner housing prior to hinging open.
Refitting
▶ Refit nozzle assembly in reverse order ensuring that the retainer 2 is horizontally
flush with the end of the mixing head.
▶ Set nozzle distance (see Ch. 9.5).
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9 Servicing
9.5 Set nozzle distance

▶ Hinge open the burner (see Ch. 9.3).
The nozzle distance dimension A is set using the auxiliary dimension 1 between
mixing head and/or retainer and nozzle head solenoid coil.
Nozzle distance (dimen- Auxiliary dimension 1
sion A)
5 mm 53 mm
10 mm 58 mm Factory setting
▶ Undo locknut 2.
▶ Adjust nozzle head 3, until auxiliary dimension 1 has been reached.
▶ Re-tighten locknut.
9.6 Removing the mixing head

▶ Remove nozzle assembly.
▶ Remove locknut 1.
▶ Lift mixing head 2 and pull out.
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9 Servicing
9.7 Set ignition electrodes

9.7.1 Set ignition electrodes nozzle assembly

The distance between the ignition electrodes and other components must be greater
than the spark gap between the electrodes.
The ignition electrodes must not touch the nozzle's atomising spray cone.
▶ Undo screw 1 on the ignition electrode holder.
▶ Set ignition electrodes
▶ Tighten screw.
mm
.. 6 3 ... 4 mm
4.
9.7.2 Set ignition electrode diffuser

▶ Remove mixing head.
▶ Undo screw 1.
▶ Set ignition electrode.
▶ Tighten screw.
2m
m
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9 Servicing
9.8 Set nozzle tubes

▶ Remove mixing head.
▶ Undo screw 1 and set nozzle tube.
▶ Tighten screw.
2.5 ... 3.0 mm
9.9 Replacing the nozzle

Do not clean nozzle, always fit new nozzle.

▶ Remove ignition electrodes.
▶ Counter-hold on the nozzle assembly using a spanner and remove nozzle.
▶ Fit new nozzle ensuring it is seated tightly.
▶ Fit and adjust ignition electrodes.
1 Nozzle
2 Nozzle assembly
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9 Servicing
9.10 Removing and refitting air damper stepping motor

Removing
▶ Remove cover of cable entry 2.
▶ Remove cover 3.
▶ Remove stepping motor plug 1 from combustion manager.
▶ Undo locknut 3 on the coupling.

▶ Remove screws 1.
▶ Remove stepping motor from the coupling.
Refitting
▶ Refit stepping motor in reverse order, ensuring correct alignment of shaft key 2.
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9 Servicing
9.11 Removing air regulator

▶ Remove air damper stepping motor.
▶ Remove inlet mesh 2.
▶ Remove air regulator 1.
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9 Servicing
9.12 Set air regulator

▶ Remove inlet mesh (see Ch. 9.11).
▶ If necessary remove air regulator (see Ch. 9.11).
Set air dampers
Only tamper proof screws should be used in the air regulator section.
If the distance of the air dampers to the housing on the stepping motor side is less
than the dimension of 0.3 mm ± 0.1:
▶ Undo screws 1.
▶ Align air dampers.
▶ Re-tighten screws.
▶ Check if air dampers have freedom of movement.
Check sleeve bearing
It must not be possible to axially move the air dampers without using force
(0 mm play).
If axial play 2 is present at the air dampers:
▶ Replace sleeve bearing.
0.3 mm ±0.1
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9 Servicing
9.13 Removing and refitting gas butterfly stepping motor

Removing
▶ Remove plug 4.
▶ Remove view port 1 - or - if stepping motor not at 0°, remove plug 2.
▶ Remove bolts 3.
If the intermediate housing or the coupling need to be replaced:

▶ Undo second locknut of coupling 2.
▶ Carefully pull coupling from drive shaft.
▶ Remove shaft keys 1.
▶ Undo fixing screws and remove intermediate housing 3.
Refitting
▶ Refit stepping motor in reverse order, ensuring correct alignment of shaft key.
▶ Push coupling carefully and without pressure onto shaft.
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9 Servicing
9.14 Removing and refitting oil quantity regulator stepping motor

Removing
▶ Remove cover of cable entry 2.
▶ Remove cover 3.
▶ Remove stepping motor plug 1.
▶ Remove view port 1 - or - if stepping motor not at 0°, remove plug 2.

▶ Remove bolts 4.
Refitting
▶ Refit stepping motor in reverse order, ensuring correct alignment of shaft key 5.
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9 Servicing
9.15 Set pump coupling

A flexible pump coupling is fitted between fan wheel and oil pump.
▶ Remove air regulator cover.
▶ Undo Allen screw 2 on the pump coupling.
▶ Align pump coupling to ensure that no axial tension is applied to the drive shaft of
the magnetic coupling and that the coupling centre piece 1 has an axial play of
1.5 mm.
▶ Tighten Allen screw.
9.16 Set magnetic coupling

In the neutral position, the clearance of the coupling discs must be 0.4 … 0.6 mm.
▶ Undo hexagonal screws 2 on the magnetic coupling.
▶ Adjust clearance 1 by axial movement.
▶ Re-tighten hexagonal screws.
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9 Servicing
9.17 Removing fan wheel

The fan wheel is connected to the motor shaft with a left hand thread screw
M8 x 30 DIN 912.
▶ Undo screw 1.
▶ Remove fan wheel with fan wheel puller from motor shaft.
9.18 Check position of inlet nozzle

▶ Open view port cover 1.
▶ Carry out a visual inspection through the view port once its cover has been opened.
✓ The arrow on the inlet nozzle 2 must point upwards.
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9 Servicing
9.19 Replace spring on pressure regulator

If the setting range of the spring used in the pressure regulator is insufficient, a dif-
ferent type of spring can be selected.
Low pressure regulator

▶ Remove closing cap 2.
▶ Turn adjusting screw 1 anticlockwise.
✓ The spring 3 is de-energised.
▶ Remove complete setting mechanism 4.
▶ Change spring.
▶ Stick label for new spring to name plate.
Type of spring/colour Setting pressure range

orange 5 … 20 mbar
blue 10 … 30 mbar
red 25 … 55 mbar
yellow 30 … 70 mbar
black 60 … 110 mbar
pink 100 … 150 mbar
grey 140 … 200 mbar
High pressure regulator

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9 Servicing
9.20 Service position switch unit AGM

▶ Remove cover.
▶ Insert screw 1 from cover.
▶ Undo screws 2.
▶ Place switch unit into service position and tighten screw 1.
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10 Troubleshooting
10 Troubleshooting
10.1 Procedures for fault conditions
Burner out of operation

If the burner does not start despite heat demand:
▶ Check voltage supply
▶ Check function and setting of all regulating, control and safety devices.
▶ Check all burner related functions.
Fault
If a fault occurs, the combustion manager initiates a controlled shutdown.
During a fault condition, the display alternates between Err.c (error code) and
Err.d (diagnostic code).
▶ Read the error code and proceed according to the error message (see installation
and operating manual combustion manager).
The burner restarts automatically as soon as the fault condition has been rectified.
Lockout
If a lockout condition occurs, the combustion manager initiates a fault shutdown and
burner lockout.
During a lockout condition, the display alternates between Loc.c (error code) and
Loc.d (diagnostic code).
▶ Read the error code and proceed according to the error message (see installation
and operating manual combustion manager).
Once the error has been rectified, the combustion manager has to be reset for restart.
Resetting
Damage resulting from incorrect servicing

