93042902 ~ 1/98 Installation and operating instructions Weishaupt dual fuel burners size 30 to 70 -weishaupt-—0085 Conformity certification We hereby confirm that Weishaupt oil burners conform to the basic requirements of the following EC guidelines: - 90/396/EEC Gas Unit Guideline = 89/336/EEC Electromagnetic Compatibility ~ 73/23/EEC Low Voltage Guideline ‘Therefore the burner carries the CE/0085 Label. The product refers to the type test 0085 of the Notified Body. Extensive quality assurance is guaranteed by a certified ‘Quality Management System to DIN EN ISO 9001 Max Weishaupt GmbH Burner and Heating Systems D-88475 Schwendi Content Title 1. General instructions 2. Burner installation 3. Burner fuel system for gas 4, Description of valve trains 4.1 Solenoid valves 4.2 Pressure regulator type FRS 433 Valve proving VPS 504 4.4 Valve proving type W-DK 3/01 5. Installation of valve trains 5.1 Safety information 5.2 Installation example 6. Soundness test of valve trains 7, Sequence test of operation 8. Preparation for first commissioning 8.1 Testing gas supply pressure 8.2 Venting gas line 8. Commissioning the gas side 9.1 Checks prior to first commissioning 8.2 Flame monitoring 9.3 Adjusting gas side 9.4 Set gas pressure switch 9.5 Set air pressure switch 96 Combustion test 9.7 Setting pressure and minimum connection pressure 10. Setting the mixing head 11. Capacity graphs 12. Oil supply 13, Pump assembly for oils M +S 14. Oil hose installation for metal hoses (oil S) 18. Oil pre-heater system 16. Pumps for oil EL M +S 17, Fan wheels attachment 18. Burner fuel system for oil 19.2 RGL 40 to RGL 70 19.3 RGMS30 to RGMS5O 19.4 RGMS60/RGMS70 19.5 Oil regulator 20, Nozzle circulation on burners RGMS30 and RGMS50 21. Nozzle selection 21.1 Two and three stage burners 21.2 Regulating burner 22. Ignition electrode and pilot setting 23. Commissioning the oil side 23.1 Tests prior to first commissioning 23.2 Adjusting the oil side 24. Sequence of operation 24.1 Pre-requisite for burner start 24.2 Symbols on the fault position icator 24.3 Basic wiring diagram for LFL 1../LGK 16... 24.4 Switching times 24.5 Sensor line between LGK 16... and QRA53 / RA 55 or sensor electrode 24.6 Technical data 25. Cam setting of limit and auxi in the servomotor 26. Throughput determination, conversion from normal to operating condition 27, Fault conditions and procedures ry switches.1. General instructions Abbreviated instructions ‘The following table gives an overview of the procedures for installation and commissioning, To ensure safe installation and commissioning allinstructions given in these installation and operating instructions must be followed, ANGER Step Action Chapter 1 Burner installation 2 2 Installation of ol supply 121016 3 Installation of gas valve trains 5 4 Soundness test of valve train 6 5 Testing gas supply pressure 8a 6 Purging the gas eupply line ar 7 Testing sequence of operation 7 8 Nozzle selection 2 Testing the mixing head 10 and 22 10 Testing the plant 9.4 and 23:1 (On two and three stage burners: 11 Commissioning gas side 9 12 Commissioning oil side 23 On regulating burners: 11 Commissioning oil side 23 12 Commissioning gas side 9 ‘To ensure safe burner operation, the burner has to be installed and commissioned by qualified personnel and all guidelines in these operating instructions have tobe followed. ‘Special attention should be paid to the relevant installation and safety guidelines given (ie. local Codes of Practice). Flame monitoring devices, limit controls, correcting elements and all other safety devices must be commissioned, and may only be replaced by, the manufacturer or the authorised agent. Failure to comply can lead to serious injury or death ‘and can cause considerable damage to the plant. Qualified personnel Qualified personnel according to this operating manual are persons who are familiar with the installation, mounting, setting and commissioning of the product and which have the necessary ‘qualifications such as: ~ Training, instruction or authorisation to switch electrical circuits and electrical devices on and off, to earth them and to mark them in accordance with the safety standards. ~ Training, instruction or authorisation to carry out installation, alteration and maintenance work on gas installations in buildings and on site. Operating instructions ‘The instalation and operating instructions included with each bumer must be displayed clearly in the plant-room. The address of the nearest service centre must be entered on the reverse of the instructions, Instruction of personnel Problems are often caused by incorrect burner operation The operating staff should be thoroughiy instructed with regard to the operation of the burner. With frequently ‘occurring burner faults, the nearest service centre must be notified. Installation The installation of oil fired equipment must be carried out to extensive guidelines and regulations. Itis the duty of the inetaller to familiarise himself with all regulations. Installation, commissioning and maintenance must be carried out with care. Fue! os to DIN 51 603 EL should be used. Wiring diagram ‘A.wiring and connection diagram must be included with every bumer delivered. Maintenance I, during maintenance, control sea! jaints have to be ‘opened, these have to be thoroughly cleaned and new seals fitted when re-assembling. Maintenance and service ‘The burners should be inspected at least once a year by the supplier or their appointed agent. The combustion quality should be checked after