Weishaupt Oil Burner

Ignition electrode settings

The following should be noted.

The distances of the ignition electrodes to the nozzle and diffuser should be checked.

The ignition electrodes must not be touched by atomised oil spray.

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

Ignition electrode-nozzle setting

Burner L5Z to L9Z Burner M5Z to MS9Z Burner L7T to L10T

Regulating burner RL3 to RL7 Regulating burners RL8 to RL11, RMS7 to RMS11

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Air regulation, burners two and three stage

Two and three stage oil burners with two air dampers

Size 5 to 11

The air intake has two air dampers.

Both air dampers are connected by a rod so that they are operated in parallel by the servomotor.

When commissioning the installation, the following mechanical settings are necessary:

  • Set the air damper for partial load operation (operation with nozzle I) by adjusting the cam swatch II - partial load in the servomotor.

  • Set the air damper for full load operation (operation with both nozzles) by adjusting the air damper for full load via the servomotor cam switch III - full load.
  • Set the switch for switching on solenoid valve 2. This is done at the cam switch I - (solenoid valve 2) in such a way that the switch is no longer depressed after approximately two thirds of the setting movement. This will prevent flame lift off due to the higher air flow.
  • The final setting of the cam switches in the servomotor for full load - switch III and partial load - switch III and partial load - switch II takes place after the flue gas measurements.

On L7T to L10T (three stage) burners, the servomotor type 1055/80 is used. This servomotor is similar in construction to the 1055/23 but has a running time of 8 secs and an additional limit switch related to 90oC angle of rotation.

Commissioning and adjusting

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Before commissioning can commence, the entire plant must be ready for operation and handed over by the installer.
The solenoid valves fitted on the burner and the isolating valves in the oil supply should be tested for correct operation.
The burner motor rotation should be verified before commissioning. With control circuit and operation switch closed the burner is briefly actuated by the burner control switch. The rotation of the burner motor must be anti-clockwise when looking at the motor cooling fan. Note the arrow direction on the motor flange.

Switch on procedure:
Open shut off valve (shut off assembly) in the oil line. Set selector switch in the control panel to "setting 2" of "full load".
Reset installation. Switch on burner.

Ignition:
After pre-purge await flame formation.

If start problems occur:

L-(M-/MS-) burners:
Check nozzles size of stage 1, if necessary select different nozzles.
Check position of auxiliary switch II in the servomotor, if necessary adjust to air requirement.

RL-(RM-/RMS-) burners:
Check position of ignition position switch in the servomotor (No III), reset if necessary.

Test sensor current with microammeter.

Full load setting:
After approx. 11 secs. the servomotor runs from ignition (partial) load to full load. (Ensure that this is carried out with excess air by previously reducing the selected pump pressure). For full load the required oil throughput has to be set and measured (the nozzle selection tables are only a guideline for setting and testing).

Carry out combustion test:

L-(M-/MS-) burners:
The oil throughput is set by adjusting the pump pressure (EL = 10-14 bar, M/MS = 20-25 bar), if necessary select different nozzle size.
Set combustion value by adjusting servomotor, auxiliary switch No III and the position of the flame tube so that with the air damper opened as much as possible a smoke number <1 and CO2>13 Vol.% can be achieved with good flame stability.

RL-(RM-/RMS-) burners:
Set oil throughput by adjusting the pump pressure (20-30 bar).
Set combustion value by adjusting the air curve band and the position of the flame tube so that with the air damper opened as much as possible a smoke number <1 and CO2>13 Vol.% can be achieved with good flame stability.

The pump pressure and flame tube position set for full load must not be readjusted.

Intermediate control ("Full load to partial load") only on regulating burners:
A step by step combustion control is required for the whole of the burner regulation range.

Set cam sequence by hand step by step in the direction of ignition load (selector switch to "Stop", disengage servomotor, adjust by hand, re-engage). Regulate combustion values by adjusting the air band. Ensure that the cam bands scribe a smooth arc.

Partial load setting:
Set selector switch in the control panel to "stage 1" or "partial load".

L-(M-/MS-) burners:
Adapt excess air to the oil throughput of the selected pump with the auxiliary switch for partial load (No II).
Measure oil throughput, if necessary select different nozzle. Set the switch point for the start of the second nozzle with auxiliary switch No I so that the excess air phase before the switch point is not too large to extinguish the flame, but on the other hand that there is not too much smoke after the connection has been made.