The combustion plant could be damaged.
▶ Do not carry out more than 2 lockout resets successively.
CAUTION ▶ Faults must be rectified by qualified personnel.
▶ Press [ENTER] key for approx. 2 seconds.
✓ rESEt is displayed.
▶ Release the key.
✓ The burner has been reset.
Exchanging the unit
▶ Select and check fault history and lockout history before replacing the combustion
manager or ABE and include when returning the unit for exchange.
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10 Troubleshooting
10.2 Rectifying faults

Fault Cause Rectification
Burner motor does not run No voltage ▶ Check voltage supply
Overload relay or motor protection ▶ Check setting
switch has tripped
Contactor defective ▶ Replace contactor
Burner motor defective ▶ Replace burner motor
No ignition Ignition electrodes too far apart or short ▶ Set ignition electrodes (see Ch. 9.7)
circuit
Ignition electrodes dirty or wet ▶ Clean and set ignition electrodes
(see Ch. 9.7)
Ceramic insulator defective ▶ Replace ignition electrodes
Ignition cable defective ▶ Replace ignition cable
Ignition unit defective ▶ Replace ignition unit
Solenoid valve does not open No voltage ▶ Check voltage supply
Coil defective ▶ Replace coil
Oil pump supplies no oil Shut off valve closed ▶ Open shut off valve
Oil supply leaking ▶ Check oil supply
Anti siphon valve does not open ▶ Check valve, if necessary replace
Oil filter of oil supply soiled ▶ Clean filter insert or replace
Oil pump defective ▶ Replace oil pump
No oil throughput at the nozzle Nozzle blocked ▶ Replace nozzle (see Ch. 9.9)
No voltage at the nozzle head solenoid ▶ Check voltage supply
coil
Nozzle head solenoid coil defective ▶ Replace coil
No flame formation despite igni- Ignition electrodes set incorrectly ▶ Set ignition electrodes (see Ch. 9.7)
tion and fuel Pressure into the mixing head too high ▶ Correct mixing pressure in ignition
load setting, if necessary adjust mixing
head (see Ch. 4.3)
No ignitable fuel/air mixture in the mixing ▶ Reduce distance between double gas
head valve and gas butterfly valve
(see Ch. 5.1)
Poor start behaviour of burner Pressure into the mixing head too high ▶ Correct mixing pressure in ignition
load setting, if necessary adjust mixing
head (see Ch. 4.3)
Ignition electrodes set incorrectly ▶ Set ignition electrodes (see Ch. 9.7)
Too much or too little fuel ▶ Correct fuel quantity in ignition posi-
tion via fuel actuator
Combustion manager does not Flame sensor soiled ▶ Clean flame sensor
detect a flame signal Flame signal insufficient ▶ Check flame signal
▶ Check flame sensor
▶ Check burner setting
Flame sensor defective ▶ Replace flame sensor
Combustion pulsating and/or Incorrect combustion air quantity ▶ Check combustion values
burner booming Mixing head set incorrectly ▶ Set mixing head (see Ch. 4.3)
Back pressure from the system ▶ Check flue gas system
(see Ch. 13.2)
Burner rating required is not Mixing head not opened far enough ▶ Set mixing head (see Ch. 4.3)
achieved Inlet nozzle fitted incorrectly ▶ Check position inlet nozzle
(see Ch. 9.18)
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10 Troubleshooting
Fault Cause Rectification

Flame failure during operation Oil supply leaking/suction resistance too ▶ Check oil supply (see Ch. 13.1)
high
Oil nozzle soiled ▶ Replace nozzle (see Ch. 9.9)
Flame signal insufficient ▶ Check flame signal
▶ Check flame sensor
▶ Check burner setting
Oil pump makes severe me- Oil pump sucks air ▶ Check oil supply is not leaking
chanical noise Suction resistance in oil line too high ▶ Clean filter
▶ Check oil supply (see Ch. 13.1)
Oil nozzle atomisation uneven Nozzle soiled/worn ▶ Replace nozzle (see Ch. 9.9)
Combustion head is contamina- Oil nozzle defective ▶ Replace nozzle (see Ch. 9.9)
ted with oil or has heavy carbon Mixing head set incorrectly ▶ Set mixing head (see Ch. 4.3)
deposits
Incorrect combustion air quantity ▶ Adjust burner
Boiler room ventilated insufficient ▶ Ensure sufficient boiler room ventila-
tion
Oil supply system at nozzle head leaking ▶ Check oil supply system
Solenoid does not close tightly Dirt particles in the solenoid valve ▶ Replace solenoid valve
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11 Spares
11 Spares
1.01
(1
1.06
(1
1.03 (1 1.05
1.07
1.10
1.04
(1
1.02
1.09
1.08
1.21
1.11
1.12
1.15
1.17
1.15
1.16
1.20
1.22
1.19
1.16
1.18
1.14
1.13
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11 Spares
Pos. Description Order No.

1.01 View port cover complete 211 314 01 02 2
1.02 View port 211 104 01 19 2
1.03 View port closing cover 211 104 01 13 2
– Spring nut 4 x 9 412 509
1.04 Hinge pin 16 x 275 211 314 01 05 7
1.05 Circlip 12 431 611
1.06 Hinge flange 217 314 01 02 7
Stud screw M12 x 55 421 028
– Washer B13 430 801
– Hexagonal nut M12 411 600
1.07 Stud screw M12 x 55 421 028
1.08 Dome nut M12 DIN 1587 412 401
1.09 Washer B 13 430 801
1.10 Flange gasket 450 x 350 191 107 00 03 7
1.11 Cable entry W-FM complete 211 104 01 05 2
1.12 Air regulator housing 211 314 02 10 7
1.13 Foam cladding rear 211 314 02 04 7
1.14 Foam cladding front 211 314 02 03 7
1.15 Screw M8 x 245 402 529
1.16 Screw M8 x 43 / 304 211 314 02 13 7
1.17 Clamping ring Ø 8 mm 490 500
1.18 Air regulator cover 211 314 02 16 7
1.19 Foam cladding air air regulator cover 211 314 02 05 7
1.20 Spring nut 6 x 20 412 506
1.21 Name plate 211 314 01 03 7
1.22 Cable entry set 211 104 01 50 2
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11 Spares
2.05
2.03
2.04
2.01
2.09
2.06 2.30
2.10
2.08
2.07 2.29 2.31
2.32
2.02
2.33
2.11 2.32
2.16
2.17
2.18
2.20
2.20 2.19
2.20
2.20
2.20
2.20
2.14 2.28
2.27
2.21
2.20 2.26
2.22
2.23 2.20
2.24 2.13
2.22
2.25
2.25 2.15
2.23 2.15
2.12
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11 Spares

