Weishaupt WL10/2-C, Installation And Operating Instructions Manual

Page 1: ... v e S o l e n o i d v a l v e f u l l l o a d F l a m e s e n s o r S e t t i n g s c r e w f o r d i f f u s e r N o z z l e a s s e m b l y C o v e r B u r n e r f l a n g e b o l t B u r n e r f l a n g e b o l t A i r d a m p e r s e r v o m o t o r B u r n e r f l a n g e B u r n e r m o t o r A i r i n t a k e h o u s i n g C o m b u s t i o n h e a d C o m b u s t i o n m a n a g e r I g n...

Page 2: ... 082 1 EN 60 335 In accordance with the guidelines EMC 89 336 EU LVD 73 23 EU EED 92 42 EU MD 98 37 EU these products are labelled as follows CE 0036 333 02 Schwendi 09 04 2002 ppa ppa Dr Lück Denkinger The burners were type tested at an independent testing station TÜV Bau und Betriebstechnik Munich and certified by DIN CERTCO Registration No 5G988 02 Comprehensive Quality Assurance is ensured by ...

Page 3: ...0 19 6 Fault conditions and procedures for rectification 20 7 Servicing 24 7 1 Safety notes on servicing 24 7 2 Servicing plan 24 7 3 Removing and refitting nozzle 25 7 4 Setting the ignition electrodes 25 7 5 Setting the mixing head 26 7 6 Removing and refitting nozzle assembly 27 7 7 Removing and refitting housing 27 7 8 Service position 28 7 9 Removing and refitting oil pump fan motor and fan w...

Page 4: ...tructions The plant operator must note that an agent of the contractor or other suitably qualified person must inspect the plant at least once a year To ensure regular inspections weishaupt recommends a service contract The contractor should instruct the plant operator in the use of the equipment prior to hand over and inform him as and when necessary of any further inspections that are required b...

Page 5: ...ply should be carried out by a qualified electrician Electrical components should be checked during servicing Loose connections and heat damaged cables should be dealt with immediately Should it be necessary to carry out work on live parts a second person should be present to switch off the mains supply in an emergency Maintenance and fault rectification Necessary installation service and inspecti...

Page 6: ...ard fuel oil Euro quality to SN 181 160 2 or prefer ably Öko fuel oil CH quality to SN 181 1602 Permissible ambient conditions see Ch 8 5 The burner must not be used outside It is only suited to inside operation The burner must not be used outside of its capacity range see capacity graphs Ch 8 2 To ensure low emission combustion heat exchangers of the three pass principle and combustion chamber di...

Page 7: ... Monitors the flame signal at each operating phase If the flame signal does not concur with the sequence of operation a safety shutdown is initiated Nozzle assembly The total oil throughput required is provided by a single nozzle The diffuser is set as required with the setting screw Sequence of operations Demand for heat from the appliance s controller Fan start pre purge of the combustion chambe...

Page 8: ...lations it is only possible to prime the pump via the nozzle line or pressure test connection when the solenoid valve is open Oil hoses Technical data Pressure class A DIN 4798 1 DN ____________________________________________ 4 Length ______________________________________ 1200 Pump side connection ______________________ G 1 8 Installation side connection nipple ______________ G 3 8 Nominal press...

Page 9: ...t use cathode protection systems with steel tanks Select pipes of correct nominal bore Joints must be oil tight Avoid sharp bends Influence of the length of the suction line Pressure loss at the filter Difference in height H between lowest oil level in the tank and the oil pump max 3 5 m Avoid placing oil tanks outdoors and in areas subject to frost With oil temperatures 0 C the separation of para...

Page 10: ...ce H between pump and tank Oil throughput pump type Pipe line diameter DN The pressure losses of additional fittings are not included in the following selection table showing pipeline diameters Oil pump on burner Solenoid valve slow closing or shut off valve to stop siphonic flow Oil tank Basic diagram of oil supply typical only max 20 m H H max 4 6 m max 20 m H max 3 5 m max 3 5 m max 4 6 m H One...

