Manual - Burner L1-L3 _GB98

8/16/2019 Manual - Burner L1-L3 _GB98

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Insta llation and operating instructionsWeishaupt oil burners L, RL, and MS izes 1 and 3

83042 002 – 1/98

B u r n e

r m o t o

r

F a n

I n t e g

r a l s w i t c h g e a

r

S e r v o

m o t o r

A i r d

a m p e

r

O i l p

u m p

O i l p

r e s s u r e l i n e

S i g h

t g l a s

s c o v e r

S o l e n

o i d v a l v e

F l a m e

s e n s

o r

S o l e n

o i d v a l v e s f o

r n o z z l e

s

I g n i t i o

n e l e c

t r o d e

H i n g

e d f l a n g

e

N o z z l

e

D i f f u

s e r

C o m b

u s t i o

n h e a d


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Co nform ity certification

We hereby confirm that Weishaupt oil burners conform tothe basic requirements of the following EU guidelines:

– 92/31/EEC Electromagnetic Compatibility Directive– 73/23/EEC Low Voltage Directive– 92/42/EEC Boiler Efficiency Directive

Therefore the burner carries the CE Label.

Extensive quality assurance is guaranteed by a certifiedQuality Management System to DIN EN ISO 9001.

Max Weishaupt GmbHBurner and Heating SystemsD-88475 Schwendi

Regu lar m aintenance saves ene rgy and protects the e nvironm ent

We recom m end regular plant maintenance of allcomb ustion equipme nt. It saves fuel and ensuresconstantly good combustion results. Excellent

comb ustion quality is a pre -requisite forenvironmentally friendly operation.

Title Page

1 . General instructions 4

2 . Burner installation 5

3 . O il supply 6

4 . Burner fuel system schem atics 8

5 . Pum ps 9

6 . O il throughput capacity charts 11

7 . N ozzle se lection 137.1 single, two or three stage burners 137.2 sliding two stage or modulating burners 14

8 . Com bustion head settings 168.1 Combustion head extensions 17

9 . Ignition e lectrode se ttings 18

10 . Regulating system RL3 19

11 . N ozzle recirculation on M burners 21

12 . O il preheaters and heating e lem ents 22

13. Air regulation, single, two andthree stage burners 2313.1 Cam settings of limit and auxiliary

switches on servomotor type 1055 2413.2 Description of operation of

servomotor type 1055 25

14. Oil/ a ir compound regulat ion on

regulating burners 2714.1 Cam setting of limit and auxiliary

switches on servomotor SQM 28

15 . Com m issioning and adjustm ent 29

1 6 . S e qu en ce of o pe ra tio n, b urn er co ntro l LO A 3 0

17. Sequence of operation LAL2... and LOK16 ... 3217.1 Requirements for burner start 3217.2 Sequence and time diagrams 3217.3 Symbols on fault position indicator 3317.4 Switching times 3417.5 Technical data 34

17.6 Basic wiring diagram 35

1 8 . F au lt co nd itio ns a nd re ctifying pro ce du re s 3 7

Contents


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1. Ge neral instructions

SafetyTo ensure sa fe burner ope ration, the b urner has to beinstalled and com missioned by qualified pe rsonneland all guidelines in these operating instructions ha veto be followe d.

Spe cial attention should be paid to the relevantinstallation and safe ty guidelines g iven (i.e. localCode s of Practice).

Flam e m onitoring devices, limit controls, correctingelem ents and all other safety devices must becomm issioned by, and m ay only be replaced by, them anufacturer or the authorised age nt.

Failure to comp ly can lead to serious injury or dea thand can cause considerable dam age to the plant.

Qu alified pe rsonnel according to this ope ratingm anual are persons who a re familiar with theinstallation, mounting, setting and commissioning ofthe product and which have the necessaryqualifications such as:

– Training, instru ction o r a uth oris atio n to sw itchelectrical circuits and electrical devices on and o ff, toearth them and to ma rk them in accordance with thesafety standards.

Operating instructionsThe installation and operating instructions included witheach burner must be displayed clearly in the plant room.We refer to DIN 4755, point 5. The address of the nearestservice centre must be entered on the reverse of theinstructions.

Instruction of pe rsonnel

Problems are often caused by incorrect burner operation.The operating staff should be thoroughly instructed withregard to the operation of the burner. With frequentlyoccurring burner faults, the nearest service centre must benotified.

InstallationThe installation of oil fired equipment must be carried out inaccordance with extensive guidelines and regulations. It isthe duty of the installer to familiarise himself with allregulations. Installation, commissioning and maintenancemust be carried out with care. Permitted fuels:– Fuel oil DIN 51603 - EL - 1– Medium fuel oils with a kinematics viscosity of maximum

75 mm2 /s at 50° C

Electrical wiringEach burner is supplied with a wiring diagram and burnerconnection diagram as standard.

Maintenance and serviceIn accordance with DIN 4755, the whole installation,including the burner, should be inspected by a qualifiedengineer of the supplier at least once a year. Thecombustion figures should be checked after each serviceand each time a fault has been rectified.

Ambient requirementsMaterial, construction and type of protection of the burner

and fuel lines are designed for use indoors. The permittedambient temperature is -15° C to + 40° C.

Electrical installationWhen installing the electrical connection cables ensurethat these are long enough to allow the burner and boilerdoor to be hinged open.

Control circuits, which are taken from one of the supplyphases, must only be connected with an earth potentialneutral conductor.

On a mains supply which is not earthed the control voltagemust be supplied via an isolating transformer.

The po le of the transforme r, which is to be used as theneutral conductor must be e arthed.

The control circuit phase and neutral conductors mustbe connected correctly.

Ensure the correct fuse ratings are not exceeded. Earthingand neutral conductors must conform to local regulations.


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2. Burner installation

Installing the burnerThe drawing shows refractory in a heating appliancewithout a cooled front. The refractory must not extendbeyond the front edge of the combustion head (dimensionl1). If it is necessary to extend the refractory beyond thecombustion head, this should take a conical form (≥ 60°).Refractory may not be required on boilers with water-cooled fronts, depending on the boiler manufacturer’sinstructions.

The boiler front plate must be prepared in accordance withthe dimensions below. The burner hinge flange can beused as a template for the plate drilling.

For an example of a burner with head extension, seechapter 8.1. Fill the air gap with resilient refractory insulation material.

Do not make solid!

Installation example of heat exchanger with refractory

Burner Combustion head Dimensions in mmsize type d1 d2 d3 d4 d5 l1

1 M1/5a 128 M8 160-170 135 150 117

3 M2/1a 140 M10 186 165 170 1323 M5/2a 160 M10 186 165 190 138

Hinged flangeThe burner can be hinged to the left or right depending onthe position of the hinge pin and by releasing the lockingnut.

Locking nut

Hinge pin

Interlock switchThe interlock switch is arranged so that the electricalcircuit is closed in the burner closed position. The circuit isbroken by the release of the tripping pin from the interlockswitch.

Tripping pin


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3. O il supp ly

Op erational safety to a grea t extent depends o n the oilsupply. Information regarding the pipe system and thedime nsions can be found in our technical work shee ts.

Termination of the oil supply must allow tension freeconnection of the flexible oil hoses. The oil connectionsmust allow the burner to swing open.

When installing the oil hose s in the sup ply and return(betwe en pu mp and rigid pipe installation), theproduct related technical drawings should b eobserved.

For fuel oil EL oil hoses to DIN 4798, Part 1, pressureclass A are supplied.

Technical data:

Nominal pressure PN = 10 barTest pressure PP = 15 barOperating temperature TB = 70°C

Suction lift operationSuction operation is possible for individual burners, whichare operated on fuel oil EL.

Ring main operationIf there are several burners or the burner is installed atsome distance, the use of a ring main system isrecommended. This system is, however, essential whenoperating with residual oil.