each service or repair.Installation conditions ‘Material, construction and type of protection of the Ibumers and gas valve trains in their standard version are ‘designed for use indoors. Permitted ambient temperature is 15°C to +40°C, Electrical installation ‘When installing the electrical connection cables ensure that these are long enough to allow the burner and boiler ‘door tobe hinged open. ‘Control circuits, which are taken from one of the supply phases, must only be connected with an earthed neutral Conductor. ‘On amains supply which is not earthed the control voltage ‘must be supplied via an isolating transformer. The pole ofthe transformer, which is to be used as the neutral conductor must be earthed. ‘The control circuit phase and neutral conductors must be connected correctly Ensure the correct fuse ratings are not exceeded. Earthing and neutral conductors must conform to local regulations. General information for gas operation ‘When installing a gas combustion system, local regulations and guidelines must be observed. The subcontractor responsible forthe installation or changes of the gas system must inform the gas supplier of the type and extent of the installation planned and the intended work. The subcontractor must ascertain that an adequate gas supply to the installation is ensured. Installation, alteration and maintenance work on gas ‘systems in buildings and on process sites, must only be carried out by installers who have a contract with the gas supplier. Gas characteristics The following information must be obtained from the gas supplier Type of gas, calorific value in kWh/m?, max. CO, content of combustion products, gas supply pressure. Gas line The gas pipework must be subject to a preliminary and main test or the combined loading test and soundness test, eccording to the pressure range intended. The air or purge gas required for the test must be expelled from the pipework. The determination of the supply pipework diameter usually results in a diameter, which is at least one pipe diameter larger than the size of the burner valve train. Gas valve train Observe the sequence and flow direction. The distance between burner and DMV valve should be as small as possible in order to guarantee trouble free start Pipe thread connection Only tested and approved sealing material should be used. Please observe individual user instructions! Soundness test Brush connection points with foam forming agents or similar, non-corroding materials. Gas types The bumer must only be operated with the type of gas stipulated on its name plate. When converting to other types of gas re-commissioning is required. A conversion kit may also be needed. Valve train installation The valve train must be fixed and supported securely. Standard connection is fom the right. Gas meter ‘The siting, size and type of gas meter is the responsibilty of the gas supplier. Only those meters, which have been approved, should be used. Ifno gas meter is fitted, as for instance on liquid petroleum gas installations, the operator has to be made aware that the burner can not be set to its ‘optimum, because basic testing is not possible without a ‘meter installation, Plant room regulations Local regulations regarding the design of plant rooms must be observed and the installation of an emergency ‘switch and a mains gas shut off system should be considered. Attention should also be paid that sufficient ventilation is available in the plant room. Any shortcoming should be noted in the commissioning report The commissioning report must be completed by the service engineer and signed by the plant operator or his authorised agent. The operator shouldbe instructed in the correct operation ofthe burner and control panel. The ‘operating instructions included with each burner must be displayed clearly in the plant room. Thermal / manual shut off system Ifa thermal / manwal shutoff system is required, this should be fitted prior to the burner fuel isolation valve(s) This installation must conform to local regulations. wwnd 2. Burner installation Installation example for standard combustion heed forheat exchanger wih eaton is Bio Blow [eel (SS eae ‘The gop between combustion head and refractory must be filed with flexible insulating material Do not make sold. ‘The drawing shows a refractory for heating appliances without cooled front. The front edge of the combustion head should protrude beyond the refractory by approx. 30 mm. Alternatively the refractory may take a conical form (260°C), Refractory may not be required on boilers with water cooled fronts, depending on the boiler manufacturer's instructions. Size Com, Dimensions in mm Installation example for combustion head with extension. Head extensions dt a1 a2 a3 ads 6 7 HO n® 30/2-A Ga0/2 305 «= 280 280 360285 M2260 868 nore 2 55 605 $0178 Gaor2 365 290 830 400.« 925 M12 008268 B55 SOA _GB0/2 300-350 —990 480390 MIG «360986 ~—«B40 690 60/2A _G6O/2 430 400480470435 MIB 10S 436 = 580730 70'"A — @7o/2 430« «480 820s B50: 8OD—ss MIG 450.—S«475.