Weishaupt WL5/1-B H-2LN Manual
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Weishaupt WL5/1-B H-2LN Manual

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Installation and operating instruction
Oil burner WL5/1-B H-2LN
83058402 1/2019-04

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Summary of Contents for Weishaupt WL5/1-B H-2LN

  • Page 1 Installation and operating instruction Oil burner WL5/1-B H-2LN 83058402 1/2019-04...

  • Page 2: Table Of Contents

    Installation and operating instruction Oil burner WL5/1-B H-2LN User instructions ...................... 4 1.1   Target group ........................ 4 1.2   Symbols ..........................  4 1.3   Guarantee and Liability .................... 5 Safety  .............................  6 2.1   Designated application .................... 6 2.2   Safety measures ...................... 6 2.2.1   Normal operation .................... 6 2.2.2  ...
  • Page 3 Installation and operating instruction Oil burner WL5/1-B H-2LN 7.3   Concluding work  ...................... 31 7.4   Check combustion ..................... 32 Shutdown ..........................  33 Servicing .......................... 34 9.1   Notes on servicing  ..................... 34 9.2   Service plan ......................... 35 9.3   Service position ...................... 36 9.4   Replace nozzle ...................... 37 9.5   Removing and refitting nozzle shut off  .............. 38 9.6  ...

  • Page 4: User Instructions

    Installation and operating instruction Oil burner WL5/1-B H-2LN 1 User instructions 1 User instructions This manual forms part of the equipment and must be kept on site. Translation of original Carefully read the manual prior to working on the unit.

  • Page 5: Guarantee And Liability

    Weishaupt parts, force majeure, unauthorised modifications made to the unit, the installation of additional components, which have not been tested with the...

  • Page 6: Safety

    Installation and operating instruction Oil burner WL5/1-B H-2LN 2 Safety 2 Safety 2.1 Designated application The burner is suitable for operation on heat exchangers to EN 303 and EN 267. If the burner is not used on combustion chambers to EN 303 and EN 267, a safety...

  • Page 7: Alterations To The Construction Of The Equipment

    Oil burner WL5/1-B H-2LN 2 Safety 2.3 Alterations to the construction of the equipment All conversions require written approval from Max Weishaupt GmbH. No additional components may be fitted, which have not been tested for use with the equipment. Do not use combustion chamber inserts, which hinder flame burnout.

  • Page 8: Product Description

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3 Product description 3.1 Type key WL5/1-B H-2LN Type: W burner Fuel: Oil EL Size Ratings size Construction Version: Nozzle assembly with oil preheating Version: LowNO 3.2 Serial number The serial number on the name plate identifies the product.

  • Page 9: Function

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.3 Function 3.3.1 Air supply Air damper The air damper regulates the air quantity required for combustion. The air damper position is set using a setting screw on the actuator.

  • Page 10: Oil Supply

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.3.2 Oil supply Oil pump The pump draws the oil through the supply line and carries it under pressure to the oil nozzle. The pressure regulating valve keeps the oil pressure constant.

  • Page 11: Electrical Components

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.3.3 Electrical components Combustion Manager The combustion manager W-FM is the control unit of the burner. It controls the sequence of operation and monitors the flame. Burner motor The burner motor drives the fan wheel and the oil pump.

  • Page 12: Program Sequence

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.3.4 Program sequence Oil preheating At heat demand and after the initialisation time (T ) has elapsed, the heat exchanger heats the oil in the nozzle assembly (T The temperature switch closes at a temperature of approx. 45 °C.
  • Page 13 Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description W-FM 05 T1 T2 Flame sensor Heating time heat exchanger Temperature or pressure regulator Initialisation time: 1 s Heat exchanger Post-purge time: 1.2 s Temperature or pressure limiter Post-purge time: 6.5 s Anti siphon valve (optional) Safety time: 4.6 s...

  • Page 14: Technical Data

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.4 Technical data 3.4.1 Approval data DIN CERTCO 5G936 Basic standards EN 267:2011 Additional standards, see EU conformity certifica- tion. 3.4.2 Electrical data Mains voltage / mains frequency 230 V/50 Hz Consumption at start max 239 W...

