Installation and operating instructions

Weishaupt oil burners L, RL, and M

Sizes 1 and 3

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Contents
Title

Page

1.

General instructions

2.

Burner installation

3.

Oil supply

4.

Burner fuel system schematics

5.

Pumps

6.

Oil throughput capacity charts

11

92/31/EEC Electromagnetic Compatibility Directive

73/23/EEC Low Voltage Directive
92/42/EEC Boiler Efficiency Directive

7.

Nozzle selection
7.1 single, two or three stage burners
7.2 sliding two stage or modulating burners

13
13
14

Therefore the burner carries the CE Label.

8.

Combustion head settings

8.1 Combustion head extensions

16
17

Extensive quality assurance is guaranteed by a certified

Quality Management System to DIN EN ISO 9001.

9.

Ignition electrode settings

18

Conformity certification
We hereby confirm that Weishaupt oil burners conform to
the basic requirements of the following EU guidelines:

Max Weishaupt GmbH

Burner and Heating Systems
D-88475 Schwendi

10. Regulating system RL3

19

11. Nozzle recirculation on M burners

21

12. Oil preheaters and heating elements

22

13. Air regulation, single, two and

three stage burners
13.1 Cam settings of limit and auxiliary
switches on servomotor type 1055
13.2 Description of operation of
servomotor type 1055

23
24
25

14. Oil/air compound regulation on

regulating burners
14.1 Cam setting of limit and auxiliary
switches on servomotor SQM

28

15. Commissioning and adjustment

29

16. Sequence of operation, burner control LOA

30

17. Sequence of operation LAL2... and LOK16 ...

17.1 Requirements for burner start
17.2 Sequence and time diagrams
17.3 Symbols on fault position indicator
17.4 Switching times
17.5 Technical data
17.6 Basic wiring diagram

32
32
32
33
34
34
35

18. Fault conditions and rectifying procedures

37

27

Regular maintenance saves energy and protects the environment

We recommend regular plant maintenance of all
combustion equipment. It saves fuel and ensures
constantly good combustion results. Excellent

combustion quality is a pre-requisite for

environmentally friendly operation.
3

1. General instructions
Safety
To ensure safe burner operation, the burner has to be
installed and commissioned by qualified personnel
and all guidelines in these operating instructions have
to be followed.
Special attention should be paid to the relevant
installation and safety guidelines given (i.e. local
Codes of Practice).
Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
commissioned by, and may only be replaced by, the
manufacturer or the authorised agent.
Failure to comply can lead to serious injury or death
and can cause considerable damage to the plant.
Qualified personnel according to this operating
manual are persons who are familiar with the
installation, mounting, setting and commissioning of
the product and which have the necessary
qualifications such as:
Training, instruction or authorisation to switch
electrical circuits and electrical devices on and off, to
earth them and to mark them in accordance with the
safety standards.
Operating instructions
The installation and operating instructions included with
each burner must be displayed clearly in the plant room.
We refer to DIN 4755, point 5. The address of the nearest
service centre must be entered on the reverse of the
instructions.
Instruction of personnel
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with
regard to the operation of the burner. With frequently
occurring burner faults, the nearest service centre must be
notified.

Installation
The installation of oil fired equipment must be carried out in
accordance with extensive guidelines and regulations. It is
the duty of the installer to familiarise himself with all
regulations. Installation, commissioning and maintenance
must be carried out with care. Permitted fuels:
Fuel oil DIN 51603 - EL - 1
Medium fuel oils with a kinematics viscosity of maximum
75 mm2/s at 50 C
Electrical wiring
Each burner is supplied with a wiring diagram and burner
connection diagram as standard.
Maintenance and service
In accordance with DIN 4755, the whole installation,
including the burner, should be inspected by a qualified
engineer of the supplier at least once a year. The
combustion figures should be checked after each service
and each time a fault has been rectified.
Ambient requirements
Material, construction and type of protection of the burner
and fuel lines are designed for use indoors. The permitted
ambient temperature is -15 C to + 40 C.
Electrical installation
When installing the electrical connection cables ensure
that these are long enough to allow the burner and boiler
door to be hinged open.
Control circuits, which are taken from one of the supply
phases, must only be connected with an earth potential
neutral conductor.
On a mains supply which is not earthed the control voltage
must be supplied via an isolating transformer.
The pole of the transformer, which is to be used as the
neutral conductor must be earthed.
The control circuit phase and neutral conductors must
be connected correctly.
Ensure the correct fuse ratings are not exceeded. Earthing
and neutral conductors must conform to local regulations.

2. Burner installation
Installing the burner
The drawing shows refractory in a heating appliance
without a cooled front. The refractory must not extend
beyond the front edge of the combustion head (dimension
l1). If it is necessary to extend the refractory beyond the
combustion head, this should take a conical form ( 60).
Refractory may not be required on boilers with watercooled fronts, depending on the boiler manufacturers
instructions.

Installation example of heat exchanger with refractory

The boiler front plate must be prepared in accordance with

the dimensions below. The burner hinge flange can be
used as a template for the plate drilling.
For an example of a burner with head extension, see
chapter 8.1.

Fill the air gap with resilient refractory insulation material.

Do not make solid!

Burner
size

Combustion head Dimensions in mm

type
d1
d2

d3

d4

d5

l1

M1/5a

128

M8

160-170

135

150

117

3
3

M2/1a
M5/2a

140
160

M10
M10

186
186

165
165

170
190

132
138

Hinged flange
The burner can be hinged to the left or right depending on
the position of the hinge pin and by releasing the locking
nut.

Locking nut
Hinge pin

Interlock switch
The interlock switch is arranged so that the electrical
circuit is closed in the burner closed position. The circuit is
broken by the release of the tripping pin from the interlock
switch.

Tripping pin

3. Oil supply
Operational safety to a great extent depends on the oil
supply. Information regarding the pipe system and the
dimensions can be found in our technical work sheets.
Termination of the oil supply must allow tension free
connection of the flexible oil hoses. The oil connections
must allow the burner to swing open.
When installing the oil hoses in the supply and return
(between pump and rigid pipe installation), the
product related technical drawings should be
observed.
For fuel oil EL oil hoses to DIN 4798, Part 1, pressure
class A are supplied.

PN
PP
TB

= 10 bar
= 15 bar
= 70C

Suction lift operation

Suction operation is possible for individual burners, which
are operated on fuel oil EL.
Ring main operation
If there are several burners or the burner is installed at
some distance, the use of a ring main system is
recommended. This system is, however, essential when
operating with residual oil.
On two pipe oil supply, the factory pre-set oil pressure of
the burner pump is influenced by the pressure of the oil
supply. The pump pressure must be measured and
corrected.
Ring main pressure regulating valve
a) Setting for distillate oil EL
Ring main pressure 1 - 1.5 bar
b) Setting for residual oil M
To avoid vaporisation of water in the fuel oil, the minimum
ring main pressure, including a safety margin, must be set
according to the following table. It is based on the
pressure, which is measured at the burner pump outlet.
Preheat temperature
C

Ring main pressure

at burner in bar

110
115
120

1,5
1,8
2,2

Filter
An oil filter must be fitted at the end of the pipeline before
the pump. The filter protects the burner from foreign
bodies in the oil and the pipeline.
If no filter is fitted then the following faults can occur:
Seizing of the pump gears
Blocking of solenoid valve and nozzle

Technical data:
Nominal pressure
Test pressure
Operating temperature

Air/gas separators
A Weishaupt air/gas separator should be fitted at the
point at which the burners two pipe system is connected.
The air/gas separator must be installed as near to the
burner as possible. The inclusion of a separator is
important on residual oil installations. When installing, the
directions shown on the separator must be observed (see
pipeline diagrams in our work sheets).