On two pipe oil supply, the factory pre-set oil pressure of the burner pump is influenced by the pressure of the oilsupply. The pump pressure must be measured andcorrected.

Ring ma in pressure regulating valvea) S etting for distillate o il ELRing main pressure 1 - 1.5 bar

b) S etting for residual oil MTo avoid vaporisation of water in the fuel oil, the minimumring main pressure, including a safety margin, must be setaccording to the following table. It is based on thepressure, which is measured at the burner pump outlet.

Preheat temperature Ring main pressure°C at burner in bar

110 1,5115 1,8120 2,2

Air/ gas separatorsA Weishaupt air/gas separator should be fitted at thepoint at which the burner’s two pipe system is connected.The air/gas separator must be installed as near to theburner as possible. The inclusion of a separator isimportant on residual oil installations. When installing, thedirections shown on the separator must be observed (seepipeline diagrams in our work sheets).

FilterAn oil filter must be fitted at the end of the pipeline beforethe pump. The filter protects the burner from foreignbodies in the oil and the pipeline.

If no filter is fitted then the following faults can occur:

Seizing of the pump gears Blocking of solenoid valve and nozzle

Installation of oil m etersWhen oil meters are fitted in the supply and return lines,the system must be protected from excess pressure by apressure relief valve installed in the return line (seepipeline diagrams in our work sheets).

A blocked return line can cause the following:– Bursting of oil hoses– Pump damage (glands on pump leaking)– Load changes without changes to the combustion air– Load changes occur if the meter is blocked up during

burner operation.– The return pressure renders the oil regulator ineffective.

Deflagration may occur on burner start.

NoteIsolating de vices in the return flow line m ust beprotecte d from u nintentional closure, e.g. ball valveswith m echanical connection or shut off de vice w ithinterlock switch. No n return valve may not be fitted o nburners with spill type noz zles.


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Oil hose connection according to burner type

Oil hoses

D N / Length m m Connection thread Connection nippleS upply Return pum p side installation side

L1Z-B 8 1000 1000 G 3/8” G 3/8”L1T-B 8 1000 1000 G 3/8” G 3/8”L3Z-A 8 1000 1000 G 3/8” G 3/8”L3T-A 8 1000 1000 G 3/8” G 3/8”RL3-A 8 1000 1000 G 3/8” G 3/8”

M1Z-B 13 800 500 G 1/2” G 1/2”M3Z-A 13 1000 700 G 1/2” G 1/2”

The pipes m ust be tested after installation, without theoil filter and hos es. The test is carried out usingcompre ssed air or nitrogen with a minimum pressure

of 5 bar. The burner m ust not be connected during thetest.


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1 Pump, without integral solenoid valve

L1: Pump type AE 67CL3: Pump type AE 97CRL: Pump type AJ6 CEM: Pump type E4 NC

3 Solenoid valve type 121 C2323, coil 9 watt(normally closed) G 1/8

4 Solenoid valve type 121 K2423, coil 19 watt(normally closed) G 1/8

5 Solenoid valve type 122 K9321, coil 19 watt(normally open) G 1/8

6 Solenoid valve type 121 K6220, coil 20 watt(normally closed) G 1/4

8 Nozzle head EL two stage(without integral shut off device)

9 Nozzle head R (without integral shut off device)

10 Nozzle head EL three stage(without integral shut off device)

11 Nozzle head M two stage(with integral shut off device)

12 Oil regulator13 Oil preheater

14 Pressure switch 1 - 10 bar(on RL set to 5 bar, on M to 7 ba r)

The two solenoid valves (4) are electrically connectedin series, as are the two solenoid valve (6).

The solenoid valve in the return (4) and (6) is fittedagainst the flow direction.

The voltages given refer to a control voltage of 23 0 V.For control voltage of 1 15 V controls with 115 V and

58V are used.

4. Burner fuel system schematics

1 1113

5 4

M, two stage < 3 0 kg/h

P

1 1113

5 4146

6

M, two stage > 30 kg/h

3

331 8

L, two stage

3

331 10

L3, three stage

P M

1 96

12 4146

4

RL, sliding two stage and modulating


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5. Pum ps

The pumps are supplied suitable for connection in a twopipe system.

The pumps are fitted with a pressure regulating device.The pressure regulating valve keeps the atomisingpressure constant.

Adjustment The suction oil line must be primed and the pump

vented prior to commissioning to prevent the pumpfrom running dry.

To check the vacuum, supply or ring main pressure,insert a connecting nipple to the suction side of thepump.

A pressure gauge must be fitted into tapping (5) tomeasure the pump pressure.

Set the pressure required on the pressure regulatingscrew (on type E remove cover nut).Clockwise rotation = pressure increaseAnticlockwise = pressure decrease

The suction resistance should not exceed 0.4 bar

Max. supply pressure onPumps type AE __________________________ 2,0 barPumps type AJ___________________________ 2,0 barPumps type E ___________________________ 5,0 bar(always measured at the pump).

Maximum supply temperature onPumps type E _____________________________ 90°C

type AE ____________________________ 70°Ctype AJ_____________________________ 70°C

Ope ration AE67 , AE97 and AJ6The pump gearing takes the oil from the supply linethrough the integral oil filter and under pressure, forces itthrough the integral pressure regulating valve to the nozzlehead.On two pipe systems, any oil that exceeds the nozzlecapacity is returned to the tank, on single pipe systems, itis returned to the pump’s inlet/suction chamber.The pumps have an internal drilling, which aids automaticpurging via the burner nozzle during commissioning.

Ope ration E4The oil passes through the integral filter, is pressurised bythe gears and flows to the pressure regulating valve. Anyexcess oil is spilled via the valve into the return line. The oilnozzle head has galleries, which allow oil circulationwithout discharge from the nozzles. A bypass inhibitspressure increase in the nozzle’s flow pipe due to oilexpansion. The oil expands due to oil preheating.

Single pipe ope rationIn some cases when operating with distillate oil EL thepumps can be used with a one pipe system.

For single pipe installations the bypass plug must beremoved and the return port has to be plugged. Thebypass plugs of the various pumps are located in differentpositions:

AE 67/AE 97 – behind the return connection screw(SW 5 / 32”)

AJ6 – behind the return connection screw(SW4)

E4 – behind the return connection screw(SW 1 /

16

”)

When commissioning, the supply line must be fullypurged.


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1 Suction connection2 Return connection

2a Oil regulator return connection3 Nozzle supply line4 Locking screw5 Manometer connection6 Vacuum gauge connection7 Pressure regulating screw

8 Coupling intermediate piece9 Axial movement 1.5 mm

10 Socket head grub screw (security)11 Oil pump connection piece

Pump E4

Pump coupling Pum p couplingThere is a flexible coupling fitted between fan rotor andpump (motor axis). When adjusting the intermediatecoupling, ensure that there is no axial tension on the pumpshaft. The coupling element on the pump should have an

axial movement of 1.5 mm. The difference can becorrected by loosening the M8 socket head screw (10) onthe drive element of the pump shaft. This screw is alsoused as a safety limit, if the pump is seized. The screw isforced out when the drive is overloaded. The faultycoupling part should be replaced.

6

1 7 4 2 2a 5

3

8 9 10 11

Fan attachmentThe fan fits on to the tapered motor shaft. A shaft key

transmits the power. The fan is secured by an M8 screwand the shaft key.

Remove the fanThe extractor Part No. 111 111 00 01/2 can be applied inthe two threaded holes provided and the fan removed.

5

3

12

67

Pump AE 67C / AE 97C

45

3

12

6

7

Pump AJ 6

4


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6. O il throughpu t capacity charts

Important note for capacity chartsThe capacity graph shows the oil throughput in relation tocombustion chamber pressure. These are maximum valuesmeasured on ideal test flame tubes to DIN 4787.

