NOx emissions <15 ppm4LN version gas burners (with Flue Gas Recirculation)

infoInformation on Ultra Low NOx gas burners

NOx emissions below 15 ppm:4LN-version Weishaupt monarch® burners

10

20

0

70

80

30

60

40

50

0 25 50 10075

Burner rating [%]

NO

x[p

pm]

The values are based on burner versions on three-pass combustion chambers with medium tem-peratures ≤ 230F (110 °C).

NOx emissions achievable when firing natural gas

For many decades, the Weishauptmonarch® brand has been known fortheir low emissions, robustness andreliable operation.

The 4LN-version of the current WM 20to WM 50 range of Weishaupt monarch®

burners can comply with the most strin-gent environmental standards in forceworldwide. A 4LN-version burner isequipped with a flue gas recirculationsystem (FGR) whose control componentsintegrated with the burner.

Specially designed mixing head assem-bly and digital combustion managementensure that the key characteristics ofWeishaupt burners – reliable ignition, ahigh degree of flame stability and safeoperation – remain very much to thefore.

Version:multiflam® 3LN

Version:1LN

Version:NR

Version:4LN

Air inlet housing with factory-preassembled flue gas recirculation components

Flue gas temperature sensor

FGR butterfly valvewith actuator

Flue gas connection

Burner versions

Version FuelsGas Oil Dual-fuel

ZM-NR ● ● ●

ZM-LN ● – –

ZM-3LN ● ● ●

ZM-4LN ● – –

Version Flue gas recirculation (FGR)Gas Oil

ZM-NR –

ZM-LN –

ZM-3LN –

ZM-4LN ● –

● Standard Optional – Not available

General arrangement of a flue gas recirculation system with a WM-series burner

Capacity graph showing maximum burner capacity at a recirculation rate of 0 % – refer to page 4 for examples of capacity reductions with x% recirculation

FGR butterfly valve and actuator

FGR temperature sensor

Shutoff valve(recommended)

Drain

InsulationFGR pipe

Break point for blanking plate

-2

0

3

5

8

0 2,500 5,000 7,500 10,000 17,500 20,000 30,00015,000 22,500

12

25,00012,500 27,500

-1

1

2

4

6

7

9

10

11

Burner model CapacityWM-G20/2-A ZM-4LN 683–5,120 MBHWM-G20/3-A ZM-4LN 1,195–6,820 MBH

Burner model CapacityWM-G30/1-A ZM-4LN 1,365–12,970 MBHWM-G30/2-A ZM-4LN 1,700–17,000 MBHWM-G30/3-A ZM-4LN 1,700–17,000 MBH

Burner type Capacity WM-G50/1-A ZM-4LN 3,410–25,600 MBH

Com

bust

ion

cham

ber r

esis

tanc

e (“

W.C

.)

Burner capacity [MBH]

Capacity reduction with flue gas recirculation

Stated ratings are based on an airtemperature of 68 F (20 °C) and an installation at sea level. For installations at higher altitudes, a reduction in capacity of 1 % per 328ft (100 m) above sea level should betaken into account.

Why does burner capacity reduce?Equipping a burner with flue gas recirculation reduces its capacity. The ex-tent of the reduction has to be calculatedindividually for each individual installation.

The burner fan was designed to supplycombustion air. If a burner is equippedwith flue gas recirculation, however,then the fan has to draw both air andflue gas and mix the two together. As aconsequence, while the overall volumesupplied by the fan remains the same,the addition of the flue gas reduces thetotal oxygen concentration. With lessoxygen in the combustion air, the burner’scapacity is reduced.