— 580730 7012-6 © (extended by 150) (extended by 150) Before hinging open the burns Transport Remove gas butterly valve crank-arm. Remove airhousing cover and remove internal reguating rod. '40 and 50 open housing cover and remove ing rod. Due to the oil hose’s connections to the nozale, RGL and RGMS buers are supplied hinged ‘open tothe right as standard Electrical wiring Each bureris supplied with a wring diagram and bumer connection diagram as standard. Interiock switch ‘The interlock switch is arranged in such a manner that the Circuit is closed in the burner closed position. In the burner ‘open position, the circuit is interrupted by the release of the tipping pin in the interlock switch, To simply installation of the bumer to the appliance, burners sizes 50 to 70 are fitted with iting rings. Burner type ht (with, valve train) Giso 135 kg RGL30 145 kg RGMS30 175 kg GLsoT 145 kg RGL40 160 kg RGMS40 200 kg RGL5O 240 kg RGMS50 280kg RGL60 330 kg RGMS6O 305 kg RGL70 435 kg RGMS70 410 kg3. Burner fuel system for gas Valve trains In accordance with EN 676 all burners must be fitted with two Class A solenoid valves. Weishaupt dual fuel burners are fitted with double solenoid valves as standard (on DN 150 with two single solenoid valves). ‘Weishaupt also recommend the use of a valve proving system. In accordance with EN 676 the use of a valve proving system is required for thermal inputs over 41,200 kW. This and ther valve train components, such as ‘gas fter and gas governor can be found in the Weishaupt accessories list. I] Legend 12 3 ms 85 6 1 BallValve < 2 Gasfiter 3 Gas governor 4 Lowgas pressure switch 4a__ High gas pressure switch, (to TRO/IM3O) 5 Double solenoid vaive (DMV) 5a__ Single solenoid valves 5b Ignition gas solenoid 6 Gas buttery valve 7 Pressure gauge with push button valve 8 Valve proving VPS 9 Burner 10 Valve leakage indicator 11 Vent valve 12 Gas pressure switch for valve proving W-0K 3/01 1 2 44 12 With2 solenoid valves and WDK SOT4. Description of valve trains 4.1 Solenoid valve train installation Function Technical data DMV-D/11 Mas, operating pressure 500 mbar ‘Two single solenoid valves, normally closed, fast opening, Valtage/trequency —~(AC) 230 V- 18%... fast closing, manual throughput adjustment of gas is ton40V's 10% So/éo ve possible by adjusting main flow at valve 1 (V1). a Installation Horizontal or vertical Pressure test point DMV-D 607/11 - 520/11 Legend 2 1 Prossureintovt 1 3. 2 Pressure between V1 and V2 Inlet connection flange 1 2 3 Pressure after V2 4 5 Outlet connection flange DMV-D 5040/11 -5125/11 Legend 41, 2 Pressure into V1 5 3) Pressure between V1 and V2 4 Ignition gas outlet 5 Pressure after V2 6 Inlet flange 7 Outlet flange Electrical connection MVD 607/5 1/4" both sides N34" with socket pg v0 61605 — . ro] Rar DNIEO With 1/4" both sides flange conection DIN2693 PNISChanging solenoid valve DMV Gas throughput adjustment 1. Switch off and isolate installation 2. Remove connection plug 3, Remove paint seal from screw A 4. Remove counter sunk screw A 5. Remove cheese head screw B 6. Remove cap (C) and metal plate (D) 7. Change solenoid, checking new unit is correct typelvoltage 8. Refit metal plate (D) and cap (C) 9. Refit screws A and B 10. Carry out a gas tightness test at test point 2 and 3: Pon = 100 - 150 mbar 11, Carry out function test 12. Switch on supplies and test burner DMV 507-5125, DMV 507-520/11 Throughput adjustment on V1 via covered adjusting screw. One turn =0.5 mmof stroke adjustment, anti-clockwise to increase flow , and vice-versa. DMV 5040-5125 Throughput adjustment on V1 via covered adjusting screw. One turn =1 mmof stroke adjustment, anti- clockwise to increase flow, and vice-versa. Factory pre-set: maximum stroke Conn of gas pressure switch to DMV Fit gas pressure switch4.2 Pressure regulator type FRS Outlet pressure adjustment —& : Factory - standard spring 5 - 20 mbar 1. Remove cap A 2. Toincrease, tum screw B clockwise. increase of outlet pressure (set value) 3. Toreduce, turn screw B anti-clockwise. ‘= reduction in outlet pressure (set value) 4. Prove the adjustment is correct. 5. Replace cap A Changing the spring = ovom> ‘Type of spring / colour Outlet pressure range mbar orange 5... 20 blue 10... 30 red 26... 55 yellow 30... 70 black 60... 110 pink 100... 150 1. Remove cap A. Tum screw B totally anti-clockwise. 2. Remove spring retainer C, and remove the spring D. 8. Fit new spring D. 4, Resft spring retainer C, and by turning screw B set the required outlet pressure. 5 Prove adjustment is correct and re-ft cap A, and new range label.4.3 Valve proving system VPS 504 Operation ‘The valve proving system type VPS 504 operates to the ‘The VPS 504 carries out a self-test during the switching pressure build-up principle. The valve proving programmer sequence. Ifa fault occurs burner ignition phase is is activated at every burner start. inhibited and the fault lamp lights. Technical data Max. operating pressure 00 mbar Fusing fitted tohousing 76,3 L250 Test volume $401 Switching current operating output max. 1 Pressure increase via lockout output max. 1 motor pump Release time =10...268 Voltage/frequency (AC) 230 V- 15 %. max number of test cycles 20/h 10 240 V + 10% / 50 Hz “Ambient temperature 15°C. 460°C ‘or ~(AC) 110 V/ 50 Hz Installation vertical or horizontal ‘ype of protection/switching duration Series 04 IP54/ 100% Ed Pre-fusing (by others) 1OAFof63AT Pressure reduction 1 Connection P., P, 2 Connection P;, P, 34. Test points‘Sequence of operation ‘Shut down condition: Valve 1 and valve 2 are closed. Pressure build-up: The internal motorised pump increases Sefer | the gas pressure in the test section by approx. 