Gas Burner

Installation and operating instructionsWeishaupt gas burnersSizes 1 to 11

83050302 – 1/98

2

Conformity certification

We hereby confirm that Weishaupt gas and dual fuelburners conform to the basic requirements of the following EC guidelines:

– 90/396/EEC Gas Equipment Guideline– 89/336/EEC Electromagnetic Compatibility– 73/23/EEC Low Voltage Guideline

Therefore the burner carries the CE/0085 Label.

The product conforms to the type test 0085 of the Notified Body.

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

Max Weishaupt GmbHBurner and Heating SystemsD-88475 Schwendi

0085

Contents

Title Page

1. General instructions 3

2. Burner installation 5

3. Burner fuel system 7

4. Description of valve trains 84.1 Solenoid valves 84.2 Pressure regulator type FRS 104.3 Valve proving VPS 504 114.4 Valve proving type W-DK 3/01 14

5. Installation of valve trains 155.1 Safety information 155.2 Installation example 16

6. Soundness test of valve trains 18

7. Sequence test of operation 18

8. Preparation for first commissioning 198.1 Testing gas supply pressure 198.2 Venting gas line 19

9. Commissioning 199.1 Checks prior to first commissioning 199.2 Flame monitoring 199.3 Adjusting gas part 209.4 Set gas pressure switch 229.5 Set air pressure switch 229.6 Combustion test 239.7 Setting pressure and minimum

connection pressure 24

10. Setting the mixing head 29

11. Capacity graphs 30

12. Setting ignition electrodes 33

13. Fan wheel attachment 33

14. Sequence of operation 3414.1 Pre-requisite for burner start 3514.2 Symbols on the fault position indicator 3514.3 Basic wiring diagram for LFL 1.../LGK16... 3614.4 Switching times 3714.5 Sensor line between LGK 16... and

QRA 53 / QRA 55 or sensor electrode 3814.6 Technical data 39

15. Cam setting of limit and auxiliary switches in the servo-motor 40 15.1 Gas burners, two stage 4015.2 Gas burners, sliding two stage

and modulating 41

16. Throughput determination, conversion from normal to operating condition 42

17. Fault conditions and procedures 44

3

1. General instructions

Abbreviated instructions

The following table gives an overview of the procedures forinstallation and commissioning.

To ensure safe installation and commissioningall instructions given in these installation andoperating instructions must be followed.

Step Action Chapter

1 Burner installation 2

2 Installation of gas valve trains 5

3 Soundness test of valve train 6

4 Testing gas supply pressure 8.1

5 Purging the gas supply line 8.2

6 Testing sequence of operation 7

7 Testing the mixing head 10

8 Testing the plant 9.1

9 Commissioning 9.3

SafetyTo ensure safe burner operation, the burner has to beinstalled and commissioned by qualified personneland all guidelines in these operating instructions haveto be followed.

Special attention should be paid to the relevantinstallation and safety guidelines given (i.e. localCodes of Practice).

Flame monitoring devices, limit controls, correctingelements and all other safety devices must becommissioned, and may only be replaced by, themanufacturer or the authorised agent.

Failure to comply can lead to serious injury or deathand can cause considerable damage to the plant.

Qualified personnel according to this operatingmanual are persons who are familiar with theinstallation, mounting, setting and commissioning ofthe product and which have the necessaryqualifications such as:-

– Training, instruction or authorisation to switchelectrical circuits and electrical devices on and off, toearth them and to mark them in accordance with thesafety standards.

– Training, instruction or authorisation to carry outinstallation, alteration and maintenance work on gasinstallations in buildings and on site.

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

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

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

Maintenance and service In accordance with DIN 4756, the whole installationincluding the burner should be inspected by a qualifiedengineer of the supplier at least once a year. Thecombustion figures should be checked after each serviceand each time an error has been rectified.

If, during maintenance, control seal joints have to beopened, these have to be thoroughly cleaned and newseals fitted when re-assembling.

Installation conditionsMaterial, construction and type of protection of the burnersand gas valve trains in their standard version are designedfor use indoors. Permitted ambient temperature is - 15°Cto + 40°C.

DANGER

4

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

Control circuits, which are taken from one of the supplyphases, must only be connected with an earthed neutralconductor.

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

The pole of the transformer, which is to be used as theneutral conductor must be earthed.

The control circuit phase and neutral conductors mustbe connected correctly.

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

General information for gas operationWhen installing a gas combustion system, localregulations and guidelines must be observed.

The subcontractor responsible for the installation orchanges of the gas system must inform the gas supplier ofthe type and extent of the installation planned and theintended work. The subcontractor must ascertain that anadequate gas supply to the installation is ensured.

Installation, alteration and maintenance work on gassystems in buildings and on process sites, must only becarried out by installers who have a contract with the gassupplier.

Gas characteristicsThe following information must be obtained from the gassupplier:Type of gas, calorific value in kWh/m3, max. CO2 content offlue gas, gas supply pressure.

Gas lineThe gas pipework must be subject to a preliminary andmain test or the combined loading test and soundnesstest, according to the pressure range intended. The air orpurge gas required for the test must be expelled from thepipework.

The determination of the pipework diameter usually gives adiameter, which is at least one diameter larger than the sizeof the burner valve train.

Gas valve trainObserve the sequence and flow direction. The distancebetween burner and DMV valve should be as small aspossible in order to guarantee trouble free start.

Pipe thread connectionOnly tested and approved sealing material should be used.Please observe individual user instructions!

Soundness testBrush connection points with foam forming agents orsimilar, non-corroding materials.

Gas typesThe burner must only be operated with the type of gasstipulated on its name plate. When converting to othertypes of gas re-commissioning is required. A conversion kitmay also be needed.

Valve train installationThe valve train must be fixed and supported securely.Standard connection is from the right.

Gas meterThe siting, size and type of gas meter are the responsibilityof the gas supplier. Only those meters, which have beenapproved, should be used. If no gas meter is fitted, as forinstance on liquid petroleum gas installations, the operatorhas to be made aware that the burner can not be set to itsoptimum, because basic testing is not possible without ameter installation.

Plant room regulationsLocal regulations regarding the design of plant rooms mustbe observed and the installation of an emergency switchand a mains gas shut off system should be considered.Attention should also be paid that sufficient ventilation isavailable in the plant room. Any shortcoming should benoted in the commissioning report.

The commissioning report must be completed by theservice engineer and signed by the plant operator or hisauthorised agent. The operator should be instructed in thecorrect operation of the burner and control panel. Theoperating instructions included with each burner must bedisplayed clearly in the plant room.

Thermal / manual shut off systemIf a thermal / manual shut off system is required, this shouldbe fitted in front of the burner fuel isolation valve(s). Thisinstallation must conform to local regulations.

5

2. Burner Mounting

Mounting to the heat exchanger

Installation example for heat exchanger with refractory

Drilling dimensions of the burner plateSize 1 to 10 Size 11

Size Combustion Dimensions in mmhead type l1 d1 d2 d3 d4 d5

1 G1/2a 112 130 160 160-170 135 M83 G3/1a 157 160 190 186 165 M105 G5/1a 200 200 240 235 210 M10

7 G7/1a 230 250 290 298 270 M128 G7/2a 230 265 300 298 270 M12

9-10 UG2/1a 233 325 360 330 305 M1211 UG3/1a 280 380 420 400 385/360* M12

* The burner can only be removed with the boiler plate

d5

d4

d3

d5

d4

d3

60°

30°

The gap between combustion headand refractory must be filled withflexible insulating material . Do notmake solid.

Hinging the burnerRemove gas butterfly rod

Electrical connectionA wiring diagram is enclosed with each burner delivery.

Interlock switchThe interlock switch is arranged in such a manner that thecircuit is closed in the burner closed position. In the burneropen position, the circuit is interrupted by the release ofthe tripping pin in the interlock switch.

Transport weight

Burner type Weight (without valve train)

G1 39 kg

G3 43 kg

G5 55 kg

G7 76 kg

G8 85 kg

G9 130 kg

G10 131 kg

G11 157 kg

6

Combustion head extension

Combustion head extensions are required on applianceswith very thick doors and boilers with a flame reversal firetube.

For easy removal of the burner internal head assembly,particularly those with head extensions, it is important, thatthe burner body is able to swing through approx. 90°.

To enable installation and service work to be carried out,the refractory should not be longer than dimension l1. Onlyvalid for standard boiler arrangements, not for specialcombustion chambers, ovens etc.

Installation example

Refractory

Burner plate

Flange gasket

Burner flange

Flexible insulating material

Combustion head

Extension

Burner Extension Dimension in mmsize mm l1 d1 d2 d3

1 100 212 120 130 1701 200 312 120 130 1701 300 412 120 130 170

3 100 257 140 160 2003 200 357 140 160 2003 300 457 140 160 200

5 100 300 180 200 2405 200 400 180 200 2405 300 500 180 200 240

7 100 330 220 250 2907 200 430 220 250 2907 300 530 220 250 290

8 200 430 220 265 3058 300 530 220 265 305

9-10 200 433 280 325 3659-10 300 533 280 325 365

11 200 480 325 380 42011 300 580 325 380 420

7

P

4a1

P

4 5a 6

95b

2 3

P

12

7 10 11

P

4a

P

5b

4 5 6

97

1 2 3 8

3. Burner fuel system for gas

With DMV valve and valve proving system VPS

With 2 solenoid valves and valve proving system W-DK 3/01

Valve trainsIn accordance with EN 676 burners must be fitted withGroup A solenoid valves.Weishaupt gas and dual fuel burners are supplied asstandard with two solenoid valves (on DN 150 with twosingle solenoid valves).

Weishaupt also recommend the use of a valve provingsystem. In accordance with EN 676 the use of a valveproving system is required for installations from 1,200 kW.This and other valve train components, such as gas filterand gas governor can be found in the Weishauptaccessories list.

Legend

1 Ball valve2 Gas filter3 Pressure regulator 4 Gas pressure switch, min.4a Gas pressure switch, max. (to TRD/IM30)5 Double Solenoid valve (DMV)5a Single solenoid valve 5b Ignition gas solenoid valve6 Gas butterfly valve7 Pressure gauge with push button valve8 VPS valve proving9 Burner10 Valve leakage indicator11 Vent valve12 Gas pressure switch for valve proving W-DK 3/01

Bild

er a

us 4

29

8

1

23

6

4

7

5

4. Description of valve trains

Function

DMV-D/11Two single solenoid valves normally closed, fast opening,fast closing, manual limiting of gas throughput is possibleby adjusting main flow at valve 1 (V1).