2.01 Motor WM-D132/210-2/14K0 380-415V 50Hz 215 316 07 01 0
with star delta switching
2.02 Star delta switching YDRT2026-M 217 315 07 43 2
– contactor 3RT2026 230V 50/60Hz 703 111
– contactor 3RT2025 230V 50/60Hz 703 110
– auxiliary switch block 1S+1OE 703 215
– electronic timer relay 703 283
2.03 Motor WM-D132/210-2/14K0 380-415V 50Hz
– with terminal board 215 316 07 02 0
– for external frequency converter 215 316 07 03 0
2.04 Motor for inbuilt frequency converter 215 316 07 04 0
Motor WM-D132/210-2/14K0 380-415V 50Hz
2.05 Frequency converter parameters preset 217 316 07 10 7
WM-D132/210-2/14K0 for W-FM 50/54
2.06 Cable gland set 211 104 01 50 2
2.07 Fan wheel TS-S 348 x 104.5 R 50Hz black 211 314 08 02 1
2.08 Screw M8 x 30 LH DIN 912 8.8 402 560
2.09 Serrated washer J 8.4 DIN 6797 431 501
2.10 Washer 8.5 x 22 x 5 211 404 08 06 7
2.11 Inlet nozzle 50Hz 211 314 02 06 7
2.12 Air inlet mesh 211 314 02 19 2
– Screws M5 x 16 Duo Taptite 409 312
2.13 Air regulator complete 211 314 02 03 2
2.14 Air regulator 211 314 02 11 7
2.15 Air damper 211 314 02 12 7
2.16 Actuator STE 50 3 Nm 651 477
2.17 Shaft key 3 x 3.7 DIN 6888 490 157
2.18 Air damper shaft with coupling 211 314 02 08 2
2.19 Air damper shaft with spring pin 211 314 02 09 2
2.20 Sleeve bearing set air regulator 211 104 02 50 2
2.21 Air regulator scale 211 314 02 17 7
2.22 Adjusting lever 211 104 02 04 7
2.23 Screw M5 x 12 with Precote 211 104 02 18 7
2.24 Ball joint rod 211 104 02 19 2
2.25 Screw M6 x 16 with Tuflock 402 268
2.26 Screw M6 x 120 DIN 7500 409 371
2.27 Washer A 6.4 DIN 125 430 400
2.28 Washer 5.1 x 11 x 0.6 430 015
2.29 Threaded socket 217 104 24 01 7
2.30 Air pressure switch
– LGW 50 A2P 2.5 - 50 mbar 691 373
– LGW 10 A2P 1.0 - 10 mbar 691 385
2.31 Plug for LGW 446 011
2.32 Threaded socket R1/8 453 003
2.33 Hose 4.0 x 1.75 300 mm 232 400 24 01 7
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11 Spares
3.01
3.01
3.06
3.02
3.02
3.03
3.05
3.03
3.04
3.26
3.25 3.08 3.08

3.29
3.24 3.07
3.23 3.09 3.11
3.28
3.22 3.10 3.09
3.21 3.13
3.09
3.15 3.10
3.20
3.09
3.19 3.16 3.10
3.10 3.12
3.17
3.08 3.13
3.30
3.60 3.14
3.27
3.09 3.18
3.49
3.61 3.10
3.09
3.52 3.10
3.10
3.60 3.31
3.37 3.09 3.10
3.59 3.54
3.36
3.51
3.58
3.55 3.53
3.56 3.48
3.50
3.32
3.57 3.33
3.53 3.34
3.50
3.52
3.35
3.39 3.34
3.38
3.45
3.40 3.47
3.44 3.46
3.43
3.42
3.41
3.62
3.40
3.63
83263302 • 2/2014-12 • La 108-130

11 Spares

3.01 Pressure hose DN 6 210 301 10 02 2
3.02 Hexagonal nut M16 x 1.5 210 104 10 08 7
3.03 Bulkhead connector 218 324 06 01 7
3.04 Screwed union EVT 12LOMD 452 502
3.05 Bypass plug BUZ 12-L with nut 211 404 13 01 2
3.06 Pressure gauge 0 to 40 bar with ball valve 121 364 85 02 0
3.07 Oil line 12 x 1.5 bulkhead conn.-oil reg. 215 324 06 03 8
3.08 Screwed union EVW 12LOMD 452 452
3.09 Screwed union XGE 12-PLR G 3/8-A 452 254
3.10 Sealing ring A 17 x 21 x 1.5 DIN 7603 Cu 440 003
3.11 Oil line 12 x 1.5 SV - bulkhead conn. supply 215 324 06 02 8
3.12 Oil quantity regulator Series S3 211 704 15 20 2
3.13 Shaft key 3 x 3.7 DIN 6888 490 157
3.14 Intermediate housing for oil regulator series B 211 704 15 27 2
3.15 View port 33 x 33 x 6 211 404 17 02 7
3.16 Oblong plug GPN 270 R 3015 446 115
3.17 Spring coupling bar series 2 217 704 15 10 7
3.18 Stepping motor STE 50 3 NM f. W-FM 54 Oil 651 488
3.19 Screwed union EVL 12-PL 452 552
3.20 Olive DPR12LX 452 773
3.21 Union nut M12LX 452 836
3.22 Threaded socket 12 x G1/4 x 42 121 464 85 02 7
3.23 Sealing ring A 13.5 x 17 x 1.5 DIN 7603 Cu 440 010
3.24 Threaded socket G1/4I x G1/2I x 40 290 504 13 03 7
3.25 Sealing ring C 6.2 x 17.5 x 2 DIN 16258 Cu 440 007
3.26 Pressure switch type DSA46 F001 1 - 10 bar 640 096
3.27 Oil line 12 x 1.5 pressure switch - SV ret. 215 324 06 04 8
3.28 Solenoid valve 5406 NC DN 13 110-120V 50Hz 604 820
3.29 Solenoid coil 110-120V 50Hz 20W 604 692
3.30 Oil line 12x1.5 strainer - SV supply 218 324 06 04 8
3.31 Strainer G 3/8 PN50 499 042
3.32 Treaded socket 12 x G3/8 x 46 prem. 121 464 85 04 2
3.33 Screwed union XGE 12-LR G1/2-A CF 452 259
3.34 Sealing ring A 21 x 26 x 1.5 DIN 7603 Cu 440 020
3.35 Pump TA5C 3010-7W 601 053
3.36 Pressure gauge -1 to +9 bar with ball valve 121 364 85 03 0
3.37 Pressure gauge 0 to 40 bar with ball valve 110 002 82 02 2
3.38 Threaded socket DN 25 M38 x 1.5 x G1/2 181 174 06 01 7
3.39 Pipe elbow DN 25 M38 x 1.5 x M38 x 1.5 x G1/8 453 252
3.40 Oil hose DN25 / 1300 mm 491 029
83263302 • 2/2014-12 • La 109-130