All ratings given are based on an air inlet tem peratureof 20°C and an alt itude of 500 m .

Warning!

The bu rner must never be operated above its capacity.

Burner size 1

Combustion head movement

lower air volume

Burner size 1 Burner types

Combustion head designationrating kW

kg/h

Burner types


kg/h

Dimensions mm

No. Combustion head Setting dimensionl d

(2) M1/5a-100K x 33 10 – 30 128(2) M1/5a-100K x 36 10 – 30 128

(3) M1/5a-105K x 33 14 – 30 128(3) M1/5a-105K x 36 14 – 30 128

(4) M1/5a-105K x 33 30 128(4) M1/5a-100K x 33 30 128

L1Z-B L1T-B (2)

M1/5a-100K x 33 M1/5a-100 K x 36120 – 415 120 – 41510 – 35 10 – 35

mbar 8

6

4

2

0

-2

0 100 200 300 400 500

5 10 15 20 25 30 35 40

kW

kg/h 0

L1Z-B L1T-B (3)

M1/5a-105K x 33 M1/5a-105 K x 3670 – 345 70 – 3456 – 29 6 – 29

mbar 8

6

4

2

0

-2

0 100 200 300 400 500kW

5 10 15 20 25 30 35 40kg/h 0

M1Z-B (4)

M1/5a-100K x 33120 – 41510,3 – 35,8

mbar 8

6

4

2

0

-2

0 100 200 300 400 500

5 10 15 20 25 30 35 40

kW

kg/h

M1Z-B (4)

M1/5a-105K x 3390 – 3457,8 – 29,7

mbar 8

6

4

2

0

-2

0 100 200 300 400 500

5 10 15 20 25 30 35 40

kW

kg/h

5-10


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Im portant note for capa city chartsThe capacity graph shows the oil throughput in relation tocombustion chamber pressure. These are maximum valuesmeasured on ideal test flame tubes to DIN 4787.

All ratings given are based on an air inlet tempe ratureof 20°C and an alt itude of 500 m .

Warning!

The bu rner must never be operated a bove its capacity.

Burner size 3

Combustion head movement

smaller air quantity

Burner size 3 Burner types


kg/h

Burner types


kg/h

Dimensions mmNo. Combustion head Setting dimension

l d

(1) M2/1a-116 x 40 40 – 60 128

(2) M5/2a-116 x 40 50 – 70 160

(3) M5/2a-116 x 40 50 – 70 160

L3Z-A, L3T-A, RL3-A (1)

M2/1a-116 x 40120 – 525

10 – 44

mbar 8

6

4

2

0

-2

0 100 200 500 600 800300 400 700

5 10 15 20 30 35 40 45 50 55 60 6525

kW

kg/h

L3Z-A, L3T-A, RL3-A (2)

M5/2a-116 x 40190 – 775

16 – 65

mbar 8

6

4

2

0

-2

0 100 200 500 600 800300 400 700

5 10 15 20 30 35 40 45 50 55 60 6525

kW

kg/h

M3Z-A (1)

M2/1a-116 x 40120 – 52510,3 – 45,3

mbar 8

6

4

2

0

-2

0 100 200 500 600 800300 400 700

5 10 15 20 30 35 40 45 50 55 60 6525

kW

kg/h 0

M3Z-A (3)

M5/2a-116 x 40190 – 77516,4 – 66,8

mbar 8

6

4

2

0

-2

0 100 200 500 600 800300 400 700kW

5 10 15 20 30 35 40 45 50 55 60 6525kg/h 0


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7. Nozz le se lection

7.1 Single, two or three stage burnerIt is recommended that solid or semi solid nozzles be usedwith a spray angle of 60° or 45°. Due to the variousconfigurations of combustion zones encountered, nobinding information can be given.

Nozzle spray angles and patterns change with alterationsto the atomising pressure. The nozzle data given applies toa nominal pressure of 7 bar.

On two stage burners the total burner rating required mustbe shared between the two nozzles. Normally the 1ststage nozzle is sized to have sufficient capacity for thebase load of approx. 2/3 of the total load. At maximumheat demands the 2nd stage nozzle supplements thethroughput of stage 1’s nozzle. A different nozzle ratio maybe required, depending upon heat demand and the designof the heating appliance (e.g. boilers with high chamberresistance).

On three stage burners the required total burner rating isshared between three nozzles.

Noz zle selection for residual oilNozzles, which are too small are often used for residual oiland therefore soon become blocked. As lower limits, werecommend the following sizes:from 0.85 US gph - up to approx. 35 mm2 /s

at 50°C

On two stage burners neither nozzle should be smallerthan indicated.

The charts are nominally based on distillate oil EL with aviscosity of 4 mm2 /s at 20° C.

Rem oving and replacing nozzlesWhen removing the nozzle, the nozzle head must be heldwith a spanner. When replacing, ensure that the nozzle istight.

Cleaning the nozzleNozzle cleaning is generally not recommended. A newnozzle should be used.

Atomising pressure

Burner type Atomising pressureapprox. bar

L1-B bis L3T-A 10 – 16M1Z-B bis M3Z-A 20 – 25

Nozzle characteristics Spray angle

Hollow spray Semi solid spray Solid spray

Nozzle selection diagram

Pressure bar

Oil throughpu t

Distillate oil γ = 0,85 (kg/dm3)

Residual oil γ = 0 ,93 (kg/dm3)

[l/h]

[kg/h]

[kg/h]


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Pressure bar

Oil throughpu t

Nozzle selection diagramsChanges in viscosity and density due to tolerances duringnozzle manufacture will lead to throughput deviations. Theatomising viscosity is max. 10 mm2 /s.

Due to the burner’s oil solenoid valves, piping andpreheater oil pressures losses are created. For an exact oilthroughput reading, the oil has to be metered or weighed.

Each regulating burner undergoes an oil throughput ratingadjustment setting and a function test during its finalmanufacturing check. However, these values can only beused as a guide. A commissioning test will have to becarried out on site, where influences, such as oil qualityand ring main pressure must be taken into account.

Residual oil γ = 0 ,93 (kg/dm3)

Distillate oil γ = 0 ,85 (kg/dm3)

[kg/h]

[kg/h]

[l/h]


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The charts show the throughput of the spill type nozzle inrelation to the supply pressure. The pump pressure on RLburners should be between 20 and 30 bar.

It should be ensured that the m inimum pressure doe snot fall below 20 b ar even at the lowe st regulatorposition.

Due to the nozzle sizing, the burner rating required with thereturn flow closed (regulator position 10) can be achieved

at a pressure below 25 bar. In this case the pumppressure must be increased to 25 bar. The higher oilthroughput that results is reduced by limiting the oilregulator. This is done by adjusting the limit switch in theservomotor to the appropriate lower regulating position.

The range of regulation is reduced accordingly by thisaction.

Nozzle return pressure - S pill type nozzle WB3 / K3The nozzle return pressure must be measured duringcommissioning. Normally this should not be set below 5bar on partial load.

For the test point a T piece is available on the solenoidvalve.

7.2 Sliding two stage and m odulating burnersNoz zle selection diagram type WB3

Spill type nozzle type WB3Spray angle 45°

Examp le of nozz le selection, type WB 3Required oil throughput: ___________________37,5 kg/hNozzle size from diagram: ________________________ 40Supply pressure from diagram: ________________25 bar

60

55

50

45

40

35

30

25

20

15

10

5

60

55

50

45

40

35

30

25

20

15

10

5

65

70

75

80

20 25 30Sup ply pressure bar

O i l t h r o u g h p u t [ k g / h ]

O

i l t h r o u

g h p u t [ k g / h ]

N o z z l e

s i z e

r e l a t i v

e

t o

3 0

b a r

Noz zle cleaningThe nozzle is dismantled into its individual parts andwashed with petrol or petroleum. The filter should alwaysbe replaced. If other individual parts are faulty or worn, thewhole nozzle should be replaced.