Technical data

Max. operating pressure 500 mbarVoltage/frequency ~(AC) 230 V - 15 %...

to 240 V + 10 % 50/60 Hzor ~(AC) 110 V 50/60 Hz

Ambient temperature -15 °C ... +60 °CInstallation Horizontal or vertical

L1 N

2 1 3

V1 V2

L2

Electrical connectionPressure test point

Legend1 Pressure into V12 Pressure between V1 and V23 Pressure after V24 Inlet flange connection5 Outlet flange connection

3

L2

3

1

L1N

2

DMV-D 5040/11 - 5125/11

231

54

Legend1, 2 Pressure into V13 Pressure between V1 and V24 Ignition gas outlet5 Pressure after V26 Inlet flange connection7 Outlet flange connection

1

23

4 2cm

4

4

V1 V2

2 3 5

2 3 5

1

1

6 7

4

4

V1 V2

1 2 3

1 2 3

DMV and GW plug

DMV-D 507/11 - 520/11

MVD 507/5

DN 3/4” with socket connection

DN150 withflange connectionDIN 2633 PN16

MV 5150/5-S

R 1/4” both sides

R 3/4"

R1/4” both sides

4.1 Solenoid valves

9

1. Switch off and isolate installation2. Remove connection plug3. Remove paint seal from screw A4. Remove counter sunk screw A5. Remove cheese head screw B6. Remove cap (C) and metal plate (D)7. Change solenoid, checking new unit is correct

type/voltage8. Refit metal plate (D) and cap (C)9. Refit screws A and B

10. Do a gas tightness test at test point 2 and 3: pmin = 100 - 150 mbar

11. Carry out function test12. Switch on supplies and test burner

Changing solenoid valve DMV

A

B

C

D

E

F

Gas throughput adjustment

DMV 507-5125 DMV 507 - 520/11 Throughput adjustment on V1 viacovered adjusting screw. One turn = 0.5 mm stroke adjustment, anti-clockwise to increase flow , and vice-versa.

DMV 5040 - 5125 Throughput adjustment on V1 viacovered adjusting screw. One turn = 1 mm stroke adjustment, anti-clockwise to increase flow , and vice-versa.

Factory pre-set: maximum stroke

V1minmax

Connection of gas pressure switch to DMV

Gas pressure switch on DMV - flanged version

10

4.2 Pressure regulator type FRS

Outlet pressure adjustment (set value) 1. Remove cap A2. To increase outlet pressure (set value), turn screw B

clockwise.

or

3. To reduce outlet pressure (set value), turn screw B anti-clockwise.

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.4. Re-fit spring retainer C, and by turning screw B set the

required outlet pressure.5 Prove adjustment is correct and re-fit cap A, and new

range label.

Type of spring / colour Outlet pressure range mbar

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

B

A

C

AB

D

Gas pressure switch on DMV - screwed version

Gas pressure switch with intermediate flange on DMV -screwed version

11

4.3 Valve proving system VPS 504

Operation

The valve proving system type VPS 504 operates to thepressure build up principle. The progr. is activated at heatrequest. Valve proving is carried out after every burner start.

The VPS 504 carries out a self-test during the switchingsequence. If a fault occur release is prohibited and an errormessage is displayed.

Technical data

Max. operating pressure 500 mbarTest volume ≤ 4,0 lPressure increase via motor pump ≈ 20 mbarVoltage/frequency ~(AC) 230 V - 15 %...

to 240 V + 10 % / 50 Hzor ~(AC) 110 V / 50 Hz

Type of protection/switching duration Series 04 IP 54 / 100 % EdPre-fusing (by others) 10 A F or 6,3 A T

Fusing fitted to housing T6,3 L 250 VSwitching current operating output max. 1A

lockout output max. 1ARelease time ≈ 10… 26 smax. number of test cycles 20 /hAmbient temperature -15 °C ... +60 °CInstallation vertical or horizontal

Pressure reduction

1 Connection pe, p1

2 Connection pa, p2

3, 4 Test points

IIIIIIIII

IIIIII

III

IIIIII

IIIIIIIII

pap2

pep1

pap2

pep1

321 VPS 504

p2pa

p1pe

p2pa

p1pe

1 2

3 4

DMV-. …MB- …

Series 04

12

Sequence of operation

V1 V2

VPS 504

p2pa

p1pe

p2pa

p1pe

A

p e

A

p + 20 mbare

V1 V2

VPS 504

p2pa

p1pe

p2pa

p1pe

p e

A

V1 V2

VPS 504

p2pa

p1pe

p2pa

p1pe

p e

p e

p e

A

Programme sequenceShut down condition: Valve 1 and valve 2 are closed.

Pressure build-up: The internal motor pump increases thegas pressure in the test section by approx. 20 mbar whencompared to the pressure pe on the inlet side of valve 1.During the test phase the inbuilt differential pressureswitch checks the test section for soundness. Once thetest pressure has been reached the motor pump isswitched off (end of test phase). The release time (10 to26 secs) depends on the test volume (max. 4.0 l). If the test section is sound, the contact to the burnercontrol is released after max. 26 secs. The yellow signallinglamp is illuminated.If the test section is not sound or if the pressure increase of+ 20 mbar is not reached during the test phase (max26secs.), the VPS 504 goes to lockout. The red signallinglamp is illuminated as long as contact is made by theregulator (heat request).An automatic restart is carried out following short termvoltage loss during the test phase or during burneroperation.

0 5 10 15 20 25 [s]30

VPS 504 "DICHT" VPrüf = 0,3 l

VPS 504 "DICHT" VPrüf = 4,0 l

VPS 504 "UNDICHT"

RegulatorPump motorSolenoid valveDiff. pres. switchRelease signal

RegulatorPump motorSolenoid valveDiff. pressure switchRelease signal

RegulatorPump motorSolenoid valveDiff. pressure switchRelease signalLockout signal

A=Programmer

Shutdown Pressure build-up Operation

Installation

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 in on the VPS 504 is complete carry out

valve proving and function test.– Ensure tight sealing when changing parts.

Remove closingplug

VPS "Sound" Vtest = 0.3 l

VPS "Sound" Vtest = 4.0 l

VPS "Not Sound"

13

Electrical connection VPS 504 series 04

With cable gland PG 13.5 and connection to screwterminals.

Potential free relay contacts must only be used forsignalling and never for burner control circuit!

Release time tFTime required by the VPS 504 to carry out a complete testcycle. The release time of the VPS 504 depends on thetest volume and inlet pressure:

V test < 1.5 l V test > 1.5 lpe > 20 - 500 mbar pe > 20 mbartF ≈ 10 s tF > 10 s

tF max / VPS 504 ≈ 26 s

Test time PtPump time of the motor pump.

Test volume V testVolume between V1 on the outlet side and V2 on the inlet side.

V test max. / VPS 504 = 4 l.

Test volume of the multiple settings units

Type Rp/DN Test volume

DMV-D(LE) 503/11 Rp 3/8 0.09 lDMV-D(LE) 507/11 Rp 3/4 0.09 lDMV-D(LE) 512/11 Rp 1 1/4 0.25 lDMV-D(LE) 520/11 Rp 2 0.25 lDMV-D(LE) 5040/11 DN 40 0.36 lDMV-D(LE) 5050/11 DN 50 0.36 lDMV-D(LE) 5065/11 DN 65 0.60 lDMV-D(LE) 5080/11 DN 80 1.70 lDMV-D(LE) 5100/11 DN 100 2.30 lDMV-D(LE) 5125/11 DN 125 3.75 l

Ø 9

Bet

rieb

Fon

ctio

nam

ento

Fun

ziam

ento

Run

Stö

rung

Dér

ange

men

tB

locc

oLo

ckou

t

126,5

Ach

tung

, War

ning

, Atte

ntio

n, A

ttent

ione

Vor

dem

Öffn

en is

t das

Ger

ät s

trom

los

zu s

chal

ten

Bef

ore

open

ing

switc

h of

f pow

er s

uppl

yO

uver

ture

uni

quem

ent h

ors

tens

ion

Prim

a di

api

re l'

apar

ecch

io to

glie

re la

cor

rent

e

Ersatzsicherung

Typ:

VP

S 5

04

Ser

ie 0

4

219

881

~(A

C)

50 H

z 23

0 V

-15°

C T

70°

C…

…

~(A

C)

50 H

z 24

0 V

-15°

C T

60°

C…

……

Sch

alts

trom

Imax

. 4A

IP54

pmax

. = 5

00 m

bar

ID-N

o.C

E-0

085A

P01

68

pape

100

224,

3

7253,7

5 13

pe

pa

147

150

Sicherung eingebaut, auswechselbarFuse built into housing, exchangeableFusibile integré dans la couvercle du boîtierinterchangeable

Typ/Type/Type/Tipo T 6,3 L 250 VBetriebsanleitung beachten!Please comply with the operating instructions!Suivre les instructions de la notice d'utilisation!Seguire le istruzioni!

Standard:Kabeldurch-führungPG 13,5

ZusätzlichKabeldurchführungPG 11 möglich

peMeßstutzen

paMeßstutzen

Sauganschluß (Gaseingang)

Druckanschluß (zur Prüfstrecke)

1NC

VPS 504Serie 04intern

2COM

3NO

4 5B

6L1

7N

8

potentialfreies Störsignal(Leitwartensignal) Betriebsspannung ~(AC) 230 V 50 Hz

}

Frei

gabe

-si

gnal

Bet

riebs

-sp

annu

ng

Nul

l-le

iter

Erd

e

dicht

undichtV3

P

Interchangeable fuses:T 6.3 L 230V to ICE 127 2/III(DIN 41662)D5 x 20

1 2 3 4

2468

1012141618202224262830

p = 300 m

bar

e

p = 100 mbar

e

p = 20 mbar

e

p = 500 mbar

e

t ≈ 10 s

V≤ 1,5 l

Anwendungsbereich

F

Prüf

t [s]F

V [l]Prüf

Installation dimensions S04/S04

VPS 504 Series 04

VPS 504Series 04internal

Potential free lockout signalOperating voltage

Rel

ease

sign

al

Ope

ratin

gvo

ltage

Neu

tral

cond

.

