infoInformation on burner technology

The Weishaupt burner range

Committedto quality

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The latest Weishaupt monarch®burners combine sophisticated, cutting-edge technology with functional design

For decades, burners that proudlycarry the Weishaupt name have beensynonymous with the extremely safe,economical, and reliable combustionof gaseous and liquid fuels.

The broad spectrum of outputs offeredby Weishaupt burners, beginning at justa few kilowatts and extending up into themulti-megawatt range, means that theysee use in a wide range of applications.

Weishaupt continually establishes newbenchmarks, facilitated by the ever-constant efforts of its own Research andDevelopment Centre. Digital combustionmanagement and the extemely lowemissions of multiflam® burners are justtwo of many examples of Weishaupt’s innovative power and the high productquality it engenders.

All Weishaupt burners are manufacturedat the company’s main plant in Schwendiin southwestern Germany. Not only doesthis extremely modern production facilityserve as a beacon of safety, precision,and cleanliness, it also allows for a rapid

response when assembling medium andlarge-sized burners, which are almost always individually configured. The highproportion of in-house production,among other things, allows Weishaupt tomeet its own demands for high levels ofquality and to ensure purpose-built itemscan be produced promptly.

Of course, Weishaupt’s range also coversthe whole gamut of modern control technology, including fully comprehensivesolutions for complex building automationprojects; future-oriented, cost-effective,and flexible.

For more than 25 years Weishaupt hasalso manufactured complete heatingsystems. Encompassing not only well-proven condensing boiler technology, thesystems can also efficiently incorporaterenewable energy sources. Solar energyfor DHW heating and central heatingsupport is represented in the Weishauptrange, as is geothermal energy, andground-source, water-source, and air-source heat pumps.

Weishaupt burners:Decades of reliability

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The above overview shows the ratingranges of Weishaupt’s burner series.

Each of these various burner series hasthen in turn several versions for use withdifferent types of application, such as,for example, downward-firing or marine

executions, or burner versions for usewith process heat plant.

Individual special executions are alwaysavailable. Yet at the same time, due tomany innovations and improvements, theactual number of burner models has

been reduced. The benefits this bringswhen designing and outfitting systemscannot be overestimated.

At a glance: The Weishaupt burner range

WSeries

WM Series

WKmono

WK series

Size 10:up to 1.25 MW

Size 40:up to 3 MW

Size 20:up to 2.6 MW

1 MW 2 MW 3 MW 4 MW

purflam®: up to 40 kW

Size 5: up to 50 kW

Sizes 10–40: up to 570 kW

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Size 70:up to 13 MW

Size 50:up to 6 MW

Size 30:up to 6.2 MW

Size 80:up to 32 MW

Size 80:up to 17 MW

5 MW 6 MW 7 MW 12 MW 17 MW 32 MW

Size 50:up to 11MW

Burner overview

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W-series burners:Proven millions of times over

All W-series burner components are neatly and compactly arranged. Components for regulating the fuel/air compoundare clearly laid out and readily accessible

The electronic ignition unit is safer and uses less power

Digital combustion management for ease of use and reliability

The burner is particularly quiet inoperation thanks to its sound-attenuated air inlet

Use of a common platform simplifies theprovision and storage of spare parts

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Burner range | Small burners up to 570 kW

The success of Weishaupt’s W-seriescompact burners is the result of a relentless focus on quality and thecustomer.

The millions of W-series burners thathave already been installed are a reliable,safe, and economical source of heat fordomestic and commercial heating andhot-water systems the world over, as wellas for countless industrial applications.

The burners, which are rated for outputsof up to 570 kW, are not only extremelycompact, they are also equipped with thelatest Weishaupt combustion technology.Digital combustion management is standard across the range, offering thehighest degree of operational reliabilityand efficiency, thanks to the micro-processor-based monitoring and controlof all burner functions.

The integration of digital technology intothe burners also opens up the possibilityof communiicating electronically with building management systems usingModbus or Profibus protocols. Remote

monitoring and diagnosis capabilities aresignificant features of modern systems.

The versatility of the W-series burners,along with their well-thought-out designand their reliability, has helped to makethem an outstanding success.

The Weishaupt purflam® oil burner is oneexample of the process of continuous development undergone by the W-seriesover the course of the past several decades. It has a special mixing assemblywhich produces a blue flame, similar to agas burner, that results in soot-free combustion with minimal emissions.