Three stage burners:

L7T to L10T
In the same sense the excess air of the intermediate load is set with the auxiliary switch V and with the movable auxiliary switch on the air damper shaft (S8 on wiring diagram) the connection point for the third stage is set.

RL-(RM/RMS-) burners:
Set and measure the required oil throughput for partial load with auxiliary switch No. VII.

If the nozzle has been changed for partial or intermediate load (two/three stage burners) the full load setting has to be tested and if necessary re-set. For partial load setting the lower ratings limits given in the graph, the flue gas temperatures as well as the instructions of the boiler manufacturer have to be noted.

Finalising work:
Test ignition load setting when burner has been commissioned. The setting is correct, if the burner starts without start impact.

Regulation burners:
If necessary correct setting at auxiliary switch No. III

2+3-Stage burners:
If necessary select new nozzles.
Setting of full and partial load will then have to be repeated.

Test and check the function of all safety equipment (i.e. oil pressure switch, thermostat, pressure stat, etc.) when the installation is in operation.

Documentation:
On full and partial load the following setting values have to be noted in the commissioning report:
Oil throughput
type of nozzle
pump pressure
supply and return pressure (on RGL burners)
CO2
smoke
flue gas temperature
fan pressure
draught or pressure in the combustion chamber
sensor current
room temperature
atomising temperature (on MS and RMS burners) air damper setting cam setting on the air band (on R burners)

Fault conditions and procedures

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

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

When it is established that the fault is not due to external conditions, the operations if the individual burner parts must be checked.

Condition Cause Remedy
1. Ignition
No ignition
ignition electrodes too far apart or grounding Adjust
Ignition electrodes dirty or damp Clean and adjust
Burner control faulty Replace burner control
Insulating body cracked Replace
Ignition transformer faulty Replace
Ignition cable charred Replace. Find and remedy cause
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2. Burner motor
Does not start Overload tripped Check setting
Contactor defective Replace
Capacitor faulty Replace
Burner motor faulty Replace
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3. Pump supplies
No oil Gears damaged Replace pump
Suction valve leaking Remove and clean or replace
Oil lines leaking Tighten joints
Shut off valves closed Open
Filter blocked  Clean
Filter leaking Replace
Quick action valve faulty Replace pump
Reduced capacity Replace pump
Mechanical pump noise Air in pump Tighten joints and purge
Vacuum in oil line too high Clean filter, open valves fully
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4. Nozzle
Uneven atomisation Swirl disc loose Remove nozzle
Tighten swirl disc
Orifice partly blocked Remove, clean
Filter blocked Remove, clean
Worn due to use Replace
No oil flow Nozzle blocked Remove, clean
Nozzle leaking  Nozzle cut off faulty Replace
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5. Burner control with flame sensor
Does not respond to flame Flame sensor obscured  Clean
Thermally overloaded  Replace
Interruption in operation sequence See under 19-19.6 Check connection and voltages
Lockout lamp on Flame fault Reset
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6. Combustion head
Contaminated with oil or has heavy carbon deposits Incorrect setting Correct setting measurements
Incorrect combustion heat Replace
Nozzle size incorrect Replace
Combustion air quantity incorrect Readjust burner
Boiler house not adequately ventilated The boiler house ventilation must be via a permanent opening, the cross section of which mush be at least 50% of all chimney cross sections relating to the plant
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7. Solenoid valve
Does not open Coil faulty Replace coil
Does not close tightly Particles on the valve seat Dismantle valve, remove foreign bodies
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8. Oil preheater
Burner does not start Thermostat for burner release does not close Increase oil temperature adjusting screw of thermostat
Thermostat for burner release faulty Replace
Thermostat for burner release loose Tighten
@ Thermostat for burner release with incorrect temperature range Replace
@ Heater element faulty Replace preheater
Poor combustion  Temperature too low Increase temperature at thermostat
For adjustment see oil preheater brochure
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9. Cleaning and lubrication regulations

Depending on the environment, fan rotor, ignition electrodes, flame sensor and air intake should be cleaned as required.

Burner moving parts require no lubrication.

Motor bearing damage, which is recognised and remedied quickly, prevents more extensive damage to the burner.

development of noise in the motor bearings must be investigated immediately.