Spill type nozzle

Type WB3

Atomising pressure

Burner type Atomising pressureapprox. bar

RL3-A 20 – 30

Test point return pressure

Test pointreturn pressure


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Weishaupt oil burners Monarch and R are supplied with achoice of combustion heads and diffusers for each sizeand capacity range. It is advisable to check that thecorrect combustion head is fitted. Combustion heads anddiffusers are marked with their type designation. Theidentification of the combustion head can be foundinternally on the neck. The external diameter of the diffuseris stamped on the side towards the burner.

Information for adjustment can be taken from thecombustion head capacity graphs.

The measurements given are empirical values, whichusually meet the requirements of most modern combustionchambers.

The combustion head for each burner is designed for themaximum oil throughput indicated in each case.

If the burner is operated in the m iddle or lower oilthroughput range the secondary the air gap betwee ndiffuser and com bustion head m ust be adjusted.

The combustion head can be adapted to the combustionchamber conditions as follows:

Moving the combustion head from the basic position.

Fitting the next size diffuser or smaller combustion head(see capacity graphs).

Both combustion head screws should be unscrewed. Thecombustion head or diffuser can then be moved orreplaced. This reduces the secondary air gap and adaptsthe air velocity to the corresponding lower oil throughputrange.

8. Setting the com bustion he ad

Combustion head removal

The burner also offers the advantage that the combustionhead with intermediate ring can be pulled through thehinged flange opening, after unscrewing both holdingscrews.Increase secondary air gap between combustion head

and diffuser for higher burner rating. reduce for lowerburner rating.

It should be noted that the distance between nozzle anddiffuser should be larger, if nozzles with small spray angleare used, than if nozzles with wide spray angle are used.

Flame tube s of higher tem perature hea t resistantsteel are a vailable for spe cial requirem ents.


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8.1 Com bustion head e xtensions

Combustion head extensions are required on boilers withvery thick doors and on reverse flame boilers. It isimpossible to hinge open the burner when combustionhead extensions are fitted.

* To enable installation and service work to be carriedout, the refractory should be no thicker than dimensionl4. This generally only applies for standard boilers, andgenerally not for combustion chambers, ovens, etc.

Designations and dimensions Note:On burner size 1 with head extensions of 200 or 300 mm,the flame viewing port on the burner lid is blanked off. Theblanking plug must not be removed.

1 Oil line extension2 Ignition line plug connection3 Burner flange4 Flange gasket5 Burner plate6 Ignition line extension7 Combustion head extension8 Refractory9 Flexible insulating material (e.g. Cerafelt), do not make

solid10 Nozzle support11 Combustion head12 Diffuser

Burner Com bustion Dimensions in mmsize head Extension Total length

type l2 l3 l4 * l5 d1 d5 d6

1 M1/5a 100 228 118 220 128 150 1101 M1/5a 200 328 218 320 128 150 110

3 M2/1a 100 238 117 230 140 170 1203 M2/1a 200 338 217 330 140 170 120

3 M5/2a 100 238 109 230 160 190 1403 M5/2a 200 338 209 330 160 190 140


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9. Ignition electrode settings

The following should be noted:

The distance of the ignition electrodes to the nozzle anddiffuser should be checked.

The ignition electrodes must not intrude into the atomisedoil spray.

The distance of the ignition electrode to the diffuser andthe nozzle must always be greater than the spark gap.

➝ 4 – 6

➝

➝2–4

➝

➝2–4

➝ ➝ 4 – 6

➝


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10. Regulating system RL3

The regulating system d oes not have a nozz le cut offvalve. The soleno id valves control the oil shut offfunction.

OperationDuring the pre-purge period solenoid valves 2 and 3 areclosed. Oil is supplied under pressure by the pump up tothe closed solenoid valve 3 in the supply line. Solenoidvalves 2 and 3 are connected electrically in series.

1. Oil system diagram After the pre-purge period has elapsed, the solenoidvalves 2 and 3 open. Oil flows to the nozzle via the nozzlesupply line 8 and to the oil regulator 5 via the return line 9.The oil regulator is in the open position (ignition position).Due to the lower return flow pressure, less oil leaves thenozzle. The greater proportion of oil flows via the nozzlereturn 9 to the oil regulator and the pump return line.

The oil pressure switch 6, when fitted, shuts down theplant if the spill back pressure is too high.

2. Oil system diagram Full load operation is produced by reducing the meteringslot in the oil regulator. This is done by rotary movement of the oil regulator (direction of rotation to the right seenfrom the shaft). This throttles the flow of oil in the returnline and the oil quantity increases at the nozzle outlet. Onshutdown the solenoid valves close and shut off the flowof oil to the nozzle and from the oil supply.

1 Pump, without solenoid valve

2 Solenoid valve type 121K2423, 115 VCoil 19 Watt (normally closed) G 1/8

3 Solenoid valve type 121K6220, 115 V**Coil 20 Watt (normally closed) G 1/8

4 Nozzle head R, without integral shut off device

5 Oil regulator

6 Pressure switch 1 to 10 bar(with EL set to 5 bar, with M to 7 bar)

7 Spill type nozzle

8 Nozzle supply

9 Nozzle return

The solenoid valves 2 a nd 3 in the nozz le return arefitted ag ainst the flow direction.

** The solenoid valves 2 and 3 in the nozzle supply andreturn (115 Volt) are electrically connected in series.

The pressure switch 6 checks the pressure in thereturn. If there is an e xcessive increase in pre ssurethe burner shu ts down. The shu t off devices closesimultaneously on shutdown.

The switch point of the pressure switch is set prior toburner delivery and does not need readjusting duringburner commissioning.

Nozzle head RL3

1. O il system diagram

2. O il system diagram

8 7


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20

Oil regulatorThe oil regulator is driven by the servomotor, and bymeans of a vee slot metering groove regulates the variableoil quantity.In order that the oil quantity is regulated with thecorrect metering slot, the ke y must a lways be fitted inthe appropriate keyway.

Each regulator has two regulating grooves, which can bechanged. Each regulator has two numbers stamped onthe side of the shaft, e.g. 00-0 (see illustration).

Both numbers are matched to the appropriate groovesize. The matching of the oil throughput is shown in thefollowing table.

Oil regulator Consumptioncode Throughput kg/h

00 0 to 500 51 to 70

Setting example: Key on number 00

Primary settingCode numberOil regulating groove

Cam identificationie. 6

Primary settingRegulating camCam 1

Shaft key


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11 . No zz le recirculation on M burners

1 Pump

2 Solenoid valve, normally closed (nozzle 2)

3 Solenoid valve, normally open (nozzle 1)

4 Solenoid valve, normally closed, 110 V

5 Nozzle head as shut off device

6 Oil preheater

7 Pressure switch in return

8 Thermostat

9 Heat insulation10 Heating cartridge

11 Nozzle shut off valve

Nozzle 1

Nozzle 2

Noz zle recirculation on two stage M burnersOperation After the minimum temperature has been reached by theseries connected terminal switch contacts in the ROBregulating control and oil preheater, burner start isreleased. The oil pump circulates the oil via the filter andsolenoid valve to the oil preheater, the oil is heated and theviscosity reduced.

The heated oil forces the oil in the burner oil systemthrough the supply oil line, nozzle head, normally opensolenoid valve stage 1 to the pump return. There is nowhot oil present throughout the whole system. The shut off device in the nozzle head remains closed and oil cannotflow through the nozzle.

Other burner components are also heated by heatingcartridges.

After termination of the pre-purge period, the solenoidvalve 3 in the nozzle return is energised and closes. The oil

pressure increases in the nozzle shut off valve and at apressure of approx. 12 bar, the nozzle shut off valve opensto commence stage 1 operation.