11 Spares
3.01
3.01
3.06
3.02
3.02
3.03
3.05
3.03
3.04
3.26
3.25 3.08 3.08

3.29
3.24 3.07
3.23 3.09 3.11
3.28
3.22 3.10 3.09
3.21 3.13
3.09
3.15 3.10
3.20
3.09
3.19 3.16 3.10
3.10 3.12
3.17
3.08 3.13
3.30
3.60 3.14
3.27
3.09 3.18
3.49
3.61 3.10
3.09
3.52 3.10
3.10
3.60 3.31
3.37 3.09 3.10
3.59 3.54
3.36
3.51
3.58
3.55 3.53
3.56 3.48
3.50
3.32
3.57 3.33
3.53 3.34
3.50
3.52
3.35
3.39 3.34
3.38
3.45
3.40 3.47
3.44 3.46
3.43
3.42
3.41
3.62
3.40
3.63
83263302 • 2/2014-12 • La 110-130

11 Spares

3.41 Threaded socket DN 25 M38 x1.5 x M26 x 1.5 181 174 06 02 7
3.42 Sealing ring A 27 x 32 x 2 DIN 7603 Cu 440 039
3.43 Collar screw X BSCH G 1/2 A 450 651
3.44 Housing XDSVW18-LR 450 650
3.45 Sealing ring X DKAZ G 1/2 A 450 652
3.46 Screwed union KOR18-12-PL 452 152
3.47 Union nut M18LX 452 803
3.48 Oil line 12 x 1.5 SV - pump return 218 324 06 05 8
3.49 Solenoid valve 6027 NC DN 10 110-120V 50Hz 604 840
3.50 Stud screw M10Fo x 25 DIN 939 421 066
3.51 Pump flange 218 214 09 03 7
3.52 Remove closing plug 256 306 06 02 7
3.53 Screw M8 x 100 218 214 09 02 7
3.54 Clamping ring Ø 8 mm 490 500
3.55 Magnetic coupling WMK20/1 long vers. 230V 218 324 09 03 2
3.56 Retaining washer 155 101 09 03 7
3.57 Screw M5 x 16 DIN 963 404 013
3.58 Bearing flange 218 404 09 01 2
3.59 Pump coupling 54,3 x D35 drilling 12 218 324 09 01 2
3.60 Universal joint 111 151 09 01 7
3.61 Coupling centre piece 301.4 mm 218 324 09 02 2
3.62 Threaded socket DN25 M38 x 1.5 x G 1 122 362 00 07 7
3.63 Sealing ring A 33 x 39 x 2 DIN 7603 Cu 440 032
83263302 • 2/2014-12 • La 111-130

11 Spares
4.01
4.02*
4.03
4.12
4.04
4.06
4.08
4.05
4.09
4.06
4.07
4.10
4.11
4.13
4.15
4.14
4.20 4.16
4.21 4.32
4.17
4.31
4.18 4.31
4.19
4.22
4.33
4.34
4.24
4.23
4.27
4.26 4.30
4.29
4.25
4.27
4.28
83263302 • 2/2014-12 • La 112-130

11 Spares

4.01 Flame tube WM-G(L)30/3 217 315 14 01 2
4.02 Extension pipe
– extended by 150 mm* 217 315 14 11 2
– extended by 300 mm* 217 315 14 12 2
4.03 Lock nut M12 x 109 151 907 01 10 7
4.04 Gasket 92 x 200 x 2 rubber cork 151 907 00 01 7
4.05 Gas butterfly DN80 w. intermediate housing cpl. 217 505 25 02 2
4.06 Shaft key 3 x 3.7 DIN 6888 490 157
4.07 Intermediate housing for gas butterfly series B 217 704 25 02 2
4.08 View port 33 x 33 x 6 211 404 17 02 7
4.09 Rectangular plug 446 115
4.10 Spring coupling bar series 2 217 704 15 10 7
4.11 Stepping motor STE50 1,2 Nm Gas 651 484
with plug cable
4.12 Mixing head cpl. 230V
– Standard 218 325 14 01 2
– extended by 150 mm* 218 325 14 04 2
– extended by 300 mm* 218 325 14 05 2
4.13 Diffuser cpl. 260K x 62 217 315 14 04 2
4.14 Nozzle tube 35 x 1.5 217 315 14 06 7
4.15 Central gas tube 8 x 1.5 217 315 14 05 7
4.16 Distributor ring 217 315 14 03 7
4.17 Clamp for electrodes 218 204 14 08 7
4.18 Ignition electrode 217 204 14 24 7
4.19 Ignition cable 11/6.4
– 800 mm (Standard) 217 204 11 08 2
– 1000mm (for 150 mm extension)* 217 204 11 10 2
4.20 Mixing tube internal
– Standard (99 x 420) 217 405 14 25 7
– extended by 150 mm* 290 405 14 05 7
– extended by 300 mm* 290 405 14 06 7
4.21 Mixing tube external
– Standard (155 x 202) 217 315 14 04 7
– extended by 150 mm* 217 315 14 09 7
– extended by 300 mm* 217 315 14 10 7
4.22 Mixing head 217 315 14 02 7
* Only in conjunction with combustion head extension.
83263302 • 2/2014-12 • La 113-130

11 Spares
4.01
4.02*
4.03
4.12
4.04
4.06
4.08
4.05
4.09
4.06
4.07
4.10
4.11
4.13
4.15
4.14
4.20 4.16
4.21 4.32
4.17
4.31
4.18 4.31
4.19
4.22
4.33
4.34
4.24
4.23
4.27
4.26 4.30
4.29
4.25
4.27
4.28
83263302 • 2/2014-12 • La 114-130

11 Spares

4.23 Nozzle head MDK60 250W 230V 50-60Hz
with solenoid coil
– Standard 211 404 10 03 2
– extended by 150 mm* 211 404 10 09 2
– extended by 300 mm* 211 404 10 07 2
4.24 Oil line 8 x 1 supply
– Standard 218 324 06 02 8
– extended by 150 mm* 218 324 06 06 8
– extended by 300 mm* 218 324 06 08 8
4.25 Oil line 8 x 1 return
– Standard 218 324 06 03 8
– extended by 150 mm* 218 324 06 07 8
– extended by 300 mm* 218 324 06 09 8
4.26 Retainer 218 324 14 03 7
4.27 Screw M6 x 18 DIN 933 401 360
4.28 Solenoid coil MDK60 230V 50-60Hz ZM 280-1 605 928
4.29 Plug cable for SV 850 mm 716 535
4.30 Electrode holder 218 324 14 02 7
4.31 Ignition electrode 218 324 11 01 7
4.32 Washer 40 x 6.6 x 2.5 177 205 14 46 7
4.33 Ignition cable 11/4.1
– 800 mm (Standard) 218 204 11 08 2
4.34 Spill type nozzle
– W 225 kg S5 50 ° V 612 816
– W 250 kg S5 50 ° V 612 817
– W 275 kg S5 50 ° V 612 818
– W 300 kg S5 50 ° V 612 819
– W 330 kg S5 50 ° V 612 820
– W 360 kg S5 50 ° V 612 821
– W 390 kg S5 50 ° V 612 822
– W 420 kg S5 50 ° V 612 823
– W 460 kg S5 50 ° V 612 824
– W 500 kg S5 50 ° V 612 825
– W 550 kg S5 50 ° V 612 826
– W 225 kg S4 50 ° 612 980
– W 250 kg S4 50 ° 612 981
– W 275 kg S4 50 ° 612 982
– W 300 kg S4 50 ° 612 983
– W 330 kg S4 50 ° 612 984
– W 360 kg S4 50 ° 612 985
– W 390 kg S4 50 ° 612 990
– W 420 kg S4 50 ° 612 991
– W 460 kg S4 50 ° 612 992
– W 500 kg S4 50 ° 612 993
– W 550 kg S4 50 ° 612 994
* Only in conjunction with combustion head extension.
83263302 • 2/2014-12 • La 115-130