  • Page 15: Emissions

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.4.5 Emissions Flue gas To EN 267 the burner complies with emission class 3. The NO values are influenced by: combustion chamber dimensions flue gas system fuel combustion air (temperature and humidity)

  • Page 16: Rating

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.4.6 Rating Combustion heat rating Combustion heat rating 16.5 … 37 kW 1.4 … 3.1 kg/h Combustion head W5/1-B-2LN The oil throughput data relates to a calorific value of 11.9 kWh/kg for fuel oil EL.

  • Page 17: Dimensions

    Installation and operating instruction Oil burner WL5/1-B H-2LN 3 Product description 3.4.7 Dimensions Burner 286 mm 30 mm 308 mm 206 ... 231 mm 3.4.8 Weight approx. 11 kg 17-72 83058402 1/2019-04 La...

  • Page 18: Installation

    Installation and operating instruction Oil burner WL5/1-B H-2LN 4 Installation 4 Installation 4.1 Installation conditions Burner type and capacity graph Burner and heat exchanger must be matched. Check burner type and burner capacity. Installation location Prior to installation ensure that: sufficient space is available for normal and service position [ch. 3.4.7],...

  • Page 19: Selecting A Nozzle

    Installation and operating instruction Oil burner WL5/1-B H-2LN 4 Installation 4.2 Selecting a nozzle Determine nozzle size. Recommended nozzles Make Size Characteristics Fluidics 0.40 … 0.60 gph 45°HF Fluidics 0.65 … 0.85 gph 60°HF Pump pressure setting 9 … 10 … 11 bar Spray characteristic and spray angle varies depending on pump pressure.

  • Page 20: Burner Installation

    Installation and operating instruction Oil burner WL5/1-B H-2LN 4 Installation 4.3 Burner installation The the combustion head sleeve 5 provided to the flame tube. Set recirculation aperture [ch. 9.10]. Secure combustion head sleeve with screws 4. Remove burner flange 1 from burner housing.

  • Page 21: Rotate Burner By 180° (Optional)

    Installation and operating instruction Oil burner WL5/1-B H-2LN 4 Installation 4.3.1 Rotate burner by 180° (optional) A pressure hose (DN 4, 286 mm) for installation rotated by 180° is required. Place stay bolt 1 into neighbouring threaded holes. Place burner into service position A [ch. 9.3].

  • Page 22: Installation

    Installation and operating instruction Oil burner WL5/1-B H-2LN 5 Installation 5 Installation 5.1 Oil supply Observe EN 12514-2, DIN 4755, TRÖI and local regulations. Check conditions for oil pump Suction resistance max 0.4 bar Supply pressure max 2 bar Supply temperature max 60 °C...
  • Page 23 Installation and operating instruction Oil burner WL5/1-B H-2LN 5 Installation Connect oil supply and observe: do not twist oil hoses avoid mechanical tension consider length of hose required for the service position, do not kink oil hoses (curve radius 1 of 50 mm must be maintained).

  • Page 24: Electrical Connection

    Installation and operating instruction Oil burner WL5/1-B H-2LN 5 Installation 5.2 Electrical connection Risk of electric shock Working on the device when voltage is applied can lead to electric shock. Isolate the device from the power supply prior to starting any work.

  • Page 25: Operation

    Installation and operating instruction Oil burner WL5/1-B H-2LN 6 Operation 6 Operation 6.1 Operating panel Damage to the combustion manager due to incorrect operation Excessive pressure applied to the illuminated push button can damage the com- bustion manager. Only lightly press illuminated push button.

  • Page 26: Commissioning

    Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning 7 Commissioning 7.1 Prerequisite Commissioning must only be carried out by qualified personnel. Only correctly carried out commissioning ensures the operational safety. Prior to commissioning ensure that: all assembly and installation work has been carried out correctly,...
  • Page 27 Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning Oil pressure measuring devices on oil pump Vacuum gauge for suction resistance/supply pressure. Pressure gauge for pump pressure. Oil leakage from oil pressure measuring devices due to constant load Oil pressure measuring devices could be damaged and cause environmental pollu- tion through leakage.