After a delay, solenoid valve 2 for stage 2 is opened by theburner control. Oil pressure is applied to the nozzle shutoff valve, which opens nozzle 2. Nozzle dribble isprevented by the tight closure of the nozzle shut off valves.

Nozzle head 'heatingHeating takes place directly in the nozzle head, which isinsulated. A heating cartridge (10) with a capacity of 100

Watts is fitted in the nozzle body. An electronic P typecontroller controls the nozzle temperature. The sensor isfitted adjacent to the oil line inlet. The ROB control can beset between temperatures of 65° and 130° C according tothe fuel quality (factory pre-setting 65° C).

When the burner shuts down, solenoid valve 3 is de-energised and opens. The atomising pressure reducesimmediately and the nozzle shut off valves close.

Noz zle head ma intenance and cleaningBoth nozzles can be replaced without affecting thefunction of the hydraulic nozzle shut off valves. If the nozzleshut off valve 1 or 2 is removed, the isolating devices in the

oil supply and return must first be closed.

Regulator type ROB

Noz zle hea ds are type tested safety shut off devices and in accordance with DIN 478 7 m ust not be interfered with.

Setting screw


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12 . Oil preheate r and heating elem ents

He ating eleme nts on burner types M 1Z-B, M3Z -A

Burner type Nozzle head Valve bock PumpWatt Watt heating

M1Z-B 100 20 80

M3Z-A 100 20 80

Check whether the fuses for the electrical pre-heatinghave been removed. The fuses should not be replaceduntil the oil line system and pre-heater are full of oil andvented (e.g. at the pressure gauge connection at thepump). The oil temperature must be measured and if necessary corrected at the oil pre-heater.

After switching on the operating switch the contactor forthe pre-heater is energised without activating the burnercontrol switch. The contactor energises the heaterelements. They heat the oil in the pre-heater until thethermostat on the pre-heater switches off. Before this oiltemperature is reached, the release thermostat in the pre-

heater is activated.

The burner must not be switched on until the requiredsupply temperature or ring main temperature for theinstallation is reached (approx. 50° to 60° C).

The heating elements in the burner are usually controlledby the burner operating switch.

The p um ps have a heating facility. The gearing coverhas a pocket for the he ating cartridge. The heatingfacility can be use d as and w hen required.

Pump heating M1Z-B, M3Z-A (special execution) Nozzle heating M1Z-B, M3Z-A

Valve block heating M1Z-B

Heating cartridge

Heating cartridge

Heating cartridge

Heating cartridge

Valve block heating M3Z-A


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13 . Air reg ulation, single, two and three s tage burners

Air regulation for single and two stage burnersSizes 1 to 3

Single stage oil burnersThe combustion air volume control damper is adjustableand can be set to firmly limit the opening cross sectionalarea for the ratings required.

Two stage oil burnersTwo stage oil burners have a servo-driven air damper,which controls the air quantity for partial and full load byaltering the amount of opening. When commissioning theplant the following mechanical settings are necessary:

Set the air damper for partial load operation (operationwith nozzle I) by using the cam switch II - partial load inthe servomotor.

Set the air damper for full load operation (operationwith both nozzles) by adjusting the air damper for mainload via the servomotor cam switch III - full load.

Set the switch for switching on solenoid valve stage 2.This is done at the servomotor cam switch I (solenoidvalve 2) in such a way that the switch is no longerdepressed after approximately two thirds of the settingmovement. This will prevent flame lift off due to thehigher air flow.

The final setting of the cam switches in the servomotorfor full load - switch III and partial load - switch II takesplace once flue gas analysis is satisfactory.

Three stage burnersFor burners L1T and L3T the servomotor type 1055 / 80 isused. This servom otor has the sam e de sign as type10 55/ 23, howe ver, relating to an angle of rotation of90 °it has a run time of 8 se conds and two additional

control cam s.

Servomotor type 1055/23

Drive motor

Switchidentification

Control camsetting aid

Air damperposition indicator

PCB pin

Drive shaft for airdamper

Printed circuitboard cover

Housing back plate

Switch positionindicator

Gear wheel (may beuncoupled for manual

adjustment)

Control cams; Auxiliaryswitch II Partial load

Auxiliary switch IStage 2

Limit switch IIIFull load

Limit switch IV Closed

Terminal rail

b l a c k

g r e e

n

g r e y


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24

0

90

M

g r a u - g r e y - g r i s

g r ü n - g r e e n - v e r t

s c h w a r z - b l a c k - n o i r

VI

V

II

I

III

IV

1

1

2

3

4

5

6

7

8

9

10

11

12

1314

15

16

17

18

Servomotor type 1055/80

Drive motor

Switchidentification

Control camsetting aid

Air damperposition indicator

PCB pin

Drive shaft for airdamper

Terminal rail

Printed circuitboard cover

Housing back plate

Switch positionindicator

Gear wheel (may beuncoupled for manual

adjustment)

Control cams;

Auxiliary switch VI,Valve stage 3

Auxiliary switch V,Interm. load/ignition load

Auxiliary switch II,Partial load

Auxiliary switch I,Valve stage 2

Limit switch III,Full load

Limit switch IV Closed

13 .1 C am setting of limit and auxiliary switches in servom otor type 10 55

The air damper position is indicated on a scale 0° to 90°by a pointer on the drive shaft.

There is a setting scale between the cam switches. Thesetting knobs on the cam switch indicate with a smallpointer on this scale, and give the switch point of theappropriate switch in relation to the air damper position.

The cam switches are set as follows using the settingscale:

Cam switches

* VI – Solenoid depending on burner rating,valve full but set to above V.load

* V – Partial load depending on burner rating,last set between I and VI for air

regulation

IV – Closed 0°

II I – Full load depending on burner rating,up to 90°

II – Partial load depending on burner rating,between 0° and approx. 50°

I – Solenoid depending on burner rating,valve, between partial andIntermediate intermediate load at approx.load 10° to 40°

* used only on version T

The limit and cam switches are marked in all wiringdiagrams with I, II, III, IV and have the function, which isshown in the connection diagram.

The connection diagram is also shown on the cover of theservomotor.

b l a c k

g r e e n

g r e y


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13 .2 De scription of function for servom otor type 10 55

Burne r switching with LO A... burne r control

Sequence of operation: 1. After the appliance on/off control has closed, control

voltage is applied to terminal 1 of the LOA...

2. Terminal 8/3 is energised. Relay K15 in the servomotoris also energised.

3. Servomotor opens the air damper.

4. The burner motor contactor is energised via the fullload limit switch III and switches the auxiliary contacts.Burner motor starts.

5. Servomotor runs to switch point ‘partial load’ II.

6. After the pre-purge period the flame is established,then operation of stage 2 via terminal 5 of the LOA.The servomotor opens the air damper and when thelimit switch I - solenoid valve stage 2 - is overrun, thevalve is energised.

7. After the controller has switched off, the burnerswitches off, terminal 8/3 and 5 on LOA are withoutvoltage. The motor contactor K1 is de-energised.Voltage is applied to the servomotor via an openingcontact. The air damper closes until the limit switchClosed IV switches off the servomotor.

B u r n e r m o t o r c o n t a c t o r

M V S t a g e 2


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Burne r switching with LAL2... burne r control

Sequence of operation: 1. After the boiler on/off control has closed between

terminals 4 and 5, terminal 6 of the burner control isenergised.

2. The burner motor starts. The voltage from terminal 11of the LAL2... control is supplied via the ‘Closed’switch IV to terminal 8 of the LAL.

3. After a short delay the air damper is opened to theswitching point of the full load limit switch III. A returninterlock signal is given to terminal 8 of the burnercontrol.

4. After the pre-purge terminal 9 is de-energised. Byenergising terminal 10 the servomotor closes the airdamper to switching point ‘Partial load’ with switch II.