11 Spares
5.06 5.22
5.23 5.21
5.05
5.20
5.19
5.02 5.24
5.03
5.08
5.09
5.04 5.07
5.01
5.15
5.12 5.16
5.14
5.11
5.10
5.18
5.13
5.17
83263302 • 2/2014-12 • La 116-130

11 Spares

5.01 ABE for W-FM 50/54 600 408
5.02 Cover complete
- ABE inbuilt 218 314 12 02 2
- ABE external 211 314 12 02 2
5.03 Switch for fuel change-over 700 397
– Label fuel change-over switch German 201 000 11 00 7
5.04 Combustion manager W-FM 54 230V 50-60Hz 600 412
5.05 Stay bolt cover W-FM 211 104 12 03 7
5.06 Mounting plate for W-FM 54 218 314 12 01 7
5.07 Fixing rope for cover 218 104 12 02 7
5.08 Inbuilt terminal rail 6 pole W-FM54/AGM60 cpl. 218 314 12 04 2
5.09 Switch unit 230V AGM 60.2A9 600 427
5.10 Plug cable ABE-W-FM
–2m 600 406
– 10 m 600 407
5.11 Connecting wire for mains/safety circuit 217 706 12 48 2
5.12 Plug cable W-FM 54 for
– Low / valve proving gas pressure switch 217 104 26 02 2
– DMV 218 104 26 01 2
5.13 Plug cable W-FM air pressure switch X3-02 217 706 12 03 2
5.14 Plug cable W-FM solenoid valve X8-03 217 706 12 07 2
5.15 Plug cable W-FM54 switch unit AGM 218 314 12 01 2
5.16 Plug cable with rectifier and plug X6-02 218 114 12 01 2
5.17 Connection cable W-FM switch unit AGM 600 429
5.18 Plug cable W-FM DSA 46 211 706 12 03 2
5.19 Ignition unit type W-ZG03 230V with W-FM plug 218 204 11 05 2
5.20 Seal for ignition unit 3 pole 218 204 11 01 7
5.21 Flame sensor QRA2 (UV cell) 600 501
– U bolt 600 601
5.22 Flange for QRA2 600 602
5.23 Limit switch complete 211 104 01 06 2
83263302 • 2/2014-12 • La 117-130

11 Spares
5.06 5.22
5.23 5.21
5.05
5.20
5.19
5.02 5.24
5.03
5.08
5.09
5.04 5.07
5.01
5.15
5.12 5.16
5.14
5.11
5.10
5.18
5.13
5.17
83263302 • 2/2014-12 • La 118-130

11 Spares

5.24 W-FM plug
– X3-02 Air pressure switch 716 301
– X3-03 Limit switch burner flange 716 302
– X3-04 Mains and safety circuit 716 303
– X3-05 Fan, alarm 716 410
– X4-02 Ignition unit 716 305
– X5-01 Min. oil pressure switch 716 307
– X5-02 Max. oil pressure switch 716 308
– X5-03 Control circuit 716 309
– X6-03 Safety valve 716 312
– X7-01 Oil valve stage 2 716 313
– X7-02 Oil valve stage 3 716 314
– X8-02 Nozzle solenoid 716 317
– X8-03 Oil valve 1 716 318
– X8-04 Fuel selection 1 716 411
– X9-04 Fuel selection 0 716 418
– X10-05 Flame sensor QRB,QRC, ionisation 716 413
– X10-06 Flame sensor QRA 716 414
– X22-02 Plug doe gas valve train 716 365
– X24-04 Gas V1 V2 716 450
– X24-05 PV Gas 716 452
– X24-06 SV Gas 716 454
– X31-01 Mains, fuel selection 716 455
– X31-02 Fuel selection 716 456
– X32-01 Conn.W-FM-valves 716 457
– X32-02 Load controller 716 458
– X64 Reserve 4-20mA 716 416
– X74 Frequency converter connection 716 417
– X75 Fuel meter 716 415
83263302 • 2/2014-12 • La 119-130

12 Technical documentation
12.1 Appliance categories
Labelling of gas and dual fuel burners to EN 676

EN 676, "Automatic forced draught burner for gaseous fuels", is used for the imple-
mentation of the basic requirements of the Gas Appliance Directive 2009/142/EC.
EN 676 from November 2003 stipulates the following appliance categories for forced
draught gas burners under point 4.4.9:
I2R for Natural Gas
I3R for Liquid Petroleum Gas
II2R/3R for Natural Gas / Liquid Petroleum Gas
The test gases listed under point 5.5.1, table 4 (EN 676) and the minimum test pres-
sures determined and listed under point 5.1.2, table 5 (EN 676) are used to provide
the evidence of service performance for the burner during type testing.
As -weishaupt- gas and dual fuel burners fulfil this requirement completely, the ap-
pliance category, as well as the test gases used with the permissible connection
pressure range, are listed on the name plate when labelling the burner to
point 6.2 (EN676). This clearly defines the suitability of the burner for use with second
and/or third family gases.
On the basis of a type test report to EN 45001/ISO 17025 from an accredited test
centre, the EU Type Testing Certificate to Gas Appliance Directive 2009/142/EC
also quotes the appliance category, the supply pressure and the country of destina-
tion.
EN 437, "Test gases, test pressures, appliance categories", describes the interrela-
tionships and the special national characteristics relating to this subject in detail.
The following tables give an overview of the interrelationships between the R Cate-
gories and the nationally used appliance categories with their types of gas and
connection pressures.
83263302 • 2/2014-12 • La 120-130