What does flue gas recirculation do?• Reduce oxygen concentration per

unit volume (cu-ft, m3) of air• Increase the air flow speed• Shorten dwell times for combustion

gases in the hot reaction zone• Lower flame temperatures

• Reduce NOx emissions

-2

-1

0

1

2

3

7

12

0 2,000 4,000 6,000 8,000 14,000 16,00010,000 12,000 18,000

8

20,000

4

5

6

9

10

11

7.6

5.2

Burner type WM-G30/3-A ZM-4LNCaspacity range Natural gas 1,700–17,000 MBH

Propane 1,700–17,000MBH

Com

bust

ion

cham

ber r

esis

tanc

e

Burner capacity [MBH]

[“W.C.] Example:

NOx emission 15 ppmBurner rating 10,580 MBHResistance (furnace pressure) 5.2 “w.c. (13 mbar)Installation altitude 1,640 ft (500 m) aslFuel – natural gas 1,000 BTU/ cu-ftFGR take-off point• Flue gas pressure 0 “w.c.• Flue gas temperature 320 F (160 °C)

Weishaupt’s standard conditions for calculatingthe burner’s capacity reduction:

• Combustion chamber 3-pass• FGR pipe length 2.5 x combustion

chamber length• Number of FGR pipe elbows 5• Flue gas pressure 0”w.c. (0 mbar)• Additional fittings none

1 Capacity reduction with FGR referenced to 15 ppm of NOx

1

Order numbers/ availability

Burner Version Order No.model

WM-G20/2-A ZM-4LN 217 218 11

WM-G20/3-A ZM-4LN 217 219 11

WM-G30/1-A ZM-4LN 217 322 12

WM-G30/2-A ZM-4LN 217 323 12

WM-G30/3-A ZM-4LN 217 324 12

WM-G50/1-A ZM-4LN 217 523 13

Gas burners

Burner Version Availabilitytype

WM-G20/2-A ZM-4LN Now

WM-G20/3-A ZM-4LN Now

WM-G30/1-A ZM-4LN Now

WM-G30/2-A ZM-4LN Now

WM-G30/3-A ZM-4LN Now

WM-G50/1-A ZM-4LN Now

WM-G50/2-A ZM-4LN 2018

Availability

6

Low NOx emissions for large burner capacity:The WKmono 80 in 4LN version

WKmono-G80 with flue gas recirculation

FGR connecting elbow with actuator and tempera-ture sensor

multiflam® mixing assembly

Flexibility with flue gas recirculationWhere the most stringent emission limitsfor nitrogen oxides are in force, Weishaupt’s multiflam® technology forgas-fired burners can be combined withflue gas recirculation. Weishaupt takes advantage of the special properties ofthe flame geometry, and with it theadaption to the combustion chamber, toreduce NOx levels.

7

General arrangement of a flue gas recirculation system with a WKmono-series burner

The multiflam® technology develo-ped and patented by Weishaupt is away to reduce nitrogen oxide emis-sions to a minimum.

At the heart of Weishaupt’s multiflam®

technology is a special mixing assemblydesign, which distributes the fuel amongprimary and secondary nozzles. This results in extremely efficient combustionthanks to recirculation of the flue gasesdirectly at the mixing assembly.

If a specific market demands ultra-lowNOx emissions, Weishaupt combinesmultiflam® technology with external fluegas recirculation. This system, which isdesigned for gaseous fuels, reducesNOxemissions to levels that will meetthe most stringent requirements of NOxemissions worldwide.

The compact FGR dosing unit is worthhighlighting. The connecting elbow incorporates the FGR butterfly valveand the associated temperature sensor.This packaged assembly allows the

system to be fully tested at the factoryand avoids additional installation workon site.

The FGR system is controlled by the W-FM 200 combustion manager. An additional software module ensures proper dosing of temperature-compen-sated volume of flue gas at all operatingstages, reliable cold start behaviour andthe highest degree of operational availa-bility.