Installation of oil meters

When oil meters are fitted in the supply and return lines,
the system must be protected from excess pressure by a
pressure relief valve installed in the return line (see
pipeline diagrams in our work sheets).
A blocked return line can cause the following:
Bursting of oil hoses
Pump damage (glands on pump leaking)
Load changes without changes to the combustion air
Load changes occur if the meter is blocked up during
burner operation.
The return pressure renders the oil regulator ineffective.
Deflagration may occur on burner start.
Note
Isolating devices in the return flow line must be
protected from unintentional closure, e.g. ball valves
with mechanical connection or shut off device with
interlock switch. Non return valve may not be fitted on
burners with spill type nozzles.

The pipes must be tested after installation, without the

oil filter and hoses. The test is carried out using
compressed air or nitrogen with a minimum pressure

of 5 bar. The burner must not be connected during the

test.

Oil hose connection according to burner type

Oil hoses
DN

Length mm
Supply

Return

Connection thread
pump side

Connection nipple
installation side

L1Z-B
L1T-B
L3Z-A
L3T-A
RL3-A

8
8
8
8
8

1000
1000
1000
1000
1000

1000
1000
1000
1000
1000

G 3/8
G 3/8
G 3/8
G 3/8
G 3/8

G 3/8
G 3/8
G 3/8
G 3/8
G 3/8

M1Z-B
M3Z-A

13
13

800
1000

500
700

G 1/2
G 1/2

G 1/2
G 1/2

4. Burner fuel system schematics

L, two stage
1

L3, three stage

3

M, two stage > 30 kg/h

M, two stage < 30 kg/h

1

10

13

11

13

11

Pump, without integral solenoid valve

L1: Pump type AE 67C
L3: Pump type AE 97C
RL: Pump type AJ6 CE
M: Pump type E4 NC

Solenoid valve type 121 C2323, coil 9 watt

(normally closed) G 1/8

Solenoid valve type 121 K2423, coil 19 watt

(normally closed) G 1/8

14

RL, sliding two stage and modulating

6

14

12

Solenoid valve type 122 K9321, coil 19 watt

(normally open) G 1/8

Solenoid valve type 121 K6220, coil 20 watt

(normally closed) G 1/4

Nozzle head EL two stage

(without integral shut off device)

14

Nozzle head R (without integral shut off device)

The two solenoid valves (4) are electrically connected

in series, as are the two solenoid valve (6).

10
11

Nozzle head EL three stage

(without integral shut off device)
Nozzle head M two stage
(with integral shut off device)

12

Oil regulator

13

Oil preheater

Pressure switch 1 - 10 bar

(on RL set to 5 bar, on M to 7 bar)

The solenoid valve in the return (4) and (6) is fitted

against the flow direction.
The voltages given refer to a control voltage of 230 V.
For control voltage of 115 V controls with 115 V and
58V are used.

5. Pumps
The pumps are supplied suitable for connection in a two
pipe system.
The pumps are fitted with a pressure regulating device.
The pressure regulating valve keeps the atomising
pressure constant.
Adjustment
The suction oil line must be primed and the pump
vented prior to commissioning to prevent the pump
from running dry.
To check the vacuum, supply or ring main pressure,
insert a connecting nipple to the suction side of the
pump.
A pressure gauge must be fitted into tapping (5) to
measure the pump pressure.
Set the pressure required on the pressure regulating
screw (on type E remove cover nut).
Clockwise rotation
=
pressure increase
Anticlockwise
=
pressure decrease
The suction resistance should not exceed 0.4 bar
Max. supply pressure on
Pumps type AE __________________________ 2,0 bar
Pumps type AJ ___________________________ 2,0 bar
Pumps type E ___________________________ 5,0 bar
(always measured at the pump).
Maximum supply temperature on
Pumps type E _____________________________ 90C
type AE ____________________________ 70C
type AJ_____________________________ 70C

Operation AE67, AE97 and AJ6

The pump gearing takes the oil from the supply line
through the integral oil filter and under pressure, forces it
through the integral pressure regulating valve to the nozzle
head.
On two pipe systems, any oil that exceeds the nozzle
capacity is returned to the tank, on single pipe systems, it
is returned to the pumps inlet/suction chamber.
The pumps have an internal drilling, which aids automatic
purging via the burner nozzle during commissioning.
Operation E4
The oil passes through the integral filter, is pressurised by
the gears and flows to the pressure regulating valve. Any
excess oil is spilled via the valve into the return line. The oil
nozzle head has galleries, which allow oil circulation
without discharge from the nozzles. A bypass inhibits
pressure increase in the nozzles flow pipe due to oil
expansion. The oil expands due to oil preheating.
Single pipe operation
In some cases when operating with distillate oil EL the
pumps can be used with a one pipe system.
For single pipe installations the bypass plug must be
removed and the return port has to be plugged. The
bypass plugs of the various pumps are located in different
positions:
AE 67/AE 97

behind the return connection screw

(SW 5/32)

AJ6

behind the return connection screw

(SW4)

E4

behind the return connection screw

(SW 1/16)

When commissioning, the supply line must be fully

purged.

Pump AE 67C / AE 97C

Pump AJ 6

7
6

5
3

1 Suction connection
2 Return connection
2a Oil regulator return connection
3 Nozzle supply line
4 Locking screw
5 Manometer connection
6 Vacuum gauge connection
7 Pressure regulating screw
8 Coupling intermediate piece
9 Axial movement 1.5 mm
10 Socket head grub screw (security)
11 Oil pump connection piece

Pump E4
6

Pump coupling
There is a flexible coupling fitted between fan rotor and
pump (motor axis). When adjusting the intermediate
coupling, ensure that there is no axial tension on the pump
shaft. The coupling element on the pump should have an
axial movement of 1.5 mm. The difference can be
corrected by loosening the M8 socket head screw (10) on
the drive element of the pump shaft. This screw is also
used as a safety limit, if the pump is seized. The screw is
forced out when the drive is overloaded. The faulty
coupling part should be replaced.

Fan attachment
The fan fits on to the tapered motor shaft. A shaft key
transmits the power. The fan is secured by an M8 screw
and the shaft key.
Remove the fan
The extractor Part No. 111 111 00 01/2 can be applied in
the two threaded holes provided and the fan removed.

10

2a

Pump coupling
8

10

11

6. Oil throughput capacity charts

Burner size 1

Important note for capacity charts

The capacity graph shows the oil throughput in relation to
combustion chamber pressure. These are maximum values
measured on ideal test flame tubes to DIN 4787.
All ratings given are based on an air inlet temperature
of 20 C and an altitude of 500 m.
Warning!
The burner must never be operated above its capacity.