  • Page 28: Setting Values

    Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning 7.1.2 Setting values Set mixing head relative to the combustion heat rating required. For this, the dif- fuser setting and the air damper setting should be matched. Determine diffuser setting and air damper setting Do not operate the burner outside of the capacity graph.
  • Page 29 Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning Set diffuser With dimension X = 0mm the indicating bolt is flush with the nozzle assembly cover. Turn screw 1, until dimension X equals the value determined. Set air damper Turn setting screw 1 until the scale shows the value determined.

  • Page 30: Adjusting The Burner

    Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning 7.2 Adjusting the burner Risk of electric shock Touching the ignition device can lead to electric shock. Do not touch ignition device during the ignition process. DANGER During commissioning check: flame signal [ch. 7.1.1],...

  • Page 31: Concluding Work

    Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning 7.3 Concluding work Oil leakage from oil pressure measuring devices due to constant load Oil pressure measuring devices could be damaged and cause environmental pollu- tion through leakage. WARNING Remove oil measuring devices once commissioning is complete.

  • Page 32: Check Combustion

    Installation and operating instruction Oil burner WL5/1-B H-2LN 7 Commissioning 7.4 Check combustion Determine excess air Slowly close air damper(s) in the relevant operating point, until the combustion limit is reached (soot number approx. 1). Measure and document O content.

  • Page 33: Shutdown

    Installation and operating instruction Oil burner WL5/1-B H-2LN 8 Shutdown 8 Shutdown For breaks in operation: Switch off burner. Close fuel shut off devices. 33-72 83058402 1/2019-04 La...

  • Page 34: Servicing

    The design lifespan of the components is listed in the service plan [ch. 9.2]. Weishaupt recommends a service contract is entered into to ensure regular in- spections.

  • Page 35: Service Plan

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.2 Service plan Components Criteria / design lifespan Service procedure Fan wheel Soiling Clean Damage Replace Air duct Soiling Clean Air damper Soiling Clean Ignition cable Damage Replace Ignition electrode...

  • Page 36: Service Position

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.3 Service position Observe notes on servicing [ch. 9.1]. Remove bolts 1. If necessary remove oil hoses. If the burner is placed into service position C: Remove actuator plug 2. Place the burner into the required service position.

  • Page 37: Replace Nozzle

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.4 Replace nozzle Observe notes on servicing [ch. 9.1]. Do not clean nozzles, always fit new nozzles. Place burner into service position B [ch. 9.3]. Unplug ignition cable 4. Undo screws 1 and remove diffuser.

  • Page 38: Removing And Refitting Nozzle Shut Off

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.5 Removing and refitting nozzle shut off Observe notes on servicing [ch. 9.1]. Removing Remove nozzle [ch. 9.4]. Counter-hold the nozzle assembly 4 using a spanner and remove nozzle holder Remove valve piston 2 and compression spring 3 using a suitable tool (e. g.

  • Page 39: Removing The Mixing Head

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.7 Removing the mixing head Observe notes on servicing [ch. 9.1]. Unplug plug No. 11 and 12. Unplug ignition cable 1. Remove flame sensor 5. Remove oil line 3. Remove pressure hose 6 from the mixing head.

  • Page 40: Removing Heat Exchanger And Temperature Switch

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.8 Removing heat exchanger and temperature switch Observe notes on servicing [ch. 9.1]. Remove mixing head [ch. 9.7]. Remove nozzle [ch. 9.4]. Remove screw 2 and remove nozzle assembly 1. Remove screw 3 and temperature switch 4.

  • Page 41: Set Mixing Head

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.9 Set mixing head Observe notes on servicing [ch. 9.1]. Set nozzle distance Place burner into service position A [ch. 9.3]. Insert checking gauge and check dimension A (2.5 … 3 mm). If the value measured deviates from dimension A: Undo screw 1.

  • Page 42: Set Recirculation Aperture

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.10 Set recirculation aperture Observe notes on servicing [ch. 9.1]. Basic setting of recirculation aperture: dimension S3 = 0 mm Undo screws 1 and set the recirculation aperture by turning. 42-72 83058402 1/2019-04 La...

  • Page 43: Removing The Air Regulator

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.11 Removing the air regulator Observe notes on servicing [ch. 9.1]. Remove actuator plug 5. Place burner into service position A [ch. 9.3]. Remove bolts 1. Remove intake housing 3. Remove bolts 4.