Ear

th

not sound

sound

V test.≤ 1,5 l

V test

Application range

Replacement fuse

Additional cableentryPG11

petest point

Suction connection (gas inlet)

Pressure connection (to the test section)

pa test point

Standardcable entryPG 13.5

14

1 Solenoid valve 12 Solenoid valve 23 Leakage indicator unit4 Vent valve5 Gas pressure switch6 Programmer fitted in

control panel

150

5 5

75

100

133

23

II

II

Fitting dimension

Plug-in unit

Sub- base Cableentry

P

13 5 624

0,2

… 0

,5 m

4.4 Valve proving system type W-DK 3/01

ConstructionThe valve proving system W-DK 3/01 consists of four mainparts:● Programmer fitted into the control panel of plant● Gas pressure switch fitted to the test section between

the solenoid valves● Vent valve (normally open) fitted into the vent line● Leakage-indicator unit fitted into the vent line

FunctionThe tightness of the solenoid valves in the gas valve train ischecked prior to each burner start.

Operation1.Test phase: During pre-purge all three solenoid valvesare closed. If pressure builds up due to possibly leakingfirst valve, the pressure increase is detected by the gaspressure switch.

2. Test phase: If the first solenoid valve is gas-tight, it isopened momentarily , but the vent valve remains closed.Gas pressure is now in the section between the threesolenoid valves. It is tested for a reduction in pressure intest section. The test is carried out by the programmer.

Gas valve train with Weishaupt valve proving system W-DK 3/01

Technical data

Weishaupt valve proving systemTypeW-DK 3/01 Typ W-DK 3/01

Mains voltage/Frequency V / Hz 220 ± 15% / 50 or 60Fusing A in accordance with the

pre-fusing of the burnercontrol

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. 9Type of protection IP 40Consumption VA approx. 4Installation as requiredWeight 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

Test resultIf a pressure increase (phase 1) or pressure decrease (phase2) is detected, the burner start is inhibited. Otherwise thesolenoid valves are tight and the burner starts.

Pressure switch setting1/2 flow pressure

15

5. Installation of valve trains

5.1 Safety notice

Risk of explosion!If the valve trains are not installed correctly,their soundness and strength cannot beguaranteed.

To avoid deadly accidents, the following safetyinstructions must be observed duringinstallation:

● Observe the maximum permitted gas pressure in thevalve train. Contact your local gas supplier to obtain theconnection pressure of the gas mains.The connection pressure must not exceed the maximumpressure recorded on the name plate.

● Valve trains must be installed securely to avoid vibrationduring operation.Suitable supports should be used (available asWeishaupt accessory).The supports must be fitted to the specific site require-ments when mounting the valve trains.

● Valve trains must be installed tension free. Nevercompensate for mistakes made during installation byover tightening the flange screws.

● Flange screws should be tightened diagonally opposite.

● Ensure flange gaskets are clean and fitted correctly.

● Only gas board approved sealing material should beused. If a connection needs to be loosened often, flangeconnections with inlaid gasket should be used.

Other installation information:On installations, which are subject to special regulationsfor steam boilers, the valve trains can be vented with a testburner. The first solenoid is fitted with a connection pointfor this test burner.

To allow the boiler door to be hinged open, a flangeconnection point, if possible at door level, should be fitted(compensator see drawings, chapter 5.2).

To achieve better start conditions, the distance betweenburner and solenoid valves (ignition and mains gas) shouldbe as small as possible.Observe sequence and flow direction of valve train.

If a thermal shut off device TAE is required, this must befitted in front of the ball valve.

DANGER

16

High pressure supply with DMV flanged

Low pressure supply with DMV flanged

11 10 9

8765a431 2a

1 3 4

9

6 7 85b

11 10

2a

5.2 Installation example

17

Low pressure supply with DMV screwed

Low pressure supply with single valves (only for nominal diameter DN 150)

1 Solenoid valve for ignition gas2a Double solenoid valve DMV2b Single valve 3 Test burner4 Gas pressure switch, max. (to TRD/IM30)5a High pressure regulator 5b Low pressure regulator6 Filter

7 Pressure gauge with push button valve8 Ball valve9 Compensator

10 Gas pressure switch, min.11 Valve proving system VPS12 Pressure switch for valve proving system W-DK 3/01

1 3 4 6 7 8

11 10

5b2a

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

12 10 9

18

6. Soundness test of valve trains

Soundness test of the gas train must be carried out withthe main isolating cock and DMV valves closed. Proceedas follows:

1. Test phase: ball cock up to 1st valve seat (V1)The test assembly is connected to the gas filter and DMVinlet. During pressure testing, the test point 2 betweenDMV valve seats V1 and V2 has to be open.

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

The test assembly is fitted to the DMV test point 2.

Test pressure in the valve train should be between 100 and150 mbar.

Wait 5 minutes for pressure equalisation.

The valve train is not leaking if the pressure drop is nomore than 1 mbar after the test period of 5 minutes haselapsed

3. Test phase: Valve train connection parts and gasbutterfly valve

The third test phase can only be carried out duringoperation and by using a leak detection solution.

Results of the pressure test must be recorded on theservice/commissioning report.

Attention!After all maintenance and commissioning work on gassupplying components a soundness test must becarried out.

1 Rubber hose with T piece2 Aspirator3 U-tube manometer or electronic manometer

1

2

3

7. Sequence test of operation

Wiring connection checkCheck that the wiring to all parts, especially the valve train,is carried out in accordance with the wiring diagramsupplied with the burner.

Testing the burnerCheck the rotation of burner motor.

Sequence test gas operation (without gas)The ball valve must be closed and the selector switch ondual fuel burners set to gas operation. Air is pumped intothe valve train by means of the hand pump still connectedfrom the soundness test. The pressure must be at least ashigh as the subsequent gas operating pressure.

The burner is switched on and the following programmeshould take place:

Versions with DMV and valve proving system VPS– Burner motor starts following successful valve proving.– The servomotor opens the air damper in approx. 40 (20)

seconds.– The full load pre-purge period is 30 seconds. – The servomotor closes the air damper to the ignition

position in approx. 35 (17) seconds.– The pre-purge time of approx. 4 seconds begins.– Gas solenoid valves are opened.– Pressure in the valve train falls.

– Gas pressure switch shuts down the burner.– Gas solenoid valves are closed.

If the gas pressure switch does not shut down the after thesafety time of 2 seconds has elapsed, then the burnercontrol locks out.

Version with two solenoid valves and valve provingsystem W-DK 3/01– Burner motor starts.– The servomotor opens the air damper in approx. 40 (20)

seconds.– The full load pre-purge period is 30 seconds. – Valve proving is carried out in accordance with the

sequence of operation (see chapter 24).– The servomotor closes the air damper to the ignition

position in approx. 35 (17) seconds.– The pre-purge time of approx. 4 seconds begins.– Gas solenoid valves are opened.– Pressure in the valve train falls.– Gas pressure switch shuts down the burner.– Gas solenoid valves are closed.

If a fault occurs during the sequence of operation seedescription of burner control LFL1... and the additionalinformation.

First test phase Second test phase

V1 V2

19

Risk of explosion!The mains gas pressure must not exceed themax. permitted pressure of the valve trains listedon the burner name plate. The mains gaspressure must be checked prior to firstcommissioning.

1. Connect pressure test unit to filter.2. Slowly open the ball valve monitoring the pressure test

unit at all times.3. Close the ball valve immediately if the mains gas

pressure exceed the max. permitted pressure of thevalve train. The burner must not be started.

4. Contact your nearest Weishaupt branch office.

8. Preparation for first commissioning

8.1 Testing the gas supply pressure

DANGER

8.2 Purging the gas supply line

PurgingThe valve train must be purged prior to firstcommissioning.

A hose leading into the open is connected to the test pointon the gas solenoid valve to discharge the air.

After purging, the test manometer or gauge isreconnected at the test point on the solenoid valve.

If a test burner is installed, this must be used to ensurethat no air is present in the equipment.

Any air or inert gas in the distribution lines must alsobe expelled form the pipework. This work is usuallycarried out by the local gas authority.

When work on the valve train involves changingcomponents, the valve train must be purged andundergo a valve proving test before the burner isswitched on again.

9. Commissioning

9.1 Checks prior to first commissioning

The whole installation must be checked prior to thefirst commissioning.

● Has the heat exchanger been installed ready foroperation?

● Are heat exchanger and system filled sufficiently withheating medium?

● Are movable exploding flaps fitted?● Is the flue gas damper open?● Are the flue gas ways free?● Are the ventilators of air heaters operating correctly?● Is the ventilation to the plant sufficient?● Has the whole installation been wired correctly?

● Have temperature switch, pressure switch and safetylimiting systems been set to operation?

● Is sufficient load available?● Has the low water safety interlock been adjusted correctly?● Have all fuel carrying parts been vented (free of air)?● Check rotation of burner motor.● Has the valve proving of the valve train been carried

out?● Is the gas supply pressure correct?

It is possible that other site-specific tests will have to becarried out. Refer to the operating instructions of individualsite components.

9.2 Flame monitoring

Minimum required sensor current in µAmin. required ionisation UV cell QRA2 ionisation current 6 70

values normally obtained >15 >120

Test for flame sensorIonisation electrode: By separating the plug connectionsin the vicinity of the terminal strip.UV cell: By withdrawal from the holder on the burnerflange.

Note: With the LGK 16... burner control and UV sensorQRA 53/55, it is only possible to measure the sensorcurrent by means of the special sensor current measuringinstrument type KF8832.

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

Microammeter (range 0... 150 µA)

Microammeter (range 0 ... 600 µAor 0 ... 1 mA)

22 24 22 23

20

9.3 Adjusting

Switch on procedure– Open ball valve.– Release gas pressure regulating spring

(see chapter 4.2).

Version Z:– Set selector switch in control panel to “stage 1” or

“partial load”.

Version ZM:– Set selector switch in control panel to “stop”

– Reset installation.– Switch on burner operating switch.