5-10
Combustion head movement
lower air volume
Burner size 1

Burner types
Combustion head designation
rating kW
kg/h

Dimensions mm
No.
Combustion head

L1Z-B

L1T-B

(2)

M1/5a-100K x 33
120 415
10 35

M1/5a-100 K x 36
120 415
10 35

L1Z-B

L1T-B

M1/5a-105K x 33
70 345
6 29

M1/5a-105 K x 36
70 345
6 29

mbar 8

mbar 8

Setting dimension
l
d

(2)
(2)

M1/5a-100K x 33
M1/5a-100K x 36

10 30
10 30

128
128

(3)
(3)

M1/5a-105K x 33
M1/5a-105K x 36

14 30
14 30

128
128

(4)
(4)

M1/5a-105K x 33
M1/5a-100K x 33

30
30

128
128

-2
kW 0
kg/h 0

Burner types
Combustion head designation
rating kW
kg/h

100
5

10

200
15

300
20

25

400
30

35

-2
kW 0

500
40

kg/h 0

(4)

M1Z-B

100
5

10

mbar 8

mbar 8

kg/h

100
5

10

200
15

20

300
25

400
30

35

500
40

20

25

400
30

35

500
40

(4)

M1/5a-105K x 33
90 345
7,8 29,7

-2

15

300

M1Z-B

M1/5a-100K x 33
120 415
10,3 35,8

kW 0

200

(3)

-2
kW 0
kg/h

100
5

10

200
15

20

300
25

400
30

35

500
40

11

Important note for capacity charts

The capacity graph shows the oil throughput in relation to
combustion chamber pressure. These are maximum values
measured on ideal test flame tubes to DIN 4787.

Burner size 3

All ratings given are based on an air inlet temperature

of 20 C and an altitude of 500 m.
Warning!
The burner must never be operated above its capacity.

Combustion head movement

smaller air quantity
Burner size 3

Burner types
Combustion head designation
rating kW
kg/h

Dimensions mm
No.
Combustion head

Setting dimension
l
d

(1)

M2/1a-116 x 40

40 60

128

(2)

M5/2a-116 x 40

50 70

160

(3)

M5/2a-116 x 40

50 70

160

Burner types
Combustion head designation
rating kW
kg/h

L3Z-A, L3T-A, RL3-A

L3Z-A, L3T-A, RL3-A

M5/2a-116 x 40
190 775
16 65

mbar 8

mbar 8

-2
kW 0
kg/h

100 200 300 400 500 600 700 800

-2
kW 0
kg/h

5 10 15 20 25 30 35 40 45 50 55 60 65

M3Z-A

(1)

5 10 15 20 25 30 35 40 45 50 55 60 65

M3Z-A

(3)

M5/2a-116 x 40
190 775
16,4 66,8

mbar 8

mbar 8

100 200 300 400 500 600 700 800

kg/h 0 5 10 15 20 25 30 35 40 45 50 55 60 65

-2
kW 0

(2)

100 200 300 400 500 600 700 800

M2/1a-116 x 40
120 525
10,3 45,3

-2
kW 0

12

(1)

M2/1a-116 x 40
120 525
10 44

100 200 300 400 500 600 700 800

kg/h 0 5 10 15 20 25 30 35 40 45 50 55 60 65

7. Nozzle selection
7.1 Single, two or three stage burner
It is recommended that solid or semi solid nozzles be used
with a spray angle of 60 or 45. Due to the various
configurations of combustion zones encountered, no
binding information can be given.

On two stage burners neither nozzle should be smaller

than indicated.

Nozzle spray angles and patterns change with alterations

to the atomising pressure. The nozzle data given applies to
a nominal pressure of 7 bar.

Removing and replacing nozzles

When removing the nozzle, the nozzle head must be held
with a spanner. When replacing, ensure that the nozzle is
tight.

On two stage burners the total burner rating required must

be shared between the two nozzles. Normally the 1st
stage nozzle is sized to have sufficient capacity for the
base load of approx. 2/3 of the total load. At maximum
heat demands the 2nd stage nozzle supplements the
throughput of stage 1s nozzle. A different nozzle ratio may
be required, depending upon heat demand and the design
of the heating appliance (e.g. boilers with high chamber
resistance).
On three stage burners the required total burner rating is
shared between three nozzles.

The charts are nominally based on distillate oil EL with a

viscosity of 4 mm2/s at 20 C.

Cleaning the nozzle

Nozzle cleaning is generally not recommended. A new
nozzle should be used.
Atomising pressure
Burner type

Atomising pressure
approx. bar

L1-B bis L3T-A

10 16
M1Z-B bis M3Z-A 20 25

Nozzle selection for residual oil

Nozzles, which are too small are often used for residual oil
and therefore soon become blocked. As lower limits, we
recommend the following sizes:
from 0.85 US gph - up to approx. 35 mm2/s
at 50 C
Spray angle

Nozzle characteristics

Hollow spray

Semi solid spray

Solid spray

Nozzle selection diagram

Pressure bar

Distillate oil = 0,85 (kg/dm3)

[l/h]

Residual oil = 0,93 (kg/dm3)

[kg/h]

Oil throughput
[kg/h]

13

Pressure bar

Oil throughput

Distillate oil = 0,85 (kg/dm3)

[l/h]

Residual oil = 0,93 (kg/dm3)

[kg/h]

[kg/h]

Nozzle selection diagrams

Changes in viscosity and density due to tolerances during
nozzle manufacture will lead to throughput deviations. The
atomising viscosity is max. 10 mm2/s.
Due to the burners oil solenoid valves, piping and
preheater oil pressures losses are created. For an exact oil
throughput reading, the oil has to be metered or weighed.
Each regulating burner undergoes an oil throughput rating
adjustment setting and a function test during its final
manufacturing check. However, these values can only be
used as a guide. A commissioning test will have to be
carried out on site, where influences, such as oil quality
and ring main pressure must be taken into account.

14

7.2 Sliding two stage and modulating burners

Nozzle selection diagram type WB3
Spill type nozzle type WB3
Spray angle 45

It should be ensured that the minimum pressure does

not fall below 20 bar even at the lowest regulator
position.

80
75

Due to the nozzle sizing, the burner rating required with the
return flow closed (regulator position 10) can be achieved
at a pressure below 25 bar. In this case the pump
pressure must be increased to 25 bar. The higher oil
throughput that results is reduced by limiting the oil
regulator. This is done by adjusting the limit switch in the
servomotor to the appropriate lower regulating position.

70

60

60

55

55

Nozzle return pressure - Spill type nozzle WB3/K3

The nozzle return pressure must be measured during
commissioning. Normally this should not be set below 5
bar on partial load.

50

50

45

45

For the test point a T piece is available on the solenoid

valve.

40

40

35

35

30

30

25

25

20

20

15

15

10

10

The range of regulation is reduced accordingly by this

action.

Test point
return pressure

Nozzle cleaning
The nozzle is dismantled into its individual parts and
washed with petrol or petroleum. The filter should always
be replaced. If other individual parts are faulty or worn, the
whole nozzle should be replaced.

Oil throughput [kg/h]

Test point return pressure

5
20

25

5
30

Nozzle size relative to 30 bar

65

Oil throughput [kg/h]

The charts show the throughput of the spill type nozzle in

relation to the supply pressure. The pump pressure on RL
burners should be between 20 and 30 bar.

Supply pressure bar

Example of nozzle selection, type WB3

Required oil throughput: ___________________37,5 kg/h
Nozzle size from diagram: ________________________ 40
Supply pressure from diagram: ________________25 bar

Spill type nozzle

Type WB3
Atomising pressure
Burner type

Atomising pressure
approx. bar

RL3-A

20 30

15

8. Setting the combustion head

Weishaupt oil burners Monarch and R are supplied with a
choice of combustion heads and diffusers for each size
and capacity range. It is advisable to check that the
correct combustion head is fitted. Combustion heads and
diffusers are marked with their type designation. The
identification of the combustion head can be found
internally on the neck. The external diameter of the diffuser
is stamped on the side towards the burner.