Alternative appliance category to I2R

Country of destination Appliance category Test gas Connection pressure
mbar
AL (Albania) I2H G 20 20
AT (Austria) I2H G 20 20
BA (Bosnia) I2H G 20 20
BE (Belgium) I2E+, I2N, I2E(R)B G 20 + G 25 Pressures
20 / 25
BG (Bulgaria) I2H G 20 20
BY (Belarus)
CH (Switzerland) I2H G 20 20
CY (Cyprus) I2H G 20 20
CZ (Czech Republic) I2H G 20 20
DE (Germany) I2ELL, I2E, I2L G 20 / G 25 20
DK (Denmark) I2H G 20 20
EE (Estonia) I2H G 20
ES (Spain) I2H G 20 20
FI (Finland) I2H G 20 20
FR (France) I2Esi, I2E+, I2L G 20 + G 25 Pressures
20 / 25
GB (United Kingdom) I2H G 20 20
GR (Greece) I2H G 20 20
HR (Croatia) I2H G 20 20
HU (Hungary) I2H G 20 20
IE (Ireland) I2H G 20 20
IS (Iceland) I2H G 20 20
IT (Italy) I2H G 20 20
LT (Lithuania)
LU (Luxembourg) I2E G 20 20
LV (Latvia)
MD (Moldova) I2H G 20 20
MK (Macedonia) I2H G 20 20
MT (Malta) I2H G 20 20
NL (The Netherlands) I2L G 25 25
NO (Norway) I2H G 20 20
PL (Poland) I2E G 20 / GZ 410 20
PT (Portugal) I2H G 20 20
RO (Romania) I2H G 20 20
SE (Sweden) I2H G 20 20
SI (Slovenia) I2H G 20 20
SK (Slovakia) I2H G 20 20
SRB (Serbia) I2H G 20 20
TR (Turkey) I2H G 20 25
UA (Ukraine) I2H G 20 20
83263302 • 2/2014-12 • La 121-130

Alternative appliance category to I3R

Country of destination Appliance category Test gas Connection pressure
mbar
AL (Albania) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
AT (Austria) I3B/P, I3P G 30 + G 31 50
BA (Bosnia) I3B/P G 30 30 (28-30)
BE (Belgium) I3+, I3P, I3B, I3B/P G 30 + G 31 Pressures
28 - 30 / 37
BG (Bulgaria) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
BY (Belarus)
CH (Switzerland) I3B/P, I3+, I3P G 30 + G 31 Pressures
28 - 30 / 37
CY (Cyprus) I3B/P, I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
CZ (Czech Republic) I3B/P, I3+, I3P G 30 + G 31 Pressures
28 - 30 / 37
DE (Germany) I3B/P, I3P G 30 + G 31 50
DK (Denmark) I3B/P G 30 + G 31 30 (28 - 30)
EE (Estonia) I3B/P G 30
ES (Spain) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
FI (Finland) I3B/P G 30 + G 31 30 (28 - 30)
FR (France) I3+, I3P, I3B G 30 Pressures
28 - 30 / 37
G 31 Pressures
112 / 148
GB (United Kingdom) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
GR (Greece) I3B/P, I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
HR (Croatia) I3B/P, I3P G 30 + G31 50
HU (Hungary) I3B/P G 30 + G31 50
IE (Ireland) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
IS (Iceland) I3B/P
IT (Italy) I3B/P, I3+, I3P G 30 + G 31 Pressures
28 - 30 / 37
LT (Lithuania)
LU (Luxembourg) I3B/P G 30
LV (Latvia)
MD (Moldova) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
MK (Macedonia) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
MT (Malta) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
NL (The Netherlands) I3B/P, I3P G 30 + G 31 30 (28 - 30)
NO (Norway) I3B/P G 30 + G 31 30 (28 - 30)
PL (Poland) I3B/P G 30
PT (Portugal) I3+, I3P, I3B G 30 Pressures
28 - 30 / 37
G 31 Pressures
50 / 67
RO (Romania) I3B/P G 30
SE (Sweden) I3B/P G 30 + G 31 30 (28 - 30)
SI (Slovenia) I3B/P G 30 30
SK (Slovakia) I3B/P G 30 30
SRB (Serbia) I3B/P, I3P G 30 + G 31 20
TR (Turkey) I3B/P G 30 + G 31 30
UA (Ukraine) I3B/P, I3P G 30 + G 31 50
83263302 • 2/2014-12 • La 122-130

Alternative appliance category to II2R/3R

Country of destination Appliance category Test gas Connection pressure Test gas Connection pressure
mbar mbar
AL (Albania) II2H3+, II2H3P G 20 20 G 31 30
AT (Austria) II2H3B/P, II2H3P G 20 20 G 30 + G 31 50
BA (Bosnia) II2H3B/P G 20 20 G 30
BE (Belgium) II2E+3P, II2H3B/P G 20, G 25 Pressures G 30 + G 31 Pressures
20 / 25 28 - 30 / 37
BG (Bulgaria) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
28 - 30 / 37
BY (Belarus)
CH (Switzerland) II1a2H, II2H3B/P, G 20 20 G 30 + G 31 Pressures
II2H3+, II2H3P 28 - 30 / 37
CY (Cyprus) II2H3B/P, II2H3+, G20 20 G 30 + G 31 Pressures
II2H3P 28 - 30 / 37
CZ (Czech Republic) II2H3B/P, II2H3+, G 20 20 G 30 + G 31 Pressures
II2H3P 28 - 30 / 37
DE (Germany) II2ELL3B/P, II2E3B/P G 20 20 G 30 + G 31 50
DK (Denmark) II1a2H, II2H3B/P G 20 G 20 G 30 + G 31 30
EE (Estonia) II2H3B/P G 20 20 G 30 30
ES (Spain) II2H3P, II2H3+ G 20 20 G 30 + G 31 Pressures
28 - 30 / 37
FI (Finland) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
FR (France) II2E+3+, II2E+3P, G 20 20 G 30 Pressures
II2Esi3B/P 28 - 30 / 37
G 31 Pressures
112 /148
GB (United Kingdom) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
28 - 30 / 37
GR (Greece) II2H3B/P, II2H3+, G 20 20 G 30 + G 31 Pressures
II2H3P 28 - 30 / 37
HR (Croatia) II2H3B/P G 20 20 G 30 + G 31 30 (28-30)
HU (Hungary) II2H3B/P G 20 20 G 30 + G 31
IE (Ireland) II2H3+, II2H3P G 20 20
IS (Iceland) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
IT (Italy) II1a2H, II2H3B/P, G 20 20 G 30 + G 31 Pressures
II2H3+, II2H3P 28 - 30 / 37
LT (Lithuania)
LU (Luxembourg) II2E3B/P G 20 20 G 30 + G 31
LV (Latvia)
MD (Moldova) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
30 / 37
MK (Macedonia) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
30 / 37
MT (Malta) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
30 / 37
NL (The Netherlands) II2L3B/P, II2L3P G 25 25 G 30 + G 31 30
NO (Norway) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
PL (Poland) II2E3B/P G 20 20 G 30 + G 31 30 (28 - 30)
PT (Portugal) II2H3+, II2H3P G 20 20 G 30 Pressures
28 - 30 / 37
G 31 Pressures
50 / 67
RO (Romania) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
SE (Sweden) II1a2H, II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
SI (Slovenia) II2H3B/P G 20 20 G 30 30
SK (Slovakia) II2H3B/P G 20 20 G 30 30
SRB (Serbia) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
TR (Turkey) II2H3B/P G 20 25 G 30 + G 31 30 + 37
UA (Ukraine) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
83263302 • 2/2014-12 • La 123-130

13 Project planning
13 Project planning
13.1 Oil supply

The operational safety of oil fired plant is only guaranteed when the installation of the
oil supply is carried out carefully. The installation must comply with country specific
and local regulations (e. g. DIN 4755, EN 12514, TRÖI).
General information relating to the oil supply