IgnitionAfter the pre-purge time has elapsed, wait for flameformation. If ignition problems occur check the pre-settingof the gas butterfly valve (nominal approx. 5 - 10° “Open”on the gas butterfly scale), as well as the position of theignition load switch in the servomotor (ZM: No. IV, Z: No.V)and if necessary increase slightly. Check sensor currentwith microammeter.

Intermediate testing (partial load to full load):After approx. 20 secs. the servomotor runs from ignition topartial load position.

Set gas pressure to table in chapter 9.7 (Setting pressureinto solenoid valve).Carry out CO test.

Version Z:– Switch off servomotor with toggle switch– Adjust regulating cam step by step with servomotor

dis-eneaged – Re-engage servomotor. – Carry out CO tests at each cam setting up to

full load setting.– Make the necessary corrections to the

pressure settings.

Version ZM:– Disengage servomotor– Turn gas regulating cam step by step by hand

and re-engage servomotor. – Carry out CO tests at each cam setting up to full load

setting.– Make the necessary corrections to the

pressure settings.

Full load settingDrive up servomotor electrically towards full load:

Version Z:– Set toggle switch in the servomotor to “On”.– Set selector switch in control panel to full load.

Version ZM:– Disengage servomotor– Turn gas regulating cam to intermediate position and

re-engage servomotor. – Set selector switch in the control panel to full load.

The required amount of gas for full load must be set andmeasured at the gas meter (the gas pressures given in thetable chapter 9.7 are only an aid for setting and adjusting).

��

�

Disengaging servomotor 1055/80

Disengaging servomotor SQM

Butterfly valve pre-setting

Setting combustion air

21

Combustion test:Regulate the amount of gas by adjusting the gas settingpressure. Regulate the combustion values by adjusting thecurve band of the air regulating cam and positioning of theregulating sleeve so that best possible values and goodflame stability are achieved with fully opened air damper.

The gas pressure set for full load must not be altered.

Intermediate check (“full load to partial load”).Version Z:

As the burner rating changes between full and partialload (high and low fire) occur quickly, it is onlynecessary to do spot checks at the intermediateratings for CO.

Start cams step by step electrically, (trip switch off,selector switch stage 1), start points with trip switch.

Version ZM:As the operating range of the burner is used atintermediate levels as well as the max. and min. levels,combustion tests are required at each cam setting.Adjust cams step by step (selector switch “Stop”,disengage servomotor, adjust, re-engageservomotor).

Adjust combustion values by adjusting the air curve band.

Ensure the curve bands have an even profile.

Partial load settingSet selector switch on control panel to “Stage 1” or“Partial load”. Set the required gas volume (throughput) bymeans of the auxiliary switch in the servomotor (Z: No 11,ZM: No.V1) and measure volume at the gas meter.

Pay attention to the minimum limits of the capacity graphs,flue gas temperatures and instructions of the boilermanufacturer.

Completing commissioningCheck ignition load setting once burner has beencommissioned, if needed adjust at the auxiliary switch inthe servomotor (Z: No.V,ZM:No.IV). The ignition loadsetting needs to be reliable and free of ignition ‘impact’,regard must be taken of local requirements coveringignition firing rate limitations. An ignition test needs to bemade with the gas pipework downstream of the safetyvalve and the head of the burner devoid of gas. Therequired measurements can be made by holding theburner in the start gas phase (Z: toggle switch inservomotor, ZM: interrupt servomotor neutral at ignitionload position).

Check the CO limit by setting burner from low fire (partialload) to high fire (full load) and high fire to low fire.

With the installation operating test the function and settingof safety equipment, i.e. gas and air pressure switches,plant temperature/pressure limit switches, interlocks.

Documentation:The following setting values have to be noted on thecommissioning report.

At ignition load: At full and partial load:Gas throughput Gas throughputSensor current Gas pressure into ball valveCO Gas pressure after ball valve

CO2With liquid petroleum gas: COtake smoke measurements Exhaust gas temperature

Fan pressureSuction/pressure in combustion chamberSensor current

22

9.4 Set gas pressure switch

Gas pressure switch type GW50A2Gas pressure switch, min.To set a pressure switch for gas, a manometer has to befitted to test point 1 of the DMV and the microammeter formeasuring of the ionisation current. When determining theswitch point, pay attention that this is not below half theregulated pressure, that the ionisation current is aminimum 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 operating2. Gradually close ball valve so that the pressure at the

pressure test unit slowly decreases.3. Setting pressure has been reached when

– 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. Ifthe ball valve is closed again, the shut down pressurecan be tested. The burner control must not go to lockout.

Gas pressure switch, max. must be set to 1.3 x pa max.

30

3540

45

50

25 20 15

1052,5mbar

GW 50 A2

9.5 Set air pressure switch

Size 1 to 3Fan pressure is measured at full load. Switch point is set to> 80% of the pressure measured at full load.

Size 5 to 11The air pressure switch is pre-set. The switch pointmust be checked and adjusted during commissioning.For this a differential pressure measurement betweenpoints ➀ and ➁ is required. Pressure behaviour ismonitored throughout the set range of the burner by thepressure test unit (i.e. U tube). The lowest differentialpressure value is used for the determination of switchpoint.

The switch point is set to > 80% of this value. To do this,the protective cap of the LGW is removed and thecalculated value is set at the setting wheel.

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

Installation dependant influences, such as flue gasrecirculation, heat exchanger, installation or air supply, onthe air pressure switch and the settings may result inadjustments having to be made.

Differential pressure test (on sizes 5 to 11)

30

3540

45

50

25 20 15

1052,5

mba

Pressure switch for air type LGW50A2

➁

➀

23

Calorific value of various types of gases and CO2 max.Gas type Calorific value Hi CO2 max.

MJ/m3 kWh/m3

First gas familyGroup A (Towns Gas) 15,12…17,64 4,20…4,90 12…13Group B (Grid Gas) 15,91…18,83 4,42…5,23 10

Second gas familyGroup LL (Natural Gas) 28,48…36,40 7,91…10,11 11,5…11,7Group E (Natural Gas) 33,91…42,70 9,42…11,86 11,8…12,5

Third gas familyPropane P 93,21 25,99 13,8Butane B 123,81 34,30 14,1

To ensure efficient and problem free operation of theinstallation, flue gas measurements must be taken.

The different maximum CO2 contents can be obtainedfrom the local gas board (guide values see table).

Excess air should not exceed 10-20% at full load and30% at partial load.

Excess air λ ≈ CO2 max.CO2 measured

The CO content must not be more than 0.005 vol.%(50ppm).

Flue gas temperature for full load (nominal load) is theresult of burner setting at nominal loading.

Flue gas temperature for partial load is the result ofthe control range adjustment.

The instructions of the manufacturer are to befollowed closely on hot water boiler installations.Normally a partial load of 50 - 65% of the nominal loadis set (some of the data may be on the boiler ratingplate).

On air heater installations the partial load is normallyeven higher. Again, the instructions of themanufacturer should be closely followed.

The flue gas installation should also be set out toprotect against damage through condensation(excluding acid proof chimneys).

9.6 Combustion test

24

9.7 Setting pressure and minimum connection pressure

The results of the following tables have been calculated onflame tubes under idealised conditions. The values aretherefore guidelines for basic settings. Small variationsmay occur when commissioning depending on individualinstallations.

* The data given for DN40 is also valid for 1 1/2” andthose for DN50 for 2” valve trains.

The combustion chamber pressure in mbar must be addedto the minimum gas pressure determined.

Selection of nominal diameter for valve trains for towns gassee separate worksheet, print No. 900.

With low pressure supplies with double solenoid valves(DMV) pressure regulators to EN 88 with safetydiaphragm are used. Maximum permissible connectionpressure into isolating valve is 300 mbar on low pressureinstallations.

With high pressure supplies HP regulators to DIN 3380are selected from the technical brochure “Pressureregulating and safety assemblies for Weishaupt gas anddual fuel burners”.

HP regulators for connection pressure up to 4 bar aredetailed in this brochure.

Max. supply pressure see burner name plate.

The data given for calorific value Hi relate to 0°C and1013.25 mbar.

Size 1

Burner Low pressure supply (gas pressure in mbar High pressure supply (setting pressure in mbar rating into isolating valve, pe.max = 300 mbar) into double solenoid valve)kW Nominal diameter of valve trains Nominal diameter of valve trains

3/4” 1” 40* 50* 65 3/4” 1” 40 50 65Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve25 25 25 25 25 25 25 25 25 25

Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 150 14 – – – – 7 – – – –200 21 10 – – – 11 – – – –220 25 11 – – – 13 – – – –250 31 13 8 – – 16 6 – – –280 37 15 9 8 – 20 7 5 5 –300 42 17 10 9 – 23 7 6 6 5320 47 18 11 9 8 25 8 6 6 5340 52 20 12 10 9 28 9 7 6 6

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 150 18 9 – – – 9 – – – –200 28 12 – – – 15 5 – – –220 33 14 9 – – 18 6 – – –250 42 16 10 8 – 22 7 5 5 –280 51 19 11 9 8 27 8 6 6 5300 58 22 12 10 9 31 9 7 6 6320 65 24 13 10 9 35 10 7 7 6340 73 26 14 11 9 39 11 8 7 6

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 150 – – – – – – – – – –200 11 – – – – 6 – – – –220 13 – – – – 7 – – – –250 16 8 – – – 8 – – – –280 18 9 – – – 10 – – – –300 20 10 – – – 11 – – – –320 23 11 – – – 12 5 – – –340 25 12 8 – – 14 6 – – –

* The data given for DN40 is also valid for 1 1/2” and those for DN50 for 2” valve trains.