Combustion head removal

Information for adjustment can be taken from the

combustion head capacity graphs.
The measurements given are empirical values, which
usually meet the requirements of most modern combustion
chambers.
The combustion head for each burner is designed for the
maximum oil throughput indicated in each case.
If the burner is operated in the middle or lower oil
throughput range the secondary the air gap between
diffuser and combustion head must be adjusted.
The combustion head can be adapted to the combustion
chamber conditions as follows:
Moving the combustion head from the basic position.
Fitting the next size diffuser or smaller combustion head
(see capacity graphs).
Both combustion head screws should be unscrewed. The
combustion head or diffuser can then be moved or
replaced. This reduces the secondary air gap and adapts
the air velocity to the corresponding lower oil throughput
range.

16

The burner also offers the advantage that the combustion

head with intermediate ring can be pulled through the
hinged flange opening, after unscrewing both holding
screws.
Increase secondary air gap between combustion head
and diffuser for higher burner rating. reduce for lower
burner rating.
It should be noted that the distance between nozzle and
diffuser should be larger, if nozzles with small spray angle
are used, than if nozzles with wide spray angle are used.
Flame tubes of higher temperature heat resistant
steel are available for special requirements.

8.1 Combustion head extensions

Burner
size

Combustion Dimensions in mm
head
Extension
Total length
type
l2
l3
l4*

l5

d1

d5

d6

1
1

M1/5a
M1/5a

100
200

228
328

118
218

220
320

128
128

150
150

110
110

3
3

M2/1a
M2/1a

100
200

238
338

117
217

230
330

140
140

170
170

120
120

3
3

M5/2a
M5/2a

100
200

238
338

109
209

230
330

160
160

190
190

140
140

Combustion head extensions are required on boilers with

very thick doors and on reverse flame boilers. It is
impossible to hinge open the burner when combustion
head extensions are fitted.

* To enable installation and service work to be carried

out, the refractory should be no thicker than dimension
l4. This generally only applies for standard boilers, and
generally not for combustion chambers, ovens, etc.

Designations and dimensions

Note:
On burner size 1 with head extensions of 200 or 300 mm,
the flame viewing port on the burner lid is blanked off. The
blanking plug must not be removed.
1
2
3
4
5
6
7
8
9

Oil line extension

Ignition line plug connection
Burner flange
Flange gasket
Burner plate
Ignition line extension
Combustion head extension
Refractory
Flexible insulating material (e.g. Cerafelt), do not make
solid
10 Nozzle support
11 Combustion head
12 Diffuser

17

9. Ignition electrode settings

The following should be noted:
The distance of the ignition electrodes to the nozzle and
diffuser should be checked.
The ignition electrodes must not intrude into the atomised
oil spray.

4
6

24

4
6

18

24

The distance of the ignition electrode to the diffuser and

the nozzle must always be greater than the spark gap.

10. Regulating system RL3

The regulating system does not have a nozzle cut off
valve. The solenoid valves control the oil shut off
function.

Nozzle head RL3

8

Operation
During the pre-purge period solenoid valves 2 and 3 are
closed. Oil is supplied under pressure by the pump up to
the closed solenoid valve 3 in the supply line. Solenoid
valves 2 and 3 are connected electrically in series.
1. Oil system diagram
After the pre-purge period has elapsed, the solenoid
valves 2 and 3 open. Oil flows to the nozzle via the nozzle
supply line 8 and to the oil regulator 5 via the return line 9.
The oil regulator is in the open position (ignition position).
Due to the lower return flow pressure, less oil leaves the
nozzle. The greater proportion of oil flows via the nozzle
return 9 to the oil regulator and the pump return line.

1. Oil system diagram

The oil pressure switch 6, when fitted, shuts down the

plant if the spill back pressure is too high.
2. Oil system diagram
Full load operation is produced by reducing the metering
slot in the oil regulator. This is done by rotary movement of
the oil regulator (direction of rotation to the right seen
from the shaft). This throttles the flow of oil in the return
line and the oil quantity increases at the nozzle outlet. On
shutdown the solenoid valves close and shut off the flow
of oil to the nozzle and from the oil supply.
1 Pump, without solenoid valve
2 Solenoid valve type 121K2423, 115 V
Coil 19 Watt (normally closed) G 1/8
3 Solenoid valve type 121K6220, 115 V**
Coil 20 Watt (normally closed) G 1/8

2. Oil system diagram

4 Nozzle head R, without integral shut off device

5 Oil regulator
6 Pressure switch 1 to 10 bar
(with EL set to 5 bar, with M to 7 bar)
7 Spill type nozzle
8 Nozzle supply
9 Nozzle return
The solenoid valves 2 and 3 in the nozzle return are
fitted against the flow direction.
** The solenoid valves 2 and 3 in the nozzle supply and
return (115 Volt) are electrically connected in series.
The pressure switch 6 checks the pressure in the
return. If there is an excessive increase in pressure
the burner shuts down. The shut off devices close
simultaneously on shutdown.
The switch point of the pressure switch is set prior to
burner delivery and does not need readjusting during
burner commissioning.

19

Oil regulator
The oil regulator is driven by the servomotor, and by
means of a vee slot metering groove regulates the variable
oil quantity.
In order that the oil quantity is regulated with the
correct metering slot, the key must always be fitted in
the appropriate keyway.

Setting example: Key on number 00

Primary setting
Code number
Oil regulating groove

Each regulator has two regulating grooves, which can be

changed. Each regulator has two numbers stamped on
the side of the shaft, e.g. 00-0 (see illustration).
Both numbers are matched to the appropriate groove
size. The matching of the oil throughput is shown in the
following table.
Oil regulator
code

Consumption
Throughput kg/h

00
0

0 to 50
51 to 70

Cam identification
ie. 6

Primary setting
Regulating cam
Cam 1

Shaft key

20

11. Nozzle recirculation on M burners

Nozzle 1

Nozzle 2

1
2
3
4
5
6
7
8
9
10
11
Nozzle recirculation on two stage M burners
Operation
After the minimum temperature has been reached by the
series connected terminal switch contacts in the ROB
regulating control and oil preheater, burner start is
released. The oil pump circulates the oil via the filter and
solenoid valve to the oil preheater, the oil is heated and the
viscosity reduced.
The heated oil forces the oil in the burner oil system
through the supply oil line, nozzle head, normally open
solenoid valve stage 1 to the pump return. There is now
hot oil present throughout the whole system. The shut off
device in the nozzle head remains closed and oil cannot
flow through the nozzle.
Other burner components are also heated by heating
cartridges.
After termination of the pre-purge period, the solenoid
valve 3 in the nozzle return is energised and closes. The oil
pressure increases in the nozzle shut off valve and at a
pressure of approx. 12 bar, the nozzle shut off valve opens
to commence stage 1 operation.