20 mbar Sptno when compared to the pressure pe on the inlet side of valve 1. During the test phase the inbuilt differential pressure switch checks the test section for soundness. an Gree the test preseurehas been reachedine pumps eseatine switched off (end of test phase). The release time (10 to 26 secs) varies on the test volume (max. 4.00 teptee fey I’ the test section is sound, the contact to the bumner ae, control is released after max. 26 secs. The yellow signal Roca lamp is illuminated. Conia Ifthe test section is not sound or if the pressure increase of +20 mbar is not reached during the test phase (max 26secs.), the VPS 504 goes to lockout. The red fauit amp, a oT remains illuminated as long as the appliance controller requests a burner start. ‘An automatic restart follows a short term voltage loss, which resets the VPS from it's fault condition. Installation remove closing plug VPS on DMV screwed VPS on DMV flanged Note: = Remove closing plug prior to installation = Properly tighten cover screw and connecting screw, avoiding over tightening! ~ Protect ange surface. Tighten screws in diagonally opposite sequence. = The unit must not be used as a lever. When work on the VPS 504 is completed, cary out valve proving and function test. Ensure tight sealing when changing parts.Electrical connection VPS 504 series 04 With cable gland PG 13.5 and connection to screw terminals, Potential free relay contacts must only be used for signalling and never for burner control circuit! Release time tF Time required by the VPS 504 to carry out a complete test cycle. The release time of the VPS 504 depends on the test volume and inlet pressure: Vows 1.51 View 21.81 Pe” >20-500mbar pe > 20 mbar f= 108 > 108 Intarchengeebie reat 321250 temax/vessoa = 265 ioe . ie 127 an Test time P, (BiN4162) Pump time of the motor pump. De20 Test volume Vix Volume between V1 on the outlet side and V2 on the inlet side . v, =41. aoe astras. vos 504 = 4 I. 204 ~ Test volume of the multiple settings units ‘pplication range Type Rp/DN Test volume DMV-D(LE) 503/11 Rp3/8 0,091 DMV-D(LE) 507/11 Rp3s/4 0,091 DMV-D(LE) 512/11 Rp 11/4 0,251 DMV-D(LE) 520/11 Rp2 0,251 DMV-D(LE) 5040/11 DN40 0,36! DMV-D(LE) 5050/11 DN50 0361 DMV-D(LE) 5065/11 DN65 0,60! ‘DMV-D(LE) 5080/11 DNEo 1701 DMV-DILE) 5100/11 DNi00 2301 DMV-D(LE) 5128/11 DN125 3751 Installation dimensions $04/S04 sass = yi + ditinlcabe cee 8 Ps ot ee o4 Standard q see ety + PG 135 Ba ; \ \ \ \\—taaemcin Sascint \ is - \, pressure comecion Scone \ Ramee _ Replacement use44 Valve proving system type W-DK 3/01 Construction The valve proving system W-DK 9/01 consists of four main parts: IE Programmer fitted into the control panel of plant Gas pressure switch fited to the test section between the solenoid valves, Vent valve (normally open) fited into the vent fine Mi Loakage-indicator unit ited into the vent ine Function The tightness of the solenoid valves in the gas valve train is checked prior ta each burner start. Operation 1. Test phase: During pre-purge alt solenoid valves are closed. If pressure builds up due to possibly leaking first valve, the pressure increase is detected by the gas pressure switch. 2. Test phase: lf the first solenoid valve is gas-tight, it is opened momentarily, but the vent valve remains closed. Gas pressure is now in the section between the solenoid valves. Itis tested for aloss in pressure in the test section. The test is controlled by the programmer. {Gas valve tain with Weishaupt valve proving system W-DK 3/01 1 Solenoid valve 1 2 Solenoid valve 2 8 Leakage indicator unit faire 3 1 4 2 5 6 5 Gas pressure switch 6 Bumer Test result fa pressure increase (phase 1) or pressure decrease (phase 2)is detected, the burner start is inhibited. Otherwise the solenoid valve seats are gas tight and the burner start continues. Pressure switch setting 1/2 flow pressure Technical data Weishaubtvae proving system Tee wx 901 Mans vltage Frequency Vite 220 1896 /80.0°60 Rang a inaceordance wih be prefeing ofthe Etimer control em. smbont temperature < Pron 60 Progremmer “Pressure switch est Wwibvathout peesure soos 2 secs 2 —Test time wih est pressure Secs 6 Type ot pretection ipo Cretenpton vA sppron 4 Instataton sereauied ts owas ressure switch GWEOAS Settngrarge mbar 25.50 Pressure switch GW/i50.A4 Seting ange bar $0..180 Ventvalve LGV 50715 Nominal diameter & are ieakage indicator (ethout dlcenne) Nominal ebameter R au Propramer Plugin unit g Sub- base g Cably entry 180 ~ 75: Fitting dimension " 5 o5 195. Installation of valve trains 5.1 Safety notice Risk of explosion! K the valve trains are not installed correctly their soundness cannot be ensured To avoid serious accidents, the following safety instructions must be observed during instalation: © Observe the maximum permitted gas pressure in the valve train, Contact your local gas supplier to obtain the ‘connection pressure of the gas supply. ‘The connection pressure must not exceed the maximum pressure shown on the name plate, © Valve trains must be installed securely to avoid vibration during operation. Suitable supports should be used (available as Weishaupt accessories) ‘The supports must be fitted to the specific site requirements when mounting the valve trains. © Vaive trains must be installed tension free. Never compensate for mistakes made during installation by over tightening the flange screws. @ Flange screws should be tightened diagonally opposite. © Ensure flange joints are clean and fitted correctly. ‘© Only gas board approved sealing material should be used. fa connection needs to be undone frequently, flange connections with inlaid gasket should be used. Other installation information: On installations, which are subject to special regulations. for steam boilers, the valve trains can be vented with a test burner. The first solenoid is fitted with a connection point for this test burner. To