Installation and operating instructions 83042902 – 1/98

Weishaupt dual fuel burners

size 30 to 70
 Content
Title Page

1. General instructions 3
2. Burner installation 5
3. Burner fuel system for gas 6
4. Description of valve trains 7
4.1 Solenoid valves 7
4.2 Pressure regulator type FRS 9

00 85 4.3 Valve proving VPS 504

4.4 Valve proving type W-DK 3/01

5. Installation of valve trains

10
13

14
5.1 Safety information 14
Conformity certification 5.2 Installation example 16
6. Soundness test of valve trains 17
We hereby confirm that Weishaupt oil burners conform to
the basic requirements of the following EC guidelines: 7. Sequence test of operation 17
8. Preparation for first commissioning 18
– 90/396/EEC Gas Unit Guideline 8.1 Testing gas supply pressure 18
– 89/336/EEC Electromagnetic Compatibility 8.2 Venting gas line 18
– 73/23/EEC Low Voltage Guideline 9. Commissioning the gas side 18
9.1 Checks prior to first commissioning 18
Therefore the burner carries the CE/0085 Label. 9.2 Flame monitoring 18
9.3 Adjusting gas side 19
The product refers to the type test 0085 of the 9.4 Set gas pressure switch 21
Notified Body. 9.5 Set air pressure switch 21
9.6 Combustion test 22
9.7 Setting pressure and
Extensive quality assurance is guaranteed by a certified minimum connection pressure 23
Quality Management System to DIN EN ISO 9001.
10. Setting the mixing head 25
Max Weishaupt GmbH 11. Capacity graphs 26
Burner and Heating Systems 12. Oil supply 28
D-88475 Schwendi 13. Pump assembly for oils M + S 30
14. Oil hose installation for metal hoses (oil S) 32
15. Oil pre-heater system 34
16. Pumps for oil EL, M + S 36
17. Fan wheels attachment 37
18. Burner fuel system for oil 38
19. Regulating systems 40
19.1 RGL 30 40
19.2 RGL 40 to RGL 70 41
19.3 RGMS30 to RGMS50 43
19.4 RGMS60/RGMS70 44
19.5 Oil regulator 45
20. Nozzle circulation on burners RGMS30
and RGMS50 46
21. Nozzle selection 47
21.1 Two and three stage burners 47
21.2 Regulating burner 49
22. Ignition electrode and pilot setting 51
23. Commissioning the oil side 52
23.1 Tests prior to first commissioning 52
23.2 Adjusting the oil side 52

24. Sequence of operation 54

24.1 Pre-requisite for burner start 55
24.2 Symbols on the fault position indicator 55
24.3 Basic wiring diagram for LFL 1.../LGK 16... 56
24.4 Switching times 57
24.5 Sensor line between LGK 16... and
QRA 53 / QRA 55 or sensor electrode 58
24.6 Technical data 59
25. Cam setting of limit and auxiliary switches
in the servomotor 60
26. Throughput determination, conversion
from normal to operating condition 60
27. Fault conditions and procedures 63

2
1. General instructions
Abbreviated instructions Safety
To ensure safe burner operation, the burner has to be
The following table gives an overview of the procedures for installed and commissioned by qualified personnel
installation and commissioning. and all guidelines in these operating instructions have
to be followed.

To ensure safe installation and commissioning Special attention should be paid to the relevant
all instructions given in these installation and installation and safety guidelines given (i.e. local
operating instructions must be followed. Codes of Practice).
DANGER
GEFAHR
Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
commissioned, and may only be replaced by, the
Step Action Chapter manufacturer or the authorised agent.
1 Burner installation 2 Failure to comply can lead to serious injury or death
and can cause considerable damage to the plant.
2 Installation of oil supply 12 to 16
Qualified personnel
3 Installation of gas valve trains 5 Qualified personnel according to this operating
manual are persons who are familiar with the
4 Soundness test of valve train 6 installation, mounting, setting and commissioning of
the product and which have the necessary
5 Testing gas supply pressure 8.1 qualifications such as:-
6 Purging the gas supply line 8.2 – Training, instruction or authorisation to switch
electrical circuits and electrical devices on and off, to
7 Testing sequence of operation 7 earth them and to mark them in accordance with the
safety standards.
8 Nozzle selection 21
– Training, instruction or authorisation to carry out
9 Testing the mixing head 10 and 22 installation, alteration and maintenance work on gas
installations in buildings and on site.
10 Testing the plant 9.1 and 23.1
Operating instructions
On two and three stage burners: The installation and operating instructions included with
each burner must be displayed clearly in the plant-room.
11 Commissioning gas side 9 The address of the nearest service centre must be entered
on the reverse of the instructions.
12 Commissioning oil side 23
Instruction of personnel
On regulating burners: Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with
11 Commissioning oil side 23 regard to the operation of the burner. With frequently
occurring burner faults, the nearest service centre must be
12 Commissioning gas side 9 notified.

Installation
The installation of oil fired equipment must be carried out
to extensive guidelines and regulations. It is the duty of the
installer to familiarise himself with all regulations.
Installation, commissioning and maintenance must be
carried out with care. Fuel oils to DIN 51 603 EL should
be used.

Wiring diagram
A wiring and connection diagram must be included with
every burner delivered.

Maintenance
If, during maintenance, control seal joints have to be
opened, these have to be thoroughly cleaned and new
seals fitted when re-assembling.

Maintenance and service

The burners should be inspected at least once a year by
the supplier or their appointed agent. The combustion
quality should be checked after each service or repair.

3
Installation conditions Gas types
Material, construction and type of protection of the The burner must only be operated with the type of gas
burners and gas valve trains in their standard version are stipulated on its name plate. When converting to other
designed for use indoors. Permitted ambient temperature types of gas re-commissioning is required. A conversion kit
is –15°C to +40°C. may also be needed.

Electrical installation Valve train installation

When installing the electrical connection cables ensure The valve train must be fixed and supported securely.
that these are long enough to allow the burner and boiler Standard connection is from the right.
door to be hinged open.
Gas meter
Control circuits, which are taken from one of the supply The siting, size and type of gas meter is the responsibility
phases, must only be connected with an earthed neutral of the gas supplier. Only those meters, which have been
conductor. approved, should be used. If no gas meter is fitted, as for
instance on liquid petroleum gas installations, the operator
On a mains supply which is not earthed the control voltage has to be made aware that the burner can not be set to its
must be supplied via an isolating transformer. optimum, because basic testing is not possible without a
meter installation.
The pole of the transformer, which is to be used as the
neutral conductor must be earthed. Plant room regulations
Local regulations regarding the design of plant rooms
The control circuit phase and neutral conductors must be must be observed and the installation of an emergency
connected correctly. switch and a mains gas shut off system should be
considered. Attention should also be paid that sufficient
Ensure the correct fuse ratings are not exceeded. Earthing ventilation is available in the plant room. Any shortcoming
and neutral conductors must conform to local regulations. should be noted in the commissioning report.
The commissioning report must be completed by the
General information for gas operation service engineer and signed by the plant operator or his
When installing a gas combustion system, local authorised agent. The operator should be instructed in the
regulations and guidelines must be observed. correct operation of the burner and control panel. The
operating instructions included with each burner must be
The subcontractor responsible for the installation or displayed clearly in the plant room.
changes of the gas system must inform the gas supplier of
the type and extent of the installation planned and the Thermal / manual shut off system
intended work. The subcontractor must ascertain that an If a thermal / manual shut off system is required, this
adequate gas supply to the installation is ensured. should be fitted prior to the burner fuel isolation valve(s).
This installation must conform to local regulations.
Installation, alteration and maintenance work on gas
systems in buildings and on process sites, must only be
carried out by installers who have a contract with the gas
supplier.

Gas characteristics
The following information must be obtained from the gas
supplier:
Type of gas, calorific value in kWh/m3, max. CO2 content
of combustion products, gas supply pressure.

Gas line
The gas pipework must be subject to a preliminary and
main test or the combined loading test and soundness
test, according to the pressure range intended. The air or
purge gas required for the test must be expelled from the
pipework.

The determination of the supply pipework diameter usually

results in a diameter, which is at least one pipe diameter
larger than the size of the burner valve train.

Gas valve train

Observe the sequence and flow direction. The distance
between burner and DMV valve should be as small as
possible in order to guarantee trouble free start.

Pipe thread connection

Only tested and approved sealing material should be
used. Please observe individual user instructions!

Soundness test
Brush connection points with foam forming agents or
similar, non-corroding materials.

4
2. Burner installation
Installation example for standard combustion head Installation example for combustion head with extension.
for heat exchanger with refractory
Size Size
30 to 50 60 and 70

The gap between combustion head and

refractory must be filled with flexible insulating
material. Do not make solid.

The drawing shows a refractory for heating appliances

without cooled front. The front edge of the combustion
head should protrude beyond the refractory by approx.
30 mm. Alternatively the refractory may take a conical form
(≥60°C). Refractory may not be required on boilers with
water cooled fronts, depending on the boiler
manufacturer’s instructions.

Size Comb. Dimensions in mm Head extensions

head I d1 d2 d3 d4 d5 d6 d7 l1➀ l1➁

30/2-A
G30/2 305 250 290 360 285 M12 260 286 455 605
40/1-B

40/2-A
G40/2 365 290 330 400 325 M12 300 326 515 665
50/1-B

50/2-A G50/2 390 350 390 480 390 M16 360 386 540 690

60/2-A G60/2 430 400 440 470 435 M16 410 436 580 730

70/1-A
G70/2 430 480 520 550 500 M16 450 475 580 730
70/2-A
➀ (extended by 150) ➁ (extended by 150)

Before hinging open the burner Transport

Remove gas butterfly valve crank-arm. Remove air housing To simplify installation of the burner to the appliance,
cover and remove internal regulating rod. burners sizes 50 to 70 are fitted with lifting rings.
On size 40 and 50 open housing cover and remove
regulating rod. Due to the oil hose’s connections to the Burner type Weight (with. valve train)
nozzle, RGL and RGMS burners are supplied hinged
open to the right as standard. GL30 135 kg
RGL30 145 kg
Electrical wiring RGMS30 175 kg
Each burner is supplied with a wiring diagram and burner
connection diagram as standard. GL40T 145 kg
RGL40 160 kg
Interlock switch RGMS40 200 kg
The interlock switch is arranged in such a manner that the
circuit is closed in the burner closed position. In the burner RGL50 240 kg
open position, the circuit is interrupted by the release of RGMS50 280 kg
the tripping pin in the interlock switch.
RGL60 330 kg
RGMS60 305 kg

RGL70 435 kg
RGMS70 410 kg

5
3. Burner fuel system for gas
Valve trains
7 5b 9 In accordance with EN 676 all burners must be fitted with
two Class A solenoid valves. Weishaupt dual fuel burners
are fitted with double solenoid valves as standard (on
DN 150 with two single solenoid valves).

Weishaupt also recommend the use of a valve proving

system. In accordance with EN 676 the use of a valve
proving system is required for thermal inputs over
1,200 kW. This and other valve train components, such as
gas filter and gas governor can be found in the Weishaupt
accessories list.
P P
Legend
1 2 3 4a 4 8 5 6 1 Ball Valve
With DMV solenoid valves and VPS valve proving
2 Gas filter
3 Gas governor
4 Low gas pressure switch
7 10 11 5b 9 4a High gas pressure switch, (to TRD/IM30)
5 Double solenoid valve (DMV)
5a Single solenoid valves
5b Ignition gas solenoid
6 Gas butterfly valve
7 Pressure gauge with push button valve
8 Valve proving VPS
9 Burner
10 Valve leakage indicator
11 Vent valve
12 Gas pressure switch for valve proving
P P P W-DK 3/01

1 2 3 4a 4 12 5a 6
With 2 solenoid valves and W-DK 3/01 valve proving

6
4. Description of valve trains
4.1 Solenoid valve train installation

Function Technical data

DMV-D/11 Max. operating pressure 500 mbar

Two single solenoid valves, normally closed, fast opening, Voltage/frequency ~(AC) 230 V - 15 %...
fast closing, manual throughput adjustment of gas is to 240 V + 10 % 50/60 Hz
possible by adjusting main flow at valve 1 (V1). en ~(AC) 110 V 50/60 Hz
Ambient temperature- -15 °C ... +60 °C
Installation Horizontal or vertical

Pressure test point Electrical connection

DMV-D 507/11 - 520/11 1 2 3

L1 N L2
V1 V2

2 1 3
1 2 3
4 5 1 2

Legend N L1
2 1 Pressure into V1
33
1 3 2 Pressure between V1 and V2
3 Pressure after V2
4 Inlet connection flange L2 V1 V2
5 Outlet connection flange

DMV-D 5040/11 - 5125/11 1 2 3

4
5 DMV- and GW plug
4
6 7

V1 V2 m
4 2c
4
6 7 1 2 3 5 1

Legend
3 4 1, 2 Pressure into V1
2 5 3 Pressure between V1 and V2 2
1 4 Ignition gas outlet 4 3
5 Pressure after V2
6 Inlet flange
7 Outlet flange

MVD 507/5 MVD 5150/5

R 3/4"

R 1/4" both sides DN 3/4" with DN150 with

socket plug R 1/4" both sides flange connection
DIN 2633 PN16

7
Changing solenoid valve DMV

A 1. Switch off and isolate installation

2. Remove connection plug
B 3. Remove paint seal from screw A
4. Remove counter sunk screw A
C 5. Remove cheese head screw B
6. Remove cap (C) and metal plate (D)
7. Change solenoid, checking new unit is correct
D
type/voltage
8. Refit metal plate (D) and cap (C)
9. Refit screws A and B
10. Carry out a gas tightness test at test point 2 and 3:
E pmin = 100 - 150 mbar
11. Carry out function test
12. Switch on supplies and test burner

Gas throughput adjustment

DMV 507-5125 DMV 507 - 520/11 Throughput adjustment on V1 via
covered adjusting screw. One turn
= 0.5 mm of stroke adjustment,
anti-clockwise to increase flow ,
max min and vice-versa.
V1 DMV 5040 - 5125 Throughput adjustment on V1 via
covered adjusting screw. One turn
= 1 mm of stroke adjustment, anti-
clockwise to increase flow, and
vice-versa.

Factory pre-set: maximum stroke

Connection of gas pressure switch to DMV

Fit gas pressure switch

8
4.2 Pressure regulator type FRS

Outlet pressure adjustment Factory - standard spring 5 - 20 mbar

1. Remove cap A
2. To increase, turn screw B clockwise.
A = increase of outlet pressure (set value)
or
B 3. To reduce, turn screw B anti-clockwise.
= reduction in outlet pressure (set value)
4. Prove the adjustment is correct.
5. Replace cap A

Changing the spring 1. Remove cap A. Turn screw B totally anti-clockwise.

2. Remove spring retainer C, and remove the spring D.
3. Fit new spring D.
A 4. Re-fit spring retainer C, and by turning screw B set the
required outlet pressure.
B 5 Prove adjustment is correct and re-fit cap A, and new
C range label.
D

Type of spring / colour Outlet pressure range

mbar

orange 5… 20
blue 10… 30
red 25… 55
yellow 30… 70
black 60… 110
pink 100… 150

9
4.3 Valve proving system VPS 504

III III
III II
I
III
III

III
III

III III III

Series 04

Operation

The valve proving system type VPS 504 operates to the The VPS 504 carries out a self-test during the switching
pressure build-up principle. The valve proving programmer sequence. If a fault occurs burner ignition phase is
is activated at every burner start. inhibited and the fault lamp lights.

Technical data

Max. operating pressure 500 mbar Fusing fitted to housing T6,3 L 250 V
Test volume ≤ 4.0 l Switching current operating output max. 1A
Pressure increase via lockout output max. 1A
motor pump ≈ 20 mbar Release time ≈ 10… 26 s
Voltage/frequency ~(AC) 230 V - 15 %... max. number of test cycles 20 /h
to 240 V + 10 % / 50 Hz Ambient temperature –15 °C ... +60 °C
or ~(AC) 110 V / 50 Hz Installation vertical or horizontal
Type of protection/switching duration
Series 04 IP 54 / 100 % Ed
Pre-fusing (by others) 10 A F of 6,3 A T

Pressure reduction

1 Connection Pe, P1
2 Connection Pa, P2 1
DMV-. …
MB- … 2
3,4 Test points
p1 p2
pe pa

pa
p2 2 p1 p2
pe VPS 504 pa 3
pe
p1 1 pe
p1
pa
p2

3 4

10
Sequence of operation
p p p p p
e e p + 20 mbar e e e
e

V1 V2 V1 V2 V1 V2

p1 p2 A = Programmer p1 p2 p1 p2
pe A pa pe A pa pe A pa

VPS 504 VPS 504 VPS 504

p1 p2 p1 p2 p1 p2
pe pa pe pa pe pa
Shutdown Pressure build-up Operation

Remove closing plug

Shut down condition: Valve 1 and valve 2 are closed.
VPS 504 "DICHT" VPrüf = 0,3 l
VPS 504” Sound” V test = 0,3 l
Regulator
Pressure build-up: The internal motorised pump increases Pump motor
Solenoid valve
the gas pressure in the test section by approx. 20 mbar Differ. press. switch
Release signal
when compared to the pressure pe on the inlet side of
valve 1. During the test phase the inbuilt differential Regulator
VPS 504 "DICHT" VPrüf = 4,0 l
VPS 504” Sound” V test = 0,3 l

pressure switch checks the test section for soundness. Pump motor
Solenoid valve
Once the test pressure has been reached the pump is Differ. press. switch
Release signal
switched off (end of test phase). The release time (10 to
VPS 504 "UNDICHT"
26 secs) varies on the test volume (max. 4.0 l). Regulator
VPS 504” Not Sound”

Pump motor
If the test section is sound, the contact to the burner Solenoid valve
Differ. press. switch
control is released after max. 26 secs. The yellow signal Release signal
lamp is illuminated. Lockout signal

If the test section is not sound or if the pressure increase of

+ 20 mbar is not reached during the test phase (max
26secs.), the VPS 504 goes to lockout. The red fault lamp 0 5 10 15 20 25 30 [s]

remains illuminated as long as the appliance controller

requests a burner start.
An automatic restart follows a short term voltage loss
which resets the VPS from it’s fault condition.