This and other developmental advanceshave all been based on one goal: theachievement of ever-more economicalreliable heat generation.

The W-series burners have outputs ranging from 12 kW up to 570 kW

W-series burners operate fully auto-matically. The digital combustionmanager follows the preprogrammedsequence of operations preciselyand controls the fuel/air compound.

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WM-series monarch® burners:A distinct design and ultimate functionality

All sizes of the latest generation of monarch® burners combine cutting-edge technology with functional form

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WM-GL30 monarch® dual-fuel burner, version ZM-R (sliding-two-stage/modulating)

WM 30 monarch® burner with integral W-FM 54 combustion manager andKS20 capacity controller

Monarch. No other brand name hasserved Weishaupt for longer or withmore distinction. It has always stoodfor low emissions, robust technology,and reliable operation.

The current range of Weishaupt monarch® burners embodies these virtueswithin an outstanding design that utilisesthe latest technology. The gas, oil, anddual-fuel burners are used to fire hot-water, steam, and heavy-duty boilers, aswell as air heaters, and they do so notonly reliably but also extremely quietly.Weishaupt used its own aerodynamicstesting facility – unique in the industry –to develop a completely new air inlet geometry that facilitates the burners’extraordinarily quiet and efficient opera-tion.

Weishaupt digital combustion managersare included as standard with the latestmonarch® burners, guaranteeing bothlow emissions and the extremely preciseand continually reproducible dosing offuel and combustion air. Furthermore, digital control of the burners opens upnumerous opportunities for automationand control through integration with building management networks and bussystems.

The burners can also be equipped withvariable speed drive and O2 trim to increase efficiency even further – flexibilitythat pays for itself. Weishaupt’s WM-seriesmonarch® burners offer a seamlessrange of rated outputs up to 11 MW.

This latest generation of burners is particularly notable for its efficiency, itslow emissions, and its reliable operation;together, as always, with Weishaupt’sclosely knit, global service network.

Sound-attenuated air regulator for particularly quiet operation

Burner housing can be hinged opento the left or right-hand side

Flame monitoring

Frequency convertor(optional)

Air pressureswitch

Burner range | Medium-sized burners up to 11000 kW

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Weishaupt WKmono 80:The next-generation monobloc burner

The WKmono 80, the next generation of monobloc burner, packs a high rating into a compact design

flexibility means the burner is suitable forthe widest range of applications.

The combustion managers are, in a nut-shell, “digital reliability”. Their adaptabilityand versatility leave nothing to be desired.VSD, O2 trim and communication withsuperordinate control systems arecommonplace features for equipment ofthis size.

Since no one fuel is the same as thenext, different mixing assemblies havebeen specially developed for use withparticular fuels. Reliable combustion witha wide range of gases and oils is therebyguaranteed.

This next generation of monobloc burnershares in Weishaupt’s guiding principlesof cost-effectiveness, efficiency, and reliability.

The WKmono 80 is a combination ofmonobloc and duobloc burner. It retains the compact and service-friendly design and uses the existingmodular construction system.

The burner, whose controls can be inbuiltor mounted in a separate control panel,uses pump stations and other systemcomponents from the WK burner range.This utmost degree of efficiency and

Mixing assembly can bewithdrawn through the

burner housing

Sound-attenuated air inlet

Aerodynamic airway

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The WKmono 80 provides a top-rate performance all the way up to 17 MW

Burner range | Monobloc burners up to 17000 kW

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WK-series industrial burners: Modular powerhouses

In classical duoblock form the WK 80 can achieve an output of 32 MW

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WK-series burners can be adapted to suit a wide range of even the most arduous of applications

temperature during operation with pre-heated combustion air. The insulationalso provides effective noise reduction.

The flexibility of the WK-series burners,coupled with their other technologicaladvantages such as digital combustionmanagement, VSD, O2 trim, and ultra-low-NOx multiflam® technology, placesthem firmly in the vanguard of industrialburners.

The test flame tube which Weishauptuses to develop its industrial burners isone of a kind. The facility allows for the

extensive testing of burners beyond the20 MW boundary, and for their advanceadaptation to specific applications.

It does not matter which fuel is to befired. Weishaupt WK-series burners areable to fire a wide variety of gases andoils reliably, provided an appropriate version of the burner is used.