▪ The oil supply should be installed in such a way that it is possible to hinge open
the burner.
▪ Do not use cathode protection system with steel tanks.
▪ Fit oil filter in front of pump, mesh aperture maximum 100 μm.
▪ With oil temperatures < 5 °C the separation of paraffin can cause oil lines, oil filters
and nozzles to become blocked. Avoid placing oil tanks and pipelines in areas
subject to frost.
Suction resistance
Pump damage due to excessive suction resistance

A suction resistance greater than 0.4 bar can damage the pump.
▶ Reduce suction resistance – or – install oil supply pump or suction unit, whilst
CAUTION observing the maximum supply pressure at the oil filter.
The suction resistance depends on:

▪ length and diameter of suction line,
▪ pressure loss of oil filter and/or other components,
▪ lowest oil level in the oil storage tank (max 3.5 m below the oil pump).
Shut off devices at the burner
Damage caused by the shut off device closing too fast

Pressure surges and cavitation can damage the components of the oil supply.
▶ When testing the operation of the limit switches the shut off device must only be
CAUTION closed until the safety shut off responds.
▶ The shut off device can only be closed completely when the burner pump has shut
off.
▪ The isolating valves operate mechanically in compound and are fitted with a limit
switch, which inhibits burner operation when the isolating valves are closed.
▪ Protect shut off devices in the return line from accidental closure.
The installation of non return valves is not permitted.
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13 Project planning
13.1.1 Single pipe oil supply

If the oil supply is via a pressurised single pipe system, a Weishaupt oil circulation
tank or technically similar, which complies with the relevant regulations, must be in-
stalled.
Recommended pump supply pressure 1 … 1.5 bar.
13.1.2 Ring main operation

Oil supply via ring main system is recommended for:
▪ large installations (industrial and district heating), which are run almost continually,
▪ larger distances,
▪ several burners.
For installation and function drawing for ring main operation see Technical work
sheets.
▪ The installation of a duplex oil pump station as ring main pump is recommended.
Cleaning and service work on the pump or oil filter is then possible during burner
operation.
▪ The supply quantity must be a minimum of one and a half to twice the total firing
rates of all burners supplied by the ring main.
▪ The burners are connected to the ring main via a two pipe system.
▪ Set ring main pressure for fuel oil EL via pressure regulating valve to 1 … 1.5 bar.
▪ The oil filter must be suitable for the ring main pressure.
▪ An oil circulation device or Weishaupt gas/air separator should be fitted at each
oil outlet point. Observe information label on separator.
13.1.3 Oil circulation unit

The ring main supply can be fitted with an oil circulation unit.
The unit consists of:
▪ oil meter,
▪ edge plate filter,
▪ circulation tank,
▪ limit switch for burner lockout,
▪ safety valve.
Smallest size to be considered is 2 (from 100 l/h). For installation instructions see the
installation and operating manual Weishaupt oil circulation unit (Print No. 434).
13.2 Flue gas system

When designing the flue gas system observe BDH Info sheet No. 32 "Requirements
on flue gas systems (see www.bdh-koeln.de).
83263302 • 2/2014-12 • La 125-130

14 Notes
14 Notes
83263302 • 2/2014-12 • La 126-130

14 Notes
83263302 • 2/2014-12 • La 127-130

15 Key word index
A External ..................................................................................16
Adjustment ................................................................... 52, 82
Air damper ...................................................... 11, 24, 92, 94 F
Air number ............................................................................80 Fabrication number .............................................................10
Air pressure ..........................................................................81 Factory presetting ...............................................................23
Air pressure switch ..................................................... 11, 78 Fan pressure ........................................................................41
Air regulator .................................................................. 93, 94 Fan wheel ..................................................................... 11, 98
Ambient conditions .............................................................17 Fault .................................................................................... 101
Aperture ........................................................................ 22, 26 Filter .................................................................................... 124
Appliance category ......................................................... 120 Flame signal .........................................................................16
Approval data .......................................................................17 Flame tube .................................................................... 22, 26
Flame tube setting ...................................................... 24, 25
B Flange gasket ......................................................................26
Backup .......................................................................... 63, 75 Flow pressure ......................................................................34
Breaks in operation ............................................................83 Flow temperature ................................................................34
Burner motor ........................................................................16 Flue gas losses ....................................................................80
Flue gas measurement ......................................................80
Flue gas system ............................................................... 125
C Flue gas temperature .........................................................80
Calorific value ......................................................................49 Fuel ........................................................................................17
Capacity graph ....................................................................19 Fuel oil ...................................................................................17
CE Pin ...................................................................................17 Fuel selection .......................................................................16
CO content ..........................................................................80 Fusing ....................................................................................17
Combustion air ...................................................................... 8
Combustion chamber pressure .......................................19 G
Combustion head ...............................................................19
Combustion head extension ..................................... 22, 25 Gas butterfly valve ..............................................................13
Combustion heat rating ............................................. 19, 24 Gas connection pressure .................................. 28, 43, 49
Combustion Manager ................................................ 16, 36 Gas family .......................................................................... 120
Combustion settings ..........................................................82 Gas filter ...............................................................................12
Combustion test ..................................................................80 Gas pressure switch ..........................................................77
Commissioning ............................................................ 40, 52 Gas setting pressure .........................................................49
Connection pressure .......................................... 28, 43, 49 Gas supply ...........................................................................28
Consumption .......................................................................17 Gas throughput ...................................................................81
Corrections ..........................................................................82 Gas tube ...............................................................................91
Coupling ...............................................................................95 Gas valve train ............................................................. 28, 30
Gas/air separator ............................................................. 125
Guarantee ............................................................................... 7
D
Data backup ................................................................. 63, 75 H
Delivery status .....................................................................23
Design lifespan ............................................................... 8, 84 Heat exchanger ...................................................................22
Dimension E ................................................................. 24, 25 High gas pressure switch ........................... 12, 29, 31, 77
Dimensions ...........................................................................20 High pressure regulator ..................................... 46, 47, 99
Dimensions S1 ....................................................................24 Hinge flange .........................................................................26
Display ........................................................................... 38, 39 Humidity ................................................................................17
Display and operating unit (ABE) ............................ 16, 38
Disposal .................................................................................. 9 I
Double gas valve ........................................... 12, 28, 29, 31 Ignition electrode ................................................................90
Drilling diagram ...................................................................22 Ignition position ........................................................... 55, 67
Ducted air intake ............................................................ 8, 19 Ignition speed .............................................................. 55, 58
Ignition unit ...........................................................................16
E Inlet nozzle ............................................................................98
Electrical connection ..........................................................36 Installation .............................................................................22
Electrical data ......................................................................17 Installation elevation ...........................................................19
Electrode ..............................................................................90 Installation location .............................................................22
Emission ................................................................................18 Isolating valve ......................................................................12
Excess air ..............................................................................80
Exchanging the unit ......................................................... 101 L
Extension ..............................................................................25 Liability ..................................................................................... 7
83263302 • 2/2014-12 • La 128-130