25

Size 3


3/4” 1” 40* 50* 65 80 3/4” 1” 40 50 65 80Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve25 25 40 40 40 40 25 25 40 40 40 40

Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 300 41 16 9 – – – 22 6 – – – –350 54 20 10 8 – – 29 8 5 – – –400 69 25 12 9 – – 37 10 6 6 – –450 86 30 14 11 9 – 46 12 7 7 6 5500 105 36 16 12 9 9 56 14 8 8 6 6550 126 42 18 13 10 9 68 17 9 9 7 6600 149 49 21 15 11 10 80 19 10 10 8 7650 174 56 23 16 12 11 93 22 11 11 9 8

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 300 57 21 10 8 – – 30 8 – – – –350 76 26 12 10 – – 40 10 6 6 – –400 98 33 15 11 9 – 52 13 7 7 6 5450 123 40 18 13 10 9 65 16 8 8 6 6500 150 49 20 14 11 9 80 19 10 9 7 6550 181 58 23 16 12 10 96 22 11 10 8 7600 214 68 27 18 13 11 114 26 13 12 9 8650 250 78 30 20 14 12 133 29 14 13 10 9

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 300 19 9 – – – – 10 – – – – –350 25 11 – – – – 13 – – – – –400 32 13 8 – – – 17 6 – – – –450 39 16 9 – – – 21 7 – – – –500 47 19 11 9 – – 26 8 6 6 5 –550 56 21 12 10 8 8 30 40 6 6 6 5600 66 25 13 11 9 9 36 11 7 7 6 6650 76 28 14 12 10 9 42 12 8 8 7 7

Size 5


3/4” 1” 40* 50* 65 80 100 3/4” 1” 40* 50* 65 80 100Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve25 25 40 50 50 50 50 25 25 40 50 50 50 50

Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 500 105 35 16 11 9 – – 56 14 8 7 5 – –550 126 42 18 12 9 8 – 67 16 9 8 6 5 5600 149 49 20 14 10 9 8 79 19 10 9 7 6 6650 174 56 23 15 11 9 9 93 22 11 10 7 6 6700 201 64 26 17 12 10 9 107 25 12 11 8 7 7800 261 82 32 20 14 11 10 139 31 15 13 10 8 8900 – 102 39 24 16 13 12 – 38 18 15 11 9 9940 – 111 42 25 17 13 12 – 41 19 16 12 10 9

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 500 150 48 20 13 10 8 – 80 18 9 8 6 5 5550 180 58 23 15 11 9 8 96 22 11 9 7 6 6600 214 67 27 17 12 10 9 113 25 12 11 8 7 6650 250 78 30 19 13 11 10 133 29 14 12 9 7 7700 289 90 34 21 14 11 10 – 33 16 13 10 8 7800 – 115 43 25 16 13 12 – 43 19 16 11 9 9900 – 144 52 30 19 15 13 – 53 23 20 13 11 10940 – 157 57 33 20 15 13 – 57 25 21 14 11 10

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 500 46 18 10 – – – – 25 7 – – – – –550 55 20 11 8 – – – 29 9 5 5 – – –600 65 23 12 9 – – – 35 10 6 6 – – –650 75 27 13 10 8 – – 40 11 7 6 5 – –700 86 30 15 11 9 8 – 46 13 8 7 6 5 5800 111 38 17 13 10 9 9 60 16 9 8 7 6 6900 139 46 21 14 11 10 9 75 19 11 9 8 7 7940 151 50 22 15 12 10 10 81 20 11 10 8 7 7


26

Size 7


3/4” 1” 40* 50* 65 80 100 125 3/4” 1” 40* 50* 65 80 100 125Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve40 40 40 50 65 65 65 65 40 40 40 50 65 65 65 65

Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 800 256 77 30 18 12 9 8 – 134 26 13 11 7 6 5 5900 – 96 37 22 13 10 9 9 – 32 16 13 9 7 6 6

1000 – 117 44 26 15 12 10 9 – 39 19 16 10 8 7 71100 – 141 52 30 17 13 11 10 – 46 22 19 11 9 8 71200 – 166 61 34 19 14 12 11 – 55 26 21 13 10 9 81400 – 224 81 44 24 17 14 12 – 73 34 28 16 12 10 91600 – 290 103 55 29 20 16 14 – 94 43 35 19 14 12 111750 – – 122 65 33 22 17 15 – 111 50 40 22 16 13 12

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 800 – 109 41 24 14 11 9 8 – 36 17 14 9 7 6 6900 – 136 50 28 16 12 10 9 – 45 21 17 11 8 7 71000 – 167 61 34 19 13 11 10 – 54 26 21 12 9 8 71100 – 201 72 40 21 15 12 11 – 65 30 24 14 10 9 81200 – 237 85 46 24 16 13 12 – 77 35 28 16 11 10 91400 – – 113 60 30 20 15 14 – 103 46 37 20 14 12 101600 – – 145 76 37 24 18 15 – 133 59 47 25 17 13 121750 – – 172 89 43 27 20 17 – – 69 55 28 19 15 13

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 800 108 35 16 11 8 – – – 57 13 7 7 – – – –900 136 43 19 13 9 – – – 71 15 9 8 6 – – –1000 166 52 22 14 10 9 – – 87 18 10 9 6 6 5 51100 200 62 26 16 11 9 9 8 105 22 12 10 7 6 6 61200 237 72 29 18 12 10 9 9 125 25 14 12 8 7 6 61400 – 97 38 23 15 12 10 10 – 33 17 15 10 8 8 71600 – 124 48 28 17 13 12 11 – 42 21 18 12 10 9 81750 – 147 56 32 19 15 13 12 – 50 25 21 13 11 10 9

Size 8


40* 50* 65 80 100 125 40* 50* 65 80 100 125Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve40 50 65 65 65 65 40 50 65 65 65 65

Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 1100 51 28 16 11 10 9 21 17 10 8 7 61200 60 33 18 13 10 9 25 20 12 8 7 71300 69 38 20 14 11 10 28 23 13 9 8 71400 79 43 22 15 12 11 32 26 14 10 9 81600 101 54 27 18 14 12 41 33 18 12 10 91800 127 66 33 21 16 14 51 40 21 14 11 102000 154 80 39 24 18 15 62 49 25 16 13 112250 193 99 47 28 20 17 77 60 30 19 15 13

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 1100 71 38 20 14 11 10 29 23 13 9 7 71200 83 44 23 15 12 10 34 27 15 10 8 71300 97 51 26 17 13 11 39 31 16 11 9 81400 111 58 29 18 14 12 45 35 18 12 10 91600 143 74 36 22 16 14 57 45 23 15 12 101800 179 92 43 25 18 15 71 55 28 17 13 112000 220 111 51 30 21 17 86 67 33 20 15 132250 276 138 63 35 24 19 107 83 40 24 18 15

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 1100 25 15 10 8 – – 11 9 6 5 – –1200 28 17 11 9 8 – 13 11 7 6 5 51300 32 20 12 10 9 8 14 12 8 6 6 61400 37 22 14 11 9 9 16 14 9 7 6 61600 46 27 16 12 10 10 20 17 11 8 7 71800 57 32 19 14 12 11 25 20 12 10 8 82000 69 38 21 15 13 12 29 24 14 11 9 92250 85 47 25 18 14 13 36 29 17 13 11 10


27

Size 9


40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve50 50 65 80 80 80 80 50 50 65 80 80 80 80

Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 1600 96 53 27 17 13 11 10 36 32 17 11 9 8 81800 120 65 32 20 15 12 11 44 40 20 13 10 9 92000 146 79 38 23 16 14 12 54 48 24 15 12 10 102200 176 94 44 26 18 15 13 64 57 28 17 13 11 112400 208 111 51 29 20 16 14 75 67 33 20 15 13 122800 279 147 67 37 25 19 17 100 89 42 24 18 15 143200 – 190 84 45 29 22 19 129 114 53 30 21 17 163500 – 225 99 52 33 25 21 – 135 62 34 24 19 18

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 1600 136 73 35 21 15 12 11 49 44 22 14 10 9 81800 170 91 42 24 17 14 12 61 55 27 16 12 10 102000 208 110 50 28 19 15 13 75 66 32 19 14 11 112200 250 132 59 33 22 17 15 89 79 38 21 16 13 122400 296 156 69 37 24 19 16 105 93 44 24 17 14 132800 – 208 91 47 30 22 19 – 124 57 31 21 17 153200 – 269 116 59 36 26 22 – – 72 38 26 20 183500 – – 136 68 41 29 24 – – 85 44 29 22 20

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 1600 44 26 15 11 10 9 8 18 16 10 7 7 6 61800 54 32 18 13 11 10 9 21 20 12 9 8 7 72000 65 38 21 14 12 11 10 26 23 14 10 8 8 82200 77 44 24 16 13 12 11 30 27 16 11 9 9 82400 91 51 27 18 14 13 11 35 32 18 12 10 9 92800 121 67 34 22 17 15 13 46 41 22 15 12 11 113200 156 85 42 26 19 17 15 59 52 28 18 15 13 123500 185 100 48 29 21 18 16 69 62 32 20 16 14 14

Size 10



Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 2000 146 78 37 22 16 13 11 53 47 24 14 11 10 92200 175 93 43 25 17 14 13 63 56 28 17 13 11 102400 207 110 50 28 19 16 14 74 66 32 19 14 12 112600 241 127 58 32 21 17 15 86 76 37 21 15 13 122800 278 146 66 36 24 18 16 99 88 41 24 17 14 133200 – 189 83 44 28 21 18 128 113 52 29 20 16 153600 – – 102 53 33 24 20 – – 64 34 24 19 173950 – – 121 61 37 27 23 – – 76 40 27 21 19

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 2000 208 110 50 28 19 15 13 74 66 31 18 13 11 102200 250 131 59 32 21 16 14 89 78 37 21 15 12 112400 296 155 68 36 23 18 15 105 92 43 24 17 13 122600 – 180 79 41 26 20 17 122 107 49 27 19 15 132800 – 208 90 46 29 21 18 – 123 56 30 21 16 143200 – – 115 58 35 25 21 – – 71 37 25 19 173600 – – 142 70 41 29 23 – – 88 45 29 22 193950 – – 169 82 47 33 26 – – 104 52 33 24 21

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 2000 65 37 20 14 11 10 9 25 23 13 9 8 7 72200 77 43 23 15 12 11 10 30 27 15 10 9 8 82400 90 50 26 17 13 12 11 34 31 17 12 10 9 82600 105 58 29 19 15 13 12 40 36 19 13 11 10 92800 120 66 33 21 16 14 12 45 41 22 14 12 10 103200 155 84 41 25 18 16 14 58 52 27 17 14 12 113600 194 104 49 29 21 17 16 71 64 32 20 16 14 133950 231 124 58 33 23 19 17 85 75 38 23 18 15 14