The WK range contains Weishaupt’slargest and most powerful burners.The modular design of the burners,coupled with their enormous 32 MWcapacity range, makes them ideallysuited to industrial applications.

The combustion air fan, pump station,and preheater station are all selected independently of the burner. This conceptoffers a high degree of flexibility for matching to the most diverse applications.

The burner housing is fitted with insulationwhich significantly reduces its surface

Modular construction for maximumflexibility, with separate combustionair fan, control panel, pump station,and preheater station

Insulated housing for a low surface temperature

Separate controls assemblyfor greater reliability

Burner range | Duobloc burners up to 32000 kW

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Weishaupt’s WM-series burners are digital, versatile, and economical, andwith a capacity range of 55–11 000 kWthey are the optimal choice for a broadband of applications. Furthermore,thanks to a programme of continual development, the range of suitable applications is growing all the time.

Weishaupt has many decades of experience in the firing of high-viscosityfuels. The aim of its WM 20 heavy-oilproject was to mount tried-and-testedHFO components on to the burner in ascompact a form as possible, and to controland regulate them using modern, digitaltechnology.

Additional innovations, such as thermallyinsulated oil lines, reduce cooling of thefuel and improve enery efficiency, whileat the same time guarding the operatoragainst accidental contact.

One burner range for all applications:Special-fuel monarch® burners

WM 20 monarch® burner in heavy-oil execution

Special executions | MFO/HFO burners

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Assured availability is an important consideration in the use of renewablefuels. With Weishaupt dual-gas burners,should the main gas type be unavailableat any time, the burner can be switchedover to the standby fuel quickly and easily.Additional system components, such asflashback arresters, ensure the highestlevels of safety when using biofuels.

Dual-gas monarch® burners

Special execution for the combustion of two different gas types

Of course, many other combinations fordifferent types of gas are available. Mixing assemblies that have been specially matched to the fuel being usedensure that combustion is clean and efficient.

Special executions | Dual-gas burners

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Special burner for the simultaneous combustion of two gas types

Simultaneous combustion:More than just one fuel

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The special swirlflame mixing assembly forms a short, stable flame with low emissions

swirlflame:Weishaupt WK 80 up to 32 MW

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Weishaupt WK-series duoblock burners are valued the world over fortheir adaptability and reliability.

Their modular construction allows thisrange of burners to be precisely matchedto the specific requirements of any largeplant.

Weishaupt has now extended the top ofthe capacity range of these burners outto 32 MW. This top rating is achievedusing Weishaupt’s swirlflame technology;a special mixing assembly that induces asignificant rotation in the fuel/air mixture.This produces a very compact and stableflame with very good combustion results.

Another focus during the developmentstages of this mixing assembly was a reduction of pressure losses in gas-sidecomponents. The solution designed nowmakes it possible to have gas supplypressures below 500 mbar at the maximum firing rate.

A special application like this is needed,when directives or regulations precludethe use of high-pressure gas supplieswithin buildings.

Detailed view of the mixing assembly

Combustion technology | swirlflame

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The multiflam® principle developedand patented by Weishaupt is an innovative way of reducing NOxemissions from combustion plant toa minimal level.

At the heart of Weishaupt’s multiflam®technology lies a special mixing assemblydesign. Fuel is distributed among severalnozzles and combusted in a primary anda secondary flame. Temperature in theflame’s core is considerably reduced, resulting in an effective reduction of nitrogen oxides.

The wide range of ratings across whichmultiflam® burners are now available isequally outstanding. All the way from theWM 10 monarch® burner right up to theWK 80 industrial burner, there is now amultiflam® burner for outputs rangingfrom 120 up to 23 000 kW.

WM-series monarch® burners are also available in multiflam® execution

Reducing emissions: The multiflam® principle

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20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

Guaranteed emission levels for 3LN-version WM 30 and WK-series burners onthrough-pass boilers, subject to Weishaupt’s published constraints

NOx[mg/m3n]

Propane Nat. gasLight oil Propane Nat. gasLight oil

Mediumtemperature ≤ 130 °C

Mediumtemperature 130–200 °C

The multiflam® mixing assembly of a WK-series burner

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Combustion technology | multiflam®

Primary oil nozzle

Secondary gas nozzles

Primary gas nozzles

Secondary oil nozzles

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Reducing emissions: Flue gas recirculation – the individual solution

Flue gas recirculation (FGR) is notnew territory for Weishaupt. Thistechnology was commonplace in the1990s for reducing NOx.