Installation

remove closing
plug

VPS on DMV screwed VPS on DMV flanged

Note:
– Remove closing plug prior to installation
– Properly tighten cover screw and connecting screw,
avoiding over-tightening!
– Protect flange surface. Tighten screws in diagonally
opposite sequence.
– The unit must not be used as a lever.
– When work on the VPS 504 is completed, carry out
valve proving and function test.
– Ensure tight sealing when changing parts.

11
Electrical connection VPS 504 series 04
VPS 504
VPS 504
With cable gland PG 13.5 and connection to screw Series 04
Serie 04
terminals. intern
internal
V3
notundicht
sound
Potential free relay contacts must only be used for
signalling and never for burner control circuit! sound
dicht
P

Release time tF
Time required by the VPS 504 to carry out a complete test
1 2 3 4 5 6 7 8
cycle. The release time of the VPS 504 depends on the

Operating
Freigabe-

spannung
NC COM NO B L1 N

Betriebs-
}
Release

voltage
Neutral
conduc
test volume and inlet pressure:

signal
signal

leiter
Null-

Erde
Earth
tor
potentialfreies Störsignal
Potential (Leitwartensignal)
free lockout signal Operating voltage
Betriebsspannung ~(AC) 230 V 50 Hz
V test < 1.5 l V test > 1.5 l
pe > 20 - 500 mbar pe > 20 mbar
tF ≈ 10 s tF > 10 s Interchangeable
fuses:
T 6,3 L 250 V
tF max / VPS 504 ≈ 26 s to
ICE 127 2/III
Test time Pt (DIN 41662)
Pump time of the motor pump. D5 x 20

Test volume Vtest

Volume between V1 on the outlet side and V2 on the inlet
side.
t F [s]
Vtest max. / VPS 504 = 4 l.
30
Test volume of the multiple settings units 28
26
Application range
Anwendungsbereich
Type Rp/DN Test volume 24
22 r
ba
20 0 m ar
DMV-D(LE) 503/11 Rp 3/8 0,09 l =
5 0 mb
p e 300
DMV-D(LE) 507/11 Rp 3/4 0,09 l 18 =
pe
16
DMV-D(LE) 512/11 Rp 1 1/4 0,25 l ar
14 mb
DMV-D(LE) 520/11 Rp 2 0,25 l p e=
100
bar
DMV-D(LE) 5040/11 DN 40 0,36 l 12 20
m
p e=
10
DMV-D(LE) 5050/11 DN 50 0,36 l
8
DMV-D(LE) 5065/11 DN 65 0,60 l tF
6 ≈ 10 s
DMV-D(LE) 5080/11 DN 80 1,70 l
4
DMV-D(LE) 5100/11 DN 100 2,30 l Vtest
Prüf

DMV-D(LE) 5125/11 DN 125 3,75 l 2 ≤ 1,5 l

1 2 3 4 Vtest
Prüf
[l]

Installation dimensions S04/S04

126,5
Sicherung eingebaut, auswechselbar
Fuse built into housing, exchangeable
Fusibile integré dans la couvercle du boîtier
interchangeable

Typ/Type/Type/Tipo T 6,3 L 250 V

Betriebsanleitung beachten!
Please comply with the operating instructions!
Suivre les instructions de la notice d'utilisation!
Seguire le istruzioni!
Zusätzlich cable
Additional
100

Kabeldurchführung
entry
PG 11PG11
möglich
147

VPS 504 Series 04

150

Standard:
Kabeldurch- pa
Standard
führung
22

cable entry
PG 13,5
PG 13.5 pe
pa pe
13
4,3

5
Ø9

53,7
72
Vor dem Öffnen ist das Gerät stromlos zu schalten

Prima di apire l'aparecchio togliere la corrente

Fonctionamento

pe Suction connection
Funziamento
Dérangement
Störung

Betrieb
Lockout
Blocco

pe
Run

Before opening switch off power supply

Achtung, Warning, Attention, Attentione

test point
Meßstutzen Sauganschluß
(gas inlet) (Gaseingang)
Ouverture uniquement hors tension

Pressure connection
Typ: VPS 504

Schaltstrom Imax. 4A
-15°C T 60°C………
Serie 04
219 881

pe
-15°C T 70°C……
~(AC) 50 Hz 230 V

~(AC) 50 Hz 240 V

pmax. = 500 mbar

pa
CE-0085AP0168

(to the test section)

Druckanschluß (zur Prüfstrecke)
test point
Meßstutzen
ID-No.
IP54

Replacement fuse
Ersatzsicherung

12
4.4 Valve proving system type W-DK 3/01

Construction Gas valve train with Weishaupt valve proving system W-DK 3/01
The valve proving system W-DK 3/01 consists of four main 1 Solenoid valve 1
parts: 2 Solenoid valve 2
■ Programmer fitted into the control panel of plant 3 Leakage indicator unit
■ Gas pressure switch fitted to the test section between 4 Vent valve 3 1 4 2 5 6
the solenoid valves 5 Gas pressure switch
■ Vent valve (normally open) fitted into the vent line 6 Burner
■ Leakage-indicator unit fitted into the vent line

Function
The tightness of the solenoid valves in the gas valve train is
checked prior to each burner start.

Operation
1. Test phase: During pre-purge all solenoid valves are
closed. If pressure builds up due to possibly leaking
first valve, the pressure increase is detected by the gas
pressure switch.
2. Test phase: If the first solenoid valve is gas-tight, it is
opened momentarily, but the vent valve remains closed.
Gas pressure is now in the section between the Test result
solenoid valves. It is tested for a loss in pressure in the If a pressure increase (phase 1) or pressure decrease
test section. The test is controlled by the programmer. (phase 2) is detected, the burner start is inhibited.
Otherwise the solenoid valve seats are gas tight and the
burner start continues.
Pressure switch setting
1/2 flow pressure

Technical data
Weishaupt valve proving system Type W-DK 3/01
Mains voltage/Frequency V / Hz 220 ± 15% / 50 or 60
Fusing A in accordance with the
pre-fusing of the
burner control
Perm. ambient temperature °C – 10…+ 60
Programmer Test times
– Pressure switch test
with/without pressure secs. 8
– Fill test section secs. 2
– Test time with test pressure secs. 9
Type of protection IP 40
Consumption VA approx. 4
Installation as required
Weight kg 0,734
Pressure switch GW50 A4 Setting range mbar 2.5…50
Pressure switch GW150 A4 Setting range mbar 30…150
Vent valve LGV 507/5 Nominal diameter R 3/4”
Leakage indicator
(without glycerine) Nominal diameter R 3/4”

Programmer

Plug-in unit
133

Sub- base
23

Cably entry
150 75
Fitting dimension

II 5 5

II 100
13
5. Installation of valve trains
5.1 Safety notice

Risk of explosion!
If the valve trains are not installed correctly, their
soundness cannot be ensured.
DANGER
GEFAHR
To avoid serious accidents, the following
safety instructions must be observed during
installation:

● Observe the maximum permitted gas pressure in the

valve train. Contact your local gas supplier to obtain the
connection pressure of the gas supply.
The connection pressure must not exceed the maximum
pressure shown on the name plate.

● Valve trains must be installed securely to avoid vibration

during operation.
Suitable supports should be used (available as
Weishaupt accessories).
The supports must be fitted to the specific site
requirements when mounting the valve trains.

● Valve trains must be installed tension free. Never

compensate for mistakes made during installation by
over tightening the flange screws.

● Flange screws should be tightened diagonally opposite.

● Ensure flange joints are clean and fitted correctly.

● Only gas board approved sealing material should be

used. If a connection needs to be undone frequently,
flange connections with inlaid gasket should be used.

Other installation information:

On installations, which are subject to special regulations
for steam boilers, the valve trains can be vented with a test
burner. The first solenoid is fitted with a connection point
for this test burner.

To allow the appliance door to be hinged open, a flange

connection point, if possible at door level, should be fitted
(compensator see drawings, chapter 5.2).

To achieve better start conditions, the distance between

burner and solenoid valves (ignition and mains gas) should
be as small as possible.
Observe sequence and flow direction of valve train.

If a thermal shut off device TAE is required, this must be

fitted in front of the ball valve.

14
5.2 Installation example

1 2a 3 4 5a 6 7 8

11 10 9

High pressure supply with DMV flanged

1 2a 3 4 5b 6 7 8

11 10 9

Low pressure supply with DMV flanged

15
 1 2a 3 4 5b 6 7 8

11 10

Low pressure supply with DMV screwed

1 2b 2b 3 4 5b 6 7 8

12 10 9

Low pressure supply with single valves (only for nominal diameter DN 150)
1 Solenoid valve for ignition gas 6 Filter
2a Double solenoid valve DMV 7 Pressure gauge with push button valve
2b Single valve 8 Ball valve
3 Test burner 9 Compensator
4 High gas pressure switch (to TRD/IM30) 10 Low gas pressure switch
5a High pressure governor 11 Valve proving system VPS
5b Low pressure governor 12 Pressure switch for valve proving system W-DK 3/01

16
6. Soundness test of valve trains
Soundness test of the gas train must be carried out with
the main isolating cock and DMV valves closed. Proceed
as follows:

1. Test phase: ball cock up to 1st valve seat (V1) V2

V1
The test assembly is connected to the gas filter and DMV
inlet. During pressure testing, the test point 2 between
DMV valve seats V1 and V2 has to be open.

2. Test phase: volume between 1st and 2nd valve seat

1
The test assembly is fitted to the DMV test point 2.
2
Test pressure in the valve train should be between 100 and
150 mbar.

Wait 5 minutes for pressure equalisation. 3

The valve train is not leaking if the pressure drop is no 1. Test phase 2. Test phase
more than 1 mbar after the test period of 5 minutes has
elapsed 1 Rubber hose with T piece
2 Aspirator
3. Test phase: Valve train connection parts and gas 3 U-tube or electronic pressure gauge
butterfly valve

The third test phase can only be carried out during

operation and by using a leak detection solution.

Results of the pressure test must be recorded on the

service/commissioning report.

Attention!
After all maintenance and commissioning work on gas
supplying components a soundness test must be
carried out.

7. Sequence test of operation

Wiring connection check If the gas pressure switch does not shut down after the
Check that the wiring to all parts, especially the valve train, safety time of 2 seconds has elapsed, then the burner
is carried out in accordance with the wiring diagram control locks out.
supplied with the burner.
Version with two solenoid valves and valve proving
Sequence test gas operation (without gas) system W-DK 3/01
The ball valve must be closed and the selector switch on – Burner motor starts.
dual fuel burners set to gas operation. Air is pumped into – The servomotor opens the air damper in approx. 40
the valve train by means of the hand pump still connected (20) seconds.
from the soundness test. The pressure must be at least as – The full load pre-purge period is 30 seconds.
high as the subsequent gas operating pressure. – Valve proving is carried out in accordance with the
sequence of operation (see chapter 24).
The burner is switched on and the following programme – The servomotor closes the air damper to the ignition
should take place: position in approx. 35 (17) seconds.
– The pre-purge time of approx. 4 seconds begins.
Versions with DMV and valve proving system VPS – Gas solenoid valves are opened.
– Burner motor starts following successful valve proving. – Pressure in the valve train falls.
– The servomotor opens the air damper in approx. 40 – Gas pressure switch shuts down the burner.
(20) seconds. – Gas solenoid valves are closed.
– The full load pre-purge period is 30 seconds.
– The servomotor closes the air damper to the ignition If a fault occurs during the sequence of operation see
position in approx. 35 (17) seconds. description of burner control LFL1... and the additional
– The pre-purge time of approx. 4 seconds begins. information.
– Gas solenoid valves are opened.
– Pressure in the valve train falls.
– Gas pressure switch shuts down the burner.
– Gas solenoid valves are closed.

17
8. Preparation for first commissioning
8.1 Testing the gas supply pressure

Risk of explosion! 1. Connect pressure gauge to filter.

The mains gas pressure must not exceed the 2. Slowly open the ball valve monitoring the pressure
max. permitted pressure of the valve trains listed gauge at all times.
DANGER
GEFAHR on the burner name plate. The mains gas pres- 3. Close the ball valve immediately if the mains gas
sure must be checked prior to commissioning. pressure exceeds the max. permitted pressure of the
valve train. The burner must not be started.
4. Contact your nearest Weishaupt branch office.

8.2 Purging the gas supply line

Purging Any air or inert gas in the distribution lines must also
The valve train must be purged prior to first be expelled from the pipework. This work is usually
commissioning. carried out by the local gas authority.

A hose leading into the open is connected to the test point When work on the valve train involves changing
on the gas solenoid valve to discharge the air. components, the valve train must be purged and
undergo a valve proving test before the burner is
After purging, the test pressure gauge is reconnected at switched on again.
the test point on the solenoid valve.

If a test burner is installed, this must be used to ensure that

no air is present in the equipment.

9. Commissioning the gas side

9.1 Checks prior to first commissioning

The whole installation must be checked prior to the ● Have temperature switch, pressure switch and safety
first commissioning. limiting systems been set to operating requirements?
● Has the heat exchanger been installed ready for ● Is sufficient load available?
operation? ● Has the low water safety interlock been adjusted
● Are heat exchanger and system filled sufficiently with correctly?
heating medium? ● Have all fuel carrying parts been vented (free of air)?
● Are movable explosion flaps fitted? ● Check rotation of burner motor.
● Is the flue gas damper open? ● Has the valve train leakage test been carried out?
● Are the flue gas ways free? ● Is the gas supply pressure correct?
● Are the air heaters fans operating correctly?
● Is the ventilation to the plant room sufficient? It is possible that other site specific tests will have to be
● Has the whole installation been wired correctly? carried out. Refer to the operating instructions of individual
site components.

9.2 Flame monitoring

Ionisation detector on LFL... and LGK... UV-detector QRA2 bij LFL

22 24 22 23

Microammeter Microammeter
(range 0...150 µA) (range 0 ...600 µA
or 0...1 mA)

Minimum required sensor current in µA Test for flame sensor

min. required Ionisation UV-cellQRA2 Ionisation electrode: By separating the plug connections
ionisation current 6 70 in the vicinity of the terminal strip.
UV cell: By withdrawal from the holder on the burner
values normally >15 >120 flange.
obtained
Note: With the LGK 16... burner control and UV sensor
QRA 53/55, it is only possible to measure the sensor
current by means of the special sensor current measuring
instrument type KF8832.
18
9.3 Adjusting gas side

On two and three stage burners GL30/40 the gas side Butterfly valve pre-setting
is commissioned prior to the oil side. On regulating
burners the oil side must be commissioned prior to the
gas side.

Switch on procedure
– Set operating switch to “gas”.
– Open ball valve.
– Release gas pressure regulating spring (see chapter 4.2).
– Set selector switch in control panel to “Stop”.
– Reset installation.
– Switch on burner operating switch.

Ignition
After the pre-purge time has elapsed, wait for flame
formation. If ignition problems occur check the pre-setting
of the gas butterfly valve (nominal approx. 5 - 10° “Open”
on the gas butterfly scale), as well as the position of the Disengaging SQM servomotor
ignition load switch in the servomotor (ZM: No. IV) and if
necessary increase slightly. Check sensor current with
microammeter.

Intermediate testing (partial load to full load):

After approx. 20 secs. the servomotor runs from ignition
to partial load position.

Set gas pressure to table in chapter 9.7 (Setting pressure

into solenoid valve).
Carry out CO test.

GL burners:
Make the necessary corrections to the pressure settings.
Version ZM:
Disengage servomotor, turn gas regulating cam by hand
and re-engage servomotor. Carry out CO tests at each Setting the gas quantity
cam setting up to full load setting.

RGL burners:
Make the necessary corrections by adjusting the gas
curve band.

Full load setting:

Drive up servomotor electrically towards full load:

Version ZM
Disengage servomotor, return gas regulating cam to its
intermediate position and re-engage servomotor. Set
selector switch in control panel to full load.

The required amount of gas for full load must be set and
measured at the gas meter (the gas pressures given in the
table chapter 9.7 are only a guide for setting and Setting the air quantity
adjusting).

Combustion test:

GL burners:
Regulate the amount of gas by adjusting the gas setting
pressure. Regulate the combustion values by adjusting
the curve band of the air regulating cam and positioning
of the regulating sleeve so that best possible values and
good flame stability are achieved with fully opened air
damper.