QRA 73 flame sensor

FGR butterfly valve

Connection hose

W-FM 200 combustion manager(FGR version)

Flue gas temperature sensor

X8-03 X8-02 X8-01 X9-03 X9-02 X9-01 X10-03 X10-02 X10-01

F3/T

4IE

C 1

27-2

/VF1

/T6,

3IE

C 1

27-2

/VF2

/T4

IEC

127

-2/V

X3-01 X3-02 X3-03 X3-04X4-01 X4-02 X4-03X5-01 X5-02 X5-03

V1

PE N L

V1

PE N L LO

IL

LG

AS

min.

max

.LT

(CP

I) L

PE N

V1L

V2L

PVL

SVL

ION

FSV/

QR

I

PE N L

Pow

er Q

RI

QR

B

FLAME

L N G0 G

LIN

E

12VA

C

X7-

03X

7-02

X7-

01

PE

V2

PE

V3

PE

X6-

03X

6-02

X6-

01

Start

Start

H0-Start

PE

SV

PE

PE min

L PE max

L ON

/OFF

3

L

2

INT

GAS

OIL

L

RES

ET

PE N L PE N L(S

TART

)

IGN

ITIO

N

L L

MO

TOR

ALAR

M

L L

FLAN

GE

LSA

FETY

LOO

P

PE LNLI

NE

VOLT

AGE

OIL

OIL

GAS

SIEMENS

Burner ControlFuel Air Ratio ControlLoad ControlOXYGEN CONTROL

FeuerungautomatBrennst.-Luftverbundst.

LeistungsreglerSauerstoffregler

LMV52.200B2 230 VAC -15% /+10%50 or 60 Hz - 6% / + 6%-20°C to + 60°C-  4°F to +140°FFCC: part 15, Class BUse wires accaptablefor at least 90°C / 194°FRefer to data sheet 7550Made in Germany

Rg.5F193CE-0085BL0373

Siemens AG

S 1312120025

1P

DIN

Drain

Insulation Manual shutoffFGR pipe

Break point for blanking plate

Low NOx emissions for large burner capacity:WK-series burners with flue gas recirculation

8

General arrangement of a flue gas recirculation system with WK-series burner and mixing box

Flue gas recirculation is also availa-ble for Weishaupt’s WK-series indus-trial burners. The special modulardesign of the WK-series burners separates burner body from com-bustion air fan, thus facilitating inno-vative and customer-oriented solu-tions.

The mixing boxThe mixing box is developed in a colla-boration with our combustion air fan manufacturer. It is fitted directly to thecombustion air fan and forms a compactassembly with fixed dimensions. The mixing box consists of a housing with anintegrated air damper register for suction control, a flanged connection foreasy installation of the FGR butterflyvalve and a sleeve with inbuilt tempera-ture sensor.

AdvantagesTo the customer, the mixing box presentsmany advantages. Precise site planscan be drawn up, if required, fully encap-sulating sound absorbers can be fabri-cated without the need for on-site mea-surements, installation times arereduced and – the crucial factor forfunctionality – everything is in the rightplace.

All in all, a convincing, complete packa-ged solution.

M

MMMM

M

Mixing boxW-FM 200 combustion manager(FGR version)

X8-03 X8-02 X8-01 X9-03 X9-02 X9-01 X10-03 X10-02 X10-01

F3/T

4IE

C 1

27-2

/VF1

/T6,

3IE

C 1

27-2

/VF2

/T4

IEC

127

-2/V

X3-01 X3-02 X3-03 X3-04X4-01 X4-02 X4-03X5-01 X5-02 X5-03

V1

PE N L

V1

PE N L LO

IL

LG

AS

min.

max

.LT

(CP

I) L

PE N

V1L

V2L

PVL

SVL

ION

FSV/

QR

I

PE N L

Pow

er Q

RI

QR

B

FLAME

L N G0 G

LIN

E

12VA

C

X7-

03X

7-02

X7-

01

PE

V2

PE

V3

PE

X6-

03X

6-02

X6-

01

Start

Start

H0-Start

PE

SV

PE

PE min

L PE max

L ON

/OFF

3

L

2

INT

GAS

OIL

L

RES

ET

PE N L PE N L(S

TART

)

IGN

ITIO

N

L L

MO

TOR

ALAR

M

L L

FLAN

GE

LSA

FETY

LOO

P

PE LNLI

NE

VOLT

AGE

OIL

OIL

GAS

SIEMENS

Burner ControlFuel Air Ratio ControlLoad ControlOXYGEN CONTROL

FeuerungautomatBrennst.-Luftverbundst.