Page 11: ...pump can run dry and thus become damaged Note the directional supply and return arrow indications on the oil pump and filter when connecting the hoses Ensure the hoses are not kinked and are tension free ATTENTION Danger of getting burned Some burner parts e g flame tube burner flange etc become hot during burner operation and should be allowed to cool prior to service work being carried out Insta...

Page 12: ...kW Conversion of the firing rate in kW to the oil throughput in kg h Oil throughput kg h firing rate kW 11 9 The table is based on information supplied by the nozzle manufacturers referenced to 7 bar For nozzle size 1 00 the use of Fluidics or Danfoss nozzles is recommended Oil throughput changes at pressures of 10 to 24 bar Example of nozzle selection for WL10 2 C vers Z Required firing rate QF 5...

Page 13: ...ect a pressure gauge to the oil pump 1 Connect pressure gauge see Ch 3 2 2 Connect vacuum gauge see Ch 3 2 ATTENTION Connect instruments Checklist for initial commissioning The heating appliance must be assembled ready for operation The operating instructions of the heat exchanger must be followed The whole plant must be wired correctly The heating appliance and the heating system must be sufficie...

Page 14: ...ing does not replace the necessary flue gas measurements and combustion optimisation Note Combustion heat rating is dependent on nozzles used see Ch 4 7 5 3 Commissioning and setting Diffuser setting X mm Basic diffuser setting values Combustion heat rating Setting the diffuser Indicating bolt Setting screw Setting the diffuser The diffuser is set depending on the full load selected and it is also...

Page 15: ...ly Pre set switch point for the full load solenoid valve MV2 Set the switch point to approx 1 3 of the setting movement between ST1 and ST2 Example air damper setting WL10 2 C vers Z Firing rate QF Full load pump pressure 22 bar 57 1 kW Partial load pump pressure 10bar 38 1 kW This results in an air damper setting for full load ST2 of 33 for partial load ST1 of 18 Switch point for the full load so...

Page 16: ... 2 4 Start full load via switch plug and set pump pressure for full load with pressure regulating screw Carry out combustion test see appendix and whilst observing the pump pressure optimise combustion by adjusting the air damper setting ST2 or the diffuser setting 5 Start partial load check preset pump pressure and adjust if necessary Carry out combustion test and optimise combustion with the air...

Page 17: ...r on partial load setting Open partial load solenoid valve Partial load operation End of waiting time Full load solenoid valve OPEN Demand partial load Full load solenoid valve CLOSED Demand full load Full load solenoid valve OPEN Post purge Switch times Start waiting time test TW 3 5 secs Pre ignition time TVZ 10 secs Post ignition time TNZ 4 secs Safety time TS 5 secs Waiting time partial load T...

Page 18: ...ontrol F4 Temperature pressure control full load H1 Fault lamp H2 Operation lamp H3 Operating lamp full load M1 Burner motor P1 Hours run meter optional P2 Hours run meter full load optional S1 Main switch S2 Remote reset optional T1 Ignition unit X3 Plug console X4 Printed circuit boards direct plug stepping motor X5 Printed circuit boards direct plug Bus S2 X6 X7 Burner connection plug Y11 Solen...

Page 19: ...ion of the push button for less than 1 second Code stops flashing combustion manager remains in the off position Press illuminated push button only lightly until the switch point can be felt Pressing the push button too hard can damage the combustion manager ATTENTION Burner operation switch off 1 sec green orange green Burner lockout reset 1 sec Burner lockout diagnostic code ON 5 sec Burner lock...

Page 20: ...ON Condition Cause Rectification Combustion manager W FM10 Interpreting lamp signals Off No heat request or no voltage supply Red Lockout Diagnostic codes to limit probable causes press reset button approx 5 seconds 2 x flashes no flame at end of safety time 3 x flashes bridging plug X3 12 missing 4 x flashes flame simulation extraneous light 6 x flashes servomotor error 4 flame failure during one...

Page 21: ...gnition unit defective Replace ignition unit Oil pump Does not supply oil Shut off valve closed Open shut off valve Suction valve leaking Clean replace suction valve Oil line leaking Tighten connections Pre filter blocked Clean pre filter Anti siphon valve does not open Check valve if necessary replace Pump filter fouled Clean pump filter Filter leaking Replace filter Oil pump defective Replace oi...