RGL burners:
The oil side settings of the air curve band and the mixing
head must not be altered. Match gas quantity to the
existing conditions by adjusting the gas curve band and
if necessary by correcting the gas pressure on the gas The gas pressure set for full load must not be altered in
governor. partial load.

19
Version ZM: Check the measurements of the CO limits when adjusting
As the operating range of the burner is used at “partial load to full load” and “full load to partial load”.
intermediate levels as well as the max. and min. levels,
combustion tests are required at each cam setting. Check and adjust the function of the safety equipment (i.e.
Adjust cams step by step (selector switch “Stop”, pressure switch for gas and air, thermostat, steam
disengage servomotor, adjust, re-engage servomotor). pressure switch...) with the installation in operation.

GL burners: Documentation:
Regulate combustion values by adjusting the air curve The following setting values must be recorded on the
band. engineer’s report and/or test sheet.

RGL burners: On ignition load:

Regulate combustion values by adjusting the air curve Gas throughput
band. Sensor current
CO
Ensure the curve bands have an even profile.
On liquid petroleum gas:
Measure smoke
Partial load setting
Set selector switch in the control panel to “Stage 1” or On full and partial load:
“Partial load”. Select the low fire setting required for partial Gas throughput
load with the auxiliary switch (Z: No. II, ZM: No. VI) and Gas pressure before ball valve
measure the gas rate at the gas meter. Gas pressure after ball valve
CO2
Finalising work CO
Check ignition load setting once burner has been Flue gas temperature
commissioned and if necessary adjust at auxiliary switch in Fan pressure
the servomotor (Z: No. V, ZM: No. IV). The setting is Draught /pressure in the combustion chamber
correct if the burner with empty mixing head starts without Sensor current
start impact. The required tests can be carried out when
the burner is stopped at the ignition load point (Z: trip
switch in servomotor, ZM: undo the neutral conductor to
servomotor once ignition load is reached).

Regulating sleeve position Regulating sleeve setting

Burner Basic setting *
type Number of Movement mm
drive lever

30/2-A 1 ~ 40

40/1-B 3 ~ 40

40/2-A 1 ~ 55

50/1-B 1 ~ 55

50/2-A 2 ~ 50

60/2-A 2 ~ 60

70/1-A 2 ~ 60 Driver lever regulating sleeve / movement setting

70/2-A 2 ~ 60

* Maximum movement of sleeve with air damper fully open

The regulating sleeves are closed at cam position 3.5 to 4.

This corresponds approximately to partial load on oil
operation.
In the ignition load position on gas and oil operation the
push rod moves into the spring sleeve.

On the burners type GL30 the regulating sleeve is set

according to rating. Adjustment during operation is not
possible.

Attention!
If the ball joint on the drive lever is screwed on to a
different thread, a lock nut has to be used (see
accessories list).

20
9.4 Set gas pressure switch

Gas pressure switch type GW50A2 To set a pressure switch for gas, a pressure measuring unit
has to be fitted to test point 1 of the DMV and the
microammeter for measuring of the ionisation current.
When determining the switch point, pay attention that this
is not below half the regulated pressure, that the ionisation
current is a minimum of 5 µA and that combustion is CO <
1000 ppm (CO increase due to excess air).

Setting is carried out in the following manner:

1. Burner is operating
30
25 20 2. Gradually close ball valve so that the pressure at the

15
pressure test unit slowly decreases.

40 35
GW

10 5
3. Setting pressure has been reached when
50 A
2

45
2,5
50 mbar
– CO increases
– sensor current is only 5 µA
– or when half the regulated gas pressure has been
reached.
4. Slowly turn the setting cam of the gas pressure switch
to the right until the burner carries out a controlled
shutdown.
5. Control - the burner is restarted with open ball valve.
If the ball valve is closed again, the shut down pressure
can be tested. The burner control must not go to
lockout.

High gas pressure switch, (to TRD/IM30)

must be set to 1.3 x pmax.

9.5 Set air pressure switch

Pressure switch for air type LGW50A2 The air pressure switch is pre-set. The switch point
must be checked and adjusted during commissioning.

For this a differential pressure measurement between

points 1 and 2 is required. Pressure behaviour is
monitored throughout the set range of the burner by the
pressure gauge. The lowest differential pressure value
20
30
25
is used for the determination of switch point. The switch
15
40 35

point is set to > 80% of this value. To do this, the

10 5

protective cap of the LGW is removed and the calculated

45

2,5
50 mba

value is set at the setting wheel.

Example:
Reduced differential 20 mbar
Switch point air pressure switch 20 x 0.8 = 16 mbar

Installation dependant influences, such as flue gas

recirculation, heat exchanger, installation or air supply, on
the air pressure switch and the settings may result in
adjustments having to be made.
Differential pressure test

21
9.6 Combustion analysis

Calorific value of various types of gas and max. CO2

Type of gas Calorific value Hi CO2 max.
MJ/m3 kWh/m3
1. Gas family
Group A (Towns Gas) 15.12…17. 64 4.20…4.90 12…13
Group B (Grid Gas) 15.91…18.83 4.42…5.23 10
2. Gas family
Group LL (Natural Gas) 28.48…36.40 7. 91…10.11 11.5…11.7
Group E (Natural Gas) 33.91…42.70 9.42…11.86 11.8…12.5
3. Gas family
Propane P 93.21 25.99 13.8
Butane B 123.81 34.30 14.1

To ensure efficient and problem free operation of the Flue gas temperature for partial load is the result of
installation, flue gas measurements must be taken. the control range adjustment.
The various maximum CO2 contents can be obtained from
the local gas board (guide values see table). The instructions of the manufacturer are to be
followed closely on hot water boiler installations.
Excess air should not exceed 10 to 20 % at full load Normally a partial load of 50 - 65% of the nominal load
and 30% at partial load. is set (some of the data may be on the boiler rating
plate).
CO2max.
Excess air λ –––––––––– On air heater installations the partial load is normally
CO2 measured even higher. Again, the instructions of the manu-
facturer should be closely followed.

The CO content must not be more than 0.005 Vol. % The flue gas installation should also be set out to
(50 ppm) protect against damage through condensation
(excluding acid proof chimneys).
Flue gas temperature for full load (nominal load) is
the result of burner setting at nominal loading.

22
9.7 Setting pressure and minimum connection pressure
The results of the following tables have been calculated may occur when commissioning, depending on individual
on flame tubes under idealised conditions. The values are installations.
therefore guidelines for basic settings. Small variations
Size 30/2 and 40/1 Size 40/2 and 50/1
Rating Low pressure supply High pressure supply Rating Low pressure supply High pressure supply
kW (gas pressure in mbar into isolating (gas pressure in mbar kW (gas pressure in mbar into isolating (gas pressure in mbar
valve, pe,max = 300 mbar) into solenoid valve) valve, pe,max = 300 mbar) into solenoid valve)
Nominal diameter of valve trains Nominal diameter of valve trains Nominal diameter of valve trains Nominal diameter of valve trains
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
Nominal diam. of gas butterfly valve Nominal diam. of gas butterfly valve Nominal diam. of gas butterfly valve Nominal diam. of gas butterfly valve
40 50 50 50 50 50 50 40 50 50 50 50 50 50 40 50 65 65 65 65 65 40 50 65 65 65 65 65

Natural Gas E, Hi = 37,26 MJ/m3 (10,35 kWh/m3), d = 0,606 Natural Gas E, Hi = 37,26 MJ/m3 (10,35 kWh/m3), d = 0,606
1200 58 31 17 12 10 9 – 23 19 11 8 7 6 6 1600 99 51 25 15 12 10 9 39 31 15 10 8 7 6
1400 79 42 23 16 13 11 10 32 25 15 11 9 8 8 1800 125 65 31 19 14 12 11 49 39 20 13 10 9 8
1600 102 54 29 20 16 14 13 42 33 19 14 12 11 10 2000 154 79 38 23 17 14 13 61 48 24 16 12 11 10
1800 128 68 36 24 19 17 16 53 42 25 18 15 14 13 2400 220 113 54 32 23 20 18 88 69 35 23 18 16 15
2000 158 83 44 29 23 21 19 65 52 31 22 19 17 16 2800 299 152 72 42 30 25 23 119 94 47 30 24 21 20
2200 190 100 53 35 27 24 22 79 63 37 26 22 20 20 3200 – 199 93 55 39 33 29 – 123 62 40 31 27 26
2400 226 118 62 42 32 28 26 94 75 44 31 26 24 23 3600 – – 117 68 48 40 36 – – 78 50 39 34 32
2550 255 133 70 46 36 31 29 106 84 49 35 30 27 26 4000 – – 143 84 59 49 44 – – 97 62 48 42 40

Natural Gas LL, Hi = 31,79 MJ/m3 (8,83 kWh/m3), d = 0641 Natural Gas LL, Hi = 31,79 MJ/m3 (8,83 kWh/m3), d = 0641
1200 83 44 23 15 12 11 10 33 26 15 10 9 8 8 1600 142 73 35 21 15 13 11 56 44 22 14 11 9 9
1400 112 59 31 20 16 14 13 45 36 20 14 12 11 10 1800 180 92 43 26 48 15 14 71 55 28 17 13 12 11
1600 145 76 39 25 20 17 16 59 46 27 18 15 14 13 2000 221 112 53 31 22 18 16 87 68 34 21 16 14 13
1800 183 95 49 32 25 22 20 75 59 34 24 20 18 17 2400 – 161 75 44 31 26 23 126 99 49 31 24 21 20
2000 226 117 60 39 30 26 24 92 73 42 29 24 22 21 2800 – 218 101 58 41 33 30 – 134 67 42 32 28 26
2200 272 141 72 46 35 31 28 111 88 50 35 29 26 25 3200 – – 131 76 53 43 39 – – 88 55 43 37 35
2400 – 167 85 54 41 36 33 132 105 60 42 35 31 30 3600 – – 165 94 66 53 48 – – 110 69 53 46 43
2550 – 188 96 61 46 40 37 – 118 67 47 39 35 34 4000 – – 203 116 80 65 58 – – 136 85 66 57 54

Liquid petroleum Gas B/P, Hi = 93,20 MJ/m3 (25,89 kWh/m3), d = 1,555 Liquid petroleum Gas B/P, Hi = 93,20 MJ/m3 (25,89 kWh/m3), d = 1,555
1200 27 16 10 8 – – – 11 9 6 – – – – 1600 43 24 13 9 7 7 6 17 14 8 5 – – –
1400 36 21 13 10 9 9 – 16 13 9 7 6 6 6 1800 54 30 16 11 9 8 7 22 17 10 7 6 5 –
1600 46 27 16 13 11 10 10 20 17 11 9 8 8 7 2000 66 36 19 13 10 9 8 27 21 12 8 7 6 6
1800 58 33 20 15 13 13 12 26 21 14 11 10 10 10 2400 95 51 26 17 14 12 11 39 31 17 12 10 9 9
2000 71 41 25 18 16 15 14 32 26 18 14 13 12 12 2800 128 68 35 23 18 16 14 53 42 23 16 14 12 12
2200 86 49 27 22 19 17 16 38 32 21 17 15 14 14 3200 166 88 45 29 23 20 18 69 55 31 21 18 16 16
2400 101 57 35 25 22 20 19 46 38 25 20 18 17 17 3600 209 110 55 36 27 24 22 87 70 38 27 22 20 19
2550 114 64 38 28 24 23 21 51 43 28 23 20 19 19 4000 258 136 68 43 33 29 27 108 86 47 33 27 25 24

Size 50/2 * The data given for DN40 is also valid for 11/2” and those
Rating Low pressure supply High pressure supply for DN50 for 2” valve trains.
kW (gas pressure in mbar into isolating (gas pressure in mbar
valve, pe,max = 300 mbar) into solenoid valve) The combustion chamber pressure in mbar must be added
Nominal diameter of valve trains Nominal diameter of valve trains
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150 to the minimum gas pressure determined.
Nominal diam. of gas butterfly valve Nominal diam. of gas butterfly valve
50 50 65 80 80 80 80 50 50 65 80 80 80 80 Selection of nominal diameter for valve trains for towns gas
Natural Gas E, Hi = 37,26 MJ/m3 (10,35 kWh/m3), d = 0,606 see separate worksheet,
2000 163 96 54 39 33 30 29 70 64 41 32 28 27 26
2500 245 140 75 52 42 38 36 102 93 56 41 36 34 33
print No. 900.
3000 – 193 100 66 52 46 43 139 126 73 52 45 41 40
3500 – – 128 81 62 54 50 – – 91 63 53 48 47 With low pressure supplies with double solenoid valves
4000 – – 159 98 73 63 58 – – 112 76 62 56 54
4500 – – 193 116 85 71 65 – – 135 88 72 64 61 (DMV) gas pressure governors with safety diaphragm are
5000 – – – 135 97 80 73 – – – 102 81 72 68 used. Maximum permissible connection pressure into
5500 – – – 156 110 90 81 – – – 117 92 80 75 isolating valve is 300 mbar on low pressure installations.
Natural Gas LL, Hi = 31,79 MJ/m3 (8,83 kWh/m3), d = 0641
2000 234 136 76 54 45 41 39 101 92 58 45 40 37 37 With high pressure supplies high pressure gas governors
2500 – 201 107 72 58 52 49 – 133 79 59 51 47 46
3000 – – 142 92 72 63 59 – – 104 74 63 58 56 to DIN 3380 are selected from the technical brochure
3500 – – 182 114 87 75 70 – – 131 90 75 68 66 “Pressure regulating and safety assemblies for Weishaupt
4000 – – – 138 102 87 80 – – – 107 88 79 76
4500 – – – 164 119 100 91 – – – 126 101 90 86
gas and dual fuel burners”.
5000 – – – – 136 113 102 – – – – 115 101 96
5500 – – – – 155 126 113 – – – – 130 112 106 High pressure gas governors for connection pressure up
LPG B/P, Sw = 93,20 MJ/m3 (25,89 kWh/m3), d = 1,555 to 4 bar are detailed in this brochure.
2000 74 47 30 24 21 20 19 35 33 23 19 18 17 17
2500 110 67 40 30 26 25 23 49 46 31 25 23 22 21
3000 152 90 52 38 32 29 28 66 61 39 31 27 26 26 Max. supply pressure see burner name plate.
3500 201 116 65 45 38 34 33 85 78 48 37 33 31 30
4000 257 147 79 54 44 39 37 107 97 58 43 38 35 34 The data given for calorific value Hi relate to 0°C and
4500 – 180 95 63 50 45 42 130 118 69 50 43 40 39
5000 – – 112 72 56 50 47 – – 81 57 49 45 43 1013.25 mbar.
5500 – – 130 82 63 55 51 – – 93 65 54 49 48

23
Size 60/2 * The data given for DN40 is also valid for 11/2” and those
Rating Low pressure supply High pressure supply for DN50 for 2” valve trains.
kW (gas pressure in mbar into isolating (gas pressure in mbar
valve, pe,max = 300 mbar) voor het dubbel magneetventiel)
Nominal diameter of valve trains Nominal diameter of valve trains
The combustion chamber pressure in mbar must be added
50* 65 80 100 125 150 40* 50* 65 80 100 125 150 to the minimum gas pressure determined.
Nominal diam. of gas butterfly valve Nominal diam. of gas butterfly valve
65 65 80 100 100 100 65 65 65 80 100 100 100
Selection of nominal diameter for valve trains for towns gas
Natural Gas E, Hi = 37,26 MJ/m3 (10,35 kWh/m3), d = 0,606 see separate worksheet, print No. 900.
3500 – 118 71 52 44 40 166 148 82 54 43 38 37
4000 – 148 87 61 51 46 – 187 101 65 51 44 42 With low pressure supplies with double solenoid valves
4500 – 181 104 72 58 52 – – 123 76 59 51 48 (DMV) gas pressure to EN 88 with safety diaphragm are
5000 – – 122 82 66 59 – – 146 89 67 57 54 used. Maximum permissible connection pressure into
5500 – – 141 93 74 65 – – 171 102 75 63 59
6000 – – 162 105 82 71 – – 198 116 84 70 65 isolating valve is 300 mbar on low pressure installations.
Natural Gas LL, Hi = 31,79 MJ/m3 (8,83 kWh/m3), d = 0641
3500 – 158 90 62 51 45 – – 107 66 51 43 41 With high pressure supplies high pressure gas governors
4000 – 200 111 74 59 52 – – 133 80 60 50 47 to DIN 3380 are selected from the technical brochure
4500 – – 134 87 68 59 – – 162 95 69 58 54
5000 – – 158 101 77 67 – – 194 111 80 65 60 “Pressure regulating and safety assemblies for Weishaupt
5500 – – 185 115 86 74 – – – 128 90 73 67 gas and dual fuel burners”.
6000 – – – 131 96 82 – – – 147 101 80 73
Liquid petroleum Gas B/P, Hi = 93,20 MJ/m3 (25,89 kWh/m3), d = 1,555 High pressure regulators for connection pressure up to
3500 107 58 39 31 28 26 76 69 42 31 26 24 23 4 bar are detailed in this brochure.
4000 136 72 47 36 32 30 96 86 51 36 30 28 27
4500 168 87 55 42 36 33 118 106 61 42 35 32 30
5000 203 103 63 47 40 37 142 127 72 48 39 35 34 Max. supply pressure see burner name plate.
5500 – 120 73 53 45 41 168 150 83 55 44 39 37
6000 – 139 82 59 49 45 197 175 96 62 49 43 41
The data given for calorific value Hi relate to 0°C and
Size 70/1 and 70/2 1013.25 mbar.
Rating Lowpressure supply High pressure supply
kW (gas pressure in mbar into isolating (gas pressure in mbar
valve, pe,max = 300 mbar) voor het dubbel magneetventiel)
Nominal diameter of valve trains Nominal diameter of valve trains
50* 65 80 100 125 150 40* 50* 65 80 100 125 150
Nominal diam. of gas butterfly valve Nominal diam. of gas butterfly valve
65 65 80 100 100 100 65 65 65 80 100 100 100
Natural Gas E, Hi = 37,26 MJ/m3 (10,35 kWh/m3), d = 0,606
5000 – – 119 79 63 56 – – 143 86 64 54 51
6000 – – 159 102 78 68 – – 195 112 81 66 61
7000 – – – 126 94 81 – – – 141 99 79 73
8000 – – – 154 112 94 – – – 174 118 93 84
9000 – – – 183 130 108 – – – – 139 107 96
10000 – – – – 150 122 – – – – 161 122 108
10500 – – – – 160 130 – – – – 173 129 114
Natural Gas LL, Hi = 31,79 MJ/m3 (8,83 kWh/m3), d = 0641
5000 – – 155 97 73 63 – – 191 108 76 62 57
6000 – – – 126 92 78 – – – 143 97 76 69
7000 – – – 159 113 93 – – – 182 120 92 82
8000 – – – – 135 109 – – – – 145 108 95
9000 – – – – 158 126 – – – – 172 125 109
10000 – – – – – 143 – – – – – 143 123
10500 – – – – – 152 – – – – – 152 131
Liquid petroleum Gas B/P, Hi = 93,20 MJ/m3 (25,89 kWh/m3), d = 1,555
5000 201 101 61 45 38 35 140 125 70 46 37 33 32
6000 – 136 80 57 47 42 194 172 93 59 47 41 39
7000 – 178 101 69 56 50 – – 120 74 56 48 45
8000 – – 124 82 65 58 – – 149 89 66 56 52
9000 – – 149 97 75 66 – – 182 106 77 64 59
10000 – – 177 112 85 74 – – – 124 89 72 67
10500 – – 192 120 91 78 – – – 134 94 76 70