Pump
Solenoid valve, normally closed (nozzle 2)
Solenoid valve, normally open (nozzle 1)
Solenoid valve, normally closed, 110 V
Nozzle head as shut off device
Oil preheater
Pressure switch in return
Thermostat
Heat insulation
Heating cartridge
Nozzle shut off valve

After a delay, solenoid valve 2 for stage 2 is opened by the

burner control. Oil pressure is applied to the nozzle shut
off valve, which opens nozzle 2. Nozzle dribble is
prevented by the tight closure of the nozzle shut off valves.
Nozzle head 'heating
Heating takes place directly in the nozzle head, which is
insulated. A heating cartridge (10) with a capacity of 100
Watts is fitted in the nozzle body. An electronic P type
controller controls the nozzle temperature. The sensor is
fitted adjacent to the oil line inlet. The ROB control can be
set between temperatures of 65 and 130 C according to
the fuel quality (factory pre-setting 65 C).
When the burner shuts down, solenoid valve 3 is deenergised and opens. The atomising pressure reduces
immediately and the nozzle shut off valves close.
Nozzle head maintenance and cleaning
Both nozzles can be replaced without affecting the
function of the hydraulic nozzle shut off valves. If the nozzle
shut off valve 1 or 2 is removed, the isolating devices in the
oil supply and return must first be closed.

Regulator type ROB

Setting screw
Nozzle heads are type tested safety shut off devices and in accordance with DIN 4787 must not be interfered with.
21

12. Oil preheater and heating elements

Heating elements on burner types M1Z-B, M3Z-A
Burner type

Nozzle head
Watt

Valve bock
Watt

Pump
heating

M1Z-B

100

20

80

M3Z-A

100

20

80

Check whether the fuses for the electrical pre-heating

have been removed. The fuses should not be replaced
until the oil line system and pre-heater are full of oil and
vented (e.g. at the pressure gauge connection at the
pump). The oil temperature must be measured and if
necessary corrected at the oil pre-heater.

The burner must not be switched on until the required

supply temperature or ring main temperature for the
installation is reached (approx. 50 to 60 C).

After switching on the operating switch the contactor for

the pre-heater is energised without activating the burner
control switch. The contactor energises the heater
elements. They heat the oil in the pre-heater until the
thermostat on the pre-heater switches off. Before this oil
temperature is reached, the release thermostat in the preheater is activated.

The pumps have a heating facility. The gearing cover

has a pocket for the heating cartridge. The heating
facility can be used as and when required.

Pump heating M1Z-B, M3Z-A (special execution)

Nozzle heating M1Z-B, M3Z-A

The heating elements in the burner are usually controlled

by the burner operating switch.

Heating cartridge

Heating cartridge

Valve block heating M1Z-B

Valve block heating M3Z-A

Heating cartridge
Heating cartridge

22

13. Air regulation, single, two and three stage burners

Single stage oil burners
The combustion air volume control damper is adjustable
and can be set to firmly limit the opening cross sectional
area for the ratings required.

Air regulation for single and two stage burners

Sizes 1 to 3

Two stage oil burners

Two stage oil burners have a servo-driven air damper,
which controls the air quantity for partial and full load by
altering the amount of opening. When commissioning the
plant the following mechanical settings are necessary:
Set the air damper for partial load operation (operation
with nozzle I) by using the cam switch II - partial load in
the servomotor.
Set the air damper for full load operation (operation
with both nozzles) by adjusting the air damper for main
load via the servomotor cam switch III - full load.
Set the switch for switching on solenoid valve stage 2.
This is done at the servomotor 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.

Three stage burners

For burners L1T and L3T the servomotor type 1055/80 is
used. This servomotor has the same design as type
1055/23, however, relating to an angle of rotation of
90 it has a run time of 8 seconds and two additional
control cams.

The final setting of the cam switches in the servomotor

for full load - switch III and partial load - switch II takes
place once flue gas analysis is satisfactory.
Servomotor type 1055/23
Housing back plate
Drive motor
Switch
identification
Control cam
setting aid
Air damper
position indicator

Switch position
indicator
Gear wheel (may be
uncoupled for manual
adjustment)
Control cams; Auxiliary
switch II Partial load
Auxiliary switch I
Stage 2

Drive shaft for air

damper
Printed circuit
board cover

Limit switch III

Full load
Limit switch IV Closed
Terminal rail

black
green
grey

PCB pin

23

Servomotor type 1055/80

Housing back plate
Drive motor
Switch position
indicator
Gear wheel (may be
uncoupled for manual
adjustment)

Control cam
setting aid

Control cams;
Auxiliary switch VI,
Valve stage 3

Air damper
position indicator

Auxiliary switch V,
Interm. load/ignition load
PCB pin

Auxiliary switch II,

Partial load

Drive shaft for air

damper

Auxiliary switch I,
Valve stage 2
Limit switch III,
Full load

Terminal rail
Printed circuit
board cover

Limit switch IV Closed

90
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

VI

II

III

IV

M
1

schwarz - black - noir

black
grn -green - vert
green
grau
grey - grey - gris

Switch
identification

13.1 Cam setting of limit and auxiliary switches in servomotor type 1055
The air damper position is indicated on a scale 0 to 90
by a pointer on the drive shaft.
There is a setting scale between the cam switches. The
setting knobs on the cam switch indicate with a small
pointer on this scale, and give the switch point of the
appropriate switch in relation to the air damper position.
The cam switches are set as follows using the setting
scale:
Cam switches
* VI

Solenoid
valve full
load

depending on burner rating,

but set to above V.

*V

Partial load
last

depending on burner rating,

set between I and VI for air
regulation

IV

Closed

III

Full load

depending on burner rating,

up to 90

II

Partial load

depending on burner rating,

between 0 and approx. 50

Solenoid
valve,
Intermediate
load

depending on burner rating,

between partial and
intermediate load at approx.
10 to 40

* used only on version T

24

The limit and cam switches are marked in all wiring

diagrams with I, II, III, IV and have the function, which is
shown in the connection diagram.
The connection diagram is also shown on the cover of the
servomotor.

13.2 Description of function for servomotor type 1055

Burner switching with LOA... burner control

5. Servomotor runs to switch point partial load II.

Sequence of operation:
1. After the appliance on/off control has closed, control
voltage is applied to terminal 1 of the LOA...

6. After the pre-purge period the flame is established,

then operation of stage 2 via terminal 5 of the LOA.
The servomotor opens the air damper and when the
limit switch I - solenoid valve stage 2 - is overrun, the
valve is energised.

2. Terminal 8/3 is energised. Relay K15 in the servomotor

is also energised.
3. Servomotor opens the air damper.

MV Stage 2

Burner motor contactor

4. The burner motor contactor is energised via the full

load limit switch III and switches the auxiliary contacts.
Burner motor starts.

7. After the controller has switched off, the burner

switches off, terminal 8/3 and 5 on LOA are without
voltage. The motor contactor K1 is de-energised.
Voltage is applied to the servomotor via an opening
contact. The air damper closes until the limit switch
Closed IV switches off the servomotor.

25

Burner switching with LAL2... burner control

Sequence of operation:
1. After the boiler on/off control has closed between
terminals 4 and 5, terminal 6 of the burner control is
energised.
2. The burner motor starts. The voltage from terminal 11
of the LAL2... control is supplied via the Closed
switch IV to terminal 8 of the LAL.
3. After a short delay the air damper is opened to the
switching point of the full load limit switch III. A return
interlock signal is given to terminal 8 of the burner
control.