5. After flame establishment, terminal 20 on the LALcontrol is energised to control stage 2.

6. The servomotor is energised via the stage 2, H/Lcontroller, and switch S2 and the air damper opens.

Version Z7. If the switch for limit switch 1 solenoid valve stage 2 is

overrun, this valve is energised.

8. After the burner is shut down, the voltage on terminal11 of the LAL closes the damper until the limit switch‘Closed IV’ switches off the servomotor.

Basic wiring diagramfor version Z

Version T6. The servomotor opens the air damper with voltage

from the terminal via switch S4, intermediate loadcontrol (see wiring diagram of burner control) and limitswitch III.

7. The auxiliary switch I energises the intermediate loadsolenoid valve.

8. Depending on the setting of the controller forintermediate load the servomotor is stopped on theswitch point of the auxiliary switch V or the air damper

is opened further.

9. The servomotor opens the air damper with voltagefrom terminal 20 via switch S2 up to the switch pointof the limit switch III if the full load controller demandsadditional heat.

10.If the auxiliary switch VI is bypassed, the full loadsolenoid valve is also energised.

11.After burner shutdown, the air damper is closed bythe voltage of terminal 11 of the LAL until the limitswitch IV switches off the servomotor.


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Setting the spring band The cam segment is driven clockwise by theservomotor to the full load position. The adjustablespring band on the cam operates the air damperlinkage and opens the damper for full air pre-purge.

At the end of the pre-purge period, the servomotorbrings the oil regulator, on the same axis of rotation asthe cam segment, and the air damper to the ignitionload position. In this position the oil regulator is wideopen, which means that only a small quantity of oil willbe atomised at the nozzle, the larger proportion flowsback via the return line.

The air damper is partially open so that the air suppliedis matched to the atomised oil quantity.

The servomotor drives the compound mechanism in acontinuous movement from partial to full load. Thismeans the air damper is opened while the oil regulatorcloses and less and less oil flows to the return line.

Adjusting the a ir quantity The cam segment has an adjustable spring band,

which is adjustable by means of socket screws. Theair quantity is matched to the oil throughput requiredby adjusting the spring band on the cam segment.

The setting of the spring band is determined at various

load positions by flue gas analysis.

Compound adjustment

Partial load (from 30 to 70%)

Full load (100%)

Ignition load (from 20 to 30%)

Basic position

Air damper with

linkage

Servomotor drive shaft

Nozzle return line

Metering slot

Oil regulating valve

Cam segment

Adjustable spring band

1 4. Oil/ air com pound regulation on regulating burners


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14 .1 Cam settings of limit and auxiliary switches in the se rvom otor type SQ M

DescriptionThe limit and auxiliary switches are set manually on theadjusting cams. The cams have a small pointer, whichindicates the appropriate switch point on a scale betweenthe cam segment.

The servomotors are supplied with the followingprovisional switch settings:

I – Open 120°II – Closed 0°III – Ignition load 30°IV – freeV – freeVI – freeVII– Partial load 50°These switch settings must be reset when commissioningto the requirements of the installation.

Ma nual actuation of the servom otorWith the lever fitted on the gearbox, the cam shaft can bedisengaged from the drive. This makes it possible to turnthe cam segment manually to any position required. Thecam segment air band can also be adjusted to match therequirements of the appliance. When the lever is in thevertical position, the drive is engaged.

The scale on the outer end of the switching cams indicate

the angular position of the servomotor.

The cams are set without tools using the setting scale.

The connection diagram is also shown inside of theservomotor cover.

Auxiliary and limit switch settings Disengage the drive

Connection diagram

I – OpenII – ClosedIII – Ignition loadIV – free

V – freeVI – freeVII– ignition load


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GeneralBefore commissioning can commence, the entire plantmust be ready for operation and handed over by theinstaller.

The burner motor rotation should be verified beforecommissioning. With control circuit and operating switchclosed, the burner is briefly actuated by the burner controlswitch. The rotation of the burner motor must be ant-clockwise when looking at the motor cooling fan. Note the

direction of the arrow of the motor flange.Che cks prior to com m issioning❏ Has the heat exchanger been mounted ready for

operation?❏ Have operating instructions of the heat exchanger

been observed?❏ Are heat exchanger and system filled sufficiently with

heating medium?❏ Are the flue gas passages free from obstruction?❏ Are explosion relieves free to operate?❏ Is the flue gas damper open?❏ Is sufficient permanent fresh air supply ensured?❏ Have temperature/pressure controls and safety limit

controls been set correctly and placed into theoperation position?

❏ Has the low water safety interlock been set correctly?❏ Have all fuel carrying pipe lines been purged of air?❏ Is the rotation of the burner motor correct?❏ Is sufficient fuel oil in the tank?❏ Has a soundness tests of the oil hydraulic been

carried out?❏ Is load available?❏ Are the oil supply pumps (if fitted) switched on?❏ Are the oil shut off devices open?❏ Are oil-supply lines and pump filled with oil?

Other installation specific tests may be required. Seeoperating instructions of individual components.

Sw itch on procedureOpen shut off valve (shut off assemblies) in the oil supply.Set selector switch in the control panel to “Stage 2” or“Full load”. Reset installation.Switch on burner operating switch.

IgnitionOnce pre-purge is complete await flame formation.If ignition problems occur:

L-(M-) burners:– Check nozzle size of stage 1; if necessary

select different nozzle– Check position of auxiliary switch II in the servo-motor, if necessary adjust to air requirement.

RL - (RM-) burners:– Check position of ignition load switch on the

servomotor (No. III), if necessary adjust setting.

Test sensor current with a microammeter.

Full load settingAfter approx. 11 secs, the servomotor runs from ignitionload (partial load) to full load setting. (Ensure this iscarried out with excess air by previously reducing therequired oil pressure). For full load the required oilthroughput must be set and measured (nozzle selection

diagrams are only an aid for setting and checking).

Carry out combustion analysis:

Other installation specific tests may be required. Seeoperating instructions of individual components.

L- (M-) burners:– Set oil throughput by adjusting pump pressure

(EL = 10 to 14 bar, M/MS = 20 to 25 bar), if necessary select different nozzle size.

– Set combustion values by adjusting servomotor,

auxiliary switch N. III and the position of theflame tube (see chapters 9 and 10) so that withfully opened air damper a smoke number 13 Vol. - % with good flamestability can be achieved.

RL- (RM-) burners:– Set oil throughput by adjusting pump pressure

(20 to 30 bar).

– Set combustion values by adjusting the aircurve band and positioning of the combustionhead so that with fully opened air damper asmoke number 13 Vol. - % withgood flame stability can be achieved.

The pump pressure must be set with a pressure gauge(see chapter 5).

The pump pressure and combustion head set for full loadmust not be readjusted.

Interm ed iate testing (“full load to pa rtial load”)only on regulating burners:A point by point combustion check is necessary for thewhole of the burner regulating range.Adjust cams manually step by step upwards from thedirection of ignition load (selector switch “Stop”,disengage servomotor, adjust, re-engage). Regulatecombustion values by adjusting the air curve bands.Ensure the curve bands have an even profile.

Partial load settingSet selector switch in the control panel to “stage 1” or“Partial load”.

L- (M-) burner– Match excess air to the oil throughput required

for the nozzle selected for partial load with theauxiliary switch (No. VII).

– Measure oil throughput, if necessary select adifferent nozzle.Set the switch point for the start of the secondnozzle with auxiliary switch No. I so that theexcess air phase before the switch point is nottoo large to extinguish the flame, but on the

other hand that there is not too much smokeafter the connection has been made.

Three stage burners;In the same way the excess air of the intermediate load isset with auxiliary switch V and the connection point for thethird stage is set with auxiliary switch VI.

RL- (RM-) burners:– Set and measure the required oil throughput for

partial load with auxiliary switch No. VII.