24
10. Setting the mixing head
Burner type Flame tube Perforated Regulating Conical Gas nozzle ø Movement Distances
diffuser sleeve ø diffuser Natural for sleeves
Type ø outer ø inner ø outer ø inner ø Gas E LPG a b c d e
GL30/2-A G30/2 250 – – 185 190 65 – – 40 – 90 – 10
RGL30/2-A G30/2 250 – – 185 190 65 – – 40 – 90 – 10
RGMS30/2-A G30/2 250 – – 185 190 65 – – 40 – 90 – 10
GL40/1-B G30/2 250 – – 185 190 65 – – 40 – 90 – 10
RGL40/1-B G30/2 250 – – 185 190 65 – – 40 – 90 – 10
RGMS40/1-B G30/2 250 – – 185 190 65 – – 40 – 90 – 10
GL40/2-A G40/2 290 – – 215 217 75 – – 40-60 – 100 – 10
RGL40/2-A G40/2 290 – – 215 217 75 – – 40-60 – 100 – 10
RGMS40/2-A G40/2 290 – – 215 217 75 – – 40-60 – 100 – 10
RGL50/1-B G40/2 290 – – 215 217 75 – – 40-60 – 100 – 10
RGMS50/1-B G40/2 290 – – 215 217 75 – – 40-60 – 100 – 10
RGL50/2-A G50/2 350 290 205 200 185 75 15 13 < 50 60 150 20 10
RGMS50/2-A G50/2 350 290 205 200 185 75 15 13 < 50 60 150 20 10
RGL60/2-A G60/2 400 345 235 230 230 70 15 13 < 60 70 180 20 10
RGMS60/2-A G60/2 400 345 235 230 230 70 15 13 < 60 70 180 20 10
RGL70/1-A G70/1a 480 425 295 290 290 120 16 13 < 60 70 180 20 10
RGL70/2-A G70/1a 480 425 295 290 290 120 16 13 < 60 70 180 20 10
RGMS70/1-A G70/1a 480 425 295 290 290 120 16 13 < 60 70 180 20 10
RGMS70/2-A G70/1a 480 425 295 290 290 120 16 13 < 60 70 180 20 10

The mixing head and flame tubes are permanently set. 40/1-B and 30/2-A
After mounting the burner on the heating appliance it must 40/2-A
50/1-B
be checked whether the annular air gap between flame
tube and diffuser or regulating sleeve is concentric.

Mixing head size 30/40

The gas distribution takes place with 4 tubes on the outside
edge of the diffuser and with 8 holes inside the mixing
tube.

On burners type GL30 the regulating sleeve is permanently

set according to the rating. Adjustment during burner
operation is not possible.

50/2-A
Mixing head size 50/60/70 60/2-A
For Natural Gas and Liquid Petroleum Gas the gas 70/1-A, 2-A
distribution is via 12 tubes, 9 with nozzles and 3 without.
Of these, 3 are straight and protrude through the
perforated diffuser, 6 are angled towards the centre
terminating behind the diffuser. They can be turned and/or
moved back. Three tubes without nozzles point towards
the centre orifice of the conical diffuser. Mixing heads for
Towns Gas require 20 tubes (additional cost).

Pressure side regulation

To achieve the largest regulating range, the mixing heads
have a pressure side regulating sleeve between diffuser
and flame tube. The regulating sleeve is operated in
conjunction with the air damper. The sleeve is closed on
partial load and opened on full load. The basic setting of
the adjusting sleeve can only be altered at the control rod
linkage and change of direction can only be done with the
drive lever (see chapter 9.3). The burners sizes 50/60/70
have a second regulating sleeve between the conical
diffuser and the perforated diffuser. Regulating sleeve in closed position Regulating sleeve in open position
at burner start and partial load at full load

25
11. Capacity graphs
Size 30/2-A

[ mbar ] Burner type

Type of combustion head
GL30/2-A
G30/2 - 190x65
Comb. head "Open"
Comb. head "Closed"
The ratings depending on pressure in the combustion
Rating kW, Natural Gas 300 – 2150 chamber are limit values, which have been measured
Liquid Petrol. Gas
Rating kg/h, Distillate Oil EL
450 – 2150
40 – 180
on idealised test flame tubes to DIN 4788, part 1 or EN
267 and DIN 4788, Part 2 or EN 676. All ratings data
16 given relate to an air temperature of 20° C and an
14 installation elevation of 500 m.
12
10
8
The oil throughput information refers to calorific values
6
of 11.91 kWh/kg for distillate oil EL and 11.24 kWh/kg
for residual oil S.
Distill. Oil EL

4
2
Modulating burners
LPG
Nat.

0
gas

-2 The modulating burner is based on the sliding two stage

[kW] 0 400 800 1200 1600 2000
burner. The modulating characteristic is obtained with a
[ mbar ] Burner type RGL30/2-A RGMS30/2-A special regulating controller, which is fitted in the control
Type of combustion head G30/2 - 190x65 G30/2 - 190x65 panel. A servomotor with 42 seconds running time is also
Rating kW, Natural Gas 300 – 2150 300 – 2150
Liquid Petrol. Gas 400 – 2150 400 – 2150 used.
Rating kg/h, Distillate Oil EL 40 – 180 –
Residual Oil S – 60 – 190
16 The burner types shown are type tested for the following
14 fuels:
12
10 Natural Gas ______________________________ E and LL
8 Liquid Petroleum Gas __________________________ B/P
6
Fuel oil ________________________________________ EL
4
Natural Gas

Residual S

2
Burners with speed control or electronic compound
Oil EL
Distill.
LPG

0
-2 regulation
[kW] 0 400 800 1200 1600 2000 There is no reduction in the rating when using speed
control or electronic compound regulation, even when
Size 40/1-B combined with O2 regulation. On burners with speed
control and electronic compound regulation and FGR as
[ mbar ] Burner type GL40/1-B, RGL40/1-B RGMS40/1-B well as with or without O2 regulation a reduction of 5 %
Type of combustion head G30/2 - 190x65 G30/2 - 190x65
Rating kW, Natural Gas/LPG 450 – 2550 450 – 2550
occurs.
Rating kg/h, Distillate Oil EL 45 – 215 –
Residual Oil S – 70 – 225
Burners with flue gas recirculation (FGR) and /or
22 O2 regulation
20
18 G, RGL, RGMS If a flue gas recirculation system or O2 regulation is
16 GL provided, then the maximum burner capacity graphs are
14
reduced by the following values:
Natural Gas and LPG

12
10
8
Reduction approx. % System
Distill. Oil S

6
Residual S

4
2
0
5% FGR
-2 10% O2 regulation
[kW] 0 500 1000 1500 2000 2500 3000 3500 4000
15% FGR with O2 regulation

Size 40/2-A With flue gas recirculation it must also be noted that the
combustion chamber resistance increases by the factor
[ mbar ] Burner type GL40/2-A, RGL40/2-A RGMS40/2-A
1.3. The exact value can be obtained from the planning
Type of combustion head G40/2 - 217x75 G40/2 - 217x75 documents for flue gas recirculation, print No. 1025.
Rating kW, Natural Gas 500 – 3450 500 – 3450
Liquid Petr. Gas 600 – 3450 600 – 3450
Please also check if combustion head extensions are
Rating kg/h, Distillate Oil EL 55 – 290 – needed with FGR (see “Special Equipment”). On burners
Residual Oil S – 90 – 300
22
with flue gas recirculation, only sound absorbers of special
20 execution may be fitted.
18 G, RGL, RGMS
16
14 GL
12
10
LPG

8
Natural Gas

Distill. Oil S

6
Residual S

4
2
0
-2
[kW] 0 500 1000 1500 2000 2500 3000 3500 4000

26
Size 50/1-B Size 50/2-A

[ mbar ] Burner type RGL50/1-B RGMS50/1-B [ mbar ] Burner type RGL50/2-A RGMS50/2-A
Type of combustion head G40/2 - 217x75 G40/2 - 217x75 Type of combustion head G50/2 - 290–185 G50/2 - 290–185
Rating kW, Natural Gas 550 – 4000 550 – 4000 Rating kW, Natural Gas 600 – 5400 600 – 5400
Liquid Petr. Gas 600 – 4000 600 – 4000 Liquid Petr. Gas 950 – 5400 950 – 5400
Rating kg/h, Distillate Oil EL 55 – 336 – Rating kg/h, Distillate Oil EL 95 – 453 –
Residual Oil S – 100 – 355 Residual Oil S – 130 – 480
22 22
20 20
18 18
16 16
14 14
12 12
10 10
LPG

8 8

Distill. Oil EL
Distill. Oil EL

Natural Gas
6 6

Residual S
Residual S
Nat. Gas

4 4
2 2

LPG
0 0
-2 -2
[kW] 0 500 1000 1500 2000 2500 3000 3500 4000 [kW] 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Bouwgrootte 60/2-A
[ mbar ] Burner type RGL60/2-A RGMS60/2-A
Type of combustion head G60/2-345–230 G60/2-345–230
Rating kW, Natural Gas 800 – 6100 800 – 6100
Liquid Petr. Gas 1000 – 6100 1000 – 6100
Rating kg/h Distillate Oil EL 110 – 512 –
Residual Oil S – 160 – 543
22
20
18
16
14
12
10
8
6
Distill. Oil EL
Natural Gas

Residual S

4
2
LPG

0
-2
[ kW ] 0 1000 2000 3000 4000 5000 6000

Size 70/1-A Size 70/2-A

[ mbar ] Burner type RGL70/1-A RGMS70/1-A [ mbar ] Burner type RGL70/2-A RGMS70/2-A
Type of combustion head G70/1a-425-290 G70/1a-425-290 Type of combustion head G70/1a-425-290 G70/1a-425-290
Rating kW, Natural Gas 1000 – 8200 1000 – 8200 Rating kW, Natural Gas 1000 – 10500 1000 – 10500
Liquid Petr. Gas 1500 – 8200 1500 – 8200 Liquid Petr. Gas 1500 – 10500 1500 – 10500
Rating kg/h Distillate Oil EL 160 – 688 – Rating kg/h Distillate Oil EL 160 – 881 –
Residual Oil S – 175 – 730 Residual Oil S – 190 – 934
22
20 22

18 20

16 18

14 16

12 14
10 12
8 10
Liquid Petr. Gas

6 8
Liquid Petr. Gas
Distill. Oil EL
Natural Gas

Residual S

4 6
Natural Gas

Distill. Oil S

Residual S

2 4
0 2
-2 0
kW ] 0 1000 2000 3000 4000 5000 6000 7000 8000 -2
[ kW ] 0 2000 4000 6000 8000 10000

27
12. Oil supply
Reliable operation to a large extent depends on the oil Setting for oil S
supply. The pipe system and sizing can be obtained from To avoid vaporisation of water in the fuel oil, the minimum
out technical worksheets. ring main pressure, including a safety margin, must be set
according to the following table. It is based on the
Ring-main system pressure, which is measured at the burner pump inlet (ring
The use of a ring main oil system is recommended and main pressure).
often essential.
Oil temperature on Ring main pressure
Note burner °C up to bar
The installation dependent ring-main pressure increases
the factory pre-set burner pump pressure. 125 2.5
130 2.7
Single pipe installation on request. 135 3.2

Suction lift operation 140 3.8

Suction lift operation is possible for individual burners 145 4.4
operating on distillate oil EL. For installation and functional 150 5.0
diagrams for ring main and suction lift operation, see
technical work sheet 5... Note
Isolating devices in the return flow line must be
Ring-main with oil filter protected from unintentional closure (e.g. ball valves
Large installations (industrial or district heating) should, if with mechanical connection or burner interlock
at all possible, be operated without interruptions. We switch).
therefore recommend the use of a duplex-pump unit,
which can operate with one or the other pump. Both Attention!
pumps are fitted with oil filters, so that it is possible to If the shut off combination is used to test the operation
clean one pump or it’s filter during burner operation. The of the end position switch, the manual lever may only
supply quantity must be at least twice the nozzle capacity be closed until the end position switch has responded.
of all burners connected to the ring main. Pre-requisite is The combination can only be shut completely when
the installation of a gas / air separator or circulation tank. the burner pump has shut off. Otherwise pressure
With residual oil installations, filters, pumps and oil lines surges and cavitation can damage the pump.
must be equipped with line heating.
The installation of non return valves is not permitted
Strainer on burners with return flow nozzles.
A strainer is fitted in the burner oil pipe work (flow), to
prevent debris, such as loosened particles from the Residual oil installation must have adequate heating
welded joints for example from reaching the solenoid of the pipework.
valves. The filter should be cleaned periodically,
particularly at the early stage of operation. The gas/air separators should be fitted as close as
possible to the burner. Single pipe installation on
Air/gas separator request.
A Weishaupt air/gas separator should be fitted at the point
at which the burner is connected to the ring-main system. On dual fuel burners without electromagnetic clutch,
The air/gas separator should be fitted as close to the the oil isolating combination must not be closed
burner as possible (see technical work sheets). It is during gas operation.
particularly important to use a separator on residual fuel oil
installations. When installing the air / gas separators,
please observe the instruction label of the unit.

Filter
A fine mesh filter between the ring main and burner pump
connection must be fitted. This filter prevents dirt particles
from the oil and pipework from reaching the burner.
Operating without filter can have the following
consequences:
■ Seizing of pump gearing
■ Blocking of solenoid valve and nozzle.

Oil supply to burner

Oil supply line to the burner termination of the oil supply
pipes must allow tension free connection of the flexible oil
hoses. Both oil and electrical connections must allow the
burner to swing open.

Pressure regulating valve in the ring main.

Setting for distillate oil EL ring-main pressure 1 ... 1.5 bar.

28
Line heating of oil supply pipes with tracer cable. Example of line heating Insulating sleeve.
Avoid winding the tracer cable in spirals round the pipe Pipe insulation of heat
but lay parallel along the pipe axis (see illustration). The resistant material
tracer cable loading is approximately 30 Watt per metre.
Operating voltage is 220 or 380 Volt. The tracer cable is Aluminium foil
laid back and forth on the pipe (see illustration), so that
both cable ends finish in the same place. It is important Cable tie
that the cable is laid closely to the pipe in order to
guarantee good heat transfer. The cable is connected with Tracing cable
so-called cold ends. The pipe insulation must be suitable
for a temperature of more than 100°C.

Attention!
Oil supply pipe
The cold ends must not be shortened.

Example of an oil supply system for residual oil S (burner size RGMS 60/70)
Burner Burner

All oil supply lines are to be fitted with line heating.

The isolating valves in the supply and return lines must fittings for the media pre-heater see separate oil pre-
be mechanically connected. For the inlet and outlet heater leaflet.