  • Page 44: Removing And Refitting Oil Pump

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.12 Removing and refitting oil pump Observe notes on servicing [ch. 9.1]. Removing Close fuel shut off devices. Unplug plug 1. Remove oil hoses 5. Remove oil line 4. Undo screws 2 and remove oil pump.

  • Page 45: Removing And Refitting Fan Wheel

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.13 Removing and refitting fan wheel Observe notes on servicing [ch. 9.1]. Removing Place housing cover into service position C [ch. 9.3]. Remove grub screw 1 and remove fan wheel. Refitting Refit fan wheel in reverse order and ensure correct alignment on the motor shaft 2,...

  • Page 46: Removing And Refitting Oil Pump Filter

    Installation and operating instruction Oil burner WL5/1-B H-2LN 9 Servicing 9.15 Removing and refitting oil pump filter Observe notes on servicing [ch. 9.1]. Removing Close fuel shut off devices. Remove bolts 1. Remove pump cover. Replace filter 3 and gasket 2.

  • Page 47: Troubleshooting

    Boiler or heating circuit control is not Check function and setting of boiler functioning or has not been set correctly or heating circuit control. Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly. 47-72 83058402 1/2019-04 La...

  • Page 48: Illuminated Push Button Red

    Installation and operating instruction Oil burner WL5/1-B H-2LN 10 Troubleshooting 10.1.2 Illuminated push button red A burner fault has occurred. The burner is in lockout. Prior to resetting, the error code can be called up and used to control the cause of the fault.
  • Page 49 Installation and operating instruction Oil burner WL5/1-B H-2LN 10 Troubleshooting Error codes with lockout The following faults must only be rectified by qualified personnel: Fault codes Fault Cause Rectification 2 x flashing Oil pump supplies no oil Oil supply leaking...
  • Page 50 Installation and operating instruction Oil burner WL5/1-B H-2LN 10 Troubleshooting The following faults must only be rectified by qualified personnel: Fault codes Fault Cause Rectification Flashing 7 times Flame has failed Oil supply leaking Check oil supply Suction resistance in front...

  • Page 51: Illuminated Push Button Flashes

    Installation and operating instruction Oil burner WL5/1-B H-2LN 10 Troubleshooting 10.1.3 Illuminated push button flashes An irregularity is present. The burner does not go to lockout. Once the fault has been rectified, the error code ceases. Error codes without lockout...

  • Page 52: Operating Problems

    Installation and operating instruction Oil burner WL5/1-B H-2LN 10 Troubleshooting 10.2 Operating problems The following faults must only be rectified by qualified personnel: Observation Cause Rectification Poor start behaviour of burner Mixing pressure too high Correct mixing pressure Ignition electrodes set incorrectly Set ignition electrodes [ch. 9.6]...

  • Page 53: Technical Documentation

    Installation and operating instruction Oil burner WL5/1-B H-2LN 11 Technical documentation 11 Technical documentation 11.1 Conversion table unit of pressure Pascal 0.1 mbar 0.01 0.00001 1 mbar 0.0001 10 mbar 1 000 0.001 100 mbar 10 000 0.01 1 bar...

  • Page 54: Wiring Diagram

    Installation and operating instruction Oil burner WL5/1-B H-2LN 11 Technical documentation 11.2 Wiring diagram For special version observe wiring diagram supplied. W-FM 05 6,3A X3:2 X3:3 X3:12 X3:11 L PE N T1 T2 S3 B4 max 16A L PE N...
  • Page 55 Installation and operating instruction Oil burner WL5/1-B H-2LN 11 Technical documentation X3:4 X3:13 X3:5 X3:6 X5:1 P11.1 Flame sensor Anti siphon valve (optional) Solenoid valve P11.1 Hours counter (optional) Remote reset (optional) Ignition unit Bus interface (optional) 55-72 83058402 1/2019-04 La...

  • Page 56: Project Planning

    Installation and operating instruction Oil burner WL5/1-B H-2LN 12 Project planning 12 Project planning 12.1 Oil supply Observe EN 12514-2, DIN 4755, TRÖI and local regulations. General information relating to the oil supply Do not use cathode protection system with steel tanks.
  • Page 57 Two pipe system In a two pipe system the oil pump is vented automatically. Ring main operation Weishaupt recommends the use of a ring main when operating several burners. 57-72 83058402 1/2019-04 La...