5. After flame establishment, terminal 20 on the LAL

control is energised to control stage 2.
6. The servomotor is energised via the stage 2, H/L
controller, and switch S2 and the air damper opens.
Version Z
7. If the switch for limit switch 1 solenoid valve stage 2 is
overrun, this valve is energised.
8. After the burner is shut down, the voltage on terminal
11 of the LAL closes the damper until the limit switch
Closed IV switches off the servomotor.

4. After the pre-purge terminal 9 is de-energised. By

energising terminal 10 the servomotor closes the air
damper to switching point Partial load with switch II.

Basic wiring diagram

for version Z

Version T
6. The servomotor opens the air damper with voltage
from the terminal via switch S4, intermediate load
control (see wiring diagram of burner control) and limit
switch III.

9. The servomotor opens the air damper with voltage

from terminal 20 via switch S2 up to the switch point
of the limit switch III if the full load controller demands
additional heat.

7. The auxiliary switch I energises the intermediate load

solenoid valve.

10. If the auxiliary switch VI is bypassed, the full load

solenoid valve is also energised.

8. Depending on the setting of the controller for

intermediate load the servomotor is stopped on the
switch point of the auxiliary switch V or the air damper
is opened further.

11. After burner shutdown, the air damper is closed by

the voltage of terminal 11 of the LAL until the limit
switch IV switches off the servomotor.

26

14. Oil/air compound regulation on regulating burners

The cam segment is driven clockwise by the
servomotor to the full load position. The adjustable
spring band on the cam operates the air damper
linkage and opens the damper for full air pre-purge.

Setting the spring band

At the end of the pre-purge period, the servomotor

brings the oil regulator, on the same axis of rotation as
the cam segment, and the air damper to the ignition
load position. In this position the oil regulator is wide
open, which means that only a small quantity of oil will
be atomised at the nozzle, the larger proportion flows
back via the return line.
The air damper is partially open so that the air supplied
is matched to the atomised oil quantity.
The servomotor drives the compound mechanism in a
continuous movement from partial to full load. This
means the air damper is opened while the oil regulator
closes and less and less oil flows to the return line.

Adjusting the air quantity

The cam segment has an adjustable spring band,
which is adjustable by means of socket screws. The
air quantity is matched to the oil throughput required
by adjusting the spring band on the cam segment.
The setting of the spring band is determined at various
load positions by flue gas analysis.

Compound adjustment
Full load (100%)

Partial load (from 30 to 70%)

Ignition load (from 20 to 30%)
Basic position
Air damper with
linkage

Nozzle return line

Metering slot
Oil regulating valve
Cam segment

Servomotor drive shaft

Adjustable spring band

27

14.1 Cam settings of limit and auxiliary switches in the servomotor type SQM
Description
The limit and auxiliary switches are set manually on the
adjusting cams. The cams have a small pointer, which
indicates the appropriate switch point on a scale between
the cam segment.
The servomotors are supplied with the following
provisional switch settings:
I Open 120
II Closed 0
III Ignition load 30
IV free
V free
VI free
VII Partial load 50
These switch settings must be reset when commissioning
to the requirements of the installation.

Auxiliary and limit switch settings

Manual actuation of the servomotor

With the lever fitted on the gearbox, the cam shaft can be
disengaged from the drive. This makes it possible to turn
the cam segment manually to any position required. The
cam segment air band can also be adjusted to match the
requirements of the appliance. When the lever is in the
vertical position, the drive is engaged.
The scale on the outer end of the switching cams indicate
the angular position of the servomotor.
The cams are set without tools using the setting scale.
The connection diagram is also shown inside of the
servomotor cover.

Disengage the drive

Connection diagram

I
II
III
IV

28

Open
Closed
Ignition load
free

V free
VI free
VII ignition load

15. Commissioning and adjusting

General
Before commissioning can commence, the entire plant
must be ready for operation and handed over by the
installer.
The burner motor rotation should be verified before
commissioning. With control circuit and operating switch
closed, the burner is briefly actuated by the burner control
switch. The rotation of the burner motor must be antclockwise when looking at the motor cooling fan. Note the
direction of the arrow of the motor flange.
Checks prior to commissioning
Has the heat exchanger been mounted ready for
operation?
Have operating instructions of the heat exchanger
been observed?
Are heat exchanger and system filled sufficiently with
heating medium?
Are the flue gas passages free from obstruction?
Are explosion relieves free to operate?
Is the flue gas damper open?
Is sufficient permanent fresh air supply ensured?
Have temperature/pressure controls and safety limit
controls been set correctly and placed into the
operation position?
Has the low water safety interlock been set correctly?
Have all fuel carrying pipe lines been purged of air?
Is the rotation of the burner motor correct?
Is sufficient fuel oil in the tank?
Has a soundness tests of the oil hydraulic been
carried out?
Is load available?
Are the oil supply pumps (if fitted) switched on?
Are the oil shut off devices open?
Are oil-supply lines and pump filled with oil?
Other installation specific tests may be required. See
operating instructions of individual components.
Switch on procedure
Open shut off valve (shut off assemblies) in the oil supply.
Set selector switch in the control panel to Stage 2 or
Full load. Reset installation.
Switch on burner operating switch.
Ignition
Once pre-purge is complete await flame formation.
If ignition problems occur:
L-(M-) burners:
Check nozzle size of stage 1; if necessary
select different nozzle
Check position of auxiliary switch II in the servomotor, if necessary adjust to air requirement.
RL - (RM-) burners:
Check position of ignition load switch on the
servomotor (No. III), if necessary adjust setting.
Test sensor current with a microammeter.
Full load setting
After approx. 11 secs, the servomotor runs from ignition
load (partial load) to full load setting. (Ensure this is
carried out with excess air by previously reducing the
required oil pressure). For full load the required oil
throughput must be set and measured (nozzle selection
diagrams are only an aid for setting and checking).

Carry out combustion analysis:

Other installation specific tests may be required. See
operating instructions of individual components.
L- (M-) burners:
Set oil throughput by adjusting pump pressure
(EL = 10 to 14 bar, M/MS = 20 to 25 bar), if
necessary select different nozzle size.
Set combustion values by adjusting servomotor,
auxiliary switch N. III and the position of the
flame tube (see chapters 9 and 10) so that with
fully opened air damper a smoke number
<1 and CO2> 13 Vol. - % with good flame
stability can be achieved.
RL- (RM-) burners:
Set oil throughput by adjusting pump pressure
(20 to 30 bar).
Set combustion values by adjusting the air
curve band and positioning of the combustion
head so that with fully opened air damper a
smoke number <1 and CO2 > 13 Vol. - % with
good flame stability can be achieved.
The pump pressure must be set with a pressure gauge
(see chapter 5).
The pump pressure and combustion head set for full load
must not be readjusted.
Intermediate testing (full load to partial load)
only on regulating burners:
A point by point combustion check is necessary for the
whole of the burner regulating range.
Adjust cams manually step by step upwards from the
direction of ignition load (selector switch Stop,
disengage servomotor, adjust, re-engage). Regulate
combustion values by adjusting the air curve bands.
Ensure the curve bands have an even profile.
Partial load setting
Set selector switch in the control panel to stage 1 or
Partial load.
L- (M-) burner
Match excess air to the oil throughput required
for the nozzle selected for partial load with the
auxiliary switch (No. VII).
Measure oil throughput, if necessary select a
different nozzle.
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;
In the same way the excess air of the intermediate load is
set with auxiliary switch V and the connection point for the
third stage is set with auxiliary switch VI.
RL- (RM-) burners:
Set and measure the required oil throughput for
partial load with auxiliary switch No. VII.
If changing the nozzle on partial or intermediate load
(two/three stage burners) the full load setting has to be rechecked and if necessary re-adjusted. For partial load
setting, the lower ratings limits of the capacity graphs, the
flue gas temperature and instructions from the boiler
manufacturer have to be observed.