Page 22: ... voltage 260 V Signal lamp remains off at No voltage available Check voltage supply heat request from boiler control Combustion manager defective Replace combustion manager Solenoid valve Solenoid valve does not open Coil defective Replace coil Signal lamp flashes red green Extraneous light Find source of light and eliminate Solenoid valve does not close Foreign particles on valve seat Replace oil...

Page 23: ...ombustion manager W FM10 and pulsing flame Interpreting light signals Burner combustion pulsating Mixing head incorrectly set Check setting of mixing head strongly or booming diffuser too close to front increase dimension S1 as edge of flame tube necessary see Ch 7 5 Wrong nozzle If possible select a nozzle with the next smallest throughput and increase the pump pressure If necessary change nozzle...

Page 24: ...ses as well as CO2 O2 CO values smoke No 3 Complete a test sheet Endangering operational safety Maintenance work on the following parts may only be carried out by the manufacturer or their appointed agent of the individual components Flame sensor Combustion manager Solenoid valve Servomotor DANGER 7 2 Servicing plan Service interval The operator should ensure that combustion plant is serviced at l...

Page 25: ...ition cables 3 Remove screw 4 Remove diffuser from the nozzle assembly 5 Remove nozzle When changing the nozzle support the nozzle assembly Spanner size nozzle nozzle assembly SW16 SW 19 Refit Refitting is carried out in reverse order Please note The correct nozzle must be selected and fitted correctly The distance between nozzle and diffuser see Ch 7 5 The ignition electrode setting see Ch 7 4 No...

Page 26: ...tting screw to scale setting 0 dimension X 0 The indicating bolt must be level with the back plate 2 Dimension S1 or L must be checked If dimensions differ 1 Set dimension S1 or L by turning the setting screw 2 Remove the cap from the end of the indicating bolt 3 With SW3 Allen key return the indicating bolt to the zero position 4 Refit the cap to the end of the indicating bolt Note Always carry o...

Page 27: ...27 7 7 Removing and refitting housing cover 7 6 Removing and refitting nozzle assembly 1 2 3 ...

Page 28: ...28 7 8 Service position 7 9 Removing and refitting oil pump fan motor and fan wheel Screw accessible via hole in fan wheel When fitting the screw should sit in the recess of the motor shaft ...

Page 29: ...29 7 10 Cleaning the air regulator housing and air damper 7 11 Removing and refitting air damper angle gear 2 2 ...

Page 30: ...30 7 12 Removal and refitting oil pump filter 7 13 Replacing internal fuse W FM10 T6 3H250V ...

Page 31: ...bustion rating 35 to 70 kW 2 9 to 5 9 kg h 8 3 Permissible fuels Fuel oil DIN 51603 1 Austria Fuel oil EL to ÖNORM C1109 Switzerland Standard oil Euro quality or preferred Öko fuel oil CH quality SN 181 160 2 8 4 Electrical data Mains voltage _______________________________ 230 V Mains frequency _____________________________ 50 Hz Consumption Start ________________________ 0 33 kW Operation ______...

Page 32: ... ______________________________approx 14 0 kg Fixing dimensions to EN 226 Burner Dims in mm type l1 l2 l3 l4 l5 l6 b1 b2 h1 h2 h3 d1 d2 d3 d4 WL10 2 C vers Z 140 345 27 476 398 51 330 165 353 270 165 99 M8 150 170 110 l1 l3 l2 l4 l5 l6 h1 h2 h3 b1 b2 d1 d2 d3 d4 ...

Page 33: ... also be set out to protect against damage through condensation excluding acid proof chimneys Determination of flue gas losses The oxygen content of the undiluted flue gas and the difference between the flue gas and the combustion air temperature must be determined The oxygen content and the flue gas temperature must be measured at the same time at one point Instead of oxygen content the carbon di...

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Page 36: ...els form the ideal unit a combination which has already proved successful in hundreds of thousands of combustion installations The advantages Cost saving during planning installation servicing and guarantee work The responsibility belongs to one manufacturer Weishaupt Thermo Unit Weishaupt Thermo Gas Weishaupt Thermo Condens These Units combine the technical innovations and operating efficiencies ...