28

Size 11



Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606 3200 – 182 82 43 26 20 16 121 106 51 27 19 14 133400 – 204 91 47 29 21 17 136 119 57 30 20 16 143600 – 228 101 51 31 22 18 – 132 63 33 22 17 153800 – – 112 56 33 24 20 – – 69 36 24 18 164000 – – 123 61 36 26 21 – – 76 39 25 19 174400 – – 146 72 41 29 23 – – 90 46 29 21 194800 – – 172 84 47 32 25 – – 106 53 33 24 215100 – – 193 93 52 35 27 – – 118 59 36 26 22

Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641 3200 – – 113 56 33 23 19 – – 70 36 23 17 153400 – – 127 63 36 25 20 – – 78 39 25 18 163600 – – 141 69 39 27 21 – – 87 43 27 19 173800 – – 156 76 42 29 23 – – 96 47 29 21 184000 – – 172 83 46 31 24 – – 105 52 31 22 194400 – – 205 98 53 35 27 – – 125 61 36 25 214800 – – – 114 61 39 30 – – – 71 41 28 245100 – – – 127 67 43 32 – – – 78 45 30 25

Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555 3200 151 81 40 24 17 14 12 54 48 25 16 12 11 103400 170 90 44 26 18 15 13 61 54 28 17 13 11 113600 189 100 48 28 19 16 14 67 59 31 19 14 12 113800 210 111 53 30 21 17 15 74 66 34 20 15 13 124000 232 122 58 32 22 18 15 82 72 37 22 16 14 134400 279 145 68 37 25 20 17 98 86 43 25 18 15 144800 – 171 79 43 28 22 19 115 101 50 29 20 17 155100 – 192 88 47 30 23 20 129 113 56 31 22 18 16


29

Combustion head dual fuel burners sizes 1 to 3 Combustion head dual fuel burners sizes 5 to 11

Flame tube setting

Nozzle star

Perforated diffuser

Conical diffuser

Perforated diffuser

G8 to G11

Diffuser

10. Setting the mixing head

Burner Flame tube Perforated Diffuser Diffuser Nozzle Flame tube type mm diffuser mm mm distances mm distances setting mm

type ø ø outer ø inner ø outer ø inner a b c d e

G1/1-E G1/2a 130 115 80 95 40 15 13 5 8 139 - 154

G3/1-E G3/1a 160 133 90 100 40 15 18 5 8 158 - 178

G5/1-D G5/1a 200 173 100 100(125)* 50(50)* 5 13 8 8 168 - 193

G7/1-D G7/1a 250 213 110 110(135)* 50(50)* 5 23 8 8 193 - 218

G8/1-D G7/2a 265 213 120 120(155)* 50(50)* 5 30 8 8 193 - 218

G9/1-D UG2/1a 325 270 130 130 70 5 33 8 10 217 - 247

G10/1-D UG2/1a 325 270 130 130 70 5 33 8 10 217 - 247

G11/1-D UG3/1a 380 315 155 155 70 5 43 8 10 274 - 304

* Diffuser special version, see spares list

30

11. Capacity graphs

Size 1

Size 3

Size 5

5

4

3

2

1

0

-1

-2

-3

-4

6

0 50 100 150 200 250 300 350kW 400

mbar Burner type G1/1-EType of combustion head G1/2a 115-95KRating kW, Natural Gas 60 – 335

Distillate oil EL 60 – 335

10

8

6

4

2

0

-2

-4

0 200 400 600 800 1000kW

12

1200

mbar Burner type G3/1-EType of combustion head G3/2a-133-100KRating kW, Natural Gas 90 – 630


10

8

6

4

2

0

-2

-4

0 200 400 600 800 1000kW

12

1200

mbar Burner type G5/1-DType of combustion head G5/1a 173-100Rating kW, Natural Gas 175 – 940


The ratings depending on pressure in the combustionchamber are limit values, which have been measuredon idealised test flame tubes to DIN 4788, part 1 or EN 267 and DIN 4788, Part 2 or EN 676. All ratings datagiven relate to an air temperature of 20° C and aninstallation elevation of 500 m.

Modulating burnersThe modulating burner is based on the sliding two stageburner. The modulating characteristic is obtained with aspecial regulating controller, which is fitted in the controlpanel. A servomotor with 42 seconds running time is alsoused.

The burner types shown are type tested for the followingfuels:

Natural Gas _______________________________ E and LL Liquid Petroleum Gas ___________________________ B/P

Burners with speed control or electronic compoundregulationThere is no reduction in the rating when using speedcontrol or electronic compound regulation, even whencombined with O2 regulation. On burners with speedcontrol and electronic compound regulation and FGR aswell as with or without O2 regulation a reduction f 5 %occurs.

Burners with flue gas recirculation (FGR) and /or O2regulationIf a flue gas recirculation system or O2 regulation isprovided, then the maximum burner capacity graphs arereduced by the following values:

Reduction approx. % System

5 % FGR or O2 regulation10 % FGR with O2 regulation

With flue gas recirculation it must also be noted that thecombustion chamber resistance increases by the factor1.3. The exact value can be obtained from the planningdocuments for flue gas recirculation, print No. 1025.Please also check if combustion head extensions areneeded with FGR (see “Special Equipment”). On burnerswith flue gas recirculation, only sound absorbers of specialexecution may be fitted.

For towns and sewage gas the maximum burnerratings in the graphs must be reduced by 10%.

Range of regulation on oil operationDual fuel burners with spill type nozzles have amaximum turndown ratio on oil operation of approx. 3 :1. It should be noted that the lower operating pointmust lie within the capacity graph.

Combustion head “Open”Combustion head “Closed” (see dimension “e”, chapter 10)

Nat

ural

gas

Des

tilla

ge o

il E

L

31

Size 7

Size 8

Size 9

10

8

6

4

2

0

-2

-4

0 400 800 1200 1600 2000kW

12

14

16



10

8

6

4

2

0

-2

-4

0 400 800 1200 1600 2000kW

12

14

16



10

8

6

4

2

0

-2

-4

0 1000 2000 3000 4000 5000kW

12

14

16

mbar Burner type G9/1-DType of combustion head UG2/1a 270-310Rating kW, Natural Gas 500 – 3600


Nat

ural

gas

Des

tilla

ge o

il E

LN

atur

al g

as


32

Size 10

Size 11

10

8

6

4

2

0

-2

-4

0 1000 2000 3000 4000 5000kW

12

14

16

mbar Burner type G10/1-DType of combustion head UG2/1a 270-130Rating kW, Natural Gas 500– 4100

Distillate oil EL 750– 4100

222426

1086420

-2-4

0 1000 2000 3000 4000 5000kW

-6

1214161820

6000

mbar Burner type G11/1-DType of combustion head UG 3/1a 3215-155Rating kW, Natural Gas 900 – 4750



Nat

ural

gas

Des

tilla

ge o

il E

LN

atur

alga

s

33

12. Ignition electrode setting

Ignition electrode setting

13. Fan wheel attachment

G8 to G11

A minimum distance of25 mm must be keptbetween ignition andionisation electrodes

Burner sizes 1 and 3The fan fits onto a cylindrical shaft. Power is transmittedvia a shaft key. The fan is secured by an M8 set screw andthe shaft key.

Burner size 5The fan fits onto a cylindrical shaft. Power is transmittedvia a shaft key. The fan is fixed to the motor shaft by an M6x 25 screw with washer.

Burner sizes 7-8On burner sizes 7-8 the fan fits onto a cylindrical shaft.Power is transmitted by a shaft key. The fan is fixed to themotor shaft by an M8 countersunk screw and washer.

Burner sizes 9-11On burner sizes 9-11 the fan fits onto a self locking coneshaft which transmits the power from the motor. Thecoupling piece is connected to the fan with two cylindricalpins. An M10 x 40 left hand threaded screw secures thecoupling piece to the motor shaft.

Removing the fan

Burner sizes 1 and 3The extractor, Part No. 111 111 00 0122, can be appliedto the two M6 threaded holes and the fan removed.Burner sizes 5-8The extractor, Part No. 111 111 00 01/2, can be appliedto the two M6 threaded holes and the fan removed.

Burner sizes 9-11To remove the fan the extractor, Part No. 121 362 0013/2is applied to the two M10 threaded holes.

Burner sizes 1 and 3 Burner size 5 Burner sizes 7 and 8 Burner sizes 9 to 11

34

14. Sequence of operation

The LFL1... burner control units are designed to providecontrol and supervision of multistage and modulatingburners. They are only suitable for burners with intermittentburner operation. The fail safe burner control LGK16... isused for burners for continuous operation.

Gas operation version ZM

Sequence diagram for air Regulator “On”

Nominal loadpre-purge

Ignition and fuel release

Ratingsregulation

Regulator “Off”

Full load

Partial loadIgnition load

Terminal on LFL/LGK “Closed”

Control circuit

Time sequence diagramfor servomotor

Sequence diagram for gas

Time sequence diagram for ignition and fuel release

Position indicator on burnercontrol

Full load

Partial loadIgnition load

“Closed”

* on size 8 to 11, ** size 1 to 7

35

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

➛ No start e.g. because the closed signal has not beensupplied to terminal 8 by the limit switch/auxiliaryswitch or because a contact has not been closed between terminals 12 and 4 or 4 and 5.

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

P Lockout because the air pressure signal has not beenreceived by the start of the air pressure check. Airpressure failure after this point also causes thecontrol to go to lockout.

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

❷ Controlled shutdown because the position signal forthe low flame position has not been supplied to terminal 8 by the auxiliary switch.

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

2 Lockout because no flame signal has been received oncompletion of the second safety time (flame signal ofthe main flame with interrupted pilot burners).

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

➛ Lockout on completion of control programme sequence due to extraneous light (e.g. flame not extinguished, leaking fuel valves) or due to a faultyflame signal (e.g. aged UV tube, fault in flame supervision circuit or similar).

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

a – b Start up sequence

b – b’ With some time variants: ‘idle steps’ of the sequence switch up to the self shut down afterburner start up (b = operating position of thesequence switch).

b(b’) – a Post purge sequence after controlled shutdown. In start position ‘a’ the sequence switchswitches itself off automatically or immediatelyinitiates another burner start, e.g. after a faulthas been corrected.