FGR was combined with multiflam®technology as emission limits were mademore stringent.

Under certain predefined conditions, theworld’s toughest NOx limits can be out-performed when FGR is used by burnersfiring gaseous fuels.

What is new in Weishaupt’s FGR systemis the perfected control of the flue gasdosing. This is effected by the FGR/COversion of the W-FM 200 combustionmanager, which makes operation of thecomplex controls very simple.

Similarly new is the integration of thetemperature-dependent flue gas dosinginto the compound regulation of fuel andair. This direct connection ensures thehighest degree of safety and operationalavailability.

Schematic representation of a WK-series burner equipped with flue gas recirculation

Combustion technology | Flue gas recirculation

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Digital combustion management: VSD, O2 trim, and CO control

0 10 20 30 40 50 60 70 80 10090

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3

0

15

6

12

9

Reduced electrical consumption

Burner capacity [%]

Mot

or r

atin

g [k

W]

without VSD

with VSDapprox. 9.4 kW

98

96

94

92

90

88

86110 130 150 170 190 210

0

2

5

O2 content [%]

Improved combustion efficiency

Flue gas temp. / Combustion air temp. [°C]

Com

bust

ion

effic

ienc

y [%

]

Example: WM-G30/3-A monarch® gas burner Influence of O2 content on flue gas temperature andcombustion eficiency

WM-GL30 dual-fuel burner with frequency convertor and O2 and CO probes

Variable speed drive (VSD), O2 trim,and CO control are not just buzz-words. They are technologies thatmake plant safer, more efficient, andmore environmentally friendly.

The availability of well-proven technologyto combat increasing energy pricesmeans that it is always beneficial tochange over to the latest equipment.With amortisation periods of just a fewyears, operating costs will be reduced ona continuing basis thereafter. And that isnot all. Continuous monitoring and control to ensure combustion is CO freemeans increased operational safety.

Two independent measurement systemsfeed into the combustion manager’scompound regulation system, allowingcontinual real-time adjustments to bemade without affecting operational availability or safety.

Digital technology | Combustion management

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Flexible communications: Compatible with building management systems

Combustion manager

Possible BMS connections

Communicationvia the internet

The digital combustion manager isthe basis of communications withother, superordinate systems. This isgenerally achieved using the eBus orModbus protocols.

All the usual burner and boiler functionscan be monitored and controlled througha direct connection with a building management system.

A graphical HMI is available as an optionto provide a user-friendly overview of theboiler. The touchscreen display allowsnumerous functions to be adjusted andmonitored, such as system parametersand setpoints of individual and multi-boiler plant and ancilliary equipment. Thecontrols specialists, Neuberger, who area part of the Weishaupt Group, are ableto design and implement complex control solutions.

Further optional components enableconnections to be made to systemsusing Profibus-DP or LON.

A recent addition to Weishaupt’s portfoliois the W-FM COM communications module. It transmits data securely overthe internet so that it can be called upand displayed in an internet browser window, facilitating accurate serviceplanning for example. Even away fromthe internet you can be kept up to datewith the operation of the burner: In theevent of a safety shutdown, an SMS textmessage is sent automatically.

Remote monitoring made easyvia tablet or laptop

Digital technology | Building management

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Control mutiple boilers efficiently:The Weishaupt MBC System

Control and visualisation via a touchscreen display

Different boiler and burner types work together even more efficiently with theMBC system

Unterschiedliche Kessel- und Brennertypen arbeiten mit dem System MKR noch effizienter zusammen.

Many multi-boiler systems could beoperated more efficiently, especiallyat partial load, if the boiler duty couldbe adjusted to suit heat demand.This is where Weishaupt Multi-BoilerControl offers a well-engineered andpractical solution.

Weishaupt MBC facilitates the modern,hydraulically optimised operation ofmulti-boiler plant by measuring and controlling the flow of water from the boilers. Speed-controlled boiler pumpsand modulating burners, together with aninnovative control concept, form an idealsolution for multi-boiler plant.

Flow rate is measured in the consumercircuit and at every heat generator.Speed-controlled boiler pumps deliver abalanced amount of water to each heatgenerator and correct for any deviationsbefore they have a detrimental effect onsystem temperature. In this way, the characteristics of the patented systemprovide outstanding control and ensurethe energetically optimised, functionally reliable operation of systems of any size.