If changing the nozzle on partial or intermediate load(two/three stage burners) the full load setting has to be re-checked and if necessary re-adjusted. For partial loadsetting, the lower ratings limits of the capacity graphs, the

flue gas temperature and instructions from the boilermanufacturer have to be observed.

15. Commissioning and adjusting


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1 6. Sequence of ope ration for burner control LOA

Se quence of operation for LOA 24 / 25 Interruption of sequence

1. Control and limit thermostats closed, Check electric supply,voltage on terminal I check connection of thermostats

2. Voltage on terminal 8/3 and 6, burner motor runs, Check connection of ignition transformerignition transformer switched on and burner motor, external light (control goes

to lockout), check light sensor

3. After approx. 13 (6) secs. voltage on terminal 4, Check wiring, burner control faultysolenoid valve nozzle 1 opens

4. Flame establishment No flame establishment,see fault conditions and procedures

5. After approx. 15 secs. voltage for the ignition Burner control faulty, check wiring

transformer (terminal 6) is interrupted

6. After approx. 15 secs voltage to terminal 5, Check wiring, control faultystage 2 energised

S witch tim es in secs. LO A 24.171 LO A 25 .171 LO A 44.255 LO A 24 .571

TV Prepurge period approx. 13 13 25 6TS Safety time max. 10 max.10 max. 5 max. 10TV Pre-ignition time approx. 13 13 25 6TST Interval 1st - 2nd stage approx. 15 15 5-8 20TNZ Post ignition time (from start of TS) approx. 15 15 5-8 20

Concluding work:Check ignition load setting when the burner has beencommissioned. The setting is correct, if the burner startswithout start impact.

Regulating burners:If necessary correct setting at auxiliary switch(No. III).

2 and 3 stage burners:If necessary select new nozzle. Full and partial

load setting will then have to be repeated.

Check and adjust operation of all safety equipment (i.e. oilpressure switch, thermostat, pressure switch etc.) whilstinstallation is in operation.

DocumentationThe following setting values for full and partial load (andposs. intermediate load) must be recorded on the reportsheet or test sheet:– Oil throughput– Nozzle type– Pump pressure– Supply and return pressure (on RL burners)– CO2– Smoke– Flue gas temperature

– Suction or pressure in the combustion chamber– Sensor current– Inlet air temperature– Air damper setting– Cam setting on air band (on R burners)


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T

M1~

LOA1 2 B 3 6 4 5 10 11 12

F3

F2

S1

F1

L N

220V 1,N 50 Hz

M1 T1 Y1 Y2 H 1

B1

A1

Fϑ

Fϑ

Functional diagram

T

M1~

LOA1 2 B 3 6 4 5 10 11 12

F3

F2

S1

F1

L N

220V 1,N 50 Hz

M1 T1 Y1 Y2 H 1

B1

A1

Fϑ

Fϑ

Functional diagram

TV

TST

TNZ

TS

Voltage present

Arrow showing direction of current

Flame present

LegendA1 Burner controlB1 Flame sensorF1 FuseF2 Temperature/pressure limit controlF3 Temperature/pressure regulatorH1 Fault indication lamp

M1 Burner motorS1 Mains switchT1 Ignition transformerY1 Solenoid valve stage 1Y2 Solenoid valve stage 2

Basic connection Basic connection

Functional diagram Function diagram s (flam e fault)

Start with flame formation

Burner“On”

OperatingpositionBurner“Off”

Flame signal at start

Start without flame formation

Flame failure during operation

Burner“On”

Operatingposition

Restart

Fault

Burner“On”

Burner“On”

Fault


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17. Sequence of operation burner control LAL2... and LOK 16...

The LAL 2... burner control units are designed to providecontrol and supervision of multi stage and modulatingburners. They are suitable for intermittent operation. Forburners operating continually without stops and starts, theburner control LOK 16... is recommended to be used.

Oil burner Z

Sequence diagram air AirRegulator“On”

Nominal loadpre-purge

Ignition and fuelrelease

Capacity regulation Regulator “Off”

Full load

I - IV Switch points

Ignition load/partial load

LAL2.../LOK16 ...

ClosedPosition indicator

Control circuit

Time sequence diagramfor servomotor

Burner fan

Seque nce diagram oil

Time sequence diagramfor ignition andfuel release

17.2 Function and tim e seque nce diagram s

The diagrams shown give the timing sequence for the airdamper regulation and the oil release and regulation.

17.1 Requirements for burner start

– Control unit reset– Air damper closed. The limit switch for Closed position

must supply voltage from terminal 11 to terminal 8.– The control contacts between terminal 112 and terminal

4 must be closed.


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a - b Start up sequence

b’ - a Post purge sequence after controlled shut down. Instart position ‘a’ the sequence switch switches itself off automatically.

17.3 S ymb ols on fault pos ition indicator

In the event of a fault condition the fuel supply is alwaysinterrupted immediately. Simultaneously the sequenceswitch stops and thus lockout is indicated. The symbolappearing above the reading mark indicates the area of thefault.

No start e.g. because the closed signal has not beensupplied to terminal 8 by the limit switch/auxiliary switchor because a contact has not been closed between

terminals 12 and 4 or 4 and 5.

Controlled shut dow n because the open signal hasnot been supplied to terminal 8 by the limit switch.

P Lockout because the air pressure signal has not beenreceived by the start of the air pressure check. Airpressure failure after this point also causes thecontrol to go to lockout (when the bu rner has beenfitted w ith an air pressure sw itch).

Lockout due to a fault in the flame supervision circuit.

Controlled shutdow n because the position signal for

the low flame position has not been supplied to terminal8 by the auxiliary switch.

1 Lockout because no flame signal has been received oncompletion of the first safety time. Any flame signalfailure after com pletion of the first safety time alsocauses the control to go to lockout.

| Lockout because the flame signal has been lost duringoperation or air pressure failure has occurred.

Lockout on completion of control programm esequence due to extraneous light or due to a fault inthe flame supervision circuit.

If lockout occurs at any other point between start and pre-ignition, which is not marked by a symbol, there is normallya premature and thus faulty flame signal.


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17.4 S witching tim esSwitching times in seconds * in start up sequence LAL 2 .14 / LAL 2.25/ LAL 2 .65 /

LO K 16 .140 LO K 16.250 LO K 16 .650

t7 Start delay for burner motor G2 2 2 2,5t16 Interval from start up to OPEN command of air damper 4 5 5t11 Run time of air damper in OPEN position optional optional optionalt10 Interval from start up to commencement of air pressure check

(if burner is fitted with air pressure switch) 6 10 10t1 Pre-purge time with air damper open 10 22,5 67,5t12 Run time of air damper to ignition position optional optional optional

t3” Pre-ignition period “long” (“Z” on terminal 15) from start from start from startt3 Pre-ignition time “short” (“Z” on terminal 16) 2 2,5 2,5t2 First safety period 4 5 5t3n Post-purge time (“Z” on terminal 15) 10 15 15t4 Interval between BV1 - BV2 8 7,5 7,5t5 Interval between end of t4 and release of load controller

or valve at terminal 20 4 7,5 7,5t20 Interval up to the self shutdown of the sequence switch

after burner start up (idle step , i.e. no change in thecontact position) 32 35 12,5

– Duration of start up (without t11 and t12) 30 47,5 92,5t6 Post purge time 10 15 15t13 Permissible after burn time 10 15 15

* Valid for frequency of 50 Hz. For 60 Hz frequency, switching times are reduced by approx. 20%.

17.5 Technical da ta burne r control

Nominal voltage _________ 220 V – 15%...240 V + 10%

Frequency ________________ 50 Hz – 6%...60 Hz + 6%

Consumption ______________________________ 3,5 VA

Fuse (built in) _________________________ M 6,3/250 E(semi time lag according to DIN 41571, sheet 20.