Legend 12 Pressure gauge 0 to 40 bar

1 Storage tank with outflow heater. 13 Adjustable pressure regulating valve (pump
2 Quick action shut off valve (mechanically connected) assembly)
with limit switch 14 Oil pre-heater (electric)
3 Filter 15 Oil pre-heater (media)
4 Ball valve 16 Oil pre-heater (media or electric)
5 Compound gauge - 1 to + 5 bar 17 Thermometer 0 to 160°C
6 Oil ring-main pump(s) 18 Adjustable pressure regulating valve (ring main)
7 Pressure gauge 0 to 10 bar 19 Line heating (media)
8 Non return valve 20 Line heating (electric)
9 Air / gas separator 21 Relief valve
10 Ball valve (mechanically connected) with limit switch
11 Pump(s)

29
13. Pump assembly for residual oils M + S
Pump capacity for Pump - Tech. Data
burner sizes 60+70 Capacity at Speed Motor at Single pump Duplex pump
approx. kg/h 150 mm2s l/h rpm 450 mm2/s kW type type

230 - 350 860 2900 1.5 SPF 10 / 38 SPZ 10 / 38

350 - 650 1770 2900 4.0 SPF 20 / 38 SPZ 20 / 38

650 - 940 2310 2900 4.0 SPF 20 / 46 SPZ 20 / 46

940 - 965 3630 2900 5.5 SPF 40 / 38 SPZ 40 / 38

Pump Setting the pressure regulating valve.

Spindle screw pumps are used, fitted with a relief valve. The cover nut 5 is removed and the required pump
This valve is set at the factory to 37 bar and protects the pressure set with the adjusting screw.
motor against overloading. This valve does not usually
require further adjustment. The actual working pressure is Clockwise rotation = pressure increase
set by the pressure regulating valve in the pump assembly. Anti clockwise rotation = pressure reduction
It is recommended that the pump assembly is placed on an
absorption base. The setting can be checked on the pressure gauge. The
pressure gauge isolating valves must be closed after
Technical information adjustments have been carried out
Max supply pressure ________________________ 5,0 bar
Max permissible vacuum______________________ 0,5 bar Ball valves on the pump assembly
Max atomising pressure _______________________ 30 bar The ball valves are only closed when the pumps are being
Oil supply temperature ________________________ 90° C repaired. Also with duplex units the ball valves remain open
Max oil-pump viscosity ____________________ 450 mm2/s on the idle pump. The fuel oil is prevented from flowing
back by the non return valve. When switching over from
Note for commissioning. one pump to the other it is only necessary to actuate the
When commissioning it must be ensured that pump(s) selector switch on the control panel.
never run dry. During commissioning, the filter, pipelines
and pumps must be pre-filled with fuel oil and vented. Isolating combination shut off valves on burner
The direction of rotation of the motor should checked. connection.
The ball valves are usually closed in cases of prolonged
Filter shutdown. They are mechanically connected and have an
High capacity filters are used, which are integrated into interlock switch. Burner operation is inhibited by this
the pump body. On duplex units one filter is connected to interlock switch when the valves are closed.
each pump. Frequency of cleaning depends on the
amount of contamination of the fuel oil. For residual oil S Attention!
the oil filters must be fitted with line heating. If the shut off combination is used to test the operation
of the end position switch, the manual lever may only
be closed until the end position switch has responded.
The combination can only be shut completely when
the burner pump has shut off. Otherwise pressure
surges and cavitation can damage the pump.

30
Single Pump station type SPF

Dimensions for pump station SPF

SPF 10/38 20/38 20/46 40/38

d1 33.7 48.3 42.4 60.3

d2 26.9 33.7 33.7 48.3

Duplex Pump station type SPZ

Dimensions for pump station SPZ

SPZ 10/38 20/38 20/46 40/38

d1 33.7 48.3 42.4 60.3

d2 26.9 33.7 33.7 48.3

➀ Fuel oil inlet (suction side) ➃ Burner return (to be provided on site)
➁ Fuel oil outlet (pressure line to burner) ➄ Cover nut for pressure adjusting screw
➂ Fuel oil return (pump return) ➅ Filter heating

14. Oil hose installation for metal hoses (residual oil S)

RGMS40/RGMS50 - example

Burner
size h l b1* b2 b3 DN Connection

30/40 690 80 200 8 470 20 M 30 x 1.5

50 780 80 200 8 470 25 M 38 x 1.5

* Dimension depends on the sizing and version of the shut

off combination (see worksheet print No. 745)

31
RGMS60/RGMS70 - example
Burner Return Supply Supply Return
size h l b1* b2 b3 r DN Connection

60 655 570 1000 130 620 240 16 M 26 x 1.5

70 760 570 1000 130 675 240 20 M 30 x 1.5

* Dimension depends on the sizing and version of the shut

off combination (see worksheet print No. 745)

Oil hoses to
be supported

General
The oil hoses and pressure hoses used are made of
corrugated high grade steel with a high grade woven wire
sleeve cover.

The oil hoses and pressure hoses are well suited for
residual oil operation if the following application rules are
observed. Resistance against the chemical effects and
temperature of the fuel oil is designed for long term
service.

The TRD411, DIN 4787 standard specifies metallic hoses

for residual oil installations.

Oil and pressure hoses must be protected from external

mechanical damage.

When installing care must be taken to ensure that the

hoses are not twisted. They must not receive torsion strain
either during installation or during later movement. It is
important that both hose ends and movement lie in one
plane.

In order to ensure torsion free installation the hose should

first be only loosely fixed at one end, then moved through
the required hose movement 2 to 3 times, so that the hose
can align without distortion, and then tighten in position.

A second spanner should be used for counter holding.

Particular care must be taken to ensure that the hoses do

not foul each other or other equipment (burner, oil line or Specification and technical data
boiler) during operation.
Oil hoses in oil supply installations (supply and return
Adequate curve radii and minimum hose lengths must be lines)
adhered to during installation. In most cases the hoses On residual oil (S) installations, the hoses must be suitable
should be supported when installed horizontally. for an operating pressure of 10 bar and an operating
temperature of 160°C. Allowing for the temperature factor
The hose connections can be fitted in either swivel for the high grade steel, the following applies for these
direction. hoses.

Example Nominal pressure _______________________ PN = 16 bar

Connect hoses without twisting. On threaded swivel Test pressure __________________________ PP = 21 bar
connections, a second spanner should be used for
counter holding. When installing the oil hoses in the supply and return
(between pump and rigid pipe installation) the product
related technical drawings should be observed.

32
Oil hoses to DIN 4798 Part 1 pressure class A are Hoses of sufficient length should be selected. An
supplied for distillate oil. Maximum hose length to additional length must be allowed for on the hose ends.
DIN 4755 = 1.5 m. This length must remain straight, i.e. the curve radius must
not commence until after this rigid section.
Heated oil hoses for residual oil operation on request,
electric rating 80 Watt.

Technical data:
Nominal pressure _______________________ PN = 10 bar
Test pressure___________________________ PP = 15 bar
Operating temperature ___________________ TB = 70° C

Pressure hoses (between pump and nozzle)

For this application the pressure hoses should be suitable
for an operating pressure of 30 bar and an operating
temperature of 160°C.

Under consideration of the temperature factor the

following applies:
Operating temperature __________________ TB = 160° C
Nominal pressure _______________________ PN = 64 bar
Test pressure___________________________ PP = 82 bar
Operating pressure _____________________ PB = 30 bar Additional length
The minimum curve radius of the hose depends on the DN Z = additional length
nominal clearance on the appliance, the material and the
type of manufacture. The application on our products has 6 80
been agreed with the hose manufacturer, using actual 8 85
equipment. For free usage and installation, the following 10 90
minimum radii must be adhered to in accordance with the
installation instructions. 12 100
Minimum radii 16 125
20 130
DN r = minimum 25 135
curve radius
When installation has been carried out the minimum radii
6 70 must be checked in the most adverse position, if
8 100 necessary a fixed stop must be fitted on site to limit the
10 110 movement.
12 110
16 210
20 240
25 250

Oil hose connection according to burner type

Oil hoses Oil hoses

DN length mm Connect. Connect. DN length mm Connect. Connect.

thread nipple thread nipple
Supply Return pump installat. Supply Return pump installat.
side side side side

GL40/1-B + 13 1000 1000 G 1/2 G 1/2 RGL60/2-A 25 1300 1300 M38 x 1,5 G 1
30/2-A RGMS60/2-A 16 1150 1500 M26 x 1,5 (18L) G 1/2
RGL40/1-B 20 1000 1000 M30 x 1,5 G1
RGMS40/1-B 20 1300 1000 M30 x 1,5 G1 RGL70/1-A 25 1300 1300 M38 x 1,5 G1
u. 30/2-A RGL70/2-A 25 1300 1300 M38 x 1,5 G1

GL 40/2A 20 1000 1000 M30 x 1,5 G1 RGMS70/1-A 20 1150 1500 M30 x 2 (22L) G 3/4
RGL40/2-A 20 1300 1300 M30 x 1,5 G1 RGMS70/2-A 20 1150 1500 M30 x 2 (22L) G 3/4
RGMS40/2-A 20 1300 1000 M30 x 1,5 G1

RGL50/1-B 25 1300 1300 M38 x 1,5 G1

RGL50/2-A 25 1300 1300 M38 x 1,5 G1

RGMS50/1-B 25 1500 1150 M38 x 1,5 G1

RGMS50/2-A 25 1500 1150 M38 x 1,5 G1

33
15. Oil pre-heater system
For burners using medium and residual fuel oil, the oil must temperature or pressure of the installation is reached.
be preheated to the temperature required for atomisation. During this period only the electric pre-heater heats the oil
and the throughput of the burner must be adapted to the
The oil can be heated electrically or with a heating pre-heat capacity of the electrical pre-heater during the
medium, or by a combination of both electrical and media starting time of the cold plant.
pre-heater. Hot water, low pressure steam, high pressure
steam and thermal fluid can be used as heating media. On downward firing burners, media pre-heaters are
rotated 90°C. The oil pre-heaters MV9 and MV10 can
On installations with media pre-heater and without only be fitted with the media outlet on top for liquid
electrical pre-heater, the following minimum pressures and media or below when using steam. If the burner is
temperatures are required for heating the residual oil S: ordered for downward firing, this is already allowed for.
If the burner is to be changed to downward firing at a
High pressure steam over 7.5 bar later stage, then extra brackets are required to fix the
Hot water from 180 – 200°C media pre-heater.
Thermal fluid from 200 – 300°C
Nozzle head heating
These temperatures and pressures must always be A heating cartridge with a capacity of 100 Watt is fitted in
available so that the oil can be heated to the temperature the nozzle body. An electronic P type controller controls
and viscosity required for atomisation. the nozzle temperature. An NTC sensor is fitted to
determine the temperature. The ROB control can be set
The pre-heater combination consists of a media pre-heater between temperatures of 65 and 130°C according to the
station and an electrical pre-heater station, which have to fuel quality.
be connected on site. The oil outlet of the media pre-
heater station should be connected to the oil inlet of the The temperature release switch in the regulating control is
electrical pre-heater station. connected in series with the oil pre-heater release
thermostat and only allows burner start after the selected
The ball valve fitted between the media and electrical nozzle head temperature and minimum oil pre-heater
pre-heater (see technical description of electrical and temperature has been reached.
media pre-heaters) is closed when the heating medium is
available. The valve must only be open during start up on
a cold plant and remain open until the final working

Electric pre-heater fitted size 50 Electric pre-heater station

Media pre-heater station

Ball valve

34
Capacity of heated components
Burner Burner Pump Nozzle Solenoid Pressure Oil
type pump Watt heat supply/ switch regulator
type Watt return Watt Watt
Watt

RGMS30/2-A TA3 100 100 20 20 20

RGMS40/1-B TA3 100 100 20 20 20

RGMS40/2-A TA3

RGMS50/1-B TA4 100 100 20 20 20

RGMS50/2-A T2

SPF 20/38
RGMS60/2-A 100 100 20 20 20
SPZ 20/38

SPF 20/46
RMS70/1-A 100 100 20 20 20
SPZ 20/46

SPF 20/56
RMS70/2-A 100 100 20 20 20
SPZ 40/38

Heated pump station Heated nozzle head

NTC sensor

Heating sleeve
Heating cartridge

Pump TA, heated Heated pressure switch

Heating
Heating cartridge cartridge

Heated oil regulator Heated solenoid valve

Heating cartridge
Heating cartridge

35
16. Pumps for fuel oils EL, M and S
Pumps type TA and T are suitable for installation in a two Pump J7
pipe system.
6 7
With a T pump, the pressure regulating valve is fitted
separately. The pipe system is arranged in such a manner
that the two pipe system has to be used.

Solenoid
Burner Pump coupling

GL30/2-A
and GL40/1-B J7 WMK2
1 5 2 6 3
RGL30/2-A, RGMS30/2-A
+ RGL40/1-B, RGMS40/1-B TA3 WMK2/1 Pump TA
7 6 6a
GL40/2 vers. T TA3 WMK2/1
RGL40/2, RGMS40/2-A TA3 WMK2/1

RGL50/1-A TA4 WMK3/1

RGL50/2-A T2 WMK3

RGMS50/1-A TA4 WMK3/1

RGMS50/2-A T2 WMK3

RGL60/2-A T2 WMK3
1 5 2 2a 3
RGL70/1-A to 600 kg T2 WMK3
RGL70/2-A from 600 kg T3 WMK3 Pump T
Adjustment 3 7 6a 6 1
■ Prior to operation, the oil line on the suction side must
be filled with fuel oil and the pump must be vented. If
this is omitted, seizing of the pump may occur due to
dry operation.

■ For testing the vacuum, the supply line pressure or the

ring main system pressure on the suction side of the
pump, screw the vacuum gauge or pressure gauge
into connection (6).
2
■ For pressure adjustment, remove the cap nut (5) and 12 2a 5
adjust the pump pressure as required.
Clockwise rotation = pressure increase CouplingT and TA
Anticlockwise rotation = pressure decrease 8 9 10 11
T
■ The vacuum at the pump inlet must not exceed 0.5 bar.

■ Maximum supply pressure ___________ 5.0 bar

Pump coupling
There is a fixed coupling fitted between fan and oil pump
(motor shaft). 8 9 10 11
TA
When adjusting the intermediate coupling, it must be
ensured that there is no axial tension on the pump drive
shaft.

The coupling element on the pump should have an axial

movement of 1.5 mm.
1 Suction connection
2 Return connection
2a Oil regulator return connection
3 Nozzle supply line
5 Pressure adjusting screw
6 Pressure gauge connection (suction side)
6a Pressure gauge (pressure side)
7 Pump
8 Coupling centre piece
9 Coupling element
10 Socket head screw
11 Pump coupling
36
Magnetic clutch Magnetic clutch
A magnetic clutch, without slip rings, carries the drive
connection between burner motor and pump on oil
operation. On gas operation the pump is de-coupled, so
that it does not undergo unnecessary wear and tear. Distance
~0.5
Distance between discs when de-coupled is 0.3 to 0.5
mm.

The clutch requires an operating voltage of 24V =.

17. Fan wheel attachment

Burner size 30 + 40 Burner size 50/1 Burner size 50/2 Burner size 60/2 Burner size 70/1, 70/2

The fan is fixed to the conical shaft of the burner motor. Burner size 70/1 and 70/2
When refitting, ensure the surface is clean and The coupling piece is connected to the fan wheel with two
undamaged. screws. For additional security the coupling piece is
connected to the motor shaft by three screws.
Burner size 30 and 40
The coupling piece is fitted to the hub. The fan wheel hub Removing the fan wheel
is connected to the motor shaft by a screw with left-hand The fan wheel must be removed with an extractor via the
thread. two existing tappings.

Burner size 50/1 and 50/2

The coupling piece is connected to the fan wheel with two
pins. For security the coupling piece is connected to the
motor shaft by a screw with left-hand thread.

Burner size 60/2

The coupling piece is connected to the fan wheel with two
screws. For security the coupling piece is connected to
the motor shaft by a left-hand threaded screw.

37
18. Fuel system for oil
Installation of oil meter If a separate pump unit is used, a pressure switch is
When oil meters are fitted in the flow and return lines, the required in the supply line. On residual oil burner types
system must be protected by a safety valve in the return RGMS, a normally open solenoid valve is required as a
line (see fuel system schematic in our work sheets). by-pass during the pre-purge period due to the limited
oil-circulating period of 45 secs. maximum. This
A blocked oil meter can lead to the following damage: makes a safer burner start possible.
Bursting of oil hoses.
Pump damage (the glands on the pump will leak). A separate pre-heater assembly is connected after the
Changes in oil throughput without changes to combustion pump.
air. Changes in oil throughput occur if the meter is blocked
during burner operation. The backpressure, which occurs,
renders the oil regulation ineffective. Deflagration may
occur on restart.

RGL30 GL30 Z and T, GL40 T

38
 RGMS30, 40 and 50 with pump fitted
RGL40 to RGL70 and oil pre-heater

RGMS60 and RGMS70 with separate pump

and oil pre-heater
Attention
The shut off devices (solenoid valves) 2 and 3 are
electrically connected in series. The solenoid coil voltage
is therefore 115V with mains voltage of 230V AC, 50 Hz.
On the shut off device (solenoid valve) 3, the directional
arrow  on the solenoid valve must point towards the
nozzle. This means that the solenoid valve in the nozzle
return is fitted against the flow direction  (during burner
operation).