● Duration of safety time with expanding flameburners.

● ● Duration of safety time with interrupted pilotburners.

14.1 Pre-requisite for burner start

– Reset control unit– Air damper closed. The limit switch for the ‘CLOSED’

position must supply voltage from terminal 11 toterminal 8.

– The control contacts for the ‘CLOSED’ position of fuelvalves or other contacts between terminal 12 and“S10” with similar control functions must be closed.

– The normally closed contact of the air pressure monitormust be closed (LP test), i.e. terminal 4 must be undervoltage.

– The contacts of the gas pressure switch “S11” and thetemperature or pressure switch “F4, F5” must also beclosed.

14.2 Symbols on the fault position indicator

36

MSM

N

M

L

S1

F4

F

br1

1

a b

a b

4 12 6

I

ar1 ar2

K1 K17

M1

N

5 13 14

1

5 4

22 15 24

3

2

22

23

23 24

22 23 24

fr1 fr3 fr2

B1

QRA5..

N

B1

uv

UV

QRA2

B1

V

FR

NTC

XIIXIIIXI

AR

XIV

VII

ar3S H

br2 VVIIIX

BR

S3

a b

ab ba

abME

a b a b

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

III I II IV

1

Y2

H6

T1 Y1 Y4

LK

F5

S10

b

A

+

II

F6

b b

b

b

b

a a

a

a

a

III

IV

M

S11

M1

VI

F3

a

Y6

N N

LGK...

LFL/LGK

LFL...

14.3 Basic wiring diagram for burner control LFL1... / LGK 16...

Legend:AR Load relay (main relay) with contacts “ar”B1 Flame sensorBR Lockout relay F Fuse in burner controlF3 Control fuseF4 Temperature or pressure switchF5 Temperature or pressure regulatorF6 Temperature or pressure regulator FULL LOADFR Flame relayH Control lamp LockoutH6 Remote indication for lockoutK1 Motor contactorLK Air damper

M1 Fan or burner motor S Reset keyS1 Burner onS3 Remote resetS10 Air pressure switchS11 Gas pressure switchT1 Ignition transformerY1 Solenoid valve ignition gas Y2 Solenoid valveY4 Solenoid valveY6 Servomotor

37

t1 Pre purge timet2 Safety timet3 Pre-ignition timet4 Interval between voltage on terminals 18 and 19t5 Interval between voltage on terminals 19 and 20t6 Post purge timet7 Interval to voltage on terminal 7t8 Duration of start up sequencet9 Second safety time *

t10 Interval to start of air pressure controlt11 Run time of air damper (Open)t12 Run time of air damper (min.)t13 Permissible after burn timet16 Interval up to OPEN command for air dampert20 Interval up to self shut down of the sequence switch

(not on all controls)

* Programme for interrupted pilot burners.

Positions of lockout indicator

Con

trol

out

puts

of

con

tact

s:

Legend for diagram of sequence switch

LFL1... / LGK16

14.4 Switching times

Switching times in seconds * in start up sequenceThe figures in brackets apply to burners with interrupted pilot.

LFL 1.122 LFL 1.322 LFL 1.622LGK 1.122 LGK 1.322 LGK 1.622

t7 Start delay for burner motor 2 2 2t16 Interval from start up to OPEN command of air damper 4 4 4t11 Run time of air damper in OPEN position optional optional optionalt10 Interval from start up to comm. of air pressure check 6 8 8t1 Pre-purge time with air damper open 10 36 66t12 Run time of air damper to ignition position optional optional optionalt3 Pre-ignition period 4 4 4t2 First safety period 2 2 2t4 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 96t6 Post purge time 10 12 12t13 Permissible after burn time 10 12 12

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

38

1 1

2

5

3

4

1

2

5

3

4

1

2

5

3

4

2

22

23

15

QRA5...

Burner control

LGK...Terminalsocket

Terminal incontrol panel

Mains cable 3 x 1.5 mm2

Single core coaxial cable

Screening

max. 60 m

Burner

Burner connectionterminal

CableAGM 1

14.5 Sensor line between LGK16... and QRA53 / QPA 55 or sensor electrode

Installation of sensor line● The connections between burner control terminal 23,

and UV cell terminal 3, as well as burner control terminal15 and UV cell terminal 4, have to be fitted as separatesingle core coaxial cables with a capacitance of max45pF/m. The coaxial cable used can be of types RG-62A/U or RG-71 B/U. The screening of these coaxialcables must be earthed on both cable ends.

● For the connection between the burner control terminals1, 2, 22 and the matching terminals of the UV cellterminals 1, 2 and 5 a normal three core, 1.5mm2 PVCcable can be used. The line length is unlimited.

● The coaxial cable and the three core cable may be fittedin the same cable duct as other mains voltage lines(control lines and motor lines).

● Maximum line length for the coaxial cable is 60m. Theconnection to the burner terminal rail and the controlpanel terminal rail must be carried out according to thewiring diagram. It is important that terminal 22 on theLGK terminal sub-base is earthed.

Test possibilities of the detector cableDue to the capacitance of the detector cable connected toterminal 15 and 23 of the LGK burner control a voltagereduction in the sensor circuit occurs due to thecapacitance loading. To obtain a reading, the voltage canbe measured at the connection terminals 22 and 23without detector cable connected and subsequently withdetector cable connected, providing the line length iswithin the stipulated limits. The voltage difference must notbe higher than 22 VAC. A higher voltage reductionindicates the danger of unsafe monitoring.

Sensor line LGK 16 with ionistion monitoringWhen fitting a sensor line for ionisation monitoring,attention has to be paid to a low capacitance installation.The coaxial cable RG-62 A/U or RG-71 B/U as well as themuch cheaper ignition cable -w- order No. 743 200, aresuitable as a sensor line. Because of the installation of thelow capacitance detector cable to terminal 24 of thecontrol (especially compared to earthed cable) the normalmax. detector cable length of 60 m can be exceeded.

Wiring diagram

39

14.6 Technical data

Mains voltage ____________220 V - 15%… 240 V + 10%Frequency__________________50 Hz - 6%… 60 Hz + 6%Consumption________________________________3,5 VAFuse (inbuilt)________________M6, 3/250 E semi time lag

according to DIN41571, sheet 2).External fuse______________________________max. 10 APermissible input current at terminal 1 ____5 A continuous,

peaks of up to 20APermissible load _________________________sup to 20Aof control terminal_______________________total max. 5ARequired switching capacity of switching devices– between terminals 4 and 5 ______________________1 A– between terminals 4 and 12 _____________________1 A– between terminals 4 and 141A cont., peaks of up to 20AMounting position ___________________________optionalProtection standard ___________________________IP 40Permissible ambient temperature__-20… + 60°C at 220 V

UV supervision with LFL1 ...Supply voltage _______________ operation 330 V ± 10%

test 380 V ± 10%Min. required sensor current ____________________70 µAMax. sensor current _____ operation 630 µA, test 1300 µA

Max. permissible cable length to detector on LFL1 ...– normal cable, wired separately ________________100 m

UV supervision with LGK 16 ...UV Ionisation

Supply voltage __280V ~ ± 10 % (without sensor current) ___________________________________245 V ~ ± 10%

Max. permitted length see ____________________________________________60 mOf sensor line (wired separately) ___________chapter 20.5

40

15. Cam setting of limit and auxiliary switches

15.1 Gas burner, two stage (servomotor 1055/80)DescriptionBy disengaging the cam from the drive wheel, the cam canbe moved to check the correct actuation of the limit andauxiliary switches by the switch cams. The cam is broughtinto the basic position (scale position 0°) and then slowlyturned clockwise to the right (when viewed from thedirection, servomotor to cam). Switch III must be actuatedby the third cam to supply the auxiliary winding ‘open’. Aftersome rotational movement, limit switch IV is no longeractuated by the fourth cam.

The switch points of the limit switches ‘open’ and ‘closed’are set on delivery to a total angle of rotation of 90°.

Limit switch adjustmentVia an indicator on the drive axis the position of the airdamper is shown on a scale 0° - 90°.

Between the switch and setting cams there is anadjustment scale. The adjustment of the cam switch isshown on this scale by a small indicator and gives theswitching point of the appropriate switch in relation to theactual air damper position. The limit switch and camswitches are marked on all wiring diagrams with I, II, III, IV,V and have the function as shown in the connectiondiagram.

The diagram is also shown on the servomotor cover.

Switch for burner adjustmentThis switch offers the facility of stopping the servomotorelectric operation.

Therefore, by also disengaging the drive mechanically, theregulating cam can be placed at any position betweenpartial and full load.

After the setting work is complete, the drive mechanismshould be re-engaged and the switch reset to the normaloperating position.

I – freeII – partial load ~ 50°III – open 90°IV – closed 0°V – ignition load ~ 10°VI – free

The switch settings must be resetwhen commissioning to therequirements of the installation.

0

90

M

grau

- gr

ey -

gris

grün

-gre

en -

vert

schw

arz

- bla

ck -

noir

VI

V

II

I

III

IV

1

123456789101112131415161718

Servomotor type 1055/80 with inbuilt cam switches I - VI Connection diagram

Servomotor

Switchidentification

Control cam aid

Air damperposition indicator

Socket pin (mustbe removedwhen changingprinted circuitboard)

Fixing for airdamper shaft

Terminal rail

Printed circuitboard cover

Bottom of housing

Switch positionindicator

Gear wheel (may beuncoupled for manual

adjustment)

Control cams: auxiliary switch VI

Auxiliary switch V,ignition load

Auxiliary switch II,partial load

Auxiliary switch I

Limit switch III, full load

Limit switch IV, Closed

blac

kgr

een

grey

41

15.2 Gas burner, sliding two stage and modulating (servomotor SQM)

DescriptionThe limit and auxiliary switches are set manually on theadjustable cams. The cams have a small pointer, whichindicates the appropriate switching point on a scalebetween the cams.

The servomotors are supplied with the following standardswitch settings:

I – Open 120°II – Closed 0°III – freeIV – Ignition load gas ~ 20°V – freeVI – Partial load gas ~ 45°VII – freeThe switch settings must be reset when commissioning tothe requirements of the installation.