allow the appliance door to be hinged open, a flange connection point, if possible at door level, should be fitted (Compensator see drawings, chapter 8.2) ‘To achieve better start conditions, the distance between burner and solenoid valves (ignition and mains gas) should be as small as possible. ‘Observe sequence and flow direction of valve train, {fa thermal shut off device TAE is required, this must be fitted in front of the ball valve.5.2 Installation example High pressure supply with DMV flanged Low pressure supply with DMV flanged 18Low pressure supply with single valves (only for nominal diameter DN 150) 1. Solenoid valve for ignition gas 6 Filter 2a Double solenoid valve DMV 7. Pressure gauge with push button valve 2b Single valve 8 Ballvalve 3 Test burner 9 Compensator 4 High gas pressure switch (to TRD/IM3O) 10 Low gas pressure switch w 8a High pressure governor 11 Valve proving system VPS 8b Low pressure governor 12. Pressure switch for valve proving system W-DK 3/01 166. Soundness test of valve trains ‘Soundness test of the gas train must be carried out with the main isolating cock and DMV valves closed. Proceed as follows: 1. Test phase: ball cock up to 1st valve seat (V1) The test assembly is connected to the gas filter and DMV inlet. During pressure testing, the test point 2 between DMV valve seats V1 and V2 has tobe open. 2. Test phase: volume between 1st and 2nd valve seat The test assembly is fitted to the DMV test point 2. ‘Test pressure in the valve train should be between 100 and 150 mbar, Wait § minutes for pressure equalisation. The valve train is not leaking i the pressure drop is no more than 1 mbar after the test period of 5 minutes has elapsed «iv 3. Test phase: Valve train connection parts and gas butterfly valve ‘The third test phase can only be carried out during operation and by using a leak detection solution. Results of the pressure test must be recorded on the ‘service/commissioning report. Attentior After all maintenance and commissioning work on gas supplying components a soundness test must be carried out. 7. Sequence test of operation Wiring connection check (Check that the wiring to all parts, especially the valve train, is carried outin accordance with the wiring diagram supplied with the burner. ‘Sequence test gas operation (without gas) The ball valve must be closed and the selector switch on dual fuel burners set to gas operation. Airis pumped into the valve train by means of the hand pump still connected from the soundness test. The pressure must be at least as high as the subsequent gas operating pressure. ‘The burner is switched on and the following programme should take place: Versions with DMV and valve proving system VPS ~ Burner motor starts following successful valve proving. = The servomotor opens the air damper in approx. 40 (20) seconds. ~ The full oad pre-purge period is 30 seconds. = The servomotor closes the air damper to the ignition position in approx. 35 (17) seconds. ~ The pre-purge time of approx. 4 seconds begins. = Gas solenoid valves are opened. = Pressure in the valve train falls. = Gas pressure switch shuts down the burner. = Gas solenoid valves are closed. 1. Test phase 2. Test phase 1 Rubber hose with T piece 2 Aspirator 8 Ustube or electronic pressure gauge Ifthe gas pressure switch does not shut down after the safety time of 2 seconds has elapsed, then the bumer control locks out. Version with two solenoid valves and valve proving ‘system W-DK 3/01 = Bumer motor starts = The servomotor opens the air damperin approx. 40, (20) seconds. ~ The full load pre-purge period is 30 seconds. = Valve proving is carried outin accordance with the sequence of operation (see chapter 24). ~ The servorotor closes the air damper to the ignition position in approx. 36 (17) seconds. ~ The pre-purge time of approx. 4 seconds begins. — Gas solenoid valves are opened. = Pressure in the valve train falls. = Gas pressure switch shuts down the bumer. = Gas solenoid valves are closed. Ifa fault occurs during the sequence of operation see description of burner control LFL1...and the additional information. ”8. Preparation for first commissioning 8.1 Testing the gas supply pressure Risk of explosion! The mains gas pressure must not exceed the max. permitted pressure ofthe valve trans listed Saaaet |on the burner name plate. The mains gas pres- sure must be checked prior to commissioning. 8.2 Purging the gas supply fine Purging The valve train must be purged prior to first ‘commissioning, ‘Ahose leading into the open is connected to the test point Con the gas solenoid valve to discharge the air After purging, the test pressure gauge is reconnected at the test point on the solenoid valve. fa test burner is installed, this must be used to ensure that, ‘no airis present in the equipment. 9. Commissioning the gas side 9.1 Checks prior to first commissioning 1. Connect pressure gauge to filter. 2. Slowly open the ball valve monitoring the pressure ‘gauge at al times. 8. Close the ball valve immediately ifthe mains gas pressure exceeds the max. permitted pressure of the valve tain. The bumer must not be started. 