Legend 6 Filter
7 Oil regulator
1 Pump 8 Oil pre-heater
2 Shut off device (solenoid valve) 9 Pressure switch 2 ... 40 bar, (supply)
Coil 20 Watt, 115V AC; 50 Hz 10 Pressure switch 0 ......10 bar, (return)
Type 321 H 2322 RGL40-60, (on EL set to 5 bar, on MS set to 7 bar)
RGMS40-60 11 Temperature switch
Type 321 H 2520 RGL70, 12 Temperature sensor (PT100)
RGMS70 13 Shut off device (solenoid valve)*
3 Shut off device (solenoid valve)* Coil 20 Watt, type 121 K 6220
Coil 20 Watt, 115V AC; 50 Hz 14 Shut off device (solenoid valve)*
Type 121 G 2320 RGL40-60, Coil 19 Watt, type 121 K 2423
RGMS40-60 15 Nozzle head EL three stage without fitted shut off
Type 121 G 2520 RGL70, device
RGMS70 16 Nozzle head
4 Shut off device, normally open
Type 322 H 7306 RGMS60-70 * fitted against the flow direction
Coil 19 Watt
5 Shut off device (Nozzle head)
Type MDK 60 RGL40/1-B,
50 Watt, 230V RGL40/2-A,
RGL50/1-B
RGMS40/1-B
RGMS40/2-A,
RGMS50/1-B

Type MDK 70 RGL50/2-A,

60 Watt, 230V RGL60/2-A,
RGMS50/2-A,
RGMS60/2-A,

Type MDK 80 RGL70/1-A,

85 Watt, 230V RGL70/2-A,
RGMS70/1-A,
RGMS70/2-A,

39
19. Regulating systems
19.1 RGL30

The regulating system has no nozzle shut off. The solenoid Nozzle head RGL30
valves carry out this function.
2 1
Operation
During pre-purge the oil solenoid valves (6), (6a), (7), (7a)
are closed. Oil is supplied at pressure by the oil pump to
the closed valve in the nozzle supply line. These valves are
connected electrically in series.

3 4 5

Operational diagram 1 Operational diagram 1

After pre-purge and fuel release by the burner control, the
oil solenoid valve (6), (6a), (7) and (7a) are opened. The oil
flows via the nozzle supply (2) to the nozzle and through
the return (3) to the oil regulator (9). The oil regulator is in
its open position (ignition setting), and due to the low line
resistance only a small volume of oil exists at the nozzle.
The greater proportion of oil flows via the nozzle return to
the oil regulator and to the pump return. The return line oil
pressure at partial load setting is approx. 10 bar.

Operational diagram 2 Operational diagram 2

Full load operation is obtained by the metering slot of the
oil regulator reducing due to the rotation of the oil regulator
by the servomotor to the full load position (turning to the
right when looking onto the shaft). This restricts the oil flow
via the return line forcing a higher oil volume to exit via the
nozzle. On burner shut the oil solenoid valves close, and
the nozzle is isolated from the oil supply.

The pressure switch 8 (set to 5 bar) supervises the

pressure in the return. If pressure rises to above 5 bar the
burner locks out.

Legend
1 Spill back nozzle
2 Nozzle supply
3 Nozzle return
4 Swirler plate
5 Nozzle plate
6 Solenoid valve in nozzle supply
6a Solenoid valve in return (fitted against the flow
direction)
7 Safety solenoid valve in nozzle supply ( second shut
off device)
7a Solenoid valve in return (fitted against the flow
direction)
8 Oil pressure switch (set to 5 bar)
9 Oil valve regulator
10 Oil pump

40
9.2 RGL 40 to RGL 70
Operation Operational diagram 1

Operational diagram 1 Closed

During burner shut down, all shut off devices (2), (3) and
(5) are closed.

Oil regulator
The servomotor drives the oil regulator, and by means of a
vee-shaped metering groove it regulates the oil quantity.
Closed
Operational diagram 2
During pre-purge, the shut off devices (2), (3) and (5) are
closed. The pump pressure set is present at the shut off
device (2).

Operational diagram 3 Operational diagram 2

After pre-purge and fuel release by the burner control
(the servomotor is in ignition load position) the burner type
RGL opens the shut off devices (2), (3) and (5) Closed
simultaneously. Fuel oil is released for combustion.

The pressure switch (10) (set to 5 bar) regulates the

pressure in the return. If the pressure increases above
the permitted level, the burner locks out. At burner
shut down the shut off devices (2), (3) and (5) close
Closed
simultaneously.

The switch point of this pressure switch was set prior to

burner delivery and does not need to be adjusted during
burner commissioning.

Attention Operational diagram 3

The shut off devices (solenoid valves) 2 and 3 are
Open
electrically switched in series. The voltage of the solenoid
coil is therefore 115 V with 230 V AC mains voltage,
50 Hz.

Legend
1 Pump
2 Shut off device (solenoid valve)
3 Shut off device (solenoid valve) Open
5 Shut off device (nozzle head)
6 Filter
7 Oil regulator

10 Pressure switch 0 ......10 bar, (return) (on EL set

to 5 bar, on MS set to 7 bar) Nozzle head size 50 to 70
13 Nozzle supply
14 Nozzle return 15 16 14 17 18 19
15 Sealing cap
16 Solenoid coil
17 Closing needle
18 Swirler plate
19 Nozzle plate


Reg.-No.

13

41
Nozzle head size 40, type MDK60
Solenoid coil Compression spring Spill type nozzle type
(as shut off spring) WS4 with shut off valve

Supply

Return

The shut off device in the nozzle head (nozzle shut off Type
device) acts as a safety shut off device in both the supply
and return. MDK60

Together with the safety shut off devices (2) and (3) MDK70
(solenoid valve) and the safety shut off device (5) in the MDK80
nozzles head, the requirement for two shut off devices in
the supply and return is met. Solenoid valve 321 H 2322
321 H 2522
The nozzle heads and safety shut off devices are type 121 G 2320
tested. 121 G 2520

Pressure switch 2…40 bar

1…10 bar

42
19.3 RGMS30 to RGMS50

1. Off position
1. Off position
During burner shut down the shut off devices (2), (3) and
(5) are closed. The shut off device (3) (fitted against the
flow direction) simultaneously prevents an increase in
pressure in the burner system resulting from heating the
oil.
Closed

Closed

2. Pre-purge period 2. Pre-purge

When heat is called for the fan for combustion chamber
pre-purge and the pump are started. Shut off device (2),
(3) and (5) are closed. The oil and air regulator then run
back to the ignition position.

Closed

Closed

3. Start phase 3. Start phase

After pre-purge both shut off devices (2) and (3) open in
the ignition position and the oil circulation period begins.
Shut off device (5) opens after this period is complete and
releases the oil for combustion. The pressure switch (10)
(set to 7 bar) monitors the pressure in the return. If the
pressure exceeds the set values, the burner shuts down.
At burner shut down, shut off devices (2), (3) and (5) close Open
simultaneously.

Depending on the temperature at the temperature switch

(11), circulation is carried out as described in the Open
sequence diagram.

Legend
1 Pump
2 Shut off device (solenoid valve)
3 Shut off device (solenoid valve)
5 Shut off device (nozzle head)
6 Filter
7 Oil regulator
8 Oil pre-heater
10 Pressure switch (return) (on MS set to 7 bar)
11 Temperature switch 60°C

43
19.4 RGMS60/RGMS70

1. Off position 1. Off position

During burner shut down the shut off devices (2), (3) and
(5) are closed. The shut off device (3) (fitted against the
flow direction) simultaneously prevents an increase in
pressure in the burner system resulting from heating the
oil. The shut off device (4) in the connection line is open.

Open
Closed Open

2. Pre-purge 2. Pre-purge
When heat is called for the fan for combustion chamber
pre-purge and the pump are started. Shut off device (2),
(3) and (5) are closed. The oil and air regulator then run
back to the ignition position.

After the release thermostat in the CROw controller, which

is fitted in the control panel, has switched over, and prior to
the commencement of the pre-purge period, preheated oil
is circulated to the burner though shut off device (4). The Closed
oil temperature is measured by the temperature sensor Closed
(11) and when the CSRW controller switch is actuated Open
after the temperature has been reached, pre-purge
commences. Shut off devices (2), (3) and (5) are closed
during this period.
The oil and air regulator runs back into ignition position.

3. Start phase
After pre-purge both shut off devices (2) and (3) open in 3. Start phase
the ignition position, valve (4) is closed. Shut off device (5)
in the nozzle head opens after the oil circulation period (up
to max. 45 secs.) is complete and releases the oil for
combustion. The pressure switch (9) (set to 18 bar)
monitors the minimum atomising pressure. If the pressure
falls below the set values, i.e. due to wear and tear of
pump, the burner shuts down. The pressure switch (10)
(set to 7 bar) monitors the pressure in the return. The
burner shuts down If the pressure exceeds 7 bar. At burner
shut down, shut off devices (2), (3) and (5) close Open
Closed Open
simultaneously and shut off device (4) opens.

Legend 9 Pressure switch (supply) set to 18 bar on EL and MS

1 Pump 10 Pressure switch (return) (on EL set to 5 bar and on
2 Shut off device (solenoid valve) MS set to 7 bar)
3 Shut off device (solenoid valve) 11 Temperature switch PT 100
4 Shut off device, normally open 12 Nozzle supply
5 Shut off device (nozzle head) 13 Nozzle return
6 Filter
7 Oil regulator
8 Oil pre-heater

44
Attention The oil regulator is driven by the servomotor, and by means
The shut off devices (solenoid valves) 2 and 3 are of a conical metering groove it regulates the oil return
electrically switched in series. The voltage of the solenoid pressure and also oil quantity, which is atomised by the
coil is therefore 115 V with 230 V AC mains voltage, 50 Hz. nozzle.

The solenoid coils type 321 H 2322, 321 H 2522 (supply) If the burner is shut down by the boiler control, then the
with 20 Watt and types 121 G 2520, 121 G 2320 (return) solenoid valve in the supply line and the magnet on the
with 20 Watt and type 322 H 7306, coil 19 Watt (shut off nozzle head are de-energised. Both shut-off devices are
device 4) must not be interchanged. immediately closed by spring pressure.

On the shut off device (solenoid valve) 3, the directional As the closing needle is seated directly at the nozzle
arrow  on the solenoid valve must point towards the orifice, the oil lines cannot drip or empty.
nozzle. This means that the solenoid valve in the nozzle
return is fitted against the flow direction  (during burner A pressure switch is fitted in the oil supply line, which
operation). monitors the minimum atomising pressure. The switch
point is set to 18 bar.
The shut off device in the nozzle (nozzle shut off valve) is
effective as one safety shut off device in both the supply On RGMS burners the oil pressure switch in the return
and return line. line is set to 7 bar.

Together with the safety shut off devices (2) and (3) The switch point of the pressure switch has been set prior
(solenoid valves) and the safety shut off device in the to burner delivery and does not need to be re-adjusted
nozzle head, the requirements for two shut off devices in during burner commissioning.
both the nozzle supply and return are met.
When cleaning the nozzle, ensure that a second spanner
The fuel oil is atomised with the pressure set at the is used to counter hold the hexagonal nut. When re-
pump (25 ... 30 bar for oil MS). The minimum oil inserting the nozzle parts make sure the sequence is
pressure must be maintained. correct. The bearing surface (ground face) must be free
from dirt and undamaged.

19.5 Oil regulator

The oil regulator is set according to oil throughput required Oil regulator
in order to ensure optimum regulation. Each regulator has
two regulating-grooves which can be changed over. Each
regulator has two code numbers embossed on the shaft,
for example 5 + 6. Primary setting
Code number
Oil regulator Usage Cam 1
code Oil throughput kg/h

1 70 … 120
2 121 … 280

3 281 … 380
4 381 … 420

5 421 … 700
6 701 … 1000

The oil regulating-groove selected can be seen from above

in the primary setting cam 1.

Cam
identification

Primary setting
regulating cam 1
corresponds to
0° on servo-
motor

Adjusting spring

45
 20. Nozzle circulation on burners RGMS 30 to RGMS 50
Nozzle head heating
As with two stage burners, regulating burners for residual
oils are also fitted with temperature controlled nozzle head
heating. This enables the nozzle head to be kept at a
constant temperature. The heating cartridge, whose
thermal output is controlled by the ROB regulating control,
has a capacity of 100 Watts. The ROB control can be set
between temperature control points of 80°C and 130°C.

An NTC sensor is fitted on the heating cartridge support to

measure the temperature. The temperature release switch
in the regulating control is connected in series with the oil
pre-heater release thermostat and only allows burner start
after the selected nozzle head temperature and minimum
oil pre-heater temperature has been reached.

Cold start with two purge times

Pre-purge
120°

100°

80°
<)) °°]]
Stellantrieb[ [<
Servomotor

60°
Second purge time
40° First purge time Post heat time

Safety valves Safety valves

20°
open closed
Safety valves Burner start
open
0°
Times (s)
Zeit [s]
40 22,5 30 35 40 5
Start up time approx. 175 sec.

Start in warm condition with oil line temperature in supply > 60°C

Pre-purge
120°

100°

80°
Stellantrieb[[<
Servomotor °]
<) °]

60°
Short
purge
40°

20°
Burner start

0°
Times (s)
Zeit [s]
40 22,5 30 5
Start up time approx. 100 sec.

46
Additional start circuits with two purge times purge period is required. The thermostat switching point is
Operation approx. 55 to 60°C. If the oil line temperature is more than
After pre-purge has taken place and the ignition position this figure before the boiler regulator switches on, then
has been reached, the safety valves are opened for only the short purge time of 5 secs. is used for the
35 secs to enable the burner fuel system components to subsequent burner start.
be heated. The safety solenoid valves are then closed for
approx. 40 secs. The oil pre-heater will regain heat and The circuit is so designed that there is a ballast effect as
can give the maximum temperature after the 40 secs. have far as the switching condition of the thermostat is
elapsed. concerned. This means that during an existing start up
After this period, the safety solenoid valves are re-opened process, any thermostat response will not produce an
and at the same time a return signal is given to the burner alteration in the sequence of operations already started,
control to continue the start up sequence. An interval of so that a cold start or a warm start always clearly takes
6 secs., determined by the burner control, produces a place once commenced.
second purge time up to the oil release and the
temperature peak of the oil heater is utilised for the If, depending on oil temperature, a warm start is required,
moment of ignition. then the start up time of the burner is shortened by up to
75 secs. due to the omission of the time delay period of
So that the cold start process does not take place when max. 40 secs.
re-starting from a warm condition, or after a short shut
down period, a thermostat, fitted in the burner fuel line The circulation return is always connected into the pump
system between oil pre-heater outlet and distribution return line.
piece, determines whether a cold or warm start with short

21. Nozzle selection

21.1 Two and three stage burners

It is recommended that solid or semi-solid nozzles be used Spray characteristic

with a spray angle of 60° and 45° respectively. Due to the
various configurations of combustion zones encountered,
no binding information can be given.

Nozzle spray angles and patterns alter depending on the

atomising pressure. The data marked on the nozzle only
applies at a pressure of 7 bar.
Solid spray Semi solid spray
On two stage burners the total burner capacity must be
divided between two nozzles. Usually nozzle 1 is sized to Spray angle
have sufficient capacity for the basic load at approximately
2/3 of the total load. At peak demands nozzle 2 is added to
the throughput. A different nozzle ratio may be required,
depending upon the heat demand and the appliance flue
gas pressure loss.

The charts are compiled using distillate oil with a viscosity

of 4 mm2/sec (cSt.) at 20°C.

Removing and replacing nozzles Atomising pressure

When removing and replacing the nozzle, the nozzle head Oil EL _________________________________ 10…16 bar
must be held with a suitable spanner. Before fitting nozzles Oil M + S ______________________________ 20…25 bar
ensure that the insert is firmly seated.
Nozzle make Solid spray Semi-solid spray
Nozzle cleaning
Nozzle cleaning is not recommended. A new nozzle should Monarch – PLP / PLHO
be fitted.
Steinen SS –

47
Nozzle selection diagrams
The diagrams are based on fuel oil to DIN 51 603.
Variations in viscosity and manufacturing tolerances result
in a throughput variation. Atomising viscosity is max.
10 mm2/s.

Because oil pressure is lost via the pre-heater and burner

fuel system, the precise oil throughput can only be
determined by weighing.

Pressure in bar
(at the nozzle)

Distillate oil γ = 0,84 [ kg/dm3]

Medium oil γ = 0,93 [ kg/dm3]

Residual oil γ = 0,97 [ kg/dm3]

Oil throughput

Pressure in bar
(at the nozzle)

Distillate oil γ = 0,84 [ kg/dm3]

Medium oil γ = 0,93 [ kg/dm3]

Residual oil γ = 0,97 [ kg/dm3]

Oil throughput

48
21.2 Regulating burners
Nozzle selection diagrams Spray angle
The diagrams show the flow rate of the regulator nozzles
depending on supply pressure. They are based on fuel oil
to DIN 51 603. Variations in viscosity and manufacturing
tolerances result in throughput variations. Atomising
viscosity is max. 10 mm2/s. Because oil pressure is lost
via the pre-heater and burner fuel system, the precise oil Type WB3/K3 Type W
throughput can only be determined by weighing.
Nozzle return pressure spill back nozzle WB3/K3 or W
Nozzle selection for residual oil operation series 4
Details of oil throughput listed in the nozzle selection When commissioning the nozzle return pressure must be
diagrams relate to fuel oil EL. Due to the higher viscosity measured. This must not be less than 5 bar for partial load
of residual oil 5% must be deducted from the required oil for WB3/K3 and 8 bar for W series 4.
throughput. Nozzle selection can be made using this
reduced value. The return pressure is measured at the test point of the oil
regulator.
Care must be taken that the minimum pump pressure does
not fall below 20 bar, even at the lowest oil regulator Nozzle cleaning
position. The nozzle has to be taken apart and each part cleaned in
petrol or paraffin. The filter sieve must be replaced. If other
For residual burners RGMS a pump pressure between
parts are defective or worn the nozzle must be replaced.
25 and 30 bar should be selected and on RGL burners
a pump pressure between 20 and 30 bar.