The outer scale on the end of the cam shaft serves as aposition indicator. With the lever fitted on the gearbox thecam switches can be disengaged from the drive. Thismakes it possible, manually, to turn the cam to any positionrequired. When the lever is in the vertical position the driveis engaged.

Connection diagram

N

I

21 1 11

II

22 2 12

III

23 3 13

V

25 5 15

IV

24 4 14

VI

26 6 16

VII

27 7 11 a b c

M~

Setting limit and auxiliary switches Disengaging the servomotor

I - Limit switch full loadII - Limit switched closedIII* - freeIV - Auxiliary switch ignition load gasV - freeVI - Auxiliary switch partial load gasVII - free

42

16. Throughput determination, conversion from normal to operating conditions

To obtain a given burner heat input rate, the gas quantitymust be calculated.

Example:Boiler nominal rating: 5000 kWEfficiency (in advance): 92%Natural gas LL (calorific value) Hi = 8.83 kWh/m3

Boiler loading =

5000–––––– = 5435 kW0.92

Gas throughput: Vn =

5435 –––––– = 616 m3/h8.83

As the gas volume is altered considerably by pressure andtemperature, the gas quantity must be calculated to theappropriate operating condition.

Operating condition for above example:

mbar

Po = Barometer level 960PG = Gas pressure* 500

Total pressure 1460

tG = Gas temperature 10°C

* Read gas pressure and gas temperature from gas meter.

See table: 960 + 500 = 1460 mbar gives the factor 1.391

In order to obtain the correct loading for the example, thegas throughput calculated must be divided by the factorread off.

Gas throughput in operating conditions:

Vn 616 VB = ––––––– = ––––––– 443 m3/h

f 1.391

With other gas pressures and gas temperatures theconversion factor can be determined according to thefollowing formula.

Po + PG 273 f = ––––––– · –––––––

1 013 273 + tG

The humidity content of the gas is small and is thereforenot taken into account in the table figures or conversionfactor.

Average yearly air pressure at various height sectors

Average geodetic Average yearly air pressure in height of supply area mbar at an average temperature at above sea level sea level of 10°C.

Northern Southern Germany Germanymbar mbar

0 1015 10171… 50 1012 1014

51…100 1006 1008101…150 1000 1002151…200 994 996201…250 988 990251…300 982 984301…350 976 978351…400 970 972401…450 964 966451…500 958 960501…550 952 954551…600 946 949601…650 941 943651…700 935 937701…750 929 931

1) 1 mbar = 0,750 Torr = 10,20 mm VS1 Torr = 1,333 mbar = 13,6 mm VS1 mm VS = 0,0735 Torr = 0,0981 mbar

Total pressure Po+PG Conversion factor fin Gas temperature tG in °Cmbar1) Torr 0 5 10 15 20 25

900 675 0.888 0.872 0.857 0.842 0.828 0.813920 690 0.908 0.892 0.876 0.861 0.846 0.832940 705 0.928 0.911 0.895 0.880 0.865 0.850960 720 0.948 0.931 0.915 0.899 0.884 0.868980 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 0.9041020 765 1.007 0.989 0.972 0.955 0.939 0.9221040 780 1.027 1.009 0.991 0.974 0.957 0.9411060 795 1.046 1.027 1.009 0.992 0.975 0.9581080 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 0.9951120 840 1.106 1.086 1.067 1.048 1.031 1.0131140 855 1.125 1.105 1.086 1.067 1.049 1.0311160 870 1.145 1.124 1.105 1.085 1.067 1.0491180 885 1.165 1.144 1.124 1.104 1.086 1.067

43

Total pressure Po+PG Conversion factor fin Gas temperature tG in °Cmbar1) Torr 0 5 10 15 20 25

1200 900 1.185 1.164 1.144 1.123 1.104 1.0851220 915 1.204 1.182 1.162 1.141 1.122 1.1031240 930 1.224 1.202 1.181 1.160 1.141 1.1211260 945 1.244 1.222 1.200 1.179 1.159 1.1401280 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 1.1751320 990 1.303 1.280 1.257 1.235 1.214 1.1941340 1005 1.323 1.299 1.277 2.254 1.233 1.2121360 1020 1.343 1.319 1.296 1.273 1.252 1.2301380 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 1.2661420 1065 1.402 1.377 1.353 1.329 1.307 1.2841440 1080 1.422 1.396 1.372 1.348 1.325 1.3031460 1095 1.441 1.415 1.391 1.366 1.342 1.3201480 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 1.3571520 1140 1.500 1.473 1.448 1.422 1.398 1.3741540 1155 1.520 1.493 1.467 1.441 1.417 1.3921560 1170 1.540 1.512 1.486 1.460 1.435 1.4111580 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 1.4461620 1215 1.599 1.570 1.543 1.516 1.490 1.4651640 1230 1.619 1.590 1.562 1.535 1.509 1.4831660 1245 1.639 1.610 1.582 1.554 1.528 1.5011680 1260 1.658 1.628 1.600 1.572 1.545 1.519

1700 1275 1.678 1.648 1.619 1.591 1.564 1.5371720 1290 1.698 1.667 1.639 1.610 1.583 1.5551740 1305 1.718 1.687 1.658 1.629 1.601 1.5741760 1320 1.737 1.706 1.676 1.647 1.619 1.5911780 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 1.6281820 1365 1.797 1.765 1.734 1.704 1.675 1.6461840 1380 1.816 1.783 1.752 1.722 1.693 1.6631860 1395 1.836 1.803 1.772 1.741 1.711 1.6821880 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 1.7181920 1440 1.895 1.861 1.829 1.796 1.766 1.7361940 1455 1.915 1.881 1.848 1.815 1.785 1.7541960 1470 1.935 1.900 1.867 1.834 1.803 1.7721980 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 1.8022050 1538 2.024 1.988 1.953 1.919 1.886 1.8542100 1575 2.073 2.036 2.000 1.965 1.932 1.8992150 1613 2.122 2.084 2.048 2.012 1.978 1.9442200 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 2.0342300 1725 2.270 2.229 2.191 2.152 2.116 2.0792350 1763 2.320 2.278 2.239 2.199 2.162 2.1252400 1800 2.369 2.326 2.286 2.246 2.208 2.1702450 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 2.2612550 1913 2.517 2.472 2.429 2.386 2.346 2.3062600 1950 2.567 2.521 2.477 2.434 2.392 2.3512650 1988 2.616 2.569 2.524 2.480 2.438 2.3962700 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 2.4872800 2100 2.764 2.714 2.667 2.620 2.576 2.5322850 2138 2.813 2.762 2.715 2.667 2.662 2.5772900 2175 2.863 2.812 2.763 2.714 2.668 2.6232950 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 2.7133100 2325 3.060 3.005 2.953 2.901 2.852 2.8033200 2400 3.159 3.102 3.048 2.995 2.944 2.8943300 2475 3.258 3.199 3.144 3.089 3.036 2.9843400 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 3.1653600 2700 3.554 3.490 3.430 3.369 3.312 3.2553700 2775 3.653 3.587 3.525 3.463 3.405 3.3463800 2850 3.751 3.684 3.620 3.556 3.496 3.4363900 2924 3.850 3.781 3.715 3.650 3.588 3.5274000 3000 3.949 3.878 3.811 3.744 3.680 3.617

44

17. Fault conditions and procedures

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

1. Check the electric supply.2. Check that the gas supply is correct and that manual

valves are open.

3. Check that all controls e.g. thermostats, pressureswitches, water level interlocks, limit and time switchesare correctly set.

4. Ensure that the burner air or gas settings have not beenaltered.

When it is established that the fault is not due to externalconditions, the burner must be tested. Reset the burnerlockout and switch on burner, by careful observation of thesequence of operations the cause can be recognised andremedied. When checking, a microammeter and a U tubemanometer must be used.

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 onor reset regulator or detector

Gas supply interrupted Open isolating valve, inform gas isolating valve closed authority if no gas for a prolonged

period.

Burner control fault Replace

Lack of air

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

Burner motor starts, lockout after Solenoid valve leaking indication Repair leakapprox. 20 secs. (only on versions on valve proving programme ifwith valve proving W-DK3/01) burner control in start position

Burner motor starts, lockout Pressure switch contact Set pressure switch correctly, after 10 secs of full load pre-purge does not 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 12)terminal 16 of burner control, no ignition, after a short time lockout occurs Ignition electrodes or ignition line Remove earth connection, replace

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

Ignition transformer faulty Replace ignition transformer

No flame establishment

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

interrupted. check voltage to terminal 17.

Condition Cause Remedy

45

Lockout after flame establishment

Ignition flame forms. Lockout Blocked filter Clean filternoccurs when running at normal load

Pressure regulating control sluggish Check breather orifice

Gas meter faulty or Inform gas authoritywater in lower lying lines.

Flame monitoring fault on ionisation

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

terminals (tighten terminals).

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

Ignition spark affected, negative Ignition transformer primaryionisation 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

Condition Cause Remedy

Regular maintenance saves energy and protects the environment

We recommend regular maintenance of combustionequipment to all plant operators. It saves fuel and ensures constantly good combustion results.

Excellent combustion quality is a pre-requisite for environmentally friendly operation.

Weishaupt productsand service

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

Oil, gas and dual fuel burners types MonarchR, G, GL, RGL – up to 10.900 kWThese are used on all types and sizes of central heating plant. The basic model which has proved successful over many years is the basis for a variety of versions. These burners have founded the outstanding reputation of Weishaupt products.

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

Weishaupt control panels, the proven complement to Weishaupt burnersWeishaupt burners and Weishaupt control panels 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 responsibilitybelongs to one manufacturer.

Weishaupt Thermo Unit / Weishaupt Thermo Gas.These Units combine the technical innovations and operatingefficiencies developed from over 1 million installations.Weishaupt Thermo Gas and Weishaupt Thermo Unit provide the ideals of complete heating centres for houses and appartments.

Product and service are the complete Weishaupt achievement An extensive service organisation guarantees Weishaupt customers the greatest possible reliability. In addition our customers are looked after by heating firms who have been working with Weishaupt for many years.

Max Weishaupt GmbH, D-88475 SchwendiTel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58Print No. 503 GB, July 98Printed in Germany. All rights reserved

Documents

Gas Burner