29

Concluding work:
Check ignition load setting when the burner has been
commissioned. The setting is correct, if the burner starts
without start impact.
Regulating burners:
If necessary correct setting at auxiliary switch
(No. III).
2 and 3 stage burners:
If necessary select new nozzle. Full and partial
load setting will then have to be repeated.
Check and adjust operation of all safety equipment (i.e. oil
pressure switch, thermostat, pressure switch etc.) whilst
installation is in operation.

Documentation
The following setting values for full and partial load (and
poss. intermediate load) must be recorded on the report
sheet or test sheet:
Oil throughput
Nozzle type
Pump pressure
Supply and return pressure (on RL burners)
CO2
Smoke
Flue gas temperature
Suction or pressure in the combustion chamber
Sensor current
Inlet air temperature
Air damper setting
Cam setting on air band (on R burners)

16. Sequence of operation for burner control LOA

Sequence of operation for LOA 24 / 25

Interruption of sequence

1. Control and limit thermostats closed,

voltage on terminal I

Check electric supply,

check connection of thermostats

2. Voltage on terminal 8/3 and 6, burner motor runs,

ignition transformer switched on

Check connection of ignition transformer

and burner motor, external light (control goes
to lockout), check light sensor

3. After approx. 13 (6) secs. voltage on terminal 4,

solenoid valve nozzle 1 opens

Check wiring, burner control faulty

4. Flame establishment

No flame establishment,
see fault conditions and procedures

5. After approx. 15 secs. voltage for the ignition

transformer (terminal 6) is interrupted

Burner control faulty, check wiring

6. After approx. 15 secs voltage to terminal 5,

stage 2 energised

Check wiring, control faulty

Switch times in secs.

LOA 24.171

LOA 25.171

LOA 44.255

LOA 24.571

TV
TS
TV
TST
TNZ

approx. 13
max. 10
approx. 13
approx. 15
approx. 15

13
max.10
13
15
15

25
max. 5
25
5-8
5-8

6
max. 10
6
20
20

30

Prepurge period
Safety time
Pre-ignition time
Interval 1st - 2nd stage
Post ignition time (from start of TS)

Functional diagram

Functional diagram

Basic connection

Basic connection

LOA

A1

10 11 12

F
F3
F
F2

LOA

A1

10 11 12

F
F3
T

F
F2

B1

B1

S1

S1
M
1~

F1

M1

F1
T1

Y1

Y2

M
1~

H1

M1

N
L
220V 1,N 50 Hz

T1

Y1

Y2

H1

N
L
220V 1,N 50 Hz

Functional diagram

Function diagrams (flame fault)

Start with flame formation

Burner
On
TV

Flame signal at start

Burner
On

TST TNZ
Operating
position
Burner
Off

Fault
TS
Start without flame formation
Burner
On

Voltage present
Arrow showing direction of current

Fault

Flame present
Flame failure during operation
Burner
On

Legend
A1 Burner control
B1 Flame sensor
F1 Fuse
F2 Temperature/pressure limit control
F3 Temperature/pressure regulator
H1 Fault indication lamp

M1
S1
T1
Y1
Y2

Burner motor
Mains switch
Ignition transformer
Solenoid valve stage 1
Solenoid valve stage 2

Operating
position
Restart

31

17. Sequence of operation burner control LAL2... and LOK 16...

The LAL 2... burner control units are designed to provide
control and supervision of multi stage and modulating
burners. They are suitable for intermittent operation. For
burners operating continually without stops and starts, the
burner control LOK 16... is recommended to be used.

17.1 Requirements for burner start

Control unit reset
Air damper closed. The limit switch for Closed position
must supply voltage from terminal 11 to terminal 8.
The control contacts between terminal 112 and terminal
4 must be closed.

17.2 Function and time sequence diagrams

The diagrams shown give the timing sequence for the air
damper regulation and the oil release and regulation.

Oil burner Z

Sequence diagram air

Regulator
Air On
Full load

I - IV Switch points
Ignition load/partial load

LAL2
.../LOK16 ...
Control circuit

Closed
Position indicator

Time sequence diagram

for servomotor
Time sequence diagram
for ignition and
fuel release
Burner fan
Sequence diagram oil

32

Nominal load
pre-purge

Ignition and fuel

release

Capacity regulation

Regulator Off

17.3 Symbols on fault position indicator

In the event of a fault condition the fuel supply is always
interrupted immediately. Simultaneously the sequence
switch stops and thus lockout is indicated. The symbol
appearing above the reading mark indicates the area of the
fault.
 No start e.g. because the closed signal has not been
supplied to terminal 8 by the limit switch/auxiliary switch
or because a contact has not been closed between
terminals 12 and 4 or 4 and 5.
 Controlled shut down because the open signal has
not been supplied to terminal 8 by the limit switch.
P Lockout because the air pressure signal has not been
received by the start of the air pressure check. Air
pressure failure after this point also causes the
control to go to lockout (when the burner has been
fitted with an air pressure switch).

a - b Start up sequence
b - a Post purge sequence after controlled shut down. In
start position a the sequence switch switches itself
off automatically.

Lockout due to a fault in the flame supervision circuit.

 Controlled shutdown because the position signal for
the low flame position has not been supplied to terminal
8 by the auxiliary switch.
1 Lockout because no flame signal has been received on
completion of the first safety time. Any flame signal
failure after completion of the first safety time also
causes the control to go to lockout.
|

Lockout because the flame signal has been lost during

operation or air pressure failure has occurred.

 Lockout on completion of control programme

sequence due to extraneous light or due to a fault in
the flame supervision circuit.
If lockout occurs at any other point between start and preignition, which is not marked by a symbol, there is normally
a premature and thus faulty flame signal.

33

17.4 Switching times

Switching times in seconds * in start up sequence

LAL 2.14/
LOK 16.140

LAL 2.25/
LOK 16.250

LAL 2.65/
LOK 16.650

t7
t16
t11
t10

2
4
optional

2
5
optional

2,5
5
optional

6
10
optional
from start
2
4
10
8

10
22,5
optional
from start
2,5
5
15
7,5

10
67,5
optional
from start
2,5
5
15
7,5

7,5

7,5

32
30
10
10

35
47,5
15
15

12,5
92,5
15
15

t1
t12
t3
t3
t2
t3n
t4
t5
t20

t6
t13

Start delay for burner motor G2

Interval from start up to OPEN command of air damper
Run time of air damper in OPEN position
Interval from start up to commencement of air pressure check
(if burner is fitted with air pressure switch)
Pre-purge time with air damper open
Run time of air damper to ignition position
Pre-ignition period long (Z on terminal 15)
Pre-ignition time short (Z on terminal 16)
First safety period
Post-purge time (Z on terminal 15)
Interval between BV1 - BV2
Interval between end of t4 and release of load controller
or valve at terminal 20
Interval up to the self shutdown of the sequence switch
after burner start up (idle step , i.e. no change in the
contact position)
Duration of start up (without t11 and t12)
Post purge time
Permissible after burn time

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

17.5 Technical data burner control

Flame monitoring with QRB (not on LOK16...)