Burner RGL30 Burners RGL40/1-B, RGL40/2-A, RGL50/1-B,

RGMS30/2-A, RGMS40/1-B, RGMS40/2-A, RGMS50/1-B
Nozzle selection diagram type WB3/K3
Regulator Type WB3 to 70 kg/h Nozzle head MDK60
nozzle Type K3 80… 230 kg/h Regulator nozzle type W series 4
Spray angle 45°/ 50° Spray angle 50°
230 K3 230 460 W 460

220 K3 220 440

210 K3 210 420 W 420

200 K3 200 400

W 390
190 K3 190
380
180 K3 180
360 W 360
170 K3 170
340
160 K3 160 W 330
320
150 K3 150
300 W 300
140 K3 140
280
130 K3 130 W 275

260
120 K3 120
W 250
110 K3 110 240

W 225
100 K3 100 220

90 K3 90 200 W 200

80 K3 80
Nozzle size relating to 30 bar

180 W 180
Nozzle size relating to 30 bar

70 WB3 70
160 W 160
65 WB3 65
140 W 140
Oil throughput [kg/h]

60 WB3 60
Oil throughput [kg/h]

W 125
120
55 WB3 55 W 110
100 W 100
50 WB3 50 W 90
80 W 80
45 WB3 45 W 70
60 W 60
40 WB3 40 W 55
W 50
40 W 45
35 WB3 35 W 40

30 WB3 30 20
20 25 30 20 25 30
Supply pressure [bar] Supply pressure [bar]

Example nozzle selection, type WB3 Example nozzle selection, type W

Oil throughput required: _____________________50 kg/h Oil throughput required: ____________________160 kg/h
Nozzle size to diagram: __________________________50 Nozzle size to diagram: _______________________W 160
Supply pressure to diagram: ___________________30 bar Supply pressure to diagram: ___________________30 bar
49
Regulator nozzle type 24 or 32 Nozzle needle classification
Swirler plate Nozzle needle
Due to the nozzle sizing it is possible that the required No. ø mm
burner rating with closed return (regulator position 10)
may need to be corrected by increasing the pressure. 24 W7 to 24 W12 2.8
32 W6 to 32 W7 3.8
With MS burners in addition to the density the from 32 W8 4.8
throughput resistance in the oil pre-heater must also
be allowed for. Removing and replacing nozzles
When removing and refitting the nozzle it must be counter
Example : held with a spanner.
Oil throughput required : ____________________300 kg/h
Nozzle specification Nozzle cleaning
to diagram : ___________________________24 D 1,7 W9 The nozzle has to be taken apart and each part cleaned in
Supply pressure to diagram ___________________25 bar petrol or paraffin. If available, compressed air is the most
Nozzle return pressure suitable cleaning agent. Cleaning tools such as steel
The nozzle return pressure must be measured when needles etc. must not be used.
commissioning. In normal cases at partial load it must not
be set below 12 bar for residual oil and 8 bar for distillate
oil EL. A T piece has been fitted to the oil regulator for
taking measurements.

Burner RGL/RGMS50/60 Burner RGL70, RGMS70

Nozzle head MDK70 Nozzle head MDK80

1050
600

1000

950
24 D 2,3 W13

500
24 D 2,2 W12 900

24 D 2,1 W12

850
24 D 2,1 W11 32 D 3,0 W10/1
Nozzle size

Nozzle size

800
24 D 2,0 W11 400 32 D 3,0 W10

24 D 1,9 W11 750

24 D 1,9 W10 32 D 2,8 W10 700

24 D 1,8 W10
300
24 D 1,8 W9 650
32 D 2,8 W9
24 D 1,7 W9

24 D 1,6 W9 32 D 2,6 W9 600

Closing pin ø 4.8

24 D 1,5 W8
550
24 D 1,4 W7 200 32 D 2,6 W8

24 D 1,4 W6
500
24 D 1,3 W6 32 D 2,4 W8
Oil throughput (kg/h)

Oil throughput (kg/h)

24 D 1,3 W5
24 D 1,3 W4
24 D 1,2 W4
450
Closing pin ø 2.8

24 D 1,1 W3 32 D 2,4 W7
24 D 1,0 W3
100
Closing pin

24 D 0,9 W2 400
32 D 2,2 W7
24 D 0,8 W2
ø 3.8

32 D 2,2 W6 350
20 25 30 20 25 30
Supply pressure (bar) Supply pressure (bar)
50
22. Ignition electrodes and ignition pilot settings
Setting of ignition electrodes and ignition pilot on regulating burners
5 …10

Ignition pilot tube

6
4…

3,5 … 4

Setting of ignition electrodes and ignition pilot on two and three stage burners
3,5 … 4 5…10

Ignition pilot tube

Nozzle 2 Nozzle 1
Nozzle 3 6
4…

Setting the ignition electrodes altered. On three-stage burners type GL the ignition
After all alterations the distances of the ignition electrodes electrodes are positioned at the same distance at nozzle 1.
from the nozzle and from the diffuser must be checked.
The correct setting dimensions can be seen in the Ignition pilot setting
drawings above. The ignition electrodes must not The front edge of the pilot tube must end approx. 5 to 10
protrude into the oil jet on dual fuel burners. mm behind the diffuser and half must protrude inside the
internal diameter of the diffuser.
If this does occur due to an extreme adjustment of the
nozzle head or combustion head, then the electrodes must
be bent, without the gap between the electrode tips being

51
23. Commissioning the oil part
23.1 Tests prior to initial commissioning

Before commissioning can commence, the entire plant ● Is load available?

must be checked. ● Has the low water safety interlock been set correctly?
● Have all fuel carrying pipe lines been purged of air?
● Has the heat exchanger been mounted ready for ● Is the rotation of the burner motor correct?
operation? ● Is sufficient fuel oil in the tank?
● Are heat exchanger and system filled sufficiently with ● Have a soundness tests of the oil hydraulic been carried
heating medium? out?
● Are the flue-gas passages free from obstruction? ● Are the oil supply pumps (if fitted) switched on?
● Have explosion flaps been fitted? ● Are the oil shut off devices open?
● Is the flue gas damper open? ● Are oil-supply lines and pump filled with oil?
● Is sufficient air supply ensured? ● Is the correct oil nozzle fitted?
● Have the operating instructions of the heat exchanger
been followed? Other installation specific tests may be required. See
● Has the whole installation been wired correctly? operating instructions of individual components.
● Have temperature regulator, pressure regulator and
safety limit controls been set correctly and place into
the operation position?

23.2 Adjusting the oil side

On regulating burners the oil side is commissioned Compound regulation gas/air or oil/air
prior to the gas side. On GL burners the gas side is
commissioned first and the oil side is matched by the
relevant nozzle selection. This results in different
procedures when commissioning.

Switch on procedure

– Set operating switch to “oil”.

– Open shut off valve (shut off assemblies) in the oil supply.
– Set selector switch in the control panel to “stop”.
– Reset installation. Suction side Oil regulation Gas Pressure
– Switch on burner operating switch. air regulation with servomotor regulation side air
regulation
Ignition
Once pre-purge is complete await flame formation. Setting air quantity

If ignition problems occur:

GL burners:
Check nozzle size of stage 1; if necessary select
different nozzle

RGL burners:
Check position of ignition load switch on the servomotor
(No. III), if necessary adjust setting.

Test sensor current on the microammeter.

Full load setting RGL burners

After approx. 20 secs, the servomotor runs from ignition
load to partial load. Disengage servomotor, manually adjust
the regulating cam step by step and re-engage Disengaging the drive
servomotor. A smoke test must be carried out at each point
of the adjusting cam. Adjusting the air curve band can
make alterations. Electrically drive the servomotor to full
load setting. For full load the required oil throughput must
be set and measured (nozzle selection diagrams are only
an aid for setting and checking). Carry out combustion
analysis:

RGL burners:
Set oil throughput by adjusting pump pressure (20 to
30 bar). Set combustion values by adjusting the air
curve band and positioning of the regulating sleeve so
that with fully opened air damper a smoke number <1
and CO2> 13 Vol. - % with good flame stability can be
achieved.

52
GL burners: Regulating sleeve position
The gas side settings of the air curve band and the
mixing head positions must not be altered. The oil
throughput is matched by adjusting the pump pressure
(10 to 14 bar), if necessary select different nozzle size.

The pump pressure and the position of mixing head set on

full load must not be adjusted.

Intermediate testing (“full load to partial load”)

RGL Burners:
A point by point combustion check is necessary at the
adjusting cam. Adjust cams manually step by step in the
direction of ignition load (selector switch “Stop”,
disengage servomotor, adjust, re-engage). Regulate
combustion values by adjusting the air curve bands.
Ensure the curve bands have an even profile.

GL burners:
The air curve band setting for must not be altered. The
transition switching points of the servomotor for the
second (third) stage nozzles (Z: No.I; ZM: V or V and III)
must be set so that the excess air phase, prior to switch
over is not too long, and the flame extinguishes, but on
the other hand that any smoke period after switch over
is as short as possible.

Partial load setting

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

RGL burners:
Set and measure the required oil throughput for partial
load with the auxiliary switch in the servomotor (No. VII).

GL burner, version ZM:

Match excess air to the oil throughput required for the
nozzle selected for partial load with the auxiliary switch
(No. VII). Measure oil throughput, if necessary select a
different nozzle. The intermediate setting on three stage
burners is carried out the same way.

GL burners, version Z:
Carry out combustion test in partial load setting (same
auxiliary switch for gas and oil) with the selected nozzle.
Measure oil throughput, if necessary select a different
nozzle.

If changing the nozzle on partial load (GL burners) the full

load setting has to be re-checked and if necessary re-
adjusted. For partial load setting, the lower ratings limits of
the capacity graphs, the flue gas temperature and
instructions from the boiler manufacturer have to be
observed.

Concluding work:
Check ignition load setting when the burner has been
commissioned:

RGL burner:
If necessary correct at auxiliary switch (No. III) on the
servomotor.

GL burners:
If necessary select new nozzle. Full and partial load
setting will then have to be repeated.

Setting is correct if the burner starts without start impact.

Check and adjust operation of safety equipment (i.e. air

pressure switch, thermostat, pressure stat etc.) whilst
installation is in operation.
53
24. Sequence of operation
Gas operation version ZM

Regulator Nominal load Ignition and Ratings Regulator “Off”

Sequence diagram for air “On” pre-purge fuel release regulation
Full load

Partial load
Ignition load
Terminal on LFL/LG “Closed”

Control circuit

Time sequence
diagram for servomotor

Full load
Sequence diagram for gas

Partial load
Ignition load
Closed
Time sequence
diagram for ignition
and fuel release

Position indicator on
burner control

Oil operation version ZM

Sequence diagram Regulator Nominal load Ignition and Ratings regulation Regulator
for air Full load “On” pre-purge fuel release “Closed”

Partial load
Ignition load
Closed
Terminal on LFL/LGK
Control circuit

Time sequence diagram

for servomotor

Sequence diagram
for oil * Programme interruption on
residual oil burners for oil
circulation to nozzle head (to DIN
4787 max. 45 secs.)

Time sequence
diagram for ignition
and fuel release

Position indicator on
burner control

The LFL1... burner control units are designed to provide

control and supervision of multistage and modulating
burners. They are only suitable for burners with intermittent
burner operation. The fail safe burner control LGK16... is
used for burners for continuous operation.

54
24.1 Pre-requisite for the burner start

– Reset control unit

– Air damper closed. The limit switch for the ‘CLOSED’
position must supply voltage from terminal 11 to
terminal 8.
– The control contacts for the ‘CLOSED’ position of fuel
valves or other contacts between terminal 12 and
“S10” with similar control functions must be closed.
– The contacts of the gas pressure switch “S11” and the
temperature or pressure switch “F4, F5” must also be
closed.

24.2 Symbols on the lockout indicator

➛ No start e.g. because the closed signal has not been If lockout occurs at any other point between start and pre-
supplied to terminal 8 by the limit switch/auxiliary ignition, which is not marked by a symbol, there is normally
switch or because a contact has not been closed a premature and thus faulty flame signal.
between terminals 12 and 4 or 4 and 5.

œ Controlled shut down because the open signal has not

been supplied to terminal 8 by the limit switch ‘A’.

P Lockout because the air pressure signal has not been

received by the start of the air pressure check. Air
pressure failure after this point also causes the control
to go to lockout.

■ Lockout due to a fault in the flame supervision circuit.

❷ Controlled shutdown because the position signal

for the low flame position has not been supplied to a–b Start up sequence
terminal 8 by the auxiliary switch.
b – b’ With some time variants: ‘idle steps’ of the
1 Lockout because no flame signal has been received sequence switch up to the self shut down after
on completion of the first safety time. Any flame signal burner start up (b = operating position of the
failure after completion of the first safety time also
causes the control to go to lockout. sequence switch).

2 Lockout because no flame signal has been received on b(b’) – a Post purge sequence after controlled shut
completion of the second safety time (flame signal of down. In start position ‘a’ the sequence switch
the main flame with interrupted pilot burners). switches itself off automatically or immediately
initiates another burner start, e.g. after a fault
I Lockout because the flame signal has been lost during has been corrected.
operation or air pressure failure has occurred.
● Duration of safety time with expanding flame
➛ Lockout on completion of control programme sequence burners.
due to extraneous light (e.g. flame not extinguished,
leaking fuel valves) or due to a faulty flame signal ●● Duration of safety time with interrupted pilot
(e.g. aged UV tube, fault in flame supervision circuit or burners.
similar).

55
24.3 Basic wiring diagram for burner control LFL1... / LGK 16...
LGK...
B1

F3 QRA5..
1
UV 2
L
M
5 4 3
S1
N
22 15 24 23
F4
1

F LFL/LGK
B1
br1
a b 22 23 24
I
a b

ar1 ar2 LFL...

uv QRA2
4 12 6 7 +
K1 K1 B1
S10
S11

22 23 24

M1 M1
F5

N N V
5 13 14
FR
fr1 fr3 fr2
a b
XII b a b
XIII a
XI IV
NTC XIV
b a a b
a b
AR VII
a b
ar3
S H
br2 II X VIII VI V III
b a a b a b a b a b
E M
BR M
A SM

3 21 2 16 17 18 19 20 9 11 10 8
F6

1
Y6 III I II IV
M
S3

H6 LK
T1 Y1 Y4 Y2
N N

Legend
AR Load relay (main relay) with contacts “ar” S Reset key
B1 Flame sensor S1 Burner "on"
BR Lockout relay S3 Remote reset
F Fuse in burner control S10 Air pressure switch
F3 Control fuse S11 Gas pressure switch
F4 Temperature or pressure switch T1 Ignition transformer
F5 Temperature or pressure regulator Y1 Solenoid valve ignition gas
F6 Temperature or pressure regulator FULL LOAD Y2 Solenoid valve
FR Flame relay Y4 Solenoid valve
H Control lamp Lockout Y6 Servomotor
H6 Remote indication for lockout
K1 Motor contactor
LK Air damper
M1 Fan or burner motor

56
 LFL1... / LGK16

Control outputs
of controls
Positions of lockout indicator

Legend for diagram of sequence switch

t1 Pre purge time t10 Interval to start of air pressure control
t2 Safety time t11 Run time of air damper (Open)
t3 Pre-ignition time t12 Run time of air damper (min.)
t4 Interval between voltage on terminals 18 and 19 t13 Permissible after burn time
t5 Interval between voltage on terminals 19 and 20 t16 Interval up to OPEN command for air damper
t6 Post purge time t20 Interval up to self shut down of the sequence switch
t7 Interval to voltage on terminal 7 (not on all controls)
t8 Duration of start up sequence
t9 Second safety time * * Programme for interrupted pilot burners.