15 Key word index
Limit switch ..........................................................................16 R

Lockout .............................................................................. 101 Rating ....................................................................................19
Low / valve proving gas pressure switch ....... 13, 29, 31 Refractory .............................................................................22
Low pressure regulator .....................................................99 Remote ..................................................................................16
Reset .................................................................................. 101
M Return ............................................................................ 27, 34
Magnetic coupling ..............................................................97 Return pressure ........................................................... 42, 71
Max. oil pressure switch ............................................ 14, 76 Ring main operation ........................................................ 125
Measuring device ................................................................41 Ring main pump ............................................................... 125
Metering slot ........................................................................14
Mixing head .................................................................. 11, 24 S
Mixing pressure ...................................................................41 Safety measures ................................................................... 8
Motor ...................................................................... 16, 17, 36 Safety shut off valve ................................................... 46, 47
Safety vent valve ......................................................... 46, 47
N Safety vent valve .................................................................47
Name plate ...........................................................................10 SAV ................................................................................ 46, 47
Noise emission value .........................................................18 SBV ................................................................................ 46, 47
Normal volume .....................................................................81 Sequence of operation ......................................................15
Nozzle ............................................................................ 23, 91 Serial number .......................................................................10
Nozzle assembly .......................................................... 14, 88 Service ..................................................................................84
Nozzle distance ...................................................................89 Service interval ....................................................................84
Nozzle selection table ........................................................23 Setting diagram ...................................................................24
Nozzle shut off .....................................................................14 Setting pressure ..................................................................49
Nozzle tube ...........................................................................91 Setting pressure range ......................................................99
Shutdown .............................................................................83
O Shutdown time ....................................................................83
Single pipe operation ...................................................... 125
Oil circulation unit ............................................................ 125 Sleeve bearing .....................................................................94
Oil filter ............................................................................... 124 Smell of gas ........................................................................... 8
Oil hose .................................................................................34 Solenoid valve .....................................................................14
Oil meter ............................................................................ 125 Sound power level ..............................................................18
Oil nozzle ...................................................................... 23, 91 Sound pressure level .........................................................18
Oil pump ................................................................ 14, 34, 42 Soundness test ...................................................................44
Oil quantity regulator ..........................................................14 Spare part .......................................................................... 105
Oil ressure measuring device ..........................................42 Speed ............................................................................ 70, 71
Oil supply .................................................................... 34, 124 Spring ....................................................................................99
Oil temperatures .............................................................. 124 Spring coupling bar ............................................................95
Oil throughput ............................................................. 14, 23 Stability problems ............................................................ 102
Operating panel ..................................................................38 Standards .............................................................................17
Operating problems ........................................................ 102 Start problems .................................................................. 102
Operating unit ......................................................................38 Stepping motor .................................................... 92, 95, 96
Operating volume ...............................................................81 Storage .................................................................................17
Suction resistance ........................................................... 124
P Supply ........................................................................... 27, 34
Partial load .................................................................... 62, 74 Supply pressure ................................................... 34, 42, 70
Password ...................................................................... 52, 64 Supply temperature ............................................................34
Pre-filter ............................................................................. 124 Supply voltage .....................................................................17
Pressure gauge ...................................................................42
Pressure measuring device ...................................... 41, 42 T
Pressure regulating screw ................................................70 Temperature .........................................................................17
Pressure regulator .................................12, 28, 46, 47, 99 Test points ............................................................................45
Pressure switch ......................................11, 14, 76, 77, 78 Test pressure .......................................................................44
Pressure switches ..............................................................51 Throughput ...........................................................................23
Pulsating ............................................................................ 102 Transport ...............................................................................17
Pump ...................................................................... 14, 34, 42 Type key ................................................................................10
Pump coupling ....................................................................97 Type of Gas ..........................................................................17
Pump pressure ..................................................... 23, 42, 70 Type of gas ........................................................................ 120
83263302 • 2/2014-12 • La 129-130

15 Key word index
V
Vacuum .............................................................................. 124
Vacuum gauge ....................................................................42
Valve proving .......................................................................13
Valve train ..................................................................... 30, 49
Voltage supply .....................................................................17
W
Weight ...................................................................................21
Z
Zero shut off ................................................................. 46, 47
83263302 • 2/2014-12 • La 130-130

83263302 • 2/2014-12 • La
Max Weishaupt GmbH · 88475 Schwendi
Weishaupt close by? Addresses, telephone numbers etc. can be found

at www.weishaupt.de
We reserve the right to make changes. All rights reserved.
The complete program:

Reliable technology and prompt, professional service
W Burners up to 570 kW Wall-hung condensing boilers
for oil and gas up to 240 kW
The compact burners, proven millions of times
over, are economical and reliable. Available as The wall-hung condensing boilers WTC-GW
gas, oil and dual fuel burners for domestic and and WTC-OW have been developed to meet
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mixing head gives almost soot-free combustion Modulating operation means these units
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These industrial burners of modular The stylish flat-plate collectors are the ideal
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collectors.
83263302 • 2/2014-12 • La

Installation and Operating Instruction: Dual Fuel Burner WM - GL30/3-A / ZM-R (W-FM 54)

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Installation and operating instruction

Dual fuel burner WM - GL30/3-A / ZM-R (W-FM 54) 83263302 • 2/2014-12

Manufacturer: Max Weishaupt GmbH

Product: Dual fuel burner type

The product described above conforms with

the regulations of directives:

GAD 2009 / 142 / EC

This product is labelled as follows:

Dr. Schloen Denkinger

Manager Research Manager Production and

1 User instructions ..................................................................................................................... 6

3 Product description ............................................................................................................. 10

83263302 • 2/2014-12 • La 3-130

5.2 Oil supply ............................................................................................................ 34

83263302 • 2/2014-12 • La 4-130

9.16 Set magnetic coupling ..................................................................................... 97

10 Troubleshooting ................................................................................................................. 101

11 Spares ...................................................................................................................................... 104

12 Technical documentation .............................................................................................. 120

13 Project planning .................................................................................................................. 124

14 Notes ........................................................................................................................................ 126

15 Key word index ................................................................................................................... 128

83263302 • 2/2014-12 • La 5-130

1.1 User guide

Immediate danger with high risk.

Danger with medium risk.

Danger with low risk.

Requires direct action

Result after an action

1.1.2 Target group

83263302 • 2/2014-12 • La 6-130

1.2 Guarantee and Liability

83263302 • 2/2014-12 • La 7-130

2.1 Designated application

2.2 When gas can be smelled

2.3 Safety measures

2.3.1 Normal operation

2.3.2 Electrical connection

83263302 • 2/2014-12 • La 8-130

2.3.3 Gas supply

2.4 Alterations to the construction of the equipment

2.5 Noise emission

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3.1 Type key

3.2 Serial number

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3.3.1 Air supply

Air pressure switch

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3.3.2 Gas supply

Double gas valve 1

Gas isolating valve 3

High gas pressure switch 5 (optional)

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Low / valve proving gas pressure switch 6

Gas butterfly valve 7

83263302 • 2/2014-12 • La 13-130