Pre-fuse (external) ________________________ max. 10APermitted input current to terminal 1 ____ 5 A continuous

peaks up to max. 20A

Permitted loadingof control terminals ___________________ 4A continuous

peaks up to max. 20Atotal max. 5A

Required switching capacity- between terminals 4 and 5 _____________________ 1 A- between terminals 4 and 12 ____________________ 1 A- between terminals 4 and 14, 5A cont.; peaks up to 20A

Mounting position __________________________ optional

Protection standard __________________________ IP 40

Permitted ambient temperature___- 20... + 60°C at 230 V

Flame mo nitoring with QRB (not on LOK1 6...)

Recommended illumination in Lux _________________ 40

Average response sensitivity of the amplifier ______ 8 µA

Max. possible detector current _______________ 160 µA

Flame failure indication during operation ≥ 3 Lux at 2856 K

Max. permitted sensor line _____________________ 20 m

Max. permitted ambient temperature _____ - 20... + 70°C

Flam e sup ervision with RAR ...

Min. required sensor current ____________________ 6 µA

Max. possible sensor current __________________ 25 µA

Permitted cable length __________________ 30 m RAR 7

Permitted ambient temperature __________ - 20... + 60°C

Note:Flame detector wiring must not be bunched together withother wiring.

Perm itted am bient conditions for electrical compone nts

Temperature Humidity Requirementsre. EMV Low voltage guideline

In operation: max. 80% rel. humidity EC directive 89/336/EEC EN 60335

-20 … +40°C EN 50081-1EN 50 082-1Transport /storage:-40 … +60°C


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17.6 B asic wiring diagram for burne r control LAL2... / LO K 1 6...

LegendAR Load relay (main relay)B1 Flame sensorBR Lockout relayF Fuse in burner controlF4 Temperature or pressure limit switchF5 Temperature or pressure controller on/off F6 Temperature or pressure controller FULL LOADFR Flame relay

H Control lamp LockoutH6 Remote indication for lockoutK1 Motor contactorLK Air damperM1 Fan or burner motorS Reset key

S1 Remote resetS10 Air pressure switch (when fitted)T1 Ignition transformerY6 ServomotorY11 Solenoid valve PARTIAL LOADY12 Solenoid valve FULL LOADY14 Additional solenoid valve

* Wire link


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Legend for diagram of seque nce switcht1 Pre purge timet2 Safety timet3 Pre-ignition timet4 Interval between voltage on terminals 18 and 19t5 Interval between voltage on terminals 19 and 20t6 Post purge timet7 Interval to voltage on terminal 7

t8 Duration of start up sequencet10 Interval to start of air pressure controlt11 Run time of air damper (Open)t12 Run time of air damper (min.)t13 Permissible after burn timet16 Interval up to OPEN command for air dampert20 Interval up to self shut down of the sequence switch

(not on all controls)

Burner controls are safety devices! Do no t open!Interference can result in unforeseen consequ ences!

Positions of lockout indicator

C o n t r o l o u t p u t s o f

c o n t a c t s :


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If faults occur the basis requirements for correct operation must first be examined.

1.Check the electric supply.2.Ensure that an oil supply is available.3.Check that all controls e.g. thermostats, pressure switches, water level interlocks,limit and time switches are correctly set.

When it is established that the fault is not due to external conditions, the operations of the individual burner parts must bechecked.

Condition Cause Rem edy

1. IgnitionNo ignition Ignition electrodes too far apart Adjust

Electrodes dirty and damp Clean, adjust

Burner control faulty Replace burner control

Insulator cracked Replace

Ignition transformer faulty Replace

Ignition cable charred Replace, find cause and remedy

2. MotorDoes not start Overload relay tripped Check setting

Contactor defective Replace

Capacitor faulty Replace

Burner motor defective Replace

3. PumpSupplies no oil Gears damaged Replace

Suction valve leaking Clean or replace

Suction line leaking Tighten joints

Isolating valve closed Open

Filter blocked Clean

Filter leaking Replace

Quick action valve leaking Replace pump

Reduced capacity Replace pump

Loud mechanical noise Air in pump Tighten joints

Vacuum in oil line too high Clean filter, open valves fully

4. NozzlesUneven atomisation Swirl disc loose Remove nozzle, tighten swirl disc

Orifice partly blocked Replace

Nozzle filter blocked Replace

Worn due to use Replace

No oil flow Nozzle blocked Replace

Nozzle leaking Nozzle cut off faulty Replace

1 8. Fault conditions and rectifying procedures


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Condition Cause Rem edy

5. Burner control with flame sensorDoes not respond to flame Flame sensor obscured Clean

Heat damaged Replace

Interruption in sequence see under 15 - 17 Check connection and voltage

Lockout lamp on Flame fault Reset

6. Combustion headContaminated with oil Wrong combustion head Replaceor heavy carbon deposits

Nozzle size incorrect Replace

Combustion air quantity incorrect Readjust burner

Boiler house not adequately The boiler house ventilation mustventilated be via a permanent opening,the cross section of which must be atleast 50% of all chimney cross sectionsassociated with the plant

7. Solenoid valveDoes not open Coil faulty Replace coil

Does not close tightly Particles on valve seat Dismantle valve, remove foreign bodies

8. Oil prehea terBurner does not start Temperature switch for oil Increase oil temperature at the

release does not close temperature adjusting screw of thetemperature controller

Temperature switch for oil Replacerelease faulty

Temperature switch for oil Tighten

release loose

Temperature switch for oil Replacerelease with incorrecttemperature range fitted

Heating element burnt out Replace preheater

Poor combustion Temperature too low Increase temperature at temperaturecontroller

For adjustment see oil preheater brochure

9. Cleaning a nd lubrication re gulations

Depending on the degree of contamination of the combustion air, fan rotor, ignition electrodes, flame sensor and air intakeshould be cleaned as required.

The moving/rotating burner parts require no lubrication.

Motor bearing damage, which is recognised and remedied quickly, prevents more extensive damage to the burner.Development of noise in the motor bearing should be investigated immediately.


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Weishaupt productsand service

Oil, gas and dua l fuel burners types W and WG/ WGLup to 570 kWThey are used mainly in houses and small buildings.Advantages: fully automatic, reliable operation, individualcomponents easily accessible, easy to service, quiet operation.

Oil, gas and dual fuel burners types M onarchR, G, GL, RGL – u p to 10 .900 kWThese are used on all types and sizes of central heatingplant. The basic model which has proved successful overmany years is the basis for a variety of versions. Theseburners have founded the outstanding reputation ofWeishaupt products.

Oil, gas and dual fuel burners types WK –up to 17.500 kWWK types are decidedly industrial burners.Advantages: Built to the modular system, load dependentvariable combustion head, sliding two stage or modulatingoperation, easy to service.

Weishaupt control panels, the p roven complem ent toWeishaupt burnersWeishaupt burners and Weishaupt control panels formthe ideal unit, a combination which has already provedsuccessful in hundreds of thousands of combustioninstallations. The advantages: Cost saving during planning,installation, servicing and guarantee work. The responsibilitybelongs to one manufacturer.

Weishaupt Thermo U nit / Weishaupt Thermo Gas.These Units combine the technical innovations and operatingefficiencies developed from over 1 million installations.Weishaupt Thermo Gas and Weishaupt Thermo Unitprovide the ideals of complete heating centres for housesand appartments.

Max Weishaupt GmbH, D-88475 SchwendiTel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58Print No. 420 GB, May 98Printed in Germany. All rights reserved

Weishaupt (U.K.) LtdStoke Gardens, Slough SL1 3QDTel. (01753) 51 23 45Fax (01753) 51 25 85

Neachells Lane, WillenhallWest Midlands WL13 3 RGTel. (01902) 60 98 41Fax (01902) 63 33 43

Documents

Manual - Burner L1-L3 _GB98