24.4 Switching times

Switching times in seconds * in start up sequence
The figures in brackets apply to burners with interrupted pilot.
LFL 1.122 LFL 1.322 LFL 1.622
LGK 1.122 LGK 1.322 LGK 1.622

t7 Start delay for burner motor 2 2 2

t16 Interval from start up to OPEN command of air damper 4 4 4
t11 Run time of air damper in OPEN position optional optional optional
t10 Interval from start up to commencement of air pressure check 6 8 8
t1 Pre-purge time with air damper open 10 36 66
t12 Run time of air damper to ignition position optional optional optional
t3 Pre-ignition period 4 4 4
t2 First safety period 2 2 2
t4 Interval between start of t2 and
release of valve at terminal 19 6 10 10
–(t9) Second safety period – (2) – (2) – (2)
t5 Interval between end of t4 and release of load
controller or valve at terminal 20 4 10 10
– Duration of start up (without t11 and t12) 30 60 96
t6 Post purge time 10 12 12
t13 Permissible after burn time 10 12 12

* Valid for frequency 50 Hz. For 60 Hz frequency switching times are reduced by approx. 20%.
57
24.5 Sensor line between LGK16... and QRA53 / QPA 55 or sensor electrode

■ The connections between burner control terminal 23, capacitance loading. To obtain a reading, the voltage can
and UV cell terminal 3, as well as burner control terminal be measured at the connection terminals 22 and 23
15 and UV cell terminal 4, have to be fitted as separate without detector cable connected and subsequently with
single core coaxial cables with a capacitance of max detector cable connected, providing the line length is
45pF/m. The coaxial cable used can be of types within the stipulated limits. The voltage difference must not
RG-62 A/U or RG-71 B/U. The screening of these be higher than 22 VAC. A higher voltage reduction
coaxial cables must be earthed on both cable ends. indicates the danger of unsafe monitoring.
■ For the connection between the burner control Detector cable LGK16 with ionisation monitoring.
terminals 1, 2, 22 and the matching terminals of the
UV cell terminals 1, 2 and 5 a normal three core, When fitting a detector cable for ionisation monitoring,
1.5mm2 PVC cable can be used. The line length is attention has to be paid to a low capacitance installation.
unlimited. The coaxial cable RG-62 A/U or RG-71 B/U as well as the
ignition cable -w- order No. 743 200, are all suitable as a
■ The coaxial cable and the three core cable may be fitted detector cable. Because of the installation of the low
in the same cable duct as other mains voltage lines capacitance detector cable to terminal 24 of the control
(control lines and motor lines). (especially compared to earthed cable) the normal max.
detector cable length of 60m can be exceeded.
■ Maximum line length for the coaxial cable is 60 m. The
connection to the burner terminal rail and the control
panel terminal rail must be carried out according to the
wiring diagram. It is important that terminal 22 on the
LGK terminal sub-base is earthed.

Test possibilities of the detector cable

Due to the capacitance of the detector cable connected
to terminal 15 and 23 of the LGK burner control a voltage
reduction in the sensor circuit occurs due to the

Wiring diagram

Burner

Burner control Terminal in control

panel Burner connection
LGK... terminal
Terminal
socket

1 Main cable 3 x 1.5 mm2 1

1 1
2 2
2 2

5 5
22 5
QRA5...

3 3
23 3

4 4
15 4

Cable
Single core coaxial cable
AGM 1

Screening

max. 60 m

58
24.6 Technical data – between terminals 4 & 12_______________________1 A
– betw. terminals 4 & 14 ____1 A cont. peaks of up to 20 A
Mains voltage ____________220 V - 15%… 240 V + 10% Mounting position ___________________________optional
Frequency _________________50 Hz - 6%… 60 Hz + 6% Protection standard ___________________________IP 40
Consumption________________________________3.5 VA Permissible ambient
Fuse (inbuilt) _______________M6, 3/250 E (semi time lag temperature __________________- 20 to + 60°C at 220 V
according to DIN 41571, sheet 2).
External fuse______________________________max. 10 A UV supervision with LFL1 ...
Permissible input current at terminal 1 ____5A continuous; Supply voltage________________operation 330 V ± 10 %
peaks of up to 20A test 380 V ± 10 %
Permissible load of control ______4A continuous, peaks of Min. required sensor current ____________________70 µA
terminals ____________________max. 20 A; total max. 5 A Max. sensor currentoperation ______630 µA, test 1300 µA
Required switching capacity of switching devices Max. permissible cable length to detector on LFL1 ...
– between terminals 4 & 5 ________________________1 A – see chapter 24.5.

25. Cam setting of limit and auxiliary switches in the servomotor

Gas and dual fuel burners, sliding two-stage and modulating
Description The switch settings must be reset when commissioning to
The limit and auxiliary switches are set manually on the the requirements of the installation.
adjustable cams. The cams have a small pointer, which
indicates the appropriate switching point on a scale The outer scale on the end of the camshaft serves as a
between the cams. position indicator. With the lever fitted on the gearbox the
cam switches can be disengaged from the drive. This
The servomotors are supplied with the following standard
makes it possible, manually, to turn the cam to any position
switch settings:
required. When the lever is in the vertical position the drive
I - Open 120° is engaged.
II - Closed 0°
III - Ignition load oil 30°
IV - Ignition load gas 20°
V - Stage 2 Oil switch (GL) 100°
VI - Partial load gas 45°
VII- Partial load oil 50°
Setting the limit and auxiliary switches Disengaging the drive

SQM10

21 1 11 22 2 12 23 3 13 24 4 14 25 5 15 26 6 16 27 7 17 a b c
N

M
~
I II III IV V VI VII
I - Limit switch Full load V - Auxiliary switch stage 2 oil
II - Limit switched closed VI - Auxiliary switch partial load gas
III* - Limit switch ignition load oil VII - Auxiliary switch partial load oil
IV - Auxiliary switch ignition load gas

* On GL... TMD burners the auxiliary switch III is used

for the intermediate load on oil operation
59
26. Throughput determination, conversion from normal to operating conditions
To obtain a given burner heat input rate, the gas quantity See table: 960 + 500 = 1460 mbar gives the factor
must be calculated. 1,391

Example: In order to obtain the correct loading for the example, the
Boiler nominal rating: 5000 kW gas throughput calculated must be divided by the factor
Efficiency (in advance): 92% read off.
Natural gas LL (calorific value) Hi = 8.83 kWh/m3
Boiler loading = Gas throughput in operating conditions:

Vn 616
5000 VB = = = 442.8 m3/h
= 5435 kW f 1,391
0,92
With other gas pressures and gas temperatures the
Gas throughput: Vn = conversion factor can be determined according to the
following formula.
5435
= 616 m3/h Po + PG 273
8,83 f = ·
1 013 273 + tG
As the gas volume is altered considerably by pressure and
temperature, the gas quantity must be calculated to the The humidity content of the gas is small and is therefore
appropriate operating condition. not taken into account in the table figures or conversion
factor.
Operating condition for above example:

mbar

Po = Barometer level 960

PG = Gas pressure* 500

Total pressure 1460

tG = Gas temperature 10°C

* Read gas pressure and gas temperature from gas

meter.

60
Average yearly air pressure at various height sectors 201…250 988 990
251…300 982 984
Average geodetic Average yearly air pressure 301…350 976 978
height of supply in mbar at a relative humidity 351…400 970 972
area above of 75% and an average 401…450 964 966
sea level temperature at sea level of 10°C. 451…500 958 960
501…550 952 954
Northern Southern 551…600 946 949
Germany Germany 601…650 941 943
mbar mbar 651…700 935 937
701…750 929 931
0 1015 1017 1)
1… 50 1012 1014 1 mbar = 0.750 Torr = 10.20 mm VS
51…100 1006 1008 1 Torr = 1.333 mbar = 13.6 mm VS
101…150 1000 1002 1 mm VS = 0.0735 Torr = 0.0981 mbar
151…200 994 996

Totalpressure Po+PG Conversion factor f

in Gas temperature tG in °C
mbar1) Torr 0 5 10 15 20 25

900 675 0.888 0.872 0.857 0.842 0.828 0.813

920 690 0.908 0.892 0.876 0.861 0.846 0.832
940 705 0.928 0.911 0.895 0.880 0.865 0.850
960 720 0.948 0.931 0.915 0.899 0.884 0.868
980 735 0.967 0.950 0.933 0.917 0.901 0.886

1000 750 0.987 0.969 0.952 0.936 0.920 0.904

1020 765 1.007 0.989 0.972 0.955 0.939 0.922
1040 780 1.027 1.009 0.991 0.974 0.957 0.941
1060 795 1.046 1.027 1.009 0.992 0.975 0.958
1080 810 1.066 1.047 1.029 1.011 0.994 0.976

1100 825 1.086 1.066 1.048 1.030 1.012 0.995

1120 840 1.106 1.086 1.067 1.048 1.031 1.013
1140 855 1.125 1.105 1.086 1.067 1.049 1.031
1160 870 1.145 1.124 1.105 1.085 1.067 1.049
1180 885 1.165 1.144 1.124 1.104 1.086 1.067

1200 900 1.185 1.164 1.144 1.123 1.104 1.085

1220 915 1.204 1.182 1.162 1.141 1.122 1.103
1240 930 1.224 1.202 1.181 1.160 1.141 1.121
1260 945 1.244 1.222 1.200 1.179 1.159 1.140
1280 960 1.264 1.241 1.220 1.198 1.178 1.158

1300 975 1.283 1.260 1.238 1.216 1.196 1.175

1320 990 1.303 1.280 1.257 1.235 1.214 1.194
1340 1005 1.323 1.299 1.277 2.254 1.233 1.212
1360 1020 1.343 1.319 1.296 1.273 1.252 1.230
1380 1035 1.362 1.338 1.314 1.291 1.269 1.248

1400 1050 1.382 1.357 1.334 1.310 1.288 1.266

1420 1065 1.402 1.377 1.353 1.329 1.307 1.284
1440 1080 1.422 1.396 1.372 1.348 1.325 1.303
1460 1095 1.441 1.415 1.391 1.366 1.342 1.320
1480 1110 1.461 1.435 1.410 1.385 1.362 1.338

1500 1125 1.481 1.454 1.429 1.404 1.380 1.357

1520 1140 1.500 1.473 1.448 1.422 1.398 1.374
1540 1155 1.520 1.493 1.467 1.441 1.417 1.392
1560 1170 1.540 1.512 1.486 1.460 1.435 1.411
1580 1185 1.560 1.532 1.505 1.479 1.454 1.429

1600 1200 1.579 1.551 1.524 1.497 1.472 1.446

1620 1215 1.599 1.570 1.543 1.516 1.490 1.465
1640 1230 1.619 1.590 1.562 1.535 1.509 1.483
1660 1245 1.639 1.610 1.582 1.554 1.528 1.501
1680 1260 1.658 1.628 1.600 1.572 1.545 1.519

61
Totalpressure Po+PG Conversion factor f
in Gas temperature tG in °C
mbar1) Torr 0 5 10 15 20 25

1700 1275 1.678 1.648 1.619 1.591 1.564 1.537

1720 1290 1.698 1.667 1.639 1.610 1.583 1.555
1740 1305 1.718 1.687 1.658 1.629 1.601 1.574
1760 1320 1.737 1.706 1.676 1.647 1.619 1.591
1780 1335 1.757 1.725 1.696 1.666 1.638 1.609

1800 1350 1.777 1.745 1.715 1.685 1.656 1.628

1820 1365 1.797 1.765 1.734 1.704 1.675 1.646
1840 1380 1.816 1.783 1.752 1.722 1.693 1.663
1860 1395 1.836 1.803 1.772 1.741 1.711 1.682
1880 1410 1.856 1.823 1.791 1.759 1.730 1.700

1900 1425 1.876 1.842 1.810 1.778 1.748 1.718

1920 1440 1.895 1.861 1.829 1.796 1.766 1.736
1940 1455 1.915 1.881 1.848 1.815 1.785 1.754
1960 1470 1.935 1.900 1.867 1.834 1.803 1.772
1980 1485 1.955 1.920 1.887 1.853 1.822 1.791

2000 1500 1.974 1.938 1.905 1.871 1.840 1.802

2050 1538 2.024 1.988 1.953 1.919 1.886 1.854
2100 1575 2.073 2.036 2.000 1.965 1.932 1.899
2150 1613 2.122 2.084 2.048 2.012 1.978 1.944
2200 1650 2.172 2.133 2.096 2.059 2.024 1.990

2250 1688 2.221 2.181 2.143 2.106 2.070 2.034

2300 1725 2.270 2.229 2.191 2.152 2.116 2.079
2350 1763 2.320 2.278 2.239 2.199 2.162 2.125
2400 1800 2.369 2.326 2.286 2.246 2.208 2.170
2450 1838 2.419 2.375 2.334 2.293 2.255 2.216

2500 1875 2.468 2.424 2.382 2.340 2.300 2.261

2550 1913 2.517 2.472 2.429 2.386 2.346 2.306
2600 1950 2.567 2.521 2.477 2.434 2.392 2.351
2650 1988 2.616 2.569 2.524 2.480 2.438 2.396
2700 2025 2.665 2.617 2.572 2.526 2.448 2.441

2750 2063 2.715 2.666 2.620 2.574 2.530 2.487

2800 2100 2.764 2.714 2.667 2.620 2.576 2.532
2850 2138 2.813 2.762 2.715 2.667 2.662 2.577
2900 2175 2.863 2.812 2.763 2.714 2.668 2.623
2950 2213 2.912 2.860 2.810 2.761 2.714 2.667

3000 2250 2.962 2.909 2.858 2.808 2.761 2.713

3100 2325 3.060 3.005 2.953 2.901 2.852 2.803
3200 2400 3.159 3.102 3.048 2.995 2.944 2.894
3300 2475 3.258 3.199 3.144 3.089 3.036 2.984
3400 2550 3.356 3.296 3.239 3.181 3.128 3.074

3500 2625 3.455 3.393 3.334 3.275 3.220 3.165

3600 2700 3.554 3.490 3.430 3.369 3.312 3.255
3700 2775 3.653 3.587 3.525 3.463 3.405 3.346
3800 2850 3.751 3.684 3.620 3.556 3.496 3.436
3900 2924 3.850 3.781 3.715 3.650 3.588 3.527
4000 3000 3.949 3.878 3.811 3.744 3.680 3.617

62
27. Fault conditions and procedures
If faults occur the basic requirements for correct operation 5. Ensure that the burner air or gas settings have not been
must first be examined. altered.

1. Check the electric supply. When it is established that the fault is not due to external
2. Check that the gas supply is correct and that manual conditions, the burner must be tested. Reset the burner
valves are open. lockout and switch on burner, by careful observation of the
3. Ensure that an oil supply is available (dual fuel burners sequence of operations the cause can be recognised and
only). remedied. When checking, a microammeter and a U tube
4. Check that all controls e.g. thermostats, pressure manometer must be used.
switches, water level interlocks, limit and time switches
are correctly set.

Condition Cause Remedy

General faults

Burner motor does not start No electric supply Close circuit

Fuse blown Replace

Neutral open circuit Repair

Motor faulty Replace

Control circuit open Look for contact break, switch on

or reset regulator or detector

Gas supply interrupted Open isolating valve, inform gas

isolating valve close authority if no gas for a prolonged
period.

Burner control fault Replace

Lack of air

Burner motor starts, after full load Air pressure switch faulty Replace
pre-purge lockout occurs

Burner motor starts, lockout after Solenoid valve leaking indication Repair leak
approx. 20 secs. (only on on valve proving programme if
versions with valve proving) burner control in start position

Burner motor starts, lockout Pressure switch contact does not Set pressure switch correctly,
after 10 secs of full load pre-purge switch in operating position if necessary replace
(air pressure too low)

Fan contaminated Clean

Burner motor rotation incorrect Correct rotation

Ignition failure

Burner motor starts, voltage on Ignition electrode gap too wide Adjust setting (see chapter 22)
terminal 16 of burner control, no
ignition, after a short ime lockout occurs

Ignition electrodes or ignition Remove earth connection,

line have earth connection, replace damaged electrodes or
insulating body fault cables.

Ignition transformer faulty Replace ignition transformer

No flame establishment

Motor starts, ignition in order, after short Solenoid valve does not open, Replace solenoid valve correct
time lockout occurs interrupted. as solenoid valve coil is faulty interruption to electric supply,
or cables check voltage to terminal 17.

63
Condition Cause Remedy

Lockout after flame establishment

Ignition flame forms. Lockout occurs Blocked filter Clean filter

when running at normal load
Pressure regulating control Check breather orifice
sluggish

Gas meter faulty or water Inform gas authority

in lower lying lines.

Flame monitoring fault on ionisation

Burner motor starts, ignition is audible, Ionisation current fluctuates, Alter position of ionisation
normal flame establishment then too low electrode, correct possible high
fault shutdown resistance in ionisation line
and terminals (tighten terminals).

Gas/air mixture setting not correct Re-adjust (see commissioning)

Ignition spark affected, Ignition transformer primary

negative ionisation current side, change phase and neutral

Flame sensor (UV cell) UV cell dirty Clean (remove oil and
grease traces)

Illumination too weak Check combustion setting

UV cell defective Replace

Pump

Supplies no oil Pump faulty Replace

Capacity decreases Replace pump

Suction valve leaking Remove suction valve and

clean or replace

Suction line leaking Seal lines

Isolating valves closed Open

Filter blocked Clean

Filter leaking Replace

Oil lines leaking Tighten unions, vent.

Severe mechanical noise Pump sucks air Tighten unions, vent

Vacuum in oil line too Clean filter, open

high valves fully.

Nozzle

Uneven atomisation Nozzle dirty or damaged Clean nozzle or replace

Regular maintenance saves energy and protects the environment

We recommend regular maintenance of combustion Excellent combustion quality is a pre-requisite for
equipment to all plant operators. It saves fuel and environmentally friendly operation.
ensures constantly good combustion results.

Max Weishaupt GmbH, D-88475 Schwendi,

Tel: (0 73 53) 83 0, Fax: (0 73 53) 8 33 58
Print No. 429 GB, May 98,
Printed in Germany, All rights reserved