4. Contact your nearest Weishaupt branch office. Any air or inert gas in the distribution lines must also be expelled from the pipework. This work is usually carried out by the local gas authority. ‘When work on the valve train involves changing components, the valve train must be purged and undergo a valve proving test before the burner is switched on again, The whole installation must be checked prior to the first commissioning. © ‘Has the heat exchanger been installed ready for operation? © Are heat exchanger and system filed sufficiently with heating medium’? @ Are movabie explosion flaps fitted? isthe flue gas damper open? Are the flue gas ways free? ‘Are the air heaters fans operating correctly? @ Is the ventilation to the plant room sufficient? © ‘Has the whole installation been wired correctly? 9.2 Flame monitoring © ‘Have temperature switch, pressure switch and safety limiting systems been set to operating requirements? © Is sufficient load available? @ Has the low water safety interlock been adjusted correctly? © Have all fuel carrying parts been vented (free of ait)? ‘Check rotation of burner motor. Has the valve train leakage test been carried out? @ Is the gas supply pressure correct? {tis possible that other site specific tests will have to be Carried out. Refer to the operating instructions of individual site components. lonisation detector on LFL.. and LGK... Microammeter (range 0..180 uA) UV-detector ORA2 bij LFL Minimum required sensor current in A ‘min, required lonisation — UV-cellORA2 nisation current 6 70. values normally aS er obtained Test for flame sensor lonisation electrode: By separating the plug connections in the vicinity of the terminat strip. ‘UV -cell: By withdrawal from the holder on the burner flange. Note: With the LGK 16... bumer control and UV sensor RA 53/55, itis only possible to measure the sensor current by means of the special sensor current measuring instrument type KF8832, ~~ ww4 9.3 Adjusting gas side On two and three stage burners GL30/40 the gas side is commissioned prior to the oil side. On regulating burners the oil side must be commissioned prior to the gas side. Switch on procedure = Set operating switch to “gas” = Open ball valve = Release gas pressure regulating spring (see chapter 4.2). ~ Set selector switch in control panel to “Stop” = Reset installation. = Switch on burner operating switch. Ignition ‘After the pre-purge time has elapsed, wait for flame formation. Ifignition problems occur check the pre-setting ‘of the gas butterfly valve (nominal approx. 5 - 10°“Open” ‘on the gas butterfly scale), as well as the position of the ignition load switch inthe servomotor (ZM: No. N} and i necessary increase slightly. Check sensor current with mmicroammeter. Intermediate testing (partial load to full oad): ‘After approx. 20 secs. the servomotor runs fro to partial load position. Set gas pragsra to table in chaptr 8.7 (Song preseue into solenoid valve Carry out CO test. GL burners: Make the necessary corrections to the pressure settings. Version ZM: Disengage servomotor, turn gas regulating cam by hand and re-engage servomotor. Carry out CO tests at each ‘cam setting up to full oad setting, RGL bumers: Make the necessary corrections by adjusting the gas curve band. Full load setting: Drive up servomotor electrically towards full load: Version ZM Disengage servomotor, return gas regulating cam to its intermediate position and re-engage servomotor. Set, selector switch in control panel to full load. The requised amount of gas for full load must be set and measured at the gas meter (the gas pressures given in the table chapter 9.7 are only a guide for setting and adjusting). Combustion test: GL bumers: Regulate the amount of gas by adjusting the gas setting pressure. Regulate the combustion values by adjusting the curve band of the air regulating cam and positioning of the regulating sleeve so that best possible values and ood flame stability are achieved with fully opened air damper. RGL bumers: The oil side settings of the air curve band and the mixing head must not be altered. Match gas quantity to the ‘existing conditions by adjusting the gas curve band and ifnecessary by correcting the gas pressure on the gas governor. Butterfly valve pre-setting ‘The gas pressure set for fullload must not be altered in partial load. 16Version ZM ‘As the operating range of the bumeris used at intermediate levels as well as the max. and min. levels, combustion tests are required at each cam setting. ‘Adjust came step by step (selector switch "Stop" disengage servomotor, adjust, re-engage servornotor) GL burners: Regulate combustion values by adjusting the air curve band. RGL bumers: Regulate combustion values by adjusting the air curve band. Ensure the curve bands have an even profile, Partial load setting Set selector switch in the control panel to “Stage 1” or “Partial load”. Select the low fire setting required for partial load with the auxiliary switch (2: No. I, 2M: No. VI) and measure the gas rate at the gas meter. Finalising work ‘Check ignition load setting once burner has been Commissioned and if necessary adjust at auxiliary switch in the servorotor (Z: No. V, ZM: No. IV). The setting is correct if the burner with empty mixing head starts without Start impact. The required tests can be carried out when the burner is stopped at the ignition load point (Z: trip switch in servomotor, ZM: undo the neural conductor to ‘servornotor once ignition load is reached), Regulating sleeve position Bumer Basic setting type Number of Movement mm. dive lever 30/2 1 ~40 401B 3 = 40 40/2A 1 ~85 501-8 t -55 502A 2 ~50 60/28 2 60 TOA 2 -60 7012-8 2 60 * Maximum movement of sleeve with air damper fully open. The regulating sleeves are closed at cam position 3.5 to 4, This corresponds approximately to partial load on ol operation. Inthe ignition load position on gas and cil operation the push rod moves into the spring sleeve. ‘On the burners type GL30 the regulating sleeve is set according to rating, Adjustment during operation is not possible. ‘Attention! If the ball joint on the drive lever is screwed on toa different thread, a lock nut has to be used (see accessories list). 