Weishaupt MBC provides measurableadvantages over conventional systems.Control precision and energy consumptionis improved even with condensing boilersor combined heat and power plant.

1 2

Setpoint Normal operation Standby Automatic Common alarm

System overviewSystem overview

System overview

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System overview

Setp

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System overview

N

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n andbySto

andby

Automatic

Common alarm

Common alarm

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1

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2

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Digital technology | Multi-boiler control

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Software from Weishaupt: Convincing resultsPrognoses you can rely on. Clear, reproducible data and facts.

Weishaupt produces software that isclear and easy to use. From system design to efficiency calculators for awide range of applications.

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MBC Efficiency Calculator

Examples of the MBC Efficiency Calculator’s user interface

Many multi-boiler systems havelarge potential energy savings. To unlock this potential, Weishaupt offers the MBC system which controlsmulti-boiler plant more efficiently.

The MBC Efficiency Calculator was developed by Weishaupt to provide reliable information on potential energysavings following the installation of anMBC system.

It allows you to consider the amortisationof the planned investment costs, givingyou a high degree of planning reliability.

Burner selection

System schematics

Amortisation

Software | MBC efficiency calculator

Effizienzrechner MKR

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Useful tools:Burner Efficiency Calculator

The Burner Efficiency Calculator canimpressively demonstrate the pay-back period for Weishupt burnerequipment.

The cost/benefit calculation returns veryaccurate results by referencing relevantburner and plant data, whether the burnerhas staged or modulating operation,VSD, O2 trim, etc. The evaluation of thesavings is based either on default or specific load profiles.

The information is documented in theform of graphics and tables, with the results of the calculations clearly laid outand easy to follow.

The Weishaupt Burner Efficiency Calculator makes potential savings readily apparent

Effizienzrechner Brenner

Software | Burner efficiency calculator

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3D heating system design with detailed, accurate views

The parts list function simplifies the provisioning of burner accessory parts

Product data library for design softwareComprehensive service is part ofWeishaupt’s philosophy. The productdata library provides support with accurately scaled drawings of burnersand acessories.

2D drawings and 3D models in AutoCADformat, a parts list function, and texts inDatanorm format help to increase theprofessionalism of your design work andreduce expenses.

Software | Product data library

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The right control panel:Individually made to your specifications

Every control panel is individually designed and built in the separate control panel production area

BoilersSafety-related requirements in accordancewith EN standards and country-specificregulations greatly affect the controlsneeded.

Weishaupt offers solutions for:• LTHW boilers• MTHW and HTHW boilers• Steam boilers• Boiler sequencing• Optimisation of multi-boiler systems

(Weishaupt MBC system)

MarineThis highly specialised field makes veryparticular demands of the equipment.

Weishaupt offers solutions in accor-dance with all of the usual standards(DNV, GL, LRS, ABS, RS, PRS, BV etc.)for the control of:• Auxillary boiler systems• Inert gas processing• Heating

Thermal process plantThermal process technology calls for numerous controls and regulators in addition to the appropriate burner controls.Typical applications include:• Thermal fluid heaters• Salt heaters• Dryers• Paint ovens• Smelters

There is a suitable control panel forevery Weishaupt burner. A range ofsystematically matched panels isavailable, supplemented by a widevariety of special executions.

The core areas for Weishaupt control panels are:

BurnersBurner and control panel from the samemanufacturer, matched to each other atthe works:• Manufactured to European and inter-

national standards• Digital combustion management with

eBUS and Modbus interfacing (canbe expanded to other bus protocols)

• Safety-oriented PLC control

System extension | Control panels

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Weishaupt systems technology:Perfectly matched components

Gas valve train and accessories

Oil-side accessories

Combustion air fan with/without VSD

Lateral sound absorber (standard) Full encapsulation (optional)

System extension | Components

Administration, burner production, control panel construction and the R&D Centre at Weishaupt’s main plant in Schwendi

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Weishaupt Headquarters Schwendi, southern Germany

Burners rated up to 32 MW are tested on the world’s largest test firing chamber in the R&D Centre

Burner assembly at the main plant in SchwendiPractical training area in Schwendi

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Max Weis haupt GmbH88475 Schwen diTe l +49 7353 830Fax +49 7353 83358www.weis haupt.de

Print. No. 83216202, November 2015Printed in Germany. All rights reserved.