LeistungsreglerSauerstoffregler

LMV52.200B2 230 VAC -15% /+10%50 or 60 Hz - 6% / + 6%-20°C to + 60°C-  4°F to +140°FFCC: part 15, Class BUse wires accaptablefor at least 90°C / 194°FRefer to data sheet 7550Made in Germany

Rg.5F193CE-0085BL0373

Siemens AG

S 1312120025

1P

DIN

Drain

Insulation Manual shutoffFGR pipe

FGR butterfly valve

FGR temperature sensor

Fabric compensator

9

Air damper register for flue gas suction control

FGR butterfly valve

Flexible compensator

Mixing box

Junction box for theelectrical components

Temperature sensor

Mixing box for flue gas recirculation at the combustion air fan

10

Functional and safe:Temperature-compensated flue gas dosing

0

10

0

20

30

40

50

60

70

80

90

160F (70C)

195F (90C)

230F (110C)

265F (130C)

300F (150C)

100%

P1P2

P3

P4P5

P6

Burner rating [%]

FGR butterfly valve positions

Maximum opening

Load-dependent opening (setting points)

Opening at 32F (0 °C)(calculated automatically)

Minimum position (adjustable)

Opening range de-pendent on fluegas temperature

Act

uato

r 3 [

°<)]

FGR te

mperature

Flue gas recirculation Burner’s air intake is connected to theboiler’ s stack and with help of burner’sfan the flue gas is drawn off and fedback into the flame mixed with the combustion air. The result: extremely lowNOx emissions.

However, the critical factor is the precisedosing of the recirculated flue gas. TheW-FM 200 combustion manager is bestequipped to control this process. Withjust two additional components – a fluegas temperature sensor and a butterflyvalve – and some additional software,the W-FM 200 can control the flow offlue gas so that the correct amount willbe fed into the combustion air under alloperating conditions, providing reliablestartup and operational behaviour – justas you would expect.

Simple commissioningThe W-FM 200’s fuel - air ratio control-ler provides up to 15 setting pointswhich can be positioned as requiredthroughout the burner’s operating range.This allows the volume of recirculatedflue gas to be matched precisely to thecombustion conditions.

Flue gas temperature is also crucial indetermining the volume of flue gas to berecirculated. The temperature of theflue gas affects its density and thus themass flow rate.

The flue gas temperature is measuredcontinuously to ensure stable burneroperating behaviour and consistentlylow NOx levels. Variations in temperatureare compensated automatically by adjustments to the FGR butterfly valve.

System-specific adaptionsBeside controlling the FGR butterflyvalve, the W-FM 200 combustion mana-ger’s software has parameters at handthat allow additional adjustments to suitsite conditions, such as defining mini-mum and maximum FGR butterfly valvepositions and make adjustments via correction factors.

11Burners with FGR on long-term test at Weishaupt factory’s boiler room

12

Weishaupt Corporation6280 Danville RoadMississauga, ON L5T 2H7, CanadaPh: (905) 564 0946 Fax: (905) 564 0949www.weishaupt-corp.com

Weishaupt America Inc.2587 Millenium Drive, Unit AElgin, IL 60124, USAPh: (847) 531 5800Fax: (847) 531 5855www.weishaupt-america.com

Print No. 83217416, October 2017Printed in Germany. All rights reserved.

Regular maintenance reduces heatingcosts and environmental pollution. Only aproperly adjusted burner can save energyand be environmentally friendly. Behindeach Weishaupt burner stands the wholeWeishaupt customer service organization.The outstanding efforts made inmaintenance and service justify theenormous trust placed in Weishaupt’sburners, for at Weishaupt, product andcustomer service belong together.

Weishaupt customer service is there foryou all year round. Whenever you needhelp, be it the supply of spare parts,technical advice or a site visit. We arethere when you need us.