20 Check the measurements of the CO limits when adjusting “partial load to fullload” and “fullload to partial load”. (Check and adjust the function of the safety equipment (ie. pressure switch for gas and air, thermostat, steam pressure switch..) with the installation in operation. Documentation: The folowing setting values must be recorded on the engineer's report and/or test sheet. Onignition load: Gas throughput ‘Sensor current co On liquid petroleum gas: Measure smoke On full and partial load: Gas throughput Gas pressure before ball valve Gas pressure after ball valve Fan pressure Draught /pressure in the combustion chamber ‘Sensor current Regulating sleeve setting Driver lever regulating sleeve / movement setting9.4 Set gas pressure switch Gas pressure switch type GW50A2 95 Set air pressure switch ‘To set a pressure switch for gas, a pressure measuring unit has to be fitted to test point 1 of the DMV and the ‘microammeter for measuring of the ionisation current. ‘When determining the switch point, pay attention that this is not below half the regulated pressure, that the ionisation Current is a minimum of 5 uA and that combustion is CO < 1000 ppm (CO increase due to excess ait). Setting is cared outin te following manner: |. Bumer is operating 2 Gradually lose bl valve so thatthe pressure atthe pressure test unit slowly decreases. 8, Setting pressure has been reached when = CO increases = sensor current is only 5 pA ~ or when half the regulated gas pressure has been reached, 4. Slowly tum the setting cam of the gas pressure switch to the right until the burner carries out a controlled shutdown, ‘8. Control - the bumeris restarted with open ball valve. If the ball valve is closed again, the shut down pressure can be tested. The burner control must not go to lockout High gas pressure switch, (to TRD/IM30) must be setto 1.3% Prax, Pressure switch for air type LGW50A2 ‘The air pressure switch is pre-set. The switch point must be checked and adjusted during commissioning. For this a differential pressure measurement between points 1 and 2s required. Pressure behaviour is ‘monitored throughout the set range of the bumer by the pressure gauge. The lowest differential pressure value i's used for the determination of switch point. The ewitch point is set to > 80% of this value. To do this, the protective cap of the LGW is removed and the calculated value is set atthe setting wheel. Example Reduced differential 20 mbar Switch point air pressure switch -20x0.8= 16 mbar Installation dependant influences, such as flue gas recirculation, heat exchanger, installation or air Supply, on the air pressure switch and the settings may result in adjustments having to be made. 29.6 Combustion analysis Calorific value of various types of gas and max. CO2 Type ct gas Caloric valve CO; max pects Min kWh : ww 7 Gas famiy Group A flewns Gas) 15.12.1764 4.20..4.90 12...18 Group B (Grid Gas) Wortaes — 442°'5.20 1 2, Gas family Group LL (Natural Gas) 2048..9840 7.91...10.11 Group E (Natural Gas) 33.91...42.70 _9.42...11.86 3. Gas family Propane P 99.21 25.90 138 Butane 8 12381 3430 ia To.ensure ecient and problem fee operation of the Fie gas temperature for partial load isthe resut of installation, flue gas measurements must be taken. the control range adjustment. ‘The various maximum CO, contents can be obtained from the local gas board (guide values see table) ‘The instructions of the manufacturer are to be followed closely on hot water boiler installations. Excess ar should not exceed 10 to 20% atfullload —-—_-Normallya patil load of 0 - 65% ofthe nominal load and 30% at partial load. is set (some of the data may be on the boller rating CO,max. Excess air. —— heater installations the partial load is normaty a CO, measured even higher Again, the Instructions of the manu facturer should be closely followed. The CO content must not be more than 0.005 Vol.% The flue gas installation should also be set out to (50 ppm) protect against damage through condensation: {excluding acid proof chimneys). Flue gas temperature for full load (nominal load) is the result of burner setting at nominal loading. - n9.7 Setting pressure and minimum connection pressure The results of the following tables have been calculated con flame tubes under idealised conditions. The values are therefore guidelines for basic settings. Small variations. ‘may occur when commissioning, depending on individual installations. Size 30/2.and 40/1 Se 40/204 50/1 Rare orem nog ee ipo omnes ae, Cepeenn ete aninug [ee remonnee Gemma SR sing [eceooone ane Sep lao rec ct Wrenencsooneeh "|e caeec ya) omic! lamer of ave ting Jeo" so" 65 "80. 100 125 150 Noma dam of ia uterty ae Nora an of ga ater ae 4050.80.86" 80"80 80 _|4ors0 50 60 50.60.50 Nominl diameter of vale tralne 0" 50" 6580. 100 "25 150, Nema a of ae tute ae |Nomnal cam fos eter vale 4076016865 e508 65 [eon g0 6005 65.6560 Nominal lamer of vive trans laov sor ¢5 "90. 