Nominal voltage _________ 220 V 15%...240 V + 10%

Recommended illumination in Lux _________________ 40

Frequency ________________ 50 Hz 6%...60 Hz + 6%

Average response sensitivity of the amplifier ______ 8 A

Consumption ______________________________ 3,5 VA

Max. possible detector current _______________ 160 A

Fuse (built in) _________________________ M 6,3/250 E

(semi time lag according to DIN 41571, sheet 20.
Pre-fuse (external) ________________________ max. 10A
Permitted input current to terminal 1 ____ 5 A continuous
peaks up to max. 20A
Permitted loading
of control terminals ___________________ 4A continuous
peaks up to max. 20A
total max. 5A
Required switching capacity
- between terminals 4 and 5 _____________________ 1 A
- between terminals 4 and 12 ____________________ 1 A
- between terminals 4 and 14, 5A cont.; peaks up to 20A
Mounting position __________________________ optional

Flame failure indication during operation 3 Lux at 2856 K

Max. permitted sensor line _____________________ 20 m
Max. permitted ambient temperature _____ - 20... + 70C
Flame supervision with RAR ...
Min. required sensor current ____________________ 6 A
Max. possible sensor current __________________ 25 A
Permitted cable length __________________ 30 m RAR 7
Permitted ambient temperature __________ - 20... + 60C
Note:
Flame detector wiring must not be bunched together with
other wiring.

Protection standard __________________________ IP 40

Permitted ambient temperature___- 20... + 60C at 230 V

Permitted ambient conditions for electrical components

Temperature
In operation:
-20 +40C
Transport /storage:
-40 +60C

34

Humidity
max. 80% rel. humidity

Requirements
re. EMV
EC directive 89/336/EEC
EN 50081-1
EN 50 082-1

Low voltage guideline

EN 60335

17.6 Basic wiring diagram for burner control LAL2... / LOK 16...

Legend
AR Load relay (main relay)
B1 Flame sensor
BR Lockout relay
F
Fuse in burner control
F4 Temperature or pressure limit switch
F5 Temperature or pressure controller on/off
F6 Temperature or pressure controller FULL LOAD
FR Flame relay
H
Control lamp Lockout
H6 Remote indication for lockout
K1 Motor contactor
LK Air damper
M1 Fan or burner motor
S
Reset key

S1
S10
T1
Y6
Y11
Y12
Y14

Remote reset
Air pressure switch (when fitted)
Ignition transformer
Servomotor
Solenoid valve PARTIAL LOAD
Solenoid valve FULL LOAD
Additional solenoid valve

Wire link

35

Control outputs of
contacts:
Positions of lockout indicator

Legend for diagram of sequence switch

t1 Pre purge time
t2 Safety time
t3 Pre-ignition time
t4 Interval between voltage on terminals 18 and 19
t5 Interval between voltage on terminals 19 and 20
t6 Post purge time
t7 Interval to voltage on terminal 7
t8 Duration of start up sequence
t10 Interval to start of air pressure control
t11 Run time of air damper (Open)
t12 Run time of air damper (min.)
t13 Permissible after burn time
t16 Interval up to OPEN command for air damper
t20 Interval up to self shut down of the sequence switch
(not on all controls)
Burner controls are safety devices! Do not open!
Interference can result in unforeseen consequences!

36

18. Fault conditions and rectifying procedures

If faults occur the basis requirements for correct operation must first be examined.
1.Check the electric supply.
2.Ensure that an oil supply is available.
3.Check that all controls e.g. thermostats, pressure switches, water level interlocks,
limit and time switches are correctly set.
When it is established that the fault is not due to external conditions, the operations of the individual burner parts must be
checked.
Condition

Cause

Remedy

1. Ignition
No ignition

Ignition electrodes too far apart

Adjust

Electrodes dirty and damp

Clean, adjust

Burner control faulty

Replace burner control

Insulator cracked

Replace

Ignition transformer faulty

Replace

Ignition cable charred

Replace, find cause and remedy

Overload relay tripped

Check setting

Contactor defective

Replace

Capacitor faulty

Replace

Burner motor defective

Replace

Gears damaged

Replace

Suction valve leaking

Clean or replace

Suction line leaking

Tighten joints

Isolating valve closed

Open

Filter blocked

Clean

Filter leaking

Replace

Quick action valve leaking

Replace pump

Reduced capacity

Replace pump

Air in pump

Tighten joints

Vacuum in oil line too high

Clean filter, open valves fully

Swirl disc loose

Remove nozzle, tighten swirl disc

Orifice partly blocked

Replace

Nozzle filter blocked

Replace

Worn due to use

Replace

No oil flow

Nozzle blocked

Replace

Nozzle leaking

Nozzle cut off faulty

Replace

2. Motor
Does not start

3. Pump
Supplies no oil

Loud mechanical noise

4. Nozzles
Uneven atomisation

37

Condition

Cause

Remedy

5. Burner control with flame sensor

Does not respond to flame

Flame sensor obscured

Clean

Heat damaged

Replace

Interruption in sequence

see under 15 - 17

Check connection and voltage

Lockout lamp on

Flame fault

Reset

6. Combustion head
Contaminated with oil
or heavy carbon deposits

Wrong combustion head

Replace

Nozzle size incorrect

Replace

Combustion air quantity incorrect

Readjust burner

Boiler house not adequately

The boiler house ventilation must

ventilated be via a permanent opening,
the cross section of which must be at
least 50% of all chimney cross sections
associated with the plant

7. Solenoid valve
Does not open

Coil faulty

Replace coil

Does not close tightly

Particles on valve seat

Dismantle valve, remove foreign bodies

Temperature switch for oil

release does not close

Increase oil temperature at the

temperature adjusting screw of the
temperature controller

Temperature switch for oil

release faulty

Replace

Temperature switch for oil

release loose

Tighten

Temperature switch for oil

release with incorrect
temperature range fitted

Replace

Heating element burnt out

Replace preheater

Temperature too low

Increase temperature at temperature

controller

8. Oil preheater
Burner does not start

Poor combustion

For adjustment see oil preheater brochure

9. Cleaning and lubrication regulations
Depending on the degree of contamination of the combustion air, fan rotor, ignition electrodes, flame sensor and air intake
should be cleaned as required.
The moving/rotating burner 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 bearing should be investigated immediately.

38

Weishaupt products
and service

Max Weishaupt GmbH, D-88475 Schwendi

Tel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58
Print No. 420 GB, May 98
Printed in Germany. All rights reserved
Weishaupt (U.K.) Ltd
Stoke Gardens, Slough SL1 3QD
Tel. (01753) 51 23 45
Fax (01753) 51 25 85
Neachells Lane, Willenhall
West Midlands WL13 3 RG
Tel. (01902) 60 98 41
Fax (01902) 63 33 43

Oil, gas and dual fuel burners types W and WG/WGL

up to 570 kW
They are used mainly in houses and small buildings.
Advantages: fully automatic, reliable operation, individual
components easily accessible, easy to service, quiet operation.

Oil, gas and dual fuel burners types Monarch

R, G, GL, RGL up to 10.900 kW
These 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 kW
WK 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 burners
Weishaupt 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 responsibility
belongs to one manufacturer.

Weishaupt Thermo Unit / Weishaupt Thermo Gas.

These Units combine the technical innovations and operating
efficiencies 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.