  • Page 58: Spares

    Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares 13 Spares 1.20 1.01 1.16 1.19 1.21 1.06 1.18 1.15 1.19 1.18 1.03 1.02 1.17 1.05 1.04 1.17 1.10 1.12 1.11 1.07 1.08 1.12 1.09 1.11 1.07 1.14 1.13 58-72...
  • Page 59 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares Pos. Description Order No. 1.01 Cover complete 241 050 01 022 1.02 Screw M8 x 15 142 013 01 157 1.03 Washer 7 + 0.2 x 18 x 0.6 430 016 1.04...
  • Page 60 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares 2.07 2.04 2.05 2.08 2.03 2.06 2.01 2.02 60-72 83058402 1/2019-04 La...
  • Page 61 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares Pos. Description Order No. 2.01 Motor ECK02/H-2 230V 50Hz 75W 652 090 2.02 Capacitor 4.0 µF 420V, AC, DB 713 473 2.03 Fan wheel TLR-S 50 Hz, 119 x 41.4-L S1 241 050 08 012 2.04...
  • Page 62 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares 3.05 3.04 3.05 3.02 3.03 3.01 3.09 3.07 3.10 3.11 3.12 3.06 3.08 3.08 62-72 83058402 1/2019-04 La...
  • Page 63 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares Pos. Description Order No. 3.01 Pump ALEV 30 C 601 857 – Filter set with seal 601 107 3.02 Solenoid coil T80 Suntec 220-240 V 50-60 Hz 604 495 3.03...
  • Page 64 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares 4.29 4.01 4.02 4.26 4.26 4.27 4.24 4.28 4.25 4.28 4.03 4.30 4.04 4.05 4.06 4.20 4.20 4.07 4.19 4.17 4.18 4.23 4.16 4.08 4.22 4.21 4.10 4.11 4.09 4.12 4.13...
  • Page 65 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares Pos. Description Order No. 4.01 Nozzle assembly complete (QRB4) 242 050 10 322 4.02 Diffuser 241 050 14 102 4.03 Guide tube with stop 241 110 10 012 4.04 Nozzle head complete 242 050 10 292 4.05...
  • Page 66 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares 5.04 5.05 5.05 5.03 5.02 5.06 5.01 5.07 66-72 83058402 1/2019-04 La...
  • Page 67 Installation and operating instruction Oil burner WL5/1-B H-2LN 13 Spares Pos. Description Order No. 5.01 Combustion manager W-FM 05, 230 V / 50/60 Hz 600 470 – Micro fuse T6.3H, IEC 127-2/5 483 011 22 457 5.02 Cover clip AGK63 600 312 5.03...

  • Page 68: Notes

    Installation and operating instruction Oil burner WL5/1-B H-2LN 14 Notes 14 Notes 68-72 83058402 1/2019-04 La...

  • Page 69: Key Word Index

    Installation and operating instruction Oil burner WL5/1-B H-2LN 15 Key word index 15 Key word index Air damper .............. 9, 28, 43 Fabrication number...............  8 Air damper setting .............. 28 Fan motor................ 45 Air number ................ 32 Fan pressure .............. 26, 29 Air regulator................ 43 Fan wheel................. 9, 45...
  • Page 70 Installation and operating instruction Oil burner WL5/1-B H-2LN 15 Key word index Measuring device.............. 26 Reverse flame .............. 52 Mixing head ............ 9, 28, 39, 41 Reverse flame boiler............ 52 Mixing pressure ............ 26, 29 Ring main operation ............ 57 Monitoring current .............. 26 Motor................ 11, 45 MPa .................. 53...
  • Page 71 83058402 1/2019-04 La...
  • Page 72 Max Weishaupt GmbH · 88475 Schwendi Weishaupt close by? Addresses, telephone numbers etc. can be found at www.weishaupt.de We reserve the right to make changes. All rights reserved. The complete program: Reliable technology and prompt, professional service W Burners up to 570 kW...

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