100 125 150 aural Ga =2796 Min 028 WN. = ODE 1300 se ay 17 210 en 8 7 6 6 Moo me a2 23 1 13 11 10 [a2 tour 9 8 8 Yeo 02 & 29 20 te 14 te | 42 33 19 14 12 11 10 Yeo 20 G0 ae 24 9 17 16 25 18 6 4 ts goo 168 aa 44 a9 23 21 19 | 65 52 31 22 19 17 Te 2mo 190 100 $9 a8 27 a4 a2 | 7 63 37 26 22 20 20 Boo ae 118 62 42 a2 ae ae | O46 75 44 31 26 24 8 2580255133 70 46 96 21 go [106 G6 49 35 30 27 26 Neal Gap. 19726 Wine .9SKYH 60506, 1600" 99 81 25 15-1210 ‘Se Gris 10 8 7 6 43 a9 20 13:10 9 woo 125 65 31 19 14 12 2400 220113 G4 32 23 20, 6 35 23 18 te is 300 20182 72 42 30 25 23 [110 4 47 80 24 21 20, 200 “= 190 43 55 50 33 29 |'' 199 2 40 St 27 26 geo "tity oe ae 40 38 | > = 78 80 99 4 a2 ooo > hag a so 4a ae | = = 97 2 48 a2 40 Naural Gag, = 9179. (6 RD YR. = 088t Nault =i 7eMUMe OE9RWNIMY.G=OR8T oo aa es aa 4a 79 eo ta ya a3 at Ts Yoo vie S931 20 18 14 19 113 foe Heo Se wo ae ae is ue | oe ey tae feoo lus Je fe 25 20 17 16 1213 goo aansta So 31 az te te | ar os at at te ia sa Yeo ia 56 «@ 2 28 22 20 1 it Moo “tier 7 a4 at a6 a0 [rae So ao at ae at oo goo mest? @2 a9 20 a8 24 nn 300 3 2 So [Sian or ao ae ae ae zoo aint f2 ae 95 31 28 ie io we 83 43 20 00 $8 a3 a7 os 200 HOS Se 8 Sem ot oe 9 a8 Mo 69 $3 46 3 a0 fe eo Stowe sate os os Gs | > Chae os 0s oF oe xi pevciou Gat 8 gt ey Gs 87 520M ROHAN, 0 " 10 gets by pe |e tee e vie0 fi joo ft So tet ooo [at wo = jee Hy woo 86 ae io 1210 oo | ar at te 3 {200 8 sco bs G1 ae 7 te x2 11 [a0 at a? : 200 i z0co igo 60 a5 20 18 te ts | so 42 23 2 Stoo ee Bs 45 a9 20 20 16 | 60 s6 3t i 2m 0 49 27 22 25s0_1%46 64 3820 ‘3600 200110 8 a6 a7 24 22 & 5) 30 27 22 20 18 #00256 138 60 43 30 20 27_|100 on eM Size 50/2 Faing Low posure oe igh pressure spy tw (Gee presume ino sores val Nomin! lamer of eve tains fto"'80" 68 "90, 100-125 150 4o"80" 65-80. 100 125 150, Nenad lant ae Nona dao us bute valve Soo 0-86" 0080-80 | 8060 30 "00 feet car 726 Mira 0S LY. 0 6 wes" 36 94 9933 70 6 28 27 6 foo Me ya0 72 82 42 a9 a6 [102 99 a8 34 39 ooo = Ya9 100 86. 62 48 49 [199 126 a at a aso = a6 oF ez sx 50 |e te 7 foo > 188 98 73 63 88 88 ‘300 399.156 05 71 68 & 000 S135 97 80 73 2 3800 rise 110 $96 2 Natral Gas UL = 31,79 in? (8.83 Kin, a=0681 fom 234196 76 Se 45041 90 Tio! 92 50 45 40 a7 2500, F107 72 $8 2 49 | 193 7 59 SI 47 3800 182114 87 78 70 ee 000 138 102.87 60 foo >> Thee 148 x00 8 Sooo 98 136.113 196 BP Sw = 9870 Wir (25,0 Kw, bo 110 67 40 99 26 95 23 | 49 46 at 2 23 22 2 ooo 152 $0 s2 38 42 20 de | 6s G1 a9 31 a7 26 36 3500 201 116 65 45 28 2 39 | 85 70 48 7 33 31 90 4000 251147 79 Se a4 90 37 [107 G7 50 49 38 35 4 Soo > eqta 2 Se so a7 | - = oF or * The data given for DN40 is also valid for 11/2" and those for DN50 for 2” valve trains. The combustion chamber pressure in mbar must be added to the minimum gas pressure determined. Selection of nominal diameter for valve trains for towns gas, ‘see separate worksheet, print No. 900. With low pressure supplies with double solencid valves (DMV) 928 pressure governors with safety diaphragm are used. Maximum permissible connection pressure into isolating valve is 300 mbar on low pressure installations. With high pressure supplies high pressure gas governors to DIN 3380 are selected from the technical brochure “Pressure regulating and safety assemblies for Weishaupt gas and dual fuel burners” High pressure gas governors for connection pressure up to.4 bar are detailed in his brochure. Max. supply pressure see burner name plate. The data given for calorific value Hi relate to 0°C and. 1013.25 mbar. 23Size 60/2 Fatng Low preswe spp EW" Ga preceuenmburinto oatog ve pews = 300 a) ameter of vave tein te 68 00 100 100 10 798 Mim? (10,25 Wh, Natural Gas U H= 9179 Mn? (8 RN, = Sniran Soecerla se: Someries cerns S000 03 103 62.47 sooo 138 ot 88 Size 70/1 and 70/2 Tahaan (se prosaunn mb ‘tor hat abe agreed Nomine| iomete cr vave sing forse 69"'80. 100 125 150 Nominal am of as tay wae Gees 60" 86 100 100 100 0506 vse 40 ve 22 54 49 5 ae S yer ror 6s Bt be a2 iMTia 8 50 es 59 146 80 87 mo 171 103.7% a 190 116 04, eas TON o7 6s st 4a 41 oe 83 Tier 95 60 58 56 662 = 2147 01 00 73 (= 99,20 Min? (2589 Win? d= 1585 eo 36 2291 36 24 23 32 30 86 51 36 30 20 77 36 ss ase sce 61 42 35 32 30 ae a |uaiar 72 40 39 35 34 4S i [tea 150 63 55 44 39 oF FaingLowpreseure snp RW" gar posers nmbarat iain mb Nomine! diameter of vale trains 50"6s 80,100 126 180, Nomina am ot gas bey abe Wich rosa snp (gas presure nme vor het ue magroctentd Nominal lamer vv eins 20"'50" 6580. 100 125 150 Nominal am of gas tery abe Fetal Gas, H=9728 Mii (10.25 Ne, =0,608, e454 8 2 lies12 gr 6s 8: 73.120 14 e000 === 184112 94 00 183 130 108 9000 180192 13800 2189 180, otro Gas UH 3379 ile? (983 KI, d=O6H oo ~~ 128 92 78 Lau reoieun Gn 78 S000 = 138 80 87 yoo00 = 177 112, 30800 192 120, 24 DOIN Ma or 3 eo 122 120 2 82 145 108 95 72 128 109, DIT IMB iS eet a) 25, BO KWH = 1.856, 40126" 70" 46 3799 92 190172 8 80 47 41 39 err 120 24 86 40 48 TIM 69 68 se 92 Bs ad * The data given for DN40 is also vai for DNSO for 2° valve trains. for 11/2" and those ‘The combustion chamber pressure in mbar must be added to the minimum gas pressure determined, Selection of nominal diameter for valve trains for towns gas ‘see separate worksheet, print No. 900, ‘With low pressure supplies with double solenoid valves {OMV) gas pressure to EN 88 with safety diaphragm are used. Maximum permissible connection pressure into isolating valve is 300 mbar on low pressure installations. With high pressure supplies high pressure gas governors to DIN 3380 are selected from the technical brochure “Pressure regulating and safety assemblies for Weishaupt gas and dual fuel bumers” High pressure regulators for connection pressure up to 4 bar are detailed in this brochure. Max. supply pressure see burner name plate. ‘The data given for calorific value Hi relate to.0